Surface sulfurization studies of Cu(InGa)Se2 thin film

Sulfurization of copper indium gallium diselenide (CIGS) thin films solar cell absorber has been used to enhance the open-circuit voltage of the device by increasing the band gap of the absorber near the interface. Sulfurization of a homogeneous co-evaporated Cu(InGa)Se₂ thin film was studied in hydrogen sulfide and in a mixture of hydrogen sulfide and hydrogen selenide gases with the inclusion of oxygen. The structural and compositional properties of the absorber layer were investigated by XRD, EDS and AES. Sulfurization in hydrogen sulfide gas forms a fully converted sulfide layer at the top of the absorber layer, which in turn forms a barrier for the current collection. Sulfurization in a mixture of hydrogen sulfide and hydrogen selenide gases forms a wide band gap Cu(InGa)(SeS)₂ layer at the surface, but at the same time there is Ga diffusion away from the surface with the inclusion of sulfur at the surface.     

Highly efficient Cu(In,Ga)Se2 mini-modules

In this contribution, we present results and the philosophy of our mini-module efforts. These efforts have achieved world record levels as well as a reproducible process. Various mini-module designs are tested using two different baseline Cu(In,Ga)Se₂ deposition recipes. Gridded mini-modules achieve highest efficiencies and are much less demanding on the ZnO:Al top contact than their conventional counterpart. For all of the designs tested, our experimental results are in the order of the expectations from our modeling. Gridded modules can achieve efficiency levels very close to those of the cells.     

Role of incorporated sulfur into the surface of Cu(InGa)Se2 thin-film absorber

High-performance Cu(InGa)Se₂ (CIGS) thin-film absorbers with an intentionally graded band-gap structure have been fabricated by a simple two-stage method using In/Cu–Ga/Mo stacked precursors and H₂Se gas. Additional sulfurization step to form a thin Cu(InGa)(SeS)₂ (CIGSS) surface layer on the absorber is necesarry to improve the device performance. In order to understand the role of S incorporated into CIGS absorber, approaches with S are discussed. One approach is carried out by changing the condition of our absorber formation process. It is verified to be possible to incorporate more S into the CIGS absorber, but difficult to improve the device performance with higher S contained CIGS absorbers because of decrease in FF. The incorporated S is concluded to be effective to improve the pn heterojunction quality due to the passivation of surface and grain boundary of CIGS absorber through the formation of a thin CIGSS surface layer.     

Improved performance of Cu(InGa)Se2 thin-film solar cells using evaporated Cd-free buffer layers

Polycrystalline Cu(InGa)Se₂ (CIGS) thin-film solar cells using evaporated In_xSe_y and ZnIn_xSe_y buffer layers are prepared. The purpose of this work is to replace the chemical bath deposited CdS buffer layer with a continuously evaporated buffer layer. In this study, a major effort is made to improve the performance of CIGS thin-film solar cells with these buffer layers. The relationship between the cell performance and the substrate temperature for these buffer layers is demonstrated. Even at the high substrate temperature of about 550°C for the buffer layer, efficiencies of more than 11% were obtained. Furthermore, the I−V characteristics of the cells using these buffer layers are compared with cells using CdS buffer layers fabricated by chemical bath deposition method. We have achieved relatively high efficiencies of over 15% using both the ZnIn_xSe_y and the CdS buffer layers.     

Cu(In,Ga)Se2-based thin-film photovoltaic modules optimized for long-term performance

In this contribution we give an overview of the mechanisms behind degradation of Cu(In,Ga)Se₂-based modules. Based on the results from a detailed analysis of power losses in modules, prior to and after extended damp heat exposure, we discuss to what extent modules can be designed to achieve enhanced long-term performance. For conventional modules, we show that the stability can be improved by optimizing the interconnect and the front contact. Furthermore, we argue that gridded modules are better from a long-term performance point of view. A novel interconnect structure, specifically designed for long-term durability, is briefly discussed.     

Progress in large-area Cu(InGa)Se2-based thin-film modules with a Zn(O,S,OH)x buffer layer

Applying basically the same innovative and robust fabrication technologies which, for the first time, led to the achievement of remarkably high efficiency of 14.2% at an aperture area of 51.7 cm² with a Zn(O,S,OH)_x buffer layer, the following goals have been targeted: (1) 13% efficiency on a 30 cm×30 cm module and (2) establishment of the fabrication technologies to attain 140 yen/W_p in the annual production capacity of 100 MW_p/a. The main focus is currently on the technology development (1) to increase the V_oc related to the CIGS absorber and (2) to improve the J_sc related to the DC-sputtered ZnO window layer with a multilayered structure. This contribution well explains the status and strategy of Showa Shell Sekiyu K.K. on the R&D of CIGS-based thin-film modules to achieve the above two goals by the end of FY2000.     

