Abstract: Solar cells include bus bars and high aspect-ratio gridlines that are printed on a substrate, and localized melting is induced to slump or flatten the gridline “vertex” portions that are disposed on the bus bars, while maintaining the high aspect-ratio of gridlines portions disposed on the substrate between the bus bars. The localized melting process is induced using one of several disclosed methods, such as rheological melting in which the two printed inks produce a compound that is relatively liquid. Localized melting is also induced using a deliquescing material (e.g., a flux or a solvent film) that is applied to the bus bar or gridline material. Also, eutectic melting is induced using a processing temperature that is between a melting point of the combined gridline/bus bar inks and the individual melting points of the inks alone. Laser-based melting and the use of copolymers is also disclosed.

Abstract: A micro-extrusion printhead assembly utilized in a micro-extrusion system to form parallel extruded gridlines of material on a substrate includes a nozzle having a tapered (e.g., triangular or trapezoidal) cross-section arranged such that a lower surface of each gridline is substantially wider than its upper edge, and such that side surfaces of the extruded gridlines reflect incident light beams into exposed surface areas of the substrate, thereby minimizing the effective shadowed surface area under the gridline. In one embodiment, the fluidic channels of each nozzle are fabricated by cutting or etching progressively wider channels into a series of rigid layers, and then stacking the rigid layers to form a layered nozzle structure. In another embodiment, a single layer is processed to include a tapered cross-section having the desired triangular or trapezoidal cross-section.

Abstract: Solar cells include bus bars and high aspect-ratio gridlines that are printed on a substrate, and localized melting is induced to slump or flatten the gridline “vertex” portions that are disposed on the bus bars, while maintaining the high aspect-ratio of gridlines portions disposed on the substrate between the bus bars. The localized melting process is induced using one of several disclosed methods, such as rheological melting in which the two printed inks produce a compound that is relatively liquid. Localized melting is also induced using a deliquescing material (e.g., a flux or a solvent film) that is applied to the bus bar or gridline material. Also, eutectic melting is induced using a processing temperature that is between a melting point of the combined gridline/bus bar inks and the individual melting points of the inks alone. Laser-based melting and the use of copolymers is also disclosed.

Abstract: Solar cells include bus bars and high aspect-ratio gridlines that are printed on a substrate, and localized melting is induced to slump or flatten the gridline “vertex” portions that are disposed on the bus bars, while maintaining the high aspect-ratio of gridlines portions disposed on the substrate between the bus bars. The localized melting process is induced using one of several disclosed methods, such as rheological melting in which the two printed inks produce a compound that is relatively liquid. Localized melting is also induced using a deliquescing material (e.g., a flux or a solvent film) that is applied to the bus bar or gridline material. Also, eutectic melting is induced using a processing temperature that is between a melting point of the combined gridline/bus bar inks and the individual melting points of the inks alone. Laser-based melting and the use of copolymers is also disclosed.

Abstract: Solar cells include bus bars and high aspect-ratio gridlines that are printed on a substrate, and localized melting is induced to slump or flatten the gridline “vertex” portions that are disposed on the bus bars, while maintaining the high aspect-ratio of gridlines portions disposed on the substrate between the bus bars. The localized melting process is induced using one of several disclosed methods, such as rheological melting in which the two printed inks produce a compound that is relatively liquid. Localized melting is also induced using a deliquescing material (e.g., a flux or a solvent film) that is applied to the bus bar or gridline material. Also, eutectic melting is induced using a processing temperature that is between a melting point of the combined gridline/bus bar inks and the individual melting points of the inks alone. Laser-based melting and the use of copolymers is also disclosed.

Abstract: A micro-extrusion printhead assembly utilized in a micro-extrusion system to form parallel extruded gridlines of material on a substrate includes a nozzle having a tapered (e.g., triangular or trapezoidal) cross-section arranged such that a lower surface of each gridline is substantially wider than its upper edge, and such that side surfaces of the extruded gridlines reflect incident light beams into exposed surface areas of the substrate, thereby minimizing the effective shadowed surface area under the gridline. In one embodiment, the fluidic channels of each nozzle are fabricated by cutting or etching progressively wider channels into a series of rigid layers, and then stacking the rigid layers to form a layered nozzle structure. In another embodiment, a single layer is processed to include a tapered cross-section having the desired triangular or trapezoidal cross-section.