Particulate silicon photovoltaic device and method of making

Claim 1

A hermetically sealed photovoltaic device comprising a substrate having an aluminum surface thereon with crushed p-type nonspherical silicon particles having a particle size range of 300-1000 micrometers sintered thereto to form an ohmic contact with said aluminum surface, an electrically insulating glass having a melting point of under 660° C. covering said crushed silicon particles and the aluminum surface of the interstices between adjacent particles, and n+ region formed in an exposed upper portion of said silicon particles to form p-n junctions in situ within said silicon particles, a transparent conductive coating comprising a tin oxide layer electrically contacting said n+ region, an electrode in ohmic contact with selective portions of said transparent conductive coating, and a transparent protective layer over said conductive layer providing a hermetic seal for said photovoltaic device.

Claim 3

A method of making an inexpensive hermetically sealed solar cell device from nonspherical particulate silicon which comprises: (a) casting p-type silicon having a resistivity of 1 to 10 ohm centimeters to provide a coarse grain structure of about 1 millimeter or larger; (b) crushing and screening said cast p-type silicon to provide a nonspherical particle size mix of about 0.3 to 1 millimeter; (c) sintering said crushed silicon particles to an aluminum layer on a substrate at a temperature of about 660° C. in a nonoxidizing atmosphere to provide ohmic contact between said crushed silicon particles and said aluminum layer; (d) coating said silicon particle-containing substrate with a low melting glass have a melting point of less than 660° C. and firing said coating at a temperature just under 660° C. for about 2 minutes to fill the interstices between said crushed silicon particles and to form an electrically insulating layer; (e) selectively etching the top surface of said coated particles with a nitric acid and hydrofluoric acid etchant mixture to remove insulating material on the top surface of said silicon particles to thereby expose bare silicon on the top of said particles; (f) forming an n+ layer of about 0.2 micrometer depth adjacent said exposed top surface of said p-type silicon particles to thereby form p-n junctions in situ in said silicon particles; (g) depositing a transparent tin oxide conductive layer over said p-n junctions to form an electrical contact thereto; (h) applying an electrode to selective portions of said conductive layer; and (i) hermetically sealing said solar cell by applying a glass cover plate to said device.

Claim 4

A method of making an inexpensive hermetically sealed solar cell device from nonspherical particulate silicon which comprises: (a) casting p-type silicon having a resistivity of 1 to 10 ohm centimeters to provide a coarse grain structure of about 1 millimeter or larger; (b) crushing and screening said cast p-type silicon to provide a nonspherical particle size mix of about 0.3 to 1 millimeter; (c) sintering said crushed silicon particles to an aluminum layer on a substrate at a temperature of about 660° C. in a nonoxidizing atmosphere to provide ohmic contact between said crushed silicon particles and said aluminum layer; (d) coating said silicon particle-containing substrate with a low melting glass have a melting point of less than 660° C. and firing said coating at a temperature just under 660° C. for about 2 minutes to fill the interstices between said crushed silicon particles and to form an electrically insulating layer; (e) selectively etching the top surface of said coated particles with a nitric acid and hydrofluoric acid etchant mixture to remove insulating material on the top surface of said silicon particles to thereby expose bare silicon on the top of said particles; (f) forming an n+ layer of about 0.2 micrometer depth adjacent said exposed top surface of said p-type silicon particles to thereby form p-n junctions in situ in said silicon particles; (g) depositing a transparent tin oxide conductive layer over said p-n junctions to form an electrical contact thereto; (h) applying an electrode to selective portions of said conductive layer; and (i) hermetically sealing said solar cell by applying a glass cover plate to said device.