PFI:AIR - TT: One-Step Process for High Efficiency Textured Solar Cells

这个PFI：空气技术翻译项目专注于翻译一项关于使用铝进行硅表面纹理处理的研究发现，以满足对硅太阳能电池低成本制造方法的需求。该项目将基于一步制造工艺制造出纳米结构硅太阳能电池的原型。一步制造工艺很重要，因为它满足了在保持高能量转换效率的同时开发可持续的、低成本的太阳能制造技术的需求。它具有以下独特的特点：它利用铝的双重作用在晶体硅中形成p-n结，同时将硅表面织构以减少反射损失；它减少了制造太阳能电池所需的工艺步骤，并且基于丰富的地球材料。与该市场中领先的竞争工艺(使用金和银来刻蚀硅表面来制造纳米结构太阳能电池)相比，这些特性提供了几个优势，包括降低工艺复杂性、提高可持续性和降低成本。该项目聘请硅纳米线太阳能电池的领先开发商BandGap Engineering Inc.提供设备测试和评估能力，协助成本模型开发，并指导这项技术从研究发现到商业现实的商业化方面的努力。该项目在从研究发现转化为商业应用的过程中解决了以下技术差距。它将研究如何使用铝薄膜同时作为p型扩散源以形成结，并作为催化剂来中介纳米织构以在表面形成减反射层。我们将研究织构形态，即纳米线和纳米锥对器件光学和光伏性能的影响。将开发钝化纳米结构表面的方法，以减少表面复合造成的效率损失。将开发该过程的综合成本模型，以指导商业化计划。该项目的总体目标是开发一种基于一步法工艺的太阳能电池原型，其功率转换效率可与使用金/银诱导蚀刻制造的最先进的纳米结构太阳能电池相媲美或更高。潜在的经济影响预计将是未来十年晶硅太阳能电池每瓦特成本的降低，这将有助于美国在可再生能源领域的竞争力。

This PFI: AIR Technology Translation project focuses on translating a research discovery on the use of aluminum for silicon surface texturing to fill the need for lower cost fabrication methods for silicon solar cells. The project will result in a prototype of a nanotextured silicon solar cell based on a one-step fabrication process. The one-step fabrication process is important because it addresses the need to develop sustainable, low cost solar manufacturing technology while maintaining high energy conversion efficiency. It has the following unique features: it uses aluminum in a dual role to form a p-n junction in crystalline silicon while simultaneously texturizing the silicon surface to reduce reflective losses; it reduces the number of processing steps required for solar cell fabrication, and it is based on earth abundant materials. These features provide several advantages including reduced process complexity, improved sustainability, and reduced cost when compared to the leading competing process which uses gold and silver to etch the silicon surface to fabricate nanotextured solar cells in this market space. The project engages Bandgap Engineering Inc., a leading developer of silicon nanowire solar cells, to provide device testing and evaluation capabilities, assist with cost model development and guide commercialization aspects in this technology translation effort from research discovery toward commercial reality. This project addresses the following technology gaps as it translates from research discovery toward commercial application. It will investigate the use of an aluminum thin film to simultaneously serve as the p-type diffusion source for junction formation and as a catalyst to mediate nanotexturing to form an anti-reflection layer on the surface. The effect of texturing morphology, i.e. nanowire versus nanocone, on the optical and photovoltaic properties of the devices will be studied. Methods to passivate the nanotextured surface will be developed to reduce efficiency losses resulting from surface recombination. A comprehensive cost model of the process will be developed to guide commercialization plans. The overall goal of the project is the development of a prototype solar cell based on the one-step process that exhibits a power conversion efficiency comparable to or higher than state-of-the-art nanotextured solar cells fabricated using gold/silver-induced etching. The potential economic impact is expected to be a reduction in the cost per Watt of crystalline silicon solar cells over the next decade, which will contribute to the U.S. competitiveness in renewable energy.