WO2011058828A1 - Cu-In-Ga-Se四元系合金スパッタリングターゲット - Google Patents
Cu-In-Ga-Se四元系合金スパッタリングターゲット Download PDFInfo
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- WO2011058828A1 WO2011058828A1 PCT/JP2010/066820 JP2010066820W WO2011058828A1 WO 2011058828 A1 WO2011058828 A1 WO 2011058828A1 JP 2010066820 W JP2010066820 W JP 2010066820W WO 2011058828 A1 WO2011058828 A1 WO 2011058828A1
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- Prior art keywords
- sputtering target
- quaternary alloy
- alloy sputtering
- bulk resistance
- target
- Prior art date
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- 238000005477 sputtering target Methods 0.000 title claims abstract description 44
- 229910002059 quaternary alloy Inorganic materials 0.000 title claims abstract description 40
- 239000011669 selenium Substances 0.000 claims abstract description 39
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000001301 oxygen Substances 0.000 claims abstract description 27
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 22
- 229910052711 selenium Inorganic materials 0.000 claims abstract description 13
- 239000010949 copper Substances 0.000 claims abstract description 12
- 229910052738 indium Inorganic materials 0.000 claims abstract description 11
- 229910052733 gallium Inorganic materials 0.000 claims abstract description 10
- 229910052802 copper Inorganic materials 0.000 claims abstract description 9
- BUGBHKTXTAQXES-UHFFFAOYSA-N Selenium Chemical compound [Se] BUGBHKTXTAQXES-UHFFFAOYSA-N 0.000 claims abstract description 7
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims abstract description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 3
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 claims abstract description 3
- 239000002245 particle Substances 0.000 claims description 30
- 239000000843 powder Substances 0.000 claims description 18
- 238000007731 hot pressing Methods 0.000 claims description 13
- 239000007858 starting material Substances 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims 1
- 230000002159 abnormal effect Effects 0.000 description 27
- 238000004544 sputter deposition Methods 0.000 description 23
- 239000002994 raw material Substances 0.000 description 22
- 230000015572 biosynthetic process Effects 0.000 description 12
- 239000010408 film Substances 0.000 description 11
- 238000000034 method Methods 0.000 description 11
- 238000003786 synthesis reaction Methods 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000010409 thin film Substances 0.000 description 6
- 230000031700 light absorption Effects 0.000 description 5
- 239000011858 nanopowder Substances 0.000 description 5
- 206010039921 Selenium deficiency Diseases 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 239000003708 ampul Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910002056 binary alloy Inorganic materials 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000012776 electronic material Substances 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002250 progressing effect Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
Classifications
-
- 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
- H01L31/0248—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies
- H01L31/0256—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by the material
- H01L31/0264—Inorganic materials
- H01L31/032—Inorganic materials including, apart from doping materials or other impurities, only compounds not provided for in groups H01L31/0272 - H01L31/0312
- H01L31/0322—Inorganic materials including, apart from doping materials or other impurities, only compounds not provided for in groups H01L31/0272 - H01L31/0312 comprising only AIBIIICVI chalcopyrite compounds, e.g. Cu In Se2, Cu Ga Se2, Cu In Ga Se2
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/0623—Sulfides, selenides or tellurides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
- C23C14/3407—Cathode assembly for sputtering apparatus, e.g. Target
- C23C14/3414—Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
-
- 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
-
- 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
- Y02E10/541—CuInSe2 material PV cells
Definitions
- the present invention relates to a CIGS quaternary alloy sputtering target used when forming a Cu—In—Ga—Se (hereinafter referred to as CIGS) quaternary alloy thin film to be a light absorption layer of a thin film solar cell.
- CIGS Cu—In—Ga—Se
- a vapor deposition method and a selenization method are known as methods for producing the light absorption layer of the thin film solar cell.
- the solar cell manufactured by the vapor deposition method has the advantage of high conversion efficiency, it has the disadvantages of low film formation speed, high cost, and low productivity.
- the selenization method is also suitable for industrial mass production, but it is a complicated and dangerous process in which a Cu—Ga and In laminated film is produced and then heat-treated in a hydrogen selenium atmosphere gas for selenization. And has the disadvantage of requiring cost and time.
