Thin Film Photovoltaics Research at the Institute of Energy Conversion
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1 Thin Film Photovoltaics Research at the Institute of Energy Conversion Bill Shafarman Institute of Energy Conversion Materials Science and Engineering 1. Status of Photovoltaics 2. IEC: History and Capabilities 3. Current Research at IEC Bill Shafarman 1 May 15, 2013
2 PV Module Experience Curve Price per Watt ($)" Source: Bloomberg New Energy Finance Bill Shafarman 2 May 15, 2013
3 PV Module Production 2012 Global Production (MW)" 40,000" 30,000" 20,000" 10,000" Europe 11%" US 3%" Japan 5%" RoW 1%" Other 16% " Asia" China 64%" 0" " Source: GTM Research Bill Shafarman 3 May 15, 2013
4 Solar Cell Technologies Si Wafer Thin Films Concentrators Bill Shafarman 4 May 15, 2013
5 Thin Film Photovoltaics Potential for low cost PV using " a-si, CdTe, and Cu(InGa)Se 2 High efficiency 20 % for Cu(InGa)Se 2 cell Low material costs Film thicknesses µm High throughput continuous manufacturing Monolithic integration for modules allows glass-in / module-out production Can use flexible substrate with " roll-to-roll processing Bill Shafarman 5 May 15, 2013
6 PV Module Manufacturing Source: National Renewable Energy Laboratory Bill Shafarman 6 May 15, 2013
7 Thin Film PV Critical Issues Materials include CdTe, Cu(InGa)Se 2, a-si Thin films (10 nm to 5 µm) on glass or foil substrates Many deposition / processing approaches Uniformity and throughput critical Cu(InGa)Se 2 Mo Glass Non-ideal materials create unique challenges Structure, interfaces, substrate effects Grid ZnO/ITO CdS Cu(InGa)Se 2 Mo Substrate Bill Shafarman 7 May 15, 2013
8 Recent History: Thin-Film PV Production 5000" 25%" Production (MW)" 4000" 3000" 2000" 1000" 20%" 15%" 10%" 55%" Thin Film Production Share" 0" 2002" 2004" 2006" 2008" 2010" 2012" 0%" Source: GTM Research Bill Shafarman 8 May 15, 2013
9 The Efficiency Gap Source: U.S. Dept. of Energy Bill Shafarman 9 May 15, 2013
10 Institute of Energy Conversion (IEC) Founded in 1972 by Karl W. Boer" to perform thin-film PV research World s oldest continuously operating " solar research facility First 10% efficient thin film " solar cell Cu 2 S/CdS, first roll-to-roll semiconductor deposition Department of Energy University " Center of Excellence since 1992 Multidisciplinary staff: 11 professional, 2 technician, 4 postdocs >20 grad students from Materials Science, Chemical Engr, Electrical Engr, Physics 1 st roll-to-roll semiconductor deposition Bill Shafarman 10 May 15, 2013
11 IEC Thin Film PV Research & Education Fundamental Research Identify and quantitatively characterize material properties and process parameters controlling device performance and stability Increase efficiencies primarily by increasing voltage Device design, fabrication, analysis, simulation Process Engineering Develop low cost, high throughput, high yield approaches Demonstrate viability for large-scale manufacture Identify and develop diagnostic tools for advanced process control Education Science and engineering students research for MS and Ph.D degrees Undergraduates honors program, senior thesis, research assistants Bill Shafarman 11 May 15, 2013
12 IEC capabilities Integrated research facility Over 20 thin-film deposition systems Materials characterization Device fabrication including monolithic module fabrication Extensive device characterization including life-testing Sputter deposition Lifetime testing XPS characterization Bill Shafarman 12 May 15, 2013
13 Working with IEC Government DOE NSF DOD National Labs Industry Direct Research Service Work Sub-contract DOE, DOD International Visiting Scholars Visiting Students Fulbright Scholars Companies IEC Workforce Development Undergraduate Graduate Post Doc Industrial Interns Bill Shafarman 13 May 15, 2013
