The invention concerns a method for doping a semiconductor substrate in accordance with the preamble to claim 1 and also a solar cell in accordance with the preamble of claim 12.
Prior art includes the heating of a semiconductor substrate using laser beams and thereby diffusing dopant from a dopant source into the semiconductor substrate. In particular, it has been suggested that such a method is used in the manufacture of selective emitters. In laser diffusions of this type, the surface of a semiconductor substrate is melted. At the same time dopant from a dopant source arranged nearby is diffused into the melted semiconductor substrate, which is subsequently cooled and recrystallised. As a result, heavier doping occurs in the melted and recrystallised region of the semiconductor substrate than in surrounding regions of the semiconductor substrate. Locally heavier dopings of this type and selective emitters created therefrom are supposed to have an advantageous effect on the efficiency of solar cells. However, it has emerged that due to the melting and subsequent recrystallisation, structural defects are formed in the semiconductor substrate which have a negative effect on efficiency and may overcompensate for the advantage of the dopant application. There is also the risk that unwanted impurities may be input into the semiconductor substrate, which reduce the efficiency of the manufactured solar cells.
To avoid these negative effects, WO 2006/012840 proposes a method in which the laser beam used is focused on the semiconductor substrate in a line focus, which is time-consuming to produce, with a high aspect ratio, i.e. with a height which is greater by orders of magnitude than the width of the line focus. This method and the equipment requirements to carry it out are time-consuming and hence cost-intensive.
The present invention is therefore based on the problem of providing a method according to the preamble of claim 1, with which the input of defects into the semiconductor substrate can be economically reduced.
This problem is solved by a generically defined method with the characteristic features of claim 1.
The invention is further based on the problem of providing a solar cell with a two-stage doping, which can be produced economically and has improved efficiency.
This problem is solved by a solar cell with the features of claim 12.
Advantageous refinements are the subject matter of the respective dependent claims.
The method according to the invention for doping a semiconductor substrate provides that the semiconductor substrate is heated by irradiation and at the same time dopant from a dopant source is thereby diffused into heated regions in the semiconductor substrate. When the semiconductor substrate is heated by irradiation with laser radiation, a surface portion of the semiconductor substrate which amounts to less than 10% of the total area of all irradiated regions is melted and recrystallised.
Consequently, only a minor surface portion of the regions of the semiconductor substrate heated by laser radiation is melted and recrystallised. This largely prevents the melting and recrystallisation which are critical with respect to the formation of defects. Surprisingly, it has emerged that in this way, in those heated regions in which no melting with subsequent crystallisation takes place, a dopant application is possible which achieves quality good enough for the formation of two-stage dopings, in particular the formation of selective emitters. Also, dopant is diffused into these heated regions, and its surface concentration is increased, which leads to a reduced contact resistance.
More heavily doped regions of a selective emitter serve to produce good electrical conductivity between a solar cell substrate used as semiconductor substrate and a metallisation arranged thereon and thus largely prevent dissipation losses of the electricity generated. While it has been assumed until now in the state of the art that to do this, a significant sheet resistance reduction is necessary in the more heavily doped regions, it has unexpectedly emerged that, using the method according to the invention, even with a comparatively small reduction in sheet resistance, the contact resistance can be greatly reduced, so that the desired good electrical conductivity can be realised between the solar cell substrate and a metallisation arranged thereon, hence the associated contact resistance can be reduced.
The semiconductor substrate can be directly irradiated with laser radiation. Alternatively, a layer arranged on the semiconductor substrate can be irradiated, for example a layer of phosphorus or borosilicate glass, which will henceforth be referred to for short as a P- or B-glass layer. In the second case, although the layer arranged on the semiconductor substrate can be irradiated directly, depending on the wavelength of the laser radiation used and the thickness of the sheet used, laser radiation can nevertheless enter the surface of the semiconductor substrate, be absorbed there and provide heating of the semiconductor substrate. In addition, or alternatively, heat transmission from the layer arranged on the semiconductor substrate into adjacent regions of the semiconductor substrate can bring about heating of the semiconductor substrate in regions adjacent the irradiated area.