- Patent Document 1 after injecting In into a Cu—Se binary alloy melt, Ga is sequentially added to form a CIGS quaternary alloy ingot. Then, the ingot is dry pulverized, and the pulverized powder is obtained. A method of manufacturing a CIGS quaternary alloy sputtering target by hot pressing is disclosed. However, the CIGS quaternary alloy sputtering target obtained by this manufacturing method has not been clarified at all about density, oxygen concentration, bulk resistance, and the like, which are important characteristics of the sputtering target.
- Non-Patent Document 1 discloses a method of manufacturing a CIGS quaternary alloy sputtering target that has been subjected to HIP processing after powder production by mechanical alloy serving as a nanopowder material, and characteristics of the target.
- HIP processing after powder production by mechanical alloy serving as a nanopowder material, and characteristics of the target.
- characteristics of the CIGS quaternary alloy sputtering target obtained by this production method although there is a qualitative description that the density is high, no specific density value is disclosed.
- Non-Patent Document 2 discloses a sintered body having a composition of Cu (In 0.8 Ga 0.2 ) Se 2 , a density of 5.5 g / cm 3 , and a relative density of 97%. Is disclosed. However, as the manufacturing method, there is only a description that the originally synthesized raw material powder is sintered by the hot press method, and a specific manufacturing method is not clearly described. Further, neither oxygen concentration nor bulk resistance of the obtained sintered body is described.
- An object of the present invention is to provide a CIGS quaternary alloy sputtering target having a high density and a low oxygen concentration, and a CIGS quaternary alloy sputtering target having a desired bulk resistance.
- the density of the CIGS quaternary alloy sputtering target is related to the synthesis temperature profile during raw material powder preparation and the set temperature during hot pressing. That is, it has been found that the target can be made dense by setting an appropriate synthesis temperature, heating rate, holding time, and the like.
- the oxygen concentration of the CIGS quaternary alloy sputtering target is related to the particle size of the raw material powder and the set temperature of the subsequent process, that is, the use of the raw material powder having an appropriate average particle size and the appropriate subsequent process. It has been found that the oxygen concentration of the target can be reduced by setting the temperature.
- the bulk resistance and its variation are related to the presence of heterogeneous phases in the CIGS quaternary alloy sputtering target, that is, the desired bulk resistance can be obtained by optimizing the raw material synthesis and hot pressing conditions, and The inventors have found that the variation in resistance value can be reduced, and have completed the present invention.
- the present invention 1.
- a quaternary alloy sputtering target composed of copper (Cu), indium (In), gallium (Ga) and selenium (Se)
- the composition is CuIn 1-x Ga x Se 2-y (where x and y are respectively Cu—, characterized in that the composition range is 0 ⁇ x ⁇ 0.5, 0 ⁇ y ⁇ 0.04, and the relative density is 90% or more.
- An In—Ga—Se sputtering target is provided.
- the present invention also provides: 2. 2. The Cu—In—Ga—Se quaternary alloy sputtering target according to 1 above, wherein the oxygen concentration is 200 wtppm or less; 3. 3. The Cu—In—Ga—Se quaternary alloy sputtering target according to 1 or 2 above, wherein the bulk resistance is in the range of 50 to 100 ⁇ cm. 4. The Cu—In—Ga—Se quaternary alloy sputtering target according to any one of 1 to 3 above, wherein variation in bulk resistance is ⁇ 5% or less in a target plane. The Cu—In—Ga—Se quaternary alloy sputtering target according to any one of 1 to 4 above, wherein the average particle diameter is 20 to 100 ⁇ m.
- the present invention also provides: 6).
- the starting material, shot or bar-shaped Cu, In, Ga, and Se, is mixed and synthesized. After passing through this sieve and adjusting the particle size, the synthesized powder is sintered by hot pressing (HP).
- the Cu—In—Ga—Se sputtering target according to any one of 1 to 6 produced by the method is provided.
- the CIGS quaternary alloy sputtering target of the present invention has an excellent effect that there is almost no abnormal discharge even if it is sputtered for a long time and that a film excellent in in-plane uniformity of the film composition can be produced.
