High Efficiency CdTe and CIGS Thin Film Solar Cells ... · High Efficiency CdTe and CIGS Thin Film...
Transcript of High Efficiency CdTe and CIGS Thin Film Solar Cells ... · High Efficiency CdTe and CIGS Thin Film...
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High Efficiency CdTe and CIGS Thin Film Solar Cells: Highlights of the Technologies
Challenges
Acknowledgement: Work performed at NREL for US DOEunder contract No. DE-AC36-99GO-10337
National Renewable Energy Laboratory • National Center for Photovoltaics
Rommel Noufi
NREL/PR-520-39773
Presented at the 2006 IEEE 4th World Conference on Photovoltaic Energy Conversion (WCPEC-4) held May 7-12, 2006 in Waikoloa, Hawaii.
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Disclaimer and Government License
This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.
Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency thereof.
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OutlineIntroduction
Highlights
- summary of device performance
- how devices are structured
- properties of thin film layers
- summary of module performance
Key Challenges
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Acknowledgements
Polycrystalline Thin Film Group – NREL
Measurement and Characterization – NREL
K. Zweibel, H. Ullal, B. von Roedern – NREL
Dale Tarrant – Shell Solar Industries
Robert Birkmire – IEC, U. of Deleware
Bernhard Dimmler – Wurth Solar
Peter Meyers – First Solar
Dennis Hollars – MIASOLE
Jeff Britt, Scott Wiedeman – Global Solar Energy
Tim Anderson – U. of Florida
W.S. Sampath – AVA TECH
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Introduction• CdTe and CIGS PV modules have the potential to reach
cost effective PV-generated electricity.
• They have transitioned from the laboratory to the market place.
• Pilot production/first-time manufacturing (US) ~ 25 MW.
• CdTe technology ramping to 75 MW.
• Enjoying a flux of venture capital funding.
• Transitioning from the lab to manufacturing has been much more difficult than anticipated.
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CIS and CdTe PV Companies
Shell Solar, CAGlobal Solar Energy, AZEnergy Photovoltaics, NJISET, CAITN/ES, CONanoSolar Inc., CADayStar Technologies, NY/CAMiaSole, CAHelioVolt, TxSolyndra, CASoloPower, CA
Wurth Solar, GermanySULFURCELL, GermanyCIS Solartechnik, GermanySolarion, GermanySolibro, SwedenCISEL, FranceShowa Shell, JapanHonda, Japan
CIS
CdTeFirst Solar, OHSolar Fields, OHAVA TECH, CO
CANRON, NY Antec Solar, Germany
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LaboratorySolar CellsLaboratorySolar Cells
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Thin Film CIGS Solar CellsEfficiency
Area(cm2)
CIGSe
CIGSe
CIGS
CIAS
CdTe
CdTe
CdTe
Area(cm2)
0.410
0.402
0.409
–
1.03
–
0.16
VOC(V)
0.697
0.67
0.83
0.621
0.845
0.840
0.814
JSC(mA/cm2)
35.1
35.1
20.9
36.0
25.9
24.4
23.56
FF(%)
79.52
78.78
69.13
75.50
75.51
65.00
73.25
Efficiency(%)
19.5
18.5
12.0
16.9
16.5
13.3
14.0
CommentsCIGSe/CdS/Cell
NREL, 3-stage processCIGSe/ZnS (O,OH)NREL, Nakada et al
Cu(In,Ga)S2/CdSDhere, FSEC
Cu(In,Al)Se2/CdSIEC, Eg = 1.15eV
CTO/ZTO/CdS/CdTeNREL, CSS
SnO2/Ga2O3/CdS/CdTeIEC, VTD
ZnO/CdS/CdTe/MetalU. of Toledo, sputtered
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CIGS CdTe
ZnO/CdS
CIGS
MoGlass
Glass
CdS
CdTe
C-Paste/Cu
Cd2SnO4/ZnSnOx
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SEM Micrographs - Sputtered MoThin Films
5 mTorr
8 mTorr
12 mTorr
100 nm
100 nm100 nm
100 nm100 nm
100 nm
PressureRate: 25Å/sec.
