Core-shell nanoparticles for photovoltaic absorber films

Abstract

A method for the preparation of CIGS-type core-shell nanoparticles produces core-shell nanoparticles that may include a quaternary or ternary metal chalcogenide core. The core may be substantially surrounded by a binary metal chalcogenide shell. A core-shell nanoparticle may be deposited on a PV cell contact (e.g., a molybdenum electrode) via solution-phase deposition. The deposited particles may then be melted or fused into a thin absorber film for use in a photovoltaic device.

Claims

1. A photovoltaic device comprising: a support; a substrate layer on the support; an absorber layer on the substrate layer, the absorber layer comprising: a matrix having one or more of Cu, In and Ga and one or more of S and Se; and a plurality of core nanoparticles dispersed throughout the matrix, the core nanoparticles comprising a metal chalcogenide having the formula
AB.sub.1-xB.sub.xC.sub.2-yC.sub.y wherein A is Cu, Zn, Ag or Cd; B and B are Al, In or Ga; C and C are S, Se or Te; 0x1; 0y2; B and B are not the same element; and C and C are not the same element.

2. The photovoltaic device recited in claim 2 further comprising a layer comprising an n-type semiconductor on top of the absorber layer.

3. The photovoltaic device recited in claim 2 further comprising a layer comprising a transparent conductor on the layer comprising the n-type semiconductor.

4. The photovoltaic device recited in claim 3 wherein the transparent conductor is any one of aluminum zinc oxide or indium tin oxide.

5. The photovoltaic device recited in claim 4 further comprising a contact layer comprising a metal selected from the group consisting of aluminum, nickel and alloys of nickel and aluminum.

6. The photovoltaic device recited in claim 1 wherein the support is selected from the group consisting of glass, silicon and organic polymers.

7. The photovoltaic device recited in claim 1 wherein the matrix comprises any one of CuInSSe and CuInGaSSe.

8. The photovoltaic device recited in claim 1 wherein the plurality of core nanoparticles are CuIn.sub.1-xGa.sub.xS.sub.2-ySe.sub.y core nanoparticles.

9. The photovoltaic device recited in claim 1 wherein the plurality of core nanoparticles are CuInGaSe core nanoparticles.

10. A composition of matter, the composition comprising: a matrix having one or more of Cu, In and Ga and one or more of S and Se; and a plurality of core nanoparticles dispersed throughout the matrix, the core nanoparticles comprising a metal chalcogenide having the formula
AB.sub.1-xB.sub.xC.sub.2-yC.sub.y wherein A is Cu, Zn, Ag or Cd; B and B are Al, In or Ga; C and C are S, Se or Te; 0x1; 0y2; B and B are not the same element; and C and C are not the same element.

11. The composition recited in claim 10 wherein the matrix comprises any one of CuInSSe and CuInGaSSe.

12. The composition recited in claim 10 wherein plurality of core nanoparticles are CuIn.sub.1-xGa.sub.xS.sub.2-ySe.sub.y.

13. The composition recited in claim 10, wherein the plurality of core nanoparticles are CuInGaSe core nanoparticles.

14. A method of forming an absorber layer in a photovoltaic device having a substrate comprising: coating a film of ink onto the substrate, the ink containing a plurality of CIGS-type core-shell nanoparticles, each CIGS-type core-shell nanoparticle comprising: a core having the formula
AB.sub.1-xB.sub.xC.sub.2-yC.sub.y where A is Cu, Zn, Ag or Cd; B and B are Al, In or Ga; C and C are S, Se or Te; 0x1; 0y2; B and B are not the same element; and C and C are not the same element; and a shell substantially surrounding the core, the shell comprising a binary metal chalcogenide having the formula M.sub.xE.sub.y, where M is a metal and E is a chalcogen; and heating the coated substrate to cause the shells of the CIGS-type core-shell nanoparticles to react and form a matrix having the cores of the CIGS-type core-shell nanoparticles dispersed therein.

15. The method recited in claim 14 further comprising heating the coated substrate in the presence of a selenium-containing gas.

16. The method recited in claim 14, wherein the shells of the CIGS-type core-shell nanoparticles comprising one or more Cu, In, and Ga and one or more of S and Se.

17. The method of claim 14, wherein the cores of the CIGS-type core-shell nanoparticles are CuIn.sub.1-xGa.sub.xS.sub.2-ySe.sub.y cores.

