Photovoltaic device and manufacturing method thereof

Abstract

The present invention was made to improve interface characteristics between a crystalline semiconductor and an amorphous semiconductor thin film so that junction characteristics can be upgraded. A manufacturing method of a photovoltaic device comprising an i-type amorphous silicon thin film (12) and a p-type amorphous silicon thin layer (13) laminated in this order on a front surface of an n-type single crystalline silicon substrate (11), and an i-type amorphous silicon layer (14) and an n-type amorphous silicon layer (15) laminated in this order on a rear surface of the single crystalline silicon substrate, wherein an i-type amorphous silicon layer (12) is formed after the front surface of the single crystalline silicon substrate (11) is exposed to a plasma discharge using mixed gas of hydrogen gas and a gas containing boron so that atoms of boron may be interposed on an interface between the single crystalline silicon substrate (11) and the i-type amorphous silicon layer (12).

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to a photovoltaic device utilizing hetero semiconductor junction and a manufacturing method thereof.

[0003] 2. Description of Prior Art

[0004] A photovoltaic device is generally categorized into single crystalline-, polycrystalline-, and amorphous-based type depending on a type of a semiconductor of a part for converting absorbed light mainly into electric current. By the way, a hybrid type photovoltaic device taking both advantages of an amorphous semiconductor thin film and a crystalline semiconductor is studied (JP, H04-130671, A). In this photovoltaic device, an intrinsic amorphous silicon thin film without dopant of a conductive impurity or a substantially intrinsic amorphous silicon thin film doped with a small amount of an element in 3B group of the periodic table such as boron is interposed on a junction interface in forming semiconductor junction by combining a crystalline silicon semiconductor and an amorphous silicon semiconductor having different conductive from each other so as to improve interface characteristics and photovoltaic conversion characteristics.

[0005] A p-n junction of this structure can be formed at a temperature of lower than 200 degrees centigrade. Therefore, good interface characteristics can be achieved even with an impure substrate, which is subject to an adverse effect of impurity or deficiency of oxygen induction under a high temperature process.

[0006] A substantially intrinsic amorphous silicon thin film without dopant of a conductive impurity or a substantially intrinsic amorphous silicon thin film, and an amorphous silicon thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity are formed on a rear surface of above-mentioned photovoltaic device to improve solar cell characteristics by BSF (Back Surface Field) effect.

[0007] FIG. 8 is a perspective view illustrating a photovoltaic device comprising a single crystalline silicon substrate with a textured surface, wherein a substantially intrinsic (i-type) amorphous semiconductor layer without dopant of a conductive impurity is interposed on a junction interface between said crystalline semiconductor and an amorphous semiconductor. As shown in the Fig., a front surface of an n-type single crystalline silicon (Si) substrate 101 is textured by alkaline etching or the like. An i-type amorphous silicon (a-Si) layer 102, a p-type amorphous silicon (a-Si) layer 103 and a transparent electrode 104 consisting of a transparent conductive film such as an ITO (Indium Tin Oxide) film are laminated in this order on the textured surface on a light receiving surface side of the single crystalline silicon substrate 101. Additionally, comb-shaped collector electrodes 105 consisting of silver (Ag) for example are formed on the transparent electrode 104.

[0008] An i-type amorphous silicon (a-Si) layer 106, an n-type amorphous silicon (a-Si) layer 107 and a transparent electrode 108 consisting of a transparent conductive film such as an ITO (Indium Tin Oxide) film are laminated in this order on a rear surface of the single crystalline silicon substrate 101 to achieve BSF effect. Additionally, comb-shaped collector electrodes 109 consisting of silver (Ag) for example are formed on the transparent electrode 108.

[0009] With above structure, light reflection is suppressed on the textured surface so that light can be taken into the device effectively.

[0010] Meanwhile, the above-mentioned photovoltaic device can be formed under a low temperature process. Because of this low temperature process, it is difficult to remove water or organic matters on the surface of the substrate completely. Therefore, impurities such as oxygen, nitrogen or carbon exist on the surface of the substrate. The one most largely included among these impurities is oxygen of density 1×1020 cm−3. Degraded interface characteristics caused by these impurities may adversely affect the p-n junction characteristics or BSF effect.

[0011] On the other hand, a method to achieve a substantially intrinsic amorphous silicon film by doping a small amount of boron is reported (Applied Physics Letters vol.68, 1996 p1201˜p1203). According to this report, it is possible to compensate adverse effect of oxygen by introducing boron of density about 1/1000 (˜1017 cm−3) into an amorphous silicon film containing oxygen of a certain density.

[0012] However, even if aforementioned amount of boron is introduced to compensate an adverse effect of oxygen, it scarcely affects solar cell characteristics. Improved interface characteristics should affect open circuit voltage mainly, but there is no change in open circuit voltage whether there is the compensation or not.

