Teodor K. Todorov

High-Efficiency Solar Cell with Earth-Abundant Liquid-Processed Absorber

2010 WILEY-VCH Verlag Gmb Chalcogenide-based solar cells provide a critical pathway to cost parity between photovoltaic (PV) and conventional energy sources. Currently, only Cu(In,Ga)(S,Se)2 (CIGS) and CdTe technologies have reached commercial module production with stable power conversion efficiencies of over 9 percent. Despite the promise of these technologies, restrictions on heavy metal usage for Cd and limitations in supply for In and Te are projected to restrict the production capacity of the existing chalcogen-based technologies to <100GWp per year, a small fraction of our growing energy needs, which are expected to double to 27 TW by 2050. Earth-abundant copper-zinc-tin-chalcogenide kesterites, Cu2ZnSnS4 and Cu2ZnSnSe4, have been examined as potential alternatives for the two leading technologies, reaching promising but not yet marketable efficiencies of 6.7% and 3.2%, respectively, by multilayer vacuum deposition. Here we show a non-vacuum, slurry-based coating method that combines advantages of both solution processing and particlebased deposition, enabling fabrication of Cu2ZnSn(Se,S)4 devices with over 9.6% efficiency—a factor of five performance improvement relative to previous attempts to use highthroughput ink-based approaches and >40% higher than previous record devices prepared using vacuum-based methods. To address the issue of cost, non-vacuum ‘‘ink’’-based approaches—both from solutions and suspensions—are being developed for chalcogenide-based absorber layer deposition to replace potentially more expensive vacuum-based techniques. True solutions allow intermixing of the constituents at a molecular level and the formation of smooth homogeneous films, as demonstrated with spin-coated CIGS absorber layers from hydrazine (N2H4) solutions. [11–13] The chemically reducing character of hydrazine stabilizes solutions of anions with direct metal-chalcogen bonding for select elements (e.g. Cu, In, Ga, Sn), without the necessity to introduce typical impurities (e.g., C, O, Cl). Suspension approaches employ solid particles designed to be deposited on a substrate and reacted or fused with each other, to form a desired crystalline phase and grain structure. Normally insoluble components can be deposited by this approach using typical liquid-based deposition (e.g., printing, spin coating, slit casting, spraying). Although high-quality large-grained absorber layers can be formed for selected systems using either solutionor particlebased deposition, numerous challenges confront each approach for more general deposition needs. Solution processing is limited by the solubility of many materials of interest (e.g., ZnSe1–xSx in hydrazine solvents—relevant for the deposition of Cu2ZnSnS4 or Cu2ZnSnSe4). In addition, volume contraction upon drying of solution-deposited layers creates stress in the film that may cause crack formation in thicker films. In suspension approaches, a common difficulty is achieving single-phase crystallization among the solid particles. Particle-based approaches (as well as some solution methods) typically require the addition of organic agents to improve wetting and particle dispersion, and to avoid film cracks and delamination. Most of these non-volatile organic additives introduce carbon contamination in the final layer. Because of these challenges, vacuum-based techniques have historically shown superior performance to liquid coating. In the case of the earth-abundant Cu2ZnSn(S,Se)4 materials, ink-based approaches have to date yielded at most <1.6% efficiency devices. Here we demonstrate an hybrid solution-particle approach, using the earth-abundant Cu2ZnSn(S,Se)4 system as an example, which enables fabrication of PV devices with over 9.6% power conversion efficiency. The slurry (or ink) employed for deposition comprises a Cu–Sn chalcogenide (S or S–Se) solution in hydrazine (see Experimental section), with the in situ formation of readily dispersible particle-based Zn-chalcogenide precursors, ZnSe(N2H4) (Figure 1a,d) or ZnS(N2H4) (Figure 1b). Thermogravimetric analysis (TGA) of the isolated selenide particle precursor shows decomposition at approximately 200 8C, with mass loss of about 20%, close to the theoretical value expected upon transition to pure ZnSe (Figure 1c,d). Deposition using this hybrid slurry successfully combines the advantages of solution and suspension deposition routes by use of solutions containing solid particles, wherein both components (i.e., solution and particle) contain metal and chalcogen elements that integrate into the final film. Using the hybrid slurry method (i) solubility limitations are resolved, as virtually any materials system can be constituted by a combination of solid and dissolved components; (ii) the dissolved components can be engineered as an efficient binding media for the particles, eliminating the need of separate organic binders; (iii) solid particles act as stress-relief and crack-deflection centers allowing the deposition of thicker layers than pure solution processes; and (iv) the intimate contact between the two phases allows rapid reaction and homogeneous phase formation. Complete conversion of all constituents of the spin-coated hybrid precursor films into a single-phase, highly crystalline Cu2ZnSn(S,Se)4 is achieved by annealing at 540 8C on a hot plate. Three main types of samples were targeted – high selenium content (A), intermediate sulfoselenide (B) and pure sulfide (C) –

