Approaches to fabricating high-efficiency ultra-thin CdTe solar cells

Thesis (Ph. D.)--University of Rochester. Dept. of Chemical Engineering, 2013.This thesis is an investigation of the fabrication, characterization and performance of high-efficiency and ultra-thin CdTe solar cells with an aim of reducing the material usage and cell manufacturing cost. Several approaches have been successfully carried out to directly or indirectly improve the device performance. Major achievements are listed below: 1) A close-spaced sublimation (CSS) process with an improved control of the deposition temperature-time profile was developed to fabricate high-quality ultra-thin CdTe films. Three key factors in the CSS process including oxygen pressure, substrate temperature and thermal etch duration were optimized. 2) A two-stage post-deposition treatment including a high temperature annealing (HTA) followed by a vaporous cadmium chloride treatment (VCC) was developed and optimized for the growth of high-quality CdTe films. The effects of HTA and VCC on ultra-thin CdTe solar cells were revealed by a combination of characterization techniques, including photoluminescence. 3) In a collaborative effort two new back contact buffers, MoOx and Te/Cu, were identified and applied in ultra-thin CdTe solar cells. Substitution of a conventional acid etching method with the new back contact buffers was found to enhance the cell efficiency from ~10% to ~13.5%. Moreover, the new buffers improved the reproducibility of cell fabrication. A low-resistance electrical back contact based on the Te/Cu buffer and Ni as electrode was developed. A thermal activation process was found necessary to promote ohmic contact formation. Cu diffusion into the Te layer and CdTe bulk layer occurred during the thermal activation process and must be controlled to prevent excessive diffusion into the CdS/CdTe junction. The effects of Cu concentration and Te thickness on device performance and cell stability were systematically investigated and a cell efficiency as high as ~15% with good stability has been achieved using an optimized Te/Cu buffer. 4) A novel vaporous zinc chloride treatment was developed for the formation of Cd1-xZnxS from CdS films. Compared with conventional fabrication methods, the VZC method features simple setup and operation and is capable of producing Cd1-xZnxS films with a homogenous structure. The Zn to Cd doping ratio in Cd1-xZnxS can be easily controlled by adjusting the process parameters. By replacing CdS with a more transparent Cd1-xZnxS as the window layer, CdTe solar cells with a higher (12-14%) short-circuit current, Jsc, have been demonstrated