SUMMARY OF THE INVENTION

[0013] The present invention was made to solve the above-mentioned conventional problem and to improve interface characteristics between a crystalline semiconductor and an amorphous semiconductor thin film so that junction characteristics can be upgraded. In a semiconductor device according to the present invention, especially in a solar cell device, it is an object of the present invention to improve open circuit voltage.

[0014] A photovoltaic device according to the present invention comprises an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film interposed on a one conductive type crystalline semiconductor to form a one conductive type or an other conductive type amorphous semiconductor thin film wherein a one conductive type or an other conductive type impurity is provided in an interface formed from said crystalline semiconductor and said intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or said substantially intrinsic amorphous semiconductor thin film.

[0015] Said amorphous semiconductor thin film includes not only an amorphous semiconductor but also a microcrystalline semiconductor.

[0016] Said crystalline semiconductor and said amorphous semiconductor thin film may be crystalline silicon and an amorphous silicon thin film respectively. Said one conductive type impurity may be an atomic element in 5B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2. And said other conductive type impurity may be an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2.

[0017] Said crystalline semiconductor and said amorphous semiconductor thin film may be crystalline silicon and an amorphous silicon thin film respectively. Said one conductive type impurity may be an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2. And said other conductive type impurity may be an atomic element in 5B group of the periodic table, whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2.

[0018] As described above, in a p-n junction formed from a crystalline semiconductor and an amorphous semiconductor thin film, junction characteristics may be improved by interposing an appropriate amount of one conductive type or other conductive type impurity in the vicinity of an interface between a substrate of a crystalline semiconductor and an amorphous semiconductor thin film to suppress recombination of carriers at the interface. Open circuit voltage can be improved in a solar cell using this junction.

[0019] Also in a BSF structure comprising said crystalline semiconductor and a substantially intrinsic amorphous semiconductor thin film, electron flow may be improved by interposing an appropriate amount of one conductive type or other conductive type impurity in the vicinity of an interface between a substrate of a crystalline semiconductor and an amorphous semiconductor thin film to moderate an effect of band offset, which leads to improvement of open circuit voltage.

[0020] A manufacturing method of the present invention comprises a process for cleaning a front surface of a one conductive type or an other conductive type crystalline semiconductor substrate by plasma discharge introducing a hydrogen gas and a gas containing a one conductive type or an other conductive type impurity, a process for forming an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film on said front surface of the crystalline semiconductor substrate, and a process for forming an amorphous semiconductor thin film thereon, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.

[0021] Also another manufacturing method of a photovoltaic device according to the present invention comprises a process for forming a first amorphous semiconductor thin film by gas phase reaction introducing a gas containing a material to constitute an amorphous semiconductor thin film on a front surface of a crystalline semiconductor substrate and a gas containing a one conductive type or an other conductive type impurity, a process for forming a substantially intrinsic second amorphous semiconductor thin film by gas phase reaction on said first amorphous semiconductor thin film, and a process for forming an amorphous semiconductor thin film on said second amorphous semiconductor thin film, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.

[0022] In addition, other manufacturing method according to the present invention comprises a process for exposing a one conductive type or an other conductive type crystalline semiconductor substrate in a heated condition to a one conductive type or an other conductive type impurity of low density as well as hydrogen gas, a process for forming an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film on a front surface of said crystalline semiconductor substrate, and a process for forming an amorphous semiconductor thin film thereon, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.

[0023] By the above-described manufacturing method, a one conductive type or an other conductive type impurity may be provided at an interface formed from said crystalline semiconductor and said intrinsic amorphous semiconductor thin film.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIGS. 1A to 1D are cross sectional views illustrating manufacturing processes of a photovoltaic device according to a first embodiment.

[0025] FIG. 2 is a band diagram of the photovoltaic device according to the first embodiment.

[0026] FIG. 3 is a pattern diagram showing impurity profiles in the depth direction when a thickness of a non-doped layer is 160 nm and that of a p-type layer is about 8 nm.

[0027] FIG. 4 is a characteristic chart of open circuit voltage according to changes in amount of diborane introduced in a slightly p-type amorphous silicon layer doped with a small amount of diborane made in the vicinity of an interface between a substrate and an amorphous layer.

[0028] FIGS. 5A to 5D are cross sectional views illustrating manufacturing processes of a photovoltaic device according to a fourth embodiment.

[0029] FIG. 6 is a characteristic chart illustrating p-density of the photovoltaic device according to the fourth embodiment analyzed by SIMS (secondary ion mass spectrometry).

[0030] FIG. 7 is a characteristic chart illustrating a relation between an output (Pmax) of the photovoltaic device according to the fourth embodiment and atomy density of phosphorous at an interface on a rear surface side.

