WO2013005738A1 - n型拡散層形成組成物、n型拡散層の製造方法及び太陽電池素子の製造方法 - Google Patents
n型拡散層形成組成物、n型拡散層の製造方法及び太陽電池素子の製造方法 Download PDFInfo
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- WO2013005738A1 WO2013005738A1 PCT/JP2012/066985 JP2012066985W WO2013005738A1 WO 2013005738 A1 WO2013005738 A1 WO 2013005738A1 JP 2012066985 W JP2012066985 W JP 2012066985W WO 2013005738 A1 WO2013005738 A1 WO 2013005738A1
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- Prior art keywords
- diffusion layer
- type diffusion
- forming composition
- layer forming
- glass
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/22—Diffusion of impurity materials, e.g. doping materials, electrode materials, into or out of a semiconductor body, or between semiconductor regions; Interactions between two or more impurities; Redistribution of impurities
- H01L21/2225—Diffusion sources
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C15/00—Surface treatment of glass, not in the form of fibres or filaments, by etching
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C3/00—Glass compositions
- C03C3/04—Glass compositions containing silica
- C03C3/076—Glass compositions containing silica with 40% to 90% silica, by weight
- C03C3/097—Glass compositions containing silica with 40% to 90% silica, by weight containing phosphorus, niobium or tantalum
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/02—Frit compositions, i.e. in a powdered or comminuted form
- C03C8/08—Frit compositions, i.e. in a powdered or comminuted form containing phosphorus
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
- C03C8/16—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions with vehicle or suspending agents, e.g. slip
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/22—Diffusion of impurity materials, e.g. doping materials, electrode materials, into or out of a semiconductor body, or between semiconductor regions; Interactions between two or more impurities; Redistribution of impurities
- H01L21/225—Diffusion of impurity materials, e.g. doping materials, electrode materials, into or out of a semiconductor body, or between semiconductor regions; Interactions between two or more impurities; Redistribution of impurities using diffusion into or out of a solid from or into a solid phase, e.g. a doped oxide layer
- H01L21/2251—Diffusion into or out of group IV semiconductors
- H01L21/2254—Diffusion into or out of group IV semiconductors from or through or into an applied layer, e.g. photoresist, nitrides
- H01L21/2255—Diffusion into or out of group IV semiconductors from or through or into an applied layer, e.g. photoresist, nitrides the applied layer comprising oxides only, e.g. P2O5, PSG, H3BO3, doped oxides
-
- 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 potential barriers
- 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 potential barriers 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1804—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 Table
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/547—Monocrystalline silicon PV cells
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to a composition for forming an n-type diffusion layer of a solar cell element, a method for producing an n-type diffusion layer, and a method for producing a solar cell element. More specifically, the present invention relates to a specific region of silicon as a semiconductor substrate. The present invention relates to a technique that makes it possible to form a mold diffusion layer.
- a p-type silicon substrate having a textured structure formed on the light receiving surface is prepared so as to promote the light confinement effect, and then a donor element-containing compound such as phosphorus oxychloride (POCl 3 ), nitrogen, oxygen
- a donor element-containing compound such as phosphorus oxychloride (POCl 3 ), nitrogen, oxygen
- POCl 3 phosphorus oxychloride
- the n-type diffusion layer is uniformly formed by performing several tens of minutes at 800 ° C. to 900 ° C. in the mixed gas atmosphere.
- phosphorus is diffused using a mixed gas
- n-type diffusion layers are formed not only on the surface but also on the side surface and the back surface. Therefore, a side etching process for removing the side n-type diffusion layer is necessary.
- the n-type diffusion layer on the back surface needs to be converted into a p + -type diffusion layer.
- An aluminum paste is applied on the n-type diffusion layer on the back surface, and the p + -type diffusion is performed from the n-type diffusion layer by the diffusion of aluminum. Was converted into a layer.
- the donor element or a compound containing the same is scattered from the solution or paste as a diffusion source, so that phosphorus is formed on the side surface and the back surface during the formation of the diffusion layer as in the gas phase reaction method using the mixed gas.
- an n-type diffusion layer is formed in addition to the applied portion.
- the upper surface of a semiconductor substrate such as a silicon substrate used for a solar cell has a texture structure in which a height difference between a convex portion and a concave portion is about 5 ⁇ m. Since it is applied to the surface of such a texture structure, the n-type diffusion layer may be formed unevenly.
- n-type diffusion layer in the gas phase reaction using phosphorus oxychloride, not only one side (usually the light-receiving surface or the surface) that originally requires the n-type diffusion layer, but also the other side ( An n-type diffusion layer is also formed on the non-light-receiving surface or back surface) and side surfaces.
- an n-type diffusion layer is formed in addition to the surface as in the gas phase reaction method.
- the compound having the donor element is volatilized and gas is diffused and diffused in a region other than the region where diffusion is required.
- the present invention has been made in view of the above-described conventional problems, and can be applied to a solar cell element using a semiconductor substrate, and can be applied to a specific region without forming an n-type diffusion layer in an unnecessary region.
- An object is to provide an n-type diffusion layer forming composition capable of forming a uniform n-type diffusion layer in a short time, a method for producing an n-type diffusion layer, and a method for producing a solar cell element.
- Means for solving the problems are as follows.
- An n-type diffusion layer forming composition comprising a donor element, a glass powder having a softening temperature of 500 ° C. or more and 900 ° C. or less and an average particle diameter of 5 ⁇ m or less, and a dispersion medium.
- the donor element is at least one selected from P (phosphorus) and Sb (antimony).
- the glass powder containing the donor element includes at least one donor element-containing material selected from the group consisting of P 2 O 3 , P 2 O 5 and Sb 2 O 3 , SiO 2 , K 2 O, Containing at least one glass component material selected from the group consisting of Na 2 O, Li 2 O, BaO, SrO, CaO, MgO, BeO, ZnO, PbO, CdO, SnO, ZrO 2 and MoO 3.
- the n-type diffusion layer forming composition according to any one of ⁇ 1> to ⁇ 3>.
- ⁇ 5> A step of applying the n-type diffusion layer forming composition according to any one of ⁇ 1> to ⁇ 4> on the semiconductor substrate, a step of applying a thermal diffusion treatment to the semiconductor substrate after the application, The manufacturing method of the n type diffused layer which has this.
- ⁇ 6> A step of applying the n-type diffusion layer forming composition according to any one of ⁇ 1> to ⁇ 4> on the semiconductor substrate, and applying a thermal diffusion treatment to the semiconductor substrate after the application, The manufacturing method of the solar cell element which has the process of forming a type
- n-type diffusion layer forming composition ⁇ 7> Use of the n-type diffusion layer forming composition according to any one of ⁇ 1> to ⁇ 4> in the production of an n-type diffusion layer.
- the present invention can be applied to a solar cell element using a semiconductor substrate, and can form a uniform n-type diffusion layer in a specific region in a short time without forming an n-type diffusion layer in an unnecessary region.
- An n-type diffusion layer forming composition, a method for producing an n-type diffusion layer, and a method for producing a solar cell element can be provided.
- FIG. 2A is a plan view of the solar cell element as seen from the surface.
- 2B is an enlarged perspective view showing a part of FIG. 2A.
- the n-type diffusion layer forming composition of the present invention will be described, and then the n-type diffusion layer and solar cell element manufacturing method using the n-type diffusion layer forming composition will be described.
- the term “process” is not limited to an independent process, and even if it cannot be clearly distinguished from other processes, the term “process” is used as long as the intended purpose of the process is achieved. included.
- “to” indicates a range including the numerical values described before and after the minimum and maximum values, respectively.
- the amount of each component in the composition is the total amount of the plurality of substances present in the composition unless there is a specific indication when there are a plurality of substances corresponding to each component in the composition. means.
