WO2021206056A1 - 半導体素子および半導体素子の製造方法 - Google Patents
半導体素子および半導体素子の製造方法 Download PDFInfo
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- WO2021206056A1 WO2021206056A1 PCT/JP2021/014502 JP2021014502W WO2021206056A1 WO 2021206056 A1 WO2021206056 A1 WO 2021206056A1 JP 2021014502 W JP2021014502 W JP 2021014502W WO 2021206056 A1 WO2021206056 A1 WO 2021206056A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M1/00—Inking and printing with a printer's forme
- B41M1/12—Stencil printing; Silk-screen printing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M1/00—Inking and printing with a printer's forme
- B41M1/26—Printing on other surfaces than ordinary paper
- B41M1/34—Printing on other surfaces than ordinary paper on glass or ceramic surfaces
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/28—Manufacture of electrodes on semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/268
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10D—INORGANIC ELECTRIC SEMICONDUCTOR DEVICES
- H10D64/00—Electrodes of devices having potential barriers
- H10D64/20—Electrodes characterised by their shapes, relative sizes or dispositions
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F10/00—Individual photovoltaic cells, e.g. solar cells
- H10F10/10—Individual photovoltaic cells, e.g. solar cells having potential barriers
- H10F10/16—Photovoltaic cells having only PN heterojunction potential barriers
- H10F10/164—Photovoltaic cells having only PN heterojunction potential barriers comprising heterojunctions with Group IV materials, e.g. ITO/Si or GaAs/SiGe photovoltaic cells
- H10F10/165—Photovoltaic cells having only PN heterojunction potential barriers comprising heterojunctions with Group IV materials, e.g. ITO/Si or GaAs/SiGe photovoltaic cells the heterojunctions being Group IV-IV heterojunctions, e.g. Si/Ge, SiGe/Si or Si/SiC photovoltaic cells
- H10F10/166—Photovoltaic cells having only PN heterojunction potential barriers comprising heterojunctions with Group IV materials, e.g. ITO/Si or GaAs/SiGe photovoltaic cells the heterojunctions being Group IV-IV heterojunctions, e.g. Si/Ge, SiGe/Si or Si/SiC photovoltaic cells the Group IV-IV heterojunctions being heterojunctions of crystalline and amorphous materials, e.g. silicon heterojunction [SHJ] photovoltaic cells
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F71/00—Manufacture or treatment of devices covered by this subclass
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F77/00—Constructional details of devices covered by this subclass
- H10F77/10—Semiconductor bodies
- H10F77/14—Shape of semiconductor bodies; Shapes, relative sizes or dispositions of semiconductor regions within semiconductor bodies
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F77/00—Constructional details of devices covered by this subclass
- H10F77/20—Electrodes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to a semiconductor element and a method for manufacturing the semiconductor element.
- Patent Document 1 describes a technique for forming a patterned electrode layer by a screen printing method.
- the screen printing method is a method of transferring a printing material filled in a pattern opening portion of a printing plate to a printed matter by moving a squeegee.
- a mesh is formed in the pattern opening portion of the printing plate by a grid-like wire.
- a patterning method of the semiconductor layer or the electrode layer there is also a wet etching method using a mask such as a patterned resist.
- Masks such as patterned resists may also be formed by screen printing.
- voids may be formed in the resist pattern that intersects and extends in the printing direction (squeegee movement direction). As a result, voids (blurring) are formed in the pattern of the semiconductor layer or the electrode layer.
- the present invention is a semiconductor device capable of reducing the formation of voids (blurring) in the patterned semiconductor layer or electrode layer even when patterning is performed using a mask formed by a screen printing method.
- An object of the present invention is to provide a method for manufacturing a semiconductor device.
- the semiconductor element according to the present invention is a semiconductor element in which a patterned semiconductor layer or electrode layer is formed on a substrate, and the semiconductor layer or the electrode layer has an elongated shape and extends in the longitudinal direction. It has a band-shaped first pattern that exists and a band-shaped second pattern that intersects in the longitudinal direction, and 90% of the angles in the second pattern make an angle on the sharp side of the angle with respect to the first pattern. Is less than 90 degrees.
- the method for manufacturing a semiconductor element according to the present invention is a method for manufacturing a semiconductor element in which a patterned semiconductor layer or an electrode layer is formed on a substrate, and the material film of the semiconductor layer or the material film of the semiconductor layer is formed on the substrate.