Cu(In,Ga)Se2 thin-film solar cells with an efficiency of 18%

An efficiency of over 18% have been achieved in Cu(In,Ga)Se₂ (CIGS) thin-film solar cells. Solar cell parameters were estimated for the cells with efficiencies of more and less than 18%. A diode quality factor n and forward current (saturated current) J₀ of the cell with over 18% efficiency are lower than those with below 18% efficiency. This would be attributed to sufficient coverage of the CdS film with excellent uniformity as a buffer and/or window layer over the CIGS film because the process of CdS film formation was improved.     

Quality control and characterization of Cu(In,Ga)Se2-based thin-film solar cells by surface photovoltage spectroscopy

Surface photovoltage spectroscopy (SPS) has been used for quality control of ZnO/CdS/ Cu(In,Ga)Se₂ (CIGS) thin-film solar cells. The results show that SPS makes it possible to detect “hard failures” following CIGS deposition, and both “hard” and “soft” failures following CdS deposition and following ZnO deposition. In addition, a semi-quantitative screening of CdS/CIGS and ZnO/CdS/CIGS samples is possible. Hence, SPS is suggested as a useful tool for in-line monitoring of CIGS-based solar cell production lines. Moreover, SPS is shown to yield important new information regarding CIGS-based solar cells: (a) A deep gap state is found in samples of superior performance. (b) As opposed to the CdS/CIGS structure, a marked decrease in the open-circuit voltage upon Na contamination in ZnO/CIGS structures is found.     

Near-band-edge photoluminescnce in Cu(In,Ga)Se2 solar cells

Photoluminescence (PL) and PL decay characteristics of the near-band-edge (NBE) PL at room temperature have been studied on the Cu(In,Ga)Se₂ (CIGS) solar cells. The carrier recombination process has been discussed with emphasis on the photovoltaic properties of the solar cell. It has been found that: (i) PL intensity of the CIGS solar cells is much stronger than that in the corresponding CIGS thin films, (ii) the PL decay time of the cell is longer than that of the CIGS film, and (iii) the PL decay time of the CIGS solar cell exhibits strong dependence on the PL excitation intensity. In the CIGS solar cell, intense PL is obtained under the open circuit condition (oc), in contrast to the very low PL yield under the short circuit (sc) condition. The PL decay time under the sc condition is much shorter than that under the oc condition. Excitation intensity dependence of PL intensity and the PL decay time have been studied, and they are discussed with relation to the photo-voltage due to the PL excitation light. PL and injection EL under the external DC bias have been studied. The mapping image of NBE-PL intensity has been compared with that of the laser beam induced current (LBIC), and the PL intensity image reflects the photovoltaic properties of the CIGS solar cells. We demonstrated that NBE-PL of the CIGS solar cell reflects the photovoltaic effect, and it can be utilized as a powerful characterization method.     

X-ray fluorescence investigation of the Ga distribution in Cu(In,Ga)Se2 thin films

The efficiencies of Cu(In,Ga)Se₂/CdS/ZnO solar cell devices in which the absorbers are produced by classical two-step processes are significantly lower that those in which co-evaporated absorbers are used. A significant problem related to two-step growth processes is the reported segregation of Ga towards the Mo back contact, resulting in separate CuInSe₂ and CuGaSe₂ phases. Furthermore, it is often reported that material losses (especially In and Ga) occur during high-temperature selenization of metallic precursors. In this study, X-ray fluorescence (XRF) analysis was used to study the diffusion behaviour of the chalcopyrite elements in single-stage and two-stage processed Cu(In,Ga)Se₂ thin films. This relatively simple characterization technique proved to be very reliable in determining the degree of selenium incorporation, possible material losses and the in-depth compositional uniformity of samples at different stages of processing. This information is especially important in the case of two-stage growth processes, involving high-temperature selenization steps of metallic precursors. Device quality Cu(In,Ga)Se₂ thin films were prepared by a relatively simple and reproducible two-step growth process in which all the metals were evaporated from one single crucible in a selenium-containing environment. The precursors were finally treated in an H₂Se/Ar atmosphere to produce fully reacted films. XRF measurement indicated no loss of In or Ga during this final selenization step, but a significant degree of element diffusion which depended on the reaction temperature. It was also possible to produce Cu(In,Ga)Se₂ thin films with an appreciable amount of Ga in the near-surface region without separated CuInSe₂ and CuGaSe₂ phases.     

