Characteristics of p-type nanocrystalline silicon thin films developed for window layer of solar cells

Different rf-power and chamber pressures have been used to deposit boron doped hydrogenated silicon films by the PECVD method. The optoelectronic and structural properties of the silicon films have been investigated. With the increase of power and pressure the crystallinity of the films increases while the absorption decreases. As a very thin p-layer is needed in p–i–n thin film solar cells the variation of properties with film thickness has been studied. The fraction of crystallinity and thus dark conductivity vary also with the thickness of the film. Conductivity as high as 2.46 S cm⁻¹ has been achieved for 400 Å thin film while for 3000 Å thick film it is 21 S cm⁻¹. Characterization of these films by XRD, Raman Spectroscopy, TEM and SEM indicate that the grain size, crystalline volume fraction as well as the surface morphology of p-layers depend on the deposition conditions as well as on the thickness of the film. Optical band gap varies from 2.19 eV to 2.63 eV. The thin p-type crystalline silicon film with high conductivity and wide band gap prepared under high power and pressure is suitable for application as window layer for Silicon thin film solar cells.     

Effect of tellurium deposition rate on the properties of Cu–In–Te based thin films and solar cells

To investigate the effects of tellurium (Te) deposition rate on the properties of Cu–In–Te based thin films (Cu/In=0.30–0.31), the films were grown on both bare and Mo-coated soda-lime glass substrates at 200 °C by co-evaporation using a molecular beam epitaxy system. The microstructural properties were examined by means of scanning electron microscopy and X-ray diffraction. The crystalline quality of the films was improved with increase in the deposition rate of Te, and exhibited a single CuIn₃Te₅ phase with a highly preferred (1 1 2) orientation. Te-deficient film (Te/(Cu+In)=1.07) grown with a low Te deposition rate showed a narrow bandgap of 0.99 eV at room temperature. The solar cell performance was affected by the deposition rate of Te. The best solar cell fabricated using CuIn₃Te₅ thin films grown with the highest deposition rate of Te (2.6 nm/s) yielded a total area (0.50 cm²) efficiency of 4.4% (V_oc=309 mV, J_sc=28.0 mA/cm², and FF=0.509) without light soaking.     

Deposition of phosphorus doped a-Si:H and μc-Si:H using a novel linear RF source

A roll-to-roll PECVD system for thin film silicon solar cells on steel foil has been developed by ECN in collaboration with Roth and Rau AG. It combines MW–PECVD for fast deposition of intrinsic Si and novel linear RF sources, which apply very mild deposition conditions, for the growth of doped Si layers. The RF and MW sources can be easily scaled up to deposition widths of up to 150 cm. Here, we report on n-type doping, achieved by RF–PECVD from a H₂/SiH₄/PH₃ mixture in the reaction chamber. The best n-type a-Si:H layers showed E_act = 0.27 eV and σ_d = 2.7 × 10^?3 S/cm. Also thin layers down to 20 nm were of device quality and were deposited at a rate of 0.4 Å/s. Furthermore, n-type μc-Si:H layers with thicknesses of 150 nm, with E_act = 0.034 eV and σ_d = 2 S/cm were grown. Good quality n-type μc-Si:H layers can be made for layer thicknesses down to 50 nm at a rate of 0.15 Å/s. To conclude, the novel RF source is well-suited for the growth of n-doped a-Si:H and μc-Si:H layers for roll-to-roll solar cell production.     

Hydrogenated amorphous and nanocrystalline silicon solar cells deposited by HWCVD and RF-PECVD on plastic substrates at 150 °C