- the semiconductor layer or In the mask forming step which includes a semiconductor layer or an electrode layer forming step for forming the electrode layer, the printing direction is for a grid-like wire forming a mesh in a pattern opening portion of a printing plate.
- the angle on the sharp side is 20 degrees or more and 40 degrees or less.
- the present invention even if patterning is performed using a mask formed by the screen printing method, it is possible to reduce the formation of voids (blurring) in the patterned semiconductor layer or electrode layer.
- FIG. 2 is a sectional view taken along line II-II of the solar cell of FIG. It is a figure which shows the 1st semiconductor layer material film formation process in the manufacturing method of the solar cell which concerns on this embodiment. It is a figure which shows the mask forming process in the manufacturing method of the solar cell which concerns on this embodiment. It is a figure which shows the 1st semiconductor layer formation process in the manufacturing method of the solar cell which concerns on this embodiment. It is a figure which shows the 1st semiconductor layer formation process in the manufacturing method of the solar cell which concerns on this embodiment. It is a figure which shows the 1st semiconductor layer formation process in the manufacturing method of the solar cell which concerns on this embodiment. It is a figure which shows the 2nd semiconductor layer material film formation process in the manufacturing method of the solar cell which concerns on this embodiment.
- FIG. 1 is a view of the solar cell according to the present embodiment as viewed from the back surface side.
- the solar cell (semiconductor element) 1 shown in FIG. 1 is a back electrode type (also referred to as back contact type or back surface bonding type) solar cell.
- the solar cell 1 includes a semiconductor substrate 11 having two main surfaces, and has a first region 7 and a second region 8 on the main surface of the semiconductor substrate 11.
- the first region 7 has a so-called comb-shaped shape, and has a plurality of finger portions 7f corresponding to the comb teeth and a bus bar portion 7b corresponding to the support portion of the comb teeth.
- the bus bar portion 7b extends in the first direction (X direction) along one side of the semiconductor substrate 11, and the finger portion 7f extends from the bus bar portion 7b in the second direction (Y direction) intersecting the first direction. ) Extends.
- the second region 8 has a so-called comb-shaped shape, and has a plurality of finger portions 8f corresponding to the comb teeth and a bus bar portion 8b corresponding to the support portion of the comb teeth.
- the bus bar portion 8b extends in the first direction (X direction) along the other side portion facing one side portion of the semiconductor substrate 11, and the finger portion 8f extends from the bus bar portion 8b in the second direction (Y). Extends in the direction).
- the finger portion 7f and the finger portion 8f form a strip extending in the second direction (Y direction), and are provided alternately in the first direction (X direction).
- the first region 7 and the second region 8 may be formed in a striped shape.
- FIG. 2 is a sectional view taken along line II-II of the solar cell of FIG.
- the solar cell 1 includes an optical adjustment layer 15 laminated on the light receiving surface side, which is the main surface (one main surface) on the light receiving side of the main surface of the semiconductor substrate 11. Further, the solar cell 1 is sequentially laminated on a part of the back surface side (mainly, the first region 7) which is the main surface (the other main surface) on the opposite side of the light receiving surface of the main surface of the semiconductor substrate 11. A first conductive semiconductor layer 25 and a first electrode layer 27 are provided. Further, the solar cell 1 includes a second conductive semiconductor layer 35 and a second electrode layer 37 which are sequentially laminated on another part (mainly, the second region 8) on the back surface side of the semiconductor substrate 11.
- the semiconductor substrate 11 is formed of a crystalline silicon material such as single crystal silicon or polycrystalline silicon.
- the semiconductor substrate 11 is, for example, an n-type semiconductor substrate in which a crystalline silicon material is doped with an n-type dopant.
- the semiconductor substrate 11 may be, for example, a p-type semiconductor substrate in which a crystalline silicon material is doped with a p-type dopant.
- Examples of the n-type dopant include phosphorus (P).
- Examples of the p-type dopant include boron (B).
- the semiconductor substrate 11 functions as a photoelectric conversion substrate that absorbs incident light from the light receiving surface side to generate optical carriers (electrons and holes).
- the optical adjustment layer 15 is formed on the light receiving surface side of the semiconductor substrate 11.
- the optical adjustment layer 15 functions as an antireflection layer that prevents reflection of incident light and also functions as a protective layer that protects the light receiving surface side of the semiconductor substrate 11.
