The invention generally relates to silicon wafer processing and, more particularly, the invention relates to texturing silicon sheet wafers.
One of the primary goals of the solar module industry is to achieve “grid-parity,” which generally means that the cost per produced watt of electricity from a solar module is comparable to the cost per produced watt of electricity produced from conventional means (i.e., from the “grid”). In its drive for grid parity, the solar industry strives both to reduce the cost of producing solar modules and improve module energy conversion efficiency.
One widely used technique to improve cell efficiency involves applying a surface texture to the face of a solar cell. To that end, solar cells formed from ribbon crystals, for example, typically are fabricated by immersing an entire ribbon crystal wafer within an acid chemistry. Undesirably, this process unnecessarily textures both sides of the wafer, thus consuming additional acid texturing chemistry.
Moreover, subsequent processes may require one side of the wafer to be smooth. For example, some subsequent processes passivate the backside of the wafer with an oxide. Such passivation processes known to the inventors, however, require a smooth surface, thus further complicating solar cell fabrication.
In accordance with one embodiment of the invention, a silicon sheet wafer has a silicon body with first and second sides. The silicon of the silicon body on the first side has a first roughness value while, in a corresponding manner, the silicon of the silicon body on the second side has a second roughness value. The second roughness value is greater than the first roughness value. More specifically, the silicon of the silicon body on the first side is substantially smooth, while the silicon of the silicon body on the second side is textured.
For example, the second roughness value may have a RMS value of greater than about 0.3 microns. In that case, the first side may be substantially smooth while the second side is textured. Moreover, the wafer may have a plurality of strings extending along its length (e.g., it may be a string ribbon wafer). In addition or alternatively, the wafer also may have a material on both the first side and the second side. This material has a greater surface tension than that of the silicon forming the wafer.
In accordance with another embodiment of the invention, an apparatus for texturing two-sided wafers has a body capable of containing texturing chemistry (i.e., not necessarily containing the chemistry at this time), and a transport mechanism for transporting wafers through the texturing chemistry. The transport mechanism is configured to substantially wet no more than one side of wafers, transported through the body, with texturing chemistry.
The transport mechanism illustratively is configured to substantially completely cover no more than one side of a wafer (transported through the body) with the texturing chemistry. For example, the transport mechanism may be configured to substantially prevent the texturing chemistry from contacting both sides of a wafer transported through the body (e.g., it is configured to permit the chemistry to contact only one side in a substantial manner).
Among other things, the transport mechanism may at least have a plurality of rollers. In that case, the body may be configured to control the level of texturing chemistry not to extend above the rollers, or to permit it to extend above the rollers. To control the chemistry level, the body may have a fluid outlet and a fluid inlet, which is in fluid communication with a pump. Alternatively, the transport mechanism may have a plurality of channels in fluid communication with a pump. To facilitate wafer transport, the body in the latter embodiment may be oriented at an angle.
During use, the apparatus also includes texturing chemistry (e.g., a combination of three acids) and a plurality of wafers within the body.
In accordance with other embodiments, an apparatus for texturing two-sided wafers has a body, a transport mechanism for transporting wafers through the body, and a spray mechanism for spraying no more than one side of wafers with a texturing chemistry within the body.
In accordance with still other embodiments, a method of texturing a two-sided silicon sheet wafer provides a texturing chemistry, and transports the wafer through the texturing chemistry in a manner that wets no more than one side of the wafer with the texturing chemistry.
Illustrative embodiments transport the wafer so that the wafer forms a meniscus with the texturing chemistry. Some techniques may apply a material to the wafer having a higher surface tension than that of the wafer. This material should facilitate formation of the meniscus.
In accordance with yet other embodiments, a method of texturing a two-sided silicon sheet wafer provides a texturing chemistry and transports the wafer through the texturing chemistry to substantially completely wet a first side of the wafer with the texturing chemistry. Moreover, the method also transports the wafer through the texturing chemistry to no more than negligibly wet a second side of the wafer.
In other embodiments, a method of texturing a sheet wafer provides a texturing chemistry in a texturing region, and transports a two-sided sheet wafer through the texturing region. The texturing chemistry wets the wafer when in the texturing region so that no more than one of the two sides of the wafer is wetted with the texturing chemistry.