In this work we present a study of the structural, optoelectronic and transport properties of a series of Si films deposited in a parameter region (namely hydrogen dilution) corresponding to a transition from amorphous-to-nanocrystalline silicon by hot-wire (HW) and radio-frequency plasma enhanced chemical vapor deposition (RF) on plastic substrates at 150 °C. To achieve a higher deposition rate of Si films by RF we used a relatively high power density (350 mW/cm²) and deposition pressure (1.5 Torr). For certain hydrogen dilution values, these deposition conditions can lead to the formation of Si crystals in the silane plasma and to a growth of polymorphous silicon film. This material has improved carrier transport properties (ambipolar diffusion length = 220 nm) and very high photosensitivity (>5 × 10⁶). The best HW amorphous silicon films exhibited lower photosensitivity (7 × 10⁴) and an ambipolar diffusion length of only 100 nm. For solar cell fabrication, we optimized the RF deposition conditions to produce very thin amorphous and nanocrystalline phosphorous and boron doped silicon layers. Our best n–i–p solar cell, with a polymorphous Si intrinsic layer deposited on plastic, has an efficiency of 5.5%, FF = 52.5%, V_OC = 920 mV, J_SC = 11.6 mA/cm². For solar cells with a nanocrystalline Si active layer deposited on glass the following results were achieved: efficiency = 3.4%, FF = 43.5%, V_OC = 460 mV, J_SC = 17.2 mA/cm²; and on plastic substrate: efficiency = 2.2%, FF = 32.7%, V_OC = 397 mV, J_SC = 17.2 mA/cm².     

Fast quantum efficiency measurement of solar cells by Fourier transform photocurrent spectroscopy

Fourier Transform Photocurrent Spectroscopy (FTPS) was introduced four years ago as a method providing fast and highly sensitive evaluation of the spectral dependence of the photoconductive thin film optical absorption coefficient. Recently the method was also applied to the quality assessment of thin film silicon solar cells. In this contribution, we present the FTPS characterization of various thin film solar cells to provide a rapid quantum efficiency (QE) measurement. Furthermore, we study the possibility of the FTPS–QE measurement of a single cell incorporated in the solar module when only the module terminals can be used for connection. FTPS results are compared to lengthy standard QE measurements. The homogeneity study was done for a-Si:H single junction solar module (30 × 30 cm) consisting of 27 series-connected subcells. The QE–FTPS measurement is proved to be very fast, enabling a quick verification of the light intensity dependence or the influence of the forward and reverse bias on QE results over the whole measured spectral range (400–1200 nm).     

Annealing in water vapor as a new method for improvement of silicon thin film properties

Electronic properties of poly-Si thin films fabricated by atmospheric pressure chemical vapor deposition (APCVD) were improved by annealing in H₂O or D₂O vapors. Hall mobility was improved from 4.45 cm⁻²/V s to 25.1 cm⁻²/V s after 1 h D₂O vapor treatment at 300 °C, i.e., nearly the same value as after optimized plasma hydrogenation. Unlike the hydrogen plasma treatment, annealing did not introduce disorder into the material, judged by the width of Raman LO-TO band. Water vapor treatment is a novel approach to improvement of thin films properties, with potentially low cost suitable for mass production of solar cells, but its mechanism is not yet clear.     

Electrical conductivity and single oscillator model properties of amorphous CuSe semiconductor thin film

The structural, optical dispersion and electrical conductivity properties of the CuSe thin film have been investigated using X-ray diffraction, electrical and optical characterization methods. X-ray diffraction results indicate that CuSe thin film has an amorphous structure. The electrical conductivity of the CuSe film increases with increasing temperature. The activation energy and room temperature conductivity values of the film were found to be 1.32 meV and 3.89 × 10⁻³ S/cm, respectively. The refractive index dispersion of the thin film obeys the single oscillator model and single oscillator parameters were determined. The E_o, n_∞, and S_o values of the CuSe thin film were found to be 5.08 eV, 3.55 and 1.92 × 10¹⁴ m⁻², respectively. The obtained results suggest that CuSe film is an amorphous semiconductor.     

Mapping of mechanical stress in silicon thin films on silicon cantilevers by Raman microspectroscopy

We have used plasma enhanced chemical vapor deposition (PECVD) to deposit silicon thin films (～0.2–1 μm) with different crystallinity fractions on Nanosensors PtIr5 coated atomic force microscopy (AFM) cantilevers (450 × 50 × 2 μm³). Microscopic measurements of Raman scattering were used to map both internal stress and extrinsic stress induced in the films by bending the cantilevers using a nanomanipulator (Kleindiek Nanotechnik MM3A). Thanks to the excellent elasticity of the cantilevers, the films could be bent to curvature radii down to 300 μm. We observed the stress induced shift of the TO–LO phonon Raman band of more than 3 cm^?1 for fully microcrystalline film corresponding to the stress ～0.8 GPa. The shift of the similar film with amorphous structure was ～2.5 cm^?1.     