- the optical adjustment layer 15 is formed of an insulating material such as a composite thereof such as silicon oxide (SiO), silicon nitride (SiN), or silicon oxynitride (SiON).
- the first conductive semiconductor layer 25 is formed in the first region 7 on the back surface side of the semiconductor substrate 11.
- the first conductive semiconductor layer 25 is formed of, for example, an amorphous silicon material.
- the first conductive semiconductor layer 25 is, for example, a p-type semiconductor layer in which an amorphous silicon material is doped with a p-type dopant (for example, the above-mentioned boron (B)).
- the second conductive semiconductor layer 35 is formed in the second region 8 on the back surface side of the semiconductor substrate 11.
- the second conductive semiconductor layer 35 is formed of, for example, an amorphous silicon material.
- the second conductive semiconductor layer 35 is, for example, an n-type semiconductor layer in which an amorphous silicon material is doped with an n-type dopant (for example, phosphorus (P) described above).
- the first conductive semiconductor layer 25 may be an n-type semiconductor layer, and the second conductive semiconductor layer 35 may be a p-type semiconductor layer.
- the first conductive semiconductor layer 25 and the second conductive semiconductor layer 35 form a strip extending in the second direction (Y direction), and are alternately arranged in the first direction (X direction). A part of the second conductive semiconductor layer 35 may overlap a part of the adjacent first conductive semiconductor layer 25 (not shown).
- a passivation layer may be formed between the semiconductor substrate 11 and the optical adjustment layer 15. Further, a passivation layer may be formed between the semiconductor substrate 11 and the first conductive semiconductor layer 25, and between the semiconductor substrate 11 and the second conductive semiconductor layer 35.
- the passivation layer is formed of, for example, an intrinsic (i-type) amorphous silicon material. The passivation layer suppresses recombination of carriers generated in the semiconductor substrate 11 and enhances carrier recovery efficiency.
- the first electrode layer 27 corresponds to the first conductive semiconductor layer 25, and is specifically formed on the first conductive semiconductor layer 25 in the first region 7 on the back surface side of the semiconductor substrate 11.
- the second electrode layer 37 corresponds to the second conductive semiconductor layer 35, and is specifically formed on the second conductive semiconductor layer 35 in the second region 8 on the back surface side of the semiconductor substrate 11.
- the first electrode layer 27 has a first transparent electrode layer 28 and a first metal electrode layer 29 that are sequentially laminated on the first conductive semiconductor layer 25.
- the second electrode layer 37 has a second transparent electrode layer 38 and a second metal electrode layer 39 that are sequentially laminated on the second conductive semiconductor layer 35.
- the first transparent electrode layer 28 and the second transparent electrode layer 38 are formed of a transparent conductive material.
- the transparent conductive material include ITO (Indium Tin Oxide: a composite oxide of indium oxide and tin oxide).
- the first metal electrode layer 29 and the second metal electrode layer 39 are formed of a conductive paste material containing a metal powder such as silver.
- the first electrode layer 27 and the second electrode layer 37 that is, the first transparent electrode layer 28, the second transparent electrode layer 38, the first metal electrode layer 29, and the second metal electrode layer 39 are in the second direction (Y direction). It has an extending strip shape and is arranged alternately in the first direction (X direction).
- the first transparent electrode layer 28 and the second transparent electrode layer 38 are separated from each other, and the first metal electrode layer 29 and the second metal electrode layer 39 are also separated from each other.
- FIG. 3A is a diagram showing a first semiconductor layer material film forming step in the solar cell manufacturing method according to the present embodiment
- FIG. 3B is a diagram showing a mask forming step in the solar cell manufacturing method according to the present embodiment.
- 3C and 3D are diagrams showing a first semiconductor layer forming step in the method for manufacturing a solar cell according to the present embodiment.
- FIG. 3E is a diagram showing a second semiconductor layer material film forming step in the solar cell manufacturing method according to the present embodiment
- FIG. 3F is a second semiconductor layer forming step in the solar cell manufacturing method according to the present embodiment.
- FIG. 3G is a diagram showing a transparent electrode layer material film forming step in the solar cell manufacturing method according to the present embodiment
- FIG. 3H is a transparent electrode layer forming step (mask) in the solar cell manufacturing method according to the present embodiment. It is a figure which shows (the forming process is omitted).
