Bifacial solar cells with back surface reflector

- Calisolar, Inc.

A simplified manufacturing process and the resultant bifacial solar cell (BSC) are provided, the simplified manufacturing process reducing manufacturing costs. The BSC includes a back surface contact grid and an overlaid blanket metal reflector. A doped amorphous silicon layer is interposed between the contact grid and the blanket layer.

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Description
CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/215,199, filed May 1, 2009, the disclosure of which is incorporated herein by reference for any and all purposes.

FIELD OF THE INVENTION

The present invention relates generally to solar cells and, in particular, to an improved structure and manufacturing process for a bifacial solar cell.

BACKGROUND OF THE INVENTION

Bifacial solar cells (BSC) may use any of a variety of different designs to achieve higher efficiencies than those typically obtained by a conventional, monofacial solar cell. One such design is shown in U.S. Pat. No. 5,665,175 which discloses a BSC configuration with first and second active regions formed on the front and back surfaces of the BSC, respectively, the two regions separated by a distance λ. The distance λ allows a leakage current to flow between the first and second active regions, thus allowing a solar cell panel utilizing such bifacial cells to continue to operate even if one or more individual solar cells become shaded or defective.

U.S. Pat. No. 7,495,167 discloses an n+pp+ structure and a method of producing the same. In the disclosed structure, the p+ layer, formed by boron diffusion, exhibits a lifetime close to that of the initial level of the substrate. In order to achieve this lifetime, the '167 patent teaches that after phosphorous gettering, the cell must be annealed at a temperature of 600° C. or less for one hour or more. In order to retain the lifetime recovered by the phosphorous and low-temperature born gettering steps, the cell then undergoes a final heat treatment step in which the cell is fired at a temperature of around 700° C. or less for one minute or less.

U.S. Patent Application Publication No. 2005/0056312 discloses an alternative technique for achieving two or more p-n junctions in a single solar cell, the disclosed technique using transparent substrates (e.g., glass or quartz substrates). In one disclosed embodiment, the BSC includes two thin-film polycrystalline or amorphous cells formed on opposing sides of a transparent substrate. Due to the design of the cell, the high temperature deposition of the absorber layers can be completed before the low temperature deposition of the window layers, thus avoiding degradation or destruction of the p-n junctions.

Although there are a variety of BSC designs and techniques for fabricating the same, these designs and techniques tend to be relatively complex, and thus expensive. Accordingly, what is needed is a solar cell design that achieves the benefits associated with bifacial solar cells while retaining the manufacturing simplicity of a monofacial solar cell. The present invention provides such a design.

SUMMARY OF THE INVENTION

The present invention provides a simplified manufacturing process and the resultant bifacial solar cell (BSC), the simplified manufacturing process reducing manufacturing costs. In accordance with the invention, the BSC utilizes a combination of a back surface contact grid and an overlaid blanket metal reflector. Additionally, a doped amorphous silicon layer is interposed between the contact grid and the blanket layer.

In one embodiment of the invention, the manufacturing method is comprised of the steps of depositing a dopant of a first conductivity type onto the back surface of a silicon substrate to form a back surface doped region where the silicon substrate is of the same conductivity type as the dopant, depositing a back surface dielectric layer over the back surface doped region, forming an active area of a second conductivity type on the front surface of the silicon substrate, etching the active area, depositing a front surface passivation and AR dielectric layer onto the active area, applying and firing front and back surface contact grids, depositing a layer of doped amorphous silicon onto the back surface contact grid and the back surface dielectric, depositing a layer of metal over the doped amorphous silicon layer, and isolating the front active area. The method may further comprise the step of depositing a conductive interface layer between the doped amorphous silicon layer and the metal layer.

In at least one embodiment of the invention, a manufacturing method is provided that is comprised of the steps of depositing a boron doped layer onto the back surface of a p-type silicon substrate, depositing a back surface dielectric over the boron doped layer, diffusing phosphorous onto the front surface of the silicon substrate to form an n+ layer and a front surface junction, removing the phosphor-silicate glass formed during the diffusion step (e.g., by etching with HF), depositing a front surface passivation and AR dielectric layer onto the n+ layer, applying front and back surface contact grids, firing the front and back surface contact grids, depositing a boron doped layer of amorphous silicon onto the back surface grid and the back surface dielectric, depositing a metal layer onto the boron doped amorphous silicon layer, and isolating the front surface junction using, for example, a laser scriber. The method may further comprise the step of depositing a conductive interface layer, for example comprised of ITO or ZnO:Al, between the boron doped amorphous silicon layer and the metal layer. The front and back surface contact grid firing steps may be performed simultaneously. Alternately, the back surface contact grid applying and firing steps may be performed prior to, or after, the front surface contact grid applying and firing steps. The boron doped layer depositing step can be formed by depositing a boron doped silicon dioxide layer using CVD, depositing a boron doped polysilicon layer using CVD, depositing a boron doped amorphous silicon layer using PE-CVD, spray coating a boric acid solution onto the back surface of the substrate, or spray/wipe coating a boron-doped spin-on glass onto the back surface of the substrate. The phosphorous diffusing step may be performed at a temperature of approximately 850° C. for a duration of approximately 10 to 20 minutes. The back surface dielectric depositing step may be performed after the step of applying the back surface contact grid.

