SOLAR CELL AND METHOD FOR MANUFACTURING THE SAME
20170330987 · 2017-11-16
Assignee
Inventors
Cpc classification
Y02E10/547
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
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
H01L31/036
ELECTRICITY
H01L31/035272
ELECTRICITY
H01L31/068
ELECTRICITY
H01L31/1804
ELECTRICITY
H01L31/0392
ELECTRICITY
International classification
H01L31/068
ELECTRICITY
H01L31/036
ELECTRICITY
H01L31/18
ELECTRICITY
Abstract
A solar cell has a P-type silicon substrate in which one main surface is a light-receiving surface and another main surface is a backside, a dielectric film on the backside, and an N-conductivity type layer in at least a part of the light-receiving surface of the P-type silicon substrate, wherein the P-type silicon substrate is a silicon substrate doped with gallium, and the backside of the P-type silicon substrate contains a diffused group III element. This provides a solar cell with excellent conversion efficiency provided with a gallium-doped substrate, and a method for manufacturing the same.
Claims
1. A solar cell comprising a P-type silicon substrate in which one main surface is a light-receiving surface and another main surface is a backside, a dielectric film on the backside, and an N-conductivity type layer in at least a part of the light-receiving surface of the P-type silicon substrate, wherein the P-type silicon substrate is a silicon substrate doped with gallium, and the backside of the P-type silicon substrate contains a diffused group III element.
2. The solar cell according to claim 1, wherein the diffusion surface concentration of the group III element in the backside is 5.0×10.sup.17 atom/cm.sup.3 or more and 2.0×10.sup.19 atom/cm.sup.3 or less.
3. The solar cell according to claim 1, wherein the group III element is boron, gallium, or aluminum.
4. The solar cell according to claim 2, wherein the group III element is boron, gallium, or aluminum.
5. A method for manufacturing a solar cell having a P-type silicon substrate in which one main surface is a light-receiving surface and another main surface is a backside, comprising the steps of: preparing a silicon substrate uniformly doped with gallium as the P-type silicon substrate, diffusing a group III element to the backside, forming an N-conductivity type layer in the light-receiving surface, and forming a dielectric film on the backside.
6. The method for manufacturing a solar cell according to claim 5, wherein the step of diffusing a group III element and the step of forming an N-conductivity type layer are performed in one thermal treatment.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
DESCRIPTION OF EMBODIMENTS
[0034] Hereinafter, the present invention will be more specifically described.
[0035] As described above, a solar cell with excellent conversion efficiency provided with a gallium-doped substrate and a method for manufacturing the solar cell has been demanded. However, when the gallium-doped substrate is used as a substrate for a solar cell, and a dielectric film is formed on the surface of the substrate as a protective film or a passivation film, the amount of gallium, which is dopant, is decreased at an area being in contact with the dielectric film and in the vicinity thereof as described above.
[0036] The inventors have diligently investigated to solve the problems. As a result, the inventors have found that, a solar cell having a gallium-doped substrate and a dielectric film, on the backside, and containing a group III element diffused in the backside of this substrate can solve the foregoing problems; thereby brought the inventive solar cell and the method for manufacturing the same to completion.
[0037] Hereinafter, an embodiment of the present invention will be specifically described with reference to FIGS, but the present invention is not limited thereto.
[0038]
[0039] The resistivity of the gallium-doped P-type silicon substrate 11 is not particularly restricted, but it can be in a range of 0.1 to 5 Ω.Math.cm, for example. The thickness
[0040] of the P-type silicon substrate 11 is not particularly restricted, and can be a thickness of 100 to 200 μm, for example. The shape and area of the main surface of the P-type silicon substrate 11 is not particularly restricted.
[0041] As shown in
[0042] Herein, the solar cell having a PERC structure means a solar cell provided with a surface passivation layer formed on the backside of the substrate, and having local contact, areas where the P-type silicon substrate is in contact with the back surface electrode. The solar cell having a PERL structure means a solar cell where the P-type dopant concentration on the contact areas is higher than that on areas other than the contact area. In these cases, the area where the back surface electrode 17 is in direct contact with the P-type silicon substrate 11 may have a pitch of 1 mm or more and 10 mm or less, for example.