RF sputter deposition of the high-quality intrinsic and n-type ZnO window layers for Cu(In,Ga)Se2-based solar cell applications

Transparent ZnO films were prepared by rf magnetron sputtering, and their electrical, optical, and structural properties were investigated under various sputtering conditions. Aluminum-doped n-type(n-ZnO) and undoped intrinsic-ZnO (i-ZnO) layers were deposited on a glass substrate by incorporating different targets in the same reaction chamber. The n-ZnO films were strongly affected by argon ambient pressure and substrate temperature, and films deposited at 2 mTorr and 100°C showed superior properties in resistivity, transmission, and figure of merit (FOM). The sheet resistance of ZnO film was less dependent on film thickness when the substrate was heated during deposition. These positive effects of elevated substrate temperature are presumably attributed to the rearrangement of the sputtered atoms by the heat energy. Also, the films are electrically uniform through the 5 cm×5 cm substrate. The maximum deviation in sheet resistance is less than 10%. All of the films showed strong (0 0 2) diffraction peak near 2θ =34°. The undoped i-ZnO films deposited in the mixture of argon and oxygen gases showed high transmission properties in the visible range, independent of the Ar/O₂ ratio, while resistivity rose with increased oxygen partial pressure. The Cu(In,Ga)Se₂ solar cells, incorporating bi-layer ZnO films (n-ZnO/i-ZnO) as window layer, were finally fabricated. The fabricated solar cells showed 14.48% solar efficiency under AM 1.5 conditions (100 mW/cm²).     

Preparation of Cu(In,Ga)Se2 thin films from Cu–Se/In–Ga–Se precursors for high-efficiency solar cells

Improved preparation process of a device quality Cu(In,Ga)Se₂ (CIGS) thin film was proposed for production of CIGS solar cells. In–Ga–Se layer were deposited on Mo-coated soda-lime glass, and then the layer was exposed to Cu and Se fluxes to form Cu–Se/In–Ga–Se precursor film at substrate temperature of over 200°C. The precursor film was annealed in Se flux at substrate temperature of over 500°C to obtain high-quality CIGS film. The solar cell with a MgF₂/ITO/ZnO/CdS/CIGS/Mo/glass structure showed an efficiency of 17.5% (V_oc=0.634 V, J_sc=36.4 mA/cm², FF=0.756).     

Design of grided Cu(In,Ga)Se2 thin-film PV modules

Results from modeling designs of Cu(In,Ga)Se₂ thin-film PV modules show that grided modules, at standard test conditions as well as at low-concentrated light, exhibit significantly improved performance when compared with conventional designs. It is further discussed that a grided design is advantageous from a synthesis and manufacturing point of view, since it provides higher front contact process tolerance and throughput as well as improved degrees of freedom of the module geometry.     

Preparation of Zn doped Cu(In,Ga)Se2 thin films by physical vapor deposition for solar cells

Cu(In,Ga)Se₂ (CIGS) surface was modified with Zn doping using vacuum evaporation. Substrate temperatures and exposure times during the Zn evaporation were changed to control a distribution of Zn in the CIGS films. Diffusion of Zn in the CIGS films was observed at the substrate temperature of over 200°C. The diffusion depth of Zn increases with increasing the exposure time at the substrate temperature of 300°C. Solar cells were fabricated using the Zn doped CIGS films. A distribution of the efficiencies decreases with increasing the exposure time of Zn vapor. The doping of Zn at the film surface improved reproducibility of a high fill factor and efficiency. A solar cell fabricated using the CIGS film modified with Zn doping showed an efficiency of 14.8%.     

Photoconductivity of Cu(In, Ga) Se2 films

Polycrystalline CuIn_{1 − x}Ga_xSe₂ (0 ≤ x < 0.3) films (CIGS) were deposited by coevaporating the elements from appropriate sources onto glass substrates (substrate temperature 720 to 820 K). Photoconductivity of the polycrystalline CIGS films with partially depleted grains were studied in the temperature range 130–285 K at various illumination levels (0–100 mW/cm²). The data at low temperature (T < 170 K) were analyzed by the grain boundary trapping model with monovalent trapping states. The grain boundary barrier height in the dark and under illumination were obtained for different x-values of CuIn_1−xGa_xSe₂ films. Addition of Ga in the polycrystalline films resulted in a significant decrease in the barrier height. Variation of the barrier height with incident intensity indicated a complex recombination mechanism to be effective in the CIGS films.     