In at least one embodiment of the invention, a bifacial solar cell (BSC) is provided that is comprised of a silicon substrate of a first conductivity type with a front surface active region of a second conductivity type and a back surface doped region of the first conductivity type, dielectric layers deposited on the front surface active region and on the back surface doped region, a front surface contact grid applied to the front surface dielectric layer which alloys through the front surface dielectric to the active region during firing, a back surface contact grid applied to the back surface dielectric layer which alloys through the back surface dielectric to the back surface doped region during firing, an amorphous silicon layer doped with a dopant of a first conductivity type deposited on the back surface contact grid and back surface dielectric, and a blanket metal layer deposited on the doped amorphous silicon layer. The BSC may further comprise a groove on the front surface of the silicon substrate, the groove isolating the front surface junction. The BSC may further comprise a conductive interface layer, for example comprised of ITO or ZnO:Al, interposed between the doped amorphous silicon layer and the metal layer. The silicon substrate may be comprised of p-type silicon, the active region may be comprised of n+ material resulting from a phosphorous diffusion step, and the doped region and the amorphous silicon layer may further comprise a boron dopant. The silicon substrate may be comprised of n-type silicon, the active region may be comprised of p+ material resulting from a boron diffusion step, and the doped region and the amorphous silicon layer may further comprise a phosphorous dopant.

In at least one embodiment of the invention, the manufacturing method is comprised of the steps of forming an active area of a second conductivity type on the front surface of a silicon substrate of a first conductivity type, etching the front surface of the silicon substrate, depositing a front surface passivation and AR dielectric layer onto the active area, depositing a back surface dielectric layer over the back surface of the silicon substrate, applying and firing front and back surface contact grids, depositing a layer of doped amorphous silicon onto the back surface contact grid and the back surface dielectric, and depositing a layer of metal over the doped amorphous silicon layer. The method may further comprise the step of removing a back surface junction formed during the active area forming step. The method may further comprise the step of depositing a conductive interface layer between the doped amorphous silicon layer and the metal layer.

In at least one embodiment of the invention, the manufacturing method is comprised of the steps of diffusing phosphorous onto the front surface of a silicon substrate to form an n+ layer and a front surface junction and onto the back surface to form a back surface junction, removing the phosphor-silicate glass formed during the diffusion step (e.g., by etching with HF), depositing a passivation and AR dielectric layer on the front surface and a back surface dielectric onto the back surface, applying and firing front and back surface contact grids, and depositing a metal layer onto the back surface contact grid and back surface dielectric. The front and back surface contact grid firing steps may be performed simultaneously. Alternately, the back surface contact grid applying and firing steps may be performed prior to, or after, the front surface contact grid applying and firing steps. The method may further comprise the step of removing the back surface junction and isolating the front surface junction. A back surface metal grid may be applied, for example by screen printing or deposition using a shadow mask, after removing the back surface junction and prior to depositing the dielectric layer on the back surface. The back surface grid applying step may be performed after removing the back surface junction and prior to depositing the dielectric layer on the back surface.

In at least one embodiment of the invention, the manufacturing method is comprised of the steps of depositing a back surface dielectric onto the back surface of a silicon substrate of a first conductivity type, forming an active area of a second conductivity type on the front surface of the silicon substrate, etching the front surface of the silicon substrate, depositing a front surface passivation and AR dielectric layer onto the active area, applying and firing front and back surface contact grids, depositing a layer of doped amorphous silicon onto the back surface contact grid and the back surface dielectric, depositing a layer of metal over the doped amorphous silicon layer, and isolating the front surface junction, for example using a laser scriber. The method may further comprise the step of depositing a conductive interface layer between the doped amorphous silicon layer and the metal layer.

In at least one embodiment of the invention, the manufacturing method is comprised of the steps of depositing a dielectric layer on the back surface of a silicon substrate, diffusing phosphorous onto the front surface of the substrate to form an n+ layer and a front surface junction, removing the phosphor-silicate glass formed during the diffusion step (e.g., by etching with HF), depositing a front surface passivation and AR dielectric layer, applying and firing front and back surface contact grids, depositing a boron doped layer of amorphous silicon onto the back surface contact grid and back surface dielectric, depositing a metal layer onto the boron doped amorphous silicon layer, and isolating the front surface junction, for example using a laser scriber. The method may further comprise the step of depositing a conductive interface layer, for example comprised of ITO or ZnO:Al, between the boron doped amorphous silicon layer and the metal layer. The front and back surface contact grid firing steps may be performed simultaneously. Alternately, the back surface contact grid applying and firing steps may be performed prior to, or after, the front surface contact grid applying and firing steps.