[0043] As described above, the dielectric film on the light-receiving surface can act as an anti-reflection film. The dielectric film on the light-receiving surface can also act as a passivation film or a protective film. The dielectric film on the backside can act as a passivation film or a protective film. For these dielectric films, it is possible to use an SiNx film (a silicon nitride film), an SiO.sub.2 film, etc., which can be formed by using a plasma CVD equipment; it is also possible to use a thermal oxide film. As the anti-reflection film, a dielectric film with the film thickness of 85 to 105 nm is suitable, showing the maximum effect to reduce the reflectance.
[0044] In the present invention, the P-type silicon substrate 11 is a silicon substrate doped with gallium. A group III element (an element of group 13) is diffused on the backside of the P-type silicon substrate 11. In
[0045] Illustrative examples of the N-type dopant contained in the N-conductivity type layer 12 include P (phosphorus), Sb (antimony), As (arsenic), and Bi (bismuth). Illustrative examples of the diffused group III element include B (boron), Ga (gallium), Al (aluminum), and In (indium), The group III element is preferably boron, gallium, or aluminum.
[0046] The diffused surface concentration of the group III element on the backside is not particularly restricted. The diffused surface concentration can be 1.0×10.sup.15 atom/cm.sup.3 or more and 1.×10.sup.20 atom/cm.sup.3 or less, for example. It is preferably 5.0×10.sup.17 atom/cm.sup.3 or more and 2.0×10.sup.19 atom/cm.sup.3 or less. The diffusion surface concentration of 5.0×10.sup.17 atom/cm.sup.3 or more can sufficiently eliminate depletion of the P-type dopant concentration in the backside. The diffusion surface concentration of 2.0×10.sup.19 atom/cm.sup.3 or less can eliminate degradation of the cell characteristics without decrease in the voltage and the conversion efficiency. Herein, the diffused surface concentration means a concentration of the group III element on the backside which is additionally doped, and does not include a concentration of gallium that is originally contained. This condition of the diffused surface concentration may be satisfied in the prescribed thickness at the side of back surface. The prescribed thickness can be 0.1 μm. It is preferable to meet this prescription to the depth of 0.5 μm.
[0047] The diffusion depth of the group III element in the backside is not particularly restricted. The diffusion depth can be in a range of 0.1 μm to 3 μm, for example.
[0048] The area for diffusing the group III element is not particularly restricted. It is desirable, however, to diffuse the group III element over the whole area of the backside in order to sufficiently eliminate depletion of the P-type dopant concentration in the backside.
[0049] The concentration of N-type dopant in the N-conductivity type layer 12 is not particularly restricted. This concentration can be 1.0×10.sup.18 atom/cm.sup.3 or more and 1.0×10.sup.20 atom/cm.sup.3 or less, for example. The N-conductivity type layer 12 can be formed on the whole area of the light-receiving surface. The shape of the N-conductivity type layer 12 can be appropriately altered in accordance with a shape of the light-receiving surface electrode 16.
[0050] Then, the inventive method for manufacturing a solar cell is described with reference to
[0051] The silicon single crystal from which the gallium-doped substrate is sliced can be produced by a CZ method, for example, as described above. In this case, gallium and a polycrystalline silicon may be introduced into a crucible in a lump to form a raw material melt. It is desirable to produce dopant by pulverizing a silicon single crystal doped with higher concentration of gallium, and then to adjust the concentration by introducing the dopant into melted polycrystalline silicon so as to have a desired concentration, since it is necessary to precisely adjust the concentration, particularly in mass production. The gallium-doped substrate can be obtained by slicing thus obtained gallium-doped silicon single crystal.
