The disclosure relates to a solar cell and manufacturing method thereof, more particular to a solar cell with a passivation layer.
Vertical multi-junction (VMJ) cell is a solar cell device which may allow output voltage higher than conventional single junction cells. Particularly the VMJ cell may operate in a high concentrated light environment. However, a carrier recombination probability is challenging to modern VMJ cells because the carrier recombination easily occurs in a surface of the VMJ cell, thereby reducing the photovoltaic conversion efficiency. The photovoltaic conversion efficiency decay causes the VMJ cell to be less widely used.
In view of the foregoing, it is greatly desired to develop a solar cell or method which may reduce the carrier recombination probability.
Patent document 1: US Patent Publication No. U.S. Pat. No. 4,332,973
Patent document 2: US Patent Publication No. U.S. Pat. No. 4,409,422
Patent document 3: US Patent Publication No. U.S. Pat. No. 4,516,314
Patent document 4: US Patent Publication No. U.S. Pat. No. 6,333,457
Patent document 5: CN Patent Application No. 102668102 A
Patent document 6: TW Patent Application No. 096123802
Patent document 7: TW Patent Application No. 095135676
Patent document 8: EP Patent Publication No. EP2077584 A2
Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
a illustrates a side view of a solar cell in accordance with some embodiments of the present disclosure.
b illustrates a partial enlarged view of a solar cell in accordance with some embodiments of the present disclosure.
a to 7b illustrate schematic views of a solar cell in various processes corresponding to the method of
It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.
It will be understood that singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
a illustrates a side view of a solar cell in accordance with some embodiments of the present disclosure. FIG. lb illustrates a partial enlarged view of a solar cell in accordance with some embodiments of the present disclosure.
Referring to
The vertical multi-junction (VMJ) cell 200 includes a plurality of PN junction substrates 200a and a plurality of electrode layers 240. The PN junction substrates 200a are spaced from each other. The PN junction substrates 200a are made of silicon (Si), and the silicon purity is between about 4N and about 11N. In some embodiments, the PN junction substrates 200a may be made of one selected from the group consisting of GaAs, Ge, InGaP, and their compositions. Each of the electrode layers 240 is disposed between and connected to two adjacent PN junction substrates 200a, which can provide ohmic contacts with low resistance, high strength bonding, and well thermal conduction. In some embodiments, the electrode layers 240 are made of one selected from the group consisting of Si, Ti, Co, W, Hf, Ta, Mo, Cr, Ag, Cu, Al, and their alloy mixtures.
In order to improve carrier injections and ohmic contacts of the VMJ cell 200, each of the PN junction substrates 200a includes a light receiving surface 210a, a P+ type diffuse doping layer 211, a P type diffuse doping layer 212, an N type diffuse doping layer 213 and an N+ type diffuse doping layer 214. The P type diffuse doping layer 212 is connected to the P+ type diffuse doping layer 211; the N type diffuse doping layer 213 is connected to the P type diffuse doping layer 212; and the N+ type diffuse doping layer 214 is connected to the N type diffuse doping layer 213. The P+ type diffuse doping layer 211 and the N+ type diffuse doping layer 214 of one PN junction substrate 200a are connected to different electrode layers 240.
The P+ type diffuse doping layer 211 has a P+ type end surface 211a. In some embodiments, a doping concentration of the P+ type diffuse doping layer 211 is between about 1019 atom/cm3 and about 1021 atom/cm3. In some embodiments, a thickness of the P+ type diffuse doping layer 211 is between about 0.3 μm and about 3 μm.
The P type diffuse doping layer 212 has a P type end surface 212a. In some embodiments, a doping concentration of the P type diffuse doping layer 212 is between about 1016 atom/cm3 and about 1020 atom/cm3. In some embodiments, a thickness of the P type diffuse doping layer 212 is between about 1 μm and about 50 μm.
The N type diffuse doping layer 213 has an N type end surface 213a. In some embodiments, a doping concentration of the N type diffuse doping layer 213 is between about 1016 atom/cm3 and about 1020 atom/cm3. In some embodiments, a thickness of the N type diffuse doping layer 213 is between about 1 μm and about 50 μm.
The N+ type diffuse doping layer 214 has an N+ type end surface 214a. In some embodiments, a doping concentration of the N+ type diffuse doping layer 214 is between about 1019 atom/cm3 and about 1021 atom/cm3. In some embodiments, a thickness of the N+ type diffuse doping layer 214 is between about 0.3 μm and about 3 μm.
In some embodiments, the light receiving surface 210a includes the P+ type end surface 211a of the P+ type diffuse doping layer 211, the P type end surface 212a of the P type diffuse doping layer 212, the N type end surface 213a of the N type diffuse doping layer 213 and the N+ type end surface 214a of the N+ type diffuse doping layer 214. In some embodiments, the light receiving surface 210a is an uneven surface.
Each of the electrode layers 240 has an exposing surface 241. To prevent the electrode layers 240 from being damaged in the process, there is a height difference h between the exposing surface 241 of each of the electrode layers 240 and the light receiving surface 210a of each of the PN junction substrates 200a. In some embodiments, a position of the exposing surface 241 is lower than that of the light receiving surface 210a.