In at least one embodiment of the invention, a bifacial solar cell (BSC) is provided that is comprised of a silicon substrate with a front surface active region of a first conductivity type, dielectric layers deposited on the front surface active region and on the back surface of the silicon substrate, a back surface contact grid applied to the back surface dielectric which alloys through the back surface dielectric to the back surface of the silicon substrate during firing, an amorphous silicon layer doped with a dopant of the first conductivity type deposited on the back surface contact grid and back surface dielectric, and a blanket metal layer deposited on the doped amorphous silicon layer. The BSC may further comprise a conductive interface layer, for example comprised of ITO or ZnO:Al, interposed between the doped amorphous silicon layer and the metal layer. The silicon substrate may be comprised of p-type silicon, the active region may be comprised of n+ material resulting from a phosphorous diffusion step, and the amorphous silicon layer may further comprise a boron dopant. The silicon substrate may be comprised of n-type silicon, the active region may be comprised of p+ material resulting from a boron diffusion step, and the amorphous silicon layer may further comprise a phosphorous dopant. The BSC may further comprise a metal grid pattern deposited directly onto the back surface of the silicon substrate and interposed between the silicon substrate and the back surface dielectric layer. The BSC may further comprise a groove on the front surface of the silicon substrate, the groove isolating the front surface junction.

A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a preferred embodiment of a BSC in accordance with the invention;

FIG. 2 illustrates the process flow for the BSC of FIG. 1;

FIG. 3 illustrates an alternate embodiment of the BSC of FIG. 1;

FIG. 4 illustrates the process flow for the BSC of FIG. 3;

FIG. 5 illustrates an alternate fabrication process for the BSC of FIG. 1;

FIG. 6 illustrates an alternate preferred embodiment of a BSC in accordance with the invention;

FIG. 7 illustrates the process flow for the BSC of FIG. 6;

FIG. 8 illustrates an alternate preferred embodiment of a BSC in accordance with the invention;

FIG. 9 illustrates the process flow for the BSC of FIG. 8;

FIG. 10 illustrates an alternate fabrication process for the BSC of FIG. 6;

FIG. 11 illustrates an alternate embodiment of the BSC of FIG. 8; and

FIG. 12 illustrates the process flow for the BSC of FIG. 11.

 DESCRIPTION OF THE SPECIFIC EMBODIMENTS

A conventional mono-facial solar cell includes a grid-shaped electrode on the front surface and a solid electrode covering the entire back surface. In contrast, in a conventional bifacial solar cell (BSC), the electrode structure is designed to allow light to enter not only from the front surface, but also from the back surface. As such, the solid electrode covering the back surface in the mono-facial cell is replaced by a grid electrode in the BSC. In such a cell, the grid-shaped back surface electrode allows light, e.g., indirect light, to enter from the rear. Additionally, such a design provides improved efficiency due to the decreased contact area of the grid-shaped back surface electrode. In accordance with the present invention, bifacial solar cells are provided that combine a non-continuous, e.g., grid-shaped, back surface electrode with a back surface reflector, thereby obtaining the advantage of improved efficiency.

FIG. 1 illustrates a cross-sectional view of a preferred BSC structure fabricated in accordance with the procedure described in FIG. 2. Silicon substrate 101 may be of either p- or n-type. In the exemplary device and process illustrated in FIGS. 1 and 2, a p-type substrate is used.

Initially, substrate 101 is prepared using any of a variety of well-known substrate preparatory processes (step 201). In general, during step 201 saw and handling induced damage is removed via an etching process, for example using a nitric and hydrofluoric (HF) acid mixture. After substrate preparation, the bottom surface of substrate 101 is doped, thereby forming a back surface doped region 103 (step 203). Preferably region 103 is doped with the same doping type as substrate 101. Increasing the doping level of region 103, compared to substrate 101, lowers the contact resistance. Additionally, doped region 103 reduces back surface recombination, a problem that is exacerbated by the inclusion of a back surface reflector. In at least one embodiment of the invention, region 103 is doped with a different doping type than that of substrate 101.

Region 103 can be formed using any of a variety of techniques. Exemplary techniques include, but are not limited to, chemical vapor deposition (CVD), plasma enhanced CVD (PE-CVD), spray coating, and spin coating. Accordingly, and assuming a p-type substrate and a p-type region 103, this region can be formed by depositing a boron doped polysilicon layer using CVD; depositing a boron doped silicon dioxide or amorphous silicon layer using PE-CVD; spray/spin coating a boric acid solution or doped spin-on glass onto the back surface of substrate 101; or by other means.

After formation of region 103, a dielectric layer 105 is deposited on the back surface of substrate 101, specifically on top of doped region 103 as shown (step 205). Preferably layer 105 is comprised of silicon nitride or silicon dioxide or a silicon dioxide/silicon nitride stack, preferably deposited using PE-CVD techniques at a temperature of 300° C. to 400° C., and has a thickness of approximately 76 nanometers for silicon nitride or 100 nanometers for silicon oxide. Next, an active region of a conductivity type different from that of the substrate is formed on the front surface of substrate 101. For example, assuming a p-type substrate, during step 207 phosphorous is diffused onto the front surface of substrate 101, creating n+ layer 107 and a p-n junction at the interface of substrate 101 and n+ layer 107. Preferably n+ layer 107 is formed using phosphoryl chloride (POCl3), where the diffusion is performed at a diffusion temperature in the range of 825° C. to 890° C., preferably at a temperature of approximately 850° C., for 10 to 20 minutes in a nitrogen atmosphere (step 207). It will be appreciated that during the phosphorous diffusion step 207, boron from region 103 is diffused into the back surface of substrate 101 to form a back surface field (BSF). The phosphor-silicate glass (PSG) formed during diffusion step 207 is then etched away, for example using a hydrofluoric (HF) etch at or near room temperature for 1 to 5 minutes (step 209). In the preferred embodiment, the front side junction has a depth of 0.3 to 0.6 microns and a surface doping concentration of about 8×1021/cm3.

