TWI549311B - 單一接面光伏電池 - Google Patents

單一接面光伏電池 Download PDF

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TWI549311B
TWI549311B TW100105725A TW100105725A TWI549311B TW I549311 B TWI549311 B TW I549311B TW 100105725 A TW100105725 A TW 100105725A TW 100105725 A TW100105725 A TW 100105725A TW I549311 B TWI549311 B TW I549311B
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semiconductor substrate
photovoltaic cell
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史蒂芬Ｗ 貝戴爾
諾瑪Ｅ 索莎 克蒂斯
基斯Ｅ 佛傑
蒂凡卓 沙達那
大福 夏杰迪
布蘭特Ａ 渥卡瑟
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萬國商業機器公司
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Description

單一接面光伏電池 【相關申請案參照】
此申請主張2009年6月9日申請的美國臨時申請號61/185,247之效益。此申請亦關於律師備審案件號YOR920100056US1、YOR920100058US1、YOR920100060US1及FIS920100005US1，每件皆讓與國際商業機器公司(International Business Machines Corporation，IBM)並皆於同一天申請為即時申請，該案全文以引用方式併入本文中。
本發明係關於使用應力誘發基板剝離的半導體基板製造。
成本限制常排除所有化合物半導體基板之使用，但最需要高技術的光伏(Photovoltaic，PV)應用(諸如衛星與空間型PV系統)如化合物半導體基板常係相對昂貴。因此需減少在製程期間的化合物基板之廢料。範例化合物半導體基板係砷化鎵(gallium arsenide，GaAs)，其在高效率多接面電池中可用作該基底基板。GaAs之高光學吸收確保少於大約10微米厚度之GaAs即足以從該太陽光譜獲取光子；該剩餘的基板材料用作載體，且對於PV電池之作用而言係不必要。
在一個態樣中，用於形成單一接面光伏電池的方法包括形成摻雜物層於半導體基板之表面上；擴散該摻雜物層進入該半導體基板以形成該半導體基板之摻雜層；形成金屬層於該摻雜層上方，其中在該金屬層中的拉伸應力係配置成在該半導體基板中造成裂紋(fracture)；從該半導體基板該裂紋處去除半導體層；以及使用該半導體層形成該單一接面光伏電池。
在一個態樣中，單一接面光伏電池包括摻雜層，其包含擴散進入半導體基板之摻雜物；圖案化導電層，其形成於該摻雜層上；半導體層，其包含位於在相對於該圖案化導電層的該摻雜層之表面上的該摻雜層上之該半導體基板；以及歐姆接觸層，其形成於該半導體層上。
附加特徵係經由本示例性具體實施例之該等技術實現。其他具體實施例係於文中詳細說明，並係視為所主張之一部分。為了較佳了解該示例性具體實施例之該等特徵，請參照該說明與該等圖式。
提供用於形成單一接面PV電池的系統與方法之具體實施例，其有以下詳細討論的示例性具體實施例。需要用於形成該基板之廢料相對少的相對薄層化合物半導體基板(諸如GaAs)的方法。剝離(spalling)提供給以符合成本效益方式從該半導體基板之較大晶圓或晶錠(ingot)形成相對薄的半導體基板層之方法，減少該基板材料之廢料。在某些具體實施例中，該相對薄層可能係少於大約50μm(microns，微米)厚，且可用於形成該單一接面PV電池。