[0031] FIG. 8 is a perspective view illustrating a photovoltaic device wherein a surface of a single crystalline silicon substrate is textured and an i-type amorphous semiconductor layer is interposed on a junction interface between the crystalline semiconductor and an amorphous semiconductor.

[0032] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when reviewed in conjunction with the accompanying drawings.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0033] Now explanations are made of embodiments according to the present invention by referring to the drawings.

[0034] (First Embodiment)

[0035] FIGS. 1A to 1D are cross sectional views illustrating manufacturing processes of a photovoltaic device according to the first embodiment.

[0036] A single crystalline silicon substrate or a polycrystalline silicon substrate may be used as a crystalline semiconductor substrate. In this embodiment, an n-type single crystalline substrate 11 of resistivity not more than 5 Ωcm and 300 μm in thickness is used. Both front and rear surfaces of this single crystalline silicon substrate 11 are textured by anisotropic etching using alkaline solution such as sodium hydroxide solution or potassium hydroxide solution.

[0037] The single crystalline silicon substrate 11 is cleaned and put into a vacuum chamber to be heated up to not more than 200 degrees centigrade so that water attached to the front surface of the substrate can be removed to the utmost. In this embodiment, the substrate is heated up to 170 degrees centigrade.

[0038] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof. It is known that this process is effective to reduce the amount of carbon on a surface of a substrate.

[0039] In this hydrogen plasma process of the first embodiment, diborane gas (B2H6) is introduced as well as hydrogen gas (H2) to decompose and attach boron (B) onto the front surface so that boron is introduced into an interface of the single crystalline silicon substrate. Table 1 shows conditions for this process.

[0040] After that, silane gas (SiH4) and diluting gas of hydrogen gas (H2) are introduced and a non-doped i-type amorphous silicon layer 12 is formed by plasma CVD method while maintaining the substrate temperature 170 degrees centigrade. Then silane gas (SiH4), diluting gas of hydrogen gas (H2) and dopant gas of diborane gas (BZH6) are introduced and a p-type amorphous silicon layer 13 is formed sequentially by plasma CVD method to form a p-n junction (FIG. 1B). Table 1 shows conditions for this process.

[0041] Next, a hydrogenated amorphous silicon thin film is formed on the rear surface of the above-mentioned n-type single crystalline silicon substrate 11 correspondingly. First, the n-type single crystalline silicon substrate 11 is put into a vacuum chamber to be heated up to not more than 200 degrees centigrade. In this embodiment, the substrate is heated up to 170 degrees centigrade. Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge. After that, silane gas (SiH4) and diluting gas of hydrogen gas (H2) are introduced and a non-doped i-type amorphous silicon layer 14 is formed by plasma CVD method while maintaining the substrate temperature 170 degrees centigrade. Then silane gas (SiH4), diluting gas of hydrogen gas (H2) and dopant gas of phosphine gas (PH3) are introduced and an n-type amorphous silicon layer 15 is formed sequentially by plasma CVD method to form a BSF structure on the rear surface of the n-type single crystalline silicon substrate 11 (FIG. 1C). Table 1 shows conditions for this process.

[0042] An indium tin oxide (ITO) layer 16 is formed by sputtering as a front surface side electrode and silver electrodes 18 are formed by screen-printing method as collector electrodes. Also, an ITO layer 17 is formed by sputtering as a rear surface side electrode, and silver electrodes 19 are formed by screen-printing method as collector electrodes, which completes the photovoltaic device (FIG. 1D).

[0043] In the above-described embodiment, the so-called BSF structure is formed on the rear surface side but it may be omitted. When forming the BSF structure, the amorphous silicon layer may be formed from the front surface side (p-type side) as described above, or it may be formed from the rear surface side (n-type side) as well.

[0044] Detailed conditions for forming the above-mentioned photovoltaic device are shown in Table 1.

	TABLE 1
	Conditions
	Substrate
	temperature		Pressure	Power density
Process	(° C.)	Used gas	(Pa)	(mW/cm2)
Front	Hydrogen	170	H2: 100 sccm	70	8.33
surface	process		B2H6: 0˜100 sccm
side	i-type a-Si	170	SiH4: 40 sccm	40	8.33
	p-type a-Si	170	H2: 0˜100 sccm
			SiH4: 40 sccm	40	8.33
			B2H6 (2%): 40 sccm
Rear	Hydrogen	170	H2: 100 sccm	70	8.33
surface	process
side	i-type a-Si	170	SiH4: 40 sccm	40	8.33
			H2: 0˜100 sccm
	n-type a-Si	170	SiH4: 40 sccm	40	8.33
			PH3 (1%): 40 sccm

[0045] FIG. 2 is a band diagram of the photovoltaic device according to the present invention. In FIG. 2, full lines show a band diagram of the present invention, and dotted lines show a band diagram of a conventional method wherein no diborane gas is introduced in the hydrogen plasma process.