- the n-type diffusion layer forming composition of the present invention contains at least a donor element, has a softening temperature of 500 ° C. or more and 900 ° C. or less, and an average particle size of 5 ⁇ m or less (hereinafter simply referred to as “glass powder”). And a dispersion medium, and may further contain other additives as necessary in consideration of suitability for application (applicability) of the composition.
- the n-type diffusion layer forming composition contains a donor element, contains a glass powder having a softening temperature of 500 ° C. or more and 900 ° C. or less and an average particle diameter of 5 ⁇ m or less, and is applied to a semiconductor substrate.
- a material that can form an n-type diffusion layer by thermally diffusing this donor element By using an n-type diffusion layer forming composition containing a donor element, a glass powder having a softening temperature of 500 ° C. or more and 900 ° C. or less and an average particle diameter of 5 ⁇ m or less, the viscosity of the glass during the thermal diffusion treatment is increased. It does not become too low, and the glass powder melts in a short time. As a result, an n-type diffusion layer is formed at a desired site, and an unnecessary n-type diffusion layer is not formed on the back surface or side surface.
- the composition for forming an n-type diffusion layer of the present invention is applied, the side etching step that is essential in the gas phase reaction method that has been widely employed is not required, and the process is simplified.
- the step of converting the n-type diffusion layer formed on the back surface into the p + -type diffusion layer is not necessary. Therefore, the method for forming the p + -type diffusion layer on the back surface and the material, shape, and thickness of the back electrode are not limited, and the choice of manufacturing method, material, and shape to be applied is widened.
- production of the internal stress in the semiconductor substrate resulting from the thickness of a back surface electrode is suppressed, and the curvature of a semiconductor substrate is also suppressed.
- the glass powder contained in the n-type diffusion layer forming composition of the present invention is melted by firing to form a glass layer on the n-type diffusion layer.
- a glass layer is formed on the n-type diffusion layer even in a conventional gas phase reaction method or a method of applying a phosphate-containing solution or paste, and thus the glass layer produced in the present invention is a conventional method.
- it can be removed by etching. Therefore, the n-type diffusion layer forming composition of the present invention does not generate unnecessary products and does not increase the number of steps as compared with the conventional method.
- the donor component in the glass powder is difficult to volatilize even during firing, it is suppressed that the n-type diffusion layer is formed not only on the surface but also on the back surface and side surfaces due to the generation of the volatilizing gas. The reason for this is considered that the donor component is hard to volatilize because it is strongly bonded to other elements as constituent elements in the glass.
- the n-type diffusion layer forming composition of the present invention can form an n-type diffusion layer having a desired concentration at a desired site, the concentration of the n-type donor element (dopant) is high. A selective region can be formed. On the other hand, it is common to form a selective region having a high concentration of n-type donor element by a gas phase reaction method which is a general method of an n-type diffusion layer or a method using a phosphate-containing solution alone. It is difficult.
- a donor element is an element that can form an n-type diffusion layer by diffusing (doping) into a semiconductor substrate.
- a Group 15 element can be used, and examples thereof include P (phosphorus), Sb (antimony), Bi (bismuth), As (arsenic), and the like. From the viewpoints of safety, ease of vitrification, etc., P or Sb is preferred.
- Examples of the donor element-containing material used for introducing the donor element into the glass powder include P 2 O 3 , P 2 O 5 , Sb 2 O 3 , Bi 2 O 3 and As 2 O 3 , and P 2 O 3 It is preferable to use at least one selected from the group consisting of P 2 O 5 and Sb 2 O 3 .
- the glass powder containing a donor element can control a melting temperature, a softening temperature, a glass transition temperature, chemical durability, etc. by adjusting a component ratio as needed. Furthermore, it is preferable to contain the glass component substance described below.
- Glass component materials include SiO 2 , K 2 O, Na 2 O, Li 2 O, BaO, SrO, CaO, MgO, BeO, ZnO, PbO, CdO, SnO, ZrO 2 , WO 3 , MoO 3 , MnO, Examples include La 2 O 3 , Nb 2 O 5 , Ta 2 O 5 , Y 2 O 3 , TiO 2 , ZrO 2 , GeO 2 , TeO 2, and Lu 2 O 3.
- SiO 2 , K 2 O, Na 2 Preferably, at least one selected from the group consisting of O, Li 2 O, BaO, SrO, CaO, MgO, BeO, ZnO, PbO, CdO, SnO, ZrO 2 , WO 3 , MoO 3 and MnO is used.
- SiO 2 K 2 O, Na 2 O, Li 2 O, BaO, SrO, CaO, MgO, BeO, ZnO, PbO, CdO, SnO, from ZrO 2, and MoO 3 It is more preferable to use at least one selected from the group that.
- the glass powder containing a donor element include a system containing both the donor element-containing substance and the glass component substance, and a P 2 O 5 -SiO 2 system (in order of donor element-containing substance-glass component substance). in described, the same applies hereinafter), P 2 O 5 -K 2 O based, P 2 O 5 -Na 2 O-based, P 2 O 5 -Li 2 O system, P 2 O 5 -BaO-based, P 2 O 5 - SrO-based, P 2 O 5 -CaO-based, P 2 O 5 -MgO-based, P 2 O 5 -BeO based, P 2 O 5 -ZnO-based, P 2 O 5 -CdO based, P 2 O 5 -PbO system , P 2 O 5 —SnO system, P 2 O 5 —GeO 2 system, P 2 O 5 —TeO 2 system, etc., a system containing P 2 O 5 as a donor element-containing
- a glass powder containing two or more kinds of donor element-containing substances such as a P 2 O 5 —Sb 2 O 3 system and a P 2 O 5 —As 2 O 3 system, may be used.
- a composite glass containing two components has been exemplified, but glass powder containing three or more components as required may be used, such as P 2 O 5 —SiO 2 —CaO.
- the content ratio of the glass component substance in the glass powder is preferably set as appropriate in consideration of the melting temperature, the softening temperature, the glass transition temperature, and the chemical durability, and is generally 0.1% by mass to 95% by mass. It is preferable that it is 0.5 mass% or more and 90 mass% or less.
- the content ratio of SiO 2 in the case of the glass powder containing SiO 2 is preferably in the range of 10 to 90 mass%.
- the softening temperature of glass powder needs to be 500 degreeC or more and 900 degrees C or less from a viewpoint of the diffusibility at the time of a diffusion process, and dripping. Moreover, it is preferable that it is 600 to 800 degreeC, and it is more preferable that it is 700 to 800 degreeC.
- the softening temperature is less than 500 ° C., the viscosity of the glass becomes too low during the diffusion treatment and dripping occurs, so that an n-type diffusion layer may be formed in addition to the specific portion.
- the temperature is higher than 900 ° C., the glass powder may not be melted and a uniform n-type diffusion layer may not be formed.
- the softening temperature of the glass powder is in the range of 500 ° C. or higher and 900 ° C. or lower, no dripping occurs as described above, so an n-type diffusion layer is formed in a desired shape in a specific region after the diffusion treatment. It becomes possible to do.
- the n-type diffusion layer forming composition is applied in a linear pattern having a width of a ⁇ m, the linear width b after the diffusion treatment can hold a linear pattern in the range of b ⁇ 1.5 a ⁇ m.
- the softening temperature of the glass powder can be obtained from a differential heat (DTA) curve or the like using a DTG-60H type differential heat / thermogravimetric simultaneous measuring device manufactured by Shimadzu Corporation.
- DTA differential heat
- Examples of the shape of the glass powder include a substantially spherical shape, a flat shape, a block shape, a plate shape, and a scale shape.
