JP6937402B2 - 積層薄膜の製造方法、太陽電池の製造方法及び太陽電池モジュールの製造方法 - Google Patents
積層薄膜の製造方法、太陽電池の製造方法及び太陽電池モジュールの製造方法 Download PDFInfo
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- JP6937402B2 JP6937402B2 JP2020033237A JP2020033237A JP6937402B2 JP 6937402 B2 JP6937402 B2 JP 6937402B2 JP 2020033237 A JP2020033237 A JP 2020033237A JP 2020033237 A JP2020033237 A JP 2020033237A JP 6937402 B2 JP6937402 B2 JP 6937402B2
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- photoelectric conversion
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- H01L31/0248—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies
- H01L31/0256—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by the material
- H01L31/0264—Inorganic materials
- H01L31/0328—Inorganic materials including, apart from doping materials or other impurities, semiconductor materials provided for in two or more of groups H01L31/0272 - H01L31/032
- H01L31/0336—Inorganic materials including, apart from doping materials or other impurities, semiconductor materials provided for in two or more of groups H01L31/0272 - H01L31/032 in different semiconductor regions, e.g. Cu2X/CdX hetero- junctions, X being an element of Group VI of the Periodic Table
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- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
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- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
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Description
第1実施形態は、積層薄膜と積層薄膜の製造方法に関する。図1に積層薄膜100の断面概念図を示す。図1に示す積層薄膜100は、第1透明電極1、第1透明電極1上に形成された光電変換層2とを有する。
第2実施形態は、太陽電池と太陽電池の製造方法に関する。図5に太陽電池200の断面概念図を示す。図5に示す太陽電池200は、第1透明電極1、光電変換層2、n型層3、第2透明電極4とを有する。第1透明電極1と光電変換層2が積層した積層体は、第1実施形態の積層薄膜100である。光電変換層2は、第1透明電極1とn型層3の間に配置される。n型層3は、光電変換層2と第2透明電極4との間に配置される。光電変換層2とn型層3は、pn接合を形成する。第1透明電極1と光電変換層2は、第1実施形態と共通するためその説明は省略される。例えば、n型層3と第2透明電極4の間などに図示しない中間層を配置することも出来る。光電変換層2よりもナローバンドギャップな光電変換層を有する太陽電池(例えば、Si太陽電池)を第2実施形態の太陽電池200と積層させて多接合型太陽電池とすることが出来る。
第3実施形態は、太陽電池モジュールに関する。図7に太陽電池モジュール300の一部の断面模式図を示す。図7の太陽電池モジュール300は、トップセル301とボトムセル302を有する。なお、太陽電池モジュール300としては、図8の断面模式図に示すようにボトムセル302を省略した実施形態の太陽電池200(図7のトップセル301)を有する単接合型の太陽電池モジュール304とすることもできる。トップセル301の太陽電池には、第2実施形態の太陽電池200を用いる。トップセル301とボトムセル302は、図示しない接着層で接続されていることが好ましい。
第5実施形態は太陽光発電システムに関する。第4実施形態の太陽電池モジュール300は、第5実施形態の太陽光発電システムにおいて、発電を行う発電機として用いることができる。実施形態の太陽光発電システムは、太陽電池モジュールを用いて発電を行うものであって、具体的には、発電を行う太陽電池モジュールと、発電した電気を電力変換する手段と、発電した電気をためる蓄電手段又は発電した電気を消費する負荷とを有する。図10に実施形態の太陽光発電システム400の構成概念図を示す。図10の太陽光発電システムは、太陽電池モジュール401(300)と、電力変換装置402と、蓄電池403と、負荷404とを有する。蓄電池403と負荷404は、どちらか一方を省略しても良い。負荷404は、蓄電池403に蓄えられた電気エネルギーを利用することもできる構成にしてもよい。電力変換装置402は、変圧や直流交流変換などの電力変換を行う回路又は素子を含む装置である。電力変換装置402の構成は、発電電圧、蓄電池403や負荷404の構成に応じて好適な構成を採用すればよい。
