Ruixiao Lia,
Hanying Wangab,
Yuping Taia,
Jintao Bai*b and
Hui Wang*ab
aKey Laboratory of Synthetic and Natural Functional Molecule Chemistry (Ministry of Education), College of Chemistry & Materials Science, Northwest University, Xi’an 710069, P. R. China. E-mail: huiwang@nwu.edu.cn; Fax: +86 29 8830 3798; Tel: +86 29 8836 3115
bNational Key Laboratory of Photoelectric Technology and Functional Materials (Culture Base), National Photoelectric Technology and Functional Materials & Application of International Science and Technology Cooperation Base, Institute of Photonics & Photon-Technology, Northwest University, Xi’an 710069, P. R. China. E-mail: jintaobai@sina.cn; baijt@nwu.edu.cn; Fax: +86 29 8830 3798; Tel: +86 29 8830 3877
First published on 14th April 2016
In this paper, the best composition and ratio of solvents for the organic medium in back-side silver pastes was selected through a series of orthogonal experiments. The results showed that the volatility of the organic medium mentioned above was better than the others. The back-side silver paste prepared using this organic medium had appropriate viscosity (4.36 Pa s) and less residual ash content (0.75 wt%) when the composition of the solid substances in the organic medium was: acrylic resin 3.50 wt%, phenoxy resin 2.30 wt%, and ethyl cellulose 2.40 wt%. The properties of this paste were investigated after it was printed and further sintered to form back-side silver electrodes on solar cells. Scanning electron microscopy images showed that these back-side silver electrodes had a smoother and more dense surface, a more appropriate width and thickness, and closer contact with the silicon wafer and a larger welding tension. As a result, the photoelectric conversion efficiency of the solar cells printed by this back-side silver paste reached 18.06%.
Viscosity is an important measurement index of organic media.3 If the viscosity of the organic medium is too low, the silver paste is diluted and flows after printing; while if the viscosity of the organic medium is too high, the silver paste is too viscous to be printed. The drying temperatures of well-printed back-side silver electrodes are usually from 150 °C to 250 °C, so the boiling point of the solvent should not be too high in the preparation of organic media. In order to store back-side silver pastes at room temperature, the organic medium is required to not volatilize at room temperature, but it can volatilize gradually if the temperature rises slowly from 70 °C to 250 °C. Further, the efficiency of solar cells reduces as the residual ash content of the organic medium on the sintered electrode increases. Meanwhile, back-side silver electrodes do not have thin grid lines, so thixotropy of the organic media is not demanded. Thus, organic media for better performance of back-side silver pastes should have appropriate viscosity, uniform volatilization, and reduced residual ash content.
In this paper, the influence of the composition and ratio of solvents and the ratio of different solid additives on the viscosity, volatilization and residual ash content of organic media were studied. Finally, a kind of organic media with a more appropriate viscosity, more uniform volatilization and less residual ash content, was obtained and used in back-side silver pastes . The thick film morphologies and the electrical properties of back-side silver electrodes printed using the above-mentioned silver pastes were tested. The experimental results showed that the back-side silver electrode made of the organic medium whose properties were better than the others had a smoother and more dense surface, a more appropriate width and thickness, closer contact with the silicon wafers and a larger welding tension. The solar cell printed using the corresponding silver paste also had a higher photoelectric conversion efficiency.