- the n-type diffusion layer forming composition has a coating property (applicability) and uniform diffusibility. From this point, it is desirable that the shape is substantially spherical, flat or plate-like.
- the average particle diameter of the glass powder is required to be 5 ⁇ m or less. Further, it is preferably 0.1 ⁇ m to 5 ⁇ m, and more preferably 0.5 ⁇ m to 4 ⁇ m. By making the glass powder have an average particle diameter of 5 ⁇ m or less, even when a glass powder having a softening temperature in the above range is used, it is melted in a short time and a smooth glass layer is easily obtained. Therefore, a uniform n-type diffusion layer can be formed by setting the average particle diameter of the glass powder to 5 ⁇ m or less.
- a uniform n-type diffusion layer can be confirmed, for example, as variations in sheet resistance (standard deviation: ⁇ ) in the n-type diffusion layer surface obtained by coating on a semiconductor substrate.
- ⁇ standard deviation
- the variation ( ⁇ ) in the sheet resistance value is 10 or less, preferably 5 or less, more preferably 2 or less, it can be evaluated that a uniform n-type diffusion layer is formed.
- a sheet resistance measured by a four probe method at 25 ° C. using a Loresta-EP MCP-T360 type low resistivity meter manufactured by Mitsubishi Chemical Corporation is employed.
- ⁇ is obtained by calculating the square root of the sum of the squares of the deviations of the sheet resistance values of 25 points obtained by the above-described measurement method for the coated surface by the number of data.
- the upper surface of a semiconductor substrate used in a solar cell has a texture structure in which the height difference between the convex portion and the concave portion is about 5 ⁇ m.
- the average particle diameter of glass represents a volume average particle diameter, and can be measured by a laser scattering diffraction method particle size distribution analyzer (manufactured by Beckman Coulter, Inc.) or the like.
- the d90 of the glass powder used in the present invention is preferably 20 ⁇ m or less. D90 is more preferably 15 ⁇ m or less, and further preferably 10 ⁇ m or less.
- d90 refers to the particle diameter at which 90% of the total particle diameter is accumulated sequentially from the particle having the smallest particle diameter when a volume distribution accumulation curve of particle diameter is drawn.
- the volume distribution integrated curve can be measured in the same manner as the average particle diameter, and can be measured by a laser scattering diffraction particle size distribution measuring apparatus (manufactured by Beckman Coulter, Inc.).
- d90 of the glass powder is 20 ⁇ m or less, after applying the n-type diffusion layer forming composition to the upper surface of the semiconductor substrate, the generation of large pores due to coarse particles is suppressed, and the distribution of donor elements is made more uniform. There is a tendency to be able to.
- the glass powder in the present invention requires that the softening temperature of the glass powder is 500 ° C. to 900 ° C. and the average particle diameter is 5 ⁇ m or less.
- the glass softening temperature is preferably 600 ° C. to 800 ° C.
- the average particle size is preferably 0.1 ⁇ m to 5 ⁇ m
- the glass softening temperature is 700 ° C. to 800 ° C.
- the average particle size is 0.5 ⁇ m. More preferably, it is 4 ⁇ m.
- the softening temperature of the glass powder is 500 ° C. to 900 ° C.
- the average particle size is preferably 5 ⁇ m or less
- d90 is preferably 20 ⁇ m or less
- the softening temperature of the glass is 600 ° C. to 800 ° C. More preferably, the average particle size is 0.1 ⁇ m to 5 ⁇ m, d90 is more preferably 15 ⁇ m or less
- the softening temperature of the glass is 700 ° C. to 800 ° C.
- the average particle size is 0.5 ⁇ m to 4 ⁇ m
- d90 is 10 ⁇ m or less.
- the glass softening temperature is 600 ° C. to 800 ° C.
- the average particle diameter is 0.1 ⁇ m to 5 ⁇ m
- d90 is 15 ⁇ m or less
- the glass powder containing the donor element is P 2
- At least one donor element-containing material selected from the group consisting of O 3 , P 2 O 5 and Sb 2 O 3 , and SiO 2 , K 2 O, Na 2 O, Li 2 O, BaO, SrO, CaO, More preferably, it contains at least one glass component material selected from the group consisting of MgO, BeO, ZnO, PbO, CdO, SnO, ZrO 2 and MoO 3
- the glass softening temperature is 700 ° C.
- a glass powder containing the donor element, P 2 O 3, P 2 O 5 and S At least one donor element-containing material selected from the group consisting of 2 O 3, SiO 2, K 2 O, Na 2 O, Li 2 O, BaO, SrO, CaO, MgO, BeO, ZnO, PbO, CdO It is even more preferable to contain at least one glass component substance selected from the group consisting of SnO, ZrO 2 and MoO 3 .
- the glass powder containing a donor element is produced by the following procedure.
- raw materials for example, the donor element-containing material and the glass component material are weighed and filled in a crucible.
- the crucible material include platinum, platinum-rhodium, iridium, alumina, quartz, and carbon.
- the material of the crucible is appropriately selected in consideration of the melting temperature, atmosphere, reactivity with the molten material, and the like.
- the donor element-containing substance and the glass component substance are heated at a temperature corresponding to the glass composition in an electric furnace to obtain a melt. At this time, it is desirable to stir the melt uniformly.
- the obtained melt is poured onto a zirconia substrate, a carbon substrate or the like to vitrify the melt. Finally, the glass is crushed into powder.
- a known method such as a jet mill, a bead mill, or a ball mill can be applied to the pulverization.
- the content ratio of the glass powder containing the donor element in the n-type diffusion layer forming composition is determined in consideration of the suitability for application (coating property), the diffusibility of the donor element, and the like.
- the content ratio of the glass powder in the n-type diffusion layer forming composition is preferably 0.1% by mass or more and 95% by mass or less, more preferably 1% by mass or more and 90% by mass or less, The content is more preferably 1.5% by mass or more and 85% by mass or less, and particularly preferably 2% by mass or more and 80% by mass or less.
- the dispersion medium is a medium in which the glass powder is dispersed in the composition. Specifically, at least one selected from the group consisting of a binder and a solvent is employed as the dispersion medium.
- binder examples include polyvinyl alcohol, polyacrylamide resin, polyvinyl amide resin, polyvinyl pyrrolidone, polyethylene oxide resin, polysulfonic acid, acrylamide alkyl sulfonic acid, cellulose ether resin, cellulose derivative, carboxymethyl cellulose, hydroxyethyl cellulose, ethyl cellulose, gelatin, starch And starch derivatives, sodium alginate and sodium alginate derivatives, xanthan and xanthan derivatives, gua and gua derivatives, scleroglucan and scleroglucan derivatives, tragacanth and tragacanth derivatives, dextrin and dextrin derivatives, (meth) acrylic acid resin, (meth) Acrylic ester resins (eg, alkyl (meth) acrylate resins, dimethyl Ruaminoechiru (meth) acrylate resin, etc.), butadiene resins, styrene resins, and copo
- the molecular weight of the binder is not particularly limited, and it is desirable to adjust appropriately in view of the desired viscosity as the composition.
- the solvent examples include acetone, methyl ethyl ketone, methyl-n-propyl ketone, methyl-i-propyl ketone, methyl-n-butyl ketone, methyl-i-butyl ketone, methyl-n-pentyl ketone, methyl-n-hexyl ketone, Ketone solvents such as diethyl ketone, dipropyl ketone, di-i-butyl ketone, trimethylnonanone, cyclohexanone, cyclopentanone, methylcyclohexanone, 2,4-pentanedione, acetonylacetone; diethyl ether, methyl ethyl ether, methyl- n-propyl ether, di-i-propyl ether, tetrahydrofuran, methyltetrahydrofuran, dioxane, dimethyldioxane, ethylene glycol di
- composition for forming an n-type diffusion layer ⁇ -terpineol, diethylene glycol mono-n-butyl ether, and diethylene glycol mono-n-butyl ether are preferred, and ⁇ -terpineol, diethylene glycol mono-n— are preferred from the viewpoint of applicability to the substrate.