チャンバー内で白板ガラス基板上に、裏面側の第1透明電極としてITO透明導電膜、その上にSbドープしたSnO2透明導電膜を堆積する。透明な第1透明電極が形成された部材を1×10−3[Pa]以下になるまでチャンバー内を減圧する。次に、酸素とアルゴンガスの雰囲気中でRFマグネトロンスパッタリング法により500℃で加熱して光電変換層として亜酸化銅化合物を成膜する。このとき酸素分圧は0.035[Pa]で堆積速度は、0.04[μm/min]で、膜厚は2μmである。室温でスパッタリング法によりp−亜酸化銅層上にn型のZn0.8Ge0.2Oxを堆積し、その後、表面側の第2透明電極としてAZO透明導電膜を堆積する。また表面側の第2透明電極堆積時には亜酸化銅の酸化を抑制するため室温で成膜しているが、例えばAZOを用いる事により室温でも低抵抗な膜が得られる。AZOのターゲットは、ZnOに対してAl2O3の割合が2wt%とした。反射防止膜を付けて光取り込み量を改善する場合は、その上に反射防止膜として例えば、MgF2を堆積する。
チャンバー内で白板ガラス基板上に、裏面側の第1透明電極としてITO透明導電膜、その上にSbドープしたSnO2透明導電膜を堆積する。透明な第1透明電極が形成された部材を1×10−3[Pa]以下になるまでチャンバー内を減圧する。次に、酸素とアルゴンガスの雰囲気中でDCマグネトロンスパッタリング法により450℃で加熱して光電変換層として亜酸化銅化合物を成膜する。このとき酸素分圧は0.15[Pa]で堆積速度は、0.2[μm/min]で、光電変換層の膜厚は2μmである。室温でスパッタリング法によりp−亜酸化銅層上にn型のZn0.8Ge0.2Oxを堆積する。その後、表面側の第2透明電極としてAZO透明導電膜を堆積する。AZOのターゲットは、ZnOに対してAl2O3の割合が2wt%とした。その上に反射防止膜としてMgF2を堆積する。
堆積速度を0.032[μm/min]とし、酸素分圧を0.0166[Pa]とし、膜厚を2μmとしたこと以外は実施例1と同様に太陽電池を作製する。
堆積速度を0.017[μm/min]とし、酸素分圧を0.025[Pa]とし、膜厚を2μmとしたこと以外は実施例1と同様に太陽電池を作製する。
490℃でスパッタリングして3μm厚のCu2O膜を成膜したこと以外は実施例1と同様に太陽電池を作製する。
350℃でスパッタリングして500nm厚のCu2O膜を成膜したこと以外は実施例1と同様に太陽電池を作製する。
300℃でスパッタリングして1.5μm厚のCu2O膜を成膜したこと以外は実施例1と同様に太陽電池を作製する。
チャンバー内で白板ガラス基板上に、裏面側の第1透明電極としてITO透明導電膜、その上にSbドープしたSnO2透明導電膜を堆積する。透明な第1透明電極が形成された部材を1×10−3[Pa]以下になるまでチャンバー内を減圧する。次に、酸素とアルゴンガスの雰囲気中でRFマグネトロンスパッタリング法により500℃で加熱して光電変換層として亜酸化銅化合物を成膜する。このとき酸素分圧は0.009[Pa]で堆積速度は、0.04[μm/min]で、光電変換層の膜厚は2μmである。室温でスパッタリング法によりp−亜酸化銅層上にn型のZn0.8Ge0.2Oxを堆積する。その後、表面側の第2透明電極としてAZO透明導電膜を堆積する。また表面側の第2透明電極堆積時には亜酸化銅の酸化を抑制するため室温で成膜しているが、例えばAZOを用いる事により室温でも低抵抗な膜が得られる。AZOのターゲットは、ZnOに対してAl2O3の割合が2wt%とした。その上に反射防止膜としてMgF2を堆積する。
堆積速度を0.01[μm/min]とし、酸素分圧を0.034[Pa]とし、膜厚を580nmとしたこと以外は実施例1と同様に太陽電池を作製する。
堆積速度を0.01[μm/min]とし、酸素分圧を0.034[Pa]とし、膜厚を2μmとしたこと以外は実施例1と同様に太陽電池を作製する。
堆積速度を0.017[μm/min]とし、酸素分圧を0.034[Pa]とし、膜厚を500nmとしたこと以外は実施例1と同様に太陽電池を作製する。
堆積速度を0.0325[μm/min]とし、酸素分圧を0.0147[Pa]とし、膜厚を650nmとしたこと以外は実施例1と同様に太陽電池を作製する。
堆積速度を0.0333[μm/min]とし、酸素分圧を0.0035[Pa]としたこと以外は実施例1と同様に太陽電池を作製する。
室温でスパッタリングしてCu2O膜を成膜したこと以外は実施例1と同様に太陽電池を作製する。
200℃でスパッタリングしてCu2O膜を成膜したこと以外は実施例1と同様に太陽電池を作製する。
SbドープしたSnO2透明導電膜を堆積せずにITO膜上に500℃でスパッタリングしてCu2O膜を成膜すると基板が変形したため、Cu2O膜の成膜を中止した。
明細書中、一部の元素は、元素記号のみで表している。
Claims (9)
- 基板と前記基板上に第1透明電極が成膜された基材の前記第1透明電極上に銅を主成分とするターゲットを用いて酸素分圧0.01[Pa]以上4.8[Pa]以下の雰囲気でスパッタすることによって光電変換層を成膜する工程を含み、
前記光電変換層の成膜において、前記酸素分圧が上記の範囲内であることを満たし、かつ、堆積速度をd[μm/min]とするとき、前記酸素分圧が0.5×d[Pa]以上1.5×d[Pa]以下であり、
前記光電変換層の成膜において、前記基材の温度が300℃以上600℃以下である積層薄膜の製造方法。 - 前記光電変換層の成膜において、前記基材の温度が350℃以上550℃以下であることを満たす請求項1記載の積層薄膜の製造方法。
- 前記光電変換層の成膜において、前記酸素分圧が1.5×10+9×e(−30000/スパッタ温度[K])以上である請求項1又は2に記載の積層薄膜の製造方法。
- 前記光電変換層の成膜において、前記堆積速度は、0.02[μm/min]以上4[μm/min]以下である請求項1ないし3のいずれか1項に記載の積層薄膜の製造方法。
- 前記光電変換層の成膜において、堆積速度をd[μm/min]とするとき、前記酸素分圧が0.55×d[Pa]以上1.4×d[Pa]以下である請求項1ないし4のいずれか1項に記載の積層薄膜の製造方法。
- 前記光電変換層は、亜酸化銅を主体とするp型の化合物半導体層である請求項1ないし5のいずれか1項に記載の積層薄膜の製造方法
- 前記第1透明電極は、酸化スズを含む請求項1ないし6のいずれか1項に記載の積層薄膜の製造方法。
- 請求項1ないし7のいずれか一項に記載の積層薄膜の製造方法で積層薄膜を製造する太陽電池の製造方法。
- 請求項1ないし7のいずれか一項に記載の積層薄膜の製造方法で積層薄膜を製造する太陽電池モジュールの製造方法。
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