US20130217169A1 - Bifacial solar cells with back surface doping - Google Patents
Bifacial solar cells with back surface doping Download PDFInfo
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- US20130217169A1 US20130217169A1 US13/849,813 US201313849813A US2013217169A1 US 20130217169 A1 US20130217169 A1 US 20130217169A1 US 201313849813 A US201313849813 A US 201313849813A US 2013217169 A1 US2013217169 A1 US 2013217169A1
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- 239000000758 substrate Substances 0.000 claims abstract description 35
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims abstract description 13
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- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 26
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- 238000002161 passivation Methods 0.000 claims description 6
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 claims description 5
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- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 3
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- 238000005530 etching Methods 0.000 claims description 3
- OYLRFHLPEAGKJU-UHFFFAOYSA-N phosphane silicic acid Chemical compound P.[Si](O)(O)(O)O OYLRFHLPEAGKJU-UHFFFAOYSA-N 0.000 claims description 3
- 239000005368 silicate glass Substances 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
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- 238000002955 isolation Methods 0.000 abstract 1
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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
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
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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
- H01L31/0224—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
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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
- H01L31/04—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
- H01L31/06—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 characterised by at least one potential-jump barrier or surface barrier
- H01L31/068—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 characterised by at least one potential-jump barrier or surface barrier the potential barriers being only of the PN homojunction type, e.g. bulk silicon PN homojunction solar cells or thin film polycrystalline silicon PN homojunction solar cells
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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
- H01L31/04—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
- H01L31/06—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 characterised by at least one potential-jump barrier or surface barrier
- H01L31/068—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 characterised by at least one potential-jump barrier or surface barrier the potential barriers being only of the PN homojunction type, e.g. bulk silicon PN homojunction solar cells or thin film polycrystalline silicon PN homojunction solar cells
- H01L31/0684—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 characterised by at least one potential-jump barrier or surface barrier the potential barriers being only of the PN homojunction type, e.g. bulk silicon PN homojunction solar cells or thin film polycrystalline silicon PN homojunction solar cells double emitter cells, e.g. bifacial solar cells
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- H—ELECTRICITY
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- 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
- H01L31/1804—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof comprising only elements of Group IV of the Periodic System
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- 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
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- 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
- the present invention relates generally to solar cells and, in particular, to an improved structure and manufacturing process for a bifacial solar cell.
- Bifacial solar cells may use any of a variety of different designs to achieve higher efficiencies than those typically obtained by a conventional, monofacial solar cell.
- One such design is shown in U.S. Pat. No. 5,665,175 which discloses a BSC configuration with first and second active regions formed on the front and back surfaces of the BSC, respectively, the two regions separated by a distance ⁇ .
- the distance ⁇ allows a leakage current to flow between the first and second active regions, thus allowing a solar cell panel utilizing such bifacial cells to continue to operate even if one or more individual solar cells become shaded or defective.
- U.S. Pat. No. 7,495,167 discloses an n + pp + structure and a method of producing the same.
- the p + layer formed by boron diffusion, exhibits a lifetime close to that of the initial level of the substrate.
- the '167 patent teaches that after phosphorous gettering, the cell must be annealed at a temperature of 600° C. or less for one hour or more.
- the cell then undergoes a final heat treatment step in which the cell is fired at a temperature of around 700° C. or less for one minute or less.
- U.S. Patent Application Publication No. 2005/0056312 discloses an alternative technique for achieving two or more p-n junctions in a single solar cell, the disclosed technique using transparent substrates (e.g., glass or quartz substrates).
- the BSC includes two thin-film polycrystalline or amorphous cells formed on opposing sides of a transparent substrate. Due to the design of the cell, the high temperature deposition of the absorber layers can be completed before the low temperature deposition of the window layers, thus avoiding degradation or destruction of the p-n junctions.
- a manufacturing method is provided that is comprised of the steps of depositing a boron doped layer onto the back surface of a p-type silicon substrate, depositing a back surface dielectric over the boron doped layer, diffusing phosphorous onto the front surface of the silicon substrate to form an n + layer and a front surface junction, removing the phosphor-silicate glass formed during the diffusion step (e.g., by etching with HF), depositing a front surface passivation and AR dielectric layer onto the n + layer, applying front and back surface contact grids, firing the front and back surface contact grids, and isolating the front surface junction, for example using a laser scriber.
