The present patent document relates generally to photovoltaic cells. In particular, the present patent document relates to a tunneling photovoltaic device and a method of manufacturing the same.
Photovoltaic (“PV”) cells are semiconductor devices that generate power by turning photons into charge carriers and electric current which can be harvested. This electrical energy can be immediately used or stored for future use. Given the infinite source of solar energy, PV cells are a promising device for generating electricity at low cost and with low to zero emissions.
In order to generate electricity from light, photons are absorbed by a semiconductor, such as silicon (“Si”), gallium arsenide (“GaAs”), or germanium. A p-n junction is formed in a typical PV device, wherein P-type doped semiconductor material, having an abundance of holes, and an N-type doped semiconductor material, having an abundance of electrons, are electrically connected at a junction. An incident photon generates electron-hole pairs (“EHP”) in the conduction and valance bands of the semiconductor. The EHPs are then separated by an electric field formed at the p-n junction and collected at electrodes on either side of the p-n junction. This gives rise to a current that can be used to drive a load, which is connected to the electrodes through an external circuit.
Two factors limit the efficiency of conventional p-n junction PV cells. The first factor is material absorption. Most commercial PV cells use silicon as the light-absorbing material. The Si bandgap, which is approximately 1.12 eV at room temperature, makes it difficult to capture the long-wavelength portion of the solar spectra associated with infrared. Furthermore silicon is an indirect bandgap material which reduces the absorption coefficient. The second factor limiting efficiency is carrier collection efficiency. As EHPs split at the junction and drift towards the contacts for collection, a large number of them recombine and lose their energy to heat, also known as phonons. A greater number of EHPs can be formed by increasing the thickness of the PV cell, which result in greater light absorption. To absorb more light, the cell needs to have a thickness on the order of tens of microns. However, this is at odds with carrier transport since the longer the EHPs need to travel before they reach the contacts, the higher the chances of recombination of the EHPs, in which case the energy absorbed from light is dissipated as heat.
Although the PV industry has been battling these two limiting factors for decades, both still limit the practical internal quantum energy conversion efficiency of Si PVs to less than about 28% in the laboratory and less than about 25% in commercial use. Higher efficiency PV cells, having up to approximately 40% efficiency, have been made of materials other than Si, for example group III-V elements of the periodic table. An example is GaAs—which has a more efficient direct bandgap than Si (an indirect bandgap semiconductor)—in a sophisticated hetero-junction structure. However, the high cost of these materials and complex structures prevent commercial applications.
Metal-insulator-semiconductor (“MIS”) structures for PV applications offer an alternative to p-n junction devices. Use of a MIS for PV applications instead of the more traditional p-n junction was demonstrated in 1970's. A MIS PV with an efficacy of 17.6% was fabricated by Godfrey et al., 655 mV open-circuit voltage, 17.6% efficient silicon MIS solar cells, 34 Appl. Phys. Lett. 790-93 (Jun. 1, 1979), which is fully incorporated herein by reference. This was higher than a standard PV at the time. In 1997, a MIS PV with an efficiency of 18.5% was reported by Metz et al., 18.5% efficient first-generation MIS inversion-layer silicon solar cells, 1997 Photovoltaic Specialists Conference 31-34 (Sep. 29 to Oct. 3, 1997), which is fully incorporated herein by reference. The relative lack of efficiency of such MIS PV structures is primarily due to use of silicon dioxide (SiO2) as the insulator in the tunnel barrier. SiO2 has a large energy band offset to the silicon conduction band (φb=3.1 eV) which constitutes a large potential barrier for electrons. Therefore to have effective tunneling and a high short-circuit current (“ISC”), a very thin SiO2 layer is needed. Given that the above efficiencies were obtained with already very thin SiO2 layers of approximately ten to fifteen angstroms, it is impractical to manufacture these cells at a large scale or further boost efficiency by reducing the SiO2 thickness.
A tunneling photovoltaic is disclosed. In an embodiment the tunneling photovoltaic comprises a semiconductor substrate, a tunneling layer comprising a high-κ dielectric formed on the semiconductor substrate, first electrode formed on the tunneling layer, and a second electrode formed on the semiconductor substrate.
In another embodiment, the tunneling layer comprises hafnium oxide.
In another embodiment, the tunneling layer comprises a high-κ dielectric selected from the group consisting of titanium dioxide, aluminum oxide, lanthanum oxide, zirconium oxide, tantalum oxide, nitrided hafnium silicate, and zirconium silicate.
In another embodiment, the tunneling layer is between ten and fifty angstroms thick.
In another embodiment, the tunneling layer comprises a high-κ dielectric that has an effective electron mass at room temperature less than an effective electron mass of silicon dioxide at room temperature.
In another embodiment, the semiconductor substrate comprises silicon. In another embodiment, the silicon substrate comprises P-type doped silicon.
In another embodiment, the first electrode comprises aluminum.