[0046] In the photovoltaic device formed by the above-described method, the substantially i-type amorphous silicon layer 12, the n-type amorphous silicon layer 13 and the ITO layer 16 are formed and laminated in this order on the n-type single crystalline silicon substrate 11. Excessive amount of boron to compensate the i-type amorphous silicon layer is introduced into the interface between the substrate 11 and the i-type amorphous silicon layer 12.

[0047] As shown in FIG. 2, excessive amount of boron to compensate the amorphous layer introduced into the interface between the single crystalline silicon substrate 11 and the i-type amorphous silicon layer 12 makes the crystalline silicon layer 12 in the vicinity of the interface slightly p-type, and at the same time, a localized electric field intensity inside the single crystalline silicon substrate 11 in the vicinity of the interface becomes strong. Therefore, electrons and positive holes existing in the vicinity of the interface can be separated more effectively, resulting in low probability of recombination at the interface. Also, carriers may transfer easily because a barrier of band discontinuity at the interface becomes relatively small. As a result, open circuit voltage in solar cell characteristics is improved.

[0048] The electric field intensity inside the i-type amorphous silicon layer becomes weak then, but it is still strong enough to let carriers in the amorphous layer transfer easily.

[0049] When too much amount of boron is supplied, the electric field intensity inside the i-type amorphous silicon layer 12 becomes weak so that recombination of carriers in this part increases. Further supply of boron is approximately identical to a p-type amorphous silicon layer directly laminated on the n-type single crystalline silicon substrate, which leads to recombination through excessive boron, resulting in degraded solar cell characteristics.

[0050] A photovoltaic device according to the present invention is made under the conditions shown in Table 1. Output characteristics of this photovoltaic device are shown in Table 2. The above-mentioned photovoltaic device wherein no diborane gas is introduced in the hydrogen plasma process is used as a comparative example. In these samples, the BSF layers on the rear surface sides are formed at the same time.

	TABLE 2
	Voc (V)	Isc (A)	F. F.	Pmax (W)
without introduction of B2H6	0.670	3.72	0.75	1.87
with introduction of B2H6	0.692	3.70	0.76	1.95

[0051] As shown in Table 2, open circuit voltage of the photovoltaic device wherein diborane gas is introduced in the hydrogen plasma process is improved, and the effectiveness of the present invention is confirmed.

[0052] In the embodiment shown in Table 1, the thickness of the i-type amorphous silicon layer is about 7 nm and that of the p-type layer is about 5 nm. Because it is beyond the limit of resolution in the depth direction (10 nm to 20 nm) of existing secondary ion mass spectrometers, FIG. 3 shows impurity profiles in the depth direction when the thickness of the i-type amorphous silicon layer is 160 nm and that of the p-type layer is about 8 nm.

[0053] Atomy density of boron at the interface is obtained as follows. The value obtained by measuring the layers in the depth direction from the front amorphous silicon layer side by SIMS (secondary ion mass spectroscopy) analysis is integrated in the depth direction, which is voluminal density of boron. Then surface density at the interface is calculated from voluminal density in the vicinity of the interface in the depth direction (2 nm to 3 nm), which is called here atomy density of boron at the interface.

[0054] Dotted lines in the Fig. show locations of interfaces forming each layer, which is expected from profiles. Amount of boron existing at the substrate interface is about 6×1011 cm−2 by atomy density at the interface. The amount of boron in the intrinsic (i-type) amorphous silicon layer and the amount of boron inside the substrate are smaller than the amount of boron in the p-type amorphous silicon surface and the amount of boron at the interface of the substrate respectively and such declines are more moderate than the Gaussian distribution. Experience shows that this is because of implantation effect in sputtering during SIMS analysis.

[0055] Therefore, it seems that density of boron is drastically lowered at each interface in reality, and little boron is diffused from the i-type amorphous silicon layer or the surface of the substrate into the substrate. It seems that if an actual solar cell is measured by a method with high degree of separation in the depth direction (1 nm to 2 nm) such as low voltage SIMS, the result will be accompanied by profiles analogous to that of boron (B) in FIG. 3.

[0056] (Second Embodiment)

[0057] Next, explanations are made of the second embodiment. A single crystalline silicon substrate is cleaned and put into a vacuum chamber to be heated up to not more than 200 degrees centigrade so that water attached to a front surface of the substrate can be removed to the utmost. In this embodiment, the substrate is heated up to 170 degrees centigrade.

[0058] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof. Then, hydrogen gas (H2), diborane gas (B2H6), silane gas (SiH4) are introduced and the substrate is exposed to plasma discharge to laminate on the front surface of the substrate a first amorphous silicon layer {circle over (1)} of thickness about 1 nm doped with a slightly p-type impurity of low density so that boron is introduced in the vicinity of an interface. After that, a p-n junction is formed by laminating an i-type amorphous silicon layer {circle over (2)} and a p-type amorphous silicon layer in this order, as in the first embodiment. An indium tin oxide (ITO) layer is formed by sputtering as a front surface side electrode and silver electrodes are formed by screen-printing method as collector electrodes.