基板剝離藉由施加一層或多層拉伸應力金屬層至該基板而於基板中誘發裂紋。當剝離係用於具有<111>或<100>表面結晶晶向的GaAs基板上時，該裂紋軌跡可能係不穩定，導致困難與不一致的層去除。然而，<110>表面晶向化合物半導體基板之使用相較於<111>與<100>表面結晶晶向而言，具有相對一致的基板剝離特性。
圖1例示用於單一接面PV電池之形成的方法100之具體實施例。該半導體基板可包含n型或p型半導體基板。該化合物半導體基板可包含化合物半導體基板，在某些具體實施例中諸如GaAs，且在某些具體實施例中可具有<110>表面結晶晶向。參照圖2至圖6討論圖1。在區塊101中，摻雜物層202係形成於半導體基板201上，如圖2中所示。摻雜物層202可藉由任何適當方法形成，其包括但不限於電鍍、CVD(chemical vapor deposition，化學氣相沉積)、PVD(physical vapor deposition，物理氣相沉積)或網版印刷。摻雜物層202可包含鋅(zinc，Zn)，或者含鋅層(在某些具體實施例中)。
在區塊102中，摻雜物層202擴散進入半導體基板201，產生如顯示於圖3中的摻雜層301。摻雜層301可具有如基板201之摻雜型態的相同摻雜型態(p型或n型)，或者其可能係相反。摻雜層301可包含用於單一接面PV電池的背面電場(back surface field，BSF)或電接觸層。在某些具體實施例中，摻雜層301亦可用作晶種層。另外，在區塊103中，使用任何適當技術(其包括但不限於化學氣相沉積(CVD)、物理氣相沉積(PVD)或浸鍍(諸如鈀浸鍍))可如顯示於圖3中形成視需要之晶種層302，以為了隨後使用電化學或無電電鍍技術的化學鍍製備基板201之表面。晶種層302係視需要；若該基板包含n型半導體基板201，則晶種層302可不存在。在某些具體實施例中，晶種層302可在擴散步驟102之前沉積於摻雜物層202上；在其他具體實施例中，晶種層302可在擴散步驟102之後沉積於摻雜層301上。晶種層302可包含一層或多層金屬層。晶種層302可對於摻雜層301形成歐姆接觸，及/或用作蝕刻停止層(諸如鈦(titanium，Ti))以在後處理(以下參照圖6討論)期間去除應力金屬層401時保護下方層。
在區塊104中，一層應力金屬401係形成於摻雜層301(或者在晶種層302係存在的具體實施例中的視需要晶種層302)上方，如顯示於圖4中。應力金屬401可藉由電鍍形成，且其在某些具體實施例中可包含鎳(nickel，Ni)。在某些具體實施例中包含摻雜層301的該等原子可和應力金屬401一起形成合金，舉例來說，NiZn。在其他具體實施例中摻雜層301可用作摻雜層301與應力金屬401兩者(例如摻雜層301可包含拉伸應力Zn)。在某些具體實施例中應力金屬層401可多於大約2μm厚，且在某些示例性具體實施例中介於3μm和10μm之間。在基板201包含n型半導體基板的具體實施例中，應力金屬401可不需要播晶種(seeding)而直接電鍍於基板201之表面上。在某些具體實施例中，在應力金屬401中所含有的該拉伸應力可能多於大約100 MPa(megapascals，兆帕)。
在區塊105中，應力金屬401、視需要之晶種層302、摻雜層301及半導體層501係從半導體基板201剝離，如圖5中所示。剝離可包含受控制的或自發性剝離。受控制的剝離可藉由黏著撓性(flexible)處理層502於應力金屬層401上而執行，使用撓性處理層502與在應力金屬401中所含有的該拉伸應力以引發在基板201內的裂紋503，並從基板201去除半導體層501、視需要之晶種層302、摻雜半導體層301、拉伸應力層401及撓性處理層502。處理層502可包含塑料、聚合物、玻璃或金屬之薄膜，且在某些具體實施例中可能係水溶性。處理層502亦可包含特殊的黏著帶，其在熱能、光學或化學上可從應力金屬401卸下。另外，在自發性剝離中，在應力金屬層401中的該拉伸應力可自行引發裂紋503，將半導體層501和基板201隔開而不需要處理層502。在某些具體實施例中，半導體層501可能少於大約50μm厚。由於在金屬層401中的該拉伸應力，故在某些具體實施例中半導體層501與摻雜半導體層301在剝離之後可具備剩餘的壓縮應變。不管剝離之前或之後，在半導體層501與摻雜半導體層301中所含有的該應變之規模可藉由改變金屬層401之厚度及/或應力而控制。使用半導體層501所建立的PV電池之該等光學性質可藉由調整在半導體層501中的應變量而調節。
