Humidity control and method for thin film photovoltaic materials

• US 8,673,675 B2
• Filed: 05/12/2011
• Issued: 03/18/2014
• Est. Priority Date: 09/30/2008
• Status: Expired due to Fees

• Current Assignee: Stion Corporation
• Original Assignee: Stion Corporation
• Inventors: Wieting, Robert D.
• Primary Examiner(s): Lebentritt, Michael
• Application Number:
  US13/106,257
• Publication Number:
  US 20110212565A1
• Time in Patent Office: 1,041 Days
• Field of Search: 438 61- 64, 438 89- 96, 257/E21.001, 257/29.255, 257/31.001, 257/6, 257/27, 257/117, 257/126
• US Class Current: 438/64
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0749 including a AIBIIICVI compound, e.g. CdS/CulnSe2 [CIS] heterojunction solar cells
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H01L 31/1876 Particular processes or apparatus for batch treatment of the devices
• CPC Class Codes: Y02E 10/541 CuInSe2 material PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method for processing a thin film photovoltaic module. The method includes providing a plurality of substrates, each of the substrates having a first electrode layer and an overlying absorber layer composed of copper indium gallium selenide (CIGS) or copper indium selenide (CIS) material. The absorber material comprises a plurality of sodium bearing species. The method maintains the plurality of substrates in a controlled environment after formation of at least the absorber layer through one or more processes up to a lamination process. The controlled environment has a relative humidity of less than 10% and a temperature ranging from about 10 degrees Celsius to about 40 degrees Celsius. The method subjects the plurality of substrates to a liquid comprising water at a temperature from about 10 degrees Celsius to about 80 degrees Celsius to process the plurality of substrates after formation of the absorber layer. The plurality of substrates having the absorber layer is subjected to an environment having a relative humidity of greater than about 10% to a time period of less then four hours.

Claims

1. A method for processing a thin film photovoltaic module, the method comprising:

subjecting a plurality of substrates to a desiccated environment having a relative humidity of less than about 10%, wherein each substrate of the plurality of substrates includes an absorber layer overlying a first electrode, and wherein the absorber comprises a plurality of sodium bearing species having a sodium concentration of at least about 5×

10¹⁹ atoms per cm³;

subjecting the plurality of substrates to a liquid comprising water at a temperature from about 10 degrees Celsius to about 80 degrees Celsius to process the plurality of substrates;

subjecting the plurality of substrates to an environment having a relative humidity of greater than about 10% to a time period of less than four hours; and

after the step of subjecting the plurality of substrates to a liquid, forming a window layer over the absorber layer.

2. The method of claim 1 further comprising performing a lamination process on at least one of the plurality of substrates in a modular form as a solar module, the solar module being characterized by an efficiency parameter at a first efficiency level before the lamination process and a second efficiency level after the lamination process, the first efficiency level being within a predetermined amount of the second efficiency level.

3. The method of claim 1 wherein the relative humidity of greater than 10% is characterized by a water vapor species having a high chemical activity.

4. The method of claim 2 further performing a light soaking process on the solar module to increase an efficiency level from a third efficiency to a fourth efficiency.

5. The method of claim 4 wherein the light soaking process comprises subjecting the solar module to electromagnetic radiation derived from a solar or a solar equivalent light source.

6. The method of claim 4 wherein the light soaking process is maintained for about thirty hours or less.

7. The method of claim 2 wherein the second efficiency level is greater than the first efficiency level by at least 1 percent point.

8. The method of claim 2 wherein the second efficiency level is greater than the first efficiency level by at least 2 percent.

9. The method of claim 1 wherein subjecting the plurality of substrates to a liquid includes forming a window layer overlying the absorber layer.

10. The method of claim 9 wherein the window layer comprises a cadmium sulfide material.

11. The method of claim 1 wherein the liquid comprises a cadmium species, an organosulfur species, and an ammonium species provided in a bath maintained at a bath temperature ranging from about 50 degree Celsius to about 60 degree Celsius.

12. The method of claim 1 further comprises a patterning process after forming the window layer.

13. The method of claim 12 wherein the patterning process is a mechanical patterning process removing selected portions of the absorber layer material and the window layer material.

14. The method of claim 1 further comprising forming a second electrode layer overlying the window layer, the second electrode layer comprises a transparent conductive oxide selected from:

ITO, SnO;

F or ZnO;

Al.

15. The method of claim 14 further comprises patterning the transparent conductive oxide layer.

16. A method for processing a thin film photovoltaic module, the method comprising:

subjecting a substrate to a desiccated environment having a relative humidity of less than 10%, wherein the substrate includes an absorber layer overlying a first electrode, and wherein the absorber comprises a plurality of sodium bearing species having a sodium concentration of at least about 5×

10¹⁸ atoms per cm³;

subjecting the substrate to a liquid comprising water at a temperature from about 10 degrees Celsius to about 80 degrees Celsius to process the plurality of substrates after formation of the absorber layer;

subjecting the substrate having the absorber layer to an environment having a relative humidity of greater than about 10% to a time period of less than four hours; and

performing a lamination process on at least the substrate to form a solar module, the solar module being characterized by an efficiency parameter at a first efficiency level before the lamination process and a second efficiency level after the lamination process.

17. The method of claim 16 further performing a light soaking process on the solar module to increase its efficiency level.

18. The method of claim 17 wherein the light soaking process comprises subjecting the solar module to electromagnetic radiation derived from a solar or a solar equivalent light source.

19. The method of claim 16 wherein the liquid comprises a cadmium species, an organosulfur species, and an ammonium species provided in a bath maintained at a bath temperature ranging from about 50 degree Celsius to about 60 degree Celsius.

20. The method of claim 16 wherein the first efficiency level is less than the second efficiency level by at least 1 percent point.