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. |