US20100024880A1 - Solar cell and method for manufacturing the same - Google Patents

Solar cell and method for manufacturing the same Download PDF

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Publication number
US20100024880A1
US20100024880A1 US12/533,892 US53389209A US2010024880A1 US 20100024880 A1 US20100024880 A1 US 20100024880A1 US 53389209 A US53389209 A US 53389209A US 2010024880 A1 US2010024880 A1 US 2010024880A1
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substrate
layer
passivation
passivation layer
reflection
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Seongeun Lee
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LG Electronics Inc
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LG Electronics Inc
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Publication of US20100024880A1 publication Critical patent/US20100024880A1/en
Priority to US13/728,604 priority Critical patent/US8759140B2/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/02—Details
    • H01L31/0216—Coatings
    • H01L31/02161—Coatings for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/02167—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/04—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 adapted as photovoltaic [PV] conversion devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/02—Details
    • H01L31/0216—Coatings
    • H01L31/02161—Coatings for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/02167—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • H01L31/02168—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells the coatings being antireflective or having enhancing optical properties for the solar cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • H01L31/02—Details
    • H01L31/0224—Electrodes
    • H01L31/022408—Electrodes for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/022425—Electrodes for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/547—Monocrystalline silicon PV cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • Embodiments of the present invention relate to a solar cell and a method for manufacturing the same.
  • a general solar cell includes a substrate and an emitter layer, formed of a semiconductor, each having a different conductive type such as a p-type and an n-type, and electrodes respectively formed on the substrate and the emitter layer.
  • the general solar cell also includes a p-n junction formed at an interface between the substrate and the emitter layer.
  • each of the electron-hole pairs is separated into electrons and holes by the photovoltaic effect.
  • the separated electrons move to the n-type semiconductor (e.g., the emitter layer) and the separated holes move to the p-type semiconductor (e.g., the substrate), and then the electrons and holes are collected by the electrodes electrically connected to the emitter layer and the substrate, respectively.
  • the electrodes are connected to each other using electric wires to thereby obtain an electric power.
  • a method of forming an electrode of a solar cell includes selectively forming a passivation layer exposing at least a portion of a substrate on a portion of the substrate including an emitter layer, the passivation layer including at least one layer, forming a first electrode electrically connected to the emitter layer, and forming a plurality of second electrodes on the exposed portion of the substrate to electrically connect the plurality of second electrodes to the substrate.
  • the passivation layer may be formed on a surface of the substrate on which light is not incident.
  • the forming of the passivation layer may include positioning a mask including a plurality of openings and a plurality of blocking portions on the substrate, and forming a layer on portions of the substrate facing the openings and forming a plurality of exposed portions of the substrate facing the blocking portions to form the passivation layer including the plurality of posing portions, wherein the plurality of second electrodes are electrically connected to the substrate through the plurality of posing portions.
  • a solar cell includes a substrate of a first conductive type, an emitter layer of a second conductive type opposite the first conductive type on the substrate, first and second anti-reflection layers that are sequentially positioned on the emitter layer, a first electrode electrically connected to the emitter layer, first to third passivation layers that are sequentially positioned on the substrate, each of the first to third passivation layers including a plurality of exposed portions, and a plurality of second electrodes electrically connected to portions of the substrate exposed by the plurality of exposedg portions.
  • the first anti-reflection layer may be formed of silicon nitride (SiNx:H), and the second anti-reflection layer may be formed of silicon oxynitride (SiOxNy).
  • a refractive index of the first anti-reflection layer may be greater than a refractive index of the second anti-reflection layer.
  • the first anti-reflection layer may have a refractive index of about 2.2 to 2.6, and the second anti-reflection layer may have a refractive index of about 1.3 to 1.6.
  • the first passivation layer may be formed of silicon oxide (SiO x ), the second passivation layer may be formed of silicon nitride (SiNx:H), and the third passivation layer may be formed of silicon oxynitride (SiOxNy).
