High voltage Cu(In,Ga)S2 solar modules

Sulfurcell (SC) has been running a pilot production for thin-film solar modules using CuInS₂-chalcopyrite (CIS) as absorber material since 2004. Since then production technology has been constantly improved with module power values exceeding 64 W, corresponding to an aperture area efficiency level of about 9%. Small area (0.5 cm2) cells cut out of such CIS modules reach maximum efficiencies close to 11%. Strong efforts have been made to develop a new sequential Cu(In,Ga)S₂ (CIGS) process suitable for production of large-scale CIGS solar modules thereby enabling module efficiencies above 10%. CIGS-based solar cells are—quite similar to CIS-based modules—prepared from sputtered metals subsequently sulfurized using rapid thermal processing in sulfur vapor. Such Cu(In,Ga)S₂ solar cells reach material record efficiencies about 13%. The cells are characterized by high open-circuit voltages up to 890 mV. Based on the results of the “Helmholtz Zentrum Berlin” (HZB), Sulfurcell has successfully scaled this process to our typical module size of 125 cm × 65 cm and is currently piloting the process for mass production. This paper will give an overview of electrical and structural parameters of world's first large-scale CIGS modules. CIGS module and cell parameters will be compared with standard CIS module and cell parameters and measured CIGS efficiency temperature coefficients will be compared with typical temperature coefficients of modules based on established PV technologies.     

A detailed study of the series resistance effect on CdS/CdTe solar cells with Cu/Mo back contact

CdS/CdTe thin film solar cells with an area of 1 cm² were obtained and studied in detail. A ZnO buffer layer was deposited by reactive RF-sputtering on commercial ITO substrates. The CdS layer was grown on ZnO also by using RF-sputtering and CdTe thin film was deposited by conventional CSS technique. The chlorination of the solar cells is performed into Freon atmosphere at 400 °C. The CdTe thin film surface was chemically etched by using Br-Methanol solution. The back contact was deposited using RF-sputtering from a pure Cu and Mo targets. The procedure developed in this work led us to make systematically solar cells with good efficiency. However, the series resistance has a high value for an area of 1 cm² (22 Ω cm²). In order to make more detailed study, the solar cell with an area of 1 cm² was divided in a 3 × 3 matrix. A good homogeneity in cell properties is observed and the efficiency increases to more than 11%, fundamentally through decreasing series resistance.     

Dependence of efficiency of thin-film CdS/CdTe solar cell on parameters of absorber layer and barrier structure

Dependences of the open-circuit voltage, short-circuit current, fill factor, and efficiency of a CdS/CdTe solar cell on the resistivity and thickness of the p-CdTe absorber layer, the noncompensated acceptor concentration N_a-N_d, and carrier lifetime τ in CdTe, are investigated, and optimization of these parameters in order to improve the solar cell efficiency is performed. It has been shown that the observed low efficiency of CdS/CdTe solar cells is caused by the too short electron lifetime in the range of 10^− 10-10^− 9 s and too thin (3-5 µm) CdTe layer currently used for fabrication of CdTe/CdS solar cells. To achieve an efficiency of 28-30%, the resistivity and thickness of the CdTe absorber layer, the noncompensated acceptor concentration, and carrier lifetime should be ∼ 0.1 Ω·cm, ≥ 20-30 µm, ≥ 10¹⁶ cm^− 3, and ≥ 10^− 6 s, respectively.     

Pilot production of large-area CuInS2-based solar modules

A pilot production of CuInS₂-based thin-film solar modules has been established in Berlin, Germany. To date, its 125 cm × 65 cm modules have produced an aperture area conversion efficiency as high as 7.6%, and avenues towards even higher performance levels have been identified. The pilot production features industrially-proven sputtering technology for material deposition and a new rapid thermal process allowing a five-minute sulfurization cycle time. The first thousand modules produced (representing a total of 45 kWp) were subjected to statistical analysis documenting the continuous enhancement of module power over the early months of pilot production. Transient effects were found that influence module I(V) characteristics cause inaccurately low module power measurements when flasher-type sun-simulators are used in testing — a phenomenon correctable by the introduction of a pre-test light-soaking procedure. In order to verify the post-light-soaking test results data from outdoor measurements taken under standard test conditions as well as performance data of outdoor PV systems were analyzed. A higher energy output on a Wh/Wp-basis found for CuInS₂-based solar modules than for polycrystalline silicon-based solar modules is presumed to be due to a lower temperature coefficient. For evaluating the long-term future potential of the new CuInS₂-based technology, a cost model is introduced to assess the economic relevance of uptime, cycle time and yield values, and to show that both efficiency and productivity are crucial for high-capacity manufacture of thin-film solar modules.     

