Interconnection Technology and Reliability Testing for III-V Solar Cells and Modules

At our Concentrator Technology Evaluation Center (Con-TEC), we develop assembly and interconnection technologies as well as manufacturing processes for advanced photovoltaic systems. Our work covers applications ranging from concentrator photovoltaics (CPV) and thermophotovoltaics to optical power transfer and dense array receivers for CPV tower power plants.

A particular focus is on integrating high-performance components into robust systems. Under highly concentrated radiation, extreme thermal and mechanical stresses occur, so that reliability is largely determined by the quality of the assembly and interconnection technology. In particular, the thermal coupling of the components, the stability of the interconnection points , and the long-term durability of materials and optical components are crucial for superior performance and  a long service lifetime.

We develop scalable manufacturing processes across industrial value chains – from assembly design through high-precision assembly and bonding to module and system integration. Our infrastructure enables the production of prototypes and small batches under near-industry conditions, as well as the evaluation of new materials, designs, and processes.

We verify the reliability of our systems through comprehensive accelerated aging tests and detailed material and component characterization. Combined with modeling and simulation, this yields a deep understanding of degradation mechanisms, which is specifically applied to the optimization of designs and processes.

In this way, we support our partners in transforming innovative high-performance components into durable, economically producible products.

Our R&D Services on the Topic "Interconnection Technology and Reliability Testing for III-V Solar Cells and Modules" Include:

Assembly and Interconnection Technology

  • Development of highly reliable interconnect and packaging concepts
  • Integration of III-V components onto substrates and printed circuit boards
  • Process development for soldering, adhesive bonding, wire bonding, and hybrid contacts

Manufacturing & Scaling

  • Production-oriented process development (including panel-based approaches)
  • Prototype and small-batch production at Con-TEC
  • Inline and offline quality assurance

Reliability & Aging

  • Accelerated aging tests (temperature, humidity, UV, cycles)
  • Investigation of thermo-mechanical stresses under high heat flux density
  • Lifetime models and degradation analysis

Characterization & Diagnosis

  • Electrical, mechanical, and optical analysis of assemblies
  • Material analysis and root cause analysis
  • Development of quality assurance strategies

Modeling & Design Support

  • Thermo-mechanical simulation (FEM, CFD)
  • Multiphysics coupling of optical, electrical, and thermal effects
  • Design for reliability

R&D Infrastructure

This infrastructure is available to us at Fraunhofer ISE for our research and development activities:

 

Center for High Efficiency Solar Cells

We test and optimize advanced PV technologies in more than 1000 m² of state-of-the-art clean room and laboratory space. Innovative processes and technologies are researched in this center for future use in industry, including wet-chemical processes, photo and laser lithography, nanoimprint laboratory, vapor deposition of metals and dielectrics.

 

CalLab PV Cells

The accredited calibration laboratory CalLab PV Cells at Fraunhofer ISE offers high-precision, reproducible calibrations and measurements of all types of solar cells according to international standards, for example, spectral responsivity/quantum efficiency, reflectance, current-voltage measurements, especially under variable spectra and intensities, various broadband and laser light sources as well as filters are available.

 

Concentrator Technology Evaluation Center Con-TEC

Con-TEC has a wide range of assembly and connection technologies available for the development and assembly of customized modules and packages. We test components and production processes with a focus on reliability and material analysis. We develop prototypes and produce small series to evaluate new components, designs and processes.

 

Lab Structuring and Photonics

We develop solutions based on micro- and nanostructures for solar cells and other photovoltaic components such as photovoltaic cells for transmitting power using laser light, but also for related components such as LEDs.

Selected Reserach-Projects

 

50 Prozent

Monolithic III-V Multi-Junction Solar Cells with More than 50 % Efficiency under Concentrated Irradiation

 

micro-CPV

Development of a Highly Concentrating CPV Module Based on Modern Micro-Production Technology

 

H2Demo

Development of Demonstrators for Direct Solar Water Splitting

 

HIPERION

Hybrid Photovoltaics for Efficiency Record using Integrated Optical Technology

 

QuintuMod

Development of a Low-cost and High Efficient Solar Module Using a Solar Cell with 5-pn Junctions

 

HyCon

Solar Hydrogen Generation Using a HyCon System

 

PoTaSi

Demonstration of the Potential of Monolithic Tandem Solar Cells Made of III-V Semiconductors and Silicon