Patent Application
20090087370
The present invention relates generally to photovoltaic materials. More particularly, the present invention provides a method and structure for processing semiconductor materials used for the manufacture of photovoltaic devices. Merely by way of example, the present method and structure have been implemented using a commercial source of iron disilicide, but it would be recognized that the invention may have other configurations.
From the beginning of time, mankind has been challenged to find ways of harnessing energy. Energy comes in the forms such as petrochemical, hydroelectric, nuclear, wind, biomass, solar, and more primitive forms such as wood and coal. Over the past century, modern civilization has relied upon petrochemical energy as an important energy source. Petrochemical energy includes gas and oil. Gas includes lighter forms such as butane and propane, commonly used to heat homes and serve as fuel for cooking. Gas also includes gasoline, diesel, and jet fuel, commonly used for transportation purposes. Heavier forms of petrochemicals can also be used to heat homes in some places. Unfortunately, the supply of petrochemical fuel is limited and essentially fixed based upon the amount available on Earth. Additionally, as more people use petrochemicals in growing amounts, it is rapidly becoming a scarce resource, which will eventually be depleted over time.
More recently, environmentally clean and renewable sources of energy have been desired. An example of a clean source of energy is hydroelectric power. Hydroelectric power is derived from electric generators driven by the flow of water produced by dams such as the Hoover Dam in Nevada. The electric power generated is used to power a large portion of the city of Los Angeles in California. Clean and renewable sources of energy also include wind, waves, biomass, and the like. That is, windmills convert wind energy into more useful forms of energy such as electricity. Still other types of clean energy include solar energy. Specific details of solar energy can be found throughout the present background and more particularly below.
Solar energy technology generally converts electromagnetic radiation from the sun to other useful forms of energy. These other forms of energy include thermal energy and electrical power. For electrical power applications, solar cells are often used. Although solar energy is environmentally clean and has been successful to a point, many limitations remain to be resolved before it becomes widely used throughout the world. As an example, one type of solar cell uses crystalline materials, which are derived from semiconductor material ingots. These crystalline materials can be used to fabricate optoelectronic devices that include photovoltaic and photodiode devices that convert electromagnetic radiation into electrical power. However, crystalline materials are often costly and difficult to make on a large scale. Additionally, devices made from such crystalline materials often have low energy conversion efficiencies. Other types of solar cells use “thin film” technology to form a thin film of photosensitive material to be used to convert electromagnetic radiation into electrical power. Similar limitations exist with the use of thin film technology in making solar cells. That is, efficiencies are often poor. Additionally, film reliability is often poor and cannot be used for extensive periods of time in conventional environmental applications. Often, thin films are difficult to mechanically integrate with each other. These and other limitations of these conventional technologies can be found throughout the present specification and more particularly below.
From the above, it is seen that improved techniques for manufacturing photovoltaic materials and resulting devices are desired.
According to embodiments of the present invention, a method and a system for forming semiconductor materials for photovoltaic applications is provided. More particularly, the present invention provides a method and structure for processing semiconductor materials used for the manufacture of photovoltaic devices. Merely by way of example, the method has been used to provide beta iron disilicide for photovoltaic application. But it would be recognized that the present invention has a much broader range of applicability.
In a specific embodiment, the method includes providing a first sample of iron disilicide. The first sample of iron disilicide comprises at least alpha iron disilicide, beta phase iron disilicide, and epsilon phase iron silicide and characterized by a first particle size. The method includes maintaining the first sample of iron disilicide in an inert environment and subjecting the first sample of iron disilicide to an heating process while maintaining the first sample of iron disilicide in the inert environment to form a second sample of iron disilicide. The second sample of iron disilicide comprises substantially beta phase iron disilicide (greater than about 90 percent). The second iron disilicide is characterized by a second particle size. The method forms a first mixture of material comprising the second sample of iron disilicide and an organic solvent. In a specific embodiment, the first mixture of material including the second sample of iron disilicide is subjected to a grinding process. The method includes removing the organic solvent; and forms a third sample of iron disilicide comprising substantially beta iron disilicide. The third sample of iron disilicide is characterized by a third particle size.