  • the first passivation layer may have a maximum refractive index
  • the third passivation layer may have a minimum refractive index
  • a thickness of the first electrode may be greater than a sum of thicknesses of the first and second anti-reflection layers.
  • a method for manufacturing a solar cell includes forming an emitter layer of a second conductive type opposite a first conductive type on a substrate of the first conductive type, sequentially positioning the substrate in a plurality of chambers to form an anti-reflection layer on the emitter layer and to form a passivation layer including at least one exposed portion on a rear surface of the substrate opposite an incident surface of the substrate, coating a first paste on the anti-reflection layer to form a first electrode pattern, coating a second paste on the passivation layer and on a portion of the substrate exposed by the exposed portion to form a second electrode conductive layer pattern, and performing a thermal process on the substrate having the first electrode pattern and the second electrode conductive layer pattern to form a plurality of first electrodes electrically connected to the emitter layer and to form a second electrode conductive layer including at least one second electrode electrically connected to the substrate.
  • a number of chambers may be equal to a sum of a number of layers constituting the anti-reflection layer and a number of layers constituting the passivation layer, wherein a different source gas may be injected into each of the plurality of chambers.
  • the anti-reflection layer may include first and second anti-reflection layers each having a different refractive index.
  • the first anti-reflection layer may be formed of silicon nitride (SiNx:H), and the second anti-reflection layer may be formed of silicon oxynitride (SiOxNy).
  • the passivation layer may include first, second, and third passivation layers each having a different refractive index.
  • the first passivation layer positioned closest to the substrate may have a maximum refractive index
  • the third passivation layer positioned farthest away from the substrate may have a minimum refractive index
  • the first passivation layer may be formed of silicon oxide (SiO x ), the second passivation layer may be formed of silicon nitride (SiNx:H), and the third passivation layer may be formed of silicon oxynitride (SiOxNy).
  • the forming of the anti-reflection layer and the passivation layer may include independently performing a layer formation process in each of the plurality of chambers.
  • the forming of the anti-reflection layer and the passivation layer may include positioning a mask including at least one opening and at least one blocking portion on the substrate and performing the layer formation process on the substrate using the mask to form the first, second, and third passivation layers, wherein the same mask may be used to form the first, second, and third passivation layers.
  • the layer formation process may use a chemical vapor deposition (CVD) method.
  • CVD chemical vapor deposition
  • FIG. 1 is a partial perspective view of a solar cell according to an exemplary embodiment of the present invention
  • FIG. 2 is a cross-sectional view taken along the line II-II of FIG. 1 ;
  • FIGS. 3A to 3F are cross-sectional views sequentially showing each of steps in a method for manufacturing a solar cell according to an exemplary embodiment of the present invention.
  • FIGS. 4A and 4B show examples of a mask according to an exemplary embodiment of the present invention.
  • FIGS. 1 and 2 First, a solar cell according to an exemplary embodiment of the present invention will be described with reference to FIGS. 1 and 2 .
  • FIG. 1 is a partial perspective view of a solar cell according to an exemplary embodiment of the present invention and FIG. 2 is a cross-sectional view taken along the line II-II of FIG. 1 .
  • a solar cell 1 includes a substrate 110 , an emitter layer 120 on an incident surface (hereinafter, referred to as “a front surface”) of the substrate 110 , on which light is incident, an anti-reflection layer 130 on the emitter layer 120 , a passivation layer 190 on a rear surface of the substrate 110 opposite the front surface of the substrate 110 , a plurality of front electrodes 141 electrically connected to the emitter layer 120 , a plurality of front electrode current collectors 142 , a rear electrode conductive layer 155 , and a plurality of back surface fields (BSFs) 171 .
  • a front surface an incident surface
  • a passivation layer 190 on a rear surface of the substrate 110 opposite the front surface of the substrate 110
  • a plurality of front electrodes 141 electrically connected to the emitter layer 120
  • a plurality of front electrode current collectors 142 a plurality of front electrode current collectors 142
  • a rear electrode conductive layer 155 a plurality of back
  • the plurality of front electrode current collectors 142 are connected to the plurality of front electrodes 141 and extend in a direction intersecting the front electrodes 141 .
