Method of fabricating silicon nanowire solar cell device having upgraded metallurgical grade silicon substrate

A simplified method for fabricating a solar cell device is provided. The solar cell device has silicon nanowires (SiNW) grown on an upgraded metallurgical grade (UMG) silicon (Si) substrate. Processes of textured surface process and anti-reflection thin film process can be left out for further saving costs on equipment and manufacture investment. Thus, a low-cost Si-based solar cell device can be easily fabricated for wide application.

TECHNICAL FIELD OF THE DISCLOSURE

The present disclosure relates to making a solar cell device; more particularly, relates to simplifying processes of fabricating a low-cost silicon (Si)-based solar cell device by using atmospheric pressure chemical vapor deposition (APCVD) to directly grow silicon nanowires (SiNW) on an upgraded metallurgical grade (UMG) Si substrate.

DESCRIPTION OF THE RELATED ARTS

A need for energy grows fast nowadays and storage of petrochemical material is thus reduced rapidly. Cost for energy becomes higher with crises of earth warming, climate change and environment pollution.

Solar energy is a green and ever-lasting energy. The solar energy shown on earth for a day may fulfill needs of all people. Therefore, low-cost solar energy for wide application is very important to us.

Until the end of 2009, the market of crystallized Si solar cell still occupies more than 80 percents (%) global market of solar cells; and, at least for the next decade, it may remains as the main stream. Therein, the thin-film solar cells occupies about 10˜20% of the market, which are mainly solar cells of copper indium gallium siselenide (CIGS) and non-crystallized Si thin film. Hence, a key issue for popularizing use of solar energy is to find a method for making a Si-based solar cell with low cost.

Traditional crystallized Si solar cells on the market are made of crystallized Si plates through Siemens method. Yet, the method has a high technical threshold with high equipment and manufacture investment. During 2008 to 2009, the price of the Si material for Siemens method had been raised to 500 US dollars per kilograms (USD/kg). Although the price is dropped down to 50˜60 USD/kg now, it is still as high as several times, even 10 times, to the price of traditional petrochemical material.

Besides, although thin-film solar cell is proclaimed to have acceptable reduced price, its initial investment on equipment is still high and its conversion rate is low and unstable. Hence, the prior arts do not fulfill all users' requests on actual use.

SUMMARY OF THE DISCLOSURE

The main purpose of the present disclosure relates is to simplify processes of fabricating a low-cost Si-based solar cell device by using APCVD to directly grow SiNW on a UMG Si substrate.

To achieve the above purpose, the present disclosure is a method of fabricating a SiNW solar cell device having a UMG silicon substrate, comprising steps of: (a) obtaining a UMG Si substrate having a purity lower than 99.999% (5N) and a thickness not thicker than 200 micrometers (μm); (b) cleaning a surface of the UMG Si substrate to be put into an e-gun evaporation equipment for forming a nickel (Ni) metal thin film covered on the surface of the UMG Si substrate; (c) putting the UMG Si plate into a reaction chamber of an APCVD equipment to be heated up for forming a teardrop-shaped Ni—Si liquid phase alloy with the Ni metal thin film and the UMG Si substrate, where at least some drops of the Ni—Si liquid phase alloy are distributed on a surface of the UMG Si plate and having a nanometer scale; (d) obtaining disilane (Si2H6) for a SiNW process with hydrogen (H2) as a carrier gas and providing a doping gas to form SiNWs on the surface of the UMG Si plate started from the drops of the Ni—Si liquid phase alloy; (e) providing another doping gas to form a thin film on an outside surface of each SiNW for forming a P-N junction; and (f) sequentially forming a transparent conductive electrode through a sputtering deposition process, and then processing a screen printing for forming a front contact of silver paste and a back contact of aluminum paste. Accordingly, a novel method of fabricating a SiNW solar cell device having a UMG silicon substrate is obtained.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Please refer toFIG. 1toFIG. 8, which are views showing a preferred embodiment according to the present disclosure; and views showing a substrate, a covered film, a heating-up process, SiNWs, a positive-negative (P-N) junction, a screen printing and front contacts. As shown in the figures, the present disclosure is a method of fabricating a silicon nanowire (SiNW) solar cell device having an upgraded metallurgical grade (UMG) silicon (Si) substrate, comprising the following steps:

(a) Selecting substrate11: InFIG. 2, a positive type (p-type) UMG Si plate1is selected as a substrate, which has a purity lower than 99.999% (5N) and a thickness not thicker than 200 micrometers (μm) and can be a p-type or a negative type (n-type) UMG Si plate.

