III-V solar cell structure with multi-layer back surface field
09680045 ยท 2017-06-13
Assignee
Inventors
- Bahman Hekmatshoartabari (White Plains, NY, US)
- Ali Khakifirooz (Los Altos, CA, US)
- Ghavam G. Shahidi (Pound Ridge, NY, US)
- Davood Shahrjerdi (White Plains, NY, US)
Cpc classification
H10F10/161
ELECTRICITY
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H10F10/163
ELECTRICITY
Y02E10/544
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E10/52
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H10F77/1248
ELECTRICITY
H10F77/413
ELECTRICITY
International classification
H01L21/00
ELECTRICITY
H01L31/0735
ELECTRICITY
H01L31/18
ELECTRICITY
H01L31/0232
ELECTRICITY
Abstract
Photovoltaic devices including direct gap III-V absorber materials and operatively associated back structures enhance efficiency by enabling photon recycling. The back structures of the photovoltaic devices include wide bandgap III-V layers, highly doped (In)GaAs layers, patterned oxide layers and metal reflectors that directly contact the highly doped (In)GaAs layers through vias formed in the back structures. Localized ohmic contacts are formed in the back structures of the devices.
Claims
1. A method comprising: obtaining a top portion of a solar cell structure, the top portion of the solar cell structure including an absorbing layer comprising a direct gap III-V material and an emitter layer on a first side of the absorbing layer; epitaxially depositing a wide bandgap III-V layer and a highly doped (In)GaAs layer on a second side of the absorbing layer; depositing an electrically insulating reflector layer on the second side of the absorbing layer and over the wide bandgap III-V layer and the highly doped (In)GaAs layer; patterning the electrically insulating reflector layer; patterning one of the wide bandgap III-V layer and the highly doped (In)GaAs layer; and depositing a metal reflector layer on the second side of the absorbing layer such that the metal reflector layer directly contacts the highly doped (In)GaAs layer at a plurality of locations.
2. The method of claim 1, wherein the electrically insulating reflector layer includes silicon dioxide.
3. The method of claim 1, wherein the top portion of the solar cell structure further includes multiple junctions and a tunnel junction.
4. The method of claim 1, wherein the step of epitaxially depositing the wide bandgap III-V layer and the highly doped (In)GaAs layer on the second side of the absorbing layer further includes: depositing the highly doped (In)GaAs layer directly on the top portion of the solar cell structure, and depositing the wide bandgap III-V layer over the highly doped (In)GaAs layer, and further wherein the step of patterning one of the wide bandgap III-V layer and the highly doped (In)GaAs layer includes patterning the wide bandgap III-V layer to expose portions of the highly doped (In)GaAs layer.
5. The method of claim 4, wherein the highly doped (In)GaAs layer has a thickness smaller than the diffusion length of minority carriers in the highly doped (In)GaAs layer.
6. The method of claim 5, wherein the electrically insulating reflector layer includes silicon dioxide.
7. The method of claim 5, wherein the wide bandgap III-V layer is deposited directly on the highly doped (In)GaAs layer, the electrically insulating reflector layer is deposited directly on the wide bandgap III-V layer, and the metal reflector layer is deposited directly on the electrically insulating reflector layer following sequential patterning of the electrically insulating reflector layer and the wide bandgap III-V layer.
8. The method of claim 5, wherein the highly doped (In)GaAs layer deposited on the second side of the absorbing layer has a final thickness between ten and one hundred nanometers.
9. The method of claim 1, wherein the step of epitaxially depositing the wide bandgap III-V layer and the highly doped (In)GaAs layer on the second side of the absorbing layer further includes: depositing the wide bandgap III-V layer directly on the top portion of the solar cell structure, and depositing the highly doped (In)GaAs layer over the wide bandgap III-V layer, and further wherein the step of patterning one of the wide bandgap III-V layer and the highly doped (In)GaAs layer includes patterning the highly doped (In)GaAs layer to expose portions of the wide bandgap III-V layer.
