TL;DR
Longi and Yangzhou University have developed a new laser manufacturing process for heterojunction back-contact solar cells, achieving a record efficiency of 27.27%. The breakthrough addresses laser shock wave damage, improving device stability and performance, bringing ultra-high-efficiency photovoltaics closer to industrial viability.
Longi and Yangzhou University have announced the development of a heterojunction back-contact solar cell achieving a record efficiency of 27.27%, using a novel laser manufacturing process designed to mitigate shock-wave damage. This advancement could significantly impact high-efficiency photovoltaic production and industry standards.
The research team from Longi and Yangzhou University employed a laser-based manufacturing strategy that addresses the damaging effects of shock waves generated during laser patterning of silicon wafers. By focusing on the interaction between ultrafast laser pulses and the rear-side silicon nitride (SiNx) layer, they identified a non-thermal ablation process that causes rapid bond breaking and localized plasma formation, which in turn produces shock waves capable of damaging the silicon lattice.
Through comparative analysis of two sample groups—one with a rear-side SiNx layer and one without—the team observed that the SiNx layer significantly amplifies shock-wave effects, leading to microcracks, loss of pyramidal texture, and degradation of passivation layers. To counteract this, the researchers experimented with alternative front-side textures, including submicron and rounded-top pyramids, which demonstrated improved stability under laser processing. The champion device achieved a power conversion efficiency of 27.27%, with an open-circuit voltage of 745.0 mV, a short-circuit current of 7,439 mA, and a fill factor of 86.19%. This performance closely approaches the record efficiency of 28.13% set by Longi previously, confirming the potential for industrial application.
Impact of Shock Wave Mitigation on Solar Cell Efficiency
This development is significant because it demonstrates a viable pathway to produce ultra-high-efficiency heterojunction solar cells at an industrial scale. By addressing the mechanical damage caused by laser shock waves, the new manufacturing approach enhances device stability and performance, potentially leading to more reliable, cost-effective high-efficiency solar modules. The achievement of over 27% efficiency places this technology among the most advanced in the field, narrowing the gap toward commercially viable ultra-high-efficiency photovoltaics.
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Advances in Laser Manufacturing and HJT Technology
Heterojunction (HJT) solar cells are among the most efficient photovoltaic technologies, with record efficiencies exceeding 28%. Longi has been a leader in developing high-performance HJT cells, but manufacturing challenges—particularly laser-induced damage—have limited scalability. Recent research has focused on optimizing laser patterning processes to prevent microcracks and preserve passivation layers. The new technique, developed collaboratively with Yangzhou University, introduces a laser–SiNx interaction mechanism that minimizes damage, enabling the production of high-efficiency cells with improved stability. This breakthrough aligns with industry trends toward integrating laser processing for patterning and contact formation, emphasizing the importance of controlling laser-induced shock waves.
“Our work not only addresses a major contradiction in laser-based manufacturing but also offers a practical, industry-ready route toward ultra-high-efficiency photovoltaics.”
— an anonymous researcher
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Unresolved Aspects of Manufacturing Scalability
It remains unclear how easily the new laser mitigation techniques can be scaled for mass production and whether the improved stability and efficiency can be maintained over long-term operational periods. Further validation and industrial trials are needed to confirm commercial viability.
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Next Steps Toward Commercial Deployment
The research team is expected to focus on scaling the manufacturing process, testing long-term stability, and integrating these techniques into existing production lines. Industry partners may begin pilot projects to evaluate the commercial readiness of the technology, with broader adoption anticipated if results continue to meet performance and reliability benchmarks.
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Key Questions
How does the new laser process improve solar cell efficiency?
The process reduces laser shock wave damage that causes microcracks and passivation loss, enabling higher-quality, more stable heterojunction cells with efficiencies near 27.3%.
Can this manufacturing method be used at industrial scale?
While promising, it is still uncertain how easily the technique can be scaled for mass production. Further validation and pilot testing are required to confirm scalability.
How does this efficiency compare to existing commercial solar cells?
The 27.27% efficiency achieved is close to the world record of 28.13% set by Longi, placing this development among the most advanced heterojunction cells available today.
What are the main advantages of the new front-side texture design?
The submicron, rounded-top pyramids disperse stress waves more effectively, reducing damage during laser processing and improving passivation stability.
When might this technology become commercially available?
If scaling and long-term stability are confirmed, commercial deployment could occur within the next few years, depending on industry adoption and further development efforts.
Source: PV Magazine