- FIG. 3I is a diagram showing a metal electrode layer forming step in the method for manufacturing a solar cell according to the present embodiment. 3A to 3I show the back surface side of the semiconductor substrate 11, and omit the front surface side of the semiconductor substrate 11.
- the first conductive semiconductor layer material film 25Z is laminated (film-formed) on the entire back surface side of the semiconductor substrate 11 by using, for example, the CVD method or the PVD method (first semiconductor layer). Material film forming process).
- the first conductive semiconductor layer material film 25Z in the second region 8 is removed from the back surface side of the semiconductor substrate 11 to pattern the semiconductor substrate 11 into the first region 7.
- the first conductive semiconductor layer 25 is formed.
- the mask material include photosensitive or non-photosensitive organic resist materials.
- a part of the first conductive semiconductor layer material film 25Z (that is, a part of the first conductive semiconductor layer material film 25Z) in the second region 8 is used by a wet etching method using the mask 90.
- the etching solution for the p-type semiconductor film include an acidic solution such as a mixed solution of ozone dissolved in hydrofluoric acid or a mixed solution of hydrofluoric acid and nitric acid
- examples of the etching solution for the n-type semiconductor film include. Examples thereof include an alkaline solution such as an aqueous solution of potassium hydroxide.
- the mask 90 is peeled off.
- the second conductive semiconductor layer material film 35Z is laminated (film-formed) on the entire back surface side of the semiconductor substrate 11 by using, for example, the CVD method or the PVD method (second semiconductor). Layer material film forming process).
- the second conductive semiconductor layer material film 35Z in the first region 7 is removed, so that the second region 8 is patterned.
- the conductive semiconductor layer 35 is formed.
- a patterned mask 90 is formed on the second conductive semiconductor layer material film 35Z in the second region 8 by using a screen printing method (mask formation). Process).
- the second conductive semiconductor layer material film 35Z (that is, a part of the second conductive semiconductor layer material film 35Z) in the first region 7 is removed.
- a patterned second conductive semiconductor layer 35 is formed in the second region 8 (second semiconductor layer forming step). Then, the mask 90 is peeled off.
- the optical adjustment layer 15 may be formed on the entire surface of the semiconductor substrate 11 on the light receiving surface side (not shown).
- a transparent electrode layer material film 28Z is formed on the first conductive semiconductor layer 25 and the second conductive semiconductor layer 35 so as to straddle them (transparent electrode layer material film forming step).
- a method for forming the transparent electrode layer material film 28Z for example, a CVD method or a PVD method is used.
- the transparent electrode layer material film 28Z at the boundary between the first region 7 and the second region 8 is removed to pattern the semiconductor substrate 11 into the first region 7.
- the first transparent electrode layer 28 is formed, and the second transparent electrode layer 38 patterned in the second region 8 is formed.
- a pattern is used on the transparent electrode layer material film 28Z in the first region 7 and on the transparent electrode layer material film 28Z in the second region 8 by using a screen printing method.
- the modified mask 90 is formed (mask forming step).
- the transparent electrode layer material film 28Z (that is, a part of the transparent electrode layer material film 28Z) at the boundary between the first region 7 and the second region 8 is removed by a wet etching method using the mask 90.
- the first transparent electrode layer 28 patterned in the first region 7 is formed, and the second transparent electrode layer 38 patterned in the second region 8 is formed (transparent electrode layer forming step).
- the etching solution for the transparent electrode layer material film include an acidic solution such as hydrochloric acid (HCl).
- the first metal electrode layer 29 is formed on the first transparent electrode layer 28, and the second metal electrode layer 39 is formed on the second transparent electrode layer 38.
- Metal electrode layer forming step As a method for forming the first metal electrode layer 29 and the second metal electrode layer 39, a printing method, a coating method, or the like is used. Through the above steps, the back electrode type solar cell 1 of the present embodiment is completed.
- the first conductive semiconductor layer 25 and the first transparent electrode layer 28 are elongated patterns, and are band-shaped first patterns extending in the longitudinal direction (Y direction). It may have 25A, 28A and a strip-shaped second pattern 25B, 28B extending in the lateral direction (X direction) intersecting the longitudinal direction.
- the long-shaped patterned mask 90 intersects with the strip-shaped first pattern 90A extending in the longitudinal direction (Y direction) in the longitudinal direction.
- a mask 90 having a band-shaped second pattern 90B extending in the lateral direction (X direction) is formed.
