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Scientists at the Fraunhofer Institute for Solar Energy Systems ISE have succeeded in reducing the silver consumption of TOPCon solar cells to 1.1 milligrams per watt peak. Currently, TOPCon solar cells require an average of 10 to 12 milligrams of silver per watt peak. To the reduction, they tested an electroplating-based inline metallization process on pilot systems developed by RENA Technologies GmbH. By combining ultrashort UV laser structuring with the electrochemical deposition of nickel, copper, and silver, the research team produced M10-sized TOPCon solar cells with an efficiency of 24 percent. Compared to PERC solar cells, TOPCon solar cells have higher silver consumption, hence solar cell manufacturers are under particular cost pressure to reduce it.

Steel production generates large quantities of so-called “furnace gases,” which are rich in hydrogen and carbon oxides. In the Carbon2Chem® project, partners from industry and research are investigating the material utilization of these gases. The Fraunhofer Institute for Solar Energy Systems ISE demonstrated the conversion of purified steel mill exhaust gases into methanol in a mini-plant over a period of more than 5,000 hours. Modeling the process in a digital twin of the plant helped researchers optimize it and significantly increase productivity. The simulation platform developed can now also be used for other applications, such as the production of jet fuels.

ISC Konstanz and the Fraunhofer Institute for Solar Energy Systems ISE have conducted an analysis of the market situation for PV manufacturing equipment on behalf of the VDMA. The study forecasts that the global annual capital expenditure (CAPEX) for PV manufacturing equipment is projected to rise from 16.6 billion dollars in 2025 to 43.8 billion dollars by 2035, resulting in a cumulative global market volume of USD 250-300 billion in the next ten years. The study provides a comprehensive overview of global PV manufacturing, key technological trends, and the competitiveness of European machinery and equipment manufacturers.

Charging infrastructure for battery-powered heavy-duty and passenger transport is crucial for a successful transportation transition. The trend here is toward higher charging power and, consequently, higher charging currents and voltages. The collaborative project “HV-MELA-BAT” therefore developed the power electronic converters required for XXL charging, as well as a con-tact system for high currents and voltages. Thanks to a high switching frequency, the isolated DC/DC converter achieves a volumetric power density of 9 kW/l while maintaining a record-breaking efficiency of 99.26 percent. A buffer storage unit was integrated to ensure full charging power even at power-limited grid connection points.

A consortium of scientists from the Fraunhofer Institute for Solar Energy Systems ISE and Smart Battery Solutions GmbH succeeded in replacing the steel connectors used to interconnect battery cells with copper during resistance projection welding. In doing so, the team demonstrated something that had long been considered impossible in the battery industry: Until now, battery manufacturers looking to switch to more powerful, copper-interconnected batteries had to replace their projection welding systems with laser welding systems.