Abstract: The invention relates to a method for producing a photovoltaic solar cell having a front side designed for coupling in light, comprising the following method steps: A Producing a plurality of cutouts in a semiconductor substrate of a base doping type, B Producing one or more emitter regions of an emitter doping type at least at the front side of the semiconductor substrate, wherein the emitter doping type is opposite to the base doping type, C Applying an electrically insulating insulation layer and D Producing metallic feed through structures in the cutouts, at least one metallic base contact structure at the rear side of the solar cell, which is formed in an electrically conductive manner with the semiconductor substrate in a base doping region, at least one metallic front-side contact structure at the front side of the solar cell, which is formed in an electrically conductive manner with the emitter region at the front side of the semiconductor substrate, and at least one rear-side contact structure at the rear side of the solar cell, which is formed in a manner electrically conductively connected to the feed through contact structure. The invention is characterized in that in method step B and/or a further method step in addition a feed through emitter region of the emitter doping type extending from the front side to the rear side is formed in each case in the semiconductor substrate on the walls of the cutouts, in that in method step C the insulation layer is applied in a manner covering the rear side of the semiconductor substrate, if appropriate further intervening intermediate layers, in that in method step D the rear side contact structure is applied to the insulation layer, if appropriate to further intermediate layers, in such a way that the rear-side contact structure extends to regions of the semiconductor substrate having base doping and, in these regions, on account of the intervening insulation layer, an electrical insulation is formed between rear-side contact structure and semiconductor substrate, and the base contact structure is applied to the insulation layer, if appropriate to further intermediate layers, in such a way that the base contact structure penetrates through the insulation layer at least in regions, such that an electrically conductive connection is produced between base contact structure and semiconductor substrate. The invention furthermore relates to a photovoltaic solar cell.
PHOTOVOLTAIC SOLAR CELL AND METHOD FOR PRODUCING A PHOTOVOLTAIC SOLAR CELL DESCRIPTION
The invention relates to a photovoltaic solar cell in accordance with the
preamble of claim 13, and to a method for producing a photovoltaic solar cell
in accordance with the preamble of claim 1.
Photovoltaic solar cells typically consist of a semiconductor structure having
a base region and an emitter region, wherein the semiconductor structure is
typically substantially formed by a semiconductor substrate, such as a silicon
substrate, for example. Light is coupled into the semiconductor structure
typically via the front side of the solar cell, such that generation of electron-
hole pairs takes place after absorption of the coupled-in light in the solar cell.
A pn junction forms between base and emitter region, the generated charge
carrier pairs being separated at said junction. Furthermore, a solar cell
comprises a metallic emitter contact and also a metallic base contact, which
are respectively electrically conductively connected to the emitter and to the
base. Via these metallic contacts, the charge carriers separated at the pn
junction can be conducted away and thus fed to an external electric circuit or
an adjacent solar cell in the case of module interconnection.
Various solar cell structures are known, wherein the present invention
relates to those solar cell structures in which both electrical contacts of the
solar cell are arranged on the rear side, wherein electrical contact can be
made with the base of the solar cell via a metallic base contact structure
arranged on the rear side, and electrical contact can be made with the
emitter of the solar cell via a metallic rear-side contact structure arranged on
the rear side. This is in contrast to standard solar cells, in which typically the
metallic emitter contact is situated on the front side and the metallic base
contact is situated on the rear side of the solar cell.
In this case, the invention relates to a specific configuration of a solar cell
with which contact can be made on the rear side, the metal wrap-through
solar cell (MWT solar cell). This solar cell, known from EP 985233 and van
Kerschaver et al. "A novel silicon solar cell structure with both external
polarity contacts on the back surface" Proceedings of the 2nd World
Conference on Photovoltaic Energy Conversion, Vienna, Austria, 1998, indeed
has a metallic front-side contact structure arranged at the front side of the
solar cell designed for coupling in light, said front-side contact structure
being electrically conductively connected to the emitter region. However, the
solar cell furthermore has a multiplicity of cutouts extending from the front
side to the rear side in the semiconductor substrate, metallic feedthrough
structures penetrating through said cutouts and said cutouts being
electrically conductively connected on the rear side to one or more metallic
rear-side contact structures, such that electrical contact can be made with the
emitter region on the rear side via the rear-side contact structure, the
feedthrough structure and the front-side contact structure.
The MWT structure has the advantage that the charge carriers are collected
from the emitter at the front side via the front-side contact structure and,
consequently, no ohmic losses arise as a result of possible charge carrier
transport within the semiconductor substrate from the front side to the rear
side with regard to the emitter region. Furthermore, the capability of making
contact both with the base region and with the emitter region on the rear side
results in a simpler interconnection of the MWT solar cells in the module
compared with standard solar cells.
What is disadvantageous about the MWT structure is that, compared with
standard solar cells, it is necessary to produce additional structures such as,
for example, the cutouts and the metallic feedthrough structures through the
cutouts, thus resulting in a higher complexity and hence higher costs
compared with the production of standard solar cells. Moreover, in particular
in the case of inaccurate processing on the walls of the cutouts and also in the
region in which the rear-side contact structures cover the rear side of the
solar cell, there are risks concerning the formation of additional loss
mechanisms: in particular, short-circuit currents can occur if the rear-side
contact structure through a fault penetrates into the base region of the
semiconductor substrate (so-called "spiking"), as a result of which the
efficiency of the solar cell is considerably reduced.
For this reason, EP 0 985 233 proposes leading the emitter through the
cutouts and, at the rear side, at least beyond the regions covered by the rear-
side contact structure, such that the rear-side contact structure, serving for
making contact with the emitter externally, covers no region of the
semiconductor substrate having the base doping.
However, this requires complex processing and a plurality of cost-intensive
masking steps.
Therefore, the invention is based on the object of providing a photovoltaic
solar cell having an MWT structure, and a method for producing such a solar
cell which is suitable for implementation in industrial production lines and,
in particular, is more cost-effective than the previously known MWT
structures and methods for producing them.
This object is achieved by a method as claimed in claim 1 and a photovoltaic
solar cell as claimed in claim 13. Advantageous configurations of the method
are found in claims 2 to 12. Advantageous configurations of the solar cell are
found in claims 14 to 16.
The photovoltaic solar cell according to the invention has a front side
designed for coupling in light and comprises a semiconductor substrate of a
base doping type, and at least one emitter region of an emitter doping type
formed at the front side, said emitter doping type being opposite to the base
doping type. In this case, doping types are the n-type doping and the p-type
doping opposite thereto.
The solar cell furthermore comprises at least one metallic front-side contact
structure which is formed on the front side for the purpose of collecting
current and which is electrically conductively connected to the emitter region,
at least one metallic base contact structure which is arranged at a rear side of
the solar cell and is electrically conductively connected to the semiconductor
substrate in a region of the base doping type, at least one cutout extending
from the front side to the rear side in the semiconductor substrate and at
least one metallic feedthrough structure, wherein the feedthrough structure
is arranged in the cutout from the front side to the rear side of the
semiconductor substrate and is electrically conductively connected to the
front-side contact structure, and at least one metallic rear-side contact
structure which is arranged at the rear side and is electrically conductively
connected to the feedthrough structure.