- the front and back surface contact grid firing steps may be performed simultaneously. Alternately, the back surface contact grid applying and firing steps may be performed prior to, or after, the front surface contact grid applying and firing steps.
- the boron doped layer depositing step can be formed by depositing a boron doped silicon dioxide layer using CVD, depositing a boron doped polysilicon layer using CVD, depositing a boron doped amorphous silicon layer using PE-CVD, spray coating a boric acid solution onto the back surface of the substrate, spray/wipe coating a boron-doped spin-on glass onto the back surface of the substrate, or by other means.
- the phosphorous diffusing step may be performed at a temperature in the range of 825° C. to 890° C. for a duration of approximately 10 to 20 minutes.
- a bifacial solar cell (BSC) is provided that is comprised of a silicon substrate of a first conductivity type with a front surface active region of a second conductivity type and a back surface doped region of the first conductivity type, dielectric layers deposited on the front surface active region and on the back surface doped region, a front surface contact grid applied to the front surface passivation and AR dielectric layer which alloys through the front surface dielectric to the active region during firing, a back surface contact grid applied to the back surface dielectric layer which alloys through the back surface dielectric to the back surface doped region during firing, and a groove on the front surface of the silicon substrate, the groove isolating the front surface junction.
- BSC bifacial solar cell
- the silicon substrate may be comprised of p-type silicon, the active region may be comprised of n + material resulting from a phosphorous diffusion step, and the doped region may be comprised of a boron dopant.
- the silicon substrate may be comprised of n-type silicon, the active region may be comprised of p + material resulting from a boron diffusion step, and the doped region may be comprised of a phosphorous dopant.
- FIG. 1 illustrates a preferred embodiment of a BSC in accordance with the invention
- FIG. 2 illustrates the process flow for the BSC of FIG. 1 ;
- FIG. 3 illustrates an alternate process flow for the BSC of FIG. 1 .
- FIG. 1 illustrates a cross-sectional view of a preferred bifacial solar cell (BSC) structure fabricated in accordance with the procedure described in FIGS. 2 and 3 .
- Silicon substrate 101 may be of either p- or n-type. In the exemplary device and process illustrated in FIGS. 1-3 , a p-type substrate is used.
- substrate 101 is prepared using any of a variety of well-known substrate preparatory processes (step 201 ).
- saw and handling induced damage is removed via an etching process, for example using a nitric and hydrofluoric (HF) acid mixture.
- the bottom surface of substrate 101 is doped, thereby forming a back surface doped region 103 (step 203 ).
- Region 103 is doped with the same doping type as substrate 101 .
- doped region 103 reduces back surface recombination and the effects of a positive potential in the back surface insulator to attract minority carriers to the back surface and thus away from the front surface collecting junction.
- Region 103 can be formed using any of a variety of techniques. Exemplary techniques include, but are not limited to, chemical vapor deposition (CVD), plasma enhanced CVD (PE-CVD), spray coating, and spin coating. Accordingly, and assuming a p-type substrate, region 103 can be formed by depositing a boron doped polysilicon layer using CVD; depositing a boron doped silicon dioxide or amorphous silicon layer using PE-CVD; spray/spin coating a boric acid solution or doped spin-on glass onto the back surface of substrate 101 ; or by other means.
- CVD chemical vapor deposition
- PE-CVD plasma enhanced CVD
- spray coating and spin coating. Accordingly, and assuming a p-type substrate, region 103 can be formed by depositing a boron doped polysilicon layer using CVD; depositing a boron doped silicon dioxide or amorphous silicon layer using PE-CVD; spray/spin coating a boric acid solution or doped spin-on glass onto
- a dielectric layer 105 is deposited on the back surface of substrate 101 , specifically on top of doped region 103 as shown (step 205 ).
- layer 105 is comprised of either silicon nitride or silicon dioxide, preferably deposited at a temperature of 300° C. to 400° C., and has a thickness of approximately 76 nanometers for silicon nitride or 100 nanometers for silicon dioxide.
- layer 105 is comprised of silicon oxynitride.
- layer 105 is comprised of a dielectric stack, for example 70 nanometers of silicon nitride on 10 nanometers of silicon dioxide or aluminum oxide.