Anlagen für die Solarzellen‐Schichterzeugung benötigen hervorragend ausgelegte Vakuumsysteme

Vacuum pumps are an enabling technology for solar power because all modules require vacuum processing at various stages of production. Specially engineered products that are helping to make solar modules more affordable by reducing equipment downtime and improving process performance are essential to become a successful partner for the solar industry. The processes used for thin film technology are extremely demanding. Pump performance for high flows of light gases must be achieved and in parallel safety aspects must be considered carefully. The pump solutions must be extreme reliable in order to guarantee maximum tool up‐time which is mandatory for a production line in order to be cost competitive. Design and performance of such solutions must be qualified in close collaboration between pump supplier and the equipment producer together wi^th the user of the equipment. Experience and know how from industries using similar processes like semiconductor, large area coating or FPD production can be applied for solar production lines which can help to reduce time to market. The article will outline the specific needs for thin film solar cells based on amorphous silicon and CdTe.     

Development of an energy-binned photon-counting detector for X-ray and gamma-ray imaging

The aim of this study is to develop an energy-binned photon-counting (EBPC) detector that enables us to provide energy information of x-rays with a reasonable count statistics. We used Al-pixel/CdTe/Pt semiconductor detectors, which had an active area of 8 mm×144 mm and consisted of 18 modules aligned linearly. The size of a CdTe detector module was 8 mm×8 mm and the thickness of the CdTe crystal was 1 mm. Each module consisted of 40×40 pixels and the pixel size was 200 μm×200 μm. We applied the bias voltage of −500 V to the Pt common electrode. The detector counted the number of x-ray photons with four different energy windows, and output four energy-binned images with pixel depths of 12, 12, 11 and 10 bits at a frame rate of 1200 Hz (300 Hz×4 energy bins). The basic performance of the detector was evaluated in several experiments. The results showed that the detector realized the photon counting rate of 0.4×10⁶ counts/sec/pixel (10⁷ counts/sec/mm²), energy resolution 4.4% FWHM at 122 keV. The integral uniformity of the detector was about 1% and the differential uniformity was about 1%. In addition, the image quality was examined with a resolution chart and step-wedge phantoms made of aluminum and polymethyl methacrylate. And we compared the quality of an acquired image with that acquired with an energy integration detector. The results of these experiments showed that the developed detector had desirable intrinsic characteristics for x-ray photon counting imaging.     

CdTe-CdS solar cells — Production in a new baseline and investigation of material properties

In this paper, we describe our new baseline for CSS-CdTe-CdS solar cells on 10 × 10 cm² substrates. The deposition of the p-n junction and all the following steps were performed at the Institut für Festkörperphysik (IFK) in Jena. Using the new baseline, we are already able to produce solar cells with similar properties as commercial ones. In the batch type process, all manufacturing steps can be investigated separately. We employ Rutherford backscattering spectrometry (RBS), X-ray diffraction (XRD) and external quantum efficiency (EQE) measurements to characterise the structure of the bulk materials and interfaces. It is demonstrated that by RBS the front contact becomes accessible for thinned CdTe films. At the back contact, RBS spectra show a tellurium accumulation which is due to etching. This tellurium rich layer is confirmed by XRD with Rietveld refinement. The intermixing at the CdS-CdTe interface caused by the activation step is quantified by a bandgap determination based on EQE measurements. From the bandgap energy of the CdTe_1 − xS_x compound, we calculated the sulphur fraction x at the interface. XRD measurements imply that the activation step induces a (111) texture in CdTe. With regard to an improved manufacturing process, our cells are compared to industrial cells produced by Antec Solar Energy.     