With regard to this basic construction, the solar cell according to the
invention thus corresponds to the previously known MWT structure. What is
essential is that, in the case of the solar cell according to the invention, a
feedthrough emitter region extending from the front side to the rear side is
formed in the semiconductor substrate on the walls of the cutout.
Furthermore, an electrically insulating insulation layer is arranged on the
rear side of the semiconductor substrate, if appropriate on further
intermediate layers, and covers the rear side at least in the regions
surrounding the cutout. The rear-side contact structure is arranged on the
insulation layer, if appropriate on further intermediate layers, such that the
rear-side contact structure is electrically insulated by the insulation layer
from the semiconductor substrate lying below the insulation layer.
The solar cell according to the invention thus has for the first time an MWT
structure in which, on the one hand, a feedthrough emitter region extending
from the front side to the rear side is formed on the walls of the cutout, but in
which the rear-side contact structure assigned to the emitter has no direct
contact with the semiconductor substrate, but rather is only electrically
conductively connected via the metallic feedthrough structure to the metallic
front-side contact structure arranged on the front side and via said contact
structure to the emitter region at the front side.
The invention is based on the applicant's insight that the solar cell mentioned
can surprisingly be produced with only very low residual risks with regard to
the loss mechanisms mentioned in the introduction and thus makes possible
a cost-effective implementation of the basic MWT concept in industrial
manufacture.
The solar cell according to the invention is preferably produced by a method
according to the invention or a preferred embodiment thereof.
The method according to the invention for producing a photovoltaic solar cell
having a front side designed for coupling in light comprises the following
method steps:
A method step A involves producing a plurality of cutouts in a semiconductor
substrate of a base doping type.
A method step B involves producing one or more emitter regions of an emitter
doping type at least at the front side of the semiconductor substrate, wherein
the emitter doping type is opposite to the base doping type.
A method step C involves applying an electrically insulating insulation layer
on the rear side of the semiconductor substrate, and a method step D involves
producing metallic feedthrough structures in the cutouts. Furthermore,
method step D involves producing at least one metallic base contact structure
at the rear side of the solar cell, which is formed in an electrically conductive
manner with the semiconductor substrate in a base doping region.
Furthermore, method step D involves producing at least one metallic front-
side contact structure at the front side of the solar cell, which is formed in an
electrically conductive manner with the emitter region at the front side of the
semiconductor substrate, and producing at least one rear-side contact
structure at the rear side of the solar cell, which is formed in a manner
electrically conductively connected to the feedthrough contact structure.
These method steps are also known in the production of previously known
MWT structures.
The method according to the invention is distinguished by the fact that in
method step B in addition a feedthrough emitter region of the emitter doping
type extending from the front side to the rear side is formed in each case in
the semiconductor substrate on the walls of the cutouts, and in method step
C the insulation layer is applied in a manner covering the rear side of the
semiconductor substrate, if appropriate further intervening intermediate
layers. Furthermore, in the method according to the invention, in method
step D the rear-side contact structure is applied to the insulation layer, if
appropriate to further intermediate layers, such that the rear-side contact
structure covers regions of the semiconductor substrate having base doping
and, in these regions, on account of the intervening insulation layer, an
electrical insulation is formed between rear-side contact structure and
semiconductor substrate. Furthermore, in method step D, the base contact
structure is applied to the insulation layer, if appropriate to further
intermediate layers, in such a way that the base contact structure penetrates
through the insulation layer at least in regions, and an electrically conductive
connection is produced between base contact structure and semiconductor
substrate. The connection is formed in a region of the semiconductor
substrate having base doping.
By virtue of the fact that no emitter region has to be formed at the rear side
in the method according to the invention and the solar cell according to the
invention, a considerable simplification of the production method and hence a
reduction of costs are achieved.
The invention is furthermore based on the applicant's insight that insulation
layers can be produced in a simple manner by known methods, in such a way
that although a metallic rear-side contact structure applied to the insulation
layer covers regions of the semiconductor substrate having base doping, it is
electrically insulated therefrom by the insulation structure and, in particular,
no "spiking", i.e. faulty penetration of the insulation layer through the rear-
side contact structure, whatsoever occurs and, consequently, no losses of
efficiency as a result of short-circuit currents based thereon occur.
Consequently, the solar cell according to the invention and the method
according to the invention furthermore overcome the previously prevailing
prejudice that there is a high risk of metallic contact structures penetrating
through an insulation layer and thereby causing short-circuit currents.
Furthermore, the risk of short circuits between regions of the semiconductor
substrate having base doping and the rear-side contact structure associated
with the emitter is reduced in the solar cell according to the invention by the
use of metallization methods which do not attack the insulation layer and
form no contact with the semiconductor substrate. Preferably, therefore, the
rear-side contact structure is produced by screen printing using specific
printing pastes which do not attack the insulation layer and form no contact
with the semiconductor substrate. The use of screen printing pastes
containing no glass frit is particularly advantageous for this purpose.
Furthermore, the solar cell according to the invention and the method
according to the invention avoid risks resulting from short circuits between
through-metallization and semiconductor substrate in the cutouts by virtue
of the fact that emitter regions are likewise formed on the walls of the cutouts
and it is thus part of the functional principle of the solar cell according to the
invention that the feedthrough structures can be electrically conductively
connected to the walls of the cutouts and the feedthrough emitter regions
adjoining the latter, without causing short-circuit currents. In particular, it is
thus possible to dispense with the insulation layers on the walls of the
cutouts which are necessary in the case of previously known MWT structures
and which can only be produced by means of complex process steps and often
have fault sources as a result of holes.
The solar cell according to the invention and the method according to the
invention thus constitute an optimization of the MWT structure with regard
to cost-effective industrial manufacture and avoiding losses of efficiency in
particular on account of short-circuit currents. The insulation layer on the
rear side additionally affords the possibility of reducing the contact area
between base contact structure and semiconductor substrate and,
consequently, of at least partly achieving a surface passivation and an
improvement in internal reflection. This leads to lower recombination
currents or higher charge carrier generation rates and thus to higher
efficiencies in comparison with making contact with the semiconductor
substrate over a large area.
In one advantageous embodiment of the method according to the invention,
no emitter region extending parallel to the rear side is formed in a manner
adjoining the cutout at the rear side of the semiconductor substrate.
Correspondingly, the photovoltaic solar cell on the rear side preferably has no
emitter region extending parallel to the rear side. Although, as explained
above, the feedthrough emitter region extends from the front side to the rear
side and will therefore cover, if appropriate, a negligibly small region of the
rear side, preferably no emitter regions are formed parallel to the rear side of
the semiconductor substrate at the rear side, as known from the prior art.
In the prior art, the emitter region formed at the rear side covered at least
that region of the rear side at which the rear-side contact structure is formed.
In the preferred embodiment of the method and preferred configuration of the
solar cell according to the invention, however, no such rear-side emitter
region is formed, and so the metallic rear-side contact structure extends over
regions of the semiconductor substrate which have a base doping, but is
electrically insulated therefrom by the intervening insulation layer. This
results in a reduction of costs during production, in particular since high
throughput methods which do not allow an emitter structure to be formed on
both sides can be used for emitter formation. This is the case for back-to-back
diffusions known per se, for example, in which the semiconductor structures
are guided through the diffusion process in a manner arranged with the sides
that are not to be diffused bearing against one another.
