CN101999175A - 用于多晶硅发射极太阳能电池的简化背触点 - Google Patents

用于多晶硅发射极太阳能电池的简化背触点 Download PDF

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CN101999175A
CN101999175A CN2009801125961A CN200980112596A CN101999175A CN 101999175 A CN101999175 A CN 101999175A CN 2009801125961 A CN2009801125961 A CN 2009801125961A CN 200980112596 A CN200980112596 A CN 200980112596A CN 101999175 A CN101999175 A CN 101999175A
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皮特·G·博登
徐力
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Abstract

本发明涉及形成太阳能电池的触点。根据一个方案,根据本发明的叉合背接触(IBC)电池设计仅需要一个构图步骤来形成该叉合接合面(相对于其它设计的两个步骤)。根据另一方案,该背触点结构包括氮化硅或氮化的隧道电介质。其作用为一扩散屏障,因此可在高温工艺步骤期间维持该隧道电介质的性质,并可避免硼扩散通过该隧道电介质。根据另一方案,形成这些背触点的工艺不需要深的驱入扩散。

Description

用于多晶硅发射极太阳能电池的简化背触点
相关申请的交叉参考
本申请要求于2008年4月9日提交的美国临时申请No.61/043,672的优先权,在此通过参考的方式援引该专利申请的全部内容。
技术领域
本发明涉及太阳能电池,并且更明确地,涉及用于多晶硅发射极太阳能电池的所有背触点。
背景技术
在某些应用中偏好使用叉合背接触太阳能电池,因为其提供高效率(>20%),并且将电极置于背面,在此其不会阻断光线。此种电池之一商业范例是SunPower公司提供的A300电池。此电池的制造成本昂贵,因为需要许多构图步骤及两次扩散,以形成在该背侧产生n及p型区的扩散。如在此所使用的,背侧或背面等用语表示该太阳能电池与接收光线以利用该太阳能电池转换成电能的表面相对的表面的公知术语。
因此,对于具有较少构图及扩散步骤的工艺有兴趣,特别是若可利用快速热处理而非扩散管来完成热步骤。较不偏好扩散管,因为在载入和载出时薄的电池容易断裂,并且工艺缓慢。
已考虑过使用多晶硅发射极(polysilicon emitter,PE)结构来除去该深扩散。在1980年代早期,该PE电池表现为一平面型装置,并且有与其相关的一些专利文献。例如,美国专利公开案第2006-0256728号描述一种结构,其运用二氧化硅隧道氧化物,需要两个构图步骤以形成n和p型掺杂层。因为二氧化硅并非硼扩散的屏障,所以此结构仅可使用直接沉积(as-deposited)层,而无高温焙烧。这是一项缺点,因为通常需要焙烧来降低该多晶硅的表面电阻至可接受程度。
较早期的装置包括美国专利No.5,057,439,其描述一种与前述应用类似的结构,但需使用一高温步骤来穿隧该二氧化硅隧道层,因此形成一公知接合面。
据此,仍需要一种形成太阳能电池的所有背触点的方法,以克服现有技术的问题。
发明内容
本发明涉及太阳能电池的触点及其制造方法。根据一个方案,根据本发明的叉合背接触(interdigitated back contact,IBC)电池设计仅需要一个构图步骤来形成该叉合接合面(相对于其它设计的两个步骤)。根据另一方案,该背触点结构包括氮化硅或氮化的隧道电介质。其作用为一扩散屏障,因此可在高温工艺步骤期间维持该隧道电介质的性质,并可避免硼扩散通过该隧道电介质。根据另一方案,形成这些背触点的工艺不需要深的驱入扩散。
在这些及其它方案的进一步方案中,根据本发明实施例的太阳能电池包括一基板,其具有一正面及一背面;一第一触点结构,连接至形成在该基板背面上的一第一组多晶硅区;一第二触点结构,连接至形成在该基板背面上的一第二组多晶硅区,该第一及第二多晶硅区有相反的导电型;以及一隧道介电层,介于该第一及第二多晶硅区与该基板之间。
在这些及其它方案的其它进一步方案中,根据本发明的实施例,一种制造一太阳能电池的方法包括:制备一基板,该基板具有一正面及一背面;在该基板的背面上沉积一第一多晶硅层;在该基板的背面上沉积一第二多晶硅层,该第一及第二多晶硅层有相反的导电型;以及执行一退火,其使该第一及第二沉积多晶硅层在该基板的背面上形成各自的第一及第二多晶硅区。