Some other embodiments have an apparatus for texturing wafers with a specialized texturing region. Specifically, in some embodiments using this region, the apparatus has a body with a texturing region configured to apply texturing chemistry to a sheet wafer, and a transport mechanism for transporting sheet wafers through the texturing region. The transport mechanism and texturing region are configured to transport the sheet wafers through the texturing region to substantially wet with texturing chemistry the first side of sheet wafers passing therethrough. In a corresponding manner, the transport mechanism and texturing region are configured not to wet with the texturing chemistry the second side of sheet wafers passing therethrough.
Those skilled in the art should more fully appreciate advantages of various embodiments of the invention from the following “Description of Illustrative Embodiments,” discussed with reference to the drawings summarized immediately below.
In illustrative embodiments, specially configured texturing equipment textures no more than a single side of a sheet wafer (e.g., a wafer formed from a string ribbon crystal). Accordingly, one side of the sheet wafer is substantially smooth while the other side is textured. Details of illustrative embodiments are discussed below.
More generally, a sheet wafer is formed from a process that grows the (generally planar) wafer directly from molten material, such as the process for forming ribbon crystals. This is in contrast to conventional wafers formed from Czochralski crystal pulling techniques, which cut generally planar wafers from a large ingot of frozen wafer material. Specifically, a sheet wafer forms directly from a melt, while a wafer formed using the Czochralski techniques requires another step to make it generally planar; namely, a sawing step. In fact, this sawing step can serve as the basis for a texture on cells formed from Czochralski wafers, thus avoiding significant texturing steps for the purposes described herein for photovoltaics. Sheet wafers often do not have this benefit—instead, they often are smooth and thus, require this extra texturing step. As noted above, prior art processes known to the inventors texture both sides of a sheet wafer.
The wafer 10 shown in
In addition, the thickness of the wafer 10 varies and is very thin relative to its length and width dimensions. Specifically, the wafer may have a thickness ranging from about 190 microns to about 320 microns across its width. Despite this range, the wafer 10 may be considered to have an average thickness across its length and/or width. The wafer 10 may be formed from any of a wide variety of materials and crystal types, such as multi-crystalline, single crystalline, polycrystalline, microcrystalline or semi-crystalline materials. For example, the wafer 10 may be formed from polysilicon.
The wafer 10 shown in
As shown in
Unlike prior art sheet wafer texturing processes, illustrative embodiments texture one side of the wafer 10 only (e.g., the front surface 12, as shown in
To that end,
The texturing equipment 16A of this embodiment also has a transport mechanism 24 for transporting the wafers 10 from the wafer inlet 20, through the texturing chemistry, and through the wafer outlet 22. In illustrative embodiments, the transport mechanism 24 includes a plurality of mechanized rollers 26 that slowly move the wafers 10 through the texturing chemistry. The rollers 26 thus are configured to rotate at a speed adequate for appropriately texturing the wafers 10. Moreover, the rollers 26 preferably do not move the wafers 10 in a manner that creates an unfavorable turbulence in the texturing chemistry.
Some embodiments are capable of processing wafers 10 in parallel. For example, such embodiments may have multiple adjacent transport mechanisms 24 that each serially texture wafers 10.
The texturing chemistry may be selected based upon a number of factors, such as 1) the material forming the wafer 10, 2) the size of the wafer 10, 3) the depth of the texturing bath 18, and 4) the ultimate desired characteristics of the texture on the top surface of the wafer 10. For example, the inventors have tested various embodiments by using a combination of sulfuric acid, hydrofluoric acid, and nitric acid to texture a polysilicon ribbon wafer. When using this combination of acids, the sulfuric acid creates bubbles on the front surface 12 of the wafer 10 while the nitric acid creates a thin silicon oxide on the front surface 12 of the wafer 10. The hydrofluoric acid erodes the thin silicon oxide around each bubble, thus forming “pockmarks” (i.e., generally rounded indents) on the front silicon surface 12 of the wafer 10.