The solar cell according to the invention therefore preferably has at the rear
side a region in which the rear-side contact structure is electrically insulated
from the base-doped semiconductor substrate by the intervening insulation
layer. Correspondingly, the method according to the invention is preferably
embodied in such a way that a layer structure of this type results after the
completion of the solar cell. Preferably, at least 30%, more preferably at least
50%, in particular at least 70%, of the rear-side contact structure extends
over regions of the semiconductor substrate having base doping and is
electrically insulated therefrom by the above mentioned insulation layer. In
this preferred embodiment, therefore, at least 30%, preferably at least 50%,
in particular at least 70%, of the area of the rear-side contact structure at the
rear side overlaps base-doped regions of the semiconductor substrate.
In one preferred embodiment of the method according to the invention,
method step B is designed in such a way that the emitter structure is formed
only on the front side and, if appropriate, in the cutouts produced in method
step A. It is particularly advantageous to apply a dopant source on one side
by means of spraying, rolling, printing, a spin-on process or APCVD or
PECVD deposition with subsequent heating of the semiconductor substrate
for at least 15 min to at least 750°C, as a result of which the emitter is
formed by diffusion of the dopant into the semiconductor substrate.
In a further preferred embodiment of the method according to the invention,
an emitter is formed on the front side of the semiconductor substrate by the
methods mentioned. Method step A is carried out only after the emitter has
been formed, in such a way that during or after the production of the cutouts,
an emitter is formed on the inner wall of the cutouts. The use of a liquid-
guided laser beam is particularly advantageous for this purpose, wherein the
liquid used is enriched with a dopant of the emitter doping type and, if
appropriate, an etching liquid and, consequently, in one step the cutouts are
produced and the emitter is formed on the inner area thereof. Such a method
is known from "Laser Chemical Processing (LCP) — A versatile tool for
microstructuring applications", Kray et al., Applied Physics A 93, 2009.
It lies within the scope of the invention that in method step B an emitter is
formed at the front and rear sides of the semiconductor substrate and the
emitter is subsequently removed again at the rear side. However, it is
advantageous that before method step B, if appropriate with interposition of
further method steps, in a method step A0 a diffusion barrier layer covering
the rear side of the semiconductor substrate is applied to the rear side of the
semiconductor substrate, in order to avoid diffusion of doping material
through the diffusion barrier layer onto the semiconductor substrate. As a
result, in a simple manner, in method step B the formation of an emitter at
the rear side is avoided and the step of removing the emitter on the rear side
is correspondingly obviated.
In particular, it is advantageous to carry out method step AO before method
step A, if appropriate with interposition of further method steps. As a result,
in method step A cutouts are also produced in the diffusion barrier layer and
a diffusion barrier is thus produced in a simple manner, said diffusion barrier
making it possible for dopants to penetrate into the cutouts and thus making
it possible to form the feedthrough emitters. Particularly when applying the
diffusion barrier layer in method step AO in such a way that it covers the
entirety of the rear side, there is no need to use any cost-intensive maskings
whatsoever or appropriate methods for forming the emitter regions.
A further preferred embodiment of the method according to the invention is
based on the use of an emitter etching-back step on one side after emitter
diffusion. For this purpose, method step AO (applying a diffusion barrier on
the rear side) is replaced by a method step Ba wherein the emitter is removed
again on the rear side after diffusion has taken place. Wet-chemical etching
methods and plasma etching methods on one side can be used for this
purpose.
In the solar cell according to the invention, preferably in each cutout the
feedthrough emitter region extending from the front side to the rear side is
electrically conductively connected to the metallic feedthrough structure.
Correspondingly, such an electrically conductive connection is preferably
formed in method step D. Ohmic conduction losses are thereby reduced.
In one preferred embodiment of the method according to the invention, in
method step D the electrically conductive connection between base contact
structure and semiconductor substrate is produced by means of local action of
heat by a laser.
The formation of local electrically conductive connections between a
semiconductor substrate on which an insulation layer is applied and a metal
layer is applied thereabove is known per se (so-called "Laser Fired Contacts",
LFC) and described in US2004097062. A particularly cost-effective
realization of the method according to the invention is possible by combining
this technique for producing the electrically conductive connection between
rear-side contact structure and base region of the semiconductor substrate.
In particular, in this advantageous configuration a simplification of the
method is achieved in which the insulation layer is applied to the rear side
over the whole area. As a result, the insulation layer serves firstly as
electrical insulation between rear-side contact structure and semiconductor
substrate and also between the predominant proportion of the area of the
base contact structure and the semiconductor substrate. It is only in the local
regions in which, by means of laser action and momentary local melting of
rear-side contact structure, insulation layer and the adjoining region of the
semiconductor substrate, a melt mixture is produced that an electrically
conductive connection between rear-side contact structure and semiconductor
substrate arises in the solidified melt mixture. The combination of the
insulation layer applied over the whole area with the production of the base
contact-making by means of local heating by a laser thus makes possible a
very extensive reduction of the process steps and thus a high cost saving.
In a further advantageous embodiment, in order to produce an electrical
contact between semiconductor substrate and base contact structure, before
the base contact structure is applied, small cutouts are produced in the
insulation layer. At these locations, therefore, there is a direct contact
between semiconductor substrate and base contact structure. The production
of the cutouts is preferably achieved by laser ablation, application of etching
pastes or masked etching-back. The method of producing local cutouts in the
insulation layer with subsequent formation of the base contact structure is
known from "Silicon Solar Cells on Ultra-Thin Substrates for Large Scale
Production", G. Agostinelli et al., 21st EU PVSEC, Dresden, 2006.
One particularly advantageous embodiment of the method according to the
invention is based on the use of specific pastes in combination with a high-
temperature step for producing the local contacts between semiconductor
substrate and base contact structure. Preferably, the paste used for this
purpose contains glass frit, preferably up to 10% lead- and/or bismuth-boron
glass, or pure lead and/or bismuth oxides. In a method step Da such a paste
is applied at local regions, preferably with an area proportion of 0.1% to 20%,
particularly preferably of 0.1% to 10%. In a method step Db the
semiconductor substrate is greatly heated, preferably to temperatures of at
least 700°C for a time duration of at least 5 s. In this case, method step Db
can be carried out temporally before or after the actual formation of the base
contact structure in step D. In order to support the formation of a better local
back surface field, it is advantageous to use a paste enriched with phosphorus
or other elements corresponding to the base doping type. If the base doping is
a p-type doping, the paste contains corresponding dopants which allow a p-
type doping. In particular, aluminum, boron and/or gallium are preferably
contained.
Preferably, the base contact structure covers at least 30%, preferably at least
50%, in particular at least 80%, of the rear side of the semiconductor
substrate. The aforementioned percentage indications relate to area percent,
independently of whether the base contact structure is applied to the rear
side of the semiconductor substrate with interposition of the insulation layer
or directly.