  • the rear electrode conductive layer 155 is positioned on the passivation layer 190 and includes a plurality of rear electrodes 151 electrically connected to the substrate 110 .
  • the plurality of BSFs 171 are positioned between the substrate 110 and the plurality of rear electrodes 151 .
  • the substrate 110 may be formed of silicon doped with impurities of a first conductive type, for example, a p-type, though not required.
  • silicon include single crystal silicon, polycrystalline silicon, and amorphous silicon.
  • the substrate 110 contains impurities of a group III element such as boron (B), gallium (Ga), and Indium (In).
  • the substrate 110 may be of an n-type, and/or be made of materials other than silicon.
  • the substrate 110 may contain impurities of a group V element such as phosphor (P), arsenic (As), and antimony (Sb).
  • the surface of the substrate 110 is textured to form a textured surface corresponding to an uneven surface.
  • the emitter layer 12 is positioned on the incident surface and side portions of the substrate 110 .
  • the emitter layer 120 is an impurity portion having a second conductive type (for example, an n-type) opposite to the first conductive type of the substrate 110 .
  • the emitter layer 120 and the substrate 110 form a p-n junction.
  • a plurality of electron-hole pairs produced by light incident on the substrate 110 are separated into electrons and holes by a built-in potential difference resulting from the p-n junction. Then, the separated electrons move toward the n-type semiconductor, and the separated holes move toward the p-type semiconductor.
  • the substrate 110 is the p-type and the emitter layer 120 is the n-type
  • the separated holes move to the substrate 110 and the separated electrons move to the emitter layer 120 . Accordingly, the holes in the substrate 110 and the electrons in the emitter layer 120 become major carriers.
  • the emitter layer 120 may be of the p-type when the substrate 110 is of the n-type unlike the embodiment described above. In this case, the separated electrons move to the substrate 110 and the separated holes move to the emitter layer 120 .
  • the emitter layer 120 may be formed by doping the substrate 110 with impurities of a group V element such as P, As, and Sb.
  • the emitter layer 120 when the emitter layer 120 is of the p-type, the emitter layer 120 may be formed by doping the substrate 110 with impurities of a group III element such as B, Ga, and In.
  • the anti-reflection layer 130 is formed on the emitter layer 120 positioned on the front surface of the substrate 110 .
  • the anti-reflection layer 130 includes a first anti-reflection layer 131 and a second anti-reflection layer 132 .
  • the first anti-reflection layer 131 is made of silicon nitride (SiNx:H) and the second anti-reflection layer 132 is made of silicon oxynitride (SiOxNy).
  • x and y may be larger than “0” and less than “1”.
  • the first and second anti-reflection layers 131 and 132 changes unstable bonds such as dangling bonds existing near the surface of the emitter layer 120 into stable bonds, to decrease a disappearance of the charges moved toward the emitter layer 120 due to the unstable bonds.
  • the first anti-reflection layer 131 has a refractive index of about 2.2 to 2.6 and the second anti-reflection layer 132 has a refractive index of about 1.3 to 1.6. That is, the refractive index of the first anti-reflection layer 131 is more than that of the second anti-reflection layer 132 .
  • the plurality of front electrodes 141 are positioned on the emitter layer 120 and are electrically connected to the emitter layer 120 .
  • the plurality of front electrodes 141 are spaced apart from each other and extend in a predetermined direction.
  • the front electrodes 141 collect charges (for example, electrons) moved to the emitter layer 120 .
  • the plurality of front electrode current collectors 142 are positioned on the same level layer as the first electrodes 141 on the emitter layer 120 and extend in a direction intersecting the front electrodes 141 .
  • the front electrode current collectors 142 collect the charges transferred from the front electrodes 141 and output the charges to an external device.
  • the front electrodes 141 and the front electrode current collectors 142 are made of at least one conductive material.