For example, the P-glass- or B-glass layers already mentioned, arranged on the semiconductor substrate, can serve as dopant source. The way this is applied to the semiconductor substrate is immaterial. If silicon substrates are used as semiconductor substrates, they can, for example, be formed by phosphorus or boron diffusions of prior art. An alternative dopant source is a solution containing dopant which can be arranged on the semiconductor substrate. There is also the possibility, inter alia, of arranging the semiconductor substrate in an atmosphere containing dopant during the irradiation.
In practice, it has proven effective to heat the semiconductor substrate locally by means of local irradiation with laser radiation and to diffuse dopant locally into the heated regions. In this way economical two-stage doping structures can be formed, in particular two-stage emitters of solar cells, often referred to as selective emitters.
In one advantageous variant embodiment of the method according to the invention, the semiconductor substrate is not melted during irradiation with laser radiation. Until now, it would have been assumed that no two-stage dopings could be produced in this way. However, it has been shown that even if melting is completely prevented and hence also the recrystallisation, which is critical with respect to the formation of defects in more heavily doped regions of a two-stage or multi-stage doping, good contact resistances can be produced.
As can be deduced from
In the manufacture of solar cells, the contact resistances achieved following laser diffusion allow electrical contacts with good conductivity to be formed between the semiconductor substrate and metallic screen printing pastes, so that the efficiency of the solar cells can be improved economically. If, also, the sheet resistance in the heated regions is not reduced, or reduced only slightly, the spectral sensitivity of these regions remains comparatively high, despite the reduced contact resistance, which also improves efficiency, provided light can shine onto partial regions of the heated regions.
If silicon substrates are used as semiconductor substrates, in particular silicon discs, a green laser beam has proven effective, especially one with a wavelength of 515 nm or 532 nm.
One refinement of the method according to the invention provides that a semiconductor substrate provided in at least some sections with a surface texturing is used and irradiation with laser radiation causes structure tips of the surface texturing to melt over a cross-sectional area of less than 1 μm2, preferably over a cross-sectional area of less than 0.25 μm2. Melted parts of the structure tips are subsequently recrystallised. Said cross-sectional area extends roughly perpendicularly to the direction of incidence of the laser radiation. The surface texturing can in principle be formed in any manner known in the art, in particular wet-chemically.
Preferably, mono- or multicrystalline silicon discs are used as semiconductor substrates and the surface texturing is formed using an alkaline or acid etching solution. As a result of the surface texturing, light injection into the semiconductor substrate can be increased, which has an advantageous effect on the efficiency of solar cells.
In one preferred variant embodiment of the method according to the invention, more heavily doped regions of a two-stage doping are formed by the local diffusion of dopant into the heated regions. As a result, with only minor input of defects into the semiconductor substrate, economical two-stage dopings can be produced, in particular two-stage emitter dopings referred to as selective emitters. These in turn enable the production of more efficient solar cells. The less heavily doped regions of the two-stage doping can, for example, be formed by a planar diffusion carried out before the application of the method, in particular by a diffusion of dopant from a solution containing dopant applied to the semiconductor substrate or by a pipe diffusion. Advantageously, in the subsequent local diffusion of dopant into the heated regions, the sheet resistance, as described above, is not reduced, or only slightly reduced, so that the spectral sensitivity in more heavily doped regions is largely maintained. This makes it possible, if need be with a slightly reduced efficiency of the solar cell, to make the more heavily doped regions broader than a metallisation subsequently formed on the more heavily doped regions, so that the adjustment of the metallisation relative to the more heavily doped regions can be made with less accuracy. As a result, the solar cell production process can be structured more economically and its rejection rate reduced.
A silicon disc is preferably used as semiconductor substrate or solar cell substrate in the method according to the invention, as well as in the solar cell according to the invention.
The method according to the invention is simple to integrate into existing production processes for semiconductor components. In particular, it can be economically integrated into known solar cell production processes and be combined with further process steps, as the cell front side can be processed independently of the cell back side. So it is possible, for example, using the method according to the invention, to form a selective emitter on the front side of the solar cells and to passivate their back sides by means of dielectric sheets or a series of dielectric sheets.