- the printing material filled in the pattern opening portion 81 of the printing plate is transferred to the printed matter by moving the squeegee 83.
- a mesh is formed in the pattern opening portion 81 of the printing plate by a grid-like wire.
- the longitudinal direction of the long mask 90 that is, the main strip-shaped first pattern 90A and the printing direction (squeegee 83 moving direction) D1 are parallel to each other.
- the printing direction moving direction of the squeegee 83
- the printing direction is tilted by about 11 degrees with respect to the grid-like wires forming the mesh in the pattern opening portion 81 of the printing plate.
- a gap V1 may occur in the band-shaped second pattern 90B extending in the lateral direction (X direction) of the mask 90.
- the gap V1 is generated on the original side in the printing direction in the second pattern 90B.
- voids are also formed in the first conductive semiconductor layer 25 or the first transparent electrode layer 28 in the patterning of the first conductive semiconductor layer 25 or the first transparent electrode layer 28. It will occur.
- the generation of voids (printing faintness) in the mask 90 by the screen printing method is considered as follows.
- the number of meshes in the printing direction in the pattern opening portion 81 of the printing plate is large, and the printing plate is ejected.
- the printed material is sufficiently smoothed.
- the band-shaped second pattern 90B extending in the lateral direction (X direction) of the mask 90, the number of meshes in the printing direction in the pattern opening portion 81 of the printing plate is large. Less, the ejected printing material is not sufficiently smoothed. This phenomenon becomes more remarkable as the number of times the printing plate is used increases.
- the inventor of the present application determines the number of meshes in the printing direction in the pattern opening portion 81 of the printing plate in the band-shaped second pattern 90B extending in the lateral direction (X direction) of the mask 90. Devise to increase. Specifically, the band-shaped second pattern 90B intersecting the longitudinal direction (Y direction) of the mask 90 is formed so as not to be orthogonal to the printing direction (squeegee 83 moving direction) D1.
- the pattern of the first conductive semiconductor layer 25 and the pattern of the first transparent electrode layer 28 are different.
- -A long pattern having a strip-shaped first pattern 25A, 28A extending in the longitudinal direction (Y direction) and a strip-shaped second pattern 25B, 28B intersecting the longitudinal direction.
- the second patterns 25B and 28B have an angle of less than 90 degrees, preferably 20 degrees or more and 40 degrees or less (acute angle side) with respect to the first patterns 25A and 28A.
- the strip-shaped second pattern 90B intersecting the longitudinal direction (Y direction) of the mask 90 can be formed so as not to be orthogonal to the printing direction (moving direction of the squeegee 83), and the gap (printing) of the mask 90 can be formed.
- the occurrence of blurring) can be reduced. Therefore, even if patterning is performed using the mask 90 formed by the screen printing method, voids (blurring) are formed in the patterned first conductive semiconductor layer 25 and the first transparent electrode layer 28. Can be reduced.
- the second patterns 25B and 28B in the pattern of the first conductive semiconductor layer 25 and the pattern of the first transparent electrode layer 28 have an arc shape that is convex in the longitudinal direction (Y direction). ..
- the tangents of the arcs of the second patterns 25B and 28B gradually change in a range larger than 0 degrees and smaller than 90 degrees with respect to the linear first patterns 25A and 28A.
- the second patterns 25B and 28B are 90 degrees with respect to the first patterns 25A and 28A.
- the 90% portion, preferably the 95% portion, more preferably the 98% portion of the second patterns 25B and 28B is at an angle of less than 90 degrees (acute angle side) with respect to the first patterns 25A and 28A. You just have to do.
- the second patterns 25B and 28B in the pattern of the first conductive semiconductor layer 25 and the pattern of the first transparent electrode layer 28 have a pointed shape that is convex in the longitudinal direction (Y direction). ..
- the second patterns 25B and 28B form an angle (acute angle side) of less than 90 degrees with respect to the first patterns 25A and 28A.
- the second patterns 25B and 28B have an angle (acute angle side) of 20 degrees or more and 40 degrees or less with respect to the first patterns 25A and 28A.
- the second patterns 25B and 28B in the pattern of the first conductive semiconductor layer 25 and the pattern of the first transparent electrode layer 28 have an inverted pointed shape that is concave in the longitudinal direction (Y direction). be.
- the second patterns 25B and 28B form an angle (acute angle side) of less than 90 degrees with respect to the first patterns 25A and 28A.