In step 211, a front surface passivation and anti-reflection (AR) dielectric layer 109 is deposited, preferably comprised of silicon nitride or silicon oxynitride or a stack of materials of the silicon oxide/silicon nitride system. In one embodiment, layer 109 is comprised of an approximately 76 nanometer thick layer of silicon nitride. In another embodiment, layer 109 is comprised of approximately 10 nanometers of SiO2 under 70 nanometers of Si3N4. Preferably, layer 109 is deposited at a temperature of 300° C. to 400° C.

After deposition of the dielectric layer 109, contact grids are applied to the front and back surfaces of BSC 100 (step 213), for example using a screen printing process. In the exemplary embodiment, front contact grid 111 is comprised of silver while back contact grid 113 is comprised of an aluminum-silver mixture. In the preferred embodiment, both the front and back contact grids are aligned and use the same contact size and spacing, with electrodes being approximately 100 microns wide, 15 microns thick and spaced approximately 2.5 millimeters apart. In at least one alternate embodiment, the back contact grid uses a finer spacing in order to lessen resistance losses from lateral current flow in the substrate. Next, a contact firing step 215 is performed, preferably at a peak temperature of 750° C. for 3 seconds in air. As a result of this process, contacts 111 alloy through passivation and AR dielectric coating 109 to n+ layer 107. Similarly, contacts 113 alloy through dielectric coating 105 to layer 103. It should be understood that either a single firing step can be performed as shown, or the front surface and back surface contact grids can be applied and fired separately, thereby allowing different firing conditions to be used for each grid.

Although the back reflector may be deposited directly over back surface dielectric layer 105 and contacts 113, preferably a layer 115 of amorphous silicon is applied first to the back surface (step 217). Layer 115 is preferably thin to minimize infrared absorption and series resistance, on the order of 5 to 40 nanometers thick, and deposited using a technique such as PE-CVD. Layer 115 is heavily doped, preferably at a level of 1019/cm3 or greater, with the same dopant type as substrate 101, i.e., p-type dopant in exemplary structure which uses a p-type substrate. For the exemplary embodiment, boron is used as the dopant. Lastly, the blanket metal layer 117 is deposited on the back surface of the structure (step 219), metal layer 117 providing both a back surface reflector and means for making an electrical connection with contacts 113. Typically layer 117 is 1 to 10 microns thick, with a thinner layer preferred to minimize wafer bowing. Given the bandgap of amorphous silicon, i.e., 1.75 eV, layer 115 is transparent to the long wavelength photons that reach the reflective layer 117. Lastly, the front junction is isolated, for example using a laser scriber to form a groove on the front cell surface around the periphery of the cell (step 221).

Blanket metal layer 117 is preferably deposited using either physical vapor deposition (PVD) or screen printing, although it will be appreciated that other techniques can be used. Preferably, layer 117 has a high red reflectance, thus extending the photon path length in region 101 and increasing the absorption of photons with a wavelength near the bandgap. Additionally, low cost metals are preferred, such as aluminum. Although not shown, silver bus bars, a nickel vanadium coating or other materials can be added to the back surface of layer 117 to further enable soldering of back contacts.

FIGS. 3 and 4 illustrate an alternate embodiment utilizing a minor modification of the previously described device structure and process. In structure 300, a thin conductive interface layer 301 is added between silicon layer 115 and back surface reflector layer 117 (step 401). Layer 301 prevents the metal of layer 117, e.g., aluminum, mixing with the silicon of layer 115, thereby helping to maintain the high reflectivity of layer 117. Exemplary materials for layer 301 include indium tin oxide (ITO) and aluminum-doped zinc oxide (ZnO:Al). Optimally, the thickness of layer 301 is chosen to provide an optical match between the back surface and the metal layer 117 in the near infrared when taken in combination with the thickness of back surface dielectric layer 105. Thus, for example, if layer 105 is 50 nanometers thick, then the thickness of a ZnO:Al layer 301 should be approximately 35 nanometers thick.

FIG. 5 illustrates an alternate process for fabricating cell 100. In this process, after the formation of region 103 (step 203), the phosphorous is diffused into the front surface of substrate 101 (step 207) to create the n+ layer 107 and the p-n junction, thereby skipping back surface dielectric deposition step 205. Next, the PSG is etched away (step 209) and front surface dielectric 109 is deposited (step 211). The front surface contacts 111 and the back surface contacts are then applied (step 213), followed by the deposition of back surface dielectric layer 105 (step 501). As previously noted, back surface dielectric layer 105 is preferably comprised of silicon nitride or silicon dioxide or a silicon dioxide/silicon nitride stack. If desired, the order of steps 211, 213 and 501 can be altered, for example applying the back contact grid 113 first, followed by deposition of back surface dielectric layer 105, followed by the application of the front contact grid 111, and then followed by the deposition of the front surface dielectric layer 109.