- the composition range of In in the CIGS quaternary alloy sputtering target is CuIn 1-x Ga x Se 2-y (where x and y represent atomic ratios, respectively): 0 ⁇ x ⁇ 0.50
- x and y represent atomic ratios, respectively
- 0 ⁇ x ⁇ 0.50 To do. As x increases, the CIGS band gap increases, which is preferable because matching with the solar spectrum becomes better. However, when x exceeds 0.5, an appropriate band gap is required to absorb the solar spectrum. It will exceed. Therefore, 0 ⁇ x ⁇ 0.50, which is an appropriate range for the CIGS light absorption layer.
- Each composition can be determined by ICP analysis.
- the composition range of Se in the CIGS quaternary alloy sputtering target is CuIn 1-x Ga x Se 2-y (where x and y each represent an atomic ratio), and 0 ⁇ y ⁇ 0.04 To do. y represents the so-called selenium deficiency, and when the value of y is large, the selenium deficiency also increases, resulting in deviation from the desired composition, and the relative density of the target also decreases.
- the temperature setting at the time of synthesis must be appropriately controlled in order to obtain a desired y value.
- selenium deficiency tends to occur when the rate of temperature increase from 100 ° C. to 400 ° C. during synthesis is increased.
- the selenium concentration can be determined by ICP analysis.
- the relative density of the sintered body is 90% or more, preferably 98% or more, more preferably 99% or more.
- the relative density is a ratio of values obtained by dividing the actual absolute density of the sintered compact target measured by the Archimedes method by the theoretical density of the target having the composition.
- a low target relative density means that there are many internal vacancies in the target, so splashing and abnormal discharge starting from the vacancy area occurs when the internal vacancies are exposed during sputtering. It becomes easy to do. For this reason, the number of particles generated on the film increases, and the surface unevenness progresses at an early stage, so that abnormal discharge or the like starting from surface protrusions (nodules) easily occurs. This contributes to a decrease in conversion efficiency of the CIGS solar cell.
- One of the more important points of the CIGS quaternary alloy sputtering target of the present invention is that the oxygen content is 200 ppm or less. For this reason, the contact between the raw material powder and the atmosphere is suppressed as much as possible, and the raw material particle size is not too fine.
- the oxygen concentration is high, it is easy to form an oxide in combination with the metal component of the CIGS quaternary alloy.
- Oxide has a higher electrical resistance than metal, so the resistance difference will occur in the target surface exceeding the degree of resistance variation of single composition, abnormal discharge starting from high resistance part and the difference in sputtering rate It is easy to cause surface unevenness due to, and to cause abnormal discharge and particle generation.
- the bulk resistance is in the range of 50 to 100 ⁇ cm, preferably 50 to 80 ⁇ cm.
- a high bulk resistance is likely to cause abnormal discharge, so a low bulk resistance is preferable.
- the bulk resistance is lower than 50 ⁇ cm, the relative density of the target is low or there is a low resistance heterogeneity other than CIGS. This is not preferable because it causes problems such as nodules, abnormal discharge, and film composition deviation during long-time sputtering.
- the variation in bulk resistance is ⁇ 5% or less in the target plane.
- the reason why the bulk resistance varies is that the heterogeneous phase is contained in the target surface and the distribution thereof is uneven, which is not preferable because it causes problems such as abnormal discharge and film composition shift.
- the variation in bulk resistance can be obtained by measuring the bulk resistance at 10 points in the target plane and by dividing the difference between the minimum value or maximum value and the average value by the average value.
- the average crystal grain size is 20 to 100 ⁇ m, preferably 20 to 70 ⁇ m, more preferably 20 to 60 ⁇ m. This is because if the average particle size is too small, the oxygen concentration tends to increase. Moreover, in order to obtain such a small particle size, the particle size of the raw material powder must be very small. However, since such a raw material powder with such a small particle size is very expensive, It is unsuitable as a solar cell application requiring cost.
- the average particle diameter can be obtained by a planimetric method after lightly etching the target surface as necessary to clarify the grain boundary.
