WO2010052981A1 - 光電変換装置の製造方法および光電変換装置 - Google Patents
光電変換装置の製造方法および光電変換装置 Download PDFInfo
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- WO2010052981A1 WO2010052981A1 PCT/JP2009/067247 JP2009067247W WO2010052981A1 WO 2010052981 A1 WO2010052981 A1 WO 2010052981A1 JP 2009067247 W JP2009067247 W JP 2009067247W WO 2010052981 A1 WO2010052981 A1 WO 2010052981A1
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- layer
- intermediate contact
- photoelectric conversion
- contact layer
- separation groove
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- 238000006243 chemical reaction Methods 0.000 title claims abstract description 83
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 238000000926 separation method Methods 0.000 claims abstract description 79
- 238000000034 method Methods 0.000 claims abstract description 19
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- 230000001678 irradiating effect Effects 0.000 claims 1
- 229910021417 amorphous silicon Inorganic materials 0.000 abstract description 20
- 239000013081 microcrystal Substances 0.000 abstract 1
- 239000010408 film Substances 0.000 description 56
- 239000000758 substrate Substances 0.000 description 25
- 238000001953 recrystallisation Methods 0.000 description 22
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- 229910021424 microcrystalline silicon Inorganic materials 0.000 description 12
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 10
- 239000010409 thin film Substances 0.000 description 6
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- 238000004544 sputter deposition Methods 0.000 description 3
- 229910000577 Silicon-germanium Inorganic materials 0.000 description 2
- 229910009372 YVO4 Inorganic materials 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 239000002019 doping agent Substances 0.000 description 2
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- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
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- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000002210 silicon-based material Substances 0.000 description 2
- 238000002230 thermal chemical vapour deposition Methods 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 229910006404 SnO 2 Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
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- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
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- H01L31/182—Special manufacturing methods for polycrystalline Si, e.g. Si ribbon, poly Si ingots, thin films of polycrystalline Si
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Definitions
- the present invention relates to a method for manufacturing a photoelectric conversion device, for example, a thin film solar cell, and a photoelectric conversion device, and more particularly, to a method for manufacturing a photoelectric conversion device having an intermediate contact layer separation groove in which an intermediate contact layer is separated by a pulse laser and a photoelectric conversion device.
- the present invention relates to a conversion device.
- a structure in which a plurality of photoelectric conversion layers are stacked is known.
- a tandem solar cell in which an amorphous silicon layer and a microcrystalline silicon layer are stacked is known.
- This tandem solar cell is formed by sequentially laminating a transparent electrode, an amorphous silicon layer, a microcrystalline silicon layer, and a back electrode on a light transmissive substrate.
- a technique is known in which an intermediate contact layer electrically and optically connected is provided between the amorphous silicon layer and the microcrystalline silicon layer, and a part of incident light is reflected to further improve the photoelectric conversion efficiency. ing.
- a high voltage is obtained by obtaining a desired voltage by connecting a plurality of photoelectric conversion cells in series.
- a connection groove that penetrates the amorphous silicon layer, the intermediate contact layer, and the microcrystalline silicon layer is formed, and the back electrode is filled in the connection groove, Connect the transparent electrode.
- the intermediate contact layer has conductivity, when it is electrically connected to the connection groove filled with the back electrode, the current generated in the amorphous silicon layer or the microcrystalline silicon layer passes through the intermediate contact layer. Leaks into the connection groove.
- a technique for preventing current leakage from the intermediate contact layer to the connection groove by separating the intermediate contact layer by laser processing has been proposed (see Patent Documents 1 and 2).
- the intermediate contact layer and the amorphous silicon layer are irradiated with a laser so as to separate the intermediate contact layer, the amorphous silicon layer absorbs the thermal energy of the laser, the amorphous silicon layer melts, and is scattered with the intermediate contact layer.
- An intermediate contact layer separation groove is formed.
- the amorphous silicon layer is melted and recrystallized at the wall portion (including the bottom wall) forming the intermediate contact layer separation groove. Since this recrystallized region has changed from the original amorphous silicon, it is considered that the resistance is lowered.
- the recrystallized region whose resistance has been reduced in this way becomes a new leakage path for current, resulting in a decrease in battery performance.
- the recrystallization region 101 is connected to the amorphous p layer 105, and the acceptor atoms 105a are recrystallized from the amorphous p layer 105. Diffusion into the region 101 causes the recrystallization region 101 to have a low resistance.
- reference numeral 107 denotes a glass substrate
- 109 denotes a transparent electrode layer
- 111 denotes an amorphous i layer
- 113 denotes an intermediate contact layer.
- the present invention has been made in view of such circumstances, and provides a photoelectric conversion device manufacturing method and a photoelectric conversion device that prevent current leakage as much as possible through an intermediate contact layer separation groove.