- phosphorous is diffused onto the front surface of substrate 101 , creating n + layer 107 and a p-n junction at the interface of substrate 101 and n + layer 107 (step 207 ).
- n + layer 107 is formed using phosphoryl chloride (POCl 3 ), where the diffusion is performed at a diffusion temperature in the range of 825° C. to 890° C., preferably at a temperature of approximately 850° C., for 10 to 20 minutes in a nitrogen atmosphere (step 207 ). It will be appreciated that during the phosphorous diffusion step 207 , boron from region 103 is diffused into the back surface of substrate 101 to form a back surface field (BSF).
- BSF back surface field
- the phosphor-silicate glass (PSG) formed during diffusion step 207 is then etched away, for example using a hydrofluoric (HF) etch at or near room temperature for 1 to 5 minutes (step 209 ).
- the front side junction has a depth of 0.3 to 0.6 microns and a surface doping concentration of about 8 ⁇ 10 21 /cm 3 .
- a front surface passivation and anti-reflection (AR) dielectric layer 109 is deposited, layer 109 preferably being approximately 76 nanometers thick.
- layer 109 is comprised of silicon nitride or silicon oxynitride.
- layer 109 is deposited at a temperature of 300° C. to 400° C.
- contact grids are applied to the front and back surfaces of BSC 100 (step 213 ), for example using a screen printing process.
- front contact grid 111 is comprised of silver while back contact grid 113 is comprised of an aluminum-silver mixture.
- both the front and back contact grids are aligned and use the same contact size and spacing, with electrodes being approximately 100 microns wide, 15 microns thick and spaced approximately 2.5 millimeters apart.
- the back contact grid uses a finer spacing in order to lessen resistance losses from lateral current flow in the substrate.
- a contact firing step 213 is performed, preferably at a peak temperature of 750° C.
- FIG. 3 illustrates an alternate process for fabricating cell 100 . As illustrated, this process is identical to that shown in FIG. 2 , except that the front surface and back surface contact grids are applied and fired separately, thereby allowing different firing conditions to be used for each grid.
- contact grid 113 is applied (step 301 ) and fired (step 303 ) first, followed by the application (step 305 ) and firing (step 307 ) of front contact grid 111 .
- an n-type substrate may also be used with the invention.
- an n-type dopant such as phosphorous
- a p-type material such as boron
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Abstract
A simplified manufacturing process and the resultant bifacial solar cell (BSC) are provided, the simplified manufacturing process reducing manufacturing costs. The BSC includes an active region located on the front surface of the substrate, formed for example by a phosphorous diffusion step. The back surface includes a doped region, the doped region having the same conductivity as the substrate but with a higher doping level. Contact grids are formed, for example by screen printing. Front junction isolation is accomplished using a laser scribe.
Description
- This application is a Divisional of U.S. patent application Ser. No. 12/456,404, filed Jun. 15, 2009, which claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/215,199, filed May 1, 2009, the disclosure of which is incorporated herein by reference for any and all purposes.
- The present invention relates generally to solar cells and, in particular, to an improved structure and manufacturing process for a bifacial solar cell.
- Bifacial solar cells (BSC) may use any of a variety of different designs to achieve higher efficiencies than those typically obtained by a conventional, monofacial solar cell. One such design is shown in U.S. Pat. No. 5,665,175 which discloses a BSC configuration with first and second active regions formed on the front and back surfaces of the BSC, respectively, the two regions separated by a distance λ. The distance λ allows a leakage current to flow between the first and second active regions, thus allowing a solar cell panel utilizing such bifacial cells to continue to operate even if one or more individual solar cells become shaded or defective.
- U.S. Pat. No. 7,495,167 discloses an n+pp+ structure and a method of producing the same. In the disclosed structure, the p+ layer, formed by boron diffusion, exhibits a lifetime close to that of the initial level of the substrate. In order to achieve this lifetime, the '167 patent teaches that after phosphorous gettering, the cell must be annealed at a temperature of 600° C. or less for one hour or more. In order to retain the lifetime recovered by the phosphorous and low-temperature born gettering steps, the cell then undergoes a final heat treatment step in which the cell is fired at a temperature of around 700° C. or less for one minute or less.