After firing the front and back surface contact grids (step 215), amorphous silicon layer 115 is deposited (step 217), followed by the deposition of blanket reflective layer 117 (step 219), all as previously described. Although not shown, if desired conductive interface layer 301 may be added between silicon layer 115 and back surface reflector layer 117.

FIGS. 6 and 7 illustrate an alternate embodiment that eliminates doped region 103. In this embodiment, after substrate preparation step 201, front and back surface junctions are formed. Assuming the p-type substrate of the exemplary embodiments, phosphorous is diffused onto the front surface of substrate 101 as previously described, creating n+ layer 107 and a p-n junction at the interface of substrate 101 and n+ layer 107 (step 701). During step 701, phosphorous is also diffused onto the back surface of substrate 101, creating n+ layer 601 and a floating junction. Preferably step 701 is performed using phosphoryl chloride (POCl3) with a diffusion temperature in the range of 825° C. to 890° C., preferably at a temperature of approximately 850° C., for 10 to 20 minutes in a nitrogen atmosphere. Active region diffusing step 701 is followed by a PSG (assuming phosphorous) etching step 209, preferably using an HF etch at or near room temperature for 1 to 5 minutes.

In step 703, a front surface passivation and anti-reflection (AR) dielectric layer 603 is deposited as well as a back surface passivation and AR dielectric layer 605. In an exemplary embodiment, layers 603 and 605 are comprised of silicon nitride with an index of refraction of 2.07 and a layer thickness of approximately 76 nanometers. In an alternate embodiment, layers 603 and 605 are comprised of silicon oxynitride. In another alternate embodiment, layers 603 and 605 are comprised of a stack of two layers of different composition, for example 10 nanometers of silicon dioxide and 70 nanometers of silicon nitride. Layers 603 and 605 are preferably deposited at a temperature of 300° C. to 400° C.

Next, the front and back surface contact grids are applied (step 213) and fired (step 215), followed by deposition of blanket reflective layer 117 (step 219), all as previously described. In this embodiment, preferably front contact grid 111 is comprised of silver while back contact grid 113 is comprised of aluminum. Contact firing step 215 is preferably performed at a peak temperature of 750° C. for 3 seconds in air. As a result of this process, contacts 111 alloy through passivation and AR dielectric coating 603 to n+ layer 107. Contacts 113 alloy through passivation and AR dielectric coating 605 and back diffused layer 601 to form contact to substrate 101. As aluminum is a p-type dopant, a diode forms between back diffused layer 601 and contact 113 so that current does not flow from the back diffused layer into the contact and the back diffusion is floating. This isolates the back surface from the bulk 101 since there is zero current into a floating junction. Although not shown in FIGS. 6 and 7, if desired conductive interface layer 301 may be added between silicon layer 115 and back surface reflector layer 117. This embodiment can also separate the contact grid deposition process and firing of the front and back surface contact grids as previously described.

FIGS. 8 and 9 illustrate an alternate embodiment in which the floating junction on the back surface of the substrate is removed. In structure 800, after formation of the front junction and PSG etching, the back surface of substrate 101 is etched (step 901), thereby removing the back surface junction and providing isolation for the front junction. In a preferred embodiment, step 901 uses an isotropic wet silicon etch such as a mixture of nitric acid and HF acid. After removal of the back surface floating junction, the process continues as previously described relative to FIGS. 6 and 7. Preferably in this embodiment the back surface contact grid is comprised of an aluminum-silver mixture.

FIG. 10 illustrates an alternate process for fabricating cell 600. In this process, after preparation of substrate 101 (step 201), dielectric layer 605 is applied to the back surface of substrate 101 (step 1001). As previously described, preferably dielectric layer 603 is comprised of silicon nitride or silicon oxynitride. Applying dielectric layer 605 prior to diffusing the front surface n+ layer 107 (step 701) prevents the formation of a back surface junction. After the front surface diffusion (step 701) and the PSG etch (step 209), front surface passivation and AR dielectric layer 603 is deposited (step 1003), followed by applying (step 213) and firing (step 215) of the contact grids, deposition of amorphous silicon layer 115 (step 217), and deposition of back surface reflector 117 (step 219). Lastly, the front junction is isolated, for example using a laser scriber to form a groove on the front cell surface around the periphery of the cell (step 1005). This embodiment may also include conductive interface layer 301 between silicon layer 115 and back surface reflector layer 117 and, additionally, may separate the contact grid deposition and firing of the front and back surface contact grids as previously described.