Preparation and characterization of pulsed laser deposited CdTe thin films at higher FTO substrate temperature and in Ar + O2 atmosphere

Pulsed laser deposition (PLD) is one of the promising techniques for depositing cadmium telluride (CdTe) thin films. It has been reported that PLD CdTe thin films were almost deposited at the lower substrate temperatures (<300 °C) under vacuum conditions. However, the poor crystallinity of CdTe films prepared in this way renders them not conducive to the preparation of high-efficiency CdTe solar cells. To obtain high-efficiency solar cell devices, better crystallinity and more suitable grain size are needed, which requires the CdTe layer to be deposited by PLD at high substrate temperatures (>400 °C). In this paper, CdTe layers were deposited by PLD (KrF, λ = 248 nm, 10 Hz) at different higher substrate temperatures (T_s). Excellent performance of CdTe films was achieved at higher substrate temperatures (400 °C, 550 °C) under an atmosphere of Ar mixed with O₂ (1.2 Torr). X-ray diffraction analysis confirmed the formation of CdTe cubic phase with a strong (1 0 0) preferential orientation at all substrates temperatures on 60 mJ laser energy. The optical properties of CdTe were investigated, and the band gaps of CdTe films were 1.51 eV and 1.49 eV at substrate temperatures of 400 °C and 550 °C, respectively. Scanning electron microscopy (SEM) showed an average grain size of 0.3–0.6 μm. Thus, under these conditions of the atmosphere of Ar + O₂ (15 Torr) and at the relatively high T_s (500 °C), an thin-film (FTO/PLD-CdS (100 nm)/PLD-CdTe (~1.5 μm)/HgTe: Cu/Ag) solar cell with an efficiency of 6.68% was fabricated.     

The use of aluminium doped ZnO as transparent conductive oxide for CdS/CdTe solar cells

CdTe/CdS and CdTe/ZnO thin film solar cells were grown with a high vacuum evaporation based low temperature process (≤ 420 °C). Aluminium doped zinc oxide (AZO) was used as transparent conducting oxide (TCO) material. AZO exhibited excellent stability during the solar cell processing, and no significant change in electrical conductivity or transparency was observed. The current density loss due to absorption in the 1 μm thick AZO layer with 5 Ω per square sheet resistance was found to be 1.2 mA/cm². We investigated the influence of an intrinsic ZnO layer (i:ZnO) in combination with various CdS thicknesses. The i:ZnO layer was found to significantly increase the open circuit voltage of the solar cells with very thin CdS layer. Increasing thickness of the i:ZnO layer leads to UV absorption losses, narrowing of the depletion layer width and hence reduced collection efficiency in the long wavelength (685-830 nm) part. With AZO/i:ZnO bi-layer TCO we could achieve cell efficiencies of 15.6% on glass and 12.4% on the flexible polyimide film.     

Study of the physical properties of Bi doped CdTe thin films deposited by close space vapour transport

Bi doped cadmium telluride (CdTe:Bi) thin films were grown on glass-substrates by the close space vapour transport method. CdTe:Bi crystals grown by the vertical Bridgman method, varying the nominal Bi concentration in the range between 1 × 10¹⁷ and 8 × 10¹⁸ cm^− 3, were used in powder form for CdTe:Bi thin film deposition. Dark conductivity and photoconductivity measurements in the 90-300 K temperature range and determination by photoacoustic spectroscopy of the optical-absorption coefficient of the films in the 1.0 to 2.4 eV spectral region were carried out. The influence of Bi doping levels upon the intergrain barrier height and other associated grain boundary parameters of the polycrystalline CdTe:Bi thin films were determined from electrical, optical and morphological characterization.     