14 DOE SunShot Initiative Goal to reduce cost of PV to $1/Wp: Foundational Program to Advance Cell Efficiency 1. Low Cost Back Contact Heterojunction Solar Cells on Thin C-Si Wafers 2. Reduced Cu(InGa)Se 2 Thickness in Solar Cells Using a Superstrate Configuration 3. Advanced Precursor Reaction Processing for Cu(InGa)(SeS) 2 Solar Cells 4. Understanding the Effect of Na in Improving the Performance of CuInSe 2 Based PV 5. Enabling the CIGS Thin Film PV Technology to Meet the DOE Goal of $0.50/W Module Price (NREL) Next Generation Photovoltaics 1. Beyond the Lambertian limit Novel Low-symmetry Gratings for Ultimate Light Trapping Enhancement in Next-generation Photovoltaics (MSEG) Bill Shafarman 14 May 15, 2013
15 Leading Si Solar Cell Architectures Silicon heterojunction (SHJ) solar cell p-type a-si intrinsic a-si TCO Interdigitated back contact (IBC) solar cell n-type c-si intrinsic a-si n-type a-si TCO Standard low temperature plasma CVD for a-si passivation and doped layers Amorphous Si provides excellent surface passivation. High V OC (as high as 750 mv) Front surface No electrical contacts " (minimum optical loss) High J SC Rear surface Thick metal contacts (low Rs) High FF Bill Shafarman 15 May 15, 2013
16 Leading Si Solar Cell Architectures Silicon heterojunction (SHJ) solar cell p-type a-si intrinsic a-si TCO Interdigitated back contact (IBC) solar cell n-type c-si intrinsic a-si n-type a-si TCO intrinsic a-si buffer separate a-si p and n regions IBC-SHJ solar cell. Bill Shafarman 16 May 15, 2013
17 Heterojunction IBC cells Silicon PV research at IEC Application to thin Si wafers, low temperature processes Laser-processing for improved contacts and texturing Methods for improved light trapping and surface passivation Multi-chamber PECVD system - 30x30 cm Bill Shafarman 17 May 15, 2013
18 >18% cell efficiency achieved, " performance limited by V OC Cells fabricated in " superstrate structure CdTe Solar Cells Bill Shafarman 18 May 15, 2013
19 CdTe Research at IEC High throughput vapor transport deposition (VTD) Improve junction performance: V OC, fill factor Control CdTe doping Develop alternative device structures Develop alternative deposition and post-deposition processing routes Characterization: Film structure and chemistry Device operation VTD system Chloride vapor reactor Bill Shafarman 19 May 15, 2013
20 Cu(InGa)Se 2 Thin Films Unique properties for solar cells High optical absorption Alloying to control bandgap, 1.0 E g 1.7 ev Tolerance to polycrystalline structure and interfaces Compositional tolerance 1 Relative Absorption CIGS Si Cu(InGa)Se 2 Mo thickness (!m) Bill Shafarman 20 May 15, 2013
21 Cu(InGa)Se 2 Deposition Approaches Elemental co-evaporation Simultaneous delivery of Cu, In, Ga, Se" to hot substrate Control of film composition, gradients Precursor reaction " two-step process Cu(InGa)Se 2 co-evaporation system Different methods for precursor deposition Reaction in H 2 Se and H 2 S H 2 Se / H 2 S reactor Bill Shafarman 21 May 15, 2013
22 Cu(InGa)Se 2 Research at IEC Alloying with Ag, Al, S Wide bandgap for higher voltage, " tandem cells Reduced disorder, defects for " improved cell performance Reduce absorber thickness Optical enhancement " required for d > 1 µm Evaporation source design and " process development / control Fundamental characterization of Na incorporation Control of composition and time for reaction of Cu-Ga-In films Cu 2 ZnSnS 4 (CZTS) analog of CuInSe 2 Bill Shafarman 22 May 15, 2013
23 Flexible PV: Cu 2 S Cu(InGa)Se 2 Bill Shafarman 23 May 15, 2013
24 Thin Film Photovoltaics Potential to play a big role in our solar future Low cost processing High efficiency Module options: flexible, lightweight But critical issues remain Lack of fundamental and processing know-how Opportunities with new device structures, materials, Bill Shafarman 24 May 15, 2013
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