Kentucky Patent of the Month – June 2025
A new copper-based paste developed by Bert Thin Films, Inc. could significantly slash the manufacturing cost of solar panels. The invention tackles a long-standing industry challenge by allowing cheaper, abundant copper to replace expensive silver in solar cells without requiring costly changes to production lines. This innovation, detailed in U.S. Patent Application No. 20250212531, titled ‘Pastes for solar cells, solar cells, and methods of making same’, could boost razor-thin profit margins for solar manufacturers.
Overcoming Copper’s Challenges
For years, the solar industry has sought to replace silver to reduce expenses. While copper is an ideal low-cost alternative with comparable conductivity, its use has been plagued by problems. Copper tends to degrade silicon solar cells and oxidizes easily, which complicates manufacturing. Previous solutions like electroplating required significant capital investment in new equipment and complex processes, negating the material cost savings.
An Innovative ‘Plug-and-Play’ Solution
The patented technology is a conductive paste that can be screen-printed using the same equipment as traditional silver pastes. The unique formula blends copper particles with antimony oxide and other metal nanoparticles in an organic vehicle. When heated during manufacturing, the paste forms a stable, highly conductive layer. This process cleverly avoids the need for the separate diffusion barriers and protective capping layers required by other copper-based methods, representing a major step forward in making solar energy more affordable.
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