27%-efficiency silicon heterojunction cell with 98.6% cell-to-module ratio driving new momentum towards the 29.4% limit

Zhigang Xie (), Haijiang Lu, Guangtao Yang, Zhan Gao, Kun Zhu, Yongheng Wang, Zibo Meng, Cong Guo, Haiyang Pei, Qianqian Jiang, Hongwei Li, Shu Zhang, Haiyuan Chu, Xue Chen, Yifeng Chen () and Jifan Gao ()
Additional contact information
Zhigang Xie: Trina Solar
Haijiang Lu: Trina Solar
Guangtao Yang: Trina Solar
Zhan Gao: Trina Solar
Kun Zhu: Trina Solar
Yongheng Wang: Trina Solar
Zibo Meng: Trina Solar
Cong Guo: Trina Solar
Haiyang Pei: Trina Solar
Qianqian Jiang: Trina Solar
Hongwei Li: Trina Solar
Shu Zhang: Trina Solar
Haiyuan Chu: Trina Solar
Xue Chen: Trina Solar
Yifeng Chen: Trina Solar
Jifan Gao: Trina Solar

Nature Communications, 2025, vol. 16, issue 1, 1-11

Abstract: Abstract Silicon heterojunction technologies based on both-sided nanocrystalline contact layers currently offer the best passivation for commercial solar cells. We further improved this structure with rear-side polishing and progressive RF/VHF PECVD film deposition methods for doping layers, enabling high-pace mass production while maintaining notable passivation quality. Following this optimization, a certified cell efficiency above 27.0% and a fill factor of 87.06% are achieved on a large-area rectangular wafer (210 mm half-cell). With a multibusbar round-ribbon (smart-wire) design, we demonstrate a certified module efficiency of 25.44% and a module fill factor above 86% (for the first time) under a masked area of 1.63 m2, which is on par with the current world record module efficiency typically held by back-contact cell structures. Remarkably, the high VOC × FF value of 0.652–0.655 V was backed by a solid cell-to-module ratio of 98.6%. With respect to silicon single-junction solar cells, this work demonstrates significant progress toward Auger recombination dominance, a factor that is more critical than reducing front-side optical shading to approach the 29.4% efficiency limit.

Date: 2025
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DOI: 10.1038/s41467-025-64465-0

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