Tandem junction solar cell devices incorporating improved microcrystalline p-doped semiconductor alloy material

Claim 2

A tandem photovoltaic structure comprising: a. a plurality of n stacked solar cells, where n is an integer greater than 1; b. each cell including a plurality of layers of amorphous semiconductor alloy material in optical and electrical series relationship; said plurality of layers of each cell including therein oppositely doped layers establishing therebetween an electric field region for the collection of electron-hole pairs generated therein, wherein light impinging on said structure passes sequentially through said doped layers and said electric field regions with a portion of the light being absorbed in each of said electric field regions; and said plurality of layers including a p-doped amorphous silicon alloy layer, the improvement comprising in combination: said p-doped amorphous silicon layer being microcrystalline in that said p-doped layer is characterized by a volume fraction of crystalline inclusions greater than a threshold value at which substantial changes in electrical parameters including conductivity and activation energy occur; said volume fraction being greater than about 16-19% in a 3-D model and about 45% in a 2-D model; and said p-doped microcrystalline layer exhibiting low optical absorption, low activation energy, high electrical conductivity and having an optical gap wider than the optical gap of the corresponding amorphous silicon alloy material.

Claim 3

A structure as in claim 1, wherein all of the doped layers are microcrystalline.

Claim 4

A structure as in claim 2, wherein the deposited layers are operatively disposed to form a plurality of n-i-p solar cells.

Claim 5

A structure as in claim 3, wherein the deposited layers are stacked to form three n-i-p cells.

Claim 6

A structure as in claim 4, wherein the deposited layers are stacked to form four n-i-p cells.

Claim 7

A structure as in claim 3, wherein the semiconductor in the the layers is silicon and the dopant in the p-doped layers is boron.

Claim 8

A structure as in claim 6, wherein the p-doped layers further include hydrogen.

Claim 9

A strucuture as in claim 7, wherein the p-doped layers further include fluorine.

Claim 10

A structure as in claim 7, wherein the p-doped layers are characterized by an activation energy of less than approximately 0.05 eV.

Claim 11

A structure as in claim 7, wherein the p-doped layers are characterized by a conductivity of greater than 0.5 ohms -1 -cm -1 .

Claim 12

A structure as in claim 7, wherein the p-doped layers are characterized by an optical gap of approximately 2.0 eV.

Claim 13

A structure as in claim 7, wherein the p-doped layers are characterized by an absorption constant at 5500 angstroms of less than about 3×10 4 cm -1 .

Claim 14

A structure as in claim 1, wherein the deposited layers are stacked to form a pair of n-i-p solar cells characterized by an open circuit voltage of at least 1.8 volts, a short circuit current of at least 6.5 milliamperes per square centimeter, and a fill factor of at least 0.7.

Claim 15

A structure as in claim 1, wherein the deposited layers are stacked to form three n-i-p solar cells characterized by an open circuit voltage of at least 2.3 volts, a short circuit current of at least 6.0 milliamperes per square centimeter, and a fill factor of at least 0.7.

Claim 16

A structure as in claim 1, wherein the deposited layers are stacked to form four n-i-p solar cells characterized by an open circuit voltage of at least 3.2 volts, a short circuit current of at least 3.0 milliamperes per square centimeter, a fill factor of 0.7, and less than 5% degradation after being subjected to 1500 hours of AMl exposure.

Claim 17

A structure as in claim 1, wherein the microcrystalline material includes crystalline inclusions amounting to at least about 16-19% by volume in the amorphous network.

Claim 18

A structure as in claim 1, wherein the microcrystalline material includes crystalline inclusions amounting to at least about 45% by volume in the amorphous network.

Claim 19

A structure as in claim 1, wherein the microcrystalline material includes crystalline inclusions amounting to at least about 80% by volume in the amorphous network.

Claim 20

A tandem photovoltaic structure comprising: a. a plurality of n stacked solar cells, where n is an integer greater than 1; b. each cell including a plurality of layers of amorphous semiconductor alloy material in optical and electrical series relationship; said plurality of layers of each cell including therein oppositely doped layers establishing therebetween an electric field region for the collection of electron-hole pairs generated therein, wherein light impinging on said structure passes sequentially through said doped layers and said electric field regions with a portion of the light being absorbed in each of said electric field regions; and said plurality of layers including a p-doped amorphous silicon alloy layer, the improvement comprising in combination: said p-doped layer being microcrystalline and characterized by low optical absorption, low activation energy, high electrical conductivity, and having an optical gap wider than the optical gap of the corresponding amorphous silicon alloy material; said p-doped layer further characterized in that, as incorporated in said photovoltaic structure, said structure exhibits at least one of the following properties under AM-1 illumination: (1) a V oc of about 0.93 or greater for a single p-i-n amorphous silicon alloy solar cell of an n-cell tandem; or (2) a V oc of about 2.5 or greater when the structure is a tandem formed of three stacked p-i-n amorphous silicon alloy cells; or (3) an efficiency of about 11% or greater when the structure is a tandem formed of three stacked p-i-n amorphous silicon alloy cells; or (4) a V oc of about 0.73 or greater for a single p-i-n amorphous silicon-germanium alloy solar cell of an n-cell tandem; or (5) a V oc of about 3.3 or greater when the structure is a tandem formed of four stacked p-i-n amorphous silicon and silicon-germanium alloy cells; or (6) an efficiency of about 7.6% or greater when the structure is tandem formed of four stacked p-i-n amorphous silicon and silicon-germanium alloy cells.

Claim 21

A tandem photovoltaic structure comprising: a. a plurality of n stacked solar cells, where n is an integer greater than 1; b. each cell including a plurality of layers of amorphous semiconductor alloy material in optical and electrical series relationship; said plurality of layers of each cell including therein oppositely doped layers establishing therebetween an electric field region for the collection of electron-hole pairs generated therein, wherein light impinging on said structure passes sequentially through said doped layers and said electric field regions with a portion of the light being absorbed in each of said electric field regions; and said plurality of layers including a p-doped amorphous silicon alloy layer, the improvement comprising in combination: said p-doped layer being microcrystalline and characterized by low optical absorption, low activation energy, high electrical conductivity, and having an optical gap wider than the optical gap of the corresponding amorphous silicon alloy material; said p-doped layer further characterized in that, as incorporated in said photovoltaic structure, said structure exhibits at least one of the following properties under AM-1 illumination: (1) a V oc of about 0.93 or greater for a single p-i-n amorphous silicon alloy solar cell of an n-cell tandem; or (2) a V oc of about 2.5 or greater when the structure is a tandem formed of three stacked p-i-n amorphous silicon alloy cells; or (3) an efficiency of about 11% or greater when the structure is a tandem formed of three stacked p-i-n amorphous silicon alloy cells; or (4) a V oc of about 0.73 or greater for a single p-i-n amorphous silicon-germanium alloy solar cell of an n-cell tandem; or (5) a V oc of about 3.3 or greater when the structure is a tandem formed of four stacked p-i-n amorphous silicon and silicon-germanium alloy cells; or (6) an efficiency of about 7.6% or greater when the structure is tandem formed of four stacked p-i-n amorphous silicon and silicon-germanium alloy cells.