Insights into effects of annealing on microstructure from SnO2 thin films prepared by pulsed delivery

Tin dioxide thin films were prepared by pulsed laser deposition techniques on clean glass substrates, and the thin films were then annealed for 30 min from 50 to 550 °C with a step of 50 °C, respectively. The influence of the annealing temperature on the microstructural and morphological properties of the tin dioxide thin films was investigated using X-ray diffraction, scanning electron microscopy, transmission electron microscopy and selected area electron diffraction. The experimental results showed that the amorphous microstructure almost transformed into a polycrystalline tin dioxide phase exhibiting a preferred orientation related to the (1 1 0), (1 0 1) and (2 1 1) crystal planes with increased temperatures. The thin film annealed at 200 °C demonstrated the best crystalline properties, viz. optimum growth conditions. However, the thin film annealed at 100 °C revealed the minimum average root-mean-square roughness of 20.6 nm with average grain size of 26.6 nm. These findings indicate that the annealing temperature is very important parameter to determining the thin film quality, which involves the phase formation, microstructure and preferred orientation of the thin films.     

Preparation of indium tin oxide thin films without external heating for application in solar cells

Indium tin oxide (ITO) films were grown without external heating in an ambient of pure argon by RF-magnetron sputtering method. The influence of argon ambient pressure on the electro-optical properties of as-deposited ITO films was investigated. The morphology, structural and optical properties of ITO films were examined and characterized by X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), atomic force microscopy (AFM) and UV–VIS transmission spectroscopy. The deposited ITO films with a thickness of 300 nm show a high transparency between 80% and 90% in the visible spectrum and 14–120 Ω/□ sheet resistance under different conditions. The ITO films deposited in the optimum argon ambient pressure were used as transparent electrical contacts for thin film Cu(In,Ga)Se₂ (CIGS) solar cells. CIGS solar cells with efficiencies of the order of 7.0% were produced without antireflective films. The results have demonstrated that the developed ITO deposition technology has potential applications in thin film solar cells.     

Characterization of CdTe thin films fabricated by close spaced sublimation technique and a study of Cu doping by ion exchange process

CdTe thin films were prepared onto water-white glass substrates by the close spaced sublimation technique. The films annealed right after the deposition were then immersed in copper nitrate solution for different periods of time. These films were again annealed at 500 ^oC for 1 h to ensure the diffusion of copper in the films. The samples were characterized by X-ray diffraction and scanning electron microscopy. The electron microprobe analyzer showed an increase of copper-content in composition. The dc electrical conductivity showed a credible increase with increasing copper-content in the films. With the increase of copper-content, the hole mobility increased systematically. The optical parameters were deduced by fitting the optical transmittance in the wavelength range 300–2500 nm.     

Toward the fast deposition of highly crystallized microcrystalline silicon films with low defect density for Si thin-film solar cells

In this study, employing a high-density, low-temperature SiH₄–H₂ mixture microwave plasma, we investigate the influence of source gas supply configuration on deposition rate and structural properties of microcrystalline silicon (μc-Si) films, and demonstrate the plasma parameters for fast deposition of highly crystallized μc-Si films with low defect density. A fast deposition rate of 65 Å/s has been achieved for a SiH₄ concentration of 67% diluted in H₂ with a high Raman crystallinity of X_c > 65% and a low defect density of (1–2) × 10¹⁶ cm⁻³ by adjusting source gas supply configuration and plasma conditions. A sufficient supply of deposition precursors, such as SiH₃, as well as atomic hydrogen H on film growing surface is effective for the high-rate synthesis of highly crystallized μc-Si films, for the reduction in defect density, and for the improvement in film homogeneity and compactability. A preliminary result of p–i–n structure μc-Si thin-film solar cells using the resulting μc-Si films as an intrinsic absorption layer is presented.     

Thin film membrane based on a-SiGe: B and MEMS technology for application in cochlear implants

In this work is presented the fabrication of a thin film membrane as a bio-transducer for aural assistance detection, therefore it will operate at low pressure. The resonant membrane was deposited by PECVD technique at low temperature of deposition T = 270 °C, using SiH₄, GeH₄, and Boron gases. The membrane was suspended on a micromachined crystalline silicon frame obtained by wet chemical etching. The a-SiGe:B film presented a resistivity of 2.46 × 10³ (Ω-cm), resistance of 20.8 kΩ. Using these experimental data we succeeded in designing a simple structure for sensing low pressure variations. The output voltage of the sensor was measured for a range of pressure from 0 to 3000 Pa and at bias voltage of 10 V.     