No. | Butyl butyrate (wt%) | Diethylene glycol butylether acetate (wt%) | Tributyl citrate (wt%) | Terpineol (wt%) | Diethyl ethanedioate (wt%) | Other ingredients (wt%) | Viscosity (Pa·s) |
---|---|---|---|---|---|---|---|
1 | 80 | 0 | 0 | 0 | 0 | 20 | 0.92 |
2 | 0 | 80 | 0 | 0 | 0 | 20 | 2.45 |
3 | 0 | 0 | 80 | 0 | 0 | 20 | 22.07 |
4 | 0 | 0 | 0 | 80 | 0 | 20 | 23.24 |
5 | 0 | 0 | 0 | 0 | 80 | 20 | 1.89 |
6 | 40 | 40 | 0 | 0 | 0 | 20 | 1.48 |
7 | 40 | 0 | 40 | 0 | 0 | 20 | 3.71 |
8 | 40 | 0 | 0 | 40 | 0 | 20 | 4.01 |
9 | 40 | 0 | 0 | 0 | 40 | 20 | 1.08 |
10 | 0 | 40 | 40 | 0 | 0 | 20 | 6.45 |
11 | 0 | 40 | 0 | 40 | 0 | 20 | 6.58 |
12 | 0 | 40 | 0 | 0 | 40 | 20 | 2.05 |
13 | 0 | 0 | 40 | 40 | 0 | 20 | 13.92 |
14 | 0 | 0 | 40 | 0 | 40 | 20 | 1.84 |
15 | 0 | 0 | 0 | 40 | 40 | 20 | 2.51 |
16 | 26.67 | 26.67 | 26.67 | 0 | 0 | 20 | 2.76 |
17 | 26.67 | 26.67 | 0 | 26.67 | 0 | 20 | 1.79 |
18 | 26.67 | 26.67 | 0 | 0 | 26.67 | 20 | 1.13 |
19 | 26.67 | 0 | 26.67 | 26.67 | 0 | 20 | 2.92 |
20 | 26.67 | 0 | 26.67 | 0 | 26.67 | 20 | 1.59 |
21 | 26.67 | 0 | 0 | 26.67 | 26.67 | 20 | 1.23 |
22 | 0 | 26.67 | 26.67 | 26.67 | 0 | 20 | 5.99 |
23 | 0 | 26.67 | 26.67 | 0 | 26.67 | 20 | 2.82 |
24 | 0 | 26.67 | 0 | 26.67 | 26.67 | 20 | 2.36 |
25 | 0 | 0 | 26.67 | 26.67 | 26.67 | 20 | 4.45 |
26 | 20 | 20 | 20 | 20 | 0 | 20 | 3.07 |
27 | 20 | 20 | 20 | 0 | 20 | 20 | 2.10 |
28 | 20 | 20 | 0 | 20 | 20 | 20 | 1.93 |
29 | 20 | 0 | 20 | 20 | 20 | 20 | 3.41 |
30 | 0 | 20 | 20 | 20 | 20 | 20 | 3.92 |
31 | 16 | 16 | 16 | 16 | 16 | 20 | 3.07 |
Level | Butyl butyrate (wt%) | Diethyl ethanedioate (wt%) | Terpineol (wt%) | Tributyl citrate (wt%) |
---|---|---|---|---|
1 | 3.00 | 20.00 | 28.00 | 23.00 |
2 | 4.00 | 21.00 | 30.00 | 25.00 |
3 | 5.00 | 22.00 | 32.00 | 27.00 |
4 | 6.00 | 23.00 | 34.00 | 29.00 |
The evaporation curves of solvents in each group were obtained according to the data in the isothermal volatilization test. First, evaporation curves of five kinds of pure solvents (no. 1–5 in Table 1) are shown in Fig. 1. The ready-prepared organic media should ideally not volatilize at room temperature, but they should volatilize gradually while the temperature rises (from 70 °C to 210 °C). Therefore, we commonly selected the volatility at 150 °C to determine whether the volatility of a solvent was better or not. The volatility at 150 °C (from high to low) of the five solvents was: butyl butyrate, diethyl ethanedioate, terpineol, diethylene glycol butylether acetate and tributyl citrate. These experimental results are in accordance with the fact that the higher the boiling point of the solvent, the more difficult it is to volatilize. According to the experience we have acquired, the volatility of an organic medium made of a single solvent cannot be adjusted in the drying process. The organic medium will volatilize during the storing and printing process, which thickens the back-side of the silver paste. On one hand, if the volatility of the organic medium at a certain temperature is higher, there will be more air bubbles in the back-side silver paste, which will lead to a rougher sintered membrane and reduce the stability of the paste. On the other hand, if the volatility is lower, it takes too long for the back-side silver paste to dry. Therefore, the sintered membrane layer will be a little wet after drying and the edge of it will not be smooth, which may possibly result in more holes and poor performance of the back-side silver electrode. So mixed solvents are generally adopted to adjust the volatilization of organic media.
Volatilization of organic media composed of mixed solvents is in accordance with Henry’s law; that is, the relative content of each solvent in one mixed solvent decides the relative ratio of this mixed solvent’s vapour pressure. Therefore, the volatilization of each organic medium can be adjusted by changing the content of each solvent in the mixed solvent. By doing so, organic media will not volatilize at the room temperature under normal circumstances; however, they will volatilize gradually when the temperature increases slowly from 70 °C to 210 °C. Fig. 2 displays evaporation curves of the organic media with mixed solvents (no. 6–31 in Table 1).