- Butyl ether is mentioned as a more preferable solvent.
- the content ratio of the dispersion medium in the n-type diffusion layer forming composition is determined in consideration of applicability and donor concentration.
- the viscosity of the n-type diffusion layer forming composition is more preferably 10 mPa ⁇ s or more and 1000000 mPa ⁇ s or less in consideration of applicability.
- the method for producing an n-type diffusion layer of the present invention includes a step of applying the n-type diffusion layer forming composition on a semiconductor substrate and a step of applying a thermal diffusion treatment to the semiconductor substrate after the application.
- the manufacturing method for the solar cell element of the present invention includes a step of applying the n-type diffusion layer forming composition on a semiconductor substrate, and applying a thermal diffusion treatment to the semiconductor substrate after the application, thereby performing n-type diffusion. Forming a layer, and forming an electrode on the formed n-type diffusion layer.
- FIG. 1 is a schematic cross-sectional view conceptually showing an example of the manufacturing process of the solar cell element of the present invention.
- 10 is a p-type semiconductor substrate
- 12 is an n-type diffusion layer
- 14 is a p + -type diffusion layer
- 16 is an antireflection film
- 18 is a front electrode
- 20 is a back electrode (electrode layer).
- common constituent elements are denoted by the same reference numerals and description thereof is omitted.
- the semiconductor substrate is not limited to a silicon substrate.
- an alkaline solution is applied to a silicon substrate which is a p-type semiconductor substrate 10 to remove a damaged layer, and a texture structure is obtained by etching.
- a texture structure is obtained by etching.
- the damaged layer on the silicon surface generated when slicing from the ingot is removed with 20% by mass caustic soda.
- etching is performed with a mixed solution of 1% by mass caustic soda and 10% by mass isopropyl alcohol to form a texture structure (the description of the texture structure is omitted in the figure).
- a texture structure on the light receiving surface (surface) side, a light confinement effect is promoted, and high efficiency is achieved.
- the n-type diffusion layer forming composition layer 11 is formed by applying the n-type diffusion layer forming composition to the surface of the p-type semiconductor substrate 10, that is, the surface serving as the light receiving surface.
- the application method is not limited, and examples thereof include a printing method, a spin method, a brush coating, a spray method, a doctor blade method, a roll coater method, and an ink jet method.
- the application amount of the n-type diffusion layer forming composition is not particularly limited.
- the glass powder amount can be 0.01 g / m 2 to 100 g / m 2, and 0.1 g / m 2 to 10 g. / M 2 is preferable.
- a drying step for volatilizing the solvent contained in the composition may be necessary after application.
- drying is performed at a temperature of about 80 ° C. to 300 ° C. for about 1 to 10 minutes when using a hot plate, and about 10 to 30 minutes when using a dryer or the like.
- the drying conditions depend on the solvent composition of the n-type diffusion layer forming composition, and are not particularly limited to the above conditions in the present invention.
- the manufacturing method of the p + -type diffusion layer (high concentration electric field layer) 14 on the back surface is limited to a method by conversion from an n-type diffusion layer to a p-type diffusion layer with aluminum. Therefore, any conventionally known method can be adopted, and the options of the manufacturing method are expanded. Therefore, for example, the composition 13 containing a Group 13 element such as B (boron) can be applied to form the p + -type diffusion layer 14.
- the composition 13 containing a Group 13 element such as B (boron) for example, a glass powder containing an acceptor element is used instead of a glass powder containing a donor element, and the same as the composition for forming an n-type diffusion layer.
- a p-type diffusion layer forming composition constituted as described above can be given.
- the acceptor element may be an element belonging to Group 13, and examples thereof include B (boron), Al (aluminum), and Ga (gallium). Further, it is preferable that the glass powder containing acceptor element comprising at least one member selected from the group consisting of B 2 O 3, Al 2 O 3 and Ga 2 O 3. Furthermore, the method for applying the p-type diffusion layer forming composition to the back surface of the silicon substrate is the same as the method for applying the n-type diffusion layer forming composition described above to the silicon substrate.
- the p + -type diffusion layer 14 can be formed on the back surface by subjecting the p-type diffusion layer forming composition applied to the back surface to a thermal diffusion treatment similar to the thermal diffusion treatment in the n-type diffusion layer forming composition described later. it can.
- the thermal diffusion treatment of the p-type diffusion layer forming composition is preferably performed simultaneously with the thermal diffusion treatment of the n-type diffusion layer forming composition.
- the p-type semiconductor substrate 10 on which the n-type diffusion layer forming composition layer 11 is formed is subjected to a thermal diffusion treatment at a temperature not lower than the melting point of the glass powder in the composition, for example, 600 ° C. to 1200 ° C.
- a thermal diffusion treatment as shown in FIG. 1C, the donor element diffuses into the semiconductor substrate, and the n-type diffusion layer 12 is formed.
- a known continuous furnace, batch furnace, or the like can be applied to the thermal diffusion treatment. Further, the furnace atmosphere during the thermal diffusion treatment can be appropriately adjusted to air, oxygen, nitrogen or the like.
- the thermal diffusion treatment time can be appropriately selected according to the content of the donor element contained in the n-type diffusion layer forming composition. For example, it can be 1 minute to 60 minutes, and more preferably 2 minutes to 30 minutes.
- a glass layer such as phosphate glass is formed on the surface of the formed n-type diffusion layer 12. For this reason, this phosphate glass is removed by etching.
- etching any of known methods such as a method of immersing in an acid such as hydrofluoric acid and a method of immersing in an alkali such as caustic soda can be applied.
- the immersing time is not particularly limited, and can be generally 0.5 to 30 minutes, preferably 1 to 10 minutes.
- an n-type diffusion layer 12 is formed at a desired site, and an unnecessary n-type diffusion layer is formed on the back and side surfaces.
- a side etching process for removing an unnecessary n-type diffusion layer formed on a side surface is essential. According to the manufacturing method of the invention, the side etching process is not required, and the process is simplified. As described above, a uniform n-type diffusion layer having a desired shape and a desired shape is formed in a short time by the manufacturing method of the present invention.
- n-type diffusion layer formed on the back surface it is necessary to convert an unnecessary n-type diffusion layer formed on the back surface into a p-type diffusion layer.
- a group 13 element is added to the n-type diffusion layer on the back surface.
- a method is adopted in which an aluminum paste is applied and baked to diffuse aluminum into the n-type diffusion layer and convert it into a p-type diffusion layer.
- conversion to the p-type diffusion layer is sufficient, and in order to form a high-concentration electric field layer of the p + -type diffusion layer, a certain amount of aluminum is required. There was a need to form.
- the manufacturing method of the present invention since an unnecessary n-type diffusion layer is not formed on the back surface, it is not necessary to perform conversion from the n-type diffusion layer to the p-type diffusion layer, and the necessity of increasing the thickness of the aluminum layer is eliminated. . As a result, generation of internal stress and warpage in the silicon substrate can be suppressed. As a result, it is possible to suppress an increase in power loss and damage to the solar cell element.
- the manufacturing method of the p + -type diffusion layer (high concentration electric field layer) 14 on the back surface is limited to a method by conversion from an n-type diffusion layer to a p-type diffusion layer with aluminum. Any method can be adopted without any problem, and the choice of manufacturing method is expanded.
- a p-type diffusion layer forming composition configured in the same manner as the n-type diffusion layer forming composition is formed on the back surface (n).
