US4845043A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for fabricating photovoltaic device having improved short wavelength photoresponse
Assignee: BP Solar International LLC
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Filing: 1987-04-23
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Granted: 1989-07-04
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Expires: 2007-04-23
Abstract
Abstract Amorphous p-i-n silicon photovoltaic cells with improved short wavelength photoresponse are fabricated with reduced p-dopant contamination at the p/i interface. Residual p-dopants are removed by flushing the deposition chamber with a gaseous mixture capable of reacting with excess doping contaminants prior to the deposition of the i-layer and subsequent to the deposition of the p-layer.
Inventors
- 👤 Anthony W. Catalano
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 13:41
CPC Classifications
C; C23; C23C; C23C16/00; C23C16/22; C23C16/30; H; H10; H10F; H10F10/00; H10F10/10; H10F10/17; H10F71/00; H10F71/10; H10F71/103; Y; Y02; Y02E; Y02E10/00; Y02E10/50; Y02E10/548; Y02P; Y02P70/00; Y02P70/50; Y10; Y10S; Y10S438/00; Y10S438/931
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
159 words
A method for fabricating a photovoltaic device comprising the steps of: forming a front contact layer of transparent conductive material on a transparent superstrate; introducing said superstrate into a deposition chamber; depositing a first doped amorphous silicon-containing layer of a first conductivity type on said front contact layer from a first gaseous mixture containing silane and a first doping gas; flushing said chamber with a decontamination means for reacting with and substantially removing resdual first doping contaminants resulting from deposition of said first doped layer in a gaseous state; depositing an undoped intrinsic layer of amorphous silicon-containing material on said first doped layer in said deposition chamber from a second gaseous mixture containing a silicon-containing compound; depositing a second doped amorphous silicon-containing layer of a second conductivity type on said undoped intrinsic layer from a third gaseous mixture containing silane and a second doping gas; and forming a back contact layer of conductive material on said second doped layer.
Claim 2
Independent Claim
159 words
A method for fabricating a photovoltaic device comprising the steps of: forming a front contact layer of transparent conductive material on a transparent superstrate; introducing said superstrate into a deposition chamber; depositing a first doped amorphous silicon-containing layer of a first conductivity type on said front contact layer from a first gaseous mixture containing silane and a first doping gas; flushing said chamber with a decontamination means for reacting with and substantially removing resdual first doping contaminants resulting from deposition of said first doped layer in a gaseous state; depositing an undoped intrinsic layer of amorphous silicon-containing material on said first doped layer in said deposition chamber from a second gaseous mixture containing a silicon-containing compound; depositing a second doped amorphous silicon-containing layer of a second conductivity type on said undoped intrinsic layer from a third gaseous mixture containing silane and a second doping gas; and forming a back contact layer of conductive material on said second doped layer.
Claim 3
Dependent Claim
23 words
The method of claim 1, wherein said first doped layer is of p-type conductivity and said second doped layer is of n-type conductivity.
Claim 4
Dependent Claim
22 words
The method of claim 2, wherein said first doped layer contains a silicon carbon alloy and said first gaseous mixture includes methane.
Claim 5
Dependent Claim
28 words
The method of claim 2, wherein said decontamination means is a gaseous mixture containing nitrogen trifluoride and said first doping gas is a mixture containing silane and diborane.
Claim 6
Dependent Claim
24 words
The method of claim 4, wherein said decontamination means is a gaseous mixture of at least 10% nitrogen trifluoride in either argon or hydrogen.
Claim 7
Dependent Claim
19 words
The method of claim 5, wherein said chamber is flushed with said decontamination means for at least 600 seconds.
Claim 8
Dependent Claim
16 words
The method of claim 4, wherein said first doping gas is silane containing about 0.1-0.3% diborane.
Claim 9
Dependent Claim
17 words
The method of claim 2, wherein said second doping gas is a mixture containing silane and phosphine.
Claim 10
Dependent Claim
16 words
The method of claim 8, wherein said second doping gas is silane containing about 0.1-2% phosphine.
Claim 11
Dependent Claim
19 words
The method of claim 2, wherein said first doping gas is a mixture containing silane and aluminum or gallium.
Claim 12
Dependent Claim
19 words
The method of claim 2, wherein said second doping gas is a mixture containing silane and arsenic or antimony.