Thermally evaporated Cu2ZnSnS4 solar cells

High efficiency Cu2ZnSnS4 solar cells have been fabricated on glass substrates by thermal evaporation of Cu, Zn, Sn, and S. Solar cells with up to 6.8% efficiency were obtained with absorber layer thicknesses less than 1 μm and annealing times in the minutes. Detailed electrical analysis of the devices indicate that the performance of the devices is limited by high series resistance, a “double diode” behavior of the current voltage characteristics, and an open circuit voltage that is limited by a carrier recombination process with an activation energy below the band gap of the material.

Band tailing and efficiency limitation in kesterite solar cells

We demonstrate that a fundamental performance bottleneck for hydrazine processed kesterite Cu2ZnSn(S,Se)4 (CZTSSe) solar cells with efficiencies reaching above 11% can be the formation of band-edge tail states, which quantum efficiency and photoluminescence data indicate is roughly twice as severe as in higher-performing Cu(In,Ga)(S,Se)2 devices. Low temperature time-resolved photoluminescence data suggest that the enhanced tailing arises primarily from electrostatic potential fluctuations induced by strong compensation and facilitated by a lower CZTSSe dielectric constant. We discuss the implications of the band tails for the voltage deficit in these devices.

High Efficiency Cu2ZnSn(S,Se)4 Solar Cells by Applying a Double In2S3/CdS Emitter

High-efficiency Cu2ZnSn(S,Se)4 solar cells are reported by applying In2S3/CdS double emitters. This new structure offers a high doping concentration within the Cu2ZnSn(S,Se)4 solar cells, resulting in a substantial enhancement in open-circuit voltage. The 12.4% device is obtained with a record open-circuit voltage deficit of 593 mV.

Loss mechanisms in hydrazine-processed Cu2ZnSn(Se,S)4 solar cells

We present a device characterization study for hydrazine-processed kesterite Cu2ZnSn(Se,S)4 (CZTSSe) solar cells with a focus on pinpointing the main loss mechanisms limiting device efficiency. Temperature-dependent study and time-resolved photoluminescence spectroscopy on these cells, in comparison to analogous studies on a reference Cu(In,Ga)(Se,S)2 (CIGS) cell, reveal strong recombination loss at the CZTSSe/CdS interface, very low minority-carrier lifetimes, and high series resistance that diverges at low temperature. These findings help identify the key areas for improvement of these CZTSSe cells in the quest for a high-performance indium- and tellurium-free solar cell.

Low band gap liquid-processed CZTSe solar cell with 10.1% efficiency

A low band gap liquid-processed Cu2ZnSn(Se1−xSx)4 (CZTSSe) kesterite solar cell with x ≈ 0.03 is prepared from earth abundant metals, yielding 10.1% power conversion efficiency. This champion cell shows a band gap of 1.04 eV, higher minority-carrier lifetime, lower series resistance and lower Voc deficit compared to our previously reported higher band gap (Eg = 1.15 eV; x ≈ 0.4) cell with similar record efficiency. The ability to vary the CZTSSe band gap using sulfur content (i.e., varying x) facilitates the examination of factors limiting performance in the current generation of CZTSSe devices, as part of the thrust to achieve operational parity with CdTe and Cu(In,Ga)(S,Se)2 (CIGSSe) analogs.

