The present disclosure relates to Schottky barrier solar cells comprising at least one of a high work function region and low work function region obtained either by use of high and low work function metals or by dopant implantation into metal silicide films.
Solar cells offer great potential as alternative energy sources, which allow to convert sunlight directly into electricity. As the number of application areas for solar cells increases, it becomes desirable to provide new methods and materials for solar energy conversion that may be adapted to the application specific requirements.
A drawback in the past has been the initial cost of manufacturing solar cells. Thus, to make solar energy conversion economically viable, it is pertinent to implement production methods that reduce the manufacturing costs of solar cells.
Solar cells converts photons, typically from sunlight, into electricity by generating an electron/hole pair in a semiconductor through absorption of the photons. To avoid recombination of the electron/hole pair, and losing the photon energy in thermalization, the electron and the hole have to be separated, which is achieved by a built-in potential difference.
Typically, solar cells contain junction regions of one conductivity type (electron or hole), which are fabricated with diffused, ion implanted, or vapor deposited conducting regions placed onto the opposite conductivity type substrate. However, these so-called p/n junction solar cells require high temperature processing steps and prolonged manufacturing time frames.
In this disclosure, the built-in potential difference required to convert photons into electricity is created by providing a lightly-doped absorber having a front surface and a back surface; at least one of a high work function region disposed on the lightly-doped absorber; and at least one of a low work function region abutting the lightly-doped absorber and being spaced apart from the at least one high work function region; wherein the Schottky barrier solar cell comprises at least one of the high work function region or the low high work function region
Further, this disclosure is directed at a method of forming a Schottky barrier solar cell, providing a lightly-doped absorber having a front surface and a back surface, forming at least one of a p-doped region and a high work function region on the lightly-doped absorber, and forming at least one of a n-doped region and a low work function region abutting the lightly-doped absorber and being spaced apart from the at least one of p-doped region or high work function region, wherein the Schottky barrier solar cell comprises at least one of the high work function region or the low high work function region, and adjusting a potential difference at an interface between the high work function region with the lightly-doped absorber or the low high work function region and the lightly-doped absorber to be at least 0.2 volts
a shows a sideview of a lightly-doped absorber 100 having a front surface and a back surface. At the front surface, a high work function region 110 is provided. The back surface is provided with a low work function region 120. Alternatively, region 110 is a low work function region if 120 is a high work function region. Typically, the front surface is oriented perpendicularly towards the path of photons from light source 130, but the photons may also strike the front surface at an inclination. Thus, the front surface is the light-receiving surface.
Typically, the high work function region is formed as a high work function metal or a metal silicide. Moreover, the work function of the high work function region may be modified by incorporating a p-type dopant within the metal silicide and/or by further doping of the lightly-doped absorber and performing a drive-in anneal to force the dopants to migrate towards the interface of the lightly-doped absorber with the high work function metal or a metal silicide. Analogously, the low work function region is formed as a low work function metal or as a metal silicide. The work function of the low work function region may further be modified by incorporating a n-type dopant within the metal silicide, and, optionally, by further doping of the lightly-doped absorber and performing a drive-in anneal to force the dopants to migrate towards the interface of the lightly-doped absorber with low work function metal of metal silicide.
It is also possible that the Schottky barrier cell comprises a high work function metal as the high work function region and a low work function metal silicide as the low work function region, or vice versa.
b shows a top view of a Schottky barrier solar cell wherein a high or a low work function region 150 is provided on the front surface. Electrons are collected through collector 140 made from a conductive material.
a to 2f show various geometries contemplated in this disclosure for the arrangement of p-doped, n-doped, high work function, and low work function regions, respectively.
a shows high work function region 210 being provided on a partial area of the front surface of the lightly doped absorber and low work function region 220 being provided on the back surface of the lightly-doped absorber.
b shows low work function region 220 being provided on a partial area of the front surface of the lightly doped absorber and high work function region 210 being provided on the back surface of the lightly-doped absorber.
c shows p-doped region 230 being provided on a partial area of the front surface of the lightly doped absorber and a low work function region 220 being provided on the back surface of the lightly doped absorber.
d shows low work function region 220 being provided on a partial area of the front surface of the lightly doped absorber and p-doped region 230 being provided on the back surface of the lightly doped absorber.
e shows n-doped region 240 being provided on a partial area of the front surface of the lightly doped absorber and high work function region 210 being provided on the back surface of the lightly doped absorber.
f shows high work function region 210 being provided on a partial area of the front surface of the lightly doped absorber and n-doped region 240 being provided on the back surface of the lightly doped absorber.
a to 3e show various geometries contemplated in this disclosure for the partial arrangement of p-doped, n-doped, high work function, and low work function regions on the front and/or back surface of the lightly doped absorber.
a shows high work function region 210 being provided on a partial area of the front surface of the lightly doped absorber and low work function region 220 being provided on a partial area of the back surface of the lightly doped absorber.