[0059] A photovoltaic device of the second embodiment according to the present invention is formed under conditions shown in Table 3.

	TABLE 3
	Conditions
	Substrate		Pres-	Power
	temperature		sure	density
Process	(° C.)	Used gas	(Pa)	(mW/cm2)
Hydrogen	170	H2:100 sccm	70	8.33
process
i-type a-Si	170	H2:0˜100 sccm	40	8.33
{circle over (1)}		SiH4:40 sccm
		(B2H6/SiH4:10˜2000 ppm)
i-type a-Si	170	SiH4:40 sccm	40	8.33
{circle over (2)}
p-type	170	H2:0˜100 sccm	40	8.33
a-Si		SiH4:40 sccm
		B2H6 (2%):40 sccm

[0060] FIG. 4 is a characteristic chart of open circuit voltage according to changes in amount of boron introduced in the slightly p-type amorphous silicon layer doped with diborane gas (B2H6) which is made in the vicinity of the interface between the substrate and the amorphous silicon layer formed under conditions shown in Table 3.

[0061] As can be seen in FIG. 4, open circuit voltage increases in stages in comparison with an example without introducing diborane gas (B2H6). Open circuit voltage shifts to decrease as amount of dopant further increases. Open circuit voltage can be improved in comparison with an example without introducing diborane when the introduced amount of boron is in ranges between 1×1011 cm−2 and 5×1013 cm−2 by atomy surface density. From FIG. 4, the amount of diborane gas (B2H6) should be so controlled that atomy surface density of boron introduced in the interface between the substrate and the amorphous silicon layer will be in ranges between 1×1011 cm−2 and 5×1013 cm−2.

[0062] (Third Embodiment)

[0063] Now explanations are made of the third embodiment. A single crystalline silicon substrate is cleaned and put into a vacuum chamber to be heated up to not more than 200 degrees centigrade so that water attached to a front surface of the substrate can be removed to the utmost. In this embodiment, the substrate is heated up to 170 degrees centigrade.

[0064] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof. Hydrogen gas (H2) and diborane gas (BZH6) are introduced, and the substrate is exposed to said gases. Diborane gas (B2H6) is decomposed on and attaches to the heated surface of the substrate so that boron can be introduced in an interface. The substrate is exposed under the condition of substrate temperature of 170 degrees centigrade, density and flow rate of diborane gas (B2H6) 2% and 1000 sccm respectively, pressure 40 Pa and treating time 1-600 seconds.

[0065] After that, a p-n junction is formed by laminating an i-type amorphous silicon layer and a p-type amorphous silicon layer in this order, as in the first embodiment. An indium tin oxide (ITO) layer is formed by sputtering as a front surface side electrode and silver electrodes are formed by screen-printing method as collector electrodes.

[0066] Similarly to the first embodiment, open circuit voltage is improved in this case, too. Differences in characteristics are mainly dependent on whether the device is made with or without an exposure process. Changes in exposure conditions do not affect that much.

[0067] As described above, in the p-n junction formed from crystalline silicon and the amorphous silicon semiconductor, junction characteristics may be improved by interposing an appropriate amount of boron in the vicinity of the interface between the crystalline silicon substrate and the amorphous silicon semiconductor thin film to suppress recombination of carriers at the interface. Open circuit voltage can be improved in a solar cell using this junction.

[0068] (Fourth Embodiment)

[0069] Above-mentioned first, second and third embodiments explain how to improve a p-n junction characteristics. The fourth embodiment is to improve BSF effect. Below explanations are made of the fourth embodiment by referring to the drawings.

[0070] FIGS. 5A to 5D are cross sectional views illustrating manufacturing processes of a photovoltaic device according to the fourth embodiment.

[0071] A single crystalline silicon substrate or a polycrystalline silicon substrate can be used as a crystalline semiconductor substrate. In this fourth embodiment, an n-type single crystalline substrate 11 of resistivity not more than 5 Ωcm and 300 μm in thickness is used, as in the first embodiment. Both front and rear surfaces of this single crystalline silicon substrate 11 are textured by anisotropic etching using alkaline solution such as sodium hydroxide solution or potassium hydroxide solution.

[0072] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof.

[0073] In this hydrogen plasma process of this embodiment, phosphine gas (PH3) is introduced as well as hydrogen gas to decompose and attach phosphorous (P) onto the rear surface so that phosphorous is introduced into an interface of a rear surface of the single crystalline silicon substrate 11. Table 4 shows conditions for this process.