- the purpose is to do.
- the method for manufacturing a photoelectric conversion device and the photoelectric conversion device of the present invention employ the following means. That is, the method for manufacturing a photoelectric conversion device according to one embodiment of the present invention includes a first photoelectric conversion layer forming step of forming a first photoelectric conversion layer containing silicon as a main component, and on the first photoelectric conversion layer.
- the first photoelectric conversion layer is composed of an i layer and a p layer and an n layer formed so as to sandwich the i layer, and the intermediate contact layer separating step includes the first photoelectric conversion layer.
- the intermediate contact layer separation groove is formed so as to terminate at the i layer.
- the intermediate contact layer and the first photoelectric conversion layer are melted and scattered by the thermal energy given by the laser irradiation, and a groove is formed in the laser irradiation portion. Thereby, an intermediate contact layer separation groove for separating the intermediate contact layer is formed.
- an intermediate contact layer separation groove for separating the intermediate contact layer is formed.
- the end of the intermediate contact layer separation groove is positioned in the i layer of the first photoelectric conversion layer.
- n-layer donor atoms and the p-layer acceptor atoms are diffused in the recrystallized region to lower the resistance, and a current leakage path is prevented.
- An amorphous silicon layer is preferably used as the first photoelectric conversion layer, and a microcrystalline silicon layer is used as the second photoelectric conversion layer.
- GZO Ga-doped ZnO
- the end position of the intermediate contact layer separation groove is set to a substantially intermediate position in the film thickness direction of the i layer.
- the end position of the intermediate contact layer separation groove is kept away from the p layer and the n layer formed so as to sandwich the i layer. be able to. Thereby, it is possible to prevent the recrystallization region generated when forming the intermediate contact layer separation groove from being connected to the p layer or the n layer as much as possible.
- the range of the intermediate position of the i layer is determined in consideration that the unevenness on the surface of the transparent electrode or light transmissive substrate which is the lower layer of the first photoelectric conversion layer affects the film thickness distribution of the i layer.
- the center position of the i-layer film thickness is within ⁇ 30% of the i-layer film thickness. It is preferable to set the end position of the intermediate contact layer separation groove.
- the end position of the intermediate contact layer separation groove is determined by adjusting a power density indicating an output per unit area of the pulse laser.
- the photoelectric conversion device includes a first photoelectric conversion layer mainly composed of silicon, an intermediate contact layer electrically and optically connected to the first photoelectric conversion layer, A second photoelectric conversion layer mainly composed of silicon and electrically connected to the intermediate contact layer and penetrating the intermediate contact layer so as to separate the intermediate contact layer;
- the first photoelectric conversion layer includes an i layer, a p layer formed to sandwich the i layer, and n The intermediate contact layer separation groove terminates at the i layer of the first photoelectric conversion layer.
- the intermediate contact layer and the first photoelectric conversion layer are melted and scattered by the thermal energy given by the laser irradiation, and a groove is formed in the laser irradiation portion. Thereby, an intermediate contact layer separation groove for separating the intermediate contact layer is formed.
- an intermediate contact layer separation groove for separating the intermediate contact layer is formed.
- the end of the intermediate contact layer separation groove is positioned in the i layer of the first photoelectric conversion layer.
- n-layer donor atoms and the p-layer acceptor atoms are diffused in the recrystallized region to lower the resistance, and a current leakage path is prevented.
- An amorphous silicon layer is preferably used as the first photoelectric conversion layer, and a microcrystalline silicon layer is used as the second photoelectric conversion layer.
- GZO Ga-doped ZnO
- the end position of the intermediate contact layer separation groove is a substantially intermediate position in the film thickness direction of the i layer.
- the end position of the intermediate contact layer separation groove is kept away from the p layer and the n layer formed so as to sandwich the i layer. be able to. Thereby, it is possible to prevent the recrystallization region generated when forming the intermediate contact layer separation groove from being connected to the p layer or the n layer as much as possible.
- the intermediate position of the i layer is ⁇ 30% of the thickness of the i layer from the central position of the thickness of the i layer in consideration of the unevenness on the surface of the transparent electrode or light transmissive substrate that is the lower layer of the first photoelectric conversion layer. It is preferable to be in the range.
- the end of the intermediate contact layer separation groove is positioned in the i layer of the first photoelectric conversion layer, and the recrystallization region existing around the intermediate contact layer separation groove is connected to the n layer or the p layer. Since this is avoided, it is possible to prevent the resistance of the recrystallization region from being lowered. As a result, when the intermediate contact layer separation groove is formed, a new current leakage path is prevented from being formed, and the efficiency of the photoelectric conversion device is improved.
- FIG. 1 shows a longitudinal section of a tandem silicon thin film solar cell (photoelectric conversion device).