- the Cu—In—Ga—Se sputtering target of the present invention was prepared by mixing and synthesizing shot or bar-shaped Cu, In, Ga and Se as starting materials, and adjusting the particle size by passing the synthesized materials through a sieve. Later, the synthetic powder can be obtained by sintering by hot pressing (HP).
- the shape of the raw material is not particularly limited, it can be said that it is desirable to use shot or bar-shaped Cu, In, Ga, and Se as the raw material because the oxygen concentration increases when powder is used.
- the CIGS sintered body is processed into, for example, a diameter of 6 inches and a thickness of 6 mm, and indium or the like is attached to the backing plate as a brazing material, and this is actually sputtered. You can investigate the situation.
- Example 1 In the composition formula CuIn 1-x Ga x Se 2-y , Cu, In, Ga and Se as raw materials were weighed so that x and y were 0.2 and 0, respectively. At this time, the concentration of each raw material is 25%, 20%, 5%, and 50% for Cu, In, Ga, and Se, respectively.
- the temperature increase rate is 5 ° C./min from room temperature to 100 ° C.
- the temperature increase rate is 1 ° C./min up to 400 ° C.
- the temperature increase rate is 5 ° C./min up to 550 ° C.
- the temperature rising rate was 1.66 ° C./min up to 650 ° C., then held at 650 ° C. for 8 hours, and then cooled in the furnace for 12 hours to room temperature.
- the CIGS synthetic raw material powder obtained as described above was passed through a 120 mesh sieve, and then hot pressed (HP).
- HP conditions were as follows: from room temperature to 750 ° C., the rate of temperature increase was 10 ° C./min. Thereafter, the temperature was maintained at 750 ° C. for 3 hours. 30 minutes after the pressure reached 750 ° C., a surface pressure of 200 kgf / cm 2 was added for 2 hours and 30 minutes, and the application of pressure was stopped at the end of heating.
- the relative density of the obtained CIGS sintered body was 98.9%, the oxygen concentration was 180 ppm, the bulk resistance was 65 ⁇ cm, the variation in bulk resistance was 3.8%, and the average particle size was 60 ⁇ m.
- the sintered body was processed into a disk shape having a diameter of 6 inches and a thickness of 6 mm, and was used as a sputtering target for sputtering.
- the sputtering power was direct current (DC) 1000 W
- the atmosphere gas was argon
- the gas flow rate was 50 sccm
- the sputtering pressure was 0.5 Pa.
- the number of abnormal discharges in one hour between 20 hours and 21 hours after the sputtering time was counted and found to be 0.
- Example 2 to Example 6 Table 1 shows the results of producing targets with different compositions and performing sputtering evaluation in the same manner as in Example 1.
- x indicating the Ga concentration (atomic ratio) in Examples 2 to 6 is in the range of 0 ⁇ x ⁇ 0.5
- y indicating the degree of selenium loss is 0 ⁇ y. The range was ⁇ 0.05.
- the relative density of the CIGS sintered body of Example 2 was 98.8%, the oxygen concentration was 187 ppm, the bulk resistance was 72 ⁇ cm, the variation in bulk resistance was 3.6%, and the average particle size was 76 ⁇ m. there were.
- the number of abnormal discharges was 0 when the number of abnormal discharges in one hour between 20 hours and 21 hours was counted as the sputtering time.
- the relative density of the CIGS sintered body of Example 3 was 98.8%, the oxygen concentration was 183 ppm, the bulk resistance was 80 ⁇ cm, the variation in bulk resistance was 4.2%, and the average particle size was 55 ⁇ m.
- the number of abnormal discharges was 0 when the number of abnormal discharges in one hour between 20 hours and 21 hours was counted as the sputtering time.
- the relative density of the CIGS sintered body of Example 4 was 99.2%, the oxygen concentration was 183 ppm, the bulk resistance was 59 ⁇ cm, the variation in bulk resistance was 3.2%, and the average particle size was 49 ⁇ m.
- the number of abnormal discharges was 0 when the number of abnormal discharges in one hour between 20 hours and 21 hours was counted as the sputtering time.