10. The method of claim 9, wherein the step of depositing the electrically insulating reflector layer on the second side of the absorbing layer and over the wide bandgap III-V layer and the highly doped (In)GaAs layer further includes depositing the electrically insulating reflector layer directly on both the wide bandgap III-V layer and the patterned, highly doped (In)GaAs layer.
11. The method of claim 10, wherein the step of patterning the highly doped (In)GaAs layer to expose portions of the wide bandgap III-V layer further includes forming isolated islands or parallel rows from the highly doped (In)GaAs layer, and further wherein the step of patterning the electrically insulating reflector layer includes exposing the islands or parallel rows of the highly doped (In)GaAs layer.
12. The method of claim 11, wherein the electrically insulating reflector layer consists essentially of silicon dioxide.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(8) Direct bandgap III-V materials are attractive for making very high-efficiency photovoltaic solar cells primarily because of their strong absorption properties. This will therefore allow the majority of incident photons with an energy less than or equal to the bandgap of the III-V materials to be absorbed using thin layers. However, thin III-V solar cell structures are conventionally grown on thick GaAs or Ge substrates. This will in turn inhibit the mechanical flexibility of the solar cell while significantly contributing to the total weight of the cell and thus limiting the specific power. Therefore, the application of layer transfer techniques is important for realizing ultra-light flexible III-V solar cells. On the other hand, the possibility to access the rear of the cell by employing a layer transfer method enables the implementation of back reflectors in the solar cell structure. This feature will in principle permit the significant reduction of the thickness of the III-V absorber. In addition, direct gap III-V materials exhibit strong internal fluorescence. Therefore, the combination of this phenomenon coupled with the use of an effective back reflector offers unique opportunities for making very efficient solar cells by taking advantage of photon recycling. In the photon recycling phenomenon, radiative recombination is the primary recombination event in the absorber layer. Therefore, the energy of the emitter photon is equal to the bandgap of the absorber material. (In)GaAs is an optimal material in terms of bandgap to serve as either a stand-alone single junction or the bottom cell of a multi junction solar cell. A large portion of the emitted photons, as a result of the radiative recombination in the absorber layer, will be absorbed in a highly doped (In)GaAs contact layer. One solution is to reduce the thickness of the (In)GaAs contact layer. However, this will compromise the access series resistance.
(9) In accordance with one exemplary embodiment disclosed herein, the above-referenced problem is addressed by patterning the heavily doped (In)GaAs layer to create isolated islands in order to form localized ohmic contact. The metal contact is separated from the widegap material by an oxide reflector in such embodiments. The fabrication process of such a back structure includes two photolithography steps: one for patterning the (In)GaAs contact layer and second for opening the oxide reflector in order to access the (In)GaAs islands.
(10) In accordance with a further exemplary embodiment, a photovoltaic structure that enables photon recycling is provided. A simplified fabrication process is employed to create a double layer back surface field (BSF), whereby the first BSF layer is a hi-lo junction that is followed by a wide bandgap BSF layer. In order for implementation of the back reflector, an oxide back reflector is deposited and then the oxide reflector and wide bandgap BSF layer are sequentially etched to access the highly doped (In)GaAs BSF layer in order to form local back contacts. This process can be combined with a layer transfer process such as epitaxial layer lift-off or controlled spalling, for which the III-V structure may be grown in an inverted fashion (upside down) with the back reflector being the topmost layer prior to the layer transfer, while the solar cell structure will have the proper order for the layers after the layer transfer.
