Thursday, April 8, 2010
Thin film solar cells
The high cost of crystalline silicon wafers (they make up 40-50% of the cost of a finished module) has led the industry to look at cheaper materials to make solar cells.
The selected materials are all strong light absorbers and only need to be about 1micron thick, so materials costs are significantly reduced. The most common materials are amorphous silicon (a-Si, still silicon, but in a different form), or the polycrystalline materials: cadmium telluride (CdTe) and copper indium (gallium) diselenide (CIS or CIGS).
Each of these three is amenable to large area deposition (on to substrates of about 1 meter dimensions) and hence high volume manufacturing. The thin film semiconductor layers are deposited on to either coated glass or stainless steel sheet.
The semiconductor junctions are formed in different ways, either as a p-i-n device in amorphous silicon, or as a hetero-junction (e.g. with a thin cadmium sulphide layer) for CdTe and CIS. A transparent conducting oxide layer (such as tin oxide) forms the front electrical contact of the cell, and a metal layer forms the rear contact.
Thin film technologies are all complex. They have taken at least twenty years, supported in some cases by major corporations, to get from the stage of promising research (about 8% efficiency at 1cm2 scale) to the first manufacturing plants producing early product.
Amorphous silicon is the most well developed of the thin film technologies. In its simplest form, the cell structure has a single sequence of p-i-n layers. Such cells suffer from significant degradation in their power output (in the range 15-35%) when exposed to the sun.
The mechanism of degradation is called the Staebler-Wronski Effect, after its discoverers. Better stability requires the use of a thinner layers in order to increase the electric field strength across the material. However, this reduces light absorption and hence cell efficiency.
This has led the industry to develop tandem and even triple layer devices that contain p-i-n cells stacked one on top of the other. In the cell at the base of the structure, the a-Si is sometimes alloyed with germanium to reduce its band gap and further improve light absorption. All this added complexity has a downside though; the processes are more complex and process yields are likely to be lower.
In order to build up a practically useful voltage from thin film cells, their manufacture usually includes a laser scribing sequence that enables the front and back of adjacent cells to be directly interconnected in series, with no need for further solder connection between cells.
As before, thin film cells are laminated to produce a weather resistant and environmentally robust module. Although they are less efficient (production modules range from 5 to 8%), thin films are potentially cheaper than c-Si because of their lower materials costs and larger substrate size.
However, some thin film materials have shown degradation of performance over time and stabilized efficiencies can be 15-35% lower than initial values. Many thin film technologies have demonstrated best cell efficiencies at research scale above 13%, and best prototype module efficiencies above 10%. The technology that is most successful in achieving low manufacturing costs in the long run is likely to be the one that can deliver the highest stable efficiencies (probably at least 10%) with the highest process yields.
Amorphous silicon is the most well-developed thin film technology to-date and has an interesting avenue of further development through the use of "microcrystalline" silicon which seeks to combine the stable high efficiencies of crystalline Si technology with the simpler and cheaper large area deposition technology of amorphous silicon.
However, conventional c-Si manufacturing technology has continued its steady improvement year by year and its production costs are still falling too.
The emerging thin film technologies are starting to make significant in-roads in to grid connect markets, particularly in Germany, but crystalline technologies still dominate the market. Thin films have long held a niche position in low power (<50w)>
The selected materials are all strong light absorbers and only need to be about 1micron thick, so materials costs are significantly reduced. The most common materials are amorphous silicon (a-Si, still silicon, but in a different form), or the polycrystalline materials: cadmium telluride (CdTe) and copper indium (gallium) diselenide (CIS or CIGS).
Each of these three is amenable to large area deposition (on to substrates of about 1 meter dimensions) and hence high volume manufacturing. The thin film semiconductor layers are deposited on to either coated glass or stainless steel sheet.
The semiconductor junctions are formed in different ways, either as a p-i-n device in amorphous silicon, or as a hetero-junction (e.g. with a thin cadmium sulphide layer) for CdTe and CIS. A transparent conducting oxide layer (such as tin oxide) forms the front electrical contact of the cell, and a metal layer forms the rear contact.