- the p + -type diffusion layer (high-concentration electric field layer) 14 is preferably formed on the back surface by applying to a surface opposite to the surface to which the mold diffusion layer-forming composition is applied and baking treatment.
- the material used for the back electrode 20 is not limited to Group 13 aluminum.
- Ag (silver) or Cu (copper) can be applied, and the thickness of the back electrode 20 is also conventional. It becomes possible to form thinner.
- an antireflection film 16 is formed on the n-type diffusion layer 12.
- the antireflection film 16 is formed by applying a known technique.
- the antireflection film 16 is a silicon nitride film, it is formed by a plasma CVD method using a mixed gas of SiH 4 and NH 3 as a raw material. At this time, hydrogen diffuses into the crystal, and orbits that do not contribute to the bonding of silicon atoms, that is, dangling bonds and hydrogen are combined to inactivate defects (hydrogen passivation).
- the mixed gas flow ratio NH 3 / SiH 4 is 0.05 to 1.0
- the reaction chamber pressure is 13.3 Pa (0.1 Torr) to 266.6 Pa (2 Torr)
- the temperature is 300 ° C. to 550 ° C. and the frequency for plasma discharge is 100 kHz or more.
- a surface electrode metal paste is printed on the antireflection film 16 on the surface (light-receiving surface) by screen printing and dried to form a surface electrode metal paste layer 17.
- the metal paste for a surface electrode contains (1) metal particles and (2) glass particles as essential components, and includes (3) a resin binder and (4) other additives as necessary.
- a back electrode metal paste layer 19 is also formed on the p + -type diffusion layer 14 on the back surface.
- the material and forming method of the back electrode metal paste layer 19 are not particularly limited.
- the back electrode metal paste layer 19 including a metal such as aluminum, silver or copper may be applied and dried to form the back electrode metal paste layer 19.
- a silver paste for forming a silver electrode may be partially provided on the back surface for connection between solar cell elements in the module process.
- the electrode metal paste layer 17 is fired to complete the solar cell element.
- the antireflection film 16 that is an insulating film is melted by the glass particles contained in the electrode metal paste on the surface side, and part of the surface of the p-type semiconductor substrate 10
- the metal particles for example, silver particles
- the paste form a contact portion with the p-type semiconductor substrate 10 and solidify.
- the formed surface electrode 18 and the p-type semiconductor substrate 10 are electrically connected. This is called fire-through.
- the back electrode metal paste of the back electrode metal paste layer 19 is baked to form the back electrode 20.
- FIG. 2 indicates a bus bar electrode, and 32 indicates a finger electrode.
- the surface electrode 18 includes a bus bar electrode 30 and finger electrodes 32 intersecting with the bus bar electrode 30.
- 2A is a plan view of a solar cell element in which the surface electrode 18 includes a bus bar electrode 30 and finger electrodes 32 intersecting with the bus bar electrode 30 as viewed from the surface.
- FIG. 2B is a plan view of FIG. It is a perspective view which expands and shows a part of.
- Such a surface electrode 18 can be formed, for example, by means such as screen printing of the above metal paste, plating of the electrode material, vapor deposition of the electrode material by electron beam heating in a high vacuum, or the like.
- the surface electrode 18 composed of the bus bar electrode 30 and the finger electrode 32 is generally used as an electrode on the light receiving surface side and is well known, and it is possible to apply known forming means for the bus bar electrode and finger electrode on the light receiving surface side. it can.
- the solar cell element in which the n-type diffusion layer is formed on the front surface, the p + -type diffusion layer is formed on the back surface, and the front surface electrode and the back surface electrode are further provided on the respective layers has been described.
- a layer formation composition it is also possible to produce a back contact type solar cell element.
- the back contact type solar cell element has all electrodes provided on the back surface to increase the area of the light receiving surface. That is, in the back contact type solar cell element, it is necessary to form both the n-type diffusion region and the p + -type diffusion region on the back surface to form a pn junction structure.
- the n-type diffusion layer forming composition of the present invention can form an n-type diffusion site at a specific site, and can therefore be suitably applied to the production of a back contact type solar cell element.
- the present invention includes the use of the n-type diffusion layer forming composition in the production of an n-type diffusion layer, and the formation of the n-type diffusion layer in the production of a solar cell element including the semiconductor substrate, the n-type diffusion layer, and an electrode.
- Each use of the composition is also encompassed.
- a uniform n-type can be formed in a desired shape in a specific region in a short time without forming an unnecessary n-type diffusion layer.
- a diffusion layer can be obtained, and a solar cell element having such an n-type diffusion layer can be obtained without forming an unnecessary n-type diffusion layer.
- Example 1 P 2 O 5 —SiO 2 —CaO-based glass (softening temperature 700 ° C., P 2 O 5 : 50%, SiO 2 : 43%, having a substantially spherical particle shape, an average particle diameter of 4 ⁇ m, and a d90 of 15 ⁇ m, (CaO: 7%) 3 g of powder, 2.1 g of ethyl cellulose, and 24.9 g of terpineol were mixed using an automatic mortar kneader to make a paste, thereby preparing an n-type diffusion layer forming composition.
- the glass particle shape was determined by observing with a TM-1000 scanning electron microscope manufactured by Hitachi High-Technologies Corporation.
- the average particle diameter and d90 of the glass were calculated using a LS 13 320 type laser scattering diffraction particle size distribution analyzer (measurement wavelength: 632 nm) manufactured by Beckman Coulter, Inc.
- the softening temperature of the glass was determined from a differential heat (DTA) curve using a DTG-60H type differential heat / thermogravimetric simultaneous measuring device manufactured by Shimadzu Corporation.
- the prepared paste was applied to the surface of the p-type silicon substrate by screen printing and dried on a hot plate at 150 ° C. for 5 minutes. Next, it was kept in an oven set at 450 ° C. for 1.5 minutes to release ethyl cellulose. Subsequently, the substrate is immersed in hydrofluoric acid for 5 minutes in order to remove the glass layer by performing thermal diffusion treatment by holding it in an electric furnace set at 950 ° C. for 10 minutes in an air flow (0.9 cm / s) atmosphere. And washed with running water. Thereafter, drying was performed.
- the sheet resistance was measured at 25 ° C. by a four-probe method using a Loresta-EP MCP-T360 type low resistivity meter manufactured by Mitsubishi Chemical Corporation. Further, ⁇ represents a standard deviation, and was calculated by a square root of a sum of squares of deviations of 25 sheet resistance values in the coated surface divided by the number of data.
- Example 2 An n-type diffusion layer was formed in the same manner as in Example 1 except that the average particle diameter of the glass powder was 2 ⁇ m and d90 was 6.5 ⁇ m.
- the sheet resistance of the surface on which the n-type diffusion layer forming composition was applied was 33 ⁇ / ⁇ , P (phosphorus) diffused, and an n-type diffusion layer was formed.
- the sheet resistance on the back surface was 1000000 ⁇ / ⁇ or more, which was not measurable, and the n-type diffusion layer was not formed.
- Example 3 An n-type diffusion layer was formed in the same manner as in Example 1 except that the average particle diameter of the glass powder was 0.7 ⁇ m and d90 was 3.4 ⁇ m.
- Example 4 P 2 O 5 —SiO 2 —CaO-based glass (softening temperature 800 ° C., P 2) having a substantially spherical particle shape, an average particle diameter of 2 ⁇ m, and a d90 of 6.5 ⁇ m and a softening temperature higher than that of Example 1. (O 5 : 44%, SiO 2 : 49%, CaO: 7%) 3 g of powder, 2.1 g of ethyl cellulose, and 24.9 g of terpineol were mixed and pasted using an automatic mortar kneader, and n-type A diffusion layer forming composition was prepared.
