Optimization of capillary suspension silver pastes for enhanced metallization in silicon solar Cells: A comparative analysis of Screen-Printing and pattern transfer printing

•A novel metallized silver paste with a capillary suspension structure has been developed for use in the front of solar cells. It is suitable for screen printing and laser pattern transfer technology.•In comparison to previous transfer results, it has a larger aspect ratio of 0.63. In contrast to the conventional commercial silver paste, the transfer power is diminished by 80–100 W.•The silver paste in question exhibits higher Jsc and lower line resistance in actual production. The results of the simulation demonstrate that the cells exhibit enhanced electrical performance. With the increase in the use of crystalline silicon solar cells, it is necessary for solar cells to achieve finer and higher pre-metallization finger lines. The application of capillary suspension can alter the paste from a weakly elastic state to a highly elastic or even gel-like behavior. The preparation of a frontal silver paste based on a capillary suspension is beneficial in adjusting the rheological properties of the silver paste over a wider range. Two distinct printing methods were employed: screen-printing and laser-pattern transfer printing (PTP). Combined with the results of material, rheology and printing, the optimization of capillary suspended silver paste was explored. This article mainly introduces the elements of silver paste formation in capillary suspension and the effects of PTP technology. The metalized finger line achieved an aspect ratio of 0.63 and a transfer yield of 96 % through PTP. Compared to commercial silver paste for comparison, the transfer power is reduced by 80–100 W while achieving good transfer. It reduces the line resistance of the cell and increases the short-circuit current density (Jsc). Following the simulation of the electrical performance of the cells’ post-transfer, there was observed to be an improvement in Jsc, Voc, and Eta in comparison to the performance of commercial silver paste.