In order to reduce recombination losses, it is advantageous for at least 50%,
preferably at least 70%, in particular at least 90%, of the base contact
structure to be electrically isolated from the semiconductor substrate by the
insulation layer. The aforementioned percentage indications relate to area
percent.
The insulation layer is advantageously embodied as a dielectric layer.
Investigations by the applicant revealed that, in particular, an insulation
layer embodied as a layer system composed of aluminum oxide and silicon
nitride, preferably having a total thickness in the range of 70 nm to 130 nm,
preferably approximately 100 nm, is suitable for the method according to the
invention and the solar cell according to the invention. It likewise lies within
the scope of the invention to form the insulation layer as a silicon oxide layer,
silicon nitride layer, silicon carbide layer, titanium dioxide layer, aluminum
oxide layer, silicon-rich oxynitride layer or mixture of the aforementioned
lajrers. The insulation layer advantageously has a thickness in the range of
10 nm to 1 mm, preferably in the range of 20 nm to 100 μm., with further
preference of 30 nm to 1 μm, particularly preferably of 30 nm to 300 nm.
Furthermore, it lies within the scope of the invention to form the insulation
layer as a layer structure composed of a plurality of layers. Although this
increases the process complexity, the risk of a punch-through of the
insulation layer through rear-side contact structure and thus the risk of
short-circuit currents in this region are virtually precluded by a layer
structure. Moreover, a layer optimized with regard to the rear-side
passivation can be combined with a layer optimized for the greatest possible
insulation effect, as a result of which the efficiency of the solar cell can be
increased further. In particular, it is advantageous to use a layer having
surface charges opposite to the base doping type, in order to form a field effect
passivation of the rear side. Furthermore, the passivation of the rear side is
improved by the use of layers such as thermally grown oxide layers, for
example, which achieve a saturation of surface states.
A further simplification and hence reduction of the costs of the method
according to the invention arise by virtue of the fact that in method step A0
the diffusion barrier layer is additionally embodied as an electrically
insulating layer, by virtue of the fact that the diffusion barrier layer is not
removed in the method steps following method step B. Consequently, the
diffusion barrier layer additionally fulfils the function of electrical insulation.
In particular, it is therefore advantageous not to apply an additional
insulation layer in method step C. In this advantageous configuration of the
method according to the invention, therefore, method step C is
simultaneously performed in method step A0 and, by merely applying a layer
in method step A0 to the rear side of the semiconductor substrate, preferably
to the whole area of the rear side, the desired function of the diffusion barrier
and of the subsequent electrical insulation is ensured and, furthermore, there
is no need for a process step in order to perform a possible removal of a
diffusion barrier layer. Layers which fulfill the requirements described are,
for example, silicon nitride, aluminum oxide, titanium oxide, tantalum oxide,
silicon oxide, silicon oxynitride, mixtures of the substances mentioned or
layer systems containing one or more of said layers.
A further reduction of the risk of short circuits between rear-side contact
structure and semiconductor substrate having base doping is achieved by a
thickening of the diffusion barrier and insulation layer described in the
previous section by at least one additional layer. This thickening preferably
takes place before method step D. In particular, silicon nitride having a
thickness of 10 nm to 250 nm, preferably of 30 nm to 150 nm, with further
preference of 50 nm to 130 nm, can be used for this purpose.
Investigations by the applicant have revealed that, in particular, a dielectric
layer, preferably a silicon oxide layer, fulfills both the function of a diffusion
barrier for avoiding diffusion of doping material, and the function of an
electrical insulation. Preferably, the layer for fulfilling both functions has an
initial thickness in the range of 100 nm to 500 nm, with further preference in
the range of 150 nm to 400 nm. In a manner governed by the process, the
thickness of the dielectric layer decreases during the method steps following
the application of the layer. If the diffusion barrier layer is simultaneously
used as an insulation layer, if appropriate using a layer or a layer system
additionally applied before method step D, it is preferred to use a total layer
thickness of the insulation layer in the range of 80 nm to 400 nm, in
particular in the range of 100 nm to 250 nm. It is particularly advantageous
to form a diffusion barrier layer which also fulfills the function of an
insulation layer and simultaneously passivates the rear side of the solar cell.
Silicon oxide, in particular, can be used as diffusion barrier layer, insulation
layer and passivation layer, if appropriate in combination with a silicon
nitride layer having a layer thickness in the range of 10 nm to 250 nm,
preferably of 30 nm to 150 nm, with further preference of 50 nm to 130 nm. It
likewise lies within the scope of the invention to form the diffusion barrier as
a layer composed of silicon nitride, aluminum oxide, titanium oxide, tantalum
oxide, silicon oxide, silicon oxynitride, mixtures of the aforementioned
substances or layer systems containing one or more of said layers.
In one preferred embodiment of the method according to the invention, before
method step B, if appropriate with interposition of further method steps, the
rear side of the semiconductor substrate is leveled. The semiconductor
substrates typically used, in particular monocrystalline silicon wafers,
multicrystalline silicon wafers or microcrystalline silicon wafers, typically
have unevennesses which can lead to non-uniform coverage and losses of
efficiency resulting therefrom. Leveling avoids such losses of efficiency. The
leveling is preferably effected by removing a semiconductor layer at one side,
at the rear side, of the semiconductor substrate. In particular, it is
advantageous to achieve the removal at one side by wet-chemical etching, by
laser ablation or by plasma etching.
Preferably, in the method according to the invention, the diffusion barrier is
embodied as a silicon oxide layer. In particular, it is advantageous for the
silicon layer to be applied in a manner comprising one of the following
method steps: introducing the semiconductor substrate into an atmosphere
composed of nitrogen, oxygen, water, dichloroethylene or other gases or
mixtures of the aforementioned substances and heating the semiconductor
substrate in the aforementioned atmosphere to temperatures of at least
700°C for at least 5 min.
Applying the diffusion barrier layer, if appropriate the insulation and
passivation layer, on one side, on the rear side, of the semiconductor
structure by means of the method known per se plasma enhanced chemical
vapor deposition (PECVD), atmospheric pressure chemical vapor deposition
(APCVD) or cathode sputtering has the advantage that it is not necessary to
remove the silicon dioxide layer at undesired regions such as, for example,
the front side of the semiconductor substrate. It is likewise advantageous to
use diffusion barriers which are applied by pressure, spraying or a spin-on
process, since methods that can be industrially implemented cost-effectively
are available for this purpose.
Applying the silicon dioxide layer on both sides, on the front and rear sides, of
the semiconductor structure as a diffusion barrier layer and/or insulation
layer and/or passivation layer and subsequently removing the silicon dioxide
layer on the front side has the advantage that cost-effective methods can be
used for producing the silicon dioxide layer, in particular the production of
the silicon dioxide layer as thermal silicon dioxide layer on both sides is
known per se. Applying on both sides the silicon dioxide layer or other layers
such as, for example, silicon nitride, aluminum oxide, titanium oxide,
tantalum oxide, silicon oxynitride, mixtures of the aforementioned substances
or layer systems which can be used as a diffusion barrier layer, by means of
PECVD, APCVD, printing, spraying or deposition in a dipping bath, likewise
lies within the scope of the invention.