Claim 13
Dependent Claim
23 words
The method of claim 1, wherein said first doped layer is of n-type conductivity and said second doped layer is of p-type conductivity.
Claim 14
Dependent Claim
22 words
The method of claim 12, wherein said second doped layer contains a silicon carbon alloy and said third gaseous mixture includes methane.
Claim 15
Dependent Claim
26 words
The method of claim 1, wherein the depositions of said first doped layer, undoped intrinsic layer, and second doped layer are achieved through DC glow discharge.
Claim 16
Dependent Claim
13 words
The method of claim 1, wherein said front contact layer is tin oxide.
Claim 17
Dependent Claim
12 words
The method of claim 1, wherein said back contact layer is aluminum.
Claim 18
Dependent Claim
12 words
The method of claim 1, wherein said second gaseous mixture contains silane.
Claim 19
Dependent Claim
13 words
The method of claim 1, wherein said second gaseous mixture contains silicon tetraiodide.
Claim 20
Dependent Claim
26 words
The method of claim 1, wherein the depositions of said first doped layer, undoped intrinsic layer, and second doped layer are achieved through RF glow discharge.
Claim 21
Dependent Claim
24 words
The method of claim 1, wherein the depositions of said first doped layer, undoped intrinsic layer, and second doped layer are achieved through photo-CVD.
Claim 22
Dependent Claim
51 words
In a method of manufacturing amorphous silicon p-i-n photovoltaic devices by DC glow discharge, the improvement comprising flushing the deposition chamber with a gaseous mixture containing nitrogen trifluoride prior to depositing the intrinsic layer of semiconductor material in said deposition chamber and subsequent to depositing the boron-doped p-layer of semiconductor material.
Claim 23
Dependent Claim
51 words
In a method of manufacturing amorphous silicon p-i-n photovoltaic devices by DC glow discharge, the improvement comprising flushing the deposition chamber with a gaseous mixture containing nitrogen trifluoride prior to depositing the intrinsic layer of semiconductor material in said deposition chamber and subsequent to depositing the boron-doped p-layer of semiconductor material.
Claim 24
Independent Claim
120 words
A method of manufacturing layers of semiconductor material comprising the steps of: introducing a first reaction mixture comprising a gas containing a silicon-containing compound and a first doping gas into a deposition chamber; depositing a first doped layer comprising silicon in said deposition chamber from said first reaction mixture and forming gaseous residual contamination comprising said unreacted first doping gas and its reaction products; contacting said gaseous residual comtamination in said chamber with a decontamination gas capable of reacting with said residual contamination and substantially removing said residual contamination from said chamber; and introducing a second reaction mixture comprising a gas containing a silicon-containing compound into said chamber and depositing a second layer comprising silicon on said first doped layer.
Claim 25
Independent Claim
120 words
A method of manufacturing layers of semiconductor material comprising the steps of: introducing a first reaction mixture comprising a gas containing a silicon-containing compound and a first doping gas into a deposition chamber; depositing a first doped layer comprising silicon in said deposition chamber from said first reaction mixture and forming gaseous residual contamination comprising said unreacted first doping gas and its reaction products; contacting said gaseous residual comtamination in said chamber with a decontamination gas capable of reacting with said residual contamination and substantially removing said residual contamination from said chamber; and introducing a second reaction mixture comprising a gas containing a silicon-containing compound into said chamber and depositing a second layer comprising silicon on said first doped layer.
Claim 26
Dependent Claim
14 words
The method of claim 22, wherein said second layer is an undoped intrinsic layer.
Claim 27
Dependent Claim
34 words
The method of claim 22, wherein said second reaction mixture contains a second doping gas, and said second layer is a doped layer of a conductivity type opposite that of said first doped layer.
Claim 28
Dependent Claim
14 words
The method of claim 22, wherein said first and second layers contain amorphous silicon.
Claim 29
Dependent Claim
14 words
The method of claim 22, wherein said first and second layers contain crystalline silicon.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-07-03 | 1993-01-02 | 1993-07-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-07-03 | 1997-01-02 | 1997-07-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-07-03 | 2001-01-02 | 2001-07-04 | $7700.00 | Window Closed / Lapsed |