- the solar cell 10 includes a glass substrate (translucent substrate) 1, a transparent electrode layer 2, a top layer (first photoelectric conversion layer) 91, an intermediate contact layer 93, and a bottom layer (second photoelectric conversion layer) 92. And a back electrode layer 4.
- the top layer 91 is a photoelectric conversion layer mainly including an amorphous silicon-based semiconductor
- the bottom layer 92 is a photoelectric conversion layer mainly including a crystalline silicon-based semiconductor.
- silicon-based is a generic name including silicon (Si), silicon carbide (SiC), and silicon germanium (SiGe).
- Crystalstalline silicon means amorphous silicon, that is, silicon other than amorphous silicon, and includes microcrystalline silicon and polycrystalline silicon.
- the solar cell 10 of the present embodiment having the above-described configuration is manufactured as follows.
- the glass substrate soda float glass having a size of 1 m square is used. Specifically, a size of 1.4 m ⁇ 1.1 m and a thickness of 3.5 to 4.5 mm is used.
- the end face of the glass substrate 1 is preferably subjected to corner chamfering or R chamfering in order to prevent damage due to thermal stress or impact.
- a transparent electrode film mainly composed of a tin oxide film (SnO 2 ) is preferably used as the transparent electrode layer 2.
- This transparent electrode film has a thickness of about 500 nm to 800 nm, and can be obtained by film formation at about 500 ° C. using a thermal CVD apparatus. During the film forming process, a texture with appropriate irregularities is formed on the surface of the transparent electrode film.
- an alkali barrier film (not shown) may be interposed between the transparent electrode film and the substrate 1.
- the alkali barrier film is a silicon oxide film (SiO 2 ) having a thickness of, for example, 50 nm to 150 nm, and is obtained by performing a film forming process at about 500 ° C. with a thermal CVD apparatus.
- the glass substrate 1 is placed on an XY table, and the first harmonic (1064 nm) of the YAG laser is irradiated from the film surface side (upper side in the drawing) of the transparent electrode layer 2.
- the laser power is adjusted so as to be appropriate for the processing speed, and the glass substrate 1 and the laser beam are placed in a direction perpendicular to the series connection direction of the power generation cells 5 in the transparent electrode layer 2 (perpendicular to the drawing in the drawing) Are moved relative to each other to form the transparent electrode separation groove 12.
- the transparent electrode layer 2 is laser-etched into a strip shape having a predetermined width of about 6 mm to 15 mm.
- a p-layer film / i-layer film / n-layer film made of an amorphous silicon thin film is sequentially formed under the conditions of a reduced pressure atmosphere of 30 to 1000 Pa and a substrate temperature of about 200 ° C.
- the top layer 91 is formed (first photoelectric conversion layer forming step).
- the top layer 91 is formed on the transparent electrode layer 2 by a process gas using SiH 4 gas and H 2 gas as main raw materials.
- the p-layer, i-layer, and n-layer are laminated in this order from the sunlight incident side (glass substrate 1 side).
- the top layer 91 is 10 nm to 30 nm mainly composed of B-doped amorphous SiC as an amorphous p layer, 200 nm to 350 nm mainly composed of amorphous Si as an amorphous i layer, and amorphous as an amorphous n layer. It is composed of a 30 nm to 50 nm film thickness mainly composed of a p-doped Si layer containing microcrystalline Si in Si. Further, a buffer layer may be provided between the p layer film and the i layer film in order to improve the interface characteristics.
- a GZO (Ga doped ZnO) film is formed on the top layer 91 as the intermediate contact layer 93 (intermediate contact layer forming process).
- the GZO (Ga doped ZnO) film has a thickness of 20 nm to 100 nm and is formed by a sputtering apparatus.
- the intermediate contact layer 93 can improve the contact between the top layer 91 and the bottom layer 92 and obtain current matching.
- the intermediate contact layer 93 is a semi-reflective film, and realizes an improvement in photoelectric conversion efficiency in the top layer 91 by reflecting a part of light incident from the glass substrate 1.
- the glass substrate 1 is placed on an XY table, and a YVO4 pulse laser (hereinafter referred to as “nanosecond pulse laser”) having a wavelength of 532 nm and a pulse width of nanosecond order (1 to 100 ns) is used. Irradiation is performed from the film surface side (upper side in the figure) of the transparent electrode layer 2.
- the intermediate contact layer separation groove 14 is formed between the transparent electrode separation groove 12 and the connection groove 16 (intermediate contact layer separation step). As shown in FIG. 2, the intermediate contact layer separation groove 14 terminates at the i layer 91 i of the top layer 91. This intermediate contact layer separation step will be described in detail later.