- U.S. Patent Application Publication No. 2005/0056312 discloses an alternative technique for achieving two or more p-n junctions in a single solar cell, the disclosed technique using transparent substrates (e.g., glass or quartz substrates). In one disclosed embodiment, the BSC includes two thin-film polycrystalline or amorphous cells formed on opposing sides of a transparent substrate. Due to the design of the cell, the high temperature deposition of the absorber layers can be completed before the low temperature deposition of the window layers, thus avoiding degradation or destruction of the p-n junctions.
- Although there are a variety of BSC designs and techniques for fabricating the same, these designs and techniques tend to be relatively complex, and thus expensive. Accordingly, what is needed is a solar cell design that achieves the benefits associated with bifacial solar cells while retaining the manufacturing simplicity of a monofacial solar cell. The present invention provides such a design.
- The present invention provides a simplified manufacturing process and the resultant bifacial solar cell (BSC), the simplified manufacturing process reducing manufacturing costs. In at least one embodiment of the invention, a manufacturing method is provided that is comprised of the steps of depositing a boron doped layer onto the back surface of a p-type silicon substrate, depositing a back surface dielectric over the boron doped layer, diffusing phosphorous onto the front surface of the silicon substrate to form an n+ layer and a front surface junction, removing the phosphor-silicate glass formed during the diffusion step (e.g., by etching with HF), depositing a front surface passivation and AR dielectric layer onto the n+ layer, applying front and back surface contact grids, firing the front and back surface contact grids, and isolating the front surface junction, for example using a laser scriber. The front and back surface contact grid firing steps may be performed simultaneously. Alternately, the back surface contact grid applying and firing steps may be performed prior to, or after, the front surface contact grid applying and firing steps. The boron doped layer depositing step can be formed by depositing a boron doped silicon dioxide layer using CVD, depositing a boron doped polysilicon layer using CVD, depositing a boron doped amorphous silicon layer using PE-CVD, spray coating a boric acid solution onto the back surface of the substrate, spray/wipe coating a boron-doped spin-on glass onto the back surface of the substrate, or by other means. The phosphorous diffusing step may be performed at a temperature in the range of 825° C. to 890° C. for a duration of approximately 10 to 20 minutes.
- In at least one embodiment of the invention, a bifacial solar cell (BSC) is provided that is comprised of a silicon substrate of a first conductivity type with a front surface active region of a second conductivity type and a back surface doped region of the first conductivity type, dielectric layers deposited on the front surface active region and on the back surface doped region, a front surface contact grid applied to the front surface passivation and AR dielectric layer which alloys through the front surface dielectric to the active region during firing, a back surface contact grid applied to the back surface dielectric layer which alloys through the back surface dielectric to the back surface doped region during firing, and a groove on the front surface of the silicon substrate, the groove isolating the front surface junction. The silicon substrate may be comprised of p-type silicon, the active region may be comprised of n+ material resulting from a phosphorous diffusion step, and the doped region may be comprised of a boron dopant. The silicon substrate may be comprised of n-type silicon, the active region may be comprised of p+ material resulting from a boron diffusion step, and the doped region may be comprised of a phosphorous dopant.
- A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.
-
FIG. 1 illustrates a preferred embodiment of a BSC in accordance with the invention; -
FIG. 2 illustrates the process flow for the BSC ofFIG. 1 ; and -
FIG. 3 illustrates an alternate process flow for the BSC ofFIG. 1 . -
FIG. 1 illustrates a cross-sectional view of a preferred bifacial solar cell (BSC) structure fabricated in accordance with the procedure described inFIGS. 2 and 3 .Silicon substrate 101 may be of either p- or n-type. In the exemplary device and process illustrated inFIGS. 1-3 , a p-type substrate is used. - Initially,
substrate 101 is prepared using any of a variety of well-known substrate preparatory processes (step 201). In general, duringstep 201 saw and handling induced damage is removed via an etching process, for example using a nitric and hydrofluoric (HF) acid mixture. After substrate preparation, the bottom surface ofsubstrate 101 is doped, thereby forming a back surface doped region 103 (step 203).Region 103 is doped with the same doping type assubstrate 101. Increasing the doping level ofregion 103, compared tosubstrate 101, lowers the contact resistance. Additionally, dopedregion 103 reduces back surface recombination and the effects of a positive potential in the back surface insulator to attract minority carriers to the back surface and thus away from the front surface collecting junction. -