[0074] After that, silane gas (SiH4) and diluting gas of hydrogen gas (H2) are introduced and a non-doped i-type amorphous silicon layer 14 is formed by plasma CVD method while maintaining the substrate temperature 170 degrees centigrade. Then silane gas (SiH4), diluting gas of hydrogen gas (H2) and dopant gas of phosphine gas (PH3) are introduced and an n-type amorphous silicon layer 15 is formed sequentially by plasma CVD method to form a BSF structure on the rear surface of the n-type single crystalline silicon substrate 11 (FIG. 5B). Table 1 shows conditions for forming this process.

[0075] Next, a hydrogenated amorphous silicon thin film is formed on the rear surface of the above-mentioned n-type single crystalline silicon substrate 11 correspondingly. First, the n-type single crystalline silicon substrate 11 is put into a vacuum chamber to be heated up to not more than 200 degrees centigrade. In this fourth embodiment, the substrate is heated up to 170 degrees centigrade. Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge. After that, silane gas (SiH4) and diluting gas of hydrogen gas (H2) are introduced and a substantially i-type amorphous silicon layer 12 is formed by plasma CVD method while maintaining the substrate temperature 170 degrees centigrade. Then silane gas (SiH4), diluting gas of hydrogen gas (H2) and dopant gas of diborane gas (B2H6) are introduced and a p-type amorphous silicon layer 13 is formed sequentially by plasma CVD method to form a p-n junction (FIG. 5C). Table 4 shows conditions for forming this process.

[0076] An indium tin oxide (ITO) layer 16 is formed by sputtering as a front surface side electrode and silver electrodes 18 are formed by screen-printing method as collector electrodes. Also, an ITO layer 17 is formed by sputtering as a rear surface side electrode, and silver electrodes 19 are formed by screen-printing method as collector electrodes, which completes the photovoltaic device (FIG. 5D).

[0077] Detailed conditions for forming the above-mentioned photovoltaic device are shown in Table 4.

	TABLE 4
	Conditions
	Substrate
	temperature	Used gas	Pressure	Power density
Process	(° C.)	(sccm)	(Pa)	(mW/cm2)
Front	Hydrogen	170	H2: 100	70	8.33
surface	process
side	i-type a-Si	170	SiH4: 40	40	8.33
	p-type a-Si	170	H2: 0˜100	40	8.33
			SiH4: 40
			B2H2 (2%): 40
Rear	Hydrogen	170	H2: 100	70	8.33
surface	process		PH3 (1%):
side			0˜100
	i-type a-Si	170	SiH4: 40	40	8.33
	n-type a-Si	170	H2: 0˜100	40	8.33
			SiH4: 40
			PH3 (1%): 40

[0078] Table 5 shows output characteristics according to changes in atomy density of phosphorous at the interface by varying flow rate of phosphine gas (PH3) in the plasma process for the single crystalline silicon substrate 11 using mixed gas of hydrogen and phosphine (PH3). Atomy density of phosphorous at the interface is obtained as follows. The value obtained by measuring the layers in the depth direction from the rear amorphous silicon layer side by SIMS (secondary ion mass spectroscopy) analysis is integrated in the depth direction, which is voluminal density of phosphorous (P). Then surface density at the interface is calculated from voluminal density in the vicinity of the interface in the depth direction (2 nm to 3 nm), which is called here atomy density of phosphorous at the interface. Then surface density at the interface is calculated from voluminal density in the vicinity of the interface in the depth direction (2 nm to 3 nm), which is corresponding to the hatched area in FIG. 6. The value obtained is called here atomy density of phosphorous at the interface.

	TABLE 5
	P-density
	(cm−2)	Voc (V)	Isc (A)	FF	Pmax (W)
without introduction	9.20E + 10	0.677	3.730	0.751	1.896
of PH3
with introduction of	5.00E + 11	0.690	3.725	0.771	1.982
PH3 (a)
with introduction of	7.00E + 12	0.710	3.720	0.766	2.023
PH3 (b)
with introduction of	2.00E + 14	0.693	3.721	0.762	1.965
PH3 (c)
with introduction of	5.00E + 15	0.665	3.710	0.745	1.845
PH3 (d)

[0079] As can be seen in Table 5, open circuit voltage and fill factor (F.F.) are improved according to the fourth embodiment introducing phosphine gas (PH3) into the plasma process for the rear surface of the single crystalline silicon substrate 11 in comparison with a comparative example without introducing phosphine gas (PH3). This is because effects of band offset have been moderated by introducing phosphorous into the interface, resulting in improvement of electron flow.

[0080] FIG. 7 shows relations between cell output (Pmax) of the photovoltaic device wherein phosphine gas (PH3) is introduced in the plasma process and atomy density of phosphorous at the rear surface side.