  • An example of the conductive materials may be at least one selected from the group consisting of nickel (Ni), copper (Cu), silver (Ag), aluminum (Al), tin (Sn), zinc (Zn), indium (In), titanium (Ti), gold (Au), and a combination thereof, but may be other conductive materials.
  • the passivation layer 190 is positioned on the rear surface of the substrate 110 .
  • the passivation layer 190 includes a plurality of exposed portions 181 , through which portions of the substrate 110 are exposed.
  • the passivation layer 190 includes first to third passivation layers 191 - 193 that are sequentially positioned over the substrate 110 .
  • the first passivation layer 191 is made of silicon oxide (SiOx)
  • the second anti-reflection layer 192 is made of silicon nitride (SiNx:H)
  • the third anti-reflection layer 193 is made of silicon oxynitride (SiOxNy).
  • x and y are larger than “0” and less than “1”, respectively.
  • the respective first to third passivation layers have a reflective index that is higher depending on how close each of them are to the substrate 110 . Thereby, light passing through the substrate 110 is easily re-incident toward the substrate 110 .
  • the first passivation layer 191 positioned on the substrate 110 has the largest refractive index
  • the third passivation layer 193 positioned farthest away from the substrate 110 has the smallest refractive index.
  • the passivation layer 190 reduces the recombination of the charges near the surface of the substrate 110 . That is, the passivation layer 190 converts the unstable bonds such as the dangling bonds existing near the surface of the substrate 110 into the stable bonds, so as to decrease the disappearance of the charges moved to the substrate 110 , due to the unstable bonds.
  • the rear electrode conductive layer 155 is made of a conductive material and is positioned on the passivation layer 190 and portions of the substrate 110 exposed through the plurality of exposed portions 181 .
  • the rear electrode conductive layer 155 includes the plurality of rear electrodes 151 electrically connected to the exposed portions of the substrate 110 .
  • the rear electrodes 151 collect charges (for example, holes) moved to the substrate 110 and transfer the collected charges to the rear electrode conductive layer 155 . Thereby, the rear electrode conductive layer 155 output the charges transferred from the rear electrodes 151 to the external device.
  • the conductive material may be at least one selected from the group consisting of nickel (Ni), copper (Cu), silver (Ag), aluminum (Al), tin (Sn), zinc (Zn), indium (In), titanium (Ti), gold (Au), and a combination thereof. Other conductive materials may be used.
  • the plurality of BSFs 171 are positioned between the rear electrodes 151 and the substrate 110 .
  • the BSFs 171 are areas (for example, p+-type areas) that are more heavily doped with impurities of the same conductive type as the substrate 110 than the substrate 110 .
  • a potential barrier is formed due to an impurity doped concentration difference from the substrate 110 and each of the B SFs 171 , and thereby, the movement of the electrons to the rear surface of the substrate 110 is disturbed by the potential barrier. Accordingly, the BSFs 171 prevent or reduce the recombination and/or the disappearance of the electrons and holes near the rear surface of the substrate 110 .
  • the substrate 110 has the textured surface, the reflectance of light from the incident surface of the substrate 110 decreases, and the light is confined within the solar cell 1 through the incident and reflection operations on the textured surface. Accordingly, the absorption of light is increased, and thereby the efficiency of the solar cell 1 is improved.
  • a reflection loss of light incident toward the substrate 110 is reduced by the anti-reflection layer 130 , and thus an amount of light incident toward the substrate 110 further increases.
  • the electron-hole pairs are separated by the p-n junction of the substrate 110 and the emitter layer 120 , and the separated electrons move to the n-type emitter layer 120 and the separated holes move to the p-type substrate 110 .
  • the electrons moved to the n-type emitter layer 120 are collected by the front electrodes 141 and then are transferred to the front electrode current collectors 142 .
  • the holes moved to the p-type substrate 110 are collected by the rear electrodes 151 and then are transferred to the rear electrode conductive layer 155 .
  • the front electrode current collectors 142 are connected to the rear electrode conductive layer 155 using electric wires (not shown), current flows therethrough to thereby enable use of the current for electric power.