As seen from Fig. 2, the volatility of the organic medium with mixed solvent no. 29 is less at low temperature and reaches 55.88 wt% at 150 °C. At the same time, the volatility also increases gradually as the temperature rises, which meets the demands for organic media in the process of production. But the evaporation curves of the organic media with other mixed solvents are not so gentle or suitable as no. 29.
On the basis of the composition of the mixed solvent no. 29, the best content range of each solvent was selected through multiple tests respectively: butyl butyrate 3–6 wt%, diethyl ethanedioate 20–23 wt%, terpineol 28–34 wt%, tributyl citrate 23–29 wt%. According to the ratio of every solvent in Table 2, an orthogonal experiment was implemented as detailed in Table 3.
No. | A | B | C | D | volatility at 150 °C (wt%) |
---|---|---|---|---|---|
Butyl butyrate | Diethyl ethanedioate | Terpineol | Tributyl citrate | ||
29-1 | 1 | 2 | 3 | 3 | 41.15 |
29-2 | 2 | 4 | 1 | 2 | 38.09 |
29-3 | 3 | 4 | 3 | 4 | 36.67 |
29-4 | 4 | 2 | 1 | 1 | 40.14 |
29-5 | 1 | 3 | 1 | 4 | 39.75 |
29-6 | 2 | 1 | 3 | 1 | 41.33 |
29-7 | 3 | 1 | 1 | 3 | 51.02 |
29-8 | 4 | 3 | 3 | 2 | 51.42 |
29-9 | 1 | 1 | 4 | 2 | 41.13 |
29-10 | 2 | 3 | 2 | 3 | 39.30 |
29-11 | 3 | 3 | 4 | 1 | 40.01 |
29-12 | 4 | 1 | 2 | 4 | 37.28 |
29-13 | 1 | 4 | 2 | 1 | 40.46 |
29-14 | 2 | 2 | 4 | 4 | 38.94 |
29-15 | 3 | 2 | 2 | 2 | 41.11 |
29-16 | 4 | 4 | 4 | 3 | 39.31 |
K1 | 162.49 | 170.76 | 169.00 | 161.94 | |
K2 | 157.66 | 170.34 | 158.15 | 171.75 | |
K3 | 168.81 | 161.34 | 170.57 | 170.78 | |
K4 | 168.15 | 154.53 | 159.84 | 152.64 | |
k1 | 40.62 | 42.69 | 42.25 | 40.49 | |
k2 | 39.42 | 42.59 | 39.54 | 42.94 | |
k3 | 42.20 | 40.34 | 42.64 | 42.70 | |
k4 | 42.04 | 38.63 | 39.96 | 38.16 | |
Range | 2.78 | 4.06 | 3.10 | 4.78 | |
Sequence | D > B > C > A | ||||
Optimal level | A3 | B1 | C3 | D2 | |
Optimal combination | A3B1C3D2 |
From Table 3, it can be seen that the effect order of solvents on the evaporation quantity of organic media at 150 °C is: tributyl citrate > diethyl ethanedioate > terpineol > butyl butyrate. The optimal combination (A3B1C3D2) of mixed solvents in the organic medium is as follows: butyl butyrate 5.00 wt%, diethyl ethanedioate 20.00 wt%, terpineol 32.00 wt%, and tributyl citrate 25.00 wt%. Meanwhile, the organic medium with the best volatilization performance has the optimal combination of mixed solvents mentioned above and is named as no. 29–17.
The evaporation quantities of the organic media (no. 29-1–29-17) were measured at different temperatures, and the evaporation curves are shown in Fig. 3. As seen from Fig. 3, the volatility of the organic medium no. 29–17 is less at low temperature and reaches 53.02 wt% at 150 °C. In the meantime, its volatility also increases gradually as the temperature rises, going beyond 80.00 wt% when the temperature reaches 210 °C. The evaporation curve of the organic medium no. 29-17 is more gentle and flat than the others and the related performance of it is also better, and so it meets the requirements for organic media in the process of production.