In one example, the texturing chemistry is (all percentages approximate) 5% HF (hydrofluoric acid), 5% HNO3 (nitric acid), 90% H2SO4 (sulfuric acid). Illustrative embodiments may have a range of those acids—from 40% hydrofluoric acid, 40% nitric acid 20% sulfuric acid at one end of the spectrum, to 1% hydrofluoric acid, 1% nitric acid, and 98% sulfuric acid on another end of the spectrum. As noted above, one desirable composition has a higher sulfuric acid concentration, 80-95%, with attendant lower hydrofluoric acid and nitric acid. Of course, the hydrofluoric acid and nitric acid can be in ratios other than the noted 1:1 ratio, although such a ratio is preferred for these two acids.
Certain combinations of texturing chemistries and wafer materials undesirably can create chemical reactions that increase the temperature of the texturing chemistry. The above noted chiller thus controls these temperature increases. In addition, chemical reactions also can produce byproducts, such as water, that undesirably may impede the texturing process. For example, the combination of acids described above creates water when reacting with polysilicon. Increasing the water within the texturing chemistry undesirably can cause the bubbles formed on the front surface 12 of the wafer 10 to increase in size. In fact, this increase in size can be greater than that recommended for creating an appropriate texture.
Accordingly, to counteract the problems associated with heat and excessive water in the texturing chemistry, the texturing bath 18 has a pump inlet 28 for pumping fresh texturing chemistry into the bath 18, and a plurality of overflow outlets 30 for expelling texturing chemistry from the bath 18. The expelled texturing chemistry may be processed (e.g., chilled) for reuse in the system, or simply discarded.
To ensure appropriate texturing, however, care must be taken to minimize any turbulence within the texturing chemistry. Accordingly, the pump (not shown) must be calibrated to pump the texturing chemistry at a rate that minimizes turbulence. Considerations to take into account include the viscosity of the texturing chemistry, physical and material characteristics of the sheet wafer, and geometry of the overall equipment 16A (e.g., the shape and size of the texturing bath 18 and its various ports). The pump thus may be calibrated by conventional testing methods to determine appropriate flow rate. For example, after roughly calculating an appropriate flow rate, an operator simply may conduct a number of test runs to determine appropriate flow rate.
During operation, the pump maintains the texturing chemistry at a height that does not wet the back surface 14 of the wafer 10. For example, when no wafers 10 are in the bath 18, the texturing chemistry may be at a height that is approximately equal to the top of the rollers 26, or slightly above the top of the rollers 26.
The process begins at step 400, which removes a native oxide formed on the surface of the wafer 10. Specifically, as known by those skilled in the art, a ribbon crystal wafer undesirably can form a thin native oxide as it is drawn from a crucible of molten silicon. Accordingly, to remove this native oxide, illustrative embodiments perform a preliminary hydrofluoric acid etch on both sides of the wafer 10. This hydrofluoric etch favorably increases the hydrophobicity of the wafer 10. This increased hydrophobicity in turn more effectively forms the meniscus 32 shown in
Before, while, or after executing step 400, the process fills the empty bath 18 with an appropriate texturing chemistry (step 402). In addition, the process also prepares the remainder of the texturing equipment 16A for operation. The process concludes by passing wafers 10 through the texturing region 19/texturing chemistry (step 404).
The wafer 10 then moves to post-texturing processing areas, such as a water rinse area (not shown). Before moving to such an area, illustrative embodiments direct positive air pressure toward the wafer 10 to remove texturing chemistry residue from its front surface 12. For example, a conventional air knife (not shown) may blow air at an angle toward the front surface 12 of the wafer 10. The air knife should be configured not to create additional turbulence in the texturing chemistry. Accordingly, some embodiments may have a second air knife blowing in a generally opposite direction to that of the first air knife to counteract its potentially turbulent effects. The opposite air flow of the second air knife also may prevent the first air knife from blowing texturing chemistry onto the back surface 14 of the wafer 10.
Illustrative embodiments may form the front surface 12 to have a root mean squared roughness (hereinafter “RMS”) value of greater than about 0.3 microns. For example, during testing, the inventors used a white-light interferometer to measure RMS of the two surfaces 12 and 14. The front (textured) surface 12 had RMS values of between about 0.3 microns and about 0.7 microns. The back (untextured/smooth) surface 14 had RMS values of between about 0.006 microns and about 0.03 microns. Of course, these RMS values are illustrative and should not limit various embodiments of the invention.