b shows high work function region 210 being provided on a partial area of the front surface of the lightly doped absorber and low work function region 220 being provided on a separate partial area of the front surface of the lightly doped absorber.
c shows high work function region 210 being provided on a partial area of the back surface of the lightly doped absorber and low work function region 220 being provided on a separate partial area of the back surface of the lightly doped absorber.
d shows p-doped region 230 being provided on a partial area of the front surface of the lightly doped absorber and low work function region 220 being provided on a separate partial area of the front surface of the lightly doped absorber.
e shows high work function region 210 being provided on a partial area of the back surface of the lightly doped absorber and n-doped region 240 being provided on a separate partial area of the back surface of the lightly doped absorber.
a, 4b, and 4c show the embodiments of
d shows upper the front surface of a Schottky barrier cell wherein high work function region 210 is provided on a partial area of the front surface in the form of digits and is connected to collector 140.
e shows alternate high work function regions 210 and low work function regions 220 located on the same side of absorber region 100 and connected to collectors 140 and 145, respectively.
a-5d show various geometries in which n-/p-doped regions and/or high/low work function regions may be arranged on the front and back surface of lightly-doped absorber 100.
a shows the depth profile of the concentration of a boron doped NiSi interface as implanted and after a 600° C. anneal.
b shows the depth profile of the concentration of an arsenic doped NiSi interface as implanted, after a 500° C. anneal, and after a 700° C. anneal.
a shows the band diagram of Schottky barrier at a NiSi/nSi interface obtained via interface modification via dopant segregation.
b shows the band diagram of a Schottky barrier at a NiSi/pSi interface obtained by interface modification via dopant segregation.
The foregoing and other objects, aspects and advantages will be better understood from the following detailed description of the best and various embodiments. Throughout the various views and illustrative embodiments of the present disclosure, like reference numbers are used to designate like elements.
In a typical embodiment, a Schottky barrier solar cell is obtained by placing a metallic material with a high work function onto a part of a lightly-doped absorber and placing a second metallic material in a different location using a low work function metallic material. The high work function region and low work function region are also referred to herein as contacts. Typically, a low temperature annealing of the metallic materials is performed to form silicides if the substrate material is Si, to form gemanides if the substrate material is Ge, or to form the corresponding metal-containing regions on alternate substrates, such as GaAs. However, high and low work function silicides and germanides may also be deposited directly (e.g., by sputtering from a compound target). Placing both metallic materials as a high work function region and a low work function region on the front surface of a lightly doped absorber creates an interdigitated front contact device (IFC), but alternatively one of the metallic materials, typically the Schottky barrier forming metal, is placed on the front surface and the opposite metal on the absorber back surface. The metallic materials may be thin to be semi-transparent or thick if transparency is not required. The surface of the space between contacts is passivated and the pitch (distance between contacts) is determined by the typical diffusion length of the substrate material.
Alternatively, a silicide of the same metal can be used to form both the high and low work function junctions by incorporating p-type or n type dopants to tailor the local work function, producing high barrier height Schottky junctions and low barrier height ohmic contacts. The same flexibility as described above is still applicable: the device can be made in IFC form or with the metal junctions on alternate sides Annealing is used to create the silicides and to activate the desired dopants incorporated into the silicide or into the Si adjacent to the silicide.
Typically, the lightly doped absorber is monocrystalline or polycrystalline. With particularity, the lightly doped absorber is selected from the group consisting of Si, Ge, and SiGe alloys.
In a typical embodiment, the at least one of the high work function region or the low high work function region is selected from the group consisting of metal, metal silicide, metal germanide, or mixtures or multilayers thereof. With particularity, the metal is selected from the group consisting of nickel, platinum, nickel platinum, cobalt, titanium, and tungsten.
In another typical embodiment, the at least one of the high work function region or the low high work function region further comprises a dopant that is distributed within the metal-containing material and/or at an interface with the lightly-doped absorber and is selected from the group consisting of aluminum, arsenic, boron, gallium, indium, phosphorous, and antimony.
With particularity, the Schottky barrier solar cell comprises blanket or patterned conductive contact layer on at least part of the front surface or the back surface. Also with particularity, the at least one p-doped region or high work function region is disposed on the front surface of the absorber layer and the at least one n-doped region or low work function region is disposed on the back surface of the absorber layer, or the at least one p-doped region or high work function region is disposed on the back surface of the absorber layer and the at least one n-doped region or low work function region is disposed on the front surface of the absorber layer.
Typically, the at least one p-doped region or high work function region and the at least one n-doped region or low work function region are laterally spaced apart in an interdigitated pattern on a same surface of the lightly doped absorber. The same surface may be either the front surface or the back surface.
Also typically, the Schottky barrier solar cell comprises a supplemental doped layer on the same surface, wherein the supplemental doped layer has a same dopant as the lightly doped absorber, and wherein a concentration of the same dopant is greater in the supplemental doped layer than in the lightly doped absorber.