在區塊106中，使用半導體層501形成單一接面PV電池600。接觸層601係沉積於半導體層501上。接觸層601可包含材料，其適用於為了半導體層501而形成歐姆接觸。舉例來說，若半導體層501包含n型GaAs，則接觸層601可包含GePd(鍺鈀)或GeAu(鍺金)合金。處理基板602隨後係形成於接觸層601上。處理基板602可包含金屬箔、陶瓷、玻璃或聚合物系材料，且可能係導電。隨後去除處理層502與應力金屬401。應力金屬401可選擇性化學蝕刻，或者可藉由反應性離子蝕刻去除。在較佳具體實施例中，王水(硝酸與鹽酸混合物)溶液可用於應力金屬401之蝕刻；在此類具體實施例中，包含Ti的晶種層302可充當蝕刻停止層以保護摻雜層301與半導體層501。圖案化接觸層603a-d可藉由使用標準微影術來蝕刻任何多餘金屬圖案化視需要之晶種層302及/或摻雜層301而形成。另外，圖案化接觸層603a-d可藉由在去除應力金屬401之後，沉積或網版印刷適當金屬材料於視需要之晶種層302或摻雜層301之表面上而形成。半導體層501可含有在半導體層501中由在金屬層401中的該應力所誘發的壓縮應變量；在半導體層501中的該應變量可決定單一接面PV電池600之該等光學性質。
在示例性具體實施例中，基板201可包含<110>n型摻雜磷的GaAs，其具有大約10 Ohm/cm(歐姆/厘米)之電阻。基板201可能係直徑大約43 mm(毫米)的晶錠。應力金屬層401可藉由以Ni電鍍基板201而形成，其在25℃使用包含300 g/l(克/升)NiCl2與20 g/l硼酸的電鍍溶液以0.6 Amps(安培)之電鍍電流持續5分鐘。形成於基板201上的Ni應力金屬層401可從基板201之邊緣自發性引發裂紋(亦即自發性剝離)，其將GaAs之半導體層501和基板201隔開。GaAs之半導體層501可能係大約10μm厚，其有大約5μm厚的Ni層401。半導體層501可用於形成單一接面PV電池600。
示例性具體實施例之該等技術作用與效益包括化合物半導體基板之相對薄層之形成，其以相對符合成本效益的方式用於單一接面PV電池。
於文中所使用的術語係僅為了說明特定具體實施例之用途，且係不欲為本發明之限制。如於文中所使用，該等單數形「一(a、an)」及「該(the)」係欲亦包括該等複數形，除非該上下文明顯另有所指。將更可了解當該等用語「包含(comprises、comprising)」用於此說明書中時，明確說明所述特徵、整體、步驟、操作、元件及/或部件之存在，但並未排除一個或多個其他特徵、整體、步驟、操作、元件、部件及/或其群組之存在或附加。
在以下該等申請專利範圍中的該等對應結構、材料、行為及所有手段或步驟加功能元件之相等物係欲包括任何結構、材料或行為，其用於執行伴隨著如明確所主張其他所主張元件的功能。為了例示與說明之用途已呈現本發明之說明，但係不欲為全面性或限於本發明所揭示的形式。此領域一般技術者可在不悖離本發明之範疇與精神之前提下將可得知許多修飾例與變化例。該具體實施例係經選擇並說明以最佳解釋本發明與該實際應用之該等原理，並讓此領域其他一般技術者能夠了解用於各種具體實施例的本發明，其有如係適合於所列入考慮的該特定使用的各種修飾例。
100．．．方法
101-106．．．區塊
102．．．擴散步驟
201．．．半導體基板；基板
202．．．摻雜物層
301．．．摻雜層；摻雜半導體層
302．．．晶種層
401．．．Ni(鎳)應力金屬層；應力金屬；拉伸應力層
501．．．半導體層
502．．．撓性處理層；處理層
503．．．裂紋
600．．．單一接面PV(光伏)電池
601．．．接觸層
602．．．處理基板