附图说明
在参照附图阅读下述本发明的具体实施例的描述后,对本领域技术人员来说本发明的这些及其它方案和特征结构会变得显而易见,其中:
图1A和图1B示出根据本发明具有背触点的太阳能电池结构的两个实施例。
图1C示出可在图1A和图1B实施例内完成的背面的金属化的视图。
图2A和图2B分别示出图1A和图1B的结构的工艺流程。
具体实施方式
现在将参考附图详细描述本发明,提供这些附图作为说明范例以使本领域技术人员能够实施本发明。显然,下面的附图及实施例并无意将本发明范围限制在单个实施例中,而是借助互换某些或所有描述出或显示出的组件,其它实施例是可能的。此外,当可利用已知部件部分或完全实施本发明的某些组件时,仅会描述此种已知部件对本发明的理解必要的部分,并省略此种已知部件的其它部分的详细描述,以避免混淆本发明。在本说明书中,不应将示出单个部件的实施例视为限制性;反之,本发明意欲包括包括多个相同部件的其它实施例,反之亦然,除非在此以其它方式明确申明。此外,申请人不欲说明书或权利要求范围内的任何用词被归类为具有罕见或特别含义,除非如此明确提出。另外,本发明包括在此借助说明方式引用的已知部件的目前及未来的已知等效物。
除了其它的之外,本发明认定使用氮化硅或氮化的隧道电介质作用为扩散屏障,从而可在高温工艺步骤期间维持该隧道电介质的性质,并可避免硼扩散通过该隧道电介质。此种技术的实施例在共同审查中的美国专利申请案(AM-13306)中描述,其内容在此借助引用其全文的方式并入本文中。
图1A和图1B示出根据本发明实施例的太阳能电池的两个实施例。图1A的实施例较简单,但连接至该n型多晶硅的触点需要相当窄的线宽(假设基板102是n型硅;就p型基板而言,该掺杂是相反的)。此实施例的工艺流程在图2A示出。图1B的实施例具有相同数量的构图步骤,但使用一额外的回流退火,以能使用较宽触点接线。此实施例的工艺流程在图2B中示出。
图1C示出从该模块的背触点表面的上方观看的背触点110接线,并示出连接至该n型及p型多晶硅的这些接线110是如何叉合的。在此实施例中,这些触点接线110相对于该太阳能电池的最长尺寸纵向延伸,而n型及p型触点彼此平行且交错延伸。如进一步所示,这些n型及p型触点接线均连接至常见的各自总线结构。本领域技术人员会通晓此类触点结构,并在经过本公开的教示之后会了解如何将其结合本发明实施。此外,图1A和图1B的结构的细节可从下面的工艺流程描述而变得更加显而易见。
参照图2A和图2B的工艺流程,在两个实施例中,该电池的正面在步骤S202/S252中被织构化(textured),并在步骤S204/S254中施加例如二氧化硅或隧道氧化物及多晶硅的钝化介电涂层112。此类钝化方法在本领域中是公知的。一般接着添加例如78nm的四氮化三硅的抗反射涂层(未示出)。
然后开始背面处理。在图2A的实施例中,接下来在步骤S206形成隧道电介质104。因为欲阻止硼扩散,其包括一氮化层,通常是8-12埃厚。可使用许多制造此层的方法,例如在制造MOS IC中制造这种层的方法。然后在步骤S208沉积一层p型多晶硅106。此层的掺杂是约1-2x1019/cm3的硼。该层106约500-2000埃厚。然后在步骤S210中,使用网印或喷墨法,在接线中施加例如磷酸的n型磷掺杂涂料。这些区域的宽度必须小于少数载流子的扩散长度,其在1毫米等级。在步骤S212利用一1000℃持续30秒等级的快速热退火来驱入磷,形成与p型掺杂区106叉合的n型掺杂区108。然后可在步骤S214中利用公知方法构图并形成触点110。
图2B的实施例的工艺流程在步骤S256依循图2A实施例的流程,除了n型多晶硅108是在步骤S258使用例如与步骤S210中者类似的技术而沉积外。然后在步骤S260中于该背面上施加具有硼掺杂质的旋涂玻璃(spin-onglass,SOG)114。在步骤S262中于该p型SOG内开孔,其界定出将维持n型的区域108。在步骤S264中,该SOG在1000℃下退火30秒以驱入硼,形成该p型掺杂的区域106。可如步骤S266中所示选择性使用一较低温的第二退火,以横向流动该玻璃,而使其延伸超过该掺杂边缘,以最小化短路(shorting)。实际上,此退火在与该第一退火相同的系统中借助降低温度来完成。最后,在步骤S268利用公知方法构图并形成触点110。
虽然本发明已参考其较佳实施例具体描述,但可在不脱离本发明的精神及范围下在形式及细节上做改变及修改对于本领域技术人员而言是显而易见的。所附权利要求意欲包括此类改变及修改。