- a plasma CVD apparatus is used to reduce the pressure under a reduced pressure atmosphere of 3000 Pa or less, a substrate temperature of about 200 ° C., and a plasma generation frequency of 40 MHz to 100 MHz.
- a bottom layer 92 is formed by sequentially forming a microcrystalline p layer film / a microcrystalline i layer film / a microcrystalline n layer film made of a crystalline silicon thin film (second photoelectric conversion layer forming step).
- the bottom layer 92 has a thickness of 10 nm to 50 nm mainly composed of B-doped microcrystalline SiC as the microcrystalline p layer, and a thickness of 1.2 ⁇ m to 3 mainly composed of microcrystalline Si as the microcrystalline i layer.
- the film thickness is 20 to 50 nm mainly composed of p-doped microcrystalline Si as a microcrystalline n layer.
- the distance d between the plasma discharge electrode and the surface of the glass substrate 1 is preferably 3 mm to 10 mm. If it is smaller than 3 mm, it is difficult to keep the distance d constant from the accuracy of each component device in the film forming chamber corresponding to the large substrate, and there is a possibility that the discharge becomes unstable because it is too close. When it is larger than 10 mm, it is difficult to obtain a sufficient film forming speed (1 nm / s or more), and the uniformity of the plasma is lowered and the film quality is lowered by ion bombardment.
- the glass substrate 1 is placed on an XY table, and the second harmonic (532 nm) of the laser diode-pumped YAG laser is applied to the film surface side of the bottom layer 92 (upward in the figure) as shown by the arrow in the figure. Irradiate from the side. Pulse oscillation: 10 to 20 kHz The laser power is adjusted so as to be suitable for the processing speed, and the connection groove 16 is formed at a position spaced apart from the transparent electrode separation groove 12 by about 50 to 350 ⁇ m laterally.
- the laser may be irradiated from the glass substrate 1 side, and in this case, the intermediate contact layer 93 and the bottom layer 92 can be etched using the high vapor pressure generated by the energy absorbed by the top layer 91, so that it is more stable. Laser etching can be performed.
- the position of the laser etching line is selected in consideration of positioning tolerances so as not to intersect with the etching line in the previous process.
- the back electrode layer 4 an Ag film / Ti film is sequentially formed by a sputtering apparatus at a reduced pressure atmosphere at about 150 to 200 ° C.
- the back electrode layer 4 has a thickness of about 150 to 500 nm, and a Ti film having a high anticorrosion effect is laminated in this order with a thickness of 10 to 20 nm to protect it.
- a laminated structure of an Ag film having a thickness of about 25 nm to 100 nm and an Al film having a thickness of about 15 nm to 500 nm may be used.
- a GZO (Ga-doped ZnO) film having a film thickness of 50 to 100 nm between the bottom layer 92 and the back electrode layer 4 is formed by a sputtering apparatus.
- a film may be formed.
- the glass substrate 1 is placed on an XY table, and the second harmonic (532 nm) of the laser diode pumped YAG laser is irradiated from the glass substrate 1 side (the lower side in the figure).
- the laser light is absorbed by the top layer 91 and the bottom layer 92, and the back electrode layer 4 is exploded and removed using the high gas vapor pressure generated at this time.
- the laser pulse oscillation frequency is set to 1 to 10 kHz, the laser power is adjusted so that the processing speed is appropriate, and the cell dividing groove 18 is formed at a position spaced apart from about 250 to 400 ⁇ m laterally from the transparent electrode separation groove 12. So that laser etching.
- a solar cell is manufactured through a process of attaching a back sheet having a high waterproof effect via an adhesive filler sheet such as EVA (ethylene vinyl acetate copolymer) so as to cover the back electrode 4.
- EVA ethylene vinyl acetate copolymer
- the laser used in this process is a nanosecond pulse laser having a pulse width of 1 ns to 100 ns.
- a YVO4 laser (wavelength of 532 nm) having an oscillation frequency of 12 kHz and a beam spot diameter of 90 ⁇ m is preferably used.
- the processing speed (that is, the laser feed speed with respect to the glass substrate 1) is, for example, about 800 mm / s.
- a second high frequency (532 nm) of YAG laser or a fiber laser may be used.
- the terminal position (bottom) of the intermediate contact layer separation groove 14 is located in the i layer 91 i of the top layer 91. That is, the termination position 14L of the intermediate contact layer separation groove 14 is not located in the n layer 91n and the p layer 91p of the top layer 91. Thereby, the recrystallized region 15 formed in the wall portion (including the bottom portion) where the amorphous silicon is melted and solidified to form the intermediate contact layer separation groove 14 is separated from the n layer 91n and the p layer 91p. Can do.
- the dopant of the n layer 91n and the p layer 91p is prevented from diffusing into the recrystallized region 15, and the resistance of the recrystallized region due to the dopant can be reduced.