In order to reduce the carrier recombination probability, the passivation layer 230 is provided to cover the P+ type end surfaces 211a of the P+ type diffuse doping layers 211, the P type end surfaces 212a of the P type diffuse doping layers 212, the N type end surfaces 213a of the N type diffuse doping layers 213, the N+ type end surfaces 214a of the N+ type diffuse doping layers 214 and the exposing surfaces 241 of the electrode layers 240. The passivation layer 230 is formed by an atomic layer deposition (ALD) process. Furthermore, the passivation layer 230 is penetrable to light and is made of one selected from the group consisting of Al2O3, HfO2, La2O3, SiO2, TiO2, ZnO, ZrO2, Ta2O5, In2O3, SnO2, ITO, Fe2O3, Nb2O5, MgO, Er2O3, WN, Hf3N4, Zr3N4, AlN, and TiN.
In addition to reduce the carrier recombination probability, the passivation layer 230 also can be used to mend surface defects and dangling bonds of the PN junction substrates 200a, thereby reducing light induced degradation and enhancing the photovoltaic conversion efficiency. In some embodiments, a thickness of the passivation layer 230 is between about 10 nm and about 180 nm.
To improve a bonding strength between the passivation layer 230 and the electrode layers 240, each of the electrode layers 240 also includes a groove S recessed from the exposing surface 241, and the grooves S of the electrode layers 240 are filled with the passivation layer 230. In some embodiments, a depth D of the groove S is greater than the height difference h.
The VMJ cell 200 also includes a first end surface 220, a second end surface 221 and at least two conducting electrodes 250. The second end surface 221 is opposite to the first end surface 220. The conducting electrodes 250 are separately disposed on the first and second end surfaces 220, 221. The conducting electrodes 250 are used to output electric energy generated from the VMJ cell 200. In some embodiments, the conducting electrodes 250, the first end surface 220 and the second end surface 221 are covered with the passivation layer 230 to reduce the carrier recombination probability. In some embodiments, a width W of each of the conducting electrodes 250 is smaller than a thickness T of the VMJ cell 200.
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a to 7b illustrate schematic views of a solar cell in various processes corresponding to the method of
In
Each of the electrode layers 740 is disposed between and connected to two adjacent PN junction substrates 700a, and each of the electrode layers 740 has an exposing surface 741 and a groove S recessed from the exposing surface 741. In some embodiments, the PN junction substrates 700a and the electrode layers 740 are bonded together via thermal processing, and the thermal processing temperature is between about 400° C. and about 800° C. to ensure the electrode layers 740 to have eutectic composition. The eutectic electrode layers 740 can improve the bonding strength between the PN junction substrates 700a.
Referring to
It is important to control the atomic layer deposition rate because an unsuitable atomic layer deposition rate will make the passivation layer 730 to have non-uniform thickness and surface defects. Therefore, a suitable atomic layer deposition rate is greater than or equal to 0.03 nm/s, and the best atomic layer deposition rate is 0.1 nm/s. Furthermore, the best atomic layer deposition temperature is between about 100° C. and about 350° C.
In some embodiments, the conducting electrodes 750, the first end surface 720 and the second end surface 721 are covered with the passivation layer 730 to reduce the carrier recombination probability. In some embodiments, the grooves S of the electrode layers 740 are filled with the passivation layer 730 to improve a bonding strength between the passivation layer 730 and the electrode layers 740.
Referring to
Table 1 presents the photovoltaic performance for solar cell with and without the passivation layer 730. Under 300 suns (1 sun=0.09 W/cm2) illumination, the solar cell without the passivation layer 730 has an open-circuit voltage (Voc) of 30.03 V, a short-circuit current (Isc) of 0.11 A, a fill factor (F.F) of 0.670, and a photovoltaic conversion efficiency (η) of 6.55%. Interestingly, forming the passivation layer 730 to cover the P+ type end surfaces 711a, the P type end surfaces 712a, the N type end surfaces 713a, the N+ type end surfaces 714a and the exposing surfaces 741 improved the Isc and η values of solar cell to 0.311 A and 22.67%, respectively.
Table 2 presents the photovoltaic performance of solar cells based on passivation layers formed by different deposition processes. Under 300 suns illumination, the solar cell based on the passivation layer formed by a thin film deposition process has an open-circuit voltage (Voc) of 32.18 V, a short-circuit current (Isc) of 0.262 A, a fill factor (F.F) of 0.728, and a photovoltaic conversion efficiency (η) of 18.73%. For the passivation layer formed by the plasma atomic layer deposition (PALD) process, Isc and η were improved to 0.311 A and 22.67%, respectively, which values are greater than those obtained by the thin film deposition process.
Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As those skilled in the art will readily appreciate form the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure.
Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, and compositions of matter, means, methods or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the invention.
Number | Date | Country | Kind |
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102123167 | Jun 2013 | TW | national |
102123171 | Jun 2013 | TW | national |