  • the unstable bonds such as the dangling bonds existing near the front and rear surfaces of the substrate 110 are converted into the stable bonds by the first and second anti-reflection layers 131 and 132 positioned on the front surface of the substrate 110 and the first to third passivation layers 191 - 193 positioned on the rear surface of the substrate 110 , a surface state of the substrate 110 becomes a passivated state. Accordingly, the recombination is largely reduced, which the electrons and holes moved toward the emitter layer 120 and the substrate 110 , respectively, are combined with the unstable bonds to disappear, and thereby the efficiency of the solar cell 1 is remarkably improved.
  • FIGS. 3A to 3F , and FIGS. 4A and 4B a method for manufacturing the solar cell 1 according to the exemplary embodiment of the preset invention will be described.
  • FIGS. 3A to 3F are cross-sectional views sequentially showing each of steps in a method for manufacturing a solar cell according to an exemplary embodiment of the present invention and FIGS. 4A and 4B show examples of a mask according to an exemplary embodiment of the present invention.
  • a texturing process is performed on an incident surface of a substrate 110 to form a textured surface for scattering light incident toward the incident surface and reducing a reflectance amount of the light.
  • an anisotropy etching may be performed on the incident surface of the substrate 110 to form the textured surface. Since atoms are more densely arranged in a ( 111 ) surface than a ( 100 ) surface, an etching rate in the ( 111 ) surface is slower than that in the ( 100 ) surface. Thereby, in performing the anisotropy etching, a plurality of portions of pyramidal shapes are formed.
  • the anisotropy etching is performed using a basic solution such as KOH and NaOH as an etching solution.
  • the etching rate may be varied in accordance with components and a concentration of the etching solution, an etching temperature, and an etching time, etc.
  • the textured surface may be formed by an isotropy etching using an acid solution as the etching solution.
  • the etching solution for the isotropy etching may be HF or HNO 3 , etc.
  • a mechanical manner using a diamond cutter, a laser beam, or a physical manner using plasma may be used for the texturing process to form the textured surface, instead of the anisotropy etching or the isotropy etching.
  • a high temperature thermal process is performed on the substrate 110 in an environment containing a material (for example, PH 3 or POCl 3 ) including an impurity of a group V element such as P, As, and Sb, to diffuse the impurity of the group V element into the substrate 110 and to thereby form an emitter layer 120 on the entire surface of the substrate 110 .
  • a material for example, PH 3 or POCl 3
  • an impurity of a group V element such as P, As, and Sb
  • the thermal process is performed in the environment containing a material (for example, BN) including an impurity of a group III element, to form the emitter layer 120 of a p-type into the substrate 110 .
  • a material for example, BN
  • boron silicate glass (BSG) containing boron (B) produced when the p-type impurity or the n-type impurity is diffused inside the substrate 110 is removed through an etching process.
  • the impurity of the group III or V element may be doped into the substrate 110 . That is, by displacing the substrate 110 in a vacuum chamber and accelerating ions of the impurity toward the substrate 110 , the impurity implants into the substrate 110 to form the emitter layer 120 .
  • a rear portion of the substrate 110 is removed by a wet etching or a dry etching, etc., to remove a portion of the emitter layer 120 , which is formed on the rear surface of the substrate 110 .
  • first and second anti-reflection layers 131 and 132 are sequentially formed on the emitter layer 120 of the substrate 110 to form an anti-reflection layer 130
  • first to third passivation layers 191 - 193 are sequentially formed on the rear surface of the substrate 110 to form a passivation layer 190 .
  • the first and second anti-reflection layers 131 and 132 and the first to third passivation layer 191 - 193 are formed in a plurality of chambers 201 - 205 using a chemical vapor deposition (CVD) method such as a plasma enhanced chemical vapor deposition (PECVD) method, respectively.
  • CVD chemical vapor deposition
  • PECVD plasma enhanced chemical vapor deposition
  • five chambers 201 - 205 are sequentially disposed for forming each of the layers 131 , 132 and 191 - 193 .