- the recrystallization region 15 can be confirmed with a transmission electron microscope or the like.
- FIG. 3 illustrates the concept of setting the end position 14L of the intermediate contact layer separation groove 14.
- the thick line located at the center indicates the end position 14L of the intermediate contact layer separation tank 14.
- the vertical direction in the figure means the film thickness direction.
- a triangular wave-shaped uneven line 91i-L located below the end position 14L indicates the interface between the amorphous i layer 91i and the amorphous p layer 91p.
- This unevenness reflects the unevenness of the texture structure formed on the surface of the transparent electrode layer 2.
- a broken line 91i-Lav shown in the approximate center of the uneven line 91i-L is an average line indicating an average value of the uneven line 91i-L in the film thickness direction.
- a triangular wave-shaped uneven line 91i-U located above the end position 14L indicates the interface between the amorphous i layer 91i and the amorphous p layer 91p.
- This unevenness reflects the unevenness of the texture structure formed on the surface of the transparent electrode layer 2.
- a broken line 91i-Uav shown at substantially the center of the uneven line 2L is an average line indicating an average value of the uneven lines 91i-U in the film thickness direction.
- the end position 14L of the intermediate contact layer separation groove 14 is determined in consideration of the degree of unevenness of the uneven lines 91i-L, U.
- the position of the end position 14L is equivalent to the degree of the unevenness.
- the film thickness is set within a range of ⁇ 30% of the film thickness of the i layer from the center position of the film thickness of the amorphous i layer 91i.
- the termination depth 14L is not located in the amorphous n layer 91n.
- 70 + 35 105 nm or more is required.
- the output of the nanosecond pulse laser may be adjusted to an energy density in the range of .45 W). However, from the viewpoint of stabilizing output, it is preferable to adjust the output of the nanosecond pulse laser in the range of 0.3 to 0.4 J / cm 2 .
- the end 14L of the intermediate contact layer separation groove 14 is positioned on the amorphous i layer 91i of the top layer 91. Thereby, it is avoided that the recrystallization region 15 existing around the intermediate contact layer separation groove 14 is connected to the amorphous n layer 91n or the amorphous p layer 14p, and donor atoms from the n layer are introduced into the recrystallization region 15. Diffusion is prevented, and acceptor atoms are prevented from diffusing from the p layer into the recrystallization region 15. Therefore, the n-layer donor atoms and the p-layer acceptor atoms are prevented from diffusing into the recrystallized region 15 to lower the resistance, and a current leakage path is prevented.
- the end position 14L of the contact layer separation groove 14 is determined. Thereby, the intermediate contact layer separation groove 14 having a desired depth can be processed with good reproducibility.
- the solar cell shown in FIG. 1 has a tandem structure in which two power generation layers including the first cell layer 91 and the second cell layer 92 are stacked.
- the present invention is limited to the tandem structure. This is widely applicable when the silicon-based material is recrystallized when laser processing the intermediate contact layer separation groove. For example, three power generation layers are stacked, and the intermediate contact layer is formed between the power generation layers. It can also be used for a triple structure provided with.
- the nanosecond pulse laser is used as the laser for processing the intermediate contact layer separation groove 14.
- the present invention is not limited to this, for example, a pico having a pulse width of 10 to 750 ps.
- a second pulse laser may be used.