FIGS. 11 and 12 illustrate a variation of BFC 800. As shown in the BFC cross-sectional view of BFC 1100, a metal grid 1101 is applied directly onto the back surface of cell 101 (step 1201), thereby reducing contact resistance. Step 1201 is preferably performed after the back surface of substrate 101 has been etched to remove the back surface junction and isolate the front junction (step 901). Step 1201 is performed using either a deposition process with a shadow mask, or using a screen printing process. Preferably, metal grid 1101 is comprised of aluminum. After depositing dielectric layers 603 and 605 (step 703), contact grids 111 and 113 are applied and fired, either together or separately as previously described. Back surface contact grid 113 is registered to metal grid 1101. During the firing step, contact grid 113 alloys to metal grid 1101. Next, amorphous silicon layer 115 is deposited (step 217), followed by the deposition of blanket reflective layer 117 (step 219), all as previously described. Although not shown, if desired conductive interface layer 301 may be added between silicon layer 115 and back surface reflector layer 117.

In an alternate embodiment of that described above relative to FIGS. 11 and 12, the process eliminates the steps of applying and firing the back surface contact grid 113. In this embodiment, metal grid 1101 fires through the overlaid dielectric layer, thereby allowing metal layer 117 to connect to metal grid 1101.

As previously noted, an n-type substrate may also be used with the invention. In such an embodiment, an n-type dopant, such as phosphorous, is used in those regions which were previously described as using a p-type dopant such as boron. Similarly, in those regions which previously used a p-type dopant (e.g., boron), an n-type dopant (e.g., phosphorous) is used. Lastly, it should be understood that identical element symbols used on multiple figures refer to the same component/processing step, or components/processing steps of equal functionality.

As will be understood by those familiar with the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention.

Claims

1. A method of fabricating a bifacial solar cell (BSC), the method comprising the steps of:

depositing a dopant of a first conductivity type onto a back surface of a silicon substrate of said first conductivity type to form a back surface doped region;
depositing a back surface dielectric over said back surface doped region;
forming an active area of a second conductivity type on a front surface of said silicon substrate, said forming step including a thermal diffusing step, wherein said method includes a single thermal diffusing step;
etching said active area;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said active area;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid;
depositing a layer of amorphous silicon onto said back surface contact grid and said back surface dielectric, wherein said layer of amorphous silicon is doped with a second dopant of said first conductivity type;
depositing a layer of metal over said layer of amorphous silicon; and
isolating said active area.

2. The method of claim 1, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

3. The method of claim 1, further comprising the step of depositing a conductive interface layer between said layer of amorphous silicon and said layer of metal, wherein said conductive interface layer depositing step is performed prior to said metal layer depositing step.

4. A method of fabricating a bifacial solar cell, the method comprising the steps of:

depositing a boron doped layer on a back surface of a p-type silicon substrate;
depositing a back surface dielectric onto said boron doped layer;
diffusing phosphorous onto a front surface of said silicon substrate to form an n+ layer and a front surface junction;
removing a phosphor-silicate glass (PSG) formed during said phosphorous diffusing step;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said n+ layer;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid;
depositing a boron doped layer of amorphous silicon onto said back surface contact grid and said back surface dielectric;
depositing a metal layer onto said boron doped layer of amorphous silicon; and
isolating said front surface junction.

5. The method of claim 4, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

6. The method of claim 4, wherein said step of isolating said front surface junction is performed using a laser scriber.

7. The method of claim 4, further comprising the step of depositing a conductive interface layer between said boron doped layer of amorphous silicon and said layer of metal, wherein said conductive interface layer depositing step is performed prior to said metal layer depositing step.

8. The method of claim 7, wherein said conductive interface layer is comprised of a material selected from the group consisting of indium tin oxide and aluminum-doped zinc oxide.

9. The method of claim 4, wherein said steps of firing said back and front surface contact grids are performed simultaneously.

10. The method of claim 4, wherein said step of firing said back surface contact grid is performed prior to said step of applying said front surface contact grid.

11. The method of claim 4, wherein said boron doped layer depositing step further comprises the step of depositing a boron doped silicon dioxide layer using chemical vapor deposition.

12. The method of claim 4, wherein said boron doped layer depositing step further comprises the step of depositing a boron doped silicon layer using chemical vapor deposition.

13. The method of claim 4, wherein said boron doped layer depositing step further comprises the step of depositing a boron doped amorphous silicon layer using plasma enhanced chemical vapor deposition.

14. The method of claim 4, wherein said boron doped layer depositing step further comprises the step of spraying a boric acid solution onto said back surface of said silicon substrate.

15. The method of claim 4, wherein said boron doped layer depositing step further comprises the step of spraying a boron doped spin-on glass onto said back surface of said silicon substrate.

16. The method of claim 4, wherein said PSG removing step further comprises the step of etching said front surface with a hydrofluoric etch.

17. The method of claim 4, further comprising the step of selecting said back surface dielectric and said front surface passivation and AR dielectric from the group consisting of silicon nitrides, silicon dioxides and silicon oxynitrides.

18. The method of claim 4, wherein said phosphorous diffusing step is performed at a temperature of approximately 850° C. for a duration of approximately 10 to 20 minutes.

19. The method of claim 4, wherein said back surface dielectric depositing step is performed after said step of applying said back surface contact grid.