[0081] From FIG. 7, excellent cell output of over 1.900 W can be realized when atomy density of phosphorous at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2. Therefore, the amount of phosphine gas (PH3) introduced in the plasma process for the rear surface side of the single crystalline silicon substrate 11 should be so controlled that density of phosphorous at the interface will be in ranges between 1×1011 cm−2 and 5×1014 cm−2.

[0082] (Fifth Embodiment)

[0083] Next, descriptions are made of the fifth embodiment according to the present invention. An n-type single crystalline silicon substrate is cleaned and put into a vacuum chamber to be heated up to not more than 200 degrees centigrade so that water attached to a front surface of the substrate can be removed to the utmost. In this embodiment, the substrate is heated up to 170 degrees centigrade.

[0084] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof. Then, hydrogen gas (H2), phosphine gas (PH3) and silane gas (SiH4) are introduced and the substrate is exposed to plasma discharge to laminate on the rear surface of the substrate a fourth amorphous silicon layer {circle over (4)} of thickness about 1 nm doped with a slightly n-type impurity of low density so that phosphorous is introduced into the vicinity of an interface. After that, an i-type amorphous silicon layer {circle over (5)} and an n-type amorphous silicon layer are formed sequentially to complete a BSF structure, as in the fourth embodiment. Also as in the fourth embodiment, an i-type amorphous silicon layer and a p-type amorphous silicon layer are formed subsequently on the front surface of the n-type single crystalline silicon substrate to form a p-n junction. Indium tin oxide (ITO) layers are formed by sputtering as a front surface side electrode and as a rear surface side electrode, and silver electrodes are formed by screen-printing method as collector electrodes.

[0085] A photovoltaic device of the fifth embodiment according to the present invention is formed under conditions shown in Table 6.

	TABLE 6
	Conditions
	Substrate
	temperature		Pressure	Power density
Process	(° C.)	Used gas	(Pa)	(mW/cm2)
Rear	Hydrogen	170	H2: 100 sccm	70	8.33
surface	process
side	i-type a-Si	170	H2: 0˜100 sccm	40	8.33
	{circle over (4)}		SiH4: 40 sccm	40	8.33
			(PH3/SiH4: 10˜10000 ppm)
	i-type a-Si	170	SiH4: 40 sccm	40	8.33
	{circle over (5)}
	n-type	170	H2: 0˜100 sccm	40	8.33
	a-Si		SiH4: 40 sccm
			PH3(1%): 40 sccm

[0086] In this embodiment, as in the fourth embodiment, open circuit voltage is improved.

[0087] (Sixth Embodiment)

[0088] Next, descriptions are made for the sixth embodiment according to the present invention. An n-type single crystalline silicon substrate is cleaned and put into a vacuum chamber to be heated up to not more than 200 degrees centigrade so that water attached to a front surface of the substrate can be removed to the utmost. In this embodiment, the substrate is heated up to 170 degrees centigrade.

[0089] Next, hydrogen gas (H2) is introduced and the substrate is exposed to plasma discharge to clean the surface thereof. Hydrogen gas (H2) and phosphine gas (PH3) are introduced, and the substrate is exposed to said gases. Phosphine gas (PH3) is decomposed on and attaches to the heated surface of the substrate so that phosphorous can be introduced in an interface. The substrate is exposed under the condition of substrate temperature of 170 degrees centigrade, density and flow rate of phosphine gas (PH3) 1% and 100 sccm respectively, pressure 40 Pa and treating time 1-600 seconds.

[0090] After that, an i-type amorphous silicon layer and an n-type amorphous silicon layer are formed sequentially to complete a BSF structure, as in the fourth embodiment. Also as in the fourth embodiment, a substantially i-type amorphous silicon layer and a p-type amorphous silicon layer are formed subsequently on the front surface of the n-type single crystalline silicon substrate to form a p-n junction. Indium tin oxide (ITO) layers are formed by sputtering as a front surface side electrode and as a rear surface side electrode, and silver electrodes are formed by screen-printing method as collector electrodes.

[0091] In this embodiment, as in the fourth embodiment, open circuit voltage is improved. Differences in characteristics are mainly dependent on whether the device is made with or without an exposure process. Changes in exposure conditions do not affect that much.

[0092] By the way, though an n-type substrate is used in each of the above-described embodiment, the present invention may also apply to a photovoltaic device comprising a p-type substrate wherein an i-type amorphous silicon layer, an n-type amorphous silicon layer, an ITO film and silver electrodes on the front surface side thereof, and an i-type amorphous silicon layer, a p-type amorphous silicon layer, an ITO film and silver electrodes on the rear surface side thereof. Also, same result may be provided when the crystalline substrate is an n-type and p-type polycrystalline silicon substrate.