Thin film technologies are all complex. They have taken at least twenty years, supported in some cases by major corporations, to get from the stage of promising research (about 8% efficiency at 1cm2 scale) to the first manufacturing plants producing early product.
Amorphous silicon is the most well developed of the thin film technologies. In its simplest form, the cell structure has a single sequence of p-i-n layers. Such cells suffer from significant degradation in their power output (in the range 15-35%) when exposed to the sun.
The mechanism of degradation is called the Staebler-Wronski Effect, after its discoverers. Better stability requires the use of a thinner layers in order to increase the electric field strength across the material. However, this reduces light absorption and hence cell efficiency.
This has led the industry to develop tandem and even triple layer devices that contain p-i-n cells stacked one on top of the other. In the cell at the base of the structure, the a-Si is sometimes alloyed with germanium to reduce its band gap and further improve light absorption. All this added complexity has a downside though; the processes are more complex and process yields are likely to be lower.
In order to build up a practically useful voltage from thin film cells, their manufacture usually includes a laser scribing sequence that enables the front and back of adjacent cells to be directly interconnected in series, with no need for further solder connection between cells.
As before, thin film cells are laminated to produce a weather resistant and environmentally robust module. Although they are less efficient (production modules range from 5 to 8%), thin films are potentially cheaper than c-Si because of their lower materials costs and larger substrate size.
However, some thin film materials have shown degradation of performance over time and stabilized efficiencies can be 15-35% lower than initial values. Many thin film technologies have demonstrated best cell efficiencies at research scale above 13%, and best prototype module efficiencies above 10%. The technology that is most successful in achieving low manufacturing costs in the long run is likely to be the one that can deliver the highest stable efficiencies (probably at least 10%) with the highest process yields.
Amorphous silicon is the most well-developed thin film technology to-date and has an interesting avenue of further development through the use of "microcrystalline" silicon which seeks to combine the stable high efficiencies of crystalline Si technology with the simpler and cheaper large area deposition technology of amorphous silicon.
However, conventional c-Si manufacturing technology has continued its steady improvement year by year and its production costs are still falling too.
The emerging thin film technologies are starting to make significant in-roads in to grid connect markets, particularly in Germany, but crystalline technologies still dominate the market. Thin films have long held a niche position in low power (<50w)>
Crystalline silicon solar cells
Historically, crystalline silicon (c-Si) has been used as the light-absorbing semiconductor in most solar cells, even though it is a relatively poor absorber of light and requires a considerable thickness (several hundred microns) of material. Nevertheless, it has proved convenient because it yields stable solar cells with good efficiencies (11-16%, half to two-thirds of the theoretical maximum) and uses process technology developed from the huge knowledge base of the microelectronics industry.
Two types of crystalline silicon are used in the industry. The first is monocrystalline, produced by slicing wafers (up to 150mm diameter and 350 microns thick) from
a high-purity single crystal boule. The second is multicrystalline silicon, made by sawing a cast block of silicon first into bars and then wafers. The main trend in crystalline silicon cell manufacture is toward multicrystalline technology.
For both mono- and multicrystalline Si, a semiconductor homojunction is formed by diffusing phosphorus (an n-type dopant) into the top surface of the boron doped (p-type) Si wafer. Screen-printed contacts are applied to the front and rear of the cell, with the front contact pattern specially designed to allow maximum light exposure of the Si material with minimum electrical (resistive) losses in the cell.
Two types of crystalline silicon are used in the industry. The first is monocrystalline, produced by slicing wafers (up to 150mm diameter and 350 microns thick) from
a high-purity single crystal boule. The second is multicrystalline silicon, made by sawing a cast block of silicon first into bars and then wafers. The main trend in crystalline silicon cell manufacture is toward multicrystalline technology. For both mono- and multicrystalline Si, a semiconductor homojunction is formed by diffusing phosphorus (an n-type dopant) into the top surface of the boron doped (p-type) Si wafer. Screen-printed contacts are applied to the front and rear of the cell, with the front contact pattern specially designed to allow maximum light exposure of the Si material with minimum electrical (resistive) losses in the cell.
