As world population grows the total energy demanded increases. The energy from sources like the photovoltaic cells, emerges as a sustainable, environmentally clean and cost competitive option if produced on a large scale. The current trend in photovoltaic industry passes through increasing efficiency and reducing costs of the modules. A significant part of these costs originates in the semiconductor substrate material, therefore, the tendency is to reduce the thickness of the cells; however, the manufacturing processes need to be optimized. The aim is to implement in-line and contact-less techniques which increase productivity while reduce breakage yield. This work presents the results obtained towards that direction, particularly in the field of emitter formation and metallization.

Photovoltaic technology has now developed to the extent that it is close to fulfilling the vision of a "solar-energy world," as devices based on this technology are becoming efficient, low-cost and durable. This book provides a comprehensive treatment of thin-film silicon, a prevalent PV material, in terms of its semiconductor nature, startin

Thin film solar cells have the potential to be an important contributor to the world energy demand in the 21st century. Among all the thin film technologies, CuInGaSe2 (CIGS) thin film solar cells have achieved the highest efficiency. However, the high price of photovoltaic (PV) modules has been a major factor impeding their growth for terrestrial applications. Reduction in cost of PV modules can be realized by several ways including choosing scalable processes amenable to large area deposition, reduction in the materials consumption of active layers, and attaining faster deposition rates suitable for in-line processing. Selenization-sulfurization of sputtered metallic Cu-In-Ga precursors is known to be more amenable to large area deposition. Sputter-deposited molybdenum thin film is commonly employed as a back contact layer for CIGS solar cells. However, there are several difficulties in fabricating an optimum back contact layer. It is known that molybdenum thin films deposited at higher sputtering power and lower gas pressure exhibit better electrical conductivity. However, such films exhibit poor adhesion to the soda-lime glass substrate. On the other hand, films deposited at lower discharge power and higher pressure although exhibit excellent adhesion show lower electrical conductivity. Therefore, a multilayer structure is normally used so as to get best from the two deposition regimes. A multi-pass processing is not desirable in high volume production because it prolongs total production time and correspondingly increases the manufacturing cost. In order to make manufacturing compliant with an in-line deposition, it is justifiable having fewer deposition sequences. Thorough analysis of pressure and power relationship of film properties deposited at various parameters has been carried out. It has been shown that it is possible to achieve a molybdenum back contact of desired properties in a single deposition pass by choosing the optimum deposition parameters. It is also shown that the film deposited in a single pass is actually a composite structure. CIGS solar cells have successfully been completed on the developed single layer back contact with National Renewable Energy Laboratory (NREL) certified device efficiencies [greater than]11%. The optimization of parameters has been carried out in such a way that the deposition of back contact and metallic precursors can be carried out in identical pressure conditions which is essential for in-line deposition without a need for load-lock. It is know that the presence of sodium plays a very critical role during the growth of CIGS absorber layer and is beneficial for the optimum device performance. The effect of sodium location during the growth of the absorber layer has been studied so as to optimize its quantity and location in order to get devices with improved performance. NREL certified devices with efficiencies [greater than]12% have been successfully completed.

Photovoltaic technology has now developed to the extent that it is close to fulfilling the vision of a "solar-energy world," as devices based on this technology are becoming efficient, low-cost and durable. This book provides a comprehensive treatment of thin-film silicon, a prevalent PV material, in terms of its semiconductor nature, starting out with the physical properties, but concentrating on device applications. A special emphasis is given to amorphous silicon and microcrystalline silicon as photovoltaic materials, along with a model that allows these systems to be physically described in the simplest manner possible, thus allowing the student or scientist/engineer entering the field of thin-film electronics to master a few basic concepts that are distinct from those in the field of conventional semiconductors. The main part of the book deals with solar cells and modules by illustrating the basic functioning of these devices, along with their limitations, design optimization, testing and fabrication methods. Among the manufacturing processes discussed are plasma-assisted and hot-wire deposition, sputtering, and structuring techniques.

The world of today must face up to two contradictory energy problems: on the one hand, there is the sharply growing consumer demand in countries such as China and India. On the other hand, natural resources are dwindling. Moreover, many of those countries which still possess substantial gas and oil supplies are politically unstable. As a result, renewable natural energy sources have received great attention. Among these, solar-cell technology is one of the most promising candidates. However, there still remains the problem of the manufacturing costs of such cells. Many attempts have been made to reduce the production costs of “conventional” solar cells (manufactured from monocrystalline silicon using diffusion methods) by instead using cheaper grades of silicon, and simpler pn-junction fabrication. That is the ‘hero’ of this book; the heterojunction solar cell.

