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Title: High Efficiency Narrow Gap and Tandem Junction Devices: Final Technical Report, 1 May 2002--31 October 2004

Abstract

The work described in this report uses a modified pulsed plasma-enhanced chemical vapor deposition (PECVD) technique that has been successfully developed to fabricate state-of-the-art nc-Si materials and devices. Specifically, we have achieved the following benchmarks: nc SiH device with an efficiency of 8% achieved at a deposition rate of {approx}1 A/s; nc SiH device with an efficiency of 7% achieved at a deposition rate of {approx}5 A/s; large-area technology developed using pulsed PECVD with uniformity of +/-5% over 25 cm x 35 cm; devices have been fabricated in the large-area system (part of Phase 3); an innovative stable four-terminal (4-T) tandem-junction device of h> 9% fabricated. (Note that the 4-T device was fabricated with existing technology base and with further development can reach stabilized h of 12%); and with improvement in Voc {approx} 650 mV, from the current value of 480 mV can lead to stable 4-T device with h>16%. Toward this objective, modified pulsed PECVD was developed where layer- by-layer modification of nc-SiH has been achieved. (Note that due to budget cuts at NREL, this project was curtailed by about one year.)

Authors:
Publication Date:
Research Org.:
National Renewable Energy Lab., Golden, CO (US)
Sponsoring Org.:
US Department of Energy (US)
OSTI Identifier:
15011482
Report Number(s):
NREL/SR-520-37718
ZDJ-2-30630-31; TRN: US200507%%328
DOE Contract Number:
AC36-99-GO10337
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 1 Mar 2005; Related Information: Work performed by MVSystems, Inc., Golden, Colorado
Country of Publication:
United States
Language:
English
Subject:
14 SOLAR ENERGY; 36 MATERIALS SCIENCE; BENCHMARKS; CHEMICAL VAPOR DEPOSITION; DEPOSITION; EFFICIENCY; MODIFICATIONS; ORGANIC COMPOUNDS; VOLATILE MATTER; PV; MODULE; SOLAR CELLS; MANUFACTURER; DEVICE; NANO-CRYSTALLINE SILICON (NC-SI); CONTINUOUS WAVE (CW); QUANTUM EFFICIENCY (QE); TANDEM JUNCTIONS; LARGE AREA; SOLAR ENERGY - PHOTOVOLTAICS

Citation Formats

Madan, A. High Efficiency Narrow Gap and Tandem Junction Devices: Final Technical Report, 1 May 2002--31 October 2004. United States: N. p., 2005. Web. doi:10.2172/15011482.
Madan, A. High Efficiency Narrow Gap and Tandem Junction Devices: Final Technical Report, 1 May 2002--31 October 2004. United States. doi:10.2172/15011482.
Madan, A. Tue . "High Efficiency Narrow Gap and Tandem Junction Devices: Final Technical Report, 1 May 2002--31 October 2004". United States. doi:10.2172/15011482. https://www.osti.gov/servlets/purl/15011482.
@article{osti_15011482,
title = {High Efficiency Narrow Gap and Tandem Junction Devices: Final Technical Report, 1 May 2002--31 October 2004},
author = {Madan, A},
abstractNote = {The work described in this report uses a modified pulsed plasma-enhanced chemical vapor deposition (PECVD) technique that has been successfully developed to fabricate state-of-the-art nc-Si materials and devices. Specifically, we have achieved the following benchmarks: nc SiH device with an efficiency of 8% achieved at a deposition rate of {approx}1 A/s; nc SiH device with an efficiency of 7% achieved at a deposition rate of {approx}5 A/s; large-area technology developed using pulsed PECVD with uniformity of +/-5% over 25 cm x 35 cm; devices have been fabricated in the large-area system (part of Phase 3); an innovative stable four-terminal (4-T) tandem-junction device of h> 9% fabricated. (Note that the 4-T device was fabricated with existing technology base and with further development can reach stabilized h of 12%); and with improvement in Voc {approx} 650 mV, from the current value of 480 mV can lead to stable 4-T device with h>16%. Toward this objective, modified pulsed PECVD was developed where layer- by-layer modification of nc-SiH has been achieved. (Note that due to budget cuts at NREL, this project was curtailed by about one year.)},
doi = {10.2172/15011482},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Mar 01 00:00:00 EST 2005},
month = {Tue Mar 01 00:00:00 EST 2005}
}

Technical Report:

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  • The key objective of this subcontract was to take the first steps to extend the radio-frequency plasma-enhanced chemical vapor deposition (RF-PECVD) manufacturing technology of Energy Photovoltaics, Inc. (EPV), to the promising field of a-Si/nc-Si solar cell fabrication by demonstrating ''proof-of-concept'' devices of good efficiencies that previously were believed to be unobtainable in single-chamber reactors owing to contamination problems. A complementary goal was to find a new high-rate deposition method that can conceivably be deployed in large PECVD-type reactors. We emphasize that our goal was not to produce 'champion' devices of near-record efficiencies, but rather, to achieve modestly high efficiencies usingmore » a far simpler (cheaper) system, via practical processing methods and materials. To directly attack issues in solar-cell fabrication at EPV, the nc-Si thin films were studied almost exclusively in the p-i-n device configuration (as absorbers or i-layers), not as stand-alone films. Highly efficient, p-i-n type, nc-Si-based solar cells are generally grown on expensive, laboratory superstrates, such as custom ZnO/glass of high texture (granular surface) and low absorption. Also standard was the use of a highly effective back-reflector ZnO/Ag, where the ZnO can be surface-textured for efficient diffuse reflection. The high-efficiency ''champion'' devices made by the PECVD methods were invariably prepared in sophisticated (i.e., expensive), multi-chamber, or at least load-locked deposition systems. The electrode utilization efficiency, defined as the surface-area ratio of the powered electrode to that of the substrates, was typically low at about one (1:1). To evaluate the true potential of nc-Si absorbers for cost-competitive, commercially viable manufacturing of large-area PV modules, we took a more down-to-earth approach, based on our proven production of a-Si PV modules by a massively parallel batch process in single-chamber RF-PECVD systems, to the study of nc-Si solar cells, with the aim of producing high-efficiency a-Si/nc-Si solar cells and sub-modules.« less
  • This report covers the second year of a two-year research effort to develop back-surface, point-contact solar cells in the GaAs system for use in concentrators with up to 1000 suns illumination. In the first year, a modeling code for Si point-contact cells was applied to simulate the performance of a point-contact GaAs cell. The second-year goal was solved by using an electrochemical etching procedure borrowed from photocathode and LED technology. AlGaAs layers as thin as 2 micrometers have been removed intact from GaAs substrates in less than 2 hours. The means of forming the n /sup +/ and p/sup +/more » regions of the point-contact structures was changed from ion implantation selective epitaxial regrowth, to permit a single metallization step. The mask set for placing contacts was improved to facilitate processing. The ability to fabricate cells that have the potential to reach 30% conversion efficiency now seems to be within reach. 9 refs., 16 figs.« less
  • The overall objective of this subcontract over its two-year duration is to continue the advancement of Energy Photovoltaics, Inc.'s (EPV) a-Si production manufacturing technology and improve the production equipment used in manufacturing. This will allow EPV to reduce module costs by increasing module output, throughput, and yield. EPV conducted parallel research efforts for achieving higher stabilized module power output through improvements in several manufacturing processing steps, with particular emphasis on the thin-film deposition process. The dual goals of achieving a 20% gain in stabilized output and a 20% reduction in direct costs were accomplished. The 20% gain in stabilized outputmore » increased the power of the standard 0.79 m2 module to about 45 watts. This was achieved through optimizing the a-Si deposition process to improve stability, increasing the active area of the module, and developing a ZnO/Al back reflector to increase the light absorption of the a-Si. Additionally, improvements were made to the a-Si uniformity, and an improved TCO was incorporated into the standard product. The goal of reducing costs by 20% was exceeded, resulting in an estimated direct cost of $1.41/W, for the process in EPV's New Jersey facility. This was accomplished through a complete review of the process that resulted in lower material costs, lower labor costs, less downtime, and higher module power, as noted above. The process was streamlined and made more efficient by eliminating or combining process steps, and selected processes were automated. In addition, improvements were made to the characterization and measurement techniques used in the module optimization process.« less
  • This report contains results of research designed to fabricate single-junction p-i-n solar cells with 12% efficiency at air-mass 1 with an area of about 1 cm/sup 2/ and submodules of interconnected single-junction cells with 8% efficiency and areas of about 1000 cm/sup 2/. An objective was to control light-induced degradation to less than 2% over 720 hours of AMl illumination. A secondary objective was to design, construct, and operate a multichamber deposition system that would deposit p-i-n cells over an area of 1000 cm/sup 2/. The best efficiency obtained was 10.8% with a small-area cell (0.08 cm/sup 2/). The bestmore » stabilities and efficiencies were obtained with conventional p-i-n a-SiC:H/a-Si:H heterostructures, p-i-n/p-i-n tandem cells, and structures containing transitional affinity-graded i-layers. Small- and large-area efficiencies stayed below performance goals by about 1%, however. The multichamber deposition system was designed and operated, but a problem remained with boron contamination of the i-layer that should be investigated further. 23 refs., 53 figs., 19 tabs.« less
  • This report contains results of research designed to fabricate single-junction p-i-n solar cells with 12% efficiency at air-mass 1 with an area of about 1 cm{sup 2} and submodules of interconnected single-junction cells with 8% efficiency and areas of about 1000 cm{sup 2}. An objective was to control light-induced degradation to less than 2% over 720 hours of AMl illumination. A secondary objective was to design, construct, and operate a multichamber deposition system that would deposit p-i-n cells over an area of 1000 cm{sup 2}. The best efficiency obtained was 10.8% with a small-area cell (0.08 cm{sup 2}). The bestmore » stabilities and efficiencies were obtained with conventional p-i-n a-SiC:H/a-Si:H heterostructures, p-i-n/p-i-n tandem cells, and structures containing transitional affinity-graded i-layers. Small- and large-area efficiencies stayed below performance goals by about 1%, however. The multichamber deposition system was designed and operated, but a problem remained with boron contamination of the i-layer that should be investigated further. 23 refs., 53 figs., 19 tabs.« less