The type and content of solvent were kept the same with the organic medium no. 29-17, then different kinds of organic media were prepared by adjusting the content of solid additives, such as acrylic resin, phenoxy resin and ethyl cellulose. The viscosity and the residual ash content of these organic media were tested as shown in Table 4. From Table 4 we can see that the viscosity of the organic medium no. 29-17-6 is 4.36 Pa s and the residual ash content of no. 29-17-6 is 0.75 wt%. These two performance parameters above are appropriate for the application of the organic medium in back-side silver pastes. Therefore, the organic medium no. 29-17-6 is better than the others by comparing the viscosities and residual ash contents. If the viscosity of the organic medium is smaller, the silver paste will be too dilute; on the contrary, the silver paste will be too viscous when the viscosity of the organic medium is bigger. At the same time, the residual ash content of the organic medium is the lower the better, because the electrical performance of the solar cell will be reduced when the residual ash content is increased.
No. | Viscosity (Pa s) | Residual ash content (wt%) | Acrylic resin (wt%) | Phenoxy resin (wt%) | Ethyl cellulose (wt%) | |
---|---|---|---|---|---|---|
29-17-1 | 3.08 | 0.79 | 2.50 | 1.30 | 2.00 | |
29-17-2 | 3.12 | 0.93 | 3.00 | 1.80 | 2.00 | |
29-17-3 | 3.26 | 0.95 | 3.50 | 2.30 | 2.00 | |
29-17-4 | 3.76 | 0.99 | 2.50 | 1.30 | 2.40 | |
29-17-5 | 4.18 | 1.01 | 3.00 | 1.80 | 2.40 | |
29-17-6 | 4.36 | 0.75 | 3.50 | 2.30 | 2.40 | |
29-17-7 | 5.76 | 1.26 | 2.50 | 1.30 | 2.80 | |
29-17-8 | 6.64 | 1.38 | 3.00 | 1.80 | 2.80 | |
29-17-9 | 7.32 | 1.59 | 3.50 | 2.30 | 2.80 |
No. | Viscosity (Pa s) | Butyl butyrate (wt%) | Diethyl ethanedioate (wt%) | Terpineol (wt%) | Tributyl citrate (wt%) |
---|---|---|---|---|---|
a | 5.29 | 3.0 | 16.0 | 35.0 | 28.0 |
b | 4.36 | 5.0 | 20.0 | 32.0 | 25.0 |
c | 3.61 | 7.0 | 24.0 | 29.0 | 22.0 |
d | 3.02 | 9.0 | 28.0 | 26.0 | 19.0 |
As seen from Table 5, the viscosity of the organic medium reduces as the content of butyl butyrate and diethyl ethanedioate increases, while the viscosity of the organic medium increases with the content of terpineol and tributyl citrate. In short, the organic medium (b) has an optimal viscosity of 4.36 Pa s, which is the same as the previous conclusion.
Fig. 4 shows the TG curves of organic media (a–d). We can observe from Fig. 4(b) that the TG curve shows a horizontal line below 60 °C which indicates that the organic medium would not lose any weight at room temperature. The weight percentage of the organic medium (b) decreases slowly from 60 °C to 250 °C, and nearly 90 wt% of the organic medium has already volatilized before 250 °C, which satisfies the demand of the volatilization performance of organic media for the drying process. From 250 °C to 450 °C, the 9 wt% of weight loss is caused by the combustion of ethyl cellulose and other agents. At temperatures above 450 °C, the TG curve shows a horizontal line and the incinerated residue content is less than 1 wt%, resulting from the incomplete combustion of solid agents. Therefore, the organic medium (b) would avoid cracks in the surface of the back-side electrode grid line.
The TG curve of Fig. 4(a) shows a horizontal line at the higher temperature of 78 °C, which means that the organic medium (a) is more difficult to volatilize at low temperatures. It has less volatilization before 200 °C but volatilizes altogether after 200 °C because of higher amounts of terpineol and tributyl citrate. The TG curves of Fig. 4(c) and (d) show horizontal lines with lower temperature and the TG curves are both steep before 200 °C because there are higher amounts of butyl butyrate and diethyl ethanedioate in these two organic media.
The sintering surfaces of the back-side silver electrodes of solar cells SCa, SCb, SCc and SCd were observed by SEM10–12 as shown in Fig. 5. It can be seen that the surface of the back-side silver electrode of SCb is more dense, more smooth and has fewer holes; while the surfaces of the back-side silver electrodes of SCa and SCc have many holes and are not dense enough; moreover, the surface of the back-side silver electrode of SCd is more rough and has more holes than those of both SCa and SCc.
