Blistering of magnetron sputtered thin film CdTe devices

Magnetron sputtering is an industrially scalable technique for thin film deposition. It provides excellent coating uniformity and the deposition can be conducted at relatively low substrate temperatures. It is widely used in the manufacture of solar modules. However, its use for the deposition of thin film CdTe devices results in unusual problems. Blisters appear on the surface of the device and voids occur in the CdTe absorber. These problems appear after the cadmium chloride activation treatment. The voids often occur at the CdS/CdTe interface causing catastrophic delamination. This problem has been known for more than 25 years, but the mechanisms leading to blistering have not been understood. Using High Resolution Transmission Electron Microscopy we have discovered that during the activation process, argon trapped during the sputtering process diffuses in the lattice to form gas bubbles. The gas bubbles grow by agglomeration particularly at grain boundaries and at interfaces. The growth of the bubbles eventually leads to void formation and blistering

Operando potassium K-edge X-ray absorption spectroscopy: investigating potassium catalysts during soot oxidation.

The chemical and structural nature of potassium compounds involved in catalytic soot oxidation have been studied by a combination of temperature programmed oxidation and operando potassium K-edge X-ray absorption spectroscopy experiments. These experiments are the first known operando studies using tender X-rays (∼3.6 keV) under high temperature oxidation reaction conditions. X-ray absorption near edge structure analysis of K2CO3/Al2O3 catalysts during heating shows that, at temperatures between 100 and 200 °C, potassium species undergo a structural change from an initial hydrated K2CO3·xH2O and KHCO3 mixture to well-defined K2CO3. As the catalyst is heated from 200 °C to 600 °C, a feature associated with multiple scattering shifts to lower energy, indicating increased K2CO3 dispersion, due to its mobility at high reaction temperature. This shift was noted to be greater in samples containing soot than in control experiments without soot and can be attributed to enhanced mobility of the K2CO3, due to the interaction between soot and potassium species. No potassium species except K2CO3 could be defined during reactions, which excludes a potential reaction mechanism in which carbonate ions are the active soot-oxidising species. Simulations of K-edge absorption near edge structures were performed to rationalise the observed changes seen. Findings showed that cluster size, unit cell distortions and variation in the distribution of potassium crystallographic sites influenced the simulated spectra of K2CO3. While further simulation studies are required for a more complete understanding, the current results support the hypothesis that changes in the local structure on dispersion can influence the observed spectra. Ex situ characterisation was carried out on the fresh and used catalyst, by X-ray diffraction and X-ray photoelectron spectroscopy, which indicated changes to the carbonate species, in line with the X-ray absorption spectroscopy experiments

Cadmium chloride assisted re-crystallisation of CdTe: The effect on the CdS window layer

© 2015 Materials Research Society. The cadmium chloride annealing treatment is an essential step in the manufacture of efficient thin film CdTe solar cells. In previous work we have shown that the primary effect of the treatment is to remove high densities of stacking faults from the as-deposited material. Use of density functional theory has shown that some of the higher energy stacking faults are hole traps. Removal of these defects dramatically improves cell efficiency. In this study we focus on the effect of the activation treatment on the underlying n-type cadmium sulphide layer. A range of techniques has been used to observe the changes to the microstructure as well as the chemical and crystallographic changes as a function of treatment parameters. Electrical tests that link the device performance with the micro-structural properties of the cells have also been undertaken. Techniques used include High Resolution Transmission Electron Microscopy (HRTEM) for subgrain analysis, EDX for chemical analysis and XPS and SIMS for composition-depth profiling. By studying the effect of increasing the treatment time and temperature, we will show that the cadmium sulphide layer depletes to the point of complete dissolution into the absorber layer. We will also show that chlorine penetrates and decorates the grain boundaries in the cadmium sulphide. In addition we will show that chlorine builds up at the heterojunction and concentrates in voids at the cadmium telluride/cadmium sulphide interface. A combination of these effects damages the electrical performance of the solar cell