[0093] Though one conductive type or other conductive type impurity is introduced into an interface on either a front surface side or a rear surface side of the substrate in each of the above-described embodiment, such impurity may be introduced into interfaces on both the front and the rear surfaces side. For example, if the first and fourth embodiments are combined and impurities according to each of said two embodiments are introduced into interfaces on both the front and the rear surfaces of the substrate, advantages of said two embodiments would be combined, which may lead to further improvement of solar cell characteristics.

[0094] Though an amorphous silicon thin film is used as an amorphous semiconductor thin film in each of the above-described embodiment, a microcrystalline silicon thin film may be used as well. Though silicon is used as semiconductors in each of the above-described embodiment, same result may be provided when germanium is used.

[0095] Additionally, though phosphorous is used as an atomic element in 5B group of the periodic table in the above-described embodiments, other atomic elements in 5B group of the periodic table such as arsenic (As), stibium (Sb) and so on may also provide the same effect. And though boron is used as an atomic element in 3B group of the periodic table in the above-described embodiments, other atomic elements in 3B group of the periodic table such as alminum (Al) and so on may also provide the same effect.

[0096] As described above, in a p-n junction formed from a crystalline semiconductor and an amorphous semiconductor thin film, junction interface may be improved by interposing an appropriate amount of one conductive type or other conductive type impurity in the vicinity of an interface between a substrate of a crystalline semiconductor and an amorphous semiconductor thin film to suppress recombination of carriers at the interface. Open circuit voltage can be improved in a solar cell using this junction. Also in a BSF structure comprising said crystalline semiconductor and a substantially intrinsic amorphous semiconductor thin film, electron flow may be improved by interposing an appropriate amount of one conductive type or other conductive type impurity in the vicinity of an interface between a substrate of a crystalline semiconductor and an amorphous semiconductor thin film to moderate effects of band offset, which leads to improvement of open circuit voltage.

[0097] Although the present invention has been described and illustrated in detail, it should be clearly understood that the description discloses examples of different embodiments of the invention and is not intended to be limited to the examples or illustrations provided. Any changes or modifications within the spirit and scope of the present invention are intended to be included, the invention being limited only by the terms of the appended claims.

Claims

1. A photovoltaic device comprising a one conductive type crystalline semiconductor, an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film formed thereon, a one conductive type or an other conductive type amorphous semiconductor thin film formed on said intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film, wherein a one conductive type or an other conductive type impurity is provided at an interface formed from said crystalline semiconductor and said intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or said substantially intrinsic amorphous semiconductor thin film.

2. The photovoltaic device according to claim 1, wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, and said one conductive type impurity is an atomic element in 5B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2.

3. The photovoltaic device according to claim 1, wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, and said other conductive type impurity is an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2.

4. The photovoltaic device according to claim 1 wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, said one conductive type impurity is an atomic element in 5B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2, and said other conductive type impurity is an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2.

5. The photovoltaic device according to claim 1, wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, and said one conductive type impurity is an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2.

6. The photovoltaic device according to claim 1, wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, and said other conductive type impurity is an atomic element in 5B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2.

7. The photovoltaic device according to claim 1 wherein said crystalline semiconductor and said amorphous semiconductor thin film are crystalline silicon and an amorphous silicon thin film respectively, said one conductive type impurity is an atomic element in 3B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1013 cm−2, and said other conductive type impurity is an atomic element in 5B group of the periodic table whose atomy surface density at the interface is in ranges between 1×1011 cm−2 and 5×1014 cm−2.

8. A manufacturing method comprising a process for cleaning a front surface of a one conductive type or an other conductive type crystalline semiconductor substrate by plasma discharge introducing a hydrogen gas and a gas containing a one conductive type or an other conductive type impurity, a process for forming an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film on said front surface of the crystalline semiconductor substrate, and a process for forming an amorphous semiconductor thin film thereon, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.

9. A manufacturing method of a photovoltaic device comprising a process for forming a first amorphous semiconductor thin film by gas phase reaction introducing a gas containing a material to constitute an amorphous semiconductor thin film on a front surface of a crystalline semiconductor substrate and a gas containing a one conductive type or an other conductive type impurity, a process for forming a substantially intrinsic second amorphous semiconductor thin film by gas phase reaction on said first amorphous semiconductor thin film, and a process for forming an amorphous semiconductor thin film on said second amorphous semiconductor thin film, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.

10. A manufacturing method comprising a process for exposing a one conductive type or an other conductive type crystalline semiconductor substrate in a heated condition to a one conductive type or an other conductive type impurity of low density as well as hydrogen gas, a process for forming an intrinsic amorphous semiconductor thin film without dopant of a conductive impurity or a substantially intrinsic amorphous semiconductor thin film on a front surface of said crystalline semiconductor substrate, and a process for forming an amorphous semiconductor thin film thereon, said amorphous semiconductor thin film made to be one conductive type or other conductive type by doping a one conductive type or an other conductive type impurity.