The present disclosure relates to photovoltaic devices including, but not limited to, photodiodes, solar cells, photovoltaic modules, photovoltaic arrays, or any device comprising a layer or layers that are configured to convert light into electricity or otherwise exhibit a photovoltaic effect, i.e., the creation of a voltage or a corresponding electric current in a material upon exposure to light.
According to the subject matter of the present disclosure, photovoltaic devices are contemplated where TCO layers of the device are provided with a distribution of resonant coupling periodicities ΛR while the glass substrate of the device is provided with a distribution of diffusive coupling periodicities ΛD. The respective surface textures defining these periods are superimposed at an interface with the photoelectric conversion layer and collectively define a frequency-dependent power spectral density inversion in the device.
Contemplated photovoltaic devices will typically comprise an incident-side glass substrate, a backside reflector, a plurality of transparent conductive oxide (TCO) layers, and a photoelectric conversion layer. The incident-side TCO layer of these devices comprises surface perturbations characterized by a distribution of resonant coupling periodicities ΛR. Similarly, the incident-side glass substrate of these devices comprises surface perturbations characterized by a distribution of diffusive coupling periodicities ΛD. In accordance with many embodiments of the present disclosure, the distribution of resonant coupling periodicities ΛR and the distribution of diffusive coupling periodicities ΛD are superimposed at an incident-side interface with the photoelectric conversion layer and collectively define a frequency-dependent power spectral density inversion. In accordance with other embodiments of the present disclosure, the power spectral density of the distribution of diffusive coupling periodicities ΛD is more heavily weighted over relatively large coupling periods than the distribution of resonant coupling periodicities ΛR while the power spectral density of the distribution of resonant coupling periodicities ΛR is more heavily weighted over relatively small coupling periods than the distribution of diffusive coupling periodicities ΛR.
The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
In operation, the incident light λ passes through the incident-side glass substrate 10 into the photoelectric conversion layer 40. The semiconductor material of the photoelectric conversion layer, which may be a single junction amorphous silicon conversion layer, as is illustrated schematically in
Referring additionally to the graphs of
In
The present inventors have recognized that this superposition of the periodicities ΛD, ΛR at the incident-side interface 42 cooperates with the backside reflector 20 to cause a significant portion of the incident light λ to become trapped within the photoelectric conversion layer 40. More specifically, the resonant coupling periodicities ΛR act to couple incident light into selected waveguide modes of the TCO/silicon/TCO structure of the photovoltaic device 100, while the diffusive coupling periodicities ΛD couple light from the selected waveguide modes to other guided modes of the structure. The diffusive process enables light to linger in the absorbing core of the waveguide for a longer time than would be possible without these perturbations. This lingering enables increased absorption of the light and thus increased conversion efficiency. According to one embodiment of the present disclosure, the diffusive coupling periodicities ΛD of the incident-side glass substrate 10 are configured for diffusive coupling to waveguide modes corresponding to an effective refractive index that is approximately half way between the index of the photoelectric conversion layer 40 and the index of the incident-side TCO layer 30.
Collectively, as is illustrated in
Suitable ranges for the respective low and high spatial frequencies can vary widely according to the concepts of the present disclosure and will be at least partially dependent upon the thickness of the incident-side TCO layer 30. It is contemplated that the power spectral density inversion I can, in many cases, be established at a frequency of between approximately 0.5 μm−1 (Λ≈2000 nm) and approximately 2.0 μm−1 (Λ≈500 nm). As is the case for the inversion I illustrated in
Potentially optimum periods for the resonant coupling periodicities ΛR are between approximately 75 nm and approximately 550 nm. However, for wavelengths from 350 nm to 575 nm, 250 nm amorphous silicon layers typically absorb nearly all of the light transmitted into the a-Si layer. Accordingly, in particular implementations of the concepts of the present disclosure, light trapping processes are not as important, relatively speaking, for wavelengths from 350 nm to 575 nm. To optimize trapping of wavelengths greater than 550 nm in selected waveguide modes of the photoelectric conversion layer 40, the resonant coupling periodicities ΛR of the incident-side TCO layer 30 should be greater than or equal to approximately 150 nm. In addition, it is contemplated that the resonant coupling periodicities ΛR of the incident-side TCO layer should be less than or equal to approximately 550 nm to limit trapping to wavelengths within the absorption edge of the photoelectric conversion layer 40.
It is contemplated that the optimum periods for the diffusive coupling among the waveguide modes of the system can be determined by referring to the effective index difference between the modes, which varies as a function of the wavelength and the order of the mode. Higher-order modes close to the fundamental mode have a smaller difference in effective index with those modes adjacent to them, while higher order modes closer to cutoff (smaller effective index) have a larger difference in effective index with the modes adjacent to them. The present inventors have recognized that the optimal diffusive grating coupling period is related to the wavelength of the light divided by the effective index difference of the resonantly coupled modes. This optimal period varies from 280 nm to greater than 200 gm. However, it is contemplated that optimal diffusive coupling periodicities ΛD are likely to fall between 550 nm and 3 μm, if the intent is to couple to modes near the middle of the available effective index range (e.g., neff=3.0).