In another embodiment, the tunneling photovoltaic further includes an interfacial layer formed on the semiconductor substrate and the tunneling layer is formed on the interfacial layer. In another embodiment, the interfacial layer comprises a compound selected from the group consisting of silicon oxide, silicon nitride, and oxynitride.
A method of fabricating a tunneling photovoltaic cell is also disclosed. In an embodiment, the method comprises providing a semiconductor substrate, forming a tunneling layer comprising a high-κ dielectric on the semiconductor substrate, forming a first electrode layer on the tunneling layer; and forming a second electrode layer on the semiconductor substrate.
In another embodiment of the method, the tunneling layer comprises hafnium oxide.
In another embodiment of the method, the tunneling layer comprises a high-κ dielectric selected from the group consisting of titanium dioxide, aluminum oxide, lanthanum oxide, zirconium oxide, tantalum oxide, nitrided hafnium silicate, and zirconium silicate.
In another embodiment of the method, the tunneling layer is between ten and fifty angstroms thick.
In another embodiment of the method, the tunneling layer comprises a high-κ dielectric that has an effective electron mass at room temperature less than an effective electron mass of silicon dioxide at room temperature.
In another embodiment of the method, the semiconductor substrate comprises silicon. In another embodiment, the silicon substrate comprises P-type doped silicon.
In another embodiment of the method, the first electrode comprises aluminum.
In another embodiment, the method further includes forming the interfacial layer on the semiconductor substrate wherein the tunneling layer is formed on the interfacial layer. In another embodiment of the method, the interfacial layer comprises a compound selected from the group consisting of silicon oxide, silicon nitride, and oxynitride.
The above and other preferred features described herein, including various novel details of implementation and combination of elements, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular methods and apparatuses are shown by way of illustration only and not as limitations of the claims. As will be understood by those skilled in the art, the principles and features of the teachings herein may be employed in various and numerous embodiments without departing from the scope of the claims.
The accompanying drawings, which are included as part of the present specification, illustrate the presently preferred embodiments and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain and teach the principles of the present invention.
The figures are not necessarily drawn to scale and the elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. The figures are only intended to facilitate the description of the various embodiments described herein; the figures do not describe every aspect of the teachings disclosed herein and do not limit the scope of the claims.
A high-κ tunneling photovoltaic (“TPV”) apparatus is disclosed, as well as a method of manufacturing a high-κ TPV. Each of the features and teachings disclosed herein can be utilized separately or in conjunction with other features and teachings. Representative examples utilizing many of these additional features and teachings, both separately and in combination, are described in further detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the claims. Therefore, combinations of features disclosed in the following detailed description may not be necessary to practice the teachings in the broadest sense, and are instead taught merely to describe particularly representative examples of the present teachings.
In the following description, for purposes of explanation only, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the present invention.
The various features of the representative examples and the dependent claims may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. It is also expressly noted that all value ranges or indications of groups of entities disclose every possible intermediate value or intermediate entity for the purpose of original disclosure, as well as for the purpose of restricting the claimed subject matter. It is also expressly noted that the dimensions and the shapes of the components shown in the figures are designed to help to understand how the present teachings are practiced, but not intended to limit the dimensions and the shapes shown in the examples.
The various embodiments described herein relate to the field of PV cells. In an embodiment, a tunneling layer with specific properties is integrated with a MIS stack to form a TPV device. Specifically, PV cells that incorporate a tunneling layer in an MIS structure to improve efficiency. In p-n junction-based PV cells, electrons and holes are extracted by drift/diffusion. By contrast, charge carriers are extracted by quantum mechanical tunneling through the insulator layer in a TPV. The charge carriers may be electrons or holes, depending on the particular TPV structure. Since the tunneling occurs very quickly, typically on the order of picoseconds, the optically-generated carriers will not have a chance to recombine as they are extracted rapidly. This is because recombination typically occurs within the range of microseconds to milliseconds, much more slowly than tunneling. Additionally, absence of the p-n junction used in standard PV cells reduces recombination in the space charge region, further boosting the efficiency.
Interfacial layer 102 comprises SiOX in an embodiment. Interfacial layer 102 can also comprise Si3N4, other nitride, oxynitride, chemical oxide, or similar compounds. Interfacial layer 102 may be intentionally doped to achieve a certain flat-band voltage (“VFB”) and adjust the zero-bias field.
Tunnel layer 103 is preferably a thin layer of high-κ material. In an embodiment, tunnel layer 103 comprises hafnium oxide (HfO2). In a preferred embodiment, tunnel layer 103 can be less than fifty angstroms. For example, the high-κ layer 103 can be between fifteen and fifty angstroms. For higher efficiency, the tunnel layer should have two properties that improve efficiency: (a) a low conduction band offset with the substrate conduction band, to allow high tunneling current; and (b) the tunnel material has a low effective electron mass, in general, less than 0.5 mo. Use of high-κ dielectrics as the tunnel layer in the TPV cell satisfies both requirements.