- the relative density of the CIGS sintered body of Example 5 was 98.3%, the oxygen concentration was 188 ppm, the bulk resistance was 62 ⁇ cm, the variation in bulk resistance was 3.8%, and the average particle size was 83 ⁇ m.
- the number of abnormal discharges was one when the number of abnormal discharges in one hour between 20 hours and 21 hours was counted as the sputtering time.
- the relative density of the CIGS sintered body of Example 6 was 98.1%, the oxygen concentration was 186 ppm, the bulk resistance was 56 ⁇ cm, the variation in bulk resistance was 3.9%, and the average particle size was 66 ⁇ m.
- the number of abnormal discharges was 0 when the number of abnormal discharges in one hour between 20 hours and 21 hours was counted as the sputtering time.
- the target characteristics are as follows: relative density is 90% or more, relative density is further 98% or more, oxygen concentration is 200 ppm or less, bulk resistance is in the range of 50 to 100 ⁇ cm, bulk resistance variation is 5% or less, average particle size was in the range of 20-100 ⁇ m. Also, the number of abnormal discharges during sputtering was very small, less than 1 time, which was a good result.
- Example 1 A target was produced in the same manner as in Example 1 except that in the synthesis of the raw material powder, the rate of temperature increase from 100 ° C to 400 ° C was increased to 5 ° C / min instead of 1 ° C / min.
- the produced target had a very large amount of selenium deficiency of y of 0.1.
- the relative density was 80.6%
- the oxygen concentration was 197 ppm
- the bulk resistance was 33 ⁇ cm
- the variation in bulk resistance was 7.8%
- the average particle size was 77 ⁇ m.
- the number of abnormal discharges during sputtering was 25.
- Example 2 A target was produced in the same manner as in Example 1 except that the holding temperature during hot pressing was lowered to 650 ° C. instead of 750 ° C.
- the produced target had a relative density of 81.1%, an oxygen concentration of 185 ppm, a bulk resistance of 38 ⁇ cm, a bulk resistance variation of 9.7%, and an average particle size of 80 ⁇ m.
- the number of abnormal discharges during sputtering was 38 times.
- Example 3 A target was produced in the same manner as in Example 1 except that nanopowder having an average particle size of 100 to 200 nm was used as the raw material powder.
- the produced target had a relative density of 97.5%, an oxygen concentration of 980 ppm, a bulk resistance of 93 ⁇ cm, a bulk resistance variation of 5.7%, and an average particle size of 0.15 ⁇ m.
- the number of abnormal discharges during sputtering was 17 times.
- Example 4 A target was produced in the same manner as in Example 1 except that nanopowder having an average particle size of 50 to 150 nm was used as the raw material powder.
- the relative density of the produced target was 97.9%, the oxygen concentration was 1350 ppm, the bulk resistance was 125 ⁇ cm, the variation in bulk resistance was 8.3%, and the average particle size was 0.08 ⁇ m.
- the number of abnormal discharges during sputtering was 45 times.
- Example 5 In the synthesis of the raw material powder, a target was produced in the same manner as in Example 1 except that the synthesis holding temperature was lowered to 600 ° C. instead of 650 ° C./min. The relative density of the produced target was 86.2%, the oxygen concentration was 190 ppm, the bulk resistance was 28 ⁇ cm, the variation in bulk resistance was 9.5%, and the average particle size was 68 ⁇ m. The number of abnormal discharges during sputtering was 33 times.
- the CIGS quaternary alloy sputtering target obtained by the present invention has a density of 90% or more and an oxygen concentration of 200 wtppm or less, it can be used for a long time when a film is formed by one sputtering using this. Even if it is sputtered, there is almost no abnormal discharge, and it has an excellent effect that a film having excellent in-plane uniformity of the film composition can be obtained.
- it is useful as a material of a high conversion efficiency CIGS quaternary alloy thin film as a light absorbing layer material of a thin film solar cell.