Region 103 can be formed using any of a variety of techniques. Exemplary techniques include, but are not limited to, chemical vapor deposition (CVD), plasma enhanced CVD (PE-CVD), spray coating, and spin coating. Accordingly, and assuming a p-type substrate,region 103 can be formed by depositing a boron doped polysilicon layer using CVD; depositing a boron doped silicon dioxide or amorphous silicon layer using PE-CVD; spray/spin coating a boric acid solution or doped spin-on glass onto the back surface ofsubstrate 101; or by other means. - After formation of
region 103, adielectric layer 105 is deposited on the back surface ofsubstrate 101, specifically on top ofdoped region 103 as shown (step 205). Preferablylayer 105 is comprised of either silicon nitride or silicon dioxide, preferably deposited at a temperature of 300° C. to 400° C., and has a thickness of approximately 76 nanometers for silicon nitride or 100 nanometers for silicon dioxide. In an alternate embodiment,layer 105 is comprised of silicon oxynitride. In another alternate embodiment,layer 105 is comprised of a dielectric stack, for example 70 nanometers of silicon nitride on 10 nanometers of silicon dioxide or aluminum oxide. - After deposition of
dielectric layer 105, phosphorous is diffused onto the front surface ofsubstrate 101, creating n+ layer 107 and a p-n junction at the interface ofsubstrate 101 and n+ layer 107 (step 207). Preferably n+ layer 107 is formed using phosphoryl chloride (POCl3), where the diffusion is performed at a diffusion temperature in the range of 825° C. to 890° C., preferably at a temperature of approximately 850° C., for 10 to 20 minutes in a nitrogen atmosphere (step 207). It will be appreciated that during thephosphorous diffusion step 207, boron fromregion 103 is diffused into the back surface ofsubstrate 101 to form a back surface field (BSF). The phosphor-silicate glass (PSG) formed duringdiffusion step 207 is then etched away, for example using a hydrofluoric (HF) etch at or near room temperature for 1 to 5 minutes (step 209). In the preferred embodiment, the front side junction has a depth of 0.3 to 0.6 microns and a surface doping concentration of about 8×1021/cm3. - In
step 211, a front surface passivation and anti-reflection (AR)dielectric layer 109 is deposited,layer 109 preferably being approximately 76 nanometers thick. In the exemplary embodiment,layer 109 is comprised of silicon nitride or silicon oxynitride. Preferably,layer 109 is deposited at a temperature of 300° C. to 400° C. - After deposition of the
dielectric layer 109, contact grids are applied to the front and back surfaces of BSC 100 (step 213), for example using a screen printing process. In the exemplary embodiment,front contact grid 111 is comprised of silver while backcontact grid 113 is comprised of an aluminum-silver mixture. In the preferred embodiment, both the front and back contact grids are aligned and use the same contact size and spacing, with electrodes being approximately 100 microns wide, 15 microns thick and spaced approximately 2.5 millimeters apart. In at least one alternate embodiment, the back contact grid uses a finer spacing in order to lessen resistance losses from lateral current flow in the substrate. Next, acontact firing step 213 is performed, preferably at a peak temperature of 750° C. for 3 seconds in air. As a result of this process,contacts 111 alloy through passivation and ARdielectric coating 109 to n+ layer 107. Similarly,contacts 113 alloy throughdielectric coating 105 tolayer 103. Lastly, the front junction is isolated, for example using a laser scriber to form a groove on the front cell surface around the periphery of the cell (step 217). -
FIG. 3 illustrates an alternate process for fabricatingcell 100. As illustrated, this process is identical to that shown inFIG. 2 , except that the front surface and back surface contact grids are applied and fired separately, thereby allowing different firing conditions to be used for each grid. Preferablycontact grid 113 is applied (step 301) and fired (step 303) first, followed by the application (step 305) and firing (step 307) offront contact grid 111. - As previously noted, an n-type substrate may also be used with the invention. In such an embodiment, an n-type dopant, such as phosphorous, is used for
region 103 while a p-type material, such as boron, is diffused into the front surface to form the p-n junction at the interface ofsubstrate 101 and diffusedregion 107. - As will be understood by those familiar with the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof Accordingly, the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention.