H. Althani Thesis
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CIGS Thin Film with Eg=1.1-1.2 eV
26% Ga/(In+Ga) 31% Ga/(In+Ga)
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AES Depth Profiles
60
50
40
30
20
10
040302010
Sputter Time (min)
Cu Ga Se In
S221360
50
40
30
20
10
040302010
Sputter Time (min)
Cu Ga Se In
S2212
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CIGS Deposition System
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CIGS Formation Pathways
Deposition Methods
Evaporation of the Elements Vacuum
Sputtering of the Elements Vacuum
Nanotechnology/Nano-particles-(Inks) Printing
CVD-based (lab. R&D) Low Vacuum
1. Cu + In + Ga Cu:In:Ga intermetallic
Cu:In:Ga intermetallic + H2Se (or Se) Cu(In,Ga)Se2
2. Cu2Se + (In,Ga)2Se3 Cu(In,Ga)Se2
3. Cu + In + Ga + Se Cu(In,Ga)Se2
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Deposition of CdS
Solution (CBD): CdSO4, NH4OH, N2H4CS (Thiorea), H2O
Temperature: 60°C to 85°C
Time: 4 to 20 min.
Sputtered CdS
Ts 150-200°C
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Optical Transmission - ZnO
RF-sputtered
Target: ZnO, ZnO:Al
Rate: 1.5Å/sec.
61.6 ohm/square2300 angstroms
7.1 ohm/square7800 angstroms
3.3 ohm/square1.4 microns
CIGS bandgap
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Parameters of High Efficiency CIGS Solar Cells
Sample Number Voc (V) Jsc (mA/cm2) Fill factor (%) Efficiency (%)C1812-11 0.692 35.22 79.87 19.5
(World Record)
S2212-B1-4 0.704 34.33 79.48 19.2S2232B1-3 0.713 33.38 79.54 18.9S2232B1-2 0.717 33.58 79.41 19.1S2229A1-3 0.720 32.86 80.27 19.0S2229A1-5 0.724 32.68 80.37 19.0S2229B1-2 0.731 31.84 80.33 18.7S2213-A1-3 0.740 31.72 78.47 18.4
Tolerance to wide range of molecularity
Cu/(In+Ga) 0.95 to 0.82
Ga/(In+Ga) 0.26 to 0.31
Yields device efficiency of 17.5% to 19.5%
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Quantum Efficiency1.0
0.8
0.6
0.4
0.2
0.0
QE,
R, A
12001000800600400Wavelength (nm)
S221226% Ga
S221331% Ga
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Diode QualityJo and n (light curves)
Bandgap (eV) J0 (A/cm2) n(Diode Quality Factor)
1.10 5x10-11 1.351.12 6x10-11 1.361.12 6x10-11 1.351.21 4x10-10 1.571.22 5x10-10 1.62
R = 0.25 Ω cm2
G = 0.10 mS cm-2 (or Rsh = 10 kΩ cm2)
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Efficiency and Voc vs Eg
0.9
0.8
0.7
0.6
0.5Ope
n C
ircui
t vol
tage
(V)
1.61.51.41.31.21.11.0Absorber band gap (eV)
18
16
14
12
10
Effi
cien
cy (%
)
1.61.51.41.31.21.11.0Absorber band gap (eV)
1.7
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High Quality TCO – Cd2SnO4(CTO)
CdTe bandgap
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Solution (CBD): CdSO4, NH4OH, N2H4CS (Thiorea), H2O
Temperature: 60°C to 85°C
Time: 15 to 30 min.
