Increasing the Efficiency of Solar Cells By Transfer of Solder

Abstract

Embodiments relate to thickening a contact grid of a solar cell for increased efficiency. A mold containing soldering material is heated. The mold is aligned with the contact grid such that the soldering material is in physical contact with the contact grid. The mold is re-heated, transferring the solder material from the mold to the contact grid to create a thickened contact grid.

We claim: 
     
         1 . A solar cell, prepared by a process comprising the steps of:
 for a first body comprising a first mold, the first mold comprising at least one hollowed out area containing a solder material, heating the first body such that the solder material softens and forms within the hollowed out area;   aligning the first body with a second body, the second body comprising a contact grid with a first thickness in communication with a diode such that the solder material is in physical contact with the contact grid;   re-heating the first body such that the solder material liquefies and is transferred from the first body to the second body; and   soldering the solder material with the contact grid of the second body, including increasing the first thickness of the contact grid to a second thickness.   
     
     
         2 . The solar cell of  claim 1 , prepared by a process further comprising forming a contact grid with a third thickness greater than the second thickness, including for a third body comprising a second mold, the second mold comprising at least one hollowed out area containing a solder material, heating the second body such that the solder material softens and forms within the hollowed out area;
 aligning the third body with the second body such that the solder material is in physical contact with the contact grid;   re-heating the third body such that the solder material liquefies and is removed from the third body; and   soldering the solder material with the contact grid of the second body including increasing the contact grid thickness of the second body to a third thickness after the soldering.   
     
     
         3 . The solar cell of  claim 1 , wherein the mold is comprised of glass. 
     
     
         4 . The solar cell of  claim 1 , wherein the solder material is lead-free. 
     
     
         5 . The solar cell of  claim 1 , wherein the contact grid includes a landing area, and further comprising placing the solder in contact with the landing area when aligning the first body with the second body.