High efficiency ultra-thin sputtered CdTe solar cells

Large scale manufacturing of CdTe PV modules at the GW/yr level may be constrained due to the limited availability of the relatively rare (Te) element and the volume of potentially hazardous (Cd) material being used in the typically 3–8 μm thick CdTe absorber layer. However, we find that it is possible to reduce the CdTe layer thickness without much compromise in efficiency. The CdS/CdTe solar cells were fabricated using magnetron sputtering with ultra-thin CdTe layers in the range of 0.5–1.28 μm. The ultra-thin films and cells were characterized using X-ray diffraction (XRD), optical transmission, scanning electron microscopy (SEM), current–voltage and quantum efficiency measurements. These results were compared with those of standard 2.3 μm thick CdTe sputtered cells. Different post-deposition processing parameters were required for cells with ultra-thin and standard CdTe thicknesses to achieve high efficiency. Ultra-thin CdTe cells showed crystallographic texture and CdTe1−xSx alloy formation after CdCl2 treatment very similar to standard CdTe cells. Optimization of the post-deposition CdCl2 treatment and back-contact processing yielded cells of 11.2% efficiency with 0.7 μm CdTe compared to 13.0% obtained with standard 2.3 μm CdTe cells.