Fabrication and characterization of nanorod solar cells with an ultrathin a-Si:H absorber layer

In this paper, we present a three-dimensional nanorod solar cell design. As the backbone of the nanorod device, density-controlled zinc oxide (ZnO) nanorods were synthesized by a simple aqueous solution growth technique at 80 °C on ZnO thin film pre-coated glass substrate. The as-prepared ZnO nanorods were coated by an amorphous hydrogenated silicon (a-Si:H) light absorber layer to form a nanorod solar cell. The light management, current–voltage characteristics and corresponding external quantum efficiency of the solar cells were investigated. An energy conversion efficiency of 3.9% was achieved for the nanorod solar cells with an a-Si:H absorber layer thickness of 75 nm, which is significantly higher than the 2.6% and the 3.0% obtained for cells with the same a-Si:H absorber layer thickness on planar ZnO and on textured SnO₂:F counterparts, respectively. A short-circuit current density of 11.6 mA/cm² and correspondingly, a broad external quantum efficiency profile were achieved for the nanorod device. An absorbed light fraction higher than 80% in the wavelength range of 375–675 nm was also demonstrated for the nanorod solar cells, including a peak value of ~ 90% at 520–530 nm.     

Thin film silicon modules on plastic superstrates

The aim of this research is to fabricate high efficiency a-Si/μc-Si tandem solar cell modules on flexible (polymer) superstrates using the Helianthos concept. As a first step we began by depositing the top cell which contains an amorphous silicon (a-Si:H) i-layer of ～350 nm made by VHF PECVD at 50 MHz in a high vacuum multichamber system called ASTER, with hydrogen to silane gas flow ratio of 1:1. Such amorphous cells on-foil showed an initial active area (0.912 cm²) efficiency of 7.69% (V_oc = 0.834 V, FF = 0.71). These cells were light soaked with white light at a controlled temperature of 50 °C. The efficiency degradation was predominantly due to degradation of FF that amounted to only 11% after 1000 h of light soaking. The cell-on-foil data prove that thin film silicon modules of high stability on cheap plastics can be made at a reasonable efficiency within 30 min of deposition time. A minimodule of 8 × 7.5 cm² area (consisting of 8 cells interconnected in series) with the same single junction a-Si:H p–i–n structure had an initial efficiency of 6.7% (V_oc = 6.32 V, FF = 0.65).     

Investigation of surface treatment effect of catalyst on the lifetime for Cat-CVD method

In case of amorphous silicon (a-Si) film deposition by catalytic chemical vapor deposition (Cat-CVD) method, a metal catalyzing wire is converted to silicide and this silicidation causes shortening lifetime of the catalyzing wire. In the present work, the effect of surface carbonization of catalyzing wire against silicide formation is investigated to obtain long-life catalyzer. Characteristics of a-Si film deposited by carbonized tungsten (W) catalyzer are also investigated. Silicide layer thickness formed on carbonized catalyzing wires after 60 min a-Si film deposition decreases to half of that on uncarbonized wires. Device quality a-Si films having defect density less than 4 × 10¹⁵ cm^?3 are obtained by using carbonized W, indicating that surface carbonization of W catalyzer is effective process for industrial application of Cat-CVD method.     

Photonic and plasmonic crystal based enhancement of solar cells — Theory of overcoming the Lambertian limit

We develop a new conformal nc-Si solar cell architecture that has a periodic plasmonic back-reflector of tapered nano-pillars. Using rigorous scattering matrix simulations, we show that the optimized solar architecture has absorption that can exceed the classical 4n² limit, or the Lambertian limit of absorption by a randomly roughened back-reflector, for common thicknesses of the nc-Si absorber layer upto 1500 nm in thickness. The optimized solar architecture has pitch between 500 and 900 nm and tapered pillar heights of ~ 200 nm. The conformal solar cell geometry minimizes the reflection loss at the top surface. The enhancement over the classical limit is provided by light concentration and waveguide modes or diffraction resonances within the absorber layer. Nc-Si cells of 1000 nm thickness may generate short circuit currents in excess of 32 mA/cm², where the enhancement is more than 60% relative to a flat silver back-reflector. Sources of losses in solar cells and are identified.     