The most efficient production cells use monocrystalline c-Si with laser grooved, buried grid contacts for maximum light absorption and current collection.
Some companies are productionizing technologies that by-pass some of the inefficiencies of the crystal growth/casting and wafer sawing route. One route is to grow a ribbon of silicon, either as a plain two-dimensional strip or as an octagonal column, by pulling it from a silicon melt.
Another is to melt silicon powder on a cheap conducting substrate. These processes may bring with them other issues of lower growth/pulling rates and poorer uniformity and surface roughness.
Each c-Si cell generates about 0.5V, so 36 cells are usually soldered together in series to produce a module with an output to charge a 12V battery. The cells are hermetically sealed under toughened, high transmission glass to produce highly reliable, weather resistant modules that may be warrantied for up to 25 years.
Definition and History of Solar Cells
A solar cell is any device that directly converts the energy in light into electrical energy through the process of photovoltaics. The development of solar cell technology begins with the 1839 research of French physicist Antoine-César Becquerel. Becquerel observed the photovoltaic effect while experimenting with a solid electrode in an electrolyte solution when he saw a voltage develope when light fell upon the electrode.
Charles Fritts - First Solar Cell
According to Encyclopedia Britannica the first genuine solar cell was built around 1883 by Charles Fritts, who used junctions formed by coating selenium (a semiconductor) with an extremely thin layer of gold.Russell Ohl - Silicon Solar Cell
Early solar cells, however, had energy conversion efficiencies of under one percent. In 1941, the silicon solar cell was invented by Russell Ohl.Gerald Pearson, Calvin Fuller and Daryl Chapin - Efficient Solar Cells
In 1954, three American researchers, Gerald Pearson, Calvin Fuller and Daryl Chapin, designed a silicon solar cell capable of a six percent energy conversion efficiency with direct sunlight. The three inventors created an array of several strips of silicon (each about the size of a razorblade), placed them in sunlight, captured the free electrons and turned them into electrical current. They created the first solar panels. Bell Laboratories in New York announced the prototype manufacture of a new solar battery. Bell had funded the research. The first public service trial of the Bell Solar Battery began with a telephone carrier system (Americus, Georgia) on October 4 1955.How do Photovoltaics Work? Explained by Nasa
Photovoltaics is the direct conversion of light into electricity at the atomic level. Some materials exhibit a property known as the photoelectric effect that causes them to absorb photons of light and release electrons. When these free electrons are captured, an electric current results that can be used as electricity.
The photoelectric effect was first noted by a French physicist, Edmund Bequerel, in 1839, who found that certain materials would produce small amounts of electric current when exposed to light. In 1905, Albert Einstein described the nature of light and the photoelectric effect on which photovoltaic technology is based, for which he later won a Nobel prize in physics. The first photovoltaic module was built by Bell Laboratories in 1954. It was billed as a solar battery and was mostly just a curiosity as it was too expensive to gain widespread use. In the 1960s, the space industry began to make the first serious use of the technology to provide power aboard spacecraft. Through the space programs, the technology advanced, its reliability was established, and the cost began to decline. During the energy crisis in the 1970s, photovoltaic technology gained recognition as a source of power for non-space applications.
The diagram above illustrates the operation of a basic photovoltaic cell, also called a solar cell. Solar cells are made of the same kinds of semiconductor materials, such as silicon, used in the microelectronics industry. For solar cells, a thin semiconductor wafer is specially treated to form an electric field, positive on one side and negative on the other. When light energy strikes the solar cell, electrons are knocked loose from the atoms in the semiconductor material. If electrical conductors are attached to the positive and negative sides, forming an electrical circuit, the electrons can be captured in the form of an electric current -- that is, electricity. This electricity can then be used to power a load, such as a light or a tool.