18. The method recited in claim 14, wherein the cores of the CIGS-type core-shell nanoparticles are CuInGaSe cores.

19. The method of claim 14, wherein the plurality of CIGS-type core-shell nanoparticles comprises CuInGaSe/CuS core-shell nanoparticles and CuInGaSe/InS core-shell nanoparticles.

20. The method of claim 14, wherein the matrix comprises any one of CuInSSe and CuInGaSSe.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0010] The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings. For the purpose of illustration only, there are shown in the drawings certain embodiments. It should be understood, however, that the inventive concepts disclosed herein are not limited to the precise arrangements and instrumentalities shown in the figures.

[0011] FIG. 1 is a schematic cross-section of a core-shell nanoparticle, in accordance with an embodiment of the invention.

[0012] FIG. 2 illustrates layers of a photovoltaic device, in accordance with an embodiment of the invention.

[0013] FIG. 3 is a flow chart including exemplary steps for forming layers of CIGS materials on a substrate using CIGS-type nanoparticle inks, in accordance with an embodiment of the invention.

[0014] FIG. 4 illustrates heating and selenizing a core-shell nanoparticle composition to form a CIGS thin film, in accordance with an embodiment of the invention.

[0015] FIG. 5 is a comparison of UV-Vis and photoluminescence spectra of unshelled CIGS nanoparticles versus CIGS/InS core-shell nanoparticles, in accordance with an embodiment of the invention.

[0016] FIG. 6 presents an ICP/OES elemental analysis of unshelled CIGS nanoparticles versus CIGS/InS core-shell nanoparticles, in accordance with an embodiment of the invention.

[0017] FIG. 7 presents an XRD analysis of unshelled CIGS nanoparticles compared to that of core-shell CIGS/InS nanoparticles, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Before explaining at least one embodiment in detail, it should be understood that the inventive concepts set forth herein are not limited in their application to the construction details or component arrangements set forth in the following description or illustrated in the drawings. It should also be understood that the phraseology and terminology employed herein are merely for descriptive purposes and should not be considered limiting.

[0019] It should further be understood that any one of the described features may be used separately or in combination with other features. Other invented formulations, methods, features, and advantages will be or become apparent to one with skill in the art upon examining the drawings and the detailed description herein. It is intended that all such additional formulations, methods, features, and advantages be protected by the accompanying claims.

[0020] All references cited in this application are hereby incorporated by reference in their entirety.

[0021] As used herein, CIGS, CIS, and CIGS-type are used interchangeably and each refer to materials represented by the formula AB.sub.1-xB.sub.xC.sub.2-yC.sub.y, where A is Cu, Zn, Ag or Cd; B and B are independently Al, In or Ga; C and C are independently S, Se or Te; 0x1; and 0y2. Example materials include CuInSe.sub.2; CuInxGa.sub.1-xSe.sub.2; CuGaSe.sub.2; ZnInSe.sub.2; ZnIn.sub.xGa.sub.1-xSe.sub.2; ZnGaSe.sub.2; AgInSe.sub.2; AgIn.sub.xGa.sub.1-xSe.sub.2; AgGaSe.sub.2; CuInSe.sub.2-yS.sub.y; CuIn.sub.xGa.sub.1-xSe.sub.2-yS.sub.y; CuGaSe.sub.2-yS.sub.y; ZnInSe.sub.2-yS.sub.y; ZnIn.sub.xGa.sub.1-xSe.sub.2-yS.sub.y; ZnGaSe.sub.2-yS.sub.y; AgInSe.sub.2-yS.sub.y; AgIn.sub.xGa.sub.1-xSe.sub.2-yS.sub.y; and AgGaSe.sub.2-yS.sub.y, where 0x1; and 0y2.

[0022] The present disclosure generally relates to the preparation of CIGS-type core-shell nanoparticles. In one embodiment, the core-shell nanoparticles include a quaternary or ternary metal chalcogenide core. In another embodiment, the core may be substantially surrounded by a binary metal chalcogenide shell. In yet another embodiment, a core-shell nanoparticle may be deposited on a PV cell contact (e.g., a molybdenum electrode) via solution-phase deposition. The deposited particles may then be melted or fused into a thin absorber film.

