Current Solar Technology

A solar cell is a semiconductor device that converts photons from the sun (solar light) into electricity. The general term for a solar cell including both solar and non-solar sources of light (such as photons from incandescent bulbs) is termed a photovoltaic cell. Fundamentally, the device needs to fulfill only two functions: photogeneration of charge carriers (electrons and holes) in a light-absorbing material, and separation of the charge carriers to a conductive contact that will transmit the electricity. This conversion is called the photovoltaic effect, and the field of research related to solar cells is known as photovoltaics.

The most common configuration of this device, the first generation photovoltaic, consists of a large-area, single layer p-n junction diode, which is capable of generating usable electrical energy from light sources with the wavelengths of solar light. These cells are typically made using silicon. However, successive generations of photovoltaic cells are currently being developed that may improve the photoconversion efficiency for future photovoltaics. The second generation of photovoltaic materials is based on multiple layers of p-n junction diodes. Each layer is designed to absorb a successively longer wavelength of light (lower energy), thus absorbing more of the solar spectrum and increasing the amount of electrical energy produced. The third generation of photovoltaics is very different from the other two, and is broadly defined as a semiconductor device which does not rely on a traditional p-n junction to separate photogenerated charge carriers. These new devices include dye sensitized cells, organic polymer cells, and quantum dot solar cells.

Solar cells have many applications. They are particularly well suited to, and historically used in, situations where electrical power from the grid is unavailable, such as in remote area power systems, Earth orbiting satellites, handheld calculators, remote radiotelephones and water pumping applications. Assemblies of solar cells (in the form of modules or solar panels) on building roofs can be connected through an inverter to the electricity grid in a net metering arrangement.Because solar cells are semiconductor devices, they share many of the same processing and manufacturing techniques as other semiconductor devices such as computer and memory chips. However, the stringent requirements for cleanliness and quality control of semiconductor fabrication are a little more relaxed for solar cells. Most large-scale commercial solar cell factories today make screen printed poly-crystalline silicon solar cells. Single crystalline wafers which are used in the semiconductor industry can be made in to excellent high efficiency solar cells, but they are generally considered to be too expensive for large-scale mass production.

Poly-crystalline silicon wafers are made by wire-sawing block-cast silicon ingots into very thin (250 to 350 micrometer) slices or wafers. The wafers are usually lightly p-type doped. To make a solar cell from the wafer, a surface diffusion of n-type dopants is performed on the front side of the wafer. This forms a p-n junction a few hundred nanometers below the surface.

Antireflection coatings, which increase the amount of light coupled into the solar cell, are typically applied next. Over the past decade, silicon nitride has gradually replaced titanium dioxide as the antireflection coating of choice because of its excellent surface passivation qualities (i.e., it prevents carrier recombination at the surface of the solar cell). It is typically applied in a layer several hundred nanometers thick using plasma-enhanced chemical vapor deposition (PECVD). Some solar cells have textured front surfaces that, like antireflection coatings, serve to increase the amount of light coupled into the cell. Such surfaces can usually only be formed on single-crystal silicon, though in recent years methods of forming them on multicrystalline silicon have been developed.

The wafer is then metallized, whereby a full area metal contact is made on the back surface, and a grid-like metal contact made up of fine "fingers" and larger "busbars" is screen-printed onto the front surface using a silver paste. The rear contact is also formed by screen-printing a metal paste, typically aluminum. Usually this contact covers the entire rear side of the cell, though in some cell designs it is printed in a grid pattern. The metal electrodes will then require some kind of heat treatment or "sintering" to make Ohmic contact with the silicon. After the metal contacts are made, the solar cells are interconnected in series (and/or parallel) by flat wires or metal ribbons, and assembled into modules or "solar panels". Solar panels have a sheet of tempered glass on the front, and a polymer encapsulation on the back. Tempered glass cannot be used with amorphous silicon cells because of the high temperatures during the deposition process.

Silicon thin-films are mainly deposited by Chemical vapor deposition (typically plasma enhanced (PE-CVD)) from silane gas and hydrogen gas. Depending on the deposition's parameters, this can yield:
1 Amorphous silicon (a-Si or a-Si:H)
2 protocrystalline silicon or
3 Nanocrystalline silicon (nc-Si or nc-Si:H).

These types of silicon present dangling and twisted bonds, which results in deep defects (energy levels in the bandgap) as well as deformation of the valence and conduction bands (band tails). The solar cells made from these materials tend to have lower energy conversion efficiency than bulk silicon, but are also less expensive to produce. The quantum efficiency of thin film solar cells is also lower due to reduced number of collected charge carriers per incident photon.

Amorphous silicon has a higher bandgap (1.7 eV) than crystalline silicon (c-Si) (1.1 eV), which means it is more efficient to absorb the visible part of the solar spectrum, but it fails to collect the infrared portion of the spectrum. As nc-Si has about the same bandgap as c-Si, the two material can be combined in thin layers, creating a layered cell called a tandem cell. The top cell in a-Si absorbs the visible light and leaves the infrared part of the spectrum for the bottom cell in nanocrystalline Si, as pioneered by the Sanyo HIT cell. A patented silicon thin film technology being developed by XsunX, Inc, for building integrated photovoltaics (BIPV) in the form of semi-transparent solar cells which can be applied as window glazing. These cells function as window tinting while generating electricity.