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Abstract
Description
しかしながら、この製造方法によって得られたCIGS四元系合金スパッタリングターゲットは、スパッタリングターゲットについての重要な特性である密度、酸素濃度、バルク抵抗等については一切明らかにされていない。
しかしながら、この製造方法によって得られたCIGS四元系合金スパッタリングターゲットの特性については、密度が高かったとの定性的記載があるものの、具体的な密度の数値については一切明らかにされていない。
しかしながら、その製造方法としては、独自合成した原料粉末をホットプレス法で焼結したとの記載があるのみで、具体的な製造方法が明示されていない。また、得られた焼結体の酸素濃度やバルク抵抗についても記載されていない。
1.銅(Cu)、インジウム(In)、ガリウム(Ga)及びセレン(Se)からなる四元系合金スパッタリングターゲットにおいて、その組成がCuIn1-xGaxSe2-y(但し、x、yはそれぞれ原子比率を表す)なる組成式で表され、その組成範囲が0<x≦0.5、0≦y≦0.04であるとともに、相対密度が90%以上であることを特徴とするCu-In-Ga-Seスパッタリングターゲット、を提供する。
2.酸素濃度が200wtppm以下であることを特徴とする上記1記載のCu-In-Ga-Se四元系合金スパッタリングターゲット、
3.バルク抵抗が50~100Ωcmの範囲であることを特徴とする上記1又は2に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット
4.バルク抵抗のばらつきがターゲット面内で±5%以下であることを特徴とする上記1~3のいずれか一項に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット
5.平均粒径が20~100μmであることを特徴とする上記1~4のいずれか一項に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット、を提供する。
6.相対密度が98%以上であることを特徴とする上記1~5のいずれか一項に記載のCu-In-Ga-Seスパッタリングターゲット
7.出発原料であるショット又はバー形状のCu、In、Ga及びSeを混合して合成し、この合成原料を篩に通して粒度調整をした後に、該合成粉末をホットプレス(HP)により焼結して製造した1~6のいずれか一項に記載のCu-In-Ga-Seスパッタリングターゲット、を提供する。
xが大きくなるとCIGSのバンドギャップが大きくなるため、太陽光スペクトルとのマッチングが良くなって行くので好ましいが、xが0.5を超えると、太陽光スペクトルを吸収するのに適切なバンドギャップを超えてしまう。
したがって、CIGS光吸収層として適切な範囲である0<x≦0.50とする。なお、各組成はICP分析法で求めることができる。
yは、いわゆるセレンの欠損量を表しており、yの値が大きい場合には、セレンの欠損量も大きくなるため、所望の組成からずれることとなり、ターゲットの相対密度も低くなる。
酸化物は金属より電気抵抗が高いために、単一組成の抵抗ばらつきの程度を超えて、ターゲット面内において抵抗差が生じることになり、高抵抗部分を起点とした異常放電やスパッタ速度の違いによる表面凹凸が生じ易く、異常放電やパーティクル発生の原因となり易い。
なお、平均粒径はターゲット表面を必要に応じて軽くエッチングをして、粒界を明確にしてからプラニメトリック法で求めることができる。
また、異常放電等の状況については、CIGS焼結体を、例えば直径6インチ、厚み6mmに加工して、バッキングプレートにインジウム等をロウ材として貼り付けて、これをスパッタリングすることにより実際にその状況を調べることができる。
CuIn1-xGaxSe2-yなる組成式において、x、yがそれぞれ0.2及び0となるように、原料であるCu、In、Ga及びSeを秤量した。なお、その際、各原料の濃度は、Cu、In、Ga及びSeがそれぞれ25%、20%、5%、50%となる。
実施例1と同様の方法で、組成を変化させたターゲットを作製し、スパッタ評価を行った結果を表1にまとめて示す。表1に示すように、実施例2~実施例6のGaの濃度(原子数比)を示すxは、0<x≦0.5の範囲、セレンの欠損度合いを示すyは、0≦y≦0.05の範囲であった。
原料粉の合成において、100℃~400℃までの昇温速度を1℃/minではなく、5℃/minと大きくした以外は、実施例1と同様な方法で、ターゲットを作製した。作製されたターゲットのセレン欠損量はyが0.1と非常に大きかった。相対密度は80.6%、酸素濃度は197ppm、バルク抵抗は33Ωcm、バルク抵抗のばらつきは7.8%、平均粒径は77μmであった。スパッタ時の異常放電回数は25回であった。