20. A bifacial solar cell, comprising:

a silicon substrate of a first conductivity type with a front surface and a back surface;
a doped region of said first conductivity type located on said back surface of said silicon substrate;
a dielectric layer deposited on said doped region;
an active region of a second conductivity type located on said front surface of said silicon substrate;
a passivation and AR dielectric layer deposited on said active region;
a first contact grid applied to said dielectric layer, said first contact grid comprised of a first metal, wherein after a firing step said first contact grid is alloyed through said dielectric layer to said doped region located on said back surface of said silicon substrate;
a second contact grid applied to said passivation and AR dielectric layer, said second contact grid comprised of a second metal, wherein after said firing step said second contact grid is alloyed through said passivation and AR dielectric layer to said active region;
a amorphous silicon layer doped with a dopant of said first conductivity type, said amorphous silicon layer deposited on said first contact grid and said dielectric layer; and
a blanket layer deposited on said amorphous silicon layer, said blanket layer comprised of a third metal.

21. The bifacial solar cell of claim 20, further comprising a groove on said front surface of said silicon substrate, said groove isolating a front junction formed by said active region and said silicon substrate.

22. The bifacial solar cell of claim 20, further comprising a conductive interface layer interposed between said amorphous silicon layer and said blanket layer.

23. The bifacial solar cell of claim 22, wherein said conductive interface layer is selected from the group of materials consisting of indium tin oxide and aluminum doped zinc oxide.

24. The bifacial solar cell of claim 20, wherein said silicon substrate is comprised of a p-type silicon, said active region is comprised of n+ material resulting from a phosphorous diffusion step, and said doped region and said amorphous silicon layer further comprise a boron dopant.

25. The bifacial solar cell of claim 24, wherein said dielectric layer and wherein said passivation and AR dielectric layer are each comprised of a material selected from the group consisting of silicon nitrides, silicon dioxides and silicon oxynitrides.

26. The bifacial solar cell of claim 20, wherein said silicon substrate is comprised of an n-type silicon, said active region is comprised of p+ material resulting from a boron diffusion step, and said doped region and said amorphous silicon layer further comprise a phosphorous dopant.

27. A method of fabricating a bifacial solar cell (BSC), the method comprising the steps of:

forming an active area of a second conductivity type on a front surface of a silicon substrate of a first conductivity type, said forming step including a thermal diffusing step;
etching said front surface of said silicon substrate;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said active area and a back surface dielectric layer onto said back surface of said silicon substrate;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid;
depositing a layer of amorphous silicon onto said back surface contact grid and said back surface dielectric layer, wherein said layer of amorphous silicon is doped with a dopant of said first conductivity type; and
depositing a layer of metal over said layer of amorphous silicon.

28. The method of claim 27, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

29. The method of claim 27, further comprising the step of depositing a conductive interface layer between said layer of amorphous silicon and said layer of metal, wherein said conductive interface layer depositing step is performed prior to said metal layer depositing step.

30. The method of claim 27, further comprising the step of removing a back surface junction formed on a back surface of said silicon substrate during said active area forming step.

31. A method of fabricating a bifacial solar cell, the method comprising the steps of:

diffusing phosphorous onto a front surface of a silicon substrate to form an n+ layer and a front surface junction and onto a back surface of said silicon to form a back surface junction;
removing a phosphor-silicate glass (PSG) formed during said phosphorous diffusing step;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said n+ layer and a back surface dielectric layer onto said back surface of said silicon substrate;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid; and
depositing a metal layer onto said back surface contact grid and said back surface dielectric.

32. The method of claim 31, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

33. The method of claim 31, wherein said steps of firing said back and front surface contact grids are performed simultaneously.

34. The method of claim 31, wherein said step of firing said back surface contact grid is performed prior to said step of applying said front surface contact grid.

35. The method of claim 31, further comprising the steps of removing said back surface junction and isolating said front surface junction.

36. The method of claim 35, wherein said back surface junction removing step further comprises the step of etching said back surface.

37. The method of claim 35, wherein said step of applying said back surface contact grid is performed after said back surface junction removing step and before said back surface dielectric layer depositing step.

38. The method of claim 35, further comprising the step of applying a back surface metal grid onto said back surface of said silicon substrate, wherein said back surface metal grid applying step is performed after said back surface junction removing step and before said back surface dielectric layer depositing step, and wherein the method of claim 31 further comprises the step of aligning said back surface contact grid with said back surface metal grid.

39. The method of claim 38, wherein said back surface metal grid applying step further comprises the steps of applying a shadow mask to said back surface of said silicon substrate and depositing said back surface metal grid onto said back surface of said silicon substrate.

40. The method of claim 38, wherein said back surface metal grid applying step further comprises the step of screen printing said back surface metal grid onto said back surface of said silicon substrate.

41. The method of claim 38, wherein said step of firing said back surface contact grid is performed prior to said step of applying said front surface contact grid.

42. The method of claim 31, wherein said PSG removing step further comprises the step of etching said front surface with a hydrofluoric etch.