- the second patterns 25B and 28B have an angle (acute angle side) of 20 degrees or more and 40 degrees or less with respect to the first patterns 25A and 28A.
- the second patterns 25B and 28B in the pattern of the first conductive semiconductor layer 25 and the pattern of the first transparent electrode layer 28 have a wave shape that is uneven in the longitudinal direction (Y direction). ..
- the slope is maximum at the inflection point between the peak and the valley.
- the slope of the wave shape of the second patterns 25B and 28B gradually changes in a range larger than 0 degrees and smaller than 90 degrees with respect to the linear first patterns 25A and 28A.
- the second patterns 25B and 28B are 90 degrees with respect to the first patterns 25A and 28A.
- the 90% portion, preferably the 95% portion, more preferably the 98% portion of the second patterns 25B and 28B is at an angle of less than 90 degrees (acute angle side) with respect to the first patterns 25A and 28A. You just have to do.
- the second conductive semiconductor layer 35 and the second transparent electrode layer 38 are elongated patterns, and the first strip-shaped pattern extending in the longitudinal direction (Y direction). It may have 35A, 38A and a strip-shaped second pattern 35B, 38B extending in the lateral direction (X direction) intersecting the longitudinal direction.
- a gap V1 may occur in the band-shaped second pattern 90B extending in the lateral direction (X direction) of the mask 90.
- the void V1 printing faintness
- the patterning of the second conductive semiconductor layer 35 or the patterning of the second transparent electrode layer 38 is performed, and the second conductive semiconductor layer 35 or the second transparent electrode layer 38 is also patterned. A void is generated.
- the band-shaped second pattern 90B intersecting the longitudinal direction (Y direction) of the mask 90 is formed so as not to be orthogonal to the printing direction (squeegee 83 moving direction).
- the pattern of the second conductive semiconductor layer 35 and the pattern of the second transparent electrode layer 38 are different.
- -A long pattern having a strip-shaped first pattern 35A, 38A extending in the longitudinal direction (Y direction) and a strip-shaped second pattern 35B, 38B intersecting the longitudinal direction.
- the second patterns 35B and 38B have an angle of less than 90 degrees, preferably 20 degrees or more and 40 degrees or less (acute angle side) with respect to the first patterns 35A and 38A.
- the strip-shaped second pattern 90B extending in the longitudinal direction (Y direction) of the mask 90 can be formed so as not to be orthogonal to the printing direction (moving direction of the squeegee 83), and the gaps in the mask 90 (the gaps in the mask 90 (the squeegee 83 moving direction) can be formed. It is possible to reduce the occurrence of print blurring). Therefore, even if patterning is performed using the mask 90 formed by the screen printing method, voids (blurring) are formed in the patterned second conductive semiconductor layer 35 and the second transparent electrode layer 38. Can be reduced.
- the second patterns 35B and 38B in the pattern of the second conductive semiconductor layer 35 and the pattern of the second transparent electrode layer 38 have an arc shape that is convex in the longitudinal direction (Y direction). ..
- the tangents of the arcs of the second patterns 35B and 38B gradually change in a range larger than 0 degrees and smaller than 90 degrees with respect to the linear first patterns 35A and 38A.
- the second patterns 35B and 38B are 90 degrees with respect to the first patterns 35A and 38A.
- the 90% portion, preferably the 95% portion, more preferably the 98% portion of the second patterns 35B, 38B is at an angle of less than 90 degrees (acute angle side) with respect to the first patterns 35A, 38A. You just have to do.
- the second patterns 35B and 38B in the pattern of the second conductive semiconductor layer 35 and the pattern of the second transparent electrode layer 38 have a pointed shape that is convex in the longitudinal direction (Y direction). ..
- the second patterns 35B and 38B form an angle (acute angle side) of less than 90 degrees with respect to the first patterns 35A and 38A.
- the second patterns 35B and 38B in the pattern of the second conductive semiconductor layer 35 and the pattern of the second transparent electrode layer 38 have an inverted pointed shape that is concave in the longitudinal direction (Y direction). be.
- the second patterns 35B and 38B form an angle (acute angle side) of less than 90 degrees with respect to the first patterns 35A and 38A.
- the second patterns 35B and 38B in the pattern of the second conductive semiconductor layer 35 and the pattern of the second transparent electrode layer 38 have a wave shape that is uneven in the longitudinal direction (Y direction). ..