Advantageous methods for removing the diffusion barrier in undesired
regions, at least of the front side, include single-sided wet-chemical etching-
back, wet-chemical etching-back using an etching mask, plasma etching,
laser ablation and also the use of etching pastes by means of a printing
technique.
Applying the diffusion barrier layer (silicon oxide, silicon nitride, aluminum
oxide, titanium oxide, tantalum oxide, silicon oxynitride, mixtures of the
aforementioned substances or layer systems) on one side by means of a
printing technique onto the rear side of the semiconductor structure likewise
has the advantage that there is no need to subsequently remove the silicon
dioxide layer on the front side. Application by means of printing technology is
preferably effected by the material used for producing the diffusion barrier
layer being embedded on into a carrier substance and subsequently being
applied to the semiconductor substrate by inkjet or screen printing. This is
preferably followed by a drying step in which the carrier substance is at least
partly evaporated and the diffusion barrier layer is stabilized.
Applying the diffusion barrier layer on one side by means of spraying or
rolling onto the rear side of the semiconductor structure likewise has the
advantage that there is no need to remove a silicon dioxide layer on the front
side. The production of dielectric layers by means of spraying is known per se
and described in "TiO2 ant ire flection coatings by a low temperature spray
process", Hovel, H.J., Journal of the Electrochemical Society, 1978.
As a result of the combination of applying a diffusion barrier on the rear side
of the semiconductor substrate and as a result of the fact that an emitter
region is desired in the cutouts in the case of the solar cell according to the
invention, the emitter regions of the solar cell according to the invention can
be produced in a simple manner. Preferably, in method step B the emitter
region at the front side and the feedthrough emitter regions are produced in a
manner comprising one of the following method steps:
Producing the emitter regions by means of diffusion after depositing a dopant
source both on the front side and on the walls of the cutouts makes it possible
to use cost-effective process methods, in particular APCVD, PECVD,
spraying, printing, rolling and deposition in a dipping bath, for depositing the
dopant source. Carrying out the diffusion in an inline furnace is particularly
advantageous.
It likewise lies within the scope of the invention to produce the emitter on the
surface of the semiconductor structure at the front side of the semiconductor
substrate and on the walls of the cutouts by epitaxially growing a layer that
is oppositely doped relative to the base doping, as described in "Epitaxy of
emitters for crystalline silicon solar cells", Reber, S. et al., Proceedings of the
17th European Photovoltaic Solar Energy Conference, Munich, 2001. This has
the advantage that an emitter having high material quality and a defined
dopant concentration is formed, as a result of which the solar cell efficiency
can be increased.
Furthermore, it lies within the scope of the invention to produce a
heterostructure, in which the emitter is deposited by way of a layer.
Likewise, the emitter can also be produced by means of ion implantation.
The cutouts in which the feedthrough structure is formed in further method
steps are preferably produced by laser ablation. The advantage when using
laser methods is that it is possible to have recourse to known process
parameters and the method can be integrated cost-effectively in industrial
production lines.
Further preferred methods for producing the cutouts include the use of wet-
chemical etching methods or plasma etching methods, mechanical drilling
processes and liquid jet drilling. In one advantageous embodiment of the
method, in the case of liquid jet drilling, a laser is coupled into the liquid jet,
whereby the drilling process is accelerated. The liquid jet can contain dopant
used to dope the inner wall of the cutouts during the drilling process. This
has the advantage that the emitter only has to be implemented on one side in
method step B, and the doping of the inner walls of the cutout in method step
A, which in this case is preferably performed after method step B, with
further preference after method step C, is effected at the same time as the
cutouts are produced.
The metallic structures for making contact with the emitter, front-side
contact structure, feedthrough contact structure and rear-side contact
structure, were designated above by the three terms mentioned in order to
identify the spatial arrangement. It lies within the scope of the invention for
these structures to be embodied in a multipart fashion; it likewise lies within
the scope of the invention to form only one integral metallization structure
comprising front-side contact structure, feedthrough structure and rear-side
contact structure.
In one preferred embodiment of the method according to the invention, front-
side contact structure, rear-side contact structure and feedthrough contact
structure are formed by means of screen printing. This affords the advantage
that these processes can be used industrially in an inline method and, in
particular, the use of screen printing for producing metallic structures is
already known and, consequently, it is possible to have recourse to previously
known process parameters. In this case, screen printing paste containing
metal particles is used. In this case, preferably by means of screen printing, a
metal-containing paste is applied to the rear side of the semiconductor
substrate, if appropriate to further intermediate layers, in such a way that
the paste penetrates through the cutouts.
Advantageously, the feedthrough contact structure is formed in such a way
that, during the formation of the feedthrough contact structure, the
feedthrough emitter region is not damaged, or is only slightly damaged, and,
in particular, the feedthrough emitter region formed in method step B is not
removed during the formation of the metallic feedthrough contact structure.
In particular, it is advantageous in this case to form the feedthrough contact
structure by using a silver-containing screen printing paste.
In order to ensure sufficient penetration of the cutouts with screen printing
paste, in the method according to the invention preferably after the screen
printing paste has been applied on the front side, a pressure difference is
produced between front and rear sides of the semiconductor substrate, in
such a way that the paste is forced into the cutouts due to the pressure
difference. In this preferred embodiment, therefore, due to the pressure
difference, the paste is "sucked" from the rear side through the cutouts, with
the result that the production of the metallic feedthrough structures is
ensured in a simple manner.
When forming the rear-side contact structure by means of screen printing it
is particularly advantageous to use silver-containing pastes, preferably
without additives which attack the insulation layer on the rear side, in
particular without glass frit. It is thus possible to further reduce the risk
contact formation and hence of a short circuit between semiconductor
substrate of the base doping type and rear-side contact.
Further preferred embodiments of the method according to the invention
comprise forming front-side contact structure and/or rear-side contact
structure and/or feedthrough contact structure by electrode position,
dispensing, vapor deposition, cathode sputtering or printing methods such as,
for example, inkjet or aerosol.
Further preferred features and embodiments of the solar cell according to the
invention and of the method according to the invention are explained below
with reference to the figures and the description of the figures, in which:
Figure 1 shows a schematic illustration of a partial excerpt from an
exemplary embodiment of a solar cell according to the invention;
Figure 2 shows a process flow chart of a first exemplary embodiment of a
method according to the invention,
Figure 3 shows a process flow chart of a second exemplary embodiment of
a method according to the invention, and
Figure 4 shows a process flow chart of a third exemplary embodiment of a
method according to the invention.
The exemplary embodiment of a solar cell according to the invention, as
illustrated in Figure 1, was produced by means of the process elucidated in
figure 3 hereinafter.
The solar cell according to the invention in Figure 1 comprises a p-doped
semiconductor substrate 1 embodied as a mono- or multicrystalline silicon
wafer having a base resistance of 0.1 ohm cm to 10 ohm cm. A front-side
emitter region 2 is formed at the front side, illustrated at the top in Figure 1.
The front side has a texturing in order to increase the coupling in of light and
an antireflection layer 3 embodied as a silicon nitride layer and having a
thickness of approximately 70 nm is additionally arranged on the front side of
the semiconductor substrate 1 in order to increase the coupling in of light.