Conductive polymer PEDOT:PSS back contact for CdTe solar cell

Two types of superstrate glass/ITO/CdS/CdTe PV structures were prepared by high vacuum evaporation technique with (i) activation of CdS layer and CdS/CdTe bi-layer structure step-by-step and (ii) activation of CdS/CdTe bi-layer structure. The activation was performed by annealing the structures with CdCl₂ in air at 400 °C for 15 min. Main conditions for CdS and CdTe thin films deposition and following treatment were selected from the literature data with the purpose to prepare and compare complete CdTe solar cells with standard p + Cu_xTe back contact and conductive polymer poly(3,4-ethylenedioxythiophene) doped with polystyrene sulfonic acid (PEDOT:PSS) back contact. Obtained layers and structures were characterized using the XRD, SEM and I-V methods. Both the methods of activation treatment give comparable results from the point of view PV properties of complete solar cells. It was found that highly conductive PEDOT:PSS intermediate layer can significantly improve the back contact characteristics of CdTe. However these hybrid structures need to be further optimized to compete successfully with conventional inorganic back contacts in complete CdTe solar cells.     

Advantages of using amorphous indium zinc oxide films for window layer in Cu(In,Ga)Se2 solar cells

The advantages of using indium zinc oxide (IZO) films instead of conventional Ga-doped zinc oxide (ZnO:Ga) films for Cu(In,Ga)Se₂ (CIGS) solar cells are described. The electrical properties of IZO are independent of film thickness. IZO films have higher mobility (30-40 cm²/Vs) and lower resistivity (4-5 × 10^− 4 Ω cm) compared to ZnO:Ga films deposited without intentional heating, because the number of grain boundaries in amorphous IZO films is small. The properties of a CIGS solar cell using IZO at the window layer were better than those obtained using a conventional ZnO:Ga at the window layer; moreover, the properties tended to be independent of thickness. These results indicate that use of IZO as a transparent conducting oxide layer is expected to increase the efficiency of CIGS solar cells.     

CdTe thin film solar cells with reduced CdS film thickness

A study was performed to reduce the CdS film thickness in CdTe thin film solar cells to minimize losses in quantum efficiency. Using close space sublimation deposition for CdS and CdTe a maximum efficiency of ~ 9.5% was obtained with the standard CdS film thickness of ~ 160 nm. Reduction of the film CdS thickness to less than 100 nm leads to poor cell performance with ~ 5% efficiency, mainly due to a lower open circuit voltage. An alternative approach has been tested to reduce the CdS film thickness (~ 80 nm) by depositing a CdS double layer. The first CdS layer was deposited at high substrate temperature in the range of 520-540 °C and the second CdS layer was deposited at low substrate temperature of ~ 250 °C. The cell prepared using a CdS double layer show better performance with cell efficiency over 10%. Quantum efficiency measurement confirmed that the improvement in the device performance is due to the reduction in CdS film thickness. The effect of double layer structure on cell performance is also observed with chemical bath deposited CdS using fluorine doped SnO₂ as substrate.     

Electrochemical deposition of CdSe/CdTe multilayer nanorods for hybrid solar cell

CdSe and CdTe are composite semiconductor materials used in hybrid solar cell due to their high absorption coefficients. CdSe and CdTe have different band gaps, 1.74 eV and 1.45 eV respectively and then they can absorb solar energy in a wider range of wavelength compare to the silicon solar cell. In this research, CdSe and CdTe nanorods were fabricated using electrochemical deposition in an anodic aluminum oxide template. The electrodeposition behaviors of CdSe and CdTe were investigated using cyclic voltammetric technique. The deposition potentials of CdSe and CdTe were obtained through cyclic voltammetric technique. The effects of Te and Se ion concentration in the electrolyte on the composition of the deposits were investigated to obtain 1:1 atomic ratio. Structures of layered CdSe/CdTe nanorods were analyzed with FESEM and EDS.     

Studies of key technologies for large area CdTe thin film solar cells

The structure and main manufacturing technologies of CdTe film solar cells of large area are reviewed. Among the technologies, some have been developed for application in a pilot manufacturing line. The high resistant SnO₂ (HRT) thin films have been fabricated by PECVD. The effects of annealing on the structure and properties have been studied. A surface etching process of CdTe in low temperature and lower concentration of nitric acid has been developed. The Cd_1 − xZn_xTe ternary compound films have been studied. In order to improve the back contact layer, Cd_0.4Zn_0.6Te layer with 1.8 eV band gap as a substitute for ZnTe layer is introduced in CdTe cells. The effects of the technologies on performance of CdTe cells and feasibility of application in the modules are discussed.     

