Laser-Induced Backward Transfer of Light Reflecting Zinc Patterns on Glass for High Performance Photovoltaic Modules

Commercially available photovoltaic (PV) modules typically consist of individual silicon half-cut cells that are electrically interconnected. This interconnection method results in gaps between the cells, which do not contribute to the overall PV output power. One approach to enhance the cell-to-module power ratio is the placement of white, diffuse reflecting plastic material within these gaps. Conventionally, the process of generating reflective patterns involves several discrete steps, including film deposition, resist patterning, etching, and resist stripping. This study presents an innovative single-step procedure for the direct deposition of zinc reflective patterns onto glass substrates using laser-induced backward transfer (LIBT) and a nanosecond pulsed laser system. The process successfully produced lines and squares, demonstrating its versatility in achieving diverse geometric patterns under ambient atmospheric pressure and room temperature conditions. The evaluation of the transferred patterns included an examination of geometric dimensions and surface morphology using a 3D microscope and scanning electron microscopy (SEM) analysis at the air/Zn interface. Additionally, the thickness of the zinc film and its adhesion to the glass substrate were quantified. The angular reflectance at a wavelength of 660 nm for both the glass/Zn and air/Zn interfaces was measured.