Deposition of CdS
Vapor Transport Deposition of CdS
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CdS
ZnTe:Cu
2µm
CdTeCdS
ZnTe:Cu
CdTe Thin Film Morphology
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IEC VTD
4”x6” Pre-Heater, 600°C 2”x6” Post-Heater600°C
4”x4” Substrate
Heater/Enclosure(Hot-Press boron nitride (BN) with borate binder)
Ta Wire Confined in BN
Non-Heated RegionConstrains Deposit
CdTe
Heater
CdTeSource
Substrate
Halogen Lamp
Halogen Lamp
Close Space Sublimation (CSS)Schematic
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High-EfficiencyCTO/ZTO/CdS/CdTe Cells
Cell #Voc
(mV)Jsc
(mA/cm2)FF(%)
η(%)
Area(cm2)
W547-A 847.5 25.86 74.45 16.4 1.131W553-A 849.9 25.50 74.07 16.1 1.029W566-A 842.7 25.24 76.04 16.2 1.116W567-A 845.0 25.88 75.51 16.5 1.032W597-B 835.6 25.25 76.52 16.1 0.961W608-B 846.3 25.43 74.24 16.0 1.130W614-B 842.2 25.65 74.67 16.1 0.948
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Thin FilmModulesThin FilmModules
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Company Device Aperture Area (cm2)
Efficiency (%)
Power (W) Date
Global Solar CIGS 8390 10.2* 88.9* 05/05
Shell Solar CIGSS 7376 11.7* 86.1* 10/05
Wrth Solar CIGS 6500 13.0 84.6 06/04
First Solar CdTe 6623 10.2* 67.5* 02/04
Shell Solar GmbH CIGSS 4938 13.1 64.8 05/03
Antec Solar CdTe 6633 7.3 52.3 06/04
Shell Solar CIGSS 3626 12.8* 46.5* 03/03
Showa Shell CIGS 3600 12.8 44.15 05/03
Polycrystalline Thin Film PV Modules(standard conditions, aperture-area)
Ranked by Power
* NREL Confirmed
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CIGS and CdTe Devices and Modules Have Similar Structure and Process Sequence
Substrate Base Electrode AbsorberFirst
Scribe
ThirdScribe
TopElectrode
JunctionLayer
SecondScribe
ExternalContacts Encapsulation
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Module Monolithic Interconnect Scheme
Monolithic integration of TF solar cells can lead to significantmanufacturing cost reduction; e.g., fewer processing steps, easier automation, lower consumption of materials.
Shared characteristics lead to similar cost per unit area: $/m2.
Efficiency discriminating factor for cost per watt: $/watt.
⇐
Courtesy of Dale Tarrant, Shell Solar
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ChallengesLack of adequate science and engineering knowledge base
• Measurable material properties that are predictive of device and module performance
• Relationship between materials delivery and film growth
• Develop control and diagnostics based on material properties and film growth
• Coupling of this knowledge to industrial processes
Benefits:
• High throughput and high yield at every step of the process
• High degree of reliability and reproducibility
• Higher Performance
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Challenges (cont.)
Long-Term Stability (Durability)
• Both technologies have shown long-term stability.However, performance degradation has also been observed.
• CdTe and CIGS devices have different sensitivity to water vapor; e.g., oxidation of metal contact, change in properties of ZnO.
- Thin Film Barrier to Water Vapor
- New encapsulants and less aggressive application process
• Need for better understanding degradation mechanisms at the device level and prototype module level.
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· Product Durability:Environmental, Lifetime Tests
Recent Effort at GSE
GSE CIGS-Glass (2.3 kW at Springerville, AZ)
0.0
2.0
4.0
6.0
8.0
10.0
12.0
1-Aug-2005 1-Sep-2005 2-Oct-2005 2-Nov-2005 3-Dec-2005 3-Jan-2006 3-Feb-2006Date
DC
Effi
cien
cy (%
, at T
emp.