Characterization of CBD-CdS layers with different S/Cd ratios in the chemical bath and their relation with the efficiency of CdS/CdTe solar cells

In previous papers we have reported the improvement of the efficiency of CdS/CdTe solar cells by varying the thiourea/CdCl₂ ratio (R_tc) in the chemical bath solution used for the deposition of the CdS layers. In this work, a more complete study concerning the physical properties of Chemical Bath Deposited (CBD) CdS layers studied by photoluminescence, X-ray diffraction and optical spectroscopy are correlated to the I-V characteristics under AM 1.5 sunlight and the spectral response of CdS/CdTe solar cells. It is confirmed that the optimum R_tc for the CBD CdS films is R_tc = 5, since in this case the best solar cells were obtained and these films show the better optical and structural characteristics.     

Preparation of SnO2 thin films at low temperatures with H2 gas by the hot-wire CVD method

H₂ additional effect for crystallization of SnO₂ films prepared by the hot-wire CVD method was investigated. The crystallization of SnO₂ films starts at 170 °C. The selectivity enhancement of the solar cell substrate will contribute to reduce the cost of silicon thin film solar cells. The atomic hydrogen assisted nano-crystallization exists for the depositions of SnO₂ films by the hot-wire CVD method. Furthermore, the addition of H₂ gas improved the electrical conductivity up to 5.3 × 10⁰ S/cm. However, these effects are limited in the deposition condition of a small amount of hydrogen. Addition of much higher hydrogen concentration starts an etching effect of oxygen atoms.     

Strategies to increase CdTe solar-cell voltage

There is a significant difference in performance between today's highest efficiency of CdTe solar cells and single-crystal cells of comparable band gap. The largest contribution to this difference is the voltage, where the values for the best CdTe cells are about 230 mV below the best GaAs cells when an appropriate adjustment is made for band gap. CdTe voltage and fill-factor are currently compromised by low recombination lifetime (near 1 ns), low hole density (near 10¹⁴ cm^− 3), and in some cases an excessive back-contact barrier. Numerical simulation is used to evaluate how combinations of lifetime, carrier density, back electron reflection, and interfacial properties affect voltage and cell performance. Two different strategies for improving voltage and performance are explored.     

Influences of oxygen contamination on evaporated poly-Si thin-film solar cells by solid-phase epitaxy

The influences of the oxygen contaminations on the crystal quality and performances of the evaporated polycrystalline silicon (poly-Si) thin-film solar cells prepared by solid-phase epitaxy were investigated by applying different deposition rates and base pressures. The experimental results show that although the evaporated poly-Si thin-film solar cell obtained at high base pressures (9.33 × 10^− 5 Pa) and high deposition rate (300 nm/min) has small amount of SiO₂ precipitations, it still shows the similar good material quality and performances as the cell prepared at low base pressure (1.33 × 10^− 6 Pa) and high deposition rate (300 nm/min) with oxygen interstitials. On the other hand, the poly-Si thin-film solar cell deposited at low base pressure (1.33 × 10^− 6 Pa) and low deposition rate (50 nm/min) has large amount of SiO₂ precipitations and resulting worse material quality and hence cell performances. Therefore, the high deposition rate is desirable to maximize the solar cell performance, as well as the throughput. It is a more influential factor than the base pressure.     

Characterization of polarization phenomenon in Al-Schottky CdTe detectors using a spectroscopic analysis method

CdTe radiation detectors equipped with Schottky contacts are known to show spectral response degradation over time under biasing. Nevertheless, they can be used as high-resolution spectrometers for X-rays and gamma-rays with moderate cooling and high voltage. Spectroscopic long-term measurements have been performed with Al/CdTe/Pt pixel detectors of 0.5, 1 and 2 mm thicknesses and ²⁴¹Am source from −13 to +16 °C to evaluate how long they can be operated. Experimental results are confronted to simulations using the charge accumulation model for electric field. Activation energy for collection efficiency stability and peak shift was measured at 1.0-1.2 eV although deep acceptor levels responsible for hole detrapping during polarization were evaluated by other methods at E_V +0.6-0.8 eV. The difference is probably due to a thermal effect of pre-polarization before biasing the detector.