High-K materials, including hafnium oxide, have a smaller conduction band offset (φb) when compared to the conduction band of silicon and other semiconductors, and thus allow high levels of tunnel current with a larger physical thickness compared to the SiO2 used in the prior art. Therefore high-κ layer 103 does not have to be scaled as aggressively as would a SiO2 layer for providing a high tunnel current.
In addition to a lower barrier, high-κ materials such as hafnium oxide have a lower tunneling effective mass compared to SiO2, which makes tunneling more efficient for a given physical thickness. For example the tunneling effective mass meff of hafnium oxide is approximately 0.2 mo, where mo is the free electron mass. By contrast the effective mass meff of SiO2 is approximately 0.4 mo.
The high-κ dielectric allows efficient tunneling of electrons (holes) while providing an efficient barrier to recombination. The ISC can be modulated by altering the tunneling layer thickness and choice of material, which optimizes on the material's low band offset to the substrate material and low electron effective mass. Furthermore, ISC can be maximized independent of the VOC, which provides an additional degree of freedom in design and optimizing the output power.
Electrode layer 104, adjacent to tunnel layer 103 in this embodiment, is a collector layer having a low workfunction, for example, a metal, including aluminum, or doped cap layers, including titanium nitride (TiN). By using an electrode with appropriate workfunction, the VOC can be modulated, independent of ISC. The VOC can be tuned by the electrode workfunction and semiconductor doping level. The appropriate electrode workfunction is achieved in several different ways. An appropriate electrode workfunction can be achieved by using metals or alloys with low workfunction. Also, by using doped semiconductors and/or engineered capping layers containing materials such as titanium nitride, tantalum nitride, or similar compounds, interface charges can be created at the interface between the electrode layer 104 and the tunneling layer 103 to alter the workfunction. Similar techniques can also create interface charges at the interface between the tunneling layer 103 and the interfacial layer to alter the workfunction. Combinations of the above can be used as desired.
Furthermore, known absorption-enhancement technologies, for example antireflective coatings (AR), surface texturing, encapsulation, or passivation, can be readily applied to the TPV as well. Use of these techniques will further boost the cell efficiency. The TPV cell can thus effectively improve efficiency over known PVs without a significant increase in cost.
According to an alternative embodiment, semiconductor substrate 101 can N-type doped silicon substrate, rather than P-type doped silicon substrate. The use of an N-type doped semiconductor substrate may alter the selection of certain materials used to fabricate the interfacial layer, tunneling layer, and electrode layer. However, according to the embodiment, the tunneling layer is still a high-κ dielectric, for example hafnium oxide (HfO2).
According to another embodiment, other substrates with band gaps which enhance light absorption are used, such as Group III-V materials of the periodic table. Such III-V materials include gallium arsenide (GaAs) and indium phosphide (InP).
According to alternative embodiments, other high-κ dielectric compounds can be used in place of hafnium oxide (HfO2). Suitable compounds include metal oxides with a large bandgap and a high dielectric constant, such as titanium dioxide (TiO2), aluminum oxide (Al2O3), lanthanum oxide (La2O3), zirconium oxide (ZrO2), tantalum oxide (Ta2O5), nitrided hafnium silicates (HfSiON), silicates such as zirconium silicate (ZrSiO4), and other compounds with similar properties.
With the disclosed optimized deposition process, which includes ALD accompanied by various surface preparation and interface layers, as well as pre- and post-deposition annealing, the surface trap charge density is lowered so that generated carriers are not lost to recombination in the surface charge traps prior to tunneling. This results in the described TPV cell having a greater internal quantum efficiency than a conventional silicon PV cell. Additionally, VOC and ISC can be independently tuned to maximize power output.
According to an alternative embodiment, step 201 comprises providing an N-doped silicon substrate. Use of an N-doped silicon substrate will require other steps to be somewhat altered to take account of tunneling by holes through the tunneling layer, and their subsequent collection at the metal/alloy stack electrode, as well as the collection of electrons at the back contact electrode that is connected to the N-doped silicon substrate.
The TPV cell illustrated in
Although various embodiments have been described with respect to specific examples and subsystems, it will be apparent to those of ordinary skill in the art that the concepts disclosed herein are not limited to these specific examples or subsystems but extends to other embodiments as well. Included within the scope of these concepts are all of these other embodiments as specified in the claims that follow.
This application claims priority to the following provisional patent applications: Ser. No. 61/527,845, filed on Aug. 26, 2011; Ser. No. 61/528,710, filed on Aug. 29, 2011; and Ser. No. 61/560,741, filed on Nov. 16, 2011. Priority to these provisional applications is expressly claimed, and the disclosures of the provisional applications are hereby incorporated herein by reference in their entirety.
Number | Date | Country | |
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61527845 | Aug 2011 | US | |
61528710 | Aug 2011 | US | |
61560741 | Nov 2011 | US |