- the prepared paste was applied to the surface of the p-type silicon substrate by screen printing and dried on a hot plate at 150 ° C. for 5 minutes. Subsequently, in an air flow (0.9 cm / s) atmosphere, heat diffusion treatment is performed for 10 minutes in an electric furnace set at 950 ° C., and then the substrate is immersed in hydrofluoric acid for 5 minutes to remove the glass layer. , Washed with running water. Thereafter, drying was performed. The sheet resistance of the surface on which the n-type diffusion layer forming composition was applied was 42 ⁇ / ⁇ , and P (phosphorus) diffused to form an n-type diffusion layer.
- the sheet resistance on the back surface was 1000000 ⁇ / ⁇ or more, which was not measurable, and the n-type diffusion layer was not formed.
- n-type diffusion layer was formed in the same manner as in Example 1 except that the average particle diameter of the glass powder was 8 ⁇ m and d90 was 50 ⁇ m.
- the sheet resistance of the surface on which the n-type diffusion layer forming composition was applied was 120 ⁇ / ⁇ , P (phosphorus) diffused, and an n-type diffusion layer was formed.
- n-type diffusion layer was formed in the same manner as in Example 1 except that the average particle diameter of the glass powder was 30 ⁇ m and d90 was 110 ⁇ m.
- the substrate is immersed in hydrofluoric acid for 5 minutes in order to remove the glass layer by performing thermal diffusion treatment by holding in an electric furnace set at 950 ° C. for 10 minutes. , Washed with running water. Thereafter, drying was performed.
- the sheet resistance of the portion where the composition for forming an n-type diffusion layer was applied in a thin line was 120 ⁇ / ⁇ , P (phosphorus) was diffused, and an n-type diffusion layer was formed.
- coated thin line-shaped pattern became 400 micrometers, and since the molten glass was dripping, the selective diffusion to the specific part was not able to be performed.
- the sheet resistance of the surface on which the n-type diffusion layer forming composition was applied was 14 ⁇ / ⁇ , P (phosphorus) diffused, and an n-type diffusion layer was formed.
- the sheet resistance on the back surface was 50 ⁇ / ⁇ , and an n-type diffusion layer was also formed on the back surface.
- the sheet resistance of the surface on which the n-type diffusion layer forming composition was applied was 10 ⁇ / ⁇ , P (phosphorus) was diffused, and an n-type diffusion layer was formed.
- the sheet resistance on the back surface was 100 ⁇ / ⁇ , and an n-type diffusion layer was also formed on the back surface.
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Abstract
Description
まず、光閉じ込め効果を促して高効率化を図るよう、受光面にテクスチャー構造を形成したp型シリコン基板を準備し、続いてドナー元素含有化合物であるオキシ塩化リン(POCl3)、窒素、酸素の混合ガス雰囲気において800℃~900℃で数十分の処理を行って一様にn型拡散層を形成する。この従来の方法では、混合ガスを用いてリンの拡散を行うため、表面のみならず、側面、裏面にもn型拡散層が形成される。そのため、側面のn型拡散層を除去するためのサイドエッチング工程が必要であった。また、裏面のn型拡散層はp+型拡散層へ変換する必要があり、裏面のn型拡散層の上にアルミニウムペーストを付与して、アルミニウムの拡散によってn型拡散層からp+型拡散層に変換させていた。
<1>ドナー元素を含み、軟化温度が500℃以上900℃以下であり、平均粒子径が5μm以下であるガラス粉末と、分散媒と、を含有するn型拡散層形成組成物。
<2>前記ガラス粉末のd90が20μm以下である、請求項1に記載のn型拡散層形成組成物。
<3>前記ドナー元素が、P(リン)及びSb(アンチモン)から選択される少なくとも1種である、<1>又は<2>に記載のn型拡散層形成組成物。
<4>前記ドナー元素を含むガラス粉末が、P2O3、P2O5及びSb2O3からなる群より選択される少なくとも1種のドナー元素含有物質と、SiO2、K2O、Na2O、Li2O、BaO、SrO、CaO、MgO、BeO、ZnO、PbO、CdO、SnO、ZrO2及びMoO3からなる群より選択される少なくとも1種のガラス成分物質と、を含有する、<1>~<3>のいずれかに記載のn型拡散層形成組成物。
<5>半導体基板上に、<1>~<4>のいずれかに記載のn型拡散層形成組成物を付与する工程と、前記付与後の半導体基板に、熱拡散処理を施す工程と、を有するn型拡散層の製造方法。
<6>半導体基板上に、<1>~<4>のいずれかに記載のn型拡散層形成組成物を付与する工程と、前記付与後の半導体基板に、熱拡散処理を施して、n型拡散層を形成する工程と、形成された前記n型拡散層上に電極を形成する工程と、を有する太陽電池素子の製造方法。
<7>n型拡散層の製造における、<1>~<4>のいずれかに記載のn型拡散層形成組成物の使用。
<8>半導体基板と、n型拡散層と、電極と、を含む太陽電池素子の製造における、<1>~<4>のいずれかに記載のn型拡散層形成組成物の使用。
尚、本明細書において「工程」との語は、独立した工程だけではなく、他の工程と明確に区別できない場合であってもその工程の所期の目的が達成されれば、本用語に含まれる。また本明細書において「~」は、その前後に記載される数値をそれぞれ最小値および最大値として含む範囲を示すものとする。さらに本明細書において組成物中の各成分の量は、組成物中に各成分に該当する物質が複数存在する場合、特に断らない限り、組成物中に存在する当該複数の物質の合計量を意味する。
ここで、n型拡散層形成組成物とは、ドナー元素を含み、軟化温度が500℃以上900℃以下であり、平均粒子径が5μm以下であるガラス粉末を含有し、半導体基板に付与した後にこのドナー元素を熱拡散することでn型拡散層を形成することが可能な材料をいう。