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Fig. 5 Sintering surface SEM images of the back-side silver electrodes of SCa, SCb, SCc and SCd (at 900 °C). |
The reason behind the above experimental results is that the volatilization amount of each boiling point solvent in organic media is different at the same temperature during the sintering process. The content of low boiling point solvents in the organic medium of SCa is very little, so there are fewer holes on the surface of the electrodes at low temperatures. The incidence of holes increases with the temperature rising, because the content of solvents with high boiling point in the organic medium of SCa is higher and the solvents volatilize together at the higher temperature; so there are many holes on the surface of the back-side silver electrode of SCa, as shown in Fig. 5(a). While the content of low boiling point solvents in the organic media of SCc and SCd is higher, the holes on the surface of these back-side silver electrodes increase more and more due to the low boiling point solvents volatilizing together at low temperature at the same time, as shown in Fig. 5(c) and (d). In general, the holes on the surface of the back-side silver electrodes become fewer and the electrode surface gets more dense with the decreasing content of low boiling point solvents and the increasing content of high boiling point solvents in the paste. That is to say, when the proportion of low boiling point solvents and high boiling point solvents in the organic medium is appropriate, the surface of the back-side silver electrode of the solar cell will have fewer holes and be more dense, as shown in Fig. 5(b). This phenomenon is consistent with the TG curves in Fig. 4.
Fig. 6 shows line width and cross-sectional microstructures of back-side silver electrodes of solar cells SCa, SCb, SCc and SCd. The back-side silver electrode of the solar cell SCa has a narrower grid line and the cross-sectional height of the back-side silver electrode also seems much taller, as shown in Fig. 6(a). The back-side silver electrode grid line of the solar cell SCd is wider and thinner than the others, as shown in Fig. 6(d).
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Fig. 6 Line width and cross-sectional microstructures of back-side silver electrodes of SCa, SCb, SCc and SCd (at 900 °C). |
This is because the viscosity of the organic medium (a) is bigger, so the paste made by it will be too viscous to be printed through the screen printing plate. As the viscosity of the organic medium decreases, the back-side silver paste becomes dilute and has good liquidity, which makes the paste more easily to be printed and the solid powders can be fully dispersed in the paste. But if the viscosity is too small, the silver paste will be so dilute that it will flow after being printed, and the electrode made by it will become wider and thinner, which is harmful to the electrical performance of the solar cells. By comprehensive comparison, we found that the electrode width and thickness of the solar cell SCb are most appropriate, as shown in Fig. 6(b).
Cross-sectional microstructures of the contact interface between back-side silver electrodes and silicon wafers SCa, SCb, SCc and SCd are shown in Fig. 7. As seen from Fig. 7(b), the back-side silver electrode of the solar cell SCb was closely in contact with the silicon wafer and there are fewer holes between the electrode and the silicon wafer, which will export the electronic directly and quickly. However, there are more holes between the electrodes and silicon wafers of solar cells SCa, SCc and SCd, as shown in Fig. 7(a), (c) and (d), respectively. Therefore, the back-side silver electrode of the solar cell SCb has the most excellent performance, which is in accordance with the conclusions above in Fig. 5 and 6.
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Fig. 7 Cross-sectional microstructures of the contact interface between back-side silver electrodes and silicon wafers SCa, SCb, SCc and SCd (at 900 °C). |
As seen from Fig. 8, the back-side silver electrode of SCb has the largest welding tension (7.7 N). This is because silver particles and glass powders can be mixed adequately by the organic medium (b), which makes the back-side silver pastes have better printing performance. Another reason is that the viscosity and the volatilization of organic medium (b) are both better, which make the electrodes maintain good performance in the process of high temperature sintering. The above experimental results show that the back-side silver electrodes of SCb contact much more closely with the silicon wafer, and they also have the better welding performance.
No. | Electrical performance parameters | ||||
---|---|---|---|---|---|
Voc (V) | Isc (A) | FF (%) | Rs (Ω) | Eff | |
SCa | 0.623737 | 8.614004 | 76.92045 | 0.003489 | 0.169824 |
SCb | 0.635712 | 8.726632 | 79.22516 | 0.002308 | 0.180603 |
SCc | 0.618846 | 8.816563 | 77.98797 | 0.003001 | 0.174848 |
SCd | 0.618380 | 8.829535 | 74.95213 | 0.003716 | 0.168162 |
This journal is © The Royal Society of Chemistry 2016 |