Figure 1 merely shows a partial excerpt from the solar cell according to the
invention with just one cutout 4. The solar cell continues in a mirror-inverted
fashion toward the right and left and has a multiplicity of cutouts.
The cutout 4 extends from the front side to the rear side of the solar cell and
is embodied approximately in a cylindrical fashion.
A feedthrough emitter region 5 extending from the front side to the rear side
is formed on the walls of the cutout.
The rear side of the semiconductor substrate 1 is covered by an insulation
and passivation layer 6 formed as a layer system composed of aluminum
oxide and silicon nitride having a total thickness of 100 nm. The layer 6
covers the rear side of the semiconductor substrate over the whole area and is
in turn covered both by a metallic rear-side contact structure 7 and by a
plurality of metallic base contact structures 8, 8', wherein the base contact
structures 8, 8' penetrate through the insulation layer 6 locally at a
multiplicity of point-like contact-making regions, such that there is an
electrical contact between the base contact structures 8, 8' and the
semiconductor substrate 1 in the region of the base doping.
A metallic front-side contact structure 9 is formed at the front side of the
solar cell in accordance with figure 1, said contact structure being electrically
conductively connected directly to the emitter region 2, that is to say that no
antireflection layer 3 is arranged between front-side contact structure 9 and
emitter region 2.
Furthermore, a metallic feedthrough structure 10 is formed in the cutout 4.
Front-side contact structure 9, feedthrough structure 10 and rear-side contact
structure 7 are formed integrally and correspondingly electrically
conductively connected to one another.
It is essential that, in the regions identified by A and A' in Figure 1, although
the rear-side contact structure 7 covers the semiconductor substrate 1 in the
region of the base doping, it is electrically insulated therefrom by the
intervening insulation layer 6. No emitter region extending parallel to the
rear side is formed at the rear side of the semiconductor substrate 1 and in
particular in the regions A and A'. A negligibly small region of the rear side
which has an emitter doping is situated only in the region wherein the
feedthrough emitter region 5 appears at the rear side of the semiconductor
substrate 1.
The front-side contact structure is embodied as in previously known MWT
solar cells, presented for example in "Processing and comprehensive
characterisation of screen-printed mc-si metal wrap through (mwt) solar
cells", Clement et al., Proceedings of the 22nd European Photovoltaic Solar
Energy Conference, Milan, 2007.
The local electrically conductive connections (LFC), produced by means of
local heating by a laser, between semiconductor substrate 1 and base contact
structure 8, 8' are distributed approximately uniformly over the base contact
structure and embodied approximately in a punctiform fashion with a
spacing in the range of 100 μm to 1 mm, in this case of approximately
500 μm. Overall, approximately 98.5% of the rear side of the semiconductor
substrate is covered by the insulation layer, and approximately 1.5% by the
electrically conductive point contacts. The solar cell has cutouts having a
diameter of approximately 100 μm, wherein the cutouts are arranged on
lines; on average, one hole is formed per 4 cm2 solar cell area.
Figure 2 schematically shows one exemplary embodiment of the method
according to the invention. A p-doped multicrystalline silicon wafer having a
base resistance of 0.1 ohm cm to 10 ohm cm is subjected to surface processing
in a method step 0. In this case, the following method steps are performed:
removing surface damage originating from the production of the semi-
conductor substrate, and forming a texturing at least on the front side in
order to improve the light trapping.
Afterward, in a method step A0/C a diffusion barrier is applied over the
whole area on the rear side of the semiconductor substrate. The diffusion
barrier is embodied as a silicon oxide layer having a thickness of 250 nm and
is produced by means of PECVD or thermal oxidation with subsequent
etching-back on one side.
In a method step A, a plurality of cutouts, the so-called "MWT holes", are
subsequently produced. The MWT holes are produced by means of a laser, as
described for example in "Emitter wrap-through solar cell", Gee et al.,
Proceedings of the 23rd IEEE Photovoltaic Specialists Conference, Louisville,
1993. The holes are formed at those positions of the semiconductor substrate
at which the rear-side contact structure is arranged in the subsequent
method steps.
In a method step Al, cleaning is then optionally carried out, wherein the
semiconductor substrate is freed of possible contaminants and products of the
hole drilling process are removed. The cleaning is preferably carried out wet-
chemically using caustic liquids such as hydrofluoric acid, potassium
hydroxide solution or other substances.
A method step B subsequently involves producing the emitter region at the
front side of the semiconductor substrate and the feedthrough emitter region
on the walls of the cutouts. For this purpose, by means of deposition from the
gas phase, phosphorus-containing glass is deposited on the semiconductor
substrate and the emitter is produced by the action of temperature on the
front side and also on the walls of the cutouts, that is to say at the regions
which are not covered by the diffusion barrier layer. For this purpose, the
semiconductor substrate is heated for approximately 45 min to a temperature
of approximately 800°C to 900°C.
The silicate glass that arises in this case is subsequently removed in an
etching step by means of dipping the semiconductor substrate into
hydrofluoric acid having a concentration of approximately 10% for a time
duration of approximately 1 min.
In this exemplary embodiment, the diffusion barrier embodied as a silicon
oxide layer and applied in method step AO/C simultaneously serves as an
insulation layer and is therefore no longer removed.
Method step A0 therefore encompasses method step C in the exemplary
embodiment of the method according to the invention as illustrated in figure
2. It is only when using a screen printing method with a subsequent high-
temperature step for forming the base contact structure in method step D
that the diffusion barrier layer is also reinforced by a silicon nitride layer
having a thickness of approximately 60 nm to 120 nm.
A method step B1 subsequently involves applying an antireflection layer to
the front side of the semiconductor substrate in order to improve the coupling
in of light, wherein the antireflection layer is embodied as a silicon nitride
layer having a thickness of approximately 70 nm. The layer can likewise
constitute a layer system composed of other layers (silicon dioxide, aluminum
oxide; silicon nitride and others).
A method step D subsequently involves forming the metallic contact
structures: feedthrough contact structure, rear-side contact structure, base
contact structure and front-side contact structure.
Figure 3 shows a further exemplary embodiment of the method according to
the invention, wherein identically identified process steps are performed
analogously to the exemplary embodiment in accordance with Figure 2:
After surface processing in a method step 0, the diffusion barrier is applied to
the rear side of the semiconductor substrate over the whole area in a method
step A0, the MWT holes are produced in a method step A, and cleaning steps
are effected in a method step A1, and the diffusion of the emitter regions from
the gas phase takes place in a method step B.
In contrast to the exemplary embodiment illustrated in Figure 2, however,
the diffusion barrier applied in method step A0 is removed again in method
step B. Subsequently, a method step C involves applying an insulation and
passivation layer as a layer system composed of aluminum oxide and silicon
nitride to the rear side of the semiconductor substrate over the whole area,
which firstly passivates the semiconductor substrate with regard to the
surface recombination rate and secondly performs the function as an
insulation layer. The total thickness of the layer system is 100 nm; the layers
are produced by PECVD on the rear side of the semiconductor substrate. This
has the advantage over the exemplary embodiment illustrated in figure 2
that the layer is optimally optimized toward the passivating and insulating
property.
An ant ire flection layer is applied in method step C1.