Nanocrystalline silicon TFT process using silane diluted in argon–hydrogen mixtures

We have investigated the effect of Ar dilution on the deposition process of intrinsic nc-Si:H (hydrogenated nanocrystalline silicon) thin films used as active layers of top-gate TFTs, in order to improve the TFTs performances. The nc-Si:H films were deposited by plasma enhanced chemical vapor deposition (PECVD) at low temperature (165 °C) and the related TFTs were fabricated with a maximum process temperature of 200 °C. During the nc-Si:H films deposition, the SiH₄ fraction and the total flow of the diluting gases Ar + H₂ mixture was kept constant, H₂ being substituted by Ar. We have pointed out the active role played by the metastable states of excited Ar atoms in both the dissociation of SiH₄ and H₂ by quenching reactions in the plasma. The role of the atomic hydrogen during the film deposition seems to be promoted by the addition of argon into the discharge, leading to an increase of the deposition rate by a factor of about three and an enhancement of the crystalline quality of the nc-Si:H films. This effect is maximized when the Ar fraction in the Ar + H₂ gases mixture reaches 50%. The evolution with Ar addition of the carriers mobility of the related TFTs is closely connected to the evolution of the crystalline fraction of the intrinsic nc-Si:H film. Mobilities values as high as 8 cm² V^?1 s^?1 are obtained at the Ar fraction of 50%. For higher Ar fractions, the fall of the mobility comes with a degradation of the I_D–V_G transfer characteristics of the processed TFTs due to a degradation of the nc-Si:H films quality. OES measurements show that the evolution of the H_α intensity is closely connected to the evolution of the deposition rate, intrinsic films crystalline fraction and TFTs mobility, providing an interesting tool to monitor the TFTs performances.     

The effect of Tb doped PbTiO3 inducing layer on texture and tunable property of sol–gel derived Pb0.4Sr0.6TiO3 thin films grown on ITO/glass substrate

Highly (1 0 0)-oriented Pb_0.4Sr_0.6TiO₃ (PST40) thin films have been prepared on the Tb doped PbTiO₃ (PTT) thin film coated ITO/glass substrate by sol–gel technique. The PTT inducing layers are (1 0 0)-oriented and can help to control the orientation of PST40 thin films. Crystallization of the PST40 thin film with the PTT inducing layer is more perfect than that without PTT layer due to less distortion in the thin film. The dielectric tunability of the PST40 thin film with PTT layer therefore reaches 65%, which is 85% higher than that without PTT layer. The dielectric loss of the PST thin film is only 0.05. These results indicate that (1 0 0)-oriented Tb doped PbTiO₃ can be used as an inducing layer for highly (1 0 0)-oriented tunable materials on ITO/glass substrate.     

Fabrication and ionic conductivity of amorphous Li–Al–Ti–P–O thin film

Li⁺ ion conducting Li–Al–Ti–P–O thin films were fabricated on ITO-glass substrates at various temperatures from 25 to 400 °C by RF magnetron sputtering method. When the substrate temperature is higher than 300 °C, severe destruction of ITO films were confirmed by XRD (X-ray diffraction) and the abrupt transformation of one semi-circle into two semi-circles on the impedance spectra. These as-deposited Li–Al–Ti–P–O solid state electrolyte thin films have an amorphous structure confirmed by XRD and a single semicircle on the impedance spectra. Good transmission higher than 80% in the visible light range of these electrolyte thin films can fulfill the demand of electro-chromic devices. Field emission scanning electron microscopy and atomic force microscopy showed the denser, smoother and more uniform film structure with the enhanced substrate temperature. Measurements of impedance spectra indicate that the gradual increased conductivity of these Li–Al–Ti–P–O thin films with the elevation of substrate temperature from room temperature to 300 °C is originated from the increase of the pre-exponential factor (σ₀). The largest Li-ion conductivity can come to 2.46 × 10^? 5 S cm^? 1. This inorganic solid lithium ion conductor film will have a potential application as an electrolyte layer in the field such as lithium batteries or all-solid-state EC devices.