)
** Not at STC (Temp. is uncontrolled)** Load Point Determined by Inverters
S. Wiedeman, TFPP 2006 Global Solar Global Solar --
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Temperature Dependent Degradation
Temp Time to Failure60 24000080 940
100 168120 62
12
10
8
6ln(T
ime
to F
ail)
3.0x10-32.82.6
1/T (K-1)Ea = 0.63 eV
Ea = 2.8 eV
arb. assign 10% as “time to fail”
60 °C
80 °C
100 °C
120 °C
Different mechanisms dominate degradation at different temperatures ( ~90-120°C associated with Cu diffusion)
Cu diffusivity in CdTe:
D = 3.7 x 10-4 exp (-0.67 eV/kT)
-25
-20
-15
-10
-5
0
0 500 1000 1500 2000Stress Time (hrs)
%C
hang
e in
Eff
T=120°C
T=100°C
T=80°C
T=60°C
Stress Data Fit: y = b · x a
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CIGS Stability Dry/1-Sun/85°C/Voc Bias
“Industrial” samples showed biggest spread in light-soak behavior
After some initial “equilibration”, CIGS devices show excellent stability (dry/1-Sun/85°C/Voc bias)
Identical 3-stage process; yet very different transient recovery behavior; distinguishing difference = Mo
Modified “ZnS” junction; different characteristics on the same substrate
18
16
14
12
10
8
Tota
l-Are
a E
ffici
ency
(%)
5004003002001000
Time (hrs) @ 1 Sun, 85C, dry
Three-Stage CIGS (Contreras)Three-Stage CIGS (Ramanathan)Three-Stage CIGS (Contreras) + ZnS (Bhattacharya)Industrial; Small-Area Device (Ag contact)
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Lamination Losses with Different Encapsulants
-30
-25
-20
-15
-10
-5
0
5
10
% C
hang
e BRP-C (160°C/30m)EVA (145°C/8m)DC 1199SSL (25°C)DC 700 (25°C)GE RTV12 (25°C)
DVoc DJsc DFF Dh
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Challenges (cont.)
Thinner CIS and CdTe layers• Current thickness is 1.3 to 8 µm
• Target <0.5µm thick layers
• Maintain state-of-the-art performance
• Requires modification of deposition parameters regime
• Need for models that relate film growth to material delivery
• Device structure that maximizes photon absorption
Benefits:
• Addresses the issue of In and Te availability
• Higher throughput
• Less material usage
• Cost??
Risks:
• potential for lower performance
• changes in device physics and structure
• Non-uniformity
• lower yield?
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1 µm
Voc= 0.676 VJsc= 32 mA/cm2
FF= 79.5%; Eff = 17.2%
Thinner Absorbers0.4 µm
Voc= 0.565 VJsc= 21.3 mA/cm2
FF= 75.7%; Eff = 9.1%
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Thin Cells Summary
Shell
U. of
t (µm) Voc (V) Jsc (mA/cm2) FF (%) Eff (%)
1.0 CIGS 0.676 31.96 79.47 17.16 NREL
0.75 CIGS 0.652 26.0 74.0 12.5
0.40 CIGS 0.565 21.3 75.7 9.1
0.47 CIGS 0.576 26.8 64.2 9.9 EPV
1.3 25.26 2.66 69.2 12.8 Solar
0.87 CdTe 0.772 22.0 69.7 11.8 Toledo
CIGSSModule
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Challenges (cont.)
Need for Low-cost processes
• More relevant to CIGS technology
• Relatively slow throughput and poor material utilization becauseof complex processes
• High cost of In; ~$1000/kg
• High rate co-sputtering from the elements (in the presence of Se)
• Non-vacuum or low vacuum, simple equipment
• Innovative processes:
- CVD-based
- Nanotechnology utilizing nano-components to make CIGS, e.g. printable CIGS
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480-kW Thin Film CdTe Solar Field
Tucson Electric/First Solar
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245-kW Thin Film CIGSS Rooftop Array
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Wales CIGS - 84 kW
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San Diego CIGS - 4 kW
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· Roll-Roll production of CIGS PV· Web-based processes for all Mat’l
DepositionStainless Foil or Polyimide Film 1000-ft x 1-ft Process lots
Flexible PV Technology
S. Wiedeman, TFPP 2006 Global Solar Global Solar --
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Finally
Thin Film CIGS and CdTe technologies will become cost competitive with Si.
Challenge: obtain large investment for large facility/equipment to take advantage of high throughput and simplified manufacturing.