[0023] FIG. 1, by way of example only, illustrates a cross-section of an embodiment of a core-shell nanoparticle 101. The core-shell nanoparticle includes a core 102. The core 102 may include any metal chalcogenide having the formula AB.sub.1-xBxC.sub.2-yC.sub.y, where A is Cu, Zn, Ag or Cd; B and B are independently Al, In or Ga; C and C are independently S, Se or Te; 0x1; and 0y2. In one embodiment, the nanoparticle core 102 may be a quaternary metal chalcogenide. Without limitation, quaternary metal chalcogenide cores may include CuIn.sub.xGa.sub.1-xSe.sub.2; ZnIn.sub.xGa.sub.1-xSe.sub.2; AgIn.sub.xGa.sub.1-xSe.sub.2; CuInSe.sub.2-yS.sub.y; CuIn.sub.xGa.sub.1-xSe.sub.2-yS.sub.y; CuGaSe.sub.2-yS.sub.y; ZnInSe.sub.2-yS.sub.y; ZnGaSe.sub.2-yS.sub.y; AgInSe.sub.2-yS.sub.y; and AgGaSe.sub.2-yS.sub.y, where 0x1; and 0y2. In another embodiment, the quaternary metal chalcogenide core may include Zn instead of Ga, including but not limited to a core having the formula CuInZnS. In another embodiment, the nanoparticle core 102 may be a ternary metal chalcogenide. Without limitation, ternary metal chalcogenide cores may include CuInSe.sub.2, CuGaSe.sub.2, ZnInSe.sub.2, ZnGaSe.sub.2, AgInSe.sub.2, and AgGaSe.sub.2.

[0024] In an embodiment, the nanoparticle core 102 is substantially surrounded by a metal chalcogenide shell 103. In one embodiment, the shell 103 may include a binary metal chalcogenide having the formula M.sub.xE.sub.y, where M is any metal and E is any chalcogen. Without limitation, binary metal chalcogenide shells may include Cu.sub.xS.sub.y, In.sub.xS.sub.y, and Ga.sub.xS.sub.y where 0x2; and 0y3.

[0025] In one embodiment the core-shell nanoparticle 101 includes a core 102 made of Cu, In, Ga, and Se (i.e., a CIGSe core). The CIGSe core 102 may be substantially surrounded by a shell 103 made of CuS or InS.

[0026] In an embodiment, the aforementioned core-shell nanoparticles may be used to produce a PV cell absorber thin film. FIG. 2, by way of example only, illustrates the layers of an exemplary PV device 200 having an absorbing layer derived from core-shell nanoparticles. The exemplary layers are disposed on a support 201. The layers are: a substrate layer 202 (typically molybdenum), an absorbing layer derived from core-shell nanoparticles 203, a cadmium sulfide layer 204, an aluminum zinc oxide layer 205, and an aluminum contact layer 206. One of skill in the art will appreciate that a GIGS-based PV device may include more or fewer layers than are illustrated in FIG. 2.

[0027] Support 201 may be any type of rigid or semi-rigid material capable of supporting layers 202-206. Examples include glass, silicon, and rollable materials such as plastics. Substrate layer 202 is disposed on support layer 201 to provide electrical contact to the PV device and to promote adhesion of the core-shell nanoparticle-based absorption layer 203 to the support layer.

[0028] The absorbing layer 203 is derived from the aforementioned core-shell nanoparticles and may include one or more layers comprising Cu, In and/or Ga, Se and/or S. The core-shell nanoparticle layer may have a uniform stoichiometry throughout the layer. Alternatively, the stoichiometry of the Cu, In and/or Ga, Se and/or S may vary throughout the absorption layer 203. For example, in an embodiment, the absorption layer may include layers having varying gallium content. According to one embodiment, the ratio of In to Ga may vary as a function of depth within the layer. Likewise, the ratio of Se to S may vary within the layer. In still another embodiment, the core-shell nanoparticle-based absorbing layer 203 may be a p-type semiconductor. It may therefore be advantageous to include a layer of n-type semiconductor 204 within PV cell 200. An examples of a suitable n-type semiconductor includes, without limitation, CdS.

[0029] Top electrode 205 may be a transparent conductor, such as indium tin oxide (ITO) or aluminum zinc oxide (AZO). Contact with top electrode 205 may be provided by a metal contact 206, which may be essentially any metal, including but not limited to aluminum, nickel, or alloys thereof.