- the slope is maximum at the inflection point between the peak and the valley.
- the slope of the wave shape of the second patterns 35B and 38B gradually changes in a range larger than 0 degrees and smaller than 90 degrees with respect to the linear first patterns 35A and 38A.
- the second patterns 35B and 38B are 90 degrees with respect to the first patterns 35A and 38A.
- the 90% portion, preferably the 95% portion, more preferably the 98% portion of the second patterns 35B, 38B is at an angle of less than 90 degrees (acute angle side) with respect to the first patterns 35A, 38A. You just have to do.
- the pattern shape of the mask 90 that is, the pattern shapes of the semiconductor layer and the electrode layer is changed.
- the angle of the printing plate is changed instead of this.
- the inventor of the present application as shown in FIG. -
- the semiconductor layers 25, 35 and the transparent electrode layers 28, 38 are long patterns, and the first strip-shaped patterns 25A, 35A, 28A, 38A extending in the longitudinal direction (Y direction) and the longitudinal direction. It is a pattern having a band-shaped second pattern 25B, 35B, 28B, 38B extending in the lateral direction (X direction) intersecting with.
- the printing direction D1 (moving direction of the squeegee 83) is changed with respect to the grid-like wires forming the mesh in the pattern opening portion 81 of the printing plate. Therefore, it was found that the occurrence of voids (printing faintness) in the mask 90 can be reduced.
- the printing direction D1 (the squeegee 83 moving direction) is set, and the mesh in the pattern opening portion 81 of the printing plate is set.
- the angle is 20 degrees or more and 40 degrees or less, preferably 22 degrees or more and 35 degrees or less, and more preferably 25 degrees (the angle on the acute angle side of the two angles) with respect to the grid-like wire to be formed.
- the present invention is not limited to the above-described embodiments, and various modifications and modifications can be made.
- a heterozygous solar cell and a method for manufacturing the same are illustrated as shown in FIG. 2, but the feature of the present invention is not limited to the heterozygous solar cell.
- various solar cells such as homozygous solar cells and their manufacturing methods.
- a solar cell having a crystalline silicon substrate has been exemplified, but the present invention is not limited to this.
- a solar cell may have a gallium arsenide (GaAs) substrate.
- GaAs gallium arsenide
- the solar cell and the manufacturing method thereof have been exemplified.
- the features of the present invention are not limited to this, and can be applied to various semiconductor devices including a patterned semiconductor layer or an electrode layer and a method for manufacturing the same.