In a specific embodiment, the method includes providing a first sample of an iron disilicide. The first sample of iron disilicide comprises at least an alpha phase entity ranging from about 5% to about 20% of a total phase entity, a beta phase entity comprising about 30% to about 75% of the phase entity, and an epsilon phase entity comprising about 5% to about 20% of the total phase entity. The method includes maintaining the first sample of iron disilicide in an inert environment, for example, nitrogen, helium, argon, or others. The method subjects the first sample of iron disilicide to a thermal process while maintaining the first sample of iron disilicide in the inert environment to cause formation of a second sample of iron disilicide. The second sample of iron disilicide comprises substantially beta phase iron disilicide and characterized by a first particle size ranging from about 1 to about 20 microns. The method includes introducing an organic solvent to the second sample to form a first mixture of material comprising the second sample of iron disilicide and the organic solvent. In a specific embodiment, the method processes the first mixture of material including the second sample of iron disilicide using a grinding process to convert the second sample of iron disilicide having the first particle size to a third sample of iron disilicide having a second particle size. In a specific embodiment, the second particle size ranges from about 1 micron to about 2 microns. The method then removes the organic solvent from the third sample of iron disilicide and outputting the third sample of iron disilicide characterized by the second particle size and greater than about 90% of the beta phase entity.
Many benefits are achieved by ways of present invention. For example, the present invention uses a commercial source of iron disilicide as a starting material to form substantially pure beta phase iron disilicide. The substantially pure beta phase iron disilicide can be further processed to form iron disilicide of desired characteristics, such as particle size, bandgap, resistivity, carrier mobility, carrier density, and others. Additionally, the present method uses environmentally friendly materials that are non-toxic. Depending on the embodiment, one or more of the benefits can be achieved. These and other benefits will be described in more detailed throughout the present specification and particularly below.
According to embodiments of the present invention, a method and a system for forming semiconductor materials for photovoltaic applications is provided. More particularly, the present invention provides a method and structure for processing semiconductor materials used for the manufacture of photovoltaic devices. Merely by way of example, the method has been used to provide beta iron disilicide for photovoltaic application. But it would be recognized that the present invention has a much broader range of applicability.
1. Step 102, start;
2. Step 104, provide a first sample of iron disilicide, comprises an alpha phase entity, a beta phase entity and an epsilon phase entity;
3. Step 106, subject at least the sample of iron disilicide to a thermal process;
4. Step 108, convert the first sample of iron disilicide to a second sample of iron disilicide comprising substantially the beta phase entity (for example, greater than about 90 percent) characterized by a first particle size (about 20 mesh);
5. Step 110, mix the second sample of iron disilicide with a solvent;
6. Step 112, grind;
7. Step 114, dry;
8. Step 116, form a third sample of iron disilicide comprising substantially beta phase iron disilicide characterized by a second particle size (about 1 micron to 2 microns);
The above sequence of steps provides a method of forming a sample of iron disilicide comprising substantially beta phase iron disilicide according to an embodiment of the present invention. As shown the method uses a combination of steps, including a thermal process to convert the alpha phase and the epsilon phase iron disilicide into beta phase iron disilicide. Further, the method uses a grinding process to form the sample of iron disilicide comprising substantially beta phase iron disilicide of desired particle size. Merely by way of example, the present method has been used in fabricating photovoltaic devices. But it should be recognized that the present invention has a much broader range of applicability.
Referring to
The method includes allowing the second sample of iron disilicide to cool to about room temperature. In a specific embodiment, the cooled second sample of iron disilicide is mixed with a suitable organic solvent to form a first mixture of material 402 as shown in
As shown in
It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
This application claims priority to U.S. Provisional Patent Application No. 60/976,239, filed Sep. 28, 2007, entitled “METHOD AND MATERIAL FOR PURIFYING IRON DISILICIDE FOR PHOTOVOLTAIC APPLICATION” by inventor FREDERIC VICTOR MIKULEC et al. commonly assigned and incorporated by reference herein for all purposes. Not Applicable Not Applicable
| Number | Date | Country | |
|---|---|---|---|
| 60976239 | Sep 2007 | US |