Activation of thin film CdTe solar cells using a cadmium bromide treatment

The activation of CdTe with a cadmium chloride annealing treatment is a vital step in the fabrication of high efficiency solar cells. Thin film MZO/CdTe cells have been activated using CdBr2 instead of CdCl2 with a lower activation process temperature. Using this method, CdBr2 does activate the cell as revealed by J-V and EQE measurements. TEM and EDX elemental maps from device cross-sections confirm that bromine is present in the grain boundaries. TEM shows that the treatment removes stacking faults at 425 °C. CdBr2 treatment resulted in a relatively modest conversion efficiency of 5.49% when treated at 375 °C. Nevertheless, the experiments shed further light on the mechanisms involved in the activation

High efficiency CdTe solar cells by low temperature deposition with MgZnO HRT layer

CdTe solar cells have shown high efficiency and the technology is scalable. As a result thin film CdTe modules are competitive with crystalline silicon modules. Thin film CdTe devices with efficiency above 22% have been reported using high substrate temperatures during the deposition process. It is known that high substrate temperatures result in large grain size with a reduced number of grain boundaries and this is believed to contribute to the high efficiency. However, use of high temperature requires robust substrates and excludes the use of most flexible substrate materials. It also involves higher energy consumption and more complicated machinery. In this work we present a process for high efficiency solar cells with an improved front contact, by introducing magnesium-doped zinc oxide high resistance transparent layer. By optimizing the fabrication process we have achieved a conversion efficiency exceeding 16%, which is one of the highest reported for substrate temperatures below 500°C

Magnesium-doped Zinc Oxide as a High Resistance Transparent Layer for thin film CdS/CdTe solar cells

Magnesium-doped Zinc Oxide (MZO) was used as an alternative high resistance transparent layer for CdS/CdTe thin film solar cells. Thin films of MZO were deposited by RF magnetron sputtering and deposited on an Indium Tin Oxide contact (ITO). Thin film CdTe devices including a MZO high resistance transparent layer deposited at above 300 \ub0C yielded a mean efficiency exceeding 10.5 %. This compares with an efficiency of 8.2 % without the MZO layer. The improvement in efficiency was due to a higher open circuit voltage and fill factor. Lowering the deposition temperature of MZO reduced the performance of the devices

Cadmium Chloride Assisted Re-Crystallisation of CdTe: The Effect on the CdS Window Layer

This paper was submitted for publication in the journal MRS Online Proceedings Library and the definitive published version is available at http://dx.doi.org/10.1557/opl.2015.177© 2015 Materials Research Society. The cadmium chloride annealing treatment is an essential step in the manufacture of efficient thin film CdTe solar cells. In previous work we have shown that the primary effect of the treatment is to remove high densities of stacking faults from the as-deposited material. Use of density functional theory has shown that some of the higher energy stacking faults are hole traps. Removal of these defects dramatically improves cell efficiency. In this study we focus on the effect of the activation treatment on the underlying n-type cadmium sulphide layer. A range of techniques has been used to observe the changes to the microstructure as well as the chemical and crystallographic changes as a function of treatment parameters. Electrical tests that link the device performance with the micro-structural properties of the cells have also been undertaken. Techniques used include High Resolution Transmission Electron Microscopy (HRTEM) for subgrain analysis, EDX for chemical analysis and XPS and SIMS for composition-depth profiling. By studying the effect of increasing the treatment time and temperature, we will show that the cadmium sulphide layer depletes to the point of complete dissolution into the absorber layer. We will also show that chlorine penetrates and decorates the grain boundaries in the cadmium sulphide. In addition we will show that chlorine builds up at the heterojunction and concentrates in voids at the cadmium telluride/cadmium sulphide interface. A combination of these effects damages the electrical performance of the solar cell

Scalable Deposition of High-Efficiency Perovskite Solar Cells by Spray-Coating

Spray-deposition is a low-cost, roll-to-roll compatible technique that could potentially replace spin-coating for the deposition of highly efficient perovskite solar cells. Here, perovskite active layers were fabricated in air using an ultrasonic spray system and compared with equivalent spin-coated films. A chlorine-containing perovskite ink with a wide processing window coupled with an antisolvent extraction resulted in perovskite films with relatively rougher surfaces than those spin-coated. A power conversion efficiency (PCE) of 17.3% was achieved with an average of 16.3% from 24 devices. Despite observing differences in film roughness and structure, the performance of sprayed perovskite solar cells was comparable to that of the spin-coated cells processed in an inert atmosphere, showing the versatility of perovskite processing