High-efficiency Cu(In,Ga)Se2 thin-film solar cells with a novel In(OH)3:Zn buffer layer

We propose the inclusion of a novel In(OH)₃:Zn²⁺ buffer layer for fabricating high-efficiency CIGS solar cells. This buffer layer was deposited using a solution consisting of ZnCl₂, InCl₃·4H₂O, and thiourea. The In(OH)₃:Zn²⁺ films showed high resistivities of 2.1×10⁸ Ω cm and transmittance of above 95% in the visible range. We expected two effects due to this new buffer layer: first is the formation of a passivation layer on the CIGS surface and the second is Zn-doping into CIGS layer, resulting in the formation of a buried junction. A cell efficiency of 14.0% (V_oc: 0.575 V, J_sc: 32.1 mA/cm², FF: 0.758) was achieved by using an In(OH)₃:Zn²⁺ buffer layer, without the light soaking effect.     

Yield issues on the fabrication of 30 cm×30 cm-sized Cu(In,Ga)Se2-based thin-film modules

The approaches to establish a more robust and reproducible baseline process for 30cm×30 cm-sized CIGS-based thin-film circuits with a Zn(O,S,OH)_x buffer layer are reported, which also lead to an achievement of 12.93% efficiency on an aperture area of 864 cm². Monitoring the transparency or transmittance (%T) of dip solution as a process control parameter in the chemical bath deposition (CBD)-buffer deposition step and setting the end point of dipping the CIGS-based absorbers in the solution as the %T of 60% remarkably contribute to make our CBD-buffer deposition process more reproducible. By considering carefully the growth process of metal-organic chemical vapor deposition (MOCVD)-ZnO:B window, a thin layer of high-resistivity, intrinsic ZnO is deposited on the Zn(O,S,OH)_x buffer layer to simulate the film structure of MOCVD-ZnO:B window in the case of sputtered-5.7 GZO window. Achievement of the reproducibility of 85% for the CIGS-based thin-film circuits with a sputtered-5.7 GZO window confirms that the yield goal of 85% is surely attainable independent of window-layer deposition techniques, such as MOCVD and sputtering. In this study, it is emphasized how important to eliminate unknown factors in the fabrication process for CIGS-based thin-film modules to improve both reproducibility and efficiency.     

The effect of NaF on Cu(In, Ga)Se2 thin film solar cells

This work investigates NaF, on Mo coated sodium barrier glass, as a sodium precursor for the growth of Cu(In, Ga)Se₂ for thin film solar cells. These precursor layers are investigated by X-ray photoelectron spectroscopy (XPS) before and after annealing, and after exposure to selenium. XPS is also performed on the Cu(In, Ga)Se₂ layer, deposited with NaF. The influence of the NaF on the absorber growth is studied by Scanning Electron Microscopy (SEM) and X-ray diffraction (XRD). The electrical properties are investigated by cell fabrication and characterization. Cell results are comparable when NaF or out-diffusion of sodium from the soda lime glass are used.     

Cu(In,Ga)Se2 based photovoltaic structure by electrodeposition and processing

CuIn_1−xGa_xSe₂ (CIGS) thin films were formed from an electrodeposited CuInSe₂ (CIS) precursor by thermal processing in vacuum in which the film stoichiometry was adjusted by adding In, Ga and Se. The structure, composition, morphology and opto-electronic properties of the as-deposited and selenized CIS precursors were characterized by various techniques. A 9.8% CIGS based thin film solar cell was developed using the electrodeposited and processed film. The cell structure consisted of Mo/CIGS/CdS/ZnO/MgF₂. The cell parameters such as J_sc, V_oc, FF and η were determined from I–V characterization of the cell.     

Experimental study of graded bandgap Cu(InGa)(SeS)2 thin films grown on glass/molybdenum substrates by selenization and sulphidation

High-performance Cu(InGa)(SeS)₂ (CIGSS) thin film absorbers with an intentionally graded bandgap structure grown by a two-stage method have been studied. Materials obtained from Showa Shell Sekiyu K.K., Japan have been grown using selenization and sulphidation of the Mo/Cu–Ga/In stacked precursors. Full characterizations have been carried out using X-ray diffraction, Raman, scanning electron microscopy, atomic force microscopy, X-ray photoelectron spectroscopy (XPS), X-ray fluorescence, inductively coupled plasma mass spectroscopy, glow discharge optical emission spectroscopy (GDOES) and photoelectrochemical (PEC) techniques to study various properties. The material layers were found to be polycrystalline with the (1 1 2) preferred orientation, and the largest grains were about 2 μm. Raman measurements show the presence of at least five different phases within the material. XPS confirmed the copper depletion and the richness of sulphur at the top surface region. Although the PEC studies indicate the overall electrical conductivity of the layer as p-type, GDOES profiling reveals the segregation of different phases at different depths suggesting the possibility of having buried junctions within the material itself. The results are presented together with suggestions for further improvements of CIGSS solar cell material.