In another typical embodiment, the high work function region and the low work function region include a same metal, each modified, for example, by dopant-engineering, to have the appropriate work function. With particularity, the Schottky barrier solar cell further comprises a conductive contact, a transparent conductive oxide layer, an antireflective coating, a surface texture, and a surface passivation layer.
In a typical embodiment the lightly-doped absorber is n-doped. In yet another typical embodiment the lightly-doped absorber is p-doped.
Typically, a concentration of a dopant in the lightly-doped absorber is of from about 1·1013 atoms cm−3 to about 1·1017 atoms cm−3. Also typically, a concentration of the same dopant in the supplemental absorber region is of from about 1·1017 atoms cm−3 to about 1·1021 atoms cm−3.
With particularity, a concentration of a dopant in the p-doped region is of from about 1·1013 atoms cm−3 to about 1·1017 atoms cm−3. Also with particularity, a concentration of a dopant in the n-doped region is of from about 1·1017 atoms cm−3 to about 1·1021 atoms cm−3.
Another embodiment method of forming a Schottky barrier solar cell comprises: forming at least one of a p-doped region and a high work function region on the lightly-doped absorber, forming at least one of a n-doped region and a low work function region abutting the lightly-doped absorber and being spaced apart from the at least one of p-doped region or high work function region, wherein the Schottky barrier solar cell comprises at least one of the high work function region or the low high work function region; and adjusting a potential difference at an interface between the high work function region with the lightly-doped absorber or the low high work function region and the lightly-doped absorber to be at least 0.2 volts.
Yet another embodiment of forming a Schottky barrier solar cell comprises: providing a lightly-doped absorber having a front surface and a back surface; forming a p-doped region and an n-doped region on the lightly-doped absorber; converting at least one of the p-doped region and the n-doped region into a metal silicide film.
A Schottky barrier solar cell of metallic materials with high work functions (Wfs) and low work functions contains two built-in potential differences. Such a structure is shown in
For Schottky barrier solar cells possessing silicided contacts, a TiN cap can be deposited on top of the low Wf and high Wf metals to prevent oxidation of the metals before forming the silicide. The annealing conditions for both types of silicides are in the range of 400° C. to 600° C., with the preferred embodiment being 500° C., 30 seconds for Er silicide and 420° C., 30 seconds for Pt silicide. The TiN cap and unreacted metal are then stripped from the structure using a wet etch, such as sulfuric acid/hydrogen peroxide for Er and Aqua regia for Pt.
When two silicides are used, it is preferred to protect the first silicide formed from the cleaning and selective stripping processes performed in the forming of the second silicide. A conductive TiN cap layer can be used to protect the first silicide formed (e.g., Er silicide) from attack by HF used to clean the lightly doped absorber surface on which the second silicide (or metal) is formed. Additional layers may be used as needed.
The interdigitated device of
For the digitated and interdigitated devices of
While the examples of the present disclosure utilize Schottky barriers of metals with high work functions and low work functions to create the two potential differences, solar cells in which one potential difference is created by a Schottky barrier and a second potential difference is created by conventional doping (diffusion, ion implantation, or in-situ doping during semiconductor layer growth) are also contemplated.
In another embodiment, the same metal can be used for both silicides by adding acceptor or donor dopants into the silicide and adjacent regions of the Si . Both high Wf and low Wf can be achieved from one silicide by interface modification. A very promising way to modify the silicide /Si interface is dopant-segregation as illustrated in Fig . 11.
First, a lightly doped substrate is isolated with Field Oxide (FOX) to form active junction areas (
In a preferred embodiment, Ni is used as the metal for the metal silicide because the self-aligned Ni silicide process is well-understood and considered a mature processing method. Ni is the dominating diffusion species during the silicide reaction and NiSi has very low resistivity (about 10 μΩ·cm). The dopant-segregation can also be induced by implantation into Si, which is then followed by silicidation or by implantation into metal, which is then followed by silicidation. To further reduce processing costs, sputter pre-doped metal targets (Ni—B or Ni—As) or electrolessly plated Ni—B or Ni—As are considered to be other promising manufacturing routes.
The embodiments described hereinabove are further intended to explain best modes known of practicing it and to enable others skilled in the art to utilize the disclosure in such, or other, embodiments and with the various modifications required by the particular applications or uses. Accordingly, the description is not intended to limit it to the form disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments.
The foregoing description of the disclosure illustrates and describes the present disclosure. Additionally, the disclosure shows and describes only the preferred embodiments but, as mentioned above, it is to be understood that the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the concept as expressed herein, commensurate with the above teachings and/or the skill or knowledge of the relevant art.
The term “comprising” (and its grammatical variations) as used herein is used in the inclusive sense of “having” or “including” and not in the exclusive sense of “consisting only of” The terms “a” and “the” as used herein are understood to encompass the plural as well as the singular.
All publications, patents and patent applications cited in this specification are herein incorporated by reference, and for any and all purpose, as if each individual publication, patent or patent application were specifically and individually indicated to be incorporated by reference. In the case of inconsistencies, the present disclosure will prevail.