A number of solar cells electrically connected to each other and mounted in a support structure or frame is called a photovoltaic module. Modules are designed to supply electricity at a certain voltage, such as a common 12 volts system. The current produced is directly dependent on how much light strikes the module.
Multiple modules can be wired together to form an array. In general, the larger the area of a module or array, the more electricity that will be produced. Photovoltaic modules and arrays produce direct-current (dc) electricity. They can be connected in both series and parallel electrical arrangements to produce any required voltage and current combination.
One way to get around this limitation is to use two (or more) different cells, with more than one band gap and more than one junction, to generate a voltage. These are referred to as "multijunction" cells (also called "cascade" or "tandem" cells). Multijunction devices can achieve a higher total conversion efficiency because they can convert more of the energy spectrum of light to electricity.
As shown below, a multijunction device is a stack of individual single-junction cells in descending order of band gap (Eg). The top cell captures the high-energy photons and passes the rest of the photons on to be absorbed by lower-band-gap cells.
As an example, the multijunction device below uses a top cell of gallium indium phosphide, "a tunnel junction," to aid the flow of electrons between the cells, and a bottom cell of gallium arsenide.
Source : http://science.nasa.gov/
How Solar Cells Work
You've probably seen calculators with solar cells -- devices that never need batteries and in some cases, don't even have an off button. As long as there's enough light, they seem to work forever. You may also have seen larger solar panels, perhaps on emergency road signs, call boxes, buoys and even in parking lots to power the lights.
Although these larger panels aren't as common as solar-powered calculators, they're out there and not that hard to spot if you know where to look. In fact, photovoltaics -- which were once used almost exclusively in space, powering satellites' electrical systems as far back as 1958 -- are being used more and more in less exotic ways. The technology continues to pop up in new devices all the time, from sunglasses to electric vehicle charging stations.
The hope for a "solar revolution" has been floating around for decades -- the idea that one day we'll all use free electricity from the sun. This is a seductive promise, because on a bright, sunny day, the sun's rays give off approximately 1,000 watts of energy per square meter of the planet's surface. If we could collect all of that energy, we could easily power our homes and offices for free.
In this article, we will examine solar cells to learn how they convert the sun's energy directly into electricity. In the process, you will learn why we're getting closer to using the sun's energy on a daily basis, and why we still have more research to do before the process becomes cost-effective.
What is Photovoltaic Cell
A photovoltaic cell (PV cell) is a specialized semiconductor diode that converts visible light into direct current (DC). Some PV cells can also convert infrared (IR) or ultraviolet (UV ) radiation into DC electricity. Photovoltaic cells are an integral part of solar-electric energy systems, which are becoming increasingly important as alternative sources of utility power.
The first PV cells were made of silicon combined, or doped, with other elements to affect the behavior of electrons or holes (electron absences within atoms). Other materials, such as copper indium diselenide (CIS), cadmium telluride (CdTe), and gallium arsenide (GaAs), have been developed for use in PV cells. There are two basic types of semiconductor material, called positive (or P type) and negative (or N type). In a PV cell, flat pieces of these materials are placed together, and the physical boundary between them is called the P-N junction. The device is constructed in such a way that the junction can be exposed to visible light, IR, or UV. When such radiation strikes the P-N junction, a voltage difference is produced between the P type and N type materials. Electrodes connected to the semiconductor layers allow current to be drawn from the device.
Large sets of PV cells can be connected together to form solar modules, arrays, or panels. The use of PV cells and batteries for the generation of usable electrical energy is known as photovoltaics. One of the major advantages of photovoltaics is the fact that it is non-polluting, requiring only real estate (and a reasonably sunny climate) in order to function. Another advantage is the fact that solar energy is unlimited. Once a photovoltaic system has been installed, it can provide energy at essentially no cost for years, and with minimal maintenance.
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