Afterward, the contact structures are formed in method steps D1 to D4:
For this purpose, front-side contact structure, feedthrough structure and
rear-side contact structure are produced by means of screen printing in a
method step D1 by means of the application of paste containing metal
particles. The metal structures are formed from the applied pastes by means
of contact firing in a method step D2.
In method step D2, however, neither the rear-side contact structure nor the
base contact structure penetrates through the insulation layer applied in
method step C. In order to enable electrical contact to be made with the base
region of the semiconductor substrate, therefore, a momentary local melting
in point-like regions is achieved in a method step D3 by means of local action
of heat by means of a laser according to the LFC process, thereby achieving
the electrical contact between base contact structure and semiconductor
substrate in the base region.
Method step D4 involves heat treatment at a temperature of approximately
350°C for a time duration of at least 30 s, in order to anneal the damage and
strains that can arise as a result of the LFC process.
Figure 4 shows a further exemplary embodiment of the method according to
the invention, in which identically designated method steps correspond to
those in accordance with Figures 3 and 2.
Method steps 0, A, A1, B, C and C1 are performed as described for Figure 3.
Following method step C1, however, the base contact structure is produced as
follows:
In a method step D1', paste containing metal particles is applied to the
insulation layer on the rear side locally at a plurality of regions by means of
screen printing. If appropriate, the locally applied paste is "fired through" in
a temperature step at a temperature of at least 700°C, that is to say that a
base contact structure penetrating through the insulation layer is produced
during the temperature step, said base contact structure thus being
electrically conductively connected to the semiconductor substrate in the
region of the base doping. Preferably, the contact between semiconductor
substrate and base contact structure is produced, however, by "firing
through" the locally applied screen printing paste together with the contact
firing of the contact structures in method step D3'
Afterward, in a method step D2', once again by means of screen printing,
paste containing metal particles is applied in the regions in which front-side
contact structure, feedthrough structure and rear-side contact structure are
intended to be produced. In this case, screen printing paste is applied to the
front side and rear side in the regions in which the contact structures are
intended to be formed. In this case, the cutouts are likewise printed and the
paste is sucked into the cutouts by a pressure difference being produced
between the front and rear sides. Afterward, contact firing takes place in a
method step E3', such that the metal particles contained in the pastes are
electrically conductively connected among one another and the front-side
contact structure is electrically conductively connected to the emitter region
at the front side, but the rear-side contact structure does not penetrate
through the insulation layer. The contact firing takes place at a temperature
of at least 700°C for a time duration of at least 5 s. Preferably, a temperature
maximum of at least 730°C is achieved during the time duration mentioned.
Heat treatment as described for Figure 3 takes place in a method step D4'.
We Claim:
1. A method for producing a photovoltaic solar cell having a front side
designed for coupling in light,
comprising the following method steps:
A producing a plurality of cutouts in a semiconductor substrate (1) of a
base doping type,
B producing one or more emitter regions of an emitter doping type at
least at the front side of the semiconductor substrate, wherein the
emitter doping type is opposite to the base doping type,
C applying an electrically insulating insulation layer (6), and
D producing metallic feedthrough structures in the cutouts,
at least one metallic base contact structure (8, 8') at a rear side of the
solar cell, which is formed in an electrically conductive manner with
the semiconductor substrate (1) in a base doping region,
at least one metallic front-side contact structure (9) at the front side of
the solar cell, which is formed in an electrically conductive manner
with the emitter region (2) at the front side of the semiconductor
substrate, and
at least one rear-side contact structure (7) at the rear side of the solar
cell, which is formed in a manner electrically conductively connected to
the feedthrough contact structure,
characterized in that
in method step B and/or in a further method step in addition a
feedthrough emitter region (5) of the emitter doping type extending
from the front side to the rear side is formed in each case in the semi-
conductor substrate (1) on the walls of the cutouts,
in that in method step C the insulation layer (6) is applied in a manner
covering the rear side of the semiconductor substrate, and if
appropriate further intervening intermediate layers,
in that in method step D
the rear-side contact structure (7) is applied to the insulation layer (6),
and if appropriate to further intermediate layers, in such a way that
the rear-side contact structure (7) extends over regions of the
semiconductor substrate having base doping and, in these regions, at
least on account of the intervening insulation layer (6), an electrical
insulation is formed between rear-side contact structure (7) and
semiconductor substrate (1), and
the base contact structure (8, 8') is applied to the insulation layer (6),
and if appropriate to further intermediate layers, in such a way that
the base contact structure (8, 8') penetrates through the insulation
layer (6) at least in regions, such that an electrically conductive
connection is produced between base contact structure (8, 8') and
semiconductor substrate (1).
2. The method as claimed in claim 1,
characterized in that
no emitter region (2) extending parallel to the rear side is formed in a
manner adjoining the cutouts at the rear side of the semiconductor
substrate.
3. The method as claimed in either of the preceding claims,
characterized in that
before method step B, if appropriate with interposition of further
intermediate steps, in a method step AO a diffusion barrier layer
covering the rear side of the semiconductor substrate is applied, in
order to avoid diffusion of doping material through the diffusion
barrier layer, in particular,
in that method step AO is carried out before method step A, if
appropriate with interposition of further intermediate steps, with
further preference,
in that the diffusion barrier layer is additionally embodied as an
electrically insulating layer, in that the diffusion barrier layer is not
removed in the method steps following method step AO, and preferably
in method step C no additional insulation layer (6) is applied.
4. The method as claimed in claim 3,
characterized in that
in method step AO the diffusion barrier is embodied as a silicon oxide
layer (SiOx), preferably in that the silicon oxide layer is applied in a
manner comprising one of the following method steps:
applying the silicon oxide layer on one side, on the rear side, of the
semiconductor structure by means of PECVD, or
applying the silicon oxide layer on both sides, on the front and rear
sides, of the semiconductor structure and subsequently removing the
silicon oxide layer on the front side, wherein the silicon oxide layer is
preferably applied by means of PECVD or as a thermal silicon oxide
layer, or
applying the silicon oxide layer on one side by means of a printing
technique onto the rear side of the semiconductor structure, or
applying the silicon oxide layer on one side by means of spraying onto
the rear side of the semiconductor structure.
5. The method as claimed in any of the preceding claims,
characterized in that
in method step D the electrically conductive connection between base contact
structure (8, 8') and the semiconductor substrate (1) is produced by means of
local action of heat by a laser.
6. The method as claimed in any of the preceding claims,
characterized in that
the insulation layer (6) is embodied as a dielectric layer.
7. The method as claimed in any of the preceding claims,
characterized in that
in each of the cutouts (4) the feedthrough structure (10) is formed in an
electrically conductive manner with the respective feedthrough emitter
region (5).
8. The method as claimed in any of the preceding claims,
characterized in that
before method step B, if appropriate with interposition of further
method steps, the rear side of the semiconductor substrate is leveled,
preferably by removing a semiconductor layer at one side, at the rear side, of
the semiconductor substrate, with further preference by wet-chemical
etching, by laser ablation or by plasma etching.