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Abstract
Description
一方、中間コンタクト層は、導電性を有しているため、裏面電極が充填された接続溝と電気的に接続されると、アモルファスシリコン層や微結晶シリコン層で発生した電流が中間コンタクト層を介して接続溝へと漏れてしまう。
そこで、レーザー加工によって中間コンタクト層を分離することで、中間コンタクト層から接続溝への電流の漏洩を防止する技術が提案されている(特許文献1及び2参照)。
中間コンタクト層を分離するようにレーザーを中間コンタクト層およびアモルファスシリコン層に照射すると、レーザーの熱エネルギーをアモルファスシリコン層が吸収し、このアモルファスシリコン層が溶融し、中間コンタクト層を伴って飛散し、中間コンタクト層分離溝が形成される。この中間コンタクト層分離溝を形成する際に、中間コンタクト層分離溝を形成する壁部(底壁を含む)では、アモルファスシリコン層が溶融し再結晶する。この再結晶化した領域は、当初のアモルファスシリコンから変質しているため、低抵抗化すると考えられる。このように低抵抗化した再結晶領域は、電流の新たな漏れ経路となり、電池性能の低下を来してしまう。
具体的には、第1に、図5の左側に示すように中間コンタクト層分離溝100aが浅い場合、再結晶化領域101がアモルファスn層103に接続されてしまい、アモルファスn層103からドナー原子103aが再結晶化領域101内に拡散し、再結晶化領域101が低抵抗化してしまう。第2に、図5の右側に示すように中間コンタクト層分離溝100bが深い場合、再結晶化領域101がアモルファスp層105に接続されてしまい、アモルファスp層105からアクセプタ原子105aが再結晶化領域101内に拡散し、再結晶化領域101が低抵抗化してしまう。図5において、符号107はガラス基板、109は透明電極層、111はアモルファスi層、113は中間コンタクト層を示す。
すなわち、本発明の一態様にかかる光電変換装置の製造方法は、シリコンを主成分とする第1光電変換層を製膜する第1光電変換層製膜工程と、前記第1光電変換層上に、該第1光電変換層に対して電気的および光学的に接続される中間コンタクト層を製膜する中間コンタクト層製膜工程と、レーザーを照射して、前記中間コンタクト層を除去するとともに、前記第1光電変換層まで到達する中間コンタクト層分離溝を形成して該中間コンタクト層を分離する中間コンタクト層分離工程と、前記中間コンタクト層上および前記中間コンタクト層分離溝内に、該中間コンタクト層に対して電気的および光学的に接続されるとともに、シリコンを主成分とする第2光電変換層を製膜する第2光電変換層製膜工程とを有する光電変換装置の製造方法において、前記第1光電変換層は、i層と、該i層を挟むように製膜されたp層およびn層とから構成され、前記中間コンタクト層分離工程は、前記第1光電変換層の前記i層にて終端するように前記中間コンタクト層分離溝を形成する。
上記態様では、中間コンタクト層分離溝の終端を、第1光電変換層のi層に位置させることとした。これにより、中間コンタクト層分離溝の周囲に存在する再結晶化領域がn層またはp層に接続されることを回避し、再結晶化領域にn層からドナー原子が拡散することが防止され、また、再結晶化領域にp層からアクセプタ原子が拡散することが防止される。したがって、再結晶化領域にn層のドナー原子やp層のアクセプタ原子が拡散して低抵抗化することが回避され、電流の漏れ経路となることが防止される。
第1光電変換層としては、好適には、アモルファスシリコン層が用いられ、第2光電変換層としては、微結晶シリコン層が用いられる。中間コンタクト層としては、GZO(GaドープZnO)が好適に用いられる。
i層の中間位置の範囲としては、第1光電変換層の下層となる透明電極や光透過性基板の表面における凹凸がi層の膜厚分布に影響を与えることを考慮して決定する。凹凸の程度と同等の範囲となるように、例えば凹凸の範囲がi層膜厚の±30%の場合には、i層の膜厚の中央位置からi層膜厚の±30%の範囲に中間コンタクト層分離溝の終端位置を設定することが好ましい。
上記態様では、中間コンタクト層分離溝の終端を、第1光電変換層のi層に位置させることとした。これにより、中間コンタクト層分離溝の周囲に存在する再結晶化領域がn層またはp層に接続されることを回避し、再結晶化領域にn層からドナー原子が拡散することが防止され、また、再結晶化領域にp層からアクセプタ原子が拡散することが防止される。したがって、再結晶化領域にn層のドナー原子やp層のアクセプタ原子が拡散して低抵抗化することが回避され、電流の漏れ経路となることが防止される。
第1光電変換層としては、好適には、アモルファスシリコン層が用いられ、第2光電変換層としては、微結晶シリコン層が用いられる。
中間コンタクト層としては、GZO(GaドープZnO)が好適に用いられる。
i層の中間位置としては、第1光電変換層の下層となる透明電極や光透過性基板の表面における凹凸を考慮して、i層の膜厚の中央位置からi層膜厚の±30%の範囲にすることが好ましい。
図1には、タンデム型とされたシリコン系薄膜太陽電池(光電変換装置)の縦断面が示されている。
太陽電池10は、ガラス基板(透光性基板)1と、透明電極層2と、トップ層(第1光電変換層)91と、中間コンタクト層93と、ボトム層(第2光電変換層)92と、裏面電極層4とを備えている。本実施形態において、トップ層91は非晶質シリコン系半導体を主として有する光電変換層であり、ボトム層92は結晶質シリコン系半導体を主として有する光電変換層である。
ガラス基板1としては、1m四方の大きさとされたソーダフロートガラスが用いられる。具体的には、1.4m×1.1mの大きさとされ、板厚が3.5から4.5mmのものが用いられる。ガラス基板1の端面は、熱応力や衝撃などによる破損防止のために、コーナー面取り加工やR面取り加工が施されていることが好ましい。
トップ層91は、本実施形態では、アモルファスp層としてBドープしたアモルファスSiCを主とした膜厚10nmから30nm、アモルファスi層としてアモルファスSiを主とした膜厚200nmから350nm、アモルファスn層としてアモルファスSiに微結晶Siを含有するpドープしたSi層を主とした膜厚30nmから50nmから構成されている。また、p層膜とi層膜の間には、界面特性の向上のためにバッファー層を設けても良い。