More specifically, as known by those in the art, characterization of surface topography is challenging because surfaces generally have a distribution of asperities, ridges, pits and valleys, all of which may have variable shapes and dimensions. For this reason, the surface irregularities that form the surface texture may generally be characterized by some type of average. One common representation of surface roughness, RMS, averages the height deviation of N observed asperities Zi, from the mean, Z-bar:
Since RMS is an averaged value, surfaces that have different irregularities may have the same RMS. Furthermore, RMS is scale dependent, which means that an RMS value based on one type of measurement (e.g., using a profilometer measurement) may differ from one measured with another type of technique (e.g., using an atomic force microscope).
Accordingly, illustrative embodiments substantially completely contact the front surface 12 of the wafer 10 with texturing chemistry, but substantially prevent non-negligible amounts of texturing chemistry from contacting/wetting the back surface 14. This contact should produce a textured surface having the desired qualities for a given application. In addition, for a sheet wafer, such as one formed from a ribbon crystal, this process should maintain a substantially smooth back surface 14. Accordingly, processes requiring a smooth surface, such as a back-side passivation step with an oxide, should be simpler to perform and thus, less expensive. This eliminates the need for smoothing the back surface 14 to perform this passivation step.
Various embodiments thus produce a desired sheet wafer 10 that requires less processing for subsequent steps, such as passivation. This desired result is achieved while expending substantially less texturing chemistry than prior art processes that texture both surfaces. As a result, overall part cost should decrease when compared to prior art processes (e.g., the cost of forming a solar cell should decrease).
The embodiments described above are several of a variety of different embodiments that can texture a single side of the wafer 10. The remaining figures show additional examples for implementing illustrative embodiments of the invention.
To that end,
To control fluid flow, fluid channel has a plurality of fluid jets 36 that pump texturing chemistry or other fluid into the bath 18. The fluid jets 36 preferably pump the texturing chemistry in a predefined manner to reduce the traveling speed of the wafers 10 and ensure an appropriate chemistry level within the bath 18. The arrows in
To those ends, the jets 36 may force texturing fluid from their respective outlets in a manner that has a component/vector generally in an upstream direction. Accordingly, the fluid may exit the jets 36 in a directly upstream direction, or in a direction that is angled almost up to generally orthogonal (i.e., up to but not including about 90 degrees) to the flow of the texturing chemistry in the bath 18. Thus, a jet 36 forcing fluid ninety degrees or greater relative to the fluid flow is not considered to force fluid in a generally upstream direction.
Among other ways, the jets 36 may be pointed in an upstream direction, have a nozzle that provides that function, or both. Also, as noted above, although it forces fluid in a generally upstream direction, a given jet does not necessarily force appreciable amounts of texturing chemistry upstream. Instead, the jets 36 act to control fluid flow to assist in transporting wafers toward the outlet 22.
Of course, some embodiments may have additional fluid jets 36 and/or pump the texturing chemistry in a different manner. For example, more than one jet 36 may pump texturing chemistry in a downstream direction. Among other things,
Moreover, to provide further flow control, some embodiments can have one or more jets 36 that eject fluid in a generally downstream direction. Alternative embodiments can have both types of jets 36—one or more ejecting fluid in a generally upstream direction and one or more ejecting fluid in a generally downstream direction.
The bottom and/or side surface of the bath 18 may be specially textured to further control the flow of the texturing chemistry. For example,
Although the above discussion discloses various exemplary embodiments of the invention, it should be apparent that those skilled in the art can make various modifications that will achieve some of the advantages of the invention without departing from the true scope of the invention.
This patent application claims priority from provisional United States patent application No. 61/092,818, filed Aug. 29, 2008 entitled, “SINGLE-SIDED TEXTURED SHEET WAFER,” and naming Guenther Grupp and Brian McMullen as inventors, the disclosure of which is incorporated herein, in its entirety, by reference.
Number | Date | Country | |
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61092818 | Aug 2008 | US |