9. The method as claimed in any of the preceding claims,
characterized in that
in method step B the emitter region (2) at the front side and the
feedthrough emitter regions are produced in a manner comprising at least
one of the following method steps:
producing the emitter regions by means of diffusion from a gas
atmosphere by means of a dopant-containing gas, or
producing the emitter regions by means of diffusion after depositing a
dopant source, or
growing a highly doped layer onto the surface of the semiconductor
substrate, or
producing the feedthrough emitter region while producing the cutouts
by means of a liquid-jet-guided laser using a dopant-containing liquid.
10. The method as claimed in any of the preceding claims,
characterized in that rear-side contact structure (7) and feedthrough contact
structure are formed integrally, preferably in that front-side contact
structure (9), rear-side contact structure (7) and feedthrough contact
structure are formed integrally.
11. The method as claimed in claim 10,
characterized in that
the front-side contact structure (9), the rear-side contact structure (7)
and the feedthrough contact structure are formed by means of screen
printing, preferably in that in order to form the front-side contact structure
(9), the rear-side contact structure (7) and the feedthrough contact structure
by means of screen printing, a metal-containing paste is applied to one side,
preferably to the rear side, of the semiconductor substrate, if appropriate to
further intermediate layers, in such a way that the paste penetrates through
the cutouts.
12. The method as claimed in claim 11,
characterized in that
after the metal-containing paste has been applied, a pressure
difference is produced between the front and rear sides of the semiconductor
substrate, in such a way that the paste is forced into the cutouts due to the
pressure difference.
13. A photovoltaic solar cell having a front side designed for coupling in
light, in particular formed by a method as claimed in any of the preceding
claims,
wherein the solar cell comprises
a semiconductor substrate (1) of a base doping type,
at least one emitter region (2) of an emitter doping type formed at the
front side, said emitter doping type being opposite to the base doping
type,
at least one metallic front-side contact structure (9) which is formed on
the front side for the purpose of collecting current and which is
electrically conductively connected to the emitter region (2),
at least one metallic base contact structure (8, 8') which is arranged at
a rear side of the solar cell and is electrically conductively connected to
the semiconductor substrate (1) in a region of the base doping type,
at least one cutout (4) extending from the front side to the rear side in
the semiconductor substrate (1) and at least one metallic feedthrough
structure (10), wherein the feedthrough structure (10) is arranged in
the cutout (4) from the front side to the rear side of the semiconductor
substrate and is electrically conductively connected to the front-side
contact structure (9), and
at least one metallic rear-side contact structure (7) which is arranged
at the rear side and is electrically conductively connected to the feed-
through structure (10),
characterized
in that a feedthrough emitter region (5) extending from the front side to the
rear side is formed in the semiconductor substrate (1) on the walls of the
cutout (4),
in that an electrically insulating insulation layer (6) is arranged on the rear
side of the semiconductor substrate, if appropriate on further intermediate
layers, and covers the rear side at least in the regions surrounding the cutout
(4),
in that the rear-side contact structure (7) is arranged on the insulation layer
(6), if appropriate on further intermediate layers, such that the rear-side
contact structure (7) is electrically insulated by the insulation layer (6) from
the semiconductor substrate (1) lying below the insulation layer (6).
14. The photovoltaic solar cell as claimed in claim 13,
characterized in that on the rear side the semiconductor substrate (1) has no
emitter region (2) extending parallel to the rear side.
15. The photovoltaic solar cell as claimed in either of claims 13 and 14,
characterized in that no insulation layer (6) is formed on the walls of the
cutout (4).
16. The photovoltaic solar cell as claimed in any of claims 13 to 15,
characterized in that the insulation layer (6) is formed in a manner
completely covering the rear side of the semiconductor substrate, and if
appropriate further intermediate layers, wherein the base contact structure
(8, 8') is arranged on the insulation layer (6), if appropriate on the further
intermediate layers, and at least locally reaches through the latter and also
all the further layers lying between base contact structure (8, 8') and semi-
conductor substrate (1), such that base contact structure (8, 8') and
semiconductor substrate (1) are electrically conductively connected.
| # | Name | Date |
|---|---|---|
| 1 | 123-Kolnp-2013-(14-01-2013)SPECIFICATION.pdf | 2013-01-14 |
| 1 | 123-KOLNP-2013-(22-04-2013)-ANNEXURE TO FORM 3.pdf | 2013-04-22 |
| 2 | 123-KOLNP-2013-(22-04-2013)-CORRESPONDENCE.pdf | 2013-04-22 |
| 2 | 123-Kolnp-2013-(14-01-2013)FORM-5.pdf | 2013-01-14 |
| 3 | 123-KOLNP-2013-(22-04-2013)-PA.pdf | 2013-04-22 |
| 3 | 123-Kolnp-2013-(14-01-2013)FORM-3.pdf | 2013-01-14 |
| 4 | 123-Kolnp-2013-(14-01-2013)FORM-2.pdf | 2013-01-14 |
| 4 | 123-KOLNP-2013.pdf | 2013-01-18 |
| 5 | 123-Kolnp-2013-(14-01-2013)FORM-1.pdf | 2013-01-14 |
| 5 | 123-Kolnp-2013-(14-01-2013)ABSTRACT.pdf | 2013-01-14 |
| 6 | 123-Kolnp-2013-(14-01-2013)DRAWINGS.pdf | 2013-01-14 |
| 6 | 123-Kolnp-2013-(14-01-2013)CLAIMS.pdf | 2013-01-14 |
| 7 | 123-Kolnp-2013-(14-01-2013)DESCRIPTION (COMPLETE).pdf | 2013-01-14 |
| 7 | 123-Kolnp-2013-(14-01-2013)CORRESPONDENCE.pdf | 2013-01-14 |
| 8 | 123-Kolnp-2013-(14-01-2013)DESCRIPTION (COMPLETE).pdf | 2013-01-14 |
| 8 | 123-Kolnp-2013-(14-01-2013)CORRESPONDENCE.pdf | 2013-01-14 |
| 9 | 123-Kolnp-2013-(14-01-2013)DRAWINGS.pdf | 2013-01-14 |
| 9 | 123-Kolnp-2013-(14-01-2013)CLAIMS.pdf | 2013-01-14 |
| 10 | 123-Kolnp-2013-(14-01-2013)ABSTRACT.pdf | 2013-01-14 |
| 10 | 123-Kolnp-2013-(14-01-2013)FORM-1.pdf | 2013-01-14 |
| 11 | 123-Kolnp-2013-(14-01-2013)FORM-2.pdf | 2013-01-14 |
| 11 | 123-KOLNP-2013.pdf | 2013-01-18 |
| 12 | 123-KOLNP-2013-(22-04-2013)-PA.pdf | 2013-04-22 |
| 12 | 123-Kolnp-2013-(14-01-2013)FORM-3.pdf | 2013-01-14 |
| 13 | 123-KOLNP-2013-(22-04-2013)-CORRESPONDENCE.pdf | 2013-04-22 |
| 13 | 123-Kolnp-2013-(14-01-2013)FORM-5.pdf | 2013-01-14 |
| 14 | 123-KOLNP-2013-(22-04-2013)-ANNEXURE TO FORM 3.pdf | 2013-04-22 |
| 14 | 123-Kolnp-2013-(14-01-2013)SPECIFICATION.pdf | 2013-01-14 |