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Abstract
Description
図1は、本実施形態に係る太陽電池を裏面側からみた図である。図1に示す太陽電池(半導体素子)1は、裏面電極型(バックコンタクト型、裏面接合型ともいう。)の太陽電池である。太陽電池1は、2つの主面を備える半導体基板11を備え、半導体基板11の主面において第1領域7と第2領域8とを有する。
なお、第1導電型半導体層25がn型の半導体層であり、第2導電型半導体層35がp型の半導体層であってもよい。
次に、図3A~図3Iを参照して、本実施形態に係る太陽電池の製造方法について説明する。図3Aは、本実施形態に係る太陽電池の製造方法における第1半導体層材料膜形成工程を示す図であり、図3Bは、本実施形態に係る太陽電池の製造方法におけるマスク形成工程を示す図であり、図3Cおよび図3Dは、本実施形態に係る太陽電池の製造方法における第1半導体層形成工程を示す図である。図3Eは、本実施形態に係る太陽電池の製造方法における第2半導体層材料膜形成工程を示す図であり、図3Fは、本実施形態に係る太陽電池の製造方法における第2半導体層形成工程(マスク形成工程を省略)を示す図である。図3Gは、本実施形態に係る太陽電池の製造方法における透明電極層材料膜形成工程を示す図であり、図3Hは、本実施形態に係る太陽電池の製造方法における透明電極層形成工程(マスク形成工程を省略)を示す図である。図3Iは、本実施形態に係る太陽電池の製造方法における金属電極層形成工程を示す図である。図3A~図3Iでは、半導体基板11の裏面側を示し、半導体基板11の表面側を省略する。
その後、図3Dに示すように、マスク90を剥離する。
その後、マスク90を剥離する。
以上の工程により、本実施形態の裏面電極型の太陽電池1が完成する。
この現象は、印刷版の使用回数が増えるほど顕著に発生する。
・長尺形状のパターンであって、長手方向(Y方向)に延在する帯状の第1パターン25A,28Aと、長手方向に交差する帯状の第2パターン25B,28Bとを有し、
・第2パターン25B,28Bは、第1パターン25A,28Aに対して90度未満、好ましくは、20度以上40度以下の角度(鋭角側)をなしている。
・長尺形状のパターンであって、長手方向(Y方向)に延在する帯状の第1パターン35A,38Aと、長手方向に交差する帯状の第2パターン35B,38Bとを有し、
・第2パターン35B,38Bは、第1パターン35A,38Aに対して90度未満、好ましくは、20度以上40度以下の角度(鋭角側)をなしている。
第1実施形態では、スクリーン印刷におけるマスク90の空隙(かすれ)の発生を抑制するために、マスク90のパターン形状、すなわち半導体層および電極層のパターン形状を変更した。第2実施形態では、これに代えて、印刷版の角度を変更する。
・半導体層25,35および透明電極層28,38が、長尺形状のパターンであって、長手方向(Y方向)に延在する帯状の第1パターン25A,35A,28A,38Aと、長手方向に交差する短手方向(X方向)に延在する帯状の第2パターン25B,35B,28B,38Bとを有するパターンであり、
・長尺形状のパターン化されたマスク90であって、長手方向(Y方向)に延在する帯状の第1パターン90Aと、長手方向に交差する短手方向(X方向)に延在する帯状の第2パターン90Bとを有するマスク90を形成する、
場合であっても、図8に示すように、印刷方向D1(スキージ83移動方向)を、印刷版のパターン開孔部81における網目(メッシュ)を形成する格子状のワイヤに対して変更することにより、マスク90の空隙(印刷かすれ)の発生を低減できることを見出した。
7 第1領域
7b,8b バスバー部
7f,8f フィンガー部
8 第2領域
11 半導体基板(基板)
15 光学調整層
25 第1導電型半導体層
25A,28A 第1パターン
25B,28B 第2パターン
25Z 第1導電型半導体層材料膜
27 第1電極層
28 第1透明電極層(電極層)
28Z 透明電極層材料膜
29 第1金属電極層
35 第2導電型半導体層
35A,38A 第1パターン
35B,38B 第2パターン
35Z 第2導電型半導体層材料膜
37 第2電極層
38 第2透明電極層(電極層)
39 第2金属電極層
81 印刷版のパターン開孔部
83 スキージ
90 マスク
90A 第1パターン
90B 第2パターン
D1 印刷方向
V1 空隙(印刷かすれ)
Claims (6)
- 基板上に、パターン化された半導体層または電極層が形成された半導体素子であって、
前記半導体層または前記電極層は、長尺形状をなし、長手方向に延在する帯状の第1パターンと、前記長手方向に交差する帯状の第2パターンとを有し、
前記第2パターンにおける90%の部分が前記第1パターンに対してなす角度のうち鋭角側の角度は、90度未満である、
半導体素子。 - 前記第2パターンは、前記長手方向に凸である円弧形状、前記長手方向に凸である尖形状、前記長手方向に凹である逆尖形状、または前記長手方向に凹凸である波形状である、請求項1に記載の半導体素子。
- 前記半導体素子は、裏面電極型の太陽電池である、請求項1または2に記載の半導体素子。
- 基板上に、パターン化された半導体層または電極層が形成された半導体素子の製造方法であって、
前記基板上に、前記半導体層の材料膜または前記電極層の材料膜を形成する半導体層材料膜または電極層材料膜形成工程と、
スクリーン印刷法を用いて、前記半導体層の材料膜または前記電極層の材料膜の上に、パターン化されたマスクを形成するマスク形成工程と、
前記マスクを用いたウエットエッチング法を用いて、前記半導体層の材料膜または前記電極層の材料膜の一部を除去することにより、パターン化された前記半導体層または前記電極層を形成する半導体層または電極層形成工程と、
を含み、
前記マスク形成工程では、印刷方向が、印刷版のパターン開孔部における網目(メッシュ)を形成する格子状のワイヤに対してなす角度のうち鋭角側の角度は、20度以上40度以下である、
半導体素子の製造方法。 - 前記印刷方向は、スキージの移動方向である、請求項4に記載の半導体素子の製造方法。
- 前記半導体素子は、裏面電極型の太陽電池である、請求項4または5に記載の半導体素子の製造方法。
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