ボトム層92は、本実施形態では、微結晶p層としてBドープした微結晶SiCを主とした膜厚10nmから50nm、微結晶i層として微結晶Siを主とした膜厚1.2μmから3.0μm、微結晶n層としてpドープした微結晶Siを主とした膜厚20nmから50nmから構成されている。
当該工程に用いられるレーザーは、1nsから100nsのパルス幅を有するナノ秒パルスレーザーである。具体的には、発振周波数12kHz、ビームスポット径90μm、とされたYVO4レーザー(波長532nm)が好適に用いられる。加工速度(即ちガラス基板1に対するレーザーの送り速度)は、例えば、800mm/s程度とされる。
レーザーとしては、YAGレーザーの第2高周波(532nm)やファイバーレーザーを用いてもよい。
同図において、中央に位置する太線が中間コンタクト層分離槽14の終端位置14Lを示す。したがって、同図において上下方向が膜厚方向を意味する。
同図において終端位置14Lの下方に位置する三角波形状の凹凸線91i-Lは、アモルファスi層91iとアモルファスp層91pとの界面を示す。この凹凸は、透明電極層2の表面に形成されたテクスチャ構造の凹凸が反映されたものである。この凹凸線91i-Lの略中央に示されている破線91i-Lavは、凹凸線91i-Lの膜厚方向の平均値を示した平均線である。
同図において終端位置14Lの上方に位置する三角波形状の凹凸線91i-Uは、アモルファスi層91iとアモルファスp層91pとの界面を示す。この凹凸は、透明電極層2の表面に形成されたテクスチャ構造の凹凸が反映されたものである。この凹凸線2Lの略中央に示されている破線91i-Uavは、凹凸線91i-Uの膜厚方向の平均値を示した平均線である。
中間コンタクト層分離溝14の終端位置14Lは、凹凸線91i-L,Uの凹凸の程度を考慮して決定する。例えば、アモルファスi層91iの膜厚(破線91i-Lav,Uav間の距離)に対して±30%の凹凸が有る場合には、終端位置14Lの位置は、この凹凸の程度と同等となるように、アモルファスi層91iの膜厚の中央位置からi層膜厚の±30%の範囲に設定する。
y = -1373.4x2 + 1700x -
226.95 ・・・(1)
という二次式に表される関係がある。
このような加工深さ範囲、即ち105から305nmの範囲の加工深さでは、上式(1)は精度良く近似される。
したがって、105から305nmの加工深さを実現するためには、図4に示されているように、0.24J/cm2(12kHz,0.18W)から0.6J/cm2(12kHz,0.45W)の範囲のエネルギー密度にナノ秒パルスレーザーの出力を調整すればよい。ただし、安定化出力の観点から、0.3から0.4J/cm2の範囲にてナノ秒パルスレーザーの出力を調整するのが好ましい。
中間コンタクト層分離溝14の終端14Lを、トップ層91のアモルファスi層91iに位置させることとした。これにより、中間コンタクト層分離溝14の周囲に存在する再結晶化領域15がアモルファスn層91nまたはアモルファスp層14pに接続されることを回避し、再結晶化領域15にn層からドナー原子が拡散することが防止され、また、再結晶化領域15にp層からアクセプタ原子が拡散することが防止される。したがって、再結晶化領域15にn層のドナー原子やp層のアクセプタ原子が拡散して低抵抗化することが回避され、電流の漏れ経路となることが防止される。
2 透明電極層
4 裏面電極層
5 発電セル
10 太陽電池(光電変換装置)
14 中間コンタクト層分離溝
15 再結晶化領域
91 トップ層(第1光電変換層)
92 ボトム層(第2光電変換層)
93 中間コンタクト層
Claims (5)
- シリコンを主成分とする第1光電変換層を製膜する第1光電変換層製膜工程と、
前記第1光電変換層上に、該第1光電変換層に対して電気的および光学的に接続される中間コンタクト層を製膜する中間コンタクト層製膜工程と、
レーザーを照射して、前記中間コンタクト層を除去するとともに、前記第1光電変換層まで到達する中間コンタクト層分離溝を形成して該中間コンタクト層を分離する中間コンタクト層分離工程と、
前記中間コンタクト層上および前記中間コンタクト層分離溝内に、該中間コンタクト層に対して電気的および光学的に接続されるとともに、シリコンを主成分とする第2光電変換層を製膜する第2光電変換層製膜工程と、
を有する光電変換装置の製造方法において、
前記第1光電変換層は、i層と、該i層を挟むように製膜されたp層およびn層とから構成され、
前記中間コンタクト層分離工程は、前記第1光電変換層の前記i層にて終端するように前記中間コンタクト層分離溝を形成する光電変換装置の製造方法。 - 前記中間コンタクト層分離溝の終端位置は、前記i層の膜厚方向における略中間位置とされている請求項1に記載の光電変換装置の製造方法。
- 前記中間コンタクト層分離溝の終端位置は、前記パルスレーザーの単位面積当たりの出力を示すパワー密度を調整することによって決定される請求項1又は2に記載の光電変換装置の製造方法。
- シリコンを主成分とする第1光電変換層と、
該第1光電変換層に対して電気的および光学的に接続された中間コンタクト層と、
該中間コンタクト層に対して電気的および光学的に接続されるとともに、シリコンを主成分とする第2光電変換層と、を備え、
前記中間コンタクト層を分離するように該中間コンタクト層を貫通するとともに前記第1光電変換層まで到達する中間コンタクト層分離溝が形成された光電変換装置において、
前記第1光電変換層は、i層と、該i層を挟むように製膜されたp層およびn層とから構成され、
前記中間コンタクト層分離溝は、前記第1光電変換層の前記i層にて終端している光電変換装置。 - 前記中間コンタクト層分離溝の終端位置は、前記i層の膜厚方向における略中間位置とされている請求項4に記載の光電変換装置。