More generally, surface textures with Fourier components corresponding to diffusive coupling periodicities ΛD between 150 nm and 3 μm represent surfaces with desirable light trapping capabilities. In many cases, a full spectrum of diffusive coupling periodicities ΛD should be used to couple the guided modes of the structure amongst themselves. It is contemplated that the spectrum can vary from approximately 280 nm to approximately 20 μm, with a preferable range being between approximately 500 nm and approximately 5 μm. It is also contemplated that the diffusive coupling periodicities ΛD of the incident-side glass substrate 10 can be contained between approximately 1500 nm and approximately 3000 nm to enhance diffusive coupling among waveguide modes of the photoelectric conversion layer and inhibit coupling to untrapped or radiative modes of the photoelectric conversion layer.
Generally, as is illustrated in
In practicing embodiments of the of the present disclosure requiring superposition of the periodicities ΛD, ΛR at the incident-side interface 42 with the photoelectric conversion layer 40, it will be necessary to preserve the relatively long period texture of the incident-side glass substrate 10 so that it presents itself at the incident-side interface 42. To do so, care should be taken to ensure that the thickness of the incident-side TCO layer 30 is not excessive. As a general rule, it is contemplated that this thickness limitation will not be difficult to overcome with available TCO materials and fabrication technology because the diffusive coupling periodicities ΛD of the incident-side glass substrate 10 are relatively large, e.g., greater than approximately 1000 nm (f=1 μm−1) in the example illustrated in
Referring to
The incident-side and backside TCO layers 30, 35 are transparent electrodes, typically presented as a film of fluorine doped-SnO2, or boron or aluminum doped-ZnO, or cadmium stannate (Cd2SnO4), with a thickness on the order of approximately 1 μm. The TCO layers 30, 35 can be textured by various techniques. For example, in the case of SnO2 or ZnO films deposited by chemical vapor deposition (CVD), the texture can be controlled by controlling deposition conditions and film thickness. For sputtered films, the texture can be modified by etching such as wet etching or plasma etching. Plasma etching has also been used with CVD ZnO to control texture.
The incident-side glass substrate 10 of the photovoltaic device 100 can also be textured in a variety of ways. For example, and not by way of limitation, texturing in some conventional thin film silicon devices is accomplished by incorporating SiO2 particles in a binder and depositing the matrix on the substrate. This type of texturing is typically done using a sol-gel type process where spherical particles are suspended in liquid and the substrate is drawn through the liquid, and subsequently sintered. The spherical particles are held in place by the sintered gel. Many additional methods have been explored for creating a textured surface prior to TCO deposition. These methods include sandblasting, polystyrene microsphere deposition and etching, and chemical etching.
According to one contemplated process, an inorganic transparent substrate is provided and an adhesive is applied to the surface of the substrate. Particles are applied to the adhesive to form a coated substrate, and the coated substrate is heated to form a light scattering inorganic substrate. In another contemplated process, a monolayer of inorganic particles is formed on the surface of the transparent substrate and the coated substrate is heated above its softening point to form the light scattering surface. The inorganic particles can be pressed into the surface.
For the purposes of describing and defining the present invention, it is noted that reference herein to a variable being a “function” of a parameter or another variable is not intended to denote that the variable is exclusively a function of the listed parameter or variable. Rather, reference herein to a variable that is a “function” of a listed parameter is intended to be open ended such that the variable may be a function of a single parameter or a plurality of parameters. It is also noted that recitations herein of “at least one” component, element, etc., should not be used to create an inference that the alternative use of the articles “a” or “an” should be limited to a single component, element, etc.
It is noted that terms like “preferably,” “commonly,” and “typically,” when utilized herein, are not utilized to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to identify particular aspects of an embodiment of the present disclosure or to emphasize alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.
For the purposes of describing and defining the present invention it is noted that the terms “substantially” and “approximately” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “substantially” and “approximately” are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
Having described the subject matter of the present disclosure in detail and by reference to specific embodiments thereof, it is noted that the various details disclosed herein should not be taken to imply that these details relate to elements that are essential components of the various embodiments described herein, even in cases where a particular element is illustrated in each of the drawings that accompany the present description. Rather, the claims appended hereto should be taken as the sole representation of the breadth of the present disclosure and the corresponding scope of the various inventions described herein. Further, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.
It is noted that one or more of the following claims utilize the term “wherein” as a transitional phrase. For the purposes of defining the present invention, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term “comprising.”
This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 61/480,808 filed on Apr. 29, 2011 the content of which is relied upon and incorporated herein by reference in its entirety. This application is related to copending U.S. patent application Ser. No. 12/263,583, filed Nov. 3, 2008, U.S. patent application Ser. No. 13/033175, filed Feb. 23, 2011 and U.S. application Ser. No. 13/033,075 filed Feb. 23, 2011, but does not claim priority thereto.
Number | Date | Country | |
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61480808 | Apr 2011 | US |