Radially stacked solar cells based on 2D atomic crystals and methods for their production

• US 10,141,469 B1
• Filed: 08/31/2017
• Issued: 11/27/2018
• Est. Priority Date: 10/17/2016
• Status: Active Grant

• Current Assignee: UNM Rainforest Innovations (f/k/a STC.UNM) (The University of New Mexico)
• Original Assignee: UNM Rainforest Innovations (f/k/a STC.UNM) (The University of New Mexico)
• Inventors: Cavallo, Francesca, Mangu, Vijay Saradhi
• Primary Examiner(s): Leong, Susan D
• Application Number:
  US15/692,541
• Time in Patent Office: 453 Days
• CPC Class Codes: H01L 31/022425 for solar cells
• CPC Class Codes: H01L 31/02363 of the semiconductor body itself, e.g. textured active layers
• CPC Class Codes: H01L 31/032 including, apart from doping materials or other impurities, only compounds not provided for in groups H01L31/0272 - H01L31/0312
• CPC Class Codes: H01L 31/035281 Shape of the body
• CPC Class Codes: H01L 31/0392 including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate textured substrates H01L31/02366
• CPC Class Codes: H01L 31/0547 comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
• CPC Class Codes: H01L 31/072 the potential barriers being only of the PN heterojunction type
• CPC Class Codes: H01L 31/0725 Multiple junction or tandem solar cells
• CPC Class Codes: H01L 31/1892 methods involving the use of temporary, removable substrates
• CPC Class Codes: Y02E 10/52 PV systems with concentrators

Abstract

A solar cell for collecting solar radiation can include a barrier layer such as a dielectric barrier layer and a heterostructure including a first light absorbing layer and at least a second light absorbing layer. A method for forming the solar cell can include forming a sacrificial layer on a support substrate and forming the barrier layer on the sacrificial layer. The barrier layer is formed to have a strain gradient through its thickness. The heterostructure is attached to the barrier layer and the sacrificial layer is removed, thereby separating the barrier layer and the heterostructure from the support substrate. During the removal of the sacrificial layer, the strain gradient causes the barrier layer and heterostructure, to roll, curl, or spiral, thereby resulting in a radially stacked heterostructure that provides a light concentrating optical cavity having multiple light absorbing layers with different band gaps.

Claims

1. A method for fabricating a solar cell, comprising:

forming a sacrificial layer;

forming a barrier layer having a gradient strain on the sacrificial layer;

attaching a heterostructure comprising a first light absorbing layer and at least a second light absorbing layer to the barrier layer, wherein the second light absorbing layer is attached to the first light absorbing layer and thereby forms a heterojunction at an interface between the first light absorbing layer and the second light absorbing layer; and

removing the sacrificial layer subsequent to the attaching of the first light absorbing layer and the second light absorbing layer to the barrier layer,

wherein the barrier layer, the first light absorbing layer, and the second light absorbing layer form a spiral structure having a spiral shape resulting from the gradient strain of the barrier layer.

2. The method of claim 1, further comprising forming the sacrificial layer on a support substrate.

3. The method of claim 1, wherein:

the first light absorbing layer is a first transition metal dichalcogenide (TMDC) layer;

the second light absorbing layer is a second TMDC layer; and

the first TMDC layer is different than the second TMDC layer.

4. The method of claim 1, wherein the spiral structure comprises at least five windings.

5. The method of claim 1, wherein the method further comprises:

forming a first electrical contact that electrically contacts the first light absorbing layer; and

forming a second electrical contact that electrically contacts the second light absorbing layer.

6. The method of claim 1, further comprising attaching a reflective core to the second light absorbing layer, wherein the reflective core is positioned at a center of the spiral structure subsequent to the removing of the sacrificial layer.

7. The method of claim 6, wherein the reflective core comprises one or more of gold, aluminum, and silver, and has a diameter of from 0.5 micrometer (μ

m) to 2.0 μ

m.

8. The method of claim 6, further comprising:

attaching the reflective core to a first end of the second light absorbing layer;

forming a first electrical contact that electrically contacts the first light absorbing layer; and

forming a second electrical contact that electrically contacts the second light absorbing layer, wherein the second electrical contact is formed at a second end of the second light absorbing layer that is opposite to the first end.

9. The method of claim 1, further comprising depositing a plurality of nanostructures on the barrier layer prior to the attaching of the heterostructure to the barrier layer, wherein the first light absorbing layer is locally strained at each interface with each nanostructure.

10. The method of claim 9, wherein the first light absorbing layer comprises at least one of molybdenum disulfide (MoS₂), molybdenum diselenide (MoSe₂), tungsten disulfide (WS₂), and tungsten diselenide (WSe₂).