The photovoltaic technology has been attracting widespread attention because of its effective energy harvest by directly converting solar energy into electricity. Thin-film silicon solar cells are believed to be a promising candidate for further scaled-up production and cost reduction while maintaining the advantages of bulk silicon. The efficiency of thin-film Si solar cells critically depends on optical absorption in the silicon layer since silicon has low absorption coefficient in the red and near-infrared (IR) wavelength ranges due to its indirect bandgap nature. This thesis aims at understanding, designing, and fabricating novel photonic structures for efficiency enhancement in thin-film Si solar cells. We have explored a previously reported a photonic crystal (PC) based structure to improve light absorption in thin-film Si solar cells. The PC structure combines a dielectric grating layer and a distributed Bragg reflector (DBR) for effcient light scattering and reflection, increasing light path length in the thin-film cell. We have understood the operation principles for this design by using photonic band theories and electromagnetic wave simulations. we discover that this DBR with gratings exhibit unusual light trapping in a way different from metal reflectors and photonic crystals. The light trapping effects for the DBR with and without reflector are numerically investigated. The self-assembled anodic aluminum oxide (AAO) technique is introduced to non- lithographically fabricate the grating structure. We adjust the AAO structural parameters by using different anodization voltages, times and electrolytes. Two-step anodization is employed to obtain nearly hexagonal AAO pattern. The interpore periods of the fabricated AAO are calculated by fast Fourier transform (FFT) analysis. We have also demonstrated the fabrication of ordered patterns made of other materials like amorphous Si (a-Si) and silver by using the AAO membrane as a deposition mask. Numerical simulations predict that the fabricated AAO pattern exhibits light trapping performance comparable to the perfectly periodic grating layer. We have implemented the light trapping concepts combining the self-assembled AAO layer and the DBR in the backside of crystalline Si wafers. Photoconductivity measurements suggest that the light absorption is improved in the near-IR spectral range near the band edge of Si. Furthermore, different types of thin-film Si solar cells, including a-Si, mi- crocrystalline Si ([mu]-Si) and micromorph Si solar cells, are investigated. For demonstration, the designed structure is integrated into a 1:5 [mu]m thick [mu]c-Si solar cell. We use numerical simulations to obtain the optimal structure parameters for the grating and the DBR, and then we fabricate the optimized structures using the AAO membrane as a template. The prototype devices integrating our proposed backside structure yield a 21% improvement in efficiency. This is further verified by quantum efficiency measurements, which clearly indicate stronger light absorption in the red and near-IR spectral ranges. Lastly, we have explored the fundamental light trapping limits for thin-film Si solar cells in the wave optics regime. We develop a deterministic method to optimize periodic textures for light trapping. Deep and high-index-contrast textures exhibit strong anisotropic scattering that is outside the regime of validity of the Lambertian models commonly used to describe texture-induced absorption enhancement for normal incidence. In the weak ab- sorption regime, our optimized surface texture in two dimensions (2D) enhances absorption by a factor of 2.7[pi]n, considerably larger than the classical [pi]n Lambertian result and exceeding by almost 50% a recent generalization of Lambertian model for periodic structures in finite spectral range. Since the [pi]n Lambertian limit still applies for isotropic incident light, our optimization methodology can be thought of optimizing the angle/enhancement tradeoff for periodic textures. Based on a modified Shockley-Queisser theory, we conclude that it is possible to achieve more than 20% efficiency in a 1:5 [mu]m thick crystalline Si cell if advanced light trapping schemes can be realized.

This book provides a review of all types of silicon solar cells. The scope includes monocrocrystalline Si solar cells, polycrystalline and amorphous thin-film silicon solar cells, and tandem solar cells. Production, treatment and development of these devices are reviewed. Limitations of these devices, design optimization, testing and fabrication methods are covered. In addition, current status and future prospects for the further development of silicon solar cells are addressed. Special emphasis is given to methods of attaining high efficiency and thereby cost-effective solar power. The aim of the book is to provide the reader with a complete overview about the recent advances in the structure and technology of all generations of silicon solar cells.