The solar cell according to the invention has a solar cell substrate at least partially provided with a surface texturing and a two-stage doping. Furthermore, in more heavily doped regions of the two-stage doping, structure tips of the surface texturing are melted and recrystallised over a cross-sectional area of less than 1 μm2. Structure tips in this case means objects whose cross-sections taper at least partially with increasing distance from the solar cell substrate.
Such a solar cell can be economically manufactured using the method according to the invention. The surface texturing and the two-stage doping, which is preferably executed as selective emitter, enable a high degree of efficiency. Since the structure tips of the surface texturing are melted and recrystallised over a cross-sectional area of less than 1 μm2, low defect densities can be realised in more heavily doped regions, which has a positive effect on the efficiency of the solar cell.
In one refinement of the solar cell according to the invention, the solar cell substrate has a contact resistance of 10 mΩcm2 or less in the more heavily doped regions of the two-stage doping. Furthermore, in the more heavily doped regions of the two-stage doping it has a sheet resistance which is at least 50% of the sheet resistance value prevailing in the less heavily doped regions of the two-stage doping, preferably at least 70% and especially preferably at least 90% of the sheet resistance value prevailing in the less heavily doped regions of the two-stage doping. This enables good spectral sensitivity of the solar cell substrate in the more heavily doped regions and thus an improvement in efficiency.
One advantageous variant embodiment of this refinement provides that metallisations formed on the more heavily doped regions are narrower than the more heavily doped regions on which they are formed. As a result, when the solar cells are in operation, light falls on parts of the more heavily doped regions. Because of the only moderate to slightly reduced sheet resistance in the more heavily doped regions, however, these have good spectral sensitivity, so that compared with narrower more heavily doped regions, at most slight losses of efficiency result. Because the more heavily doped regions are wider compared with the metallisations, however, the production advantages explained above give rise to a lesser accuracy requirement in the adjustment or alignment of the metallisations with respect to the associated more heavily doped regions of the two-stage doping.
The invention will next be explained in more detail on the basis of some figures. Wherever expedient, elements with the same effect have been given the same reference numbers. The figures show:
In the embodiment from
In the embodiment of the method according to the invention shown in
The illustration of the less heavily 56 and the more heavily doped regions 58 is to be understood accordingly by means of the broken line in
In
The variant embodiments of the irradiation according to
The surface texturing according to the variant embodiments in
The partial views a) and b) in
In another variant embodiment of the method according to the invention, however, the structure tips 74 of the surface texturing are melted over a cross-sectional area 78. Partial views c) and d) show the result of carrying out the method in this way. Instead of the tapering pointed structure tips 74 in partial views a) and b), there are now melted and recrystallised structure tips 76. In one advantageous variant embodiment of the method according to the invention the structure tips of the surface texturing 73 are melted over a cross-sectional area 78 which is less than 1 μm2, preferably less than 0.25 μm2. The fact that this can be realised is illustrated by
As shown by the lateral view in
The illustrations in
In the case of the method according to the invention and also in the case of the solar cell according to the invention, monocrystalline or multicrystalline materials can be used as semiconductor- or solar cell substrate, in particular monocrystalline or multicrystalline silicon materials.
10 formation of surface texturing
12 phosphorus diffusion
14 irradiation with laser radiation
16 melting the solar cell substrate
18 diffusion dopant
20 recrystallisation
22 removal of P-glass
24 silicon nitride coating
26 metallisation
50 solar cell substrate
52 heated region
54 P-glass layer
56 less heavily doped region
58 more heavily doped region
60 laser radiation
62 irradiated region
70 solar cell
72 metallisation
73 surface texturing
74 structure tips
76 melted and recrystallised structure tips
78 cross-sectional area
h texture height
SiN silicon nitride
Number | Date | Country | Kind |
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102010010221.0 | Mar 2010 | DE | national |
102010010813.8 | Mar 2010 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/DE2011/075033 | 3/3/2011 | WO | 00 | 10/1/2012 |