(11) Exemplary solar cell structures in some exemplary embodiments include stacked layers in reverse order wherein a n++ (In)GaAs buffer layer plays dual roles as buffer and contact layers in the inverted structures. (The designation (In) signifies that the indium content is low (e.g. 1-3%) and that the InGaAs material is similar to GaAs.) The absorbing layers employed in such exemplary structures are III-V layers such as (In)GaAs. The stacked layers are grown on a germanium substrate in some embodiments. Controlled spalling may be employed as part of the fabrication process for some exemplary solar cell structures disclosed herein. The requirement for etching a buffer layer is eliminated, thereby facilitating the manufacturing process of devices using the disclosed structures.
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(13) An oxide layer 92 and a metal reflector layer 99 are formed on the BSF layer, for example a 50-200 nm thick oxide layer and a 100 nm-1 m thick gold, silver or platinum layer. A window layer 108 adjoins the emitter layer and a n++ (In)GaAs buffer layer 124A. Suitable materials for the window layer 108 include InGaP, InAlP, InGaAlP and AlGaAs. The window layer in an exemplary structure 100 is formed of Si:In.sub.0.5Ga.sub.0.5P and has a thickness of 25 nm. The active layers of the solar cell structure, namely the base 102, emitter layer 104, BSF layer 106 and window layer 108 are characterized by low defect density. In this exemplary embodiment, the highly doped (e.g. 1E18-1E19 dopant levels) contact layer 124A of the buffer region 124 formed on the substrate 22 is a Si:In.sub.0.01Ga.sub.0.99As layer having a thickness of 0.5 m and a dopant level of 3E18. Low defect density is not a requirement of the contact layer 124A, which is a passive element in the structure 100. This highly doped, electrically conductive layer 124A can be grown directly on the germanium substrate 22 and is capable of functioning as an ohmic contact layer with a metal layer (not shown) subsequently formed thereon as well as preventing antiphase defects that may otherwise occur if the active layers of the solar cell structure were grown directly on the germanium substrate 22. The indium concentration in the contact layer is low and should not exceed 2-3%. The buffer region 124 may further comprise an optional phosphide-based nucleation layer 124B (Si:In.sub.0.5Ga.sub.0.5P in this exemplary embodiment) between the germanium substrate 122 and the buffer layer 124A. The optional layer 124B has a thickness of 185 in this embodiment and a dopant level of 1E18. Such an optional layer 124B is generally grown in upright triple junction solar cells to prevent arsenic (As) diffusion in germanium, as As diffuses faster than phosphorus. This is to obtain shallower p/n junctions in germanium for such triple-junction cells. For the inverted structure where germanium is only used as a handle substrate, the growth of this layer is not required. The substrate employed in this exemplary embodiment is p-type germanium 6 off towards <111>. In alternative embodiments, the germanium substrate could be p-type or n-type and 0-15 off from <111> or <110>. The structure 100 is relatively thin and flexible. Comparing the structure 100 to the structure 70 shown in
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(16) An alternative method and resulting structure are schematically illustrated in
(17) Given the discussion thus far, it will be appreciated that, in general terms, an exemplary method includes the steps of obtaining a top portion 82 of a solar cell structure, the top portion of the solar cell structure including an absorbing layer comprising a direct gap III-V material and an emitter layer on a first side of the absorbing layer.
(18) In accordance with a further aspect, a photovoltaic device is provided that comprises a top structure 82 including an absorbing layer comprising a direct gap III-V material and an emitter layer on a first side of the absorbing layer. A back structure on the second side of the absorbing layer includes a wide bandgap III-V layer 84, a highly doped (In)GaAs layer 86, a patterned oxide reflector layer 92, and a metal reflector. One of the wide bandgap III-V layer and the highly doped (In)GaAs layer is patterned. The patterned oxide reflector layer is positioned between the metal reflector and the wide bandgap III-V layer, as shown in
(19) Those skilled in the art will appreciate that the exemplary structures discussed above can be distributed in raw form or incorporated as parts of intermediate products or end products that benefit from having photovoltaic elements therein.
(20) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Terms such as above and below are used to indicate relative positioning of elements or structures to each other as opposed to relative elevation.
(21) The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.