Claims (15)

1.一种太阳能电池,包括:
一基板,其具有一正面及一背面;
一第一触点结构,连接至形成在该基板背面上的一第一组多晶硅区;
一第二触点结构,连接至形成在该基板背面上的一第二组多晶硅区,该第一及第二多晶硅区有相反的导电型;以及
一隧道介电层,介于该第一及第二多晶硅区与该基板之间。
2.如权利要求1所述的太阳能电池,其中所述隧道介电层包括一氮化物层。
3.如权利要求1所述的太阳能电池,其中所述第一及第二触点结构彼此叉合。
4.如权利要求1所述的太阳能电池,还包括形成在该基板的正面上的一钝化电介质。
5.一种制造一太阳能电池的方法,包括:
制备一基板,该基板具有一正面及一背面;
在该基板的背面上沉积一第一多晶硅层;
在该基板的背面上沉积一第二多晶硅层,该第一及第二多晶硅层具有相反的导电型;以及
执行一退火,其使该第一及第二沉积的多晶硅层在该基板的背面上形成各自的第一及第二多晶硅区。
6.如权利要求5所述的方法,还包括:
在执行该退火步骤之前形成一隧道介电层,该隧道介电层介于该第一及第二多晶硅区与该基板之间,其中该隧道介电层由阻断从这些多晶硅区至该基板的扩散的材料构成。
7.如权利要求6所述的方法,其中所述隧道介电层包括一氮化物层。
8.如权利要求5所述的方法,其中所述沉积该第一多晶硅层的步骤包括在该背面上沉积一p型多晶硅材料薄层,且其中沉积该第二多晶硅层的步骤包括在该第一多晶硅层上构图n型多晶硅材料的接线。
9.如权利要求5所述的方法,其中所述沉积该第一多晶硅层的步骤包括在该背面上构图n型多晶硅材料的接线,且其中沉积该第二多晶硅层的步骤包括在该背面及该第一多晶硅层上沉积一p型多晶硅材料层,并且在该第二多晶硅层内开孔,以暴露出该第一多晶硅层。
10.如权利要求9所述的方法,其中所述p型多晶硅材料包括一旋涂玻璃(SOG)。
11.如权利要求9所述的方法,其中所述退火步骤包括一驱入退火,后接一回流退火。
12.如权利要求11所述的方法,其中所述驱入退火和回流退火均使用相同退火执行。
13.如权利要求5所述的方法,还包括:
形成第一及第二触点结构,分别接触该第一及第二多晶硅区。
14.如权利要求13所述的方法,其中所述第一及第二触点结构彼此叉合地形成。
15.如权利要求5所述的方法,还包括在该基板正面上形成一钝化电介质。
CN2009801125961A 2008-04-09 2009-04-09 用于多晶硅发射极太阳能电池的简化背触点 Pending CN101999175A (zh)

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US61/043,672 2008-04-09
PCT/US2009/040063 WO2009126803A2 (en) 2008-04-09 2009-04-09 Simplified back contact for polysilicon emitter solar cells

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