ホットプレス時の保持温度を750℃ではなく、650℃と低くした以外は、実施例1と同様な方法で、ターゲットを作製した。作製されたターゲットの相対密度は81.1%、酸素濃度は185ppm、バルク抵抗は38Ωcm、バルク抵抗のばらつきは9.7%、平均粒径は80μmであった。スパッタ時の異常放電回数は38回であった。
原料粉として平均粒径100~200nmのナノ粉を用いた以外は、実施例1と同様な方法で、ターゲットを作製した。作製されたターゲットの相対密度は97.5%、酸素濃度は980ppm、バルク抵抗は93Ωcm、バルク抵抗のばらつきは5.7%、平均粒径は0.15μmであった。スパッタ時の異常放電回数は17回であった。
原料粉として平均粒径50~150nmのナノ粉を用いた以外は、実施例1と同様な方法で、ターゲットを作製した。作製されたターゲットの相対密度は97.9%、酸素濃度は1350ppm、バルク抵抗は125Ωcm、バルク抵抗のばらつきは8.3%、平均粒径は0.08μmであった。スパッタ時の異常放電回数は45回であった。
原料粉の合成において、合成保持温度を650℃/minではなく、600℃と低くした以外は、実施例1と同様な方法で、ターゲットを作製した。作製されたターゲットの相対密度は86.2%、酸素濃度は190ppm、バルク抵抗は28Ωcm、バルク抵抗のばらつきは9.5%、平均粒径は68μmであった。スパッタ時の異常放電回数は33回であった。
Claims (7)
- 銅(Cu)、インジウム(In)、ガリウム(Ga)及びセレン(Se)からなる四元系合金スパッタリングターゲットにおいて、その組成がCuIn1-xGaxSe2-y(但し、x、yはそれぞれ原子比率を表す)なる組成式で表され、その組成範囲が0<x≦0.5、0≦y≦0.04であるとともに、相対密度が90%以上であることを特徴とするCu-In-Ga-Seスパッタリングターゲット。
- 酸素濃度が200wtppm以下であることを特徴とする請求項1記載のCu-In-Ga-Se四元系合金スパッタリングターゲット。
- バルク抵抗が50~100Ωcmの範囲であることを特徴とする請求項1又は2に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット。
- バルク抵抗のばらつきがターゲット面内で±5%以下であることを特徴とする請求項1~3のいずれか一項に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット。
- 平均粒径が20~100μmであることを特徴とする請求項1~4のいずれか一項に記載のCu-In-Ga-Se四元系合金スパッタリングターゲット。
- 相対密度が98%以上であることを特徴とする請求項1~5のいずれか一項に記載のCu-In-Ga-Seスパッタリングターゲット。
- 出発原料であるショット又はバー形状のCu、In、Ga及びSeを混合して合成し、この合成原料を篩に通して粒度調整した後に、該合成粉末をホットプレス(HP)により焼結して製造した請求項1~6のいずれか一項に記載のCu-In-Ga-Seスパッタリングターゲット。
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WO2013109783A1 (en) * | 2012-01-20 | 2013-07-25 | Leonard Nanis | Amalgam method for forming a sputter target useful in the manufacture of thin-film solar photovoltaic cells |
WO2013129044A1 (ja) * | 2012-02-27 | 2013-09-06 | 株式会社日本マイクロニクス | Cigs系太陽電池用合金の作製方法 |
WO2013183790A1 (ja) * | 2012-06-08 | 2013-12-12 | 株式会社フューテックファーネス | Cigsスパッタリングターゲットの製造方法 |
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WO2012098722A1 (ja) | 2011-01-17 | 2012-07-26 | Jx日鉱日石金属株式会社 | Cu-Gaターゲット及びその製造方法並びにCu-Ga系合金膜からなる光吸収層及び同光吸収層を用いたCIGS系太陽電池 |
JP2014034730A (ja) * | 2012-08-10 | 2014-02-24 | Mitsui Mining & Smelting Co Ltd | 焼結体およびスパッタリングターゲット |
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