  • the substrate 110 is moved to the next chamber 201 - 205 for forming another of the layers 131 , 132 , and 191 - 193 .
  • a source gas supplied into each chamber 201 - 205 is changed in accordance with a desired layer.
  • the first anti-reflection layer 131 is formed by silicon nitride (SiNx:H) and the second anti-reflection layer 132 is formed by silicon oxynitride (SiOxNy).
  • the first passivation layer 191 is formed by silicon oxide (SiOx)
  • the second passivation layer 191 is formed by silicon nitride (SiHx:H)
  • the third passivation layer 193 is formed by silicon oxynitride (SiOxNy).
  • a material for each of the anti-reflection layers 131 and 132 and the passivation layers 191 - 193 may be varied.
  • the first and second anti-reflection layer 131 and 132 are formed on the entire exposed surface of the substrate 110 , while the first to third passivation layers 191 - 193 include a plurality of exposed portions 181 that expose portions of a corresponding surface (for example, the rear surface) of the substrate 110 .
  • the first to third passivation layers 191 - 193 are formed using the CVD method.
  • each passivation layer 191 - 193 is formed, the chamber 203 - 205 for performing the CVD method is changed.
  • the substrate 110 is moved into a corresponding chamber 203 - 205 for forming each passivation layer 191 - 193 .
  • the same mask 300 is arranged into each camber 203 - 205 . Examples of the mask 300 according to the embodiment of the present invention are shown in FIGS. 4A and 4B .
  • An example of the mask 300 shown in FIG. 4A includes a plurality of blocking portions 310 and a plurality of openings 320 , and further includes a plurality of connectors 330 .
  • the blocking portions 310 have approximately rectangular shape.
  • the connectors 330 connect adjacent blocking portions 310 and connect the blocking portions 310 to a frame 340 . Accordingly, each of the plurality of openings 320 is surrounded by adjacent blocking portions 310 and the connectors 330 .
  • the first to third passivation layers 191 - 193 After sequentially forming the first to third passivation layers 191 - 193 , after the mask 300 shown in FIG. 4A is arranged on the substrate 110 displaced in a corresponding chamber 203 - 205 , a source gas is supplied into the chamber 203 - 205 , and then the CVD method is subjected to the substrate 110 .
  • the source gas passes through the plurality of openings 320 to be deposited on portions of the substrate 110 , which correspond to the openings 320 and to thereby form the first to third passivation layers 191 - 193 .
  • the source gas is blocked by the blocking portions 310 and the connectors 330 , the source gas is not deposited on portions of the substrate 110 , which correspond to the blocking portions 310 and the connectors 330 such that the plurality of exposed portions 181 are formed.
  • the passivation 190 includes a plurality of passivation islands corresponding to the openings 320 and the exposed portions 181 include portions corresponding to the blocking portions 310 and portions corresponding to the connectors 330 .
  • a mask 300 shown in FIG. 4B may be used to form the passivation layer 190 having the plurality of exposed portions 181 .
  • the mask 300 shown in FIG. 4B includes a plurality of blocking portions 310 and a plurality of connectors 330 connecting the blocking portions 310 and a frame 340 .
  • each of the blocking portions 310 has a stripe shape.
  • the exposed portions 181 have a pseudo stripe shape corresponding to the blocking portions 310 and the connectors 330 .
  • the masks 300 shown in FIGS. 4A and 4B are only examples. Accordingly, by varying a shape of the mask 300 , the various passivation layers 190 having the exposed portions of various shapes may be formed.
  • the anti-reflection layer 130 of a double-layered structure and the passivation layer 190 of a triple-layered structure are sequentially formed into the five sequential chambers 201 - 205 by the CVD method, and further the same mask 300 is used for forming the exposed portions 181 in the passivation 190 whenever each of the passivation layers 191 - 193 is formed.
  • layer formation processes are simplified and a layer formation time is reduced.
  • the anti-reflection layer 130 and the passivation layer 190 are formed into one chamber in a prior art.
  • the substrate 110 is moved into the one chamber and a layer formation process is performed, and then the substrate 110 is taken out from the chamber.