Claims (17)
1-20. (canceled)
21. A method of fabricating a bifacial solar cell (BSC), the method comprising the steps of:
depositing a boron doped layer on a back surface of a p-type silicon substrate;
depositing a back surface dielectric onto said boron doped layer;
diffusing phosphorous onto a front surface of said silicon substrate to form an n+ layer and a front surface junction;
removing a phosphor-silicate glass (PSG) formed during said phosphorous diffusing step;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said n+ layer;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid; and
isolating said front surface junction.
22. The method of claim 21 , wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.
23. The method of claim 21 , wherein said front surface junction isolating step further comprises the step of forming a groove on the front surface of the BSC with a laser scriber.
24. The method of claim 21 , wherein said steps of firing said back and front surface contact grids are performed simultaneously.
25. The method of claim 21 , wherein said step of firing said back surface contact grid is performed prior to said step of applying said front surface contact grid.
26. The method of claim 21 , wherein said boron doped layer depositing step further comprises the step of depositing a boron doped silicon dioxide layer using chemical vapor deposition.
27. The method of claim 21 , wherein said boron doped layer depositing step further comprises the step of depositing a boron doped silicon layer using chemical vapor deposition.
28. The method of claim 21 , wherein said boron doped layer depositing step further comprises the step of depositing a boron doped amorphous silicon layer using plasma enhanced chemical vapor deposition.
29. The method of claim 21 , wherein said boron doped layer depositing step further comprises the step of spraying a boric acid solution onto said back surface of said silicon substrate.
30. The method of claim 21 , wherein said boron doped layer depositing step further comprises the step of spraying a boron doped spin-on glass onto said back surface of said silicon substrate.
31. The method of claim 21 , wherein said PSG removing step further comprises the step of etching said front surface with a hydrofluoric etch.
32. The method of claim 21 , further comprising the step of selecting said dielectric from the group consisting of silicon nitride, silicon dioxide and silicon oxynitride.
33. The method of claim 21 , wherein said step of depositing said back surface dielectric onto said boron doped layer further comprises the step of depositing a dielectric stack onto said boron doped layer.
34. The method of claim 32 , further comprising the step of selecting materials for said dielectric stack from the group consisting of silicon nitride, silicon dioxide and aluminum oxide.
35. The method of claim 21 , wherein said phosphorous diffusing step is performed at a temperature of approximately 850° C. for a duration of approximately 10 to 20 minutes.
36. The method of claim 21 , further comprising the step of selecting said front surface passivation and AR dielectric layer from the group consisting of silicon nitride and silicon oxynitride.
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US13/849,813 US20130217169A1 (en) | 2009-05-01 | 2013-03-25 | Bifacial solar cells with back surface doping |
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US13/849,813 Abandoned US20130217169A1 (en) | 2009-05-01 | 2013-03-25 | Bifacial solar cells with back surface doping |
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US12/456,404 Expired - Fee Related US8404970B2 (en) | 2009-05-01 | 2009-06-15 | Bifacial solar cells with back surface doping |
US13/662,242 Abandoned US20130056061A1 (en) | 2009-05-01 | 2012-10-26 | Bifacial solar cells with overlaid back grid surface |
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CN102656704A (en) | 2012-09-05 |
EP2425455A2 (en) | 2012-03-07 |
CN102668114A (en) | 2012-09-12 |
WO2010126570A3 (en) | 2011-02-03 |
WO2010126571A3 (en) | 2011-01-20 |
CN102549765A (en) | 2012-07-04 |
WO2010126572A3 (en) | 2011-01-27 |
EP2425457A2 (en) | 2012-03-07 |
US20100275995A1 (en) | 2010-11-04 |
WO2010126571A2 (en) | 2010-11-04 |
JP2012525703A (en) | 2012-10-22 |
EP2425456A2 (en) | 2012-03-07 |
US8404970B2 (en) | 2013-03-26 |
US20130056061A1 (en) | 2013-03-07 |
JP2012525702A (en) | 2012-10-22 |
EP2425455A4 (en) | 2013-08-07 |
EP2425457A4 (en) | 2013-07-24 |
US8298850B2 (en) | 2012-10-30 |
WO2010126570A2 (en) | 2010-11-04 |
US20100275984A1 (en) | 2010-11-04 |
JP2012525701A (en) | 2012-10-22 |
EP2425456A4 (en) | 2013-07-31 |
US20100275983A1 (en) | 2010-11-04 |
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