Apparatus for forming transparent conductive film by sputtering and method therefor

• US 6,054,024 A
• Filed: 09/10/1997
• Issued: 04/25/2000
• Est. Priority Date: 09/12/1996
• Status: Expired due to Term

• Current Assignee: Canon Ayutthaya Limited (Canon Inc.)
• Original Assignee: Canon Ayutthaya Limited (Canon Inc.)
• Inventors: Hayashi, Ryo, Iwasaki, Yukiko, Saito, Keishi, Toyama, Noboru
• Primary Examiner(s): MCDONALD, RODNEY GLENN
• Application Number:
  US08/927,395
• Time in Patent Office: 958 Days
• Field of Search: 204/192.12, 204/192.14, 204/192.25, 204/192.26, 204/192.29, 204/298.06, 204/298.08, 204/298.23, 204/298.34
• US Class Current: 204/192.29
• CPC Class Codes: C23C 14/34 Sputtering
• CPC Class Codes: C23C 14/562 for coating elongated substrates
• CPC Class Codes: H01L 31/1884 Manufacture of transparent electrodes, e.g. TCO, ITO
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

There are provided a method which, in forming a transparent conductive film by sputtering on a semiconductor junction layer provided on a conductive substrate which bears at least the transparent conductive film thereon, comprises steps of electrically insulating the conductive substrate, and maintaining the self bias voltage Vself of the conductive substrate within a range of -50 V≦Vself<0 V, and an apparatus therefor. There can also be reduced the damage to the semiconductor layer, induced by the cations such as Ar⁺. Thus there can be produced the photovoltaic elements of a high open-circuit voltage and a high photoelectric conversion efficiency in stable manner.

Claims

1. An apparatus for forming, by sputtering, a transparent conductive film on to a semiconductor junction layer, said semiconductor junction layer being provided on a conductive substrate which bears at least said transparent conductive film thereon, comprising:

means for electrically insulating said conductive substrate; and

means for maintaining a self bias voltage Vself of said conductive substrate within a range of -50 V≦

Vself<

0 V.

2. An apparatus according to claim 1, further comprising a vacuum chamber, wherein the resistance between said vacuum chamber and said conductive substrate is 300 kΩ

or higher.

3. An apparatus according to claim 1, wherein said conductive substrate is a substrate of continuous form.

4. An apparatus according to claim 3, further comprising a vacuum chamber, wherein said continuous substrate is supported by plural rollers in said vacuum chamber.

5. An apparatus according to claim 4, wherein at least a part of each of said plural rollers is composed of an insulating material.

6. An apparatus according to claim 4, wherein said continuous substrate and said plural rollers are mutually electrically insulated by an insulating material.

7. An apparatus according to claim 4, wherein bearings of said plural rollers are composed of an insulating material.

8. An apparatus according to claim 1, wherein said substrate is provided with a reflective layer between said conductive substrate and said semiconductor junction layer.

9. A method for forming, by sputtering, a transparent conductive film on to a semiconductor junction layer, said semiconductor junction layer being provided on a conductive substrate which bears at least said transparent conductive film thereon, comprising steps of:

electrically insulating said conductive substrate; and

maintaining a self bias voltage Vself of said conductive substrate within a range of -50 V≦

Vself<

0 V.

10. A method according to claim 9, wherein said sputtering is conducted in a vacuum chamber, and the resistance between said vacuum chamber and said conductive substrate is made 300 kΩ

or higher.

11. A method according to claim 9, wherein said conductive substrate is a substrate of continuous form.

12. A method according to claim 11, wherein said sputtering is conducted in a vacuum chamber, and said continuous substrate is supported by plural rollers in said vacuum chamber.

13. A method according to claim 12, wherein at least a part of each of said plural rollers is composed of an insulating material.

14. A method according to claim 12, wherein said continuous substrate and said plural rollers are mutually electrically insulated by an insulating material.

15. A method according to claim 12, wherein bearings of said plural rollers are composed of an insulating material.

16. A method according to claim 9, wherein said substrate is provided with a reflective layer between said conductive substrate and said semiconductor junction layer.

17. A method according to claim 9, wherein said self bias voltage is regulated by adjustment of conditions for sputtering.

18. A method for producing a photovoltaic element including a step of forming, by sputtering, a transparent conductive film on to a semiconductor junction layer, said semiconductor junction layer being provided on a conductive substrate which bears at least said transparent conductive film thereon, wherein said step comprises steps of:

electrically insulating said conductive substrate; and

maintaining a self bias voltage Vself of said conductive substrate within a range of -50 V≦

Vself<

0 V.