43. A method of fabricating a bifacial solar cell (BSC), the method comprising the steps of:

depositing a back surface dielectric layer onto a back surface of a silicon substrate of a first conductivity type;
forming an active area of a second conductivity type on a front surface of said silicon substrate, said forming step including a thermal diffusing step;
etching said front surface of said silicon substrate;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said active area;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid;
depositing a layer of amorphous silicon onto said back surface contact grid and said back surface dielectric layer, wherein said layer of amorphous silicon is doped with a dopant of said first conductivity type; and
depositing a layer of metal over said layer of amorphous silicon; and
isolating said front surface junction.

44. The method of claim 43, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

45. The method of claim 43, wherein said step of isolating said front surface junction is performed using a laser scriber.

46. The method of claim 43, further comprising the step of depositing a conductive interface layer between said layer of amorphous silicon and said layer of metal, wherein said conductive interface layer depositing step is performed prior to said metal layer depositing step.

47. A method of fabricating a bifacial solar cell, the method comprising the steps of:

depositing a dielectric layer onto a back surface of a silicon substrate;
diffusing phosphorous onto a front surface of said silicon substrate to form an n+ layer and a front surface junction;
removing a phosphor-silicate glass (PSG) formed during said phosphorous diffusing step;
depositing a front surface passivation and anti-reflection (AR) dielectric layer onto said n+ layer;
applying a back surface contact grid;
applying a front surface contact grid;
firing said back surface contact grid;
firing said front surface contact grid;
depositing a boron doped layer of amorphous silicon onto said back surface contact grid and said back surface dielectric; and
depositing a metal layer onto said boron doped layer of amorphous silicon; and
isolating said front surface junction.

48. The method of claim 47, wherein said step of applying said back surface contact grid further comprises the step of screen printing said back surface contact grid, and wherein said step of applying said front surface contact grid further comprises the step of screen printing said front surface contact grid.

49. The method of claim 47, wherein said step of isolating said front surface junction is performed using a laser scriber.

50. The method of claim 47, further comprising the step of depositing a conductive interface layer between said boron doped layer of amorphous silicon and said layer of metal, wherein said conductive interface layer depositing step is performed prior to said metal layer depositing step.

51. The method of claim 50, wherein said conductive interface layer is comprised of a material selected from the group consisting of indium tin oxide and aluminum-doped zinc oxide.

52. The method of claim 47, wherein said steps of firing said back and front surface contact grids are performed simultaneously.

53. The method of claim 47, wherein said step of firing said back surface contact grid is performed prior to said step of applying said front surface contact grid.

54. The method of claim 47, wherein said PSG removing step further comprises the step of etching said front surface with a hydrofluoric etch.

55. A bifacial solar cell, comprising:

a silicon substrate of a first conductivity type with a front surface and a back surface;
a first dielectric layer deposited on said back surface of said silicon substrate;
an active region of a second conductivity type located on at least a portion of said front surface of said silicon substrate;
a second dielectric layer deposited on said active region;
a first contact grid applied to said first dielectric layer, said first contact grid comprised of a first metal, wherein after a firing step said first contact grid is alloyed through said first dielectric layer to said back surface of said silicon substrate;
a amorphous silicon layer doped with a dopant of said first conductivity type, said amorphous silicon layer deposited on said first contact grid and said first dielectric layer; and
a blanket layer deposited on said amorphous silicon layer, said blanket layer comprised of a third metal.

56. The bifacial solar cell of claim 55, further comprising a conductive interface layer interposed between said amorphous silicon layer and said blanket layer.

57. The bifacial solar cell of claim 56, wherein said conductive interface layer is selected from the group of materials consisting of indium tin oxide and aluminum doped zinc oxide.

58. The bifacial solar cell of claim 55, wherein said silicon substrate is comprised of a p-type silicon, said active region is comprised of n+ material resulting from a phosphorous diffusion step, and said amorphous silicon layer further comprises a boron dopant.

59. The bifacial solar cell of claim 55, further comprising a grid pattern of a third metal deposited directly on said back surface of said silicon substrate and interposed between said back surface of said silicon substrate and said first dielectric layer, wherein said first contact grid is registered to said grid pattern, and wherein after said firing step said first contact grid is alloyed through said first dielectric layer to said grid pattern of said third metal.

60. The bifacial solar cell of claim 55, wherein said first contact grid is applied directly to said back surface of said silicon substrate and prior to said first dielectric layer.

61. The bifacial solar cell of claim 55, further comprising a groove on said front surface of said silicon substrate, said groove isolating a front junction formed by said active region and said silicon substrate.

62. The bifacial solar cell of claim 55, wherein said silicon substrate is comprised of an n-type silicon, said active region is comprised of p+ material resulting from a boron diffusion step, and said amorphous silicon layer further comprises a phosphorous dopant.

Patent History
Publication number: 20100275995
Type: Application
Filed: Jun 15, 2009
Publication Date: Nov 4, 2010
Applicant: Calisolar, Inc. (Sunnyvale, CA)
Inventors: Martin Kaes (Berlin), Peter Borden (San Mateo, CA), Kamel Ounadjela (Belmont, CA), Andreas Kraenzl (Radolfzell), Alain Blosse (Belmont, CA), Fritz G. Kirscht (Berlin)
Application Number: 12/456,398