[0030] Methods of depositing GIGS layers on a substrate are described in U.S. patent application Ser. No. 12/324,354, filed Nov. 26, 2008, and published as Pub. No. US2009/0139574 (referred to herein as the '354 application), the entire contents of which are incorporated herein by reference. These methods may be used to deposit the core-shell nanoparticles described herein. Briefly, CIGS layers may be formed on a substrate by dispersing CIGS-type core-shell nanoparticles in an ink composition and using the ink composition to form a film on the substrate. The film is then annealed to yield a layer of CIGS material. FIG. 3 is a flow chart illustrating exemplary steps for forming layers of CIGS materials on a substrate using CIGS-type core-shell nanoparticle inks. First (301), an ink containing GIGS-type core-shell nanoparticles is used to coat a film onto the substrate using a technique such as printing, spraying, spin-coating, doctor blading, or the like. Exemplary ink compositions are described in the '354 application.

[0031] One or more annealing/sintering steps (302, 303) are typically performed following the coating step (301). The annealing step(s) may vaporize organic components of the ink and other organic species, such as capping ligands that may be present on the CIGS-type nanoparticles. The annealing step(s) also melt the GIGS-type nanoparticles. Alternatively or in addition, the deposited ink composition may be melted by reduction with H.sub.2 followed by a reactive sintering with a selenium-containing gas, such as H.sub.2Se (305). Following annealing, the film may be cooled (304) to form the GIGS layer, which preferably is made up of crystals of the GIGS material. The coating, annealing, and cooling steps may be repeated (306) multiple times to form multiple layers in the absorption layer. Each layer may include a different stoichiometry. For example, layers may be formed with different gallium concentrations by varying the gallium concentration in the starting ink composition used for each layer.

[0032] In one embodiment, the GIGS materials used in the aforementioned ink composition include one or more of the core-shell nanoparticles described herein with respect to FIG. 1. For example, the ink composition may include one or more nanoparticles that include a quaternary or ternary metal chalcogenide core substantially surrounded by a binary metal chalcogenide.

[0033] In an embodiment, a GIGS layer is derived from a blend of different types of core-shell nanoparticles. The core-shell nanoparticle cores may behave as isolated/inert to one another during the annealing/sintering process, while the shells act as a reactive material that affects grain growth. Referring to FIG. 4, by way of example only, the ink composition 401 may include a blend of CuInGaSe/CuS coreshell nanoparticles 402 with CuInGaSe/InS core-shell nanoparticles 403. The ink composition is deposited 404 on a PV cell contact 405. The deposited nanoparticles are then exposed to heat and a selenium-containing gas 406 to force a reaction between the nanoparticle shells 402, 403. The result is a GIGS layer 407 on top of the PV cell contact 405. In one embodiment, the final thin film layer 407 includes CuInGaSe 408 crystals in a matrix of CuInSSe 409. In an alternative embodiment, the deposited ink composition may include CuS, InS, and GaS shells with CuInGaSe cores to form a matrix of CuInGaSSe with large amounts of CuInGaSe.

[0034] The invention disclosed herein provides a number of advantages over conventional solid-phase deposition methods of GIGS nanoparticles. First, the nanoparticle's shell component isolates its core from the surface. Consequently, the shell may prevent gallium from reacting and thus migrating during thin film processing. This may result in a high gallium content, which affects higher band gap material and may lead to increased VOC. Second, the core-shell nanoparticles disclosed herein include a binary metal chalcogenide shell. Binary metal chalcogenides exhibit superior grain growth over quaternary or ternary metal chalcogenides. Larger grain growth leads to enhanced current (Jsc). In addition, the binary metal chalcogenide is only a small fraction of the core-shell nanoparticle volume. This design avoids grain growth control issues typically observed in forming gallium-containing materials from binary metal chalcogenides. Third, in one embodiment, the ink composition may include an excess of Cu-based shells over In-based shells with an excess of cores loaded with In/Ga. This copper-rich shell environment may maximize grain growth during sintering. On the other hand, the In/Ga cores may ultimately lead to a final film stoichiometry that is copper deficient, thereby meeting optimum electronic requirements. Fourth, in another embodiment, the core-shell nanoparticle cores may include selenium in lieu of sulfur. This means that there is no need to replace sulfur in the majority of the thin film for volume expansion. It is contemplated that, if the outer part of each particle is made up using S as the anion, the sulfur can be replaced by selenium, providing volume expansion where the reaction is most accessible and where the expansion will be of most benefit (at the surfaces where gap filling and grain boundary fusion are desired). Inasmuch as the core is composed using Se as the anion, there is no need for the reactive gas to penetrate deep into the particle to replace further S to achieve homogeneity and maintain the desired bandgap. This may allow a lower concentration of the Se reagent and/or shorter processing time and/or possibly lower processing temperature. Therefore, a less-harsh selenization process may be implemented, such as a lower concentration of H.sub.2Se or elemental selenium.