ドナー元素を含み、軟化温度が500℃以上900℃以下であり、平均粒子径が5μm以下であるガラス粉末を含むn型拡散層形成組成物を用いることで、熱拡散処理時のガラスの粘度が低くなりすぎず、またガラス粉末が短時間で溶融する。これにより、所望の部位にn型拡散層が形成され、裏面や側面には不要なn型拡散層が形成されない。
この理由として、ドナー成分はガラス中に構成元素として他の元素と強固な結合しているため、揮発しにくいものと考えられる。
ドナー元素とは、半導体基板中に拡散(ドーピング)させることによってn型拡散層を形成することが可能な元素である。ドナー元素としては第15族の元素が使用でき、例えばP(リン)、Sb(アンチモン)、Bi(ビスマス)、As(ヒ素)等が挙げられる。安全性、ガラス化の容易さ等の観点から、P又はSbが好適である。
ガラス成分物質としては、SiO2、K2O、Na2O、Li2O、BaO、SrO、CaO、MgO、BeO、ZnO、PbO、CdO、SnO、ZrO2、WO3、MoO3、MnO、La2O3、Nb2O5、Ta2O5、Y2O3、TiO2、ZrO2、GeO2、TeO2及びLu2O3等が挙げられ、SiO2、K2O、Na2O、Li2O、BaO、SrO、CaO、MgO、BeO、ZnO、PbO、CdO、SnO、ZrO2、WO3、MoO3及びMnOからなる群より選択される少なくとも1種を用いることが好ましく、SiO2、K2O、Na2O、Li2O、BaO、SrO、CaO、MgO、BeO、ZnO、PbO、CdO、SnO、ZrO2及びMoO3からなる群より選択される少なくとも1種を用いることがより好ましい。
なお、P2O5-Sb2O3系、P2O5-As2O3系等のように、2種類以上のドナー元素含有物質を含むガラス粉末でもよい。
上記では2成分を含む複合ガラスを例示したが、P2O5-SiO2-CaO等必要に応じて3成分以上の物質を含むガラス粉末でもよい。
ガラス粉末の軟化温度が500℃以上900℃以下の範囲内であれば、上述の通り、液だれが生じることもないため、拡散処理後に、特定の領域へ所望の形状にn型拡散層を形成することが可能となる。例えばaμm幅の線状パターンでn型拡散層形成組成物を付与した場合には、拡散処理後の線幅bは、b<1.5aμmの範囲の線状パターンを保持できる。
ガラス粉末を、5μm以下の平均粒子径にすることで、軟化温度が前記の範囲内にあるガラス粉末を用いた場合においても、短時間で溶融し、平滑なガラス層が得られやすくなる。そのため、ガラス粉末の平均粒子径を5μm以下にすることで、均一なn型拡散層を形成できる。
本発明では、シート抵抗としては、三菱化学(株)製Loresta-EP MCP-T360型低抵抗率計を用い四探針法により25℃で測定したものを採用する。
またσは、塗布した面内について上記の測定方法により得られた25点のシート抵抗値の偏差の2乗和をデータ数で割ったものの平方根により算出して得られたものである。
ここで、本明細書において特に断らない限り、ガラスの平均粒子径は、体積平均粒子径を表し、レーザー散乱回折法粒度分布測定装置(ベックマンコールター社製)等により測定することができる。
最初に原料、例えば、前記ドナー元素含有物質とガラス成分物質を秤量し、るつぼに充填する。るつぼの材質としては白金、白金―ロジウム、イリジウム、アルミナ、石英、炭素等が挙げられる。るつぼの材質は、溶融温度、雰囲気、溶融物質との反応性等を考慮して適宜選ばれる。
次に、前記ドナー元素含有物質及びガラス成分物質を、電気炉でガラス組成に応じた温度で加熱し融液とする。このとき融液が均一となるよう攪拌することが望ましい。
続いて得られた融液をジルコニア基板やカーボン基板等の上に流し出して融液をガラス化する。
最後にガラスを粉砕し粉末状とする。粉砕にはジェットミル、ビーズミル、ボールミル等公知の方法が適用できる。
分散媒とは、組成物中において上記ガラス粉末を分散させる媒体である。具体的に分散媒としては、バインダー及び溶剤からなる群より選択された少なくとも1種が採用される。
n型拡散層形成組成物の粘度は、付与適性を考慮して、10mPa・s以上1000000mPa・s以下であることがより好ましい。
詳細には、インゴットからスライスした際に発生するシリコン表面のダメージ層を20質量%苛性ソーダで除去する。次いで1質量%苛性ソーダと10質量%イソプロピルアルコールの混合液によりエッチングを行い、テクスチャー構造を形成する(図中ではテクスチャー構造の記載を省略する)。太陽電池素子は、受光面(表面)側にテクスチャー構造を形成することにより、光閉じ込め効果が促され、高効率化が図られる。
上記n型拡散層形成組成物の付与量としては特に制限は無いが、例えば、ガラス粉末量として0.01g/m2~100g/m2とすることができ、0.1g/m2~10g/m2であることが好ましい。
前記B(ボロン)等の第13族の元素を含む組成物13としては、例えば、ドナー元素を含むガラス粉末の代わりにアクセプタ元素を含むガラス粉末を用いて、n型拡散層形成組成物と同様にして構成されるp型拡散層形成組成物を挙げることができる。アクセプタ元素は第13族の元素であればよく、例えば、B(ボロン)、Al(アルミニウム)及びGa(ガリウム)等を挙げることができる。またアクセプタ元素を含むガラス粉末はB2O3、Al2O3及びGa2O3からなる群より選択される少なくとも1種を含むことが好ましい。
さらにp型拡散層形成組成物をシリコン基板の裏面に付与する方法は、既述のn型拡散層形成組成物をシリコン基板上に付与する方法と同様である。
熱拡散処理時間は、n型拡散層形成組成物に含まれるドナー元素の含有率に応じて適宜選択することができる。例えば、1分間~60分間とすることができ、2分間~30分間であることがより好ましい。
したがって、従来広く採用されている気相反応法によりn型拡散層を形成する方法では、側面に形成された不要なn型拡散層を除去するためのサイドエッチング工程が必須であったが、本発明の製造方法によれば、サイドエッチング工程が不要となり、工程が簡易化される。このように、本発明の製造方法によって、短時間で、所望の部位に且つ所望の形状の、均一なn型拡散層が形成される。
この内部応力は、結晶の結晶粒界に損傷を与え、電力損失が大きくなるという課題があった。また、反りは、モジュール工程における太陽電池素子の搬送や、タブ線と呼ばれる銅線との接続において、太陽電池素子を破損させ易くしていた。近年では、スライス加工技術の向上から、シリコン基板の厚みが薄型化されつつあり、更に太陽電池素子が割れ易い傾向にある。
例えば、ドナー元素を含むガラス粉末の代わりにアクセプタ元素を含むガラス粉末を用いて、n型拡散層形成組成物と同様にして構成されるp型拡散層形成組成物を、シリコン基板の裏面(n型拡散層形成組成物を付与した面とは反対側の面)に付与し、焼成処理することで、裏面にp+型拡散層(高濃度電界層)14を形成することが好ましい。
また後述するように、裏面電極20に用いる材料は第13族のアルミニウムに限定されず、例えばAg(銀)又はCu(銅)等を適用することができ、裏面電極20の厚さも従来のものよりも薄く形成することが可能となる。
より具体的には、上記混合ガス流量比NH3/SiH4が0.05~1.0、反応室の圧力が13.3Pa(0.1Torr)~266.6Pa(2Torr)、成膜時の温度が300℃~550℃、プラズマの放電のための周波数が100kHz以上の条件下で形成される。
バックコンタクト型の太陽電池素子は、電極を全て裏面に設けて受光面の面積を大きくするものである。つまりバックコンタクト型の太陽電池素子では、裏面にn型拡散部位及びp+型拡散部位の両方を形成しpn接合構造とする必要がある。本発明のn型拡散層形成組成物は、特定の部位にn型拡散部位を形成することが可能であり、よってバックコンタクト型の太陽電池素子の製造に好適に適用することができる。
粒子形状が略球状で、平均粒子径が4μm、及びd90が15μmであるP2O5-SiO2-CaO系ガラス(軟化温度700℃、P2O5:50%、SiO2:43%、CaO:7%)粉末3gと、エチルセルロース2.1gと、テルピネオール24.9gとを、自動乳鉢混錬装置を用いて混合してペースト化し、n型拡散層形成組成物を調製した。
また、σは、標準偏差を示し、塗布した面内の25点のシート抵抗値の偏差の2乗和をデータ数で割ったものの平方根により算出した。
ガラス粉末の平均粒子径を2μm、及びd90を6.5μmとした以外は実施例1と同様にして、n型拡散層形成を行った。
n型拡散層形成組成物を塗布した側の表面のシート抵抗は33Ω/□であり、P(リン)が拡散し、n型拡散層が形成されていた。また、塗布した面内のシート抵抗値のばらつきはσ=0.5であり、均一なn型拡散層が形成されていた。他方、裏面のシート抵抗は1000000Ω/□以上で測定不能であり、n型拡散層は形成されていなかった。
ガラス粉末の平均粒子径を0.7μm、及びd90を3.4μmとした以外は実施例1と同様にして、n型拡散層形成を行った。
n型拡散層形成組成物を塗布した側の表面のシート抵抗は25Ω/□であり、P(リン)が拡散しn型拡散層が形成されていた。また、塗布した面内のシート抵抗値のばらつきはσ=0.3であり、均一なn型拡散層が形成されていた。他方、裏面のシート抵抗は1000000Ω/□以上で測定不能であり、n型拡散層は形成されていなかった。