603a-d．．．圖案化接觸層
現在參照該等圖式，其中在該等幾個圖式中相似元件的編號亦相似。
圖1例示用於形成單一接面PV電池的方法之具體實施例。
圖2例示具有摻雜物層的半導體基板之具體實施例。
圖3例示具有摻雜層的半導體基板之具體實施例。
圖4例示具有應力金屬層的半導體基板之具體實施例。
圖5例示在剝離之後的半導體基板之具體實施例。
圖6例示單一接面PV電池之具體實施例。
101、102、103、104、105、106．．．區塊

Claims (16)

  1. 一種用於形成一單一接面光伏電池之方法，該方法包含：形成一摻雜物層於一半導體基板之一表面上；形成一金屬晶種層於該摻雜物層上；擴散該摻雜物層進入該半導體基板之該表面，以形成該半導體基板之一摻雜層；形成一受拉伸應力之金屬層於該金屬晶種層上；藉由該受拉伸應力之金屬層而於該摻雜層下在該半導體基板中造成一裂紋；從該半導體基板該裂紋處去除一剝離層，該剝離層包含該半導體基板之位於該裂紋之上的該摻雜層與一未摻雜層；以及藉由從該剝離層去除該受拉伸應力之金屬層以及在從該剝離層去除該受拉伸應力之金屬層的期間使用該金屬晶種層作為一蝕刻停止層，而使用該剝離層以形成該單一接面光伏電池。
  2. 如申請專利範圍第1項之方法，其中該摻雜物層包含鋅。
  3. 如申請專利範圍第1項之方法，其中該受拉伸應力之金屬層包含鎳；或者其中該受拉伸應力之金屬層係多於大約2微米厚。
  4. 如申請專利範圍第1項之方法，其中形成該受拉伸應力之金屬層包含電鍍。
  5. 如申請專利範圍第1項之方法，其中該半導體基板包含砷化鎵，其具有一<110>表面結晶晶向。
  6. 如申請專利範圍第1項之方法，其中該剝離層係受到一壓縮應變，該壓縮應變係由該受拉伸應力之金屬層所誘發。
  7. 如申請專利範圍第1項之方法，其中從該半導體基板該裂紋處去除該剝離層包含黏著一處理層於該受拉伸應力之金屬層，該處理層包含塑料、聚合物、玻璃或金屬之一薄膜或者一黏著帶其中之一。
  8. 如申請專利範圍第1項之方法，其中該剝離層係少於大約50微米厚。
  9. 如申請專利範圍第1項之方法，其中使用該剝離層形成該單一接面光伏電池包含：形成一歐姆接觸層於該半導體基板之該未摻雜層上；以及形成一處理基板層於該歐姆接觸層上方，該處理基板層包含一導電材料，其包含一金屬箔、玻璃或陶瓷材料；或者其中使用該剝離層形成該單一接面光伏電池更包含：形成一圖案化接觸層於該摻雜層之相對於該半導體基板之該未摻雜層的一表面上。
  10. 如申請專利範圍第1項之方法，其中該金屬晶種層包含鈦。
  11. 如申請專利範圍第1項之方法，更包含在使用該剝離層形成該單一接面光伏打電池的期間，圖案化該金屬晶種層以形成複數個接點至該單一接面光伏打電池。
  12. 一種單一接面光伏電池，其包含：一摻雜層，其包含擴散進入一p型半導體基板之鋅；一金屬晶種層，包含鈦且形成於該摻雜層上，在去除一受拉伸應力之金屬層的期間該金屬晶種層用以作為一蝕刻停止層；一半導體層，其包含位於該摻雜層上之該p型半導體基板，其在該摻雜層之相對於該金屬晶種層之一表面上，其中該半導體層係受到一壓縮應變，該壓縮應變係由該受拉伸應力之金屬層所誘發；以及一歐姆接觸層，其形成於該半導體層上。
  13. 如申請專利範圍第12項之單一接面光伏電池，更包含一處理基板層，其位於該歐姆接觸層上方，該處理基板層包含一導電材料，其包含一金屬箔、玻璃或陶瓷材料。
  14. 如申請專利範圍第12項之單一接面光伏電池，其中該p型半導體基板包含砷化鎵(GaAs)，其具有一<110>表面結晶晶向；或者其中該半導體層係少於大約50微米厚。
  15. 如申請專利範圍第12項之單一接面光伏電池，更包含一處理基板層，其位於該歐姆接觸層上方，該處理基板層包含一導電材料，其包含玻璃。
  16. 如申請專利範圍第12項之單一接面光伏電池，更包含一處理基板層，其位於該歐姆接觸層上方，該處理基板層包含一導電材料，其包含陶瓷材料。
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