  • the substrate 100 is again disposed into the chamber to perform the next layer formation process.
  • an etching paste is applied on corresponding portions of the passivation layer 190 formed through the above described processes and is dried, to form the exposed portions 181 in the corresponding portions of the passivation layer 190 .
  • an additional process such as a wet etching for removing the etching paste existing on the passivation layer 190 is necessary.
  • the substrate 110 is sequentially moved into the chambers 201 - 205 according to an order of layer formation to form the layers 131 , 132 , and 191 - 193 . Accordingly, whenever the layers 131 , 132 , and 191 - 193 are formed, it is not necessary to adjust the environment of the chambers 201 - 205 and to move the substrate 110 into the corresponding chamber 201 - 205 , and thereby a layer formation time is reduced. Further, since each of the layers 131 , 132 , and 191 - 193 is formed into a separated chamber, the quality of the formed layers is improved.
  • the mask 300 is also moved to form the passivation layers 191 - 193 having the same patterns as each other.
  • the layer formation time is more reduced.
  • a paste containing Ag is applied on corresponding portions of the second anti-reflection layer 132 of the anti-reflection layer 130 using a screen printing method and then is dried to form a front electrode and front electrode current collector pattern 140 .
  • the front electrode and front electrode current collector pattern 140 includes front electrode patterns and front electrode current collector patterns that extend in directions intersecting each other, respectively.
  • a width of the front electrode current collector pattern may be greater than a width of the front electrode pattern.
  • a width relationship between the front electrode current collector pattern and the front electrode pattern may be varied.
  • a paste containing Al is applied on the third passivation layer 193 and portions of substrate 110 exposed through the exposed portions 181 using the screen printing method and then is dried to form a rear electrode conductive layer pattern 150 .
  • a formation order of the patterns 140 and 150 may vary.
  • a firing process is performed on the substrate 110 , on which the front electrode and front electrode current collector pattern 140 and the rear electrode conductive layer pattern 150 are formed. That is, one thermal process is performed on the substrate 110 , to form a plurality of front electrodes 141 , a plurality of front electrode current collectors 142 , a rear electrode conductive layer 155 including a plurality of rear electrodes 151 electrically connected to the portions of the substrate 110 exposed through the exposed portions 181 , and a plurality of BSFs 171 . As a result, the solar cell 1 shown in FIGS. 1 and 2 is completed.
  • the front electrode and front electrode current collector pattern 140 sequentially passes through the contacted portions with the second anti-reflection layer 132 and the first underlying anti-reflection layer 131 and makes contact with the emitter layer 120 , to form a plurality of front electrodes 141 and a plurality of front electrode current collectors 142 .
  • a thickness of each of the first electrodes 141 and the front electrode current collectors is equal to or larger than a sum of thickness of the first and second anti-reflection layers 131 and 132 .
  • a 1 contained in the rear electrode pattern 150 is diffused to the substrate 110 contacting the rear electrode pattern 150 to form the plurality of BSFs 171 between the rear electrodes 151 and the substrate 110 .
  • the BSFs 171 are an area doped with an impurity of the same conductive type as the substrate 110 , for example, a p-type impurity.
  • An impurity doping concentration of the BSFs 171 is greater than an impurity doping concentration of the substrate 110 , and thus the BSFs 171 are a p+-type area.
  • metal components contained in the respective patterns 140 and 150 chemically coupled with layers 120 and 110 contacting the patters 140 and 150 , respectively, such that contact resistance decreases and thereby a current flowing is improved.
  • reference to front or back, with respect to electrode, a surface of the substrate, or others is not limiting.
  • such a reference is for convenience of description since front or back is easily understood as examples of first or second of the electrode, the surface of the substrate or others.

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US8759140B2 (en) 2014-06-24
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KR20100014006A (ko) 2010-02-10
EP2212921A2 (en) 2010-08-04
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US20130122635A1 (en) 2013-05-16
JP2011511453A (ja) 2011-04-07

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