Structural and elemental characterization of high efficiency Cu2ZnSnS4 solar cells

We have carried out detailed microstructural studies of phase separation and grain boundary composition in Cu2ZnSnS4 based solar cells. The absorber layer was fabricated by thermal evaporation followed by post high temperature annealing on hot plate. We show that inter-reactions between the bottom molybdenum and the Cu2ZnSnS4, besides triggering the formation of interfacial MoSx, results in the out-diffusion of Cu from the Cu2ZnSnS4 layer. Phase separation of Cu2ZnSnS4 into ZnS and a Cu–Sn–S compound is observed at the molybdenum-Cu2ZnSnS4 interface, perhaps as a result of the compositional out-diffusion. Additionally, grain boundaries within the thermally evaporated absorber layer are found to be either Cu-rich or at the expected bulk composition. Such interfacial compound formation and grain boundary chemistry likely contributes to the lower than expected open circuit voltages observed for the Cu2ZnSnS4 devices.

Optical designs that improve the efficiency of Cu2ZnSn(S,Se)4 solar cells

We present an optical-design approach that improves the short-circuit current and efficiency of Cu2ZnSn(S,Se)4 (CZTSSe) solar cells by tuning the thickness of the upper-device layers in order to maximize transmission into the CZTSSe absorber. The design approach combines optical modeling of idealized planar devices with a semi-empirical approach for treating the impact of surface roughness. Experimentally, we demonstrate that the new device architecture — which emphasizes thinner CdS and transparent-conducting layers — increases short-circuit current by about 10% in champion-caliber devices. These improvements are directly realized in the power-conversion efficiencies of CZTSSe devices, resulting in a certified improvement in the overall record power-conversion efficiency for CZTSSe from 11.1% to 12.0%. We also report comparable improvements for devices with band gaps in the range of 1.1–1.3 eV.

Electronic properties of the Cu2ZnSn(Se,S)4 absorber layer in solar cells as revealed by admittance spectroscopy and related methods

Admittance spectra and drive-level-capacitance profiles of several high performance Cu2ZnSn(Se,S)4 (CZTSSe) solar cells with bandgap ∼1.0–1.5 eV are reported. In contrast to the case for Cu(In,Ga)(S,Se)2, the CZTSSe capacitance spectra exhibit a dielectric freeze out to the geometric capacitance plateau at moderately low frequencies and intermediate temperatures (120–200 K). These spectra reveal important information regarding the bulk properties of the CZTSSe films, such as the dielectric constant and a dominant acceptor with energy level of 0.13–0.2 eV depending on the bandgap. This deep acceptor leads to a carrier freeze out effect that quenches the CZTSSe fill factor and efficiency at low temperatures.

Prospects and performance limitations for Cu–Zn–Sn–S–Se photovoltaic technology

While cadmium telluride and copper–indium–gallium–sulfide–selenide (CIGSSe) solar cells have either already surpassed (for CdTe) or reached (for CIGSSe) the 1 GW yr−1 production level, highlighting the promise of these rapidly growing thin-film technologies, reliance on the heavy metal cadmium and scarce elements indium and tellurium has prompted concern about scalability towards the terawatt level. Despite recent advances in structurally related copper–zinc–tin–sulfide–selenide (CZTSSe) absorbers, in which indium from CIGSSe is replaced with more plentiful and lower cost zinc and tin, there is still a sizeable performance gap between the kesterite CZTSSe and the more mature CdTe and CIGSSe technologies. This review will discuss recent progress in the CZTSSe field, especially focusing on a direct comparison with analogous higher performing CIGSSe to probe the performance bottlenecks in Earth-abundant kesterite devices. Key limitations in the current generation of CZTSSe devices include a shortfall in open circuit voltage relative to the absorber band gap and secondarily a high series resistance, which contributes to a lower device fill factor. Understanding and addressing these performance issues should yield closer performance parity between CZTSSe and CdTe/CIGSSe absorbers and hopefully facilitate a successful launch of commercialization for the kesterite-based technology.