Integrating Enhancement Techniques for Thin-Film Silicon Solar Cells

Abstract

Renewable energy sources, such as thin-film silicon solar cells, show a lot of potential as the technology promises low production temperatures, low cost and low material usage. Other benefits are the flexible and very lightweight modules that can be fabricated, which enable a wide variety of applications. Other benefits include the low-temperature coefficient and low toxicity of the materials used to create thin-film silicon solar cells. The downside of using thin-film silicon modules is the relatively low power conversion efficiency inherent to the amorphous and nanocrystalline silicon. Another downside of amorphous silicon solar cells is their significant initial degradation, known as the Staebler-Wronski effect. This initial degradation will stabilize after time but does limit the ultimate conversion efficiency, especially for single-junction devices.
Hydrogenated amorphous silicon (a-Si:H) and nano-crystalline silicon (nc-Si:H) solar cells can be added in series to form a tandem device, thus increasing the efficiency of thin-film silicon solar cells. Although the current will be limited for 2-terminal tandem devices, a significant increase in open circuit voltage can be achieved resulting in higher efficiencies. To achieve highly efficient thin-film silicon solar cells a combination of good optical, electrical and material properties need to be combined. Extensive research has been done to achieve such high-efficiency devices focussed on the silicon deposition conditions, glass texturing for effective light scattering and light incoupling through anti-reflection coatings. Further research is focused on Transparent Conductive Oxides (TCO) improvements and the creation of triple or quadruple junctions.
Firstly, this thesis will focus on a literature study on amorphous silicon with a high-energy bandgap, deposition conditions in PECVD chambers and an i-SiOx buffer layer. A top cell of amorphous silicon with a high-energy bandgap can improve the conversion efficiency of a-Si:H/nc-Si:H solar cells by increasing its overall V oc. The amorphous silicon is processed at high pressure (3-9mbar) and high power densities (150-400mW /cm2) in a VHF-PECVD chamber at 40.68M Hz. To improve the poor blue response of these solar cells, a buffer layer of i-SiOx is explored as such a buffer layer has proven itself under normal deposition power densities (28mW /cm2) and pressure (0.7mbar).The i-SiOx did not prove to be effective in improving the blue response. A narrow range of deposition conditions around 5mbar and 25W is found to give high-bandgap energy solar cells with a good blue response.
Secondly, literature findings on a bilayer TCO configuration of IOH (Hydrogenated Indium Oxide) and i-ZnO (intrinsic Zinc-Oxide) to improve nc-Si:H single junction solar cells are provided. Prior studies on the use of a back reflector made out of different ZnO(Zinc-Oxides) are presented. Findings in literature on micro and nano-textured glass are presented and a comparison is made in an experiment to justify the use of a specific texture. Further experiments are carried out to measure the effect of implementing the bilayer TCO and an i-ZnO back reflector and an experiment on the performance and reproducibility of a-Si on MST (modulated surface textured) glass substrates is performed. ITO textured glass is chosen as the best performing substrate and a thick 1μ i-ZnO layer as part of a bilayer TCO is shown to be most effective at light scattering. The i-ZnO as part of a bilayer TCO can also significantly improve the spectral response of a-Si:H solar cell on MST textured glass. Furthermore, the i-ZnO as a back reflector is shown to be more effective when its thickness is increased.
Thirdly, a study is performed on the functioning of the a-Si:H/nc-Si:H tandem cells with respect to the thickness of the p-layer in the tunnel recombination junction (TRJ). An experiment is carried out to improve the reproducibility of a-Si:H/nc-Si:H solar cells by increasing the hickness of p-layer in the TRJ.
The conclusion is made that the glass texturing is more influential than the thickness of the p-layer in this experiment. Further investigation of the p-layer at the front interface of the device is done by an experiment on both MST and Asahi substrates. It is shown that thicker front players do not improve the reproducibility of tandem solar cells, but a trend of more parasitic absorption is seen. Finally, a study on micro and nano-textured glass for a-Si:H/nc-Si:H solar cells is shown. The chosen ITO substrate is finally chosen to demonstrate the progress of ongoing research on the performance of a-Si:H/nc-Si:H solar cells. The bilayer TCO vs a single layer TCO is used in combination with and without a SiNx ARC.
The electrical performance of the solar cells deposited in the final experiment is likely limited by poor IOH depositions and a large contribution of parasitic absorption is shown for the samples with the SiNx ARC. Either interaction of SiNx with the IOH or a poor IOH deposition are the most likely causes. Good 1-R curves are obtained for the solar cells on ITO textured glass substrates, especially the sample with the bilayer TCO and SiNx ARC.