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CN2009801288102A CN102105991B (zh) | 2008-11-05 | 2009-10-02 | 光电转换装置的制造方法及光电转换装置 |
US13/055,297 US20110126895A1 (en) | 2008-11-05 | 2009-10-02 | Photoelectric conversion device fabrication method and photoelectric conversion device |
EP09824681A EP2346087A1 (en) | 2008-11-05 | 2009-10-02 | Photoelectric conversion device manufacturing method and photoelectric conversion device |
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JP2008284209A JP5180781B2 (ja) | 2008-11-05 | 2008-11-05 | 光電変換装置の製造方法および光電変換装置 |
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EP (1) | EP2346087A1 (ja) |
JP (1) | JP5180781B2 (ja) |
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CN103238218A (zh) * | 2010-07-29 | 2013-08-07 | 洛桑联邦理工学院(Epfl) | 多结光电器件及其生产工艺 |
Families Citing this family (7)
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CN101894903B (zh) * | 2010-06-25 | 2012-03-28 | 清华大学 | 光电转换装置 |
JP5557721B2 (ja) * | 2010-12-10 | 2014-07-23 | 株式会社日立製作所 | 太陽電池の製造方法 |
DE102012205378A1 (de) * | 2012-04-02 | 2013-10-02 | Robert Bosch Gmbh | Verfahren zur Herstellung von Dünnschichtsolarmodulen sowie nach diesem Verfahren erhältliche Dünnschichtsolarmodule |
BR112016017717B1 (pt) * | 2014-01-31 | 2022-01-25 | Flisom Ag | Método para formar pelo menos um dispositivo de cigs de película delgada e o mesmo |
KR102429868B1 (ko) | 2014-12-04 | 2022-08-05 | 삼성전자주식회사 | 플라즈몬 비아를 이용한 광 인터커넥션 소자 |
TWI590477B (zh) * | 2016-09-19 | 2017-07-01 | 聯相光電股份有限公司 | 太陽能電池鏤空電路及太陽能電池顯示裝置 |
DE102020108334A1 (de) | 2020-03-26 | 2021-09-30 | Helmholtz-Zentrum Berlin für Materialien und Energie Gesellschaft mit beschränkter Haftung | Stapelsolarzellenmodul und Verfahren zur Herstellung des Stapelsolarzellenmoduls |
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- 2009-10-02 KR KR1020117000423A patent/KR20110026472A/ko not_active Application Discontinuation
- 2009-10-02 US US13/055,297 patent/US20110126895A1/en not_active Abandoned
- 2009-10-02 WO PCT/JP2009/067247 patent/WO2010052981A1/ja active Application Filing
- 2009-10-02 CN CN2009801288102A patent/CN102105991B/zh not_active Expired - Fee Related
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US9337367B2 (en) * | 2010-07-29 | 2016-05-10 | Ecole Polytechnique Federale De Lausanne | Multiple-junction photoelectric device and its production process |
Also Published As
Publication number | Publication date |
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KR20110026472A (ko) | 2011-03-15 |
JP5180781B2 (ja) | 2013-04-10 |
EP2346087A1 (en) | 2011-07-20 |
CN102105991A (zh) | 2011-06-22 |
CN102105991B (zh) | 2013-12-04 |
US20110126895A1 (en) | 2011-06-02 |
JP2010114191A (ja) | 2010-05-20 |
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