(b) Covering with thin film12: InFIG. 3, after cleaning a surface of the UMG Si plate1, the UMG Si plate1is put into an electron-gun (e-gun) evaporation equipment to cover a nickel (Ni) metal thin film2on the UMG Si plate1, where the Ni metal thin film2has a thickness between 30 and 100 nanometers (nm) and is used as a catalyst for growing SiNW.

(c) Heating up13: InFIG. 4, the UMG Si plate1covered with the Ni metal thin film2is put into a reaction chamber3of an atmospheric pressure chemical vapor deposition (APCVD) equipment on a graphite susceptor31to be heated up. Radiofrequency coils32twined outside around the reaction chamber3are used for heating up the graphite susceptor31in the reaction chamber3to form a teardrop-shaped Ni—Si liquid phase alloy4with the Ni metal thin film2and the UMG Si plate1. Therein, at least some drops of the Ni—Si liquid phase alloy4are distributed on an upper surface of the UMG Si plate1with each of such drops having a nanometer scale.

(d) Growing SiNWs14: InFIG. 5, at a temperature between 650 and 700 Celsius degrees (° C.), feedstock gases41including disilane (Si2H6) is used for a SiNW process with hydrogen (H2) used as a carrier gas; and diborane (B2H6) is provided as a doping gas. After a time period between 1 and 10 minutes (min), p-type SiNWs5are formed on the upper surface of the UMG Si plate1to be used as a solar light absorption layer, while each SiNW5has a length of at least 10 μm and is started from a drop of the teardrop-shaped Ni—Si liquid phase alloy4. Therein, the SiNW5is grown by using a vapor-liquid-solid (VLS) mechanism revealed by Wagner and Ellis (Appl. phys. lett., 1964, 4, 89).

(e) Forming a positive-negative (P-N) P-N junction15: InFIG. 6, phosphine (PH3) is provided as another doping gas to obtain an n-type thin film6on an outside surface of each of the SiNWs5for forming a P-N junction at diffusion at a temperature of about 800 Celsius degrees (° C.)±10° C.

(f) Forming electrode and screen-printing16: Sequentially, for forming a front contact of metal8, such as a front contact of silver paste (shown inFIG. 7) and a back contact of metal9, such as a back contact of aluminum paste, a transparent conductive electrode7is formed through a sputtering deposition process and then a screen printing is processed. Thus, a SiNW solar cell device having a UMG Si substrate is fabricated.

FIG. 8shows a view of front contacts.

If the UMG Si plate provided is n-type, the doping gas used in step (d) can be PH3for growing n-type SiNWs, and the doping gas used in step (e) can be B2H6for forming an n-type thin film on an outside surface of each SiNW.

The present disclosure uses APCVD and screen printing with simplified processes and reduced cost. Only little Si material, used in SiNW, and a low cost UMG Si substrate are used for successfully growing SiNWs on the UMG Si substrate to obtain a SiNW solar cell device. On using the present disclosure, an APCVD equipment is used to grow n-type (or p-type) SiNWs for forming a p-n structure of a solar cell on a low-cost UMG Si substrate having a purity smaller then 5N with a Ni metal thin film used as a catalyst; and, at last, with materials of silver paste and aluminum paste, front and back contacts are formed through screen printing for obtaining a SiNW solar cell device having a UMG Si substrate.

Hence, the present disclosure has the following advantages:

1. APCVD is used to directly grow SiNWs without vacuum system.

2. Very little Si material is used to form solar light absorption layer, i.e. SiNWs.

3. A low-cost UMG Si material is used for a substrate with a cost one-tenth to that of a substrate made through Siemens method.

4. A simplified method for fabricating a solar cell device is provided, which is a SiNW solar cell device using a UMG Si substrate. Processes of textured surface process and anti-reflection thin film process are left out for further saving costs on equipment and manufacture.

To sum up, the present disclosure is a method of fabricating a SiNW solar cell device having a UMG Si substrate, where an APCVD equipment is used to grow n-type (or p-type) SiNWs for forming a p-n structure of a solar cell on a low-cost UMG Si substrate having a purity smaller then 5N with a Ni metal thin film used as a catalyst and, at last, with materials of silver paste and aluminum paste, front and back contacts are formed through screen printing for obtaining a SiNW solar cell device having a UMG Si substrate.

The preferred embodiments herein disclosed are not intended to unnecessarily limit the scope of the disclosure. Therefore, simple modifications or variations belonging to the equivalent of the scope of the claims and the instructions disclosed herein for a patent are all within the scope of the present disclosure.