[0052] Subsequently, slice damages on the surface of the substrate can be removed by etching with a high-concentration alkaline solution such as sodium hydroxide and potassium hydroxide in a concentration of 5 to 60%, or mixed acid of hydrofluoric acid and nitric acid, etc. as shown in
[0053] Then, the substrate surface can be processed to form micro-roughness called texture as shown in
[0054] After the damage-etching and texture formation, it is preferable to wash the substrate as shown in
[0055] Subsequently, a group III element is diffused to the backside of the gallium-doped substrate as shown in
[0056] The method for diffusing a group III element in the step (e) and the method for forming an N-conductivity type layer in the step (f) are not particularly restricted. For example, it is possible to use a method to thermally diffuse the dopant. This includes a vapor phase diffusion method in which POCl.sub.3 (phosphoryl chloride) or BBr.sub.3 (boron tribromide) is introduced into a tube furnace with carrier gas, and diffused; a coating diffusion method in which a phosphorus or boron-containing material is applied onto a substrate, and subjected to thermal treatment. The coating method in the coating diffusion method includes spin-coating method, spray-coating method, ink-jet method, and screen printing method.
[0057] In the coating diffusion method, the group III
[0058] element can be diffused by coating the backside with a material which contains a group III element followed by thermal treatment. The N-conductivity type layer can be formed by coating the light-receiving surface with a material which contains N-type dopant followed by thermal treatment. The material which contains a group III element is preferably applied to the whole area of the backside to sufficiently eliminate depletion of the P-type dopant concentration in the backside.
[0059] In this case, it is preferable to perform, the step (e) and the step (f) simultaneously, i.e., to perform diffusion of a group III element and forming of an N-conductivity type layer in a thermal treatment at one time. Such a method can reduce the number of production steps when introducing a P-type layer into the backside, and can also reduce the cost without having trouble in the process. In this way, a P-type layer having a desired surface concentration can be easily introduced into the backside by performing the step (e) and the step (f) simultaneously.
[0060] When performing the step (e) and the step (f) simultaneously, a film which contains an N-type dopant is formed at first by applying a material which contains an N-type dopant onto a light.-receiving surface, and introducing the substrate into a drying furnace to dry the material. Then, a film which contains a group III element is formed on the backside in a similar manner. By performing thermal treatment subsequently, it is possible to carry out the diffusion of a group III element and the formation of an N-conductivity type layer simultaneously in one thermal treatment. It is also possible to perform one of the diffusion of a group III element and the formation of an N-conductivity type layer by using the coating diffusion method, and to perform the other process by the vapor phase diffusion method.
[0061] For the material which contains N-type dopant, it is possible to use a phosphorus diffusion source (a phosphorus diffusion source), which turns to glass by thermal treatment. This phosphorus diffusion source includes any known ones, and can be obtained by mixing P.sub.2O.sub.5, pure water, polyvinyl alcohol (PVA), and tetraethyl orthosilicate (TEOS), for example.
[0062] For the material which contains a group III element, it is possible to use a boron diffusion source (a boron diffusion source), which turns to glass by thermal treatment. This boron diffusion source includes any known ones, and can be obtained by mixing B.sub.2O.sub.3, pure water, and PVA, for example.
[0063] By applying the phosphorus diffusion source onto the light-receiving surface of the substrate, and the boron diffusion source onto the backside, followed by performing the co-diffusion at a phosphorus diffusion temperature, it is possible to form a boron layer having a relatively low surface concentration since a boron atom has smaller diffusion coefficient compared to a phosphorus atom. This makes it possible to reduce the process cost compared to a method in which the boron layer and the phosphorus diffusion layer are formed separately. The phosphorus diffusion temperature is not particularly restricted, but generally in the range of 830 to 950° C. The boron diffusion temperature is generally in the range of 900 to 1100° C. These thermal treatments take generally 1 to 60 minutes, approximately.
[0064] The diffusion surface concentration and the diffusion depth of the group III element can be adjusted to an appropriate value in accordance with the purpose by regulating the content of B.sub.2O.sub.3 in a boron diffusion source, thermal diffusion temperature, and thermal diffusion time, for example.
[0065] Then, as shown in
[0066] After the step (e) and the step (f), not a little quantity of glass layer is formed on the surface of the substrate. The glass on the surface is removed by hydrofluoric acid, etc., as shown in
[0067] Subsequently, as shown in
[0068] Then, as shown in
[0069] Subsequently, as shown in
[0070] Then, as shown in
[0071] Subsequently, as shown in
[0072] After the foregoing printing of the electrodes, the paste for a light-receiving surface electrode and the paste for a back surface electrode are fired as shown in
[0073] In such a way, the solar cell shown in
EXAMPLES
[0074] Hereinafter, the present, invention will be specifically described by showing Examples and Comparative Example, but the present invention is not limited these Examples.