EXAMPLES

Example 1: Synthesis of a Core-Shell Nanoparticle

[0035] This example describes one method for synthesizing a CIGSe/InS core-shell nanoparticle. However, the same or similar method may be used to make any other core-shell nanoparticles described in accordance with the embodiments herein by simply substituting starting materials at appropriate ratios. For example, the core starting material CIGSe could be substituted with any metal chalcogenide having the formula AB.sub.1-xB.sub.xC.sub.2-yC.sub.y, where A is Cu, Zn, Ag or Cd; B and B are independently Al, In or Ga; C and C are independently S, Se or Te; 0x1; and 0y2. In addition, the shell starting material, indium(III)diethyldithiocarbamate, could be substituted with any chalcogenide having the formula M.sub.xE.sub.y.

[0036] In one embodiment, an oven-dried 250 ml round bottom flask was charged with 2.68 g of CIGSe core nanoparticles and subsequently fitted with a Liebig condenser. The flask was thoroughly purged with N.sub.2. 30 ml of degassed dibenzylether were added to the flask and the mixture was heated to 150 C. A vial under N.sub.2 was also charged with 0.978 g of indium(III)diethyldithiocarbamate, 14 ml of degassed dibenzylether, and 6 ml of trioctylphosphine. The resulting vial suspension was then added to the CIGSe solution, and the mixture was heated to 200 C. for 90 minutes. Finally, the mixture was allowed to cool to room temperature.

[0037] After cooling, the flask was opened to the atmosphere and the mixture was spun at 2700 G for five minutes. The supernatant was set aside and the remaining solid was dispersed in 25 ml of toluene. This dispersion was spun at 2700 G for five minutes and the supernatant was then combined with the dispersion. Any remaining solids were further dispersed in 15 ml of toluene and the mixture was spun at 2700 G for five minutes. The supernatant was again combined with the dispersion and any remaining residue was discarded. 250 ml of methanol were added to the combined supernatants and the mixture was spun at 2700 G for five minutes. The colorless supernatant was discarded and the resulting solid was re-precipitated from 25 ml dichloromethane/200 ml methanol. The precipitate was isolated by centrifugation and dried under vacuum (yield: 2.218 g).

[0038] FIG. 5, by way of example only, compares the UV-Vis and photoluminescence spectra of unshelled CIGSe nanoparticles with those of CIGSe/InS coreshell nanoparticles. In an embodiment, there is an increase in peak intensity when the CIGSe material reacts with the indium(III)diethyldithiocarbamate to form the InS shell. This is an expected outcome when a higher bandgap material is used as a shell to passivate the core nanoparticle surface. It also indicates shell formation as opposed to either separate nanoparticle formation or doping of the In and S into the existing CIGSe nanoparticles.

[0039] FIG. 6, by way of example only, presents a comparison of an ICP/OES elemental analysis of unshelled CIGSe nanoparticles with those of CIGSe/InS core-shell nanoparticles. In an embodiment, results show an increase in In and S content in the core-shell nanoparticles.

[0040] FIG. 7, by way of example only, presents a comparison of an XRD analysis of unshelled CIGS nanoparticles versus that of core-shell CIGS/InS nanoparticles, and reference patterns for CIS and CGS nanoparticles from the database of the Joint Committee on Powder Diffraction Standards (JCPDS). In an embodiment, results show that no extra peaks from other phases or materials develop upon shell formation, indicating the presence of shells as opposed to doping or separate nucleation.

[0041] The foregoing presents particular embodiments of a system embodying the principles of the invention. Those skilled in the art will be able to devise alternatives and variations which, even if not explicitly disclosed herein, embody those principles and are thus within the scope of the invention. Although particular embodiments of the present invention have been shown and described, they are not intended to limit what this patent covers. One skilled in the art will understand that various changes and modifications may be made without departing from the scope of the present invention as literally and equivalently covered by the following claims.