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End
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QE100
80
60
40
20
0
Rea
ltiv
e E
xter
nal Q
E (
%)
12001000800600400Wavelength (nm)
S2232B12 S2265B12, thin 3 stage S2297B12, thin codep
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0.4 µm Cell - Optical
80
60
40
20
0
%T
, A, Q
E
1400nm12001000800600400Wavelength (nm)
QE
Absorption
T
R of Cell
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The Best One-of-a-Kind LaboratoryCell Efficiencies for Thin Films
(Standard Conditions)
Effic
iency
(%)
CuInGaSe2CdTeAmorphous silicon (stabilized)
Univ. of MaineBoeing
Boeing
Boeing
BoeingARCO
AMETEK
NREL
BoeingEuroCIS
Univ. of So. Florida
Univ. of So. FL
BP Solar
Kodak
KodakMonosolar
Matsushita
12
8
4
0200019951990198519801975
United Solar
16
20NREL
2005
RCA
ECD
NREL
Photon Energy
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Cu
IncreasesNA in CdTe
Reduces Height andWidth of
Back Barrier
dJ/dV(FF Loss)
Grain Boundary
Shunts
CdS:Cu(Donor Compensation)
Metal
CdTe
CdS
Cu
Cu in CdTe PV DevicesThe Good, Bad, and the Ugly
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High Efficiency CdTe Cells
Replaced SnO2with Cd2SnO4 in CdTe cells, yielding improved Jsc and FF
High-efficiency CdTe cells with high Jsc
Cell#
Voc (mV)
Jsc (mA/cm2)
FF (%)
η (%)
Area (cm2)
1 847.5 25.86 74.45 16.4 1.131 2 845.0 25.88 75.51 16.5 1.032
High-efficiency CdTe cells with high fill factor
Cell#
Voc (mV)
Jsc (mA/cm2)
FF (%)
η (%)
Area (cm2)
1 842.1 24.12 77.26 15.7 1.001 2 848.1 23.97 77.34 15.7 0.976
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Effect of Zn2SnO4 Buffer Layer
Integrated high-resistivity Zn2SnO4 (ZTO) buffer layer, yielding improved device performance and reproducibility
0
10
20
30
40
50
60
70
80
90
100
200 300 400 500 600 700 800 900 1000
Wavelength (nm)
CTO/CdS/CdTe cell
CTO/ZTO/CdS/CdTe cell
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VOC Improvement
• To achieve CdTe cell with efficiency higher than 16.5%, needs Voc improvement
• Voc improvement :
(1) Optimize device process to improve junction quality (reduce A & J0) and reduce back barrier height;
(2) Study defects that limit doping and lifetime in CdTe device
• Achieved an NREL-confirmed Voc of 858 mV in a CdTe cell with an efficiency of 15.6%
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Sputtered Cd2SnO4 ~20°C
Sputtered Zn2SnO4 ~20°C
Sputtered CdS ~20°C
CSS-CdTe 550-620°C
CdCl2 treatment ~ 400°C
Back contact formation ~ 270°C
C V D-c-SnO2 500-600°C
C V D-i-SnO2 500-600°C
CSS-C dS 500-600°C
C SS-C dTe 550~620°C
CdC l2 t reatm ent ~400°C
Back contact form ation ~270°Cor C BD-CdS
~100°C
or CV D -C dS ~430°C
Time
Tem
pera
ture
• CTO, ZTO and CdS are deposited on substrate at RT by RF sputtering
• Single heat-up segment• Crystallization of CTO, ZTO,
and CdS, and interdiffusion occurs during the CdTe deposition step
• Conventional SnO2/CdS/CdTe device structure (requiring a thicker CdS layer)
• Mix “wet” and “dry”processes
• Several heat-up and cool-down process segments (consuming time and increasing thermal budget)
Improvement to the Deposition Processes
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CIGS Deposition Profile
02468
101214
0 10 20 30 40 50
Metal
rate
(Å/s)
60Runtime (min)
100
200
300
400
500
600
Monit
or te
mper
ature
(°C
)
600
602
604
606
608
610
Temperature (°C)
596
598
0
10
20
30
40
Se rate (Å/s)
Se
In CuGa
Back of substrate
temperature
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Global Solar