Example 1
[0075] First, as-sliced CZ substrate in a 156 mm square with the thickness of 200 μm and substrate resistivity of 1 Ω.Math.cm was prepared for a silicon substrate uniformly doped with gallium (
[0076] Then, this gallium-doped substrate was subjected to damage etching by immersing into a solution of hydrofluoric acid and nitric acid for 15 seconds (
[0077] Next, a boron-containing film was formed on the whole area of the backside by applying a boron diffusion source which contained boric acid onto the backside by spin-coating method, followed by drying in a drying furnace at 120° C. for about 1 minute. Then, the gallium-doped substrate having the boron-containing film formed thereon was introduced into a tube furnace, and subjected to thermal treatment at the temperature of 850° C. for the thermal treatment time of 40 minutes to diffuse the group III element to the backside of the gallium-doped substrate (
[0078] Subsequently, the gallium-doped substrate was subjected to thermal treatment under the atmosphere of phosphoryl chloride at 850° C. for 30 minutes to form an N-conductivity type layer in the light-receiving surface (
[0079] Then, the PN junction was isolated by using a plasma etcher (
[0080] This gallium-doped substrate subjected to diffusion was introduced into an oxidation furnace, and subjected to thermal treatment under an oxygen atmosphere at 900° C. for 30 minutes to form oxide layer with each layer thickness of 20 nm on the both surfaces of the substrate as dielectric films. On the light-receiving surface and the backside of the gallium-doped substrate, silicon nitride layers were formed respectively as dielectric films by using a plasma CVD equipment (
[0081] Subsequently, the dielectric film was removed just on the contact area for the electrodes on the backside by using an etching paste (
[0082] Then, on the backside of the gallium-doped substrate, an electric conductive paste mainly composed of silver was printed by a screen-printing method, and dried at 150° C. (
[0083] The electric conductive paste mainly composed of silver was also printed onto the light-receiving surface of the gallium-doped substrate by a screen-printing method, and dried at 150° C. (
[0084] This substrate coated with the electric conductive paste was introduced into a firing furnace, and the electric conductive paste, was fired at the maximum temperature of 800° C. for 5 seconds to form a back surface electrode and a light-receiving surface electrode to fabricate the solar cell shown in
Example 2
[0085] The solar cell shown in
[0086] The diffusion profile of Example 2 by secondary ion mass spectrometry (SIMS) is shown in
COMPARATIVE EXAMPLE
[0087] The solar cell shown in
[0088] On 300 pieces of solar cells thus fabricated (Example 1: 100 pieces, Example 2: 100 pieces, Comparative Example: 100 pieces), evaluations (inspections of current-voltage characteristics) were performed with a solar simulator (in an atmosphere of 25° C., irradiation intensity: 1 kW/m.sup.2, spectrum: AM 1.5 global). The results of Examples 1 and 2 and Comparative Example were shown in Table 1. The conversion efficiencies and so on in Table 1 are average values of each 100 pieces of solar cells of Examples 1 and 2 and Comparative Example.
TABLE-US-00001 TABLE 1 Short-circuit Open circuit Fill Conversion current density voltage factor efficiency Example 1 39.5 mA/cm.sup.2 653 mV 0.788 20.3% Example 2 39.1 mA/cm.sup.2 651 mV 0.792 20.2% Comparative 37.9 mA/cm.sup.2 651 mV 0.766 18.9% Example
[0089] As shown in Table 1, Examples 1 and 2, in which a group III element was diffused in the backside of each gallium-doped substrate, showed good results of the short-circuit current density, open circuit voltage, fill factor, and conversion efficiency. On the other hand, Comparative Example, in which a group III element was not diffused in the backside of the substrate, formed the inversion layer 118 in the backside of the substrate as shown in
[0090] The internal quantum efficiencies of Example 1 and Comparative Example are shown in
[0091]
[0092] It is to be noted that the present invention is not limited to the foregoing embodiment. The embodiment, is just an exemplification, and any examples that have substantially the same feature and demonstrate the same functions and effects as those in the technical concept described in claims of the present invention are included in the technical scope of the present invention.