粒子形状が略球状で、平均粒子径が2μm、及びd90が6.5μmであり、実施例1より高い軟化温度を有するP2O5-SiO2-CaO系ガラス(軟化温度800℃、P2O5:44%、SiO2:49%、CaO:7%)粉末3gと、エチルセルロース2.1gと、テルピネオール24.9gとを、自動乳鉢混錬装置を用いて混合してペースト化し、n型拡散層形成組成物を調製した。次に、調製したペーストをスクリーン印刷によってp型シリコン基板表面に塗布し、150℃のホットプレート上で5分間乾燥させた。続いて、大気フロー(0.9cm/s)雰囲気中、950℃に設定した電気炉で10分間保持して熱拡散処理を行い、その後ガラス層を除去するため基板をふっ酸に5分間浸漬し、流水洗浄を行った。その後、乾燥を行った。
n型拡散層形成組成物を塗布した側の表面のシート抵抗は42Ω/□であり、P(リン)が拡散しn型拡散層が形成されていた。また、塗布した面内のシート抵抗値のばらつきはσ=0.5であり、均一なn型拡散層が形成されていた。他方、裏面のシート抵抗は1000000Ω/□以上で測定不能であり、n型拡散層は形成されていなかった。
ガラス粉末の平均粒子径を8μm、及びd90を50μmとした以外は実施例1と同様にして、n型拡散層形成を行った。
n型拡散層形成組成物を塗布した側の表面のシート抵抗は120Ω/□であり、P(リン)が拡散し、n型拡散層が形成されていた。しかし、面内のシート抵抗値にばらつきが見られ(σ=10.7)、不均一であった。
ガラス粉末の平均粒子径を30μm、及びd90を110μmとした以外は実施例1と同様にしてn型拡散層形成を行った。
n型拡散層形成組成物を塗布した側の表面のシート抵抗は300Ω/□であり、P(リン)が拡散し、n型拡散層が形成されていた。しかし、面内のシート抵抗値にばらつきが見られ(σ=24.9)、不均一であった。
粒子形状が略球状で、平均粒子径が2μm、及びd90が6.5μmであるP2O5-SnO系ガラス(軟化温度300℃、P2O5:30%、SnO:70%)粉末3gとエチルセルロース2.1g、テルピネオール24.9gを、自動乳鉢混錬装置を用いて混合してペースト化し、n型拡散層形成組成物を調製した。
次に、調製したペーストを120μm幅の細線状に、スクリーン印刷でp型シリコン基板表面に塗布し、150℃のホットプレート上で5分間乾燥させた。続いて、窒素フロー(0.9cm/s)雰囲気中、950℃に設定した電気炉で10分間保持して熱拡散処理を行い、その後ガラス層を除去するため基板をふっ酸に5分間浸漬し、流水洗浄を行った。その後、乾燥を行った。
リン酸二水素アンモニウム(NH4H2PO4)粉末20gとエチルセルロース3gと、酢酸2-(2-ブトキシエトキシ)エチル7gとを、自動乳鉢混錬装置を用いて混合してペースト化し、n型拡散層組成物を調製した。
次に、調製したペーストをスクリーン印刷によってp型シリコン基板表面に塗布し、150℃のホットプレート上で5分間乾燥させた。続いて、1000℃に設定した電気炉で10分間保持して熱拡散処理を行い、その後ガラス層を除去するため基板をふっ酸に5分間浸漬し、流水洗浄、乾燥を行った。
リン酸二水素アンモニウム(NH4H2PO4)粉末1gと、純水7gと、ポリビニルアルコール0.7gと、イソプロピルアルコール1.5gとを、自動乳鉢混錬装置を用いて混合して溶液を調製し、n型拡散層組成物を調製した。
次に、調製した溶液をスピンコータ(2000rpm、30sec)によってp型シリコン基板表面に塗布し、150℃のホットプレート上で5分間乾燥させた。続いて、1000℃に設定した電気炉で10分間保持して熱拡散処理を行い、その後ガラス層を除去するため基板をふっ酸に5分間浸漬し、流水洗浄、乾燥を行った。
本明細書に記載された全ての文献、特許出願、及び技術規格は、個々の文献、特許出願、及び技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書に参照により取り込まれる。
Claims (6)
- ドナー元素を含み、軟化温度が500℃以上900℃以下であり、平均粒子径が5μm以下であるガラス粉末と、分散媒と、を含有するn型拡散層形成組成物。
- 前記ガラス粉末のd90が20μm以下である、請求項1に記載のn型拡散層形成組成物。
- 前記ドナー元素が、P(リン)及びSb(アンチモン)から選択される少なくとも1種である、請求項1又は請求項2に記載のn型拡散層形成組成物。
- 前記ドナー元素を含むガラス粉末が、P2O3、P2O5及びSb2O3からなる群より選択される少なくとも1種のドナー元素含有物質と、SiO2、K2O、Na2O、Li2O、BaO、SrO、CaO、MgO、BeO、ZnO、PbO、CdO、SnO、ZrO2及びMoO3からなる群より選択される少なくとも1種のガラス成分物質と、を含有する、請求項1~請求項3のいずれか1項に記載のn型拡散層形成組成物。
- 半導体基板上に、請求項1~請求項4のいずれか1項に記載のn型拡散層形成組成物を付与する工程と、
前記付与後の半導体基板に、熱拡散処理を施す工程と、
を有するn型拡散層の製造方法。 - 半導体基板上に、請求項1~請求項4のいずれか1項に記載のn型拡散層形成組成物を付与する工程と、
前記付与後の半導体基板に、熱拡散処理を施して、n型拡散層を形成する工程と、
形成された前記n型拡散層上に電極を形成する工程と、
を有する太陽電池素子の製造方法。
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Cited By (2)
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WO2016010095A1 (ja) * | 2014-07-15 | 2016-01-21 | 日立化成株式会社 | n型拡散層を有する半導体基板の製造方法及び太陽電池素子の製造方法 |
WO2016068315A1 (ja) * | 2014-10-30 | 2016-05-06 | 日立化成株式会社 | n型拡散層形成組成物、n型拡散層の製造方法及び太陽電池素子の製造方法 |
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JP5176158B1 (ja) * | 2011-07-05 | 2013-04-03 | 日立化成株式会社 | n型拡散層形成組成物、n型拡散層の製造方法及び太陽電池素子の製造方法 |
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- 2012-07-03 CN CN201510917152.2A patent/CN105551947A/zh active Pending
- 2012-07-03 KR KR1020147000418A patent/KR101384874B1/ko active IP Right Grant
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- 2012-07-03 WO PCT/JP2012/066985 patent/WO2013005738A1/ja active Application Filing
- 2012-07-03 CN CN201410048996.3A patent/CN103839787A/zh active Pending
- 2012-07-03 CN CN201280031501.5A patent/CN103650111A/zh active Pending
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Also Published As
Publication number | Publication date |
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CN103650111A (zh) | 2014-03-19 |
TWI570778B (zh) | 2017-02-11 |
CN105006429A (zh) | 2015-10-28 |
CN107093550A (zh) | 2017-08-25 |
KR20140019473A (ko) | 2014-02-14 |
JPWO2013005738A1 (ja) | 2015-02-23 |
KR101384874B1 (ko) | 2014-04-16 |
TW201308402A (zh) | 2013-02-16 |
TWI480929B (zh) | 2015-04-11 |
CN105551947A (zh) | 2016-05-04 |
TW201419384A (zh) | 2014-05-16 |
KR20140008535A (ko) | 2014-01-21 |
CN103839787A (zh) | 2014-06-04 |
JP5176158B1 (ja) | 2013-04-03 |
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