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There is a high interest for having power on demand through ultra-light, highly-efficient, and flexible photovoltaic systems. Currently, the most efficient technologies are based on a rigid format using single crystal materials and the flexible ones are based on not so efficient polycrystalline or amorphous materials. We present a new method to produce ultrathin and flexible solar cells made of single crystal crystalline silicon. We propose the use of ultrathin (<20 μm) segmented silicon (less than 1 mm in diameter) created with microsystems tools and techniques. The processing of the cells, including passivation and metallization, was done on standard thickness wafers with standard tools. The cell design is a back, point contact, interdigitated cell. The finished cells were transferred onto a 100 μm thick flexible glass substrate with patterned metal traces. Interconnections between the cell and substrate were formed with a solder reflow step. The first demonstration module prototypes transferred and connected 474 micro cells all at once. The conversion efficiency of the mini module was 12.4% with a total Voc = 7.8V. The principle shown here can be used to transfer the cells onto other flexible substrates (i.e. polymers) and achieve an ultra-light, highly efficient, and flexible photovoltaic system.

Ultrathin and Flexible Single Crystal Silicon Mini-Modules