JP2008198629A - 表面処理方法および太陽電池セル - Google Patents
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Abstract
【課題】太陽電池セルにとって良好な凹凸形状を多結晶シリコン基板表面に形成することを目的とする。
【解決手段】本発明に係る表面処理方法は、多結晶シリコン基板2の表面を処理する表面処理方法であって、反応容器1内に設けられたステージ電極3と接地電極4との間に多結晶シリコン基板2を配置する。そして、反応容器1内にClF3を含むエッチングガスを導入し、ステージ電極3と接地電極との間に高周波電力を間欠的に印加する工程とを備える。
【選択図】図1
【解決手段】本発明に係る表面処理方法は、多結晶シリコン基板2の表面を処理する表面処理方法であって、反応容器1内に設けられたステージ電極3と接地電極4との間に多結晶シリコン基板2を配置する。そして、反応容器1内にClF3を含むエッチングガスを導入し、ステージ電極3と接地電極との間に高周波電力を間欠的に印加する工程とを備える。
【選択図】図1
Description
本発明は、表面処理方法および太陽電池セルに関し、特にシリコン半導体基板の表面に微細な凹凸形状を形成する表面処理方法および太陽電池セルに関するものである。
単結晶、あるいは、多結晶シリコン(Si)基板を用いた、いわゆる結晶系太陽電池セルは、光電変換効率を高めるため、シリコン基板表面に無数の微細な凹凸形状を形成し、シリコン基板表面において光反射率の低減を図っている。太陽電池セルの受光面の凹凸形状を形成する従来の方法として、単結晶、あるいは、多結晶のシリコン基板をアルカリ水溶液中でウェットエッチングし、シリコン基板表面にピラミッド状の凹凸形状を形成する方法が広く用いられてきた。
しかしながら、上記ウェットエッチングにおいては、Siのエッチング速度は結晶の面方位に強く依存する。そのため、多結晶シリコンを基板として用いる場合には、基板全面に均一な凹凸形状を形成することができず、結果としてシリコン基板表面の光反射率を30%程度までしか低下させることができないという問題があった。
これを解決する方法として、三フッ化塩素(ClF3)ガスを用いて、シリコン基板をエッチングすることにより、表面に微細な凹凸形状を形成する方法が、非特許文献1,2、特許文献1,2に記載されている。
具体的には、真空排気した石英またはステンレス製の反応容器内にシリコン基板を配置し、この反応容器内に、例えばアルゴン(Ar)あるいは窒素(N2)ガスで希釈したClF3ガスを導入する。この反応容器には、排気系として真空ポンプが接続されており、反応容器と真空ポンプの間には、開度を変更可能な排気バルブが設けられている。この排気バルブの開度を調整することにより、反応容器内のガス圧力を一定に保ちながら、シリコン基板表面をClF3ガス雰囲気に曝すことができる。上記文献には、例えば、ガス圧は0.1〜100Torrの範囲、処理時間は10〜30分の範囲で処理することが記載されている。
以上のようにして、シリコン基板をClF3ガス雰囲気に曝すと、シリコン表面に吸着したClF3により、3Si+4ClF3→3SiF4↑+2Cl2↑という化学反応が生じる。この反応によって、基板表面のSi原子が、揮発性のSiF4分子として基板表面から脱離し、Siのエッチングが進行する。ここで、ガス中のClF3分子は様々な方向からシリコン表面に入射し、そこに吸着するので、シリコンのエッチングは等方的に進行し、いわゆる等方性エッチングが起こる。
また、非特許文献2に示されているように、ClF3は、空気内の酸素によって形成されたシリコン基板表面の自然酸化膜(SiOx)をエッチングすることは難しく、シリコンと自然酸化膜とのエッチング速度の比Si/SiOxは、最大で1000程度ある。さらに、上記自然酸化膜の膜厚や膜質は、ミクロレベルで不均一に形成されている。そのため、シリコン基板に自然酸化膜が存在している場合にClF3でエッチングを行うと、自然酸化膜がマイクロマスクとして働くため、シリコンのエッチングが進みにくい箇所や、逆に速く進む箇所が発生するようになる。こうして、シリコン表面に、無数の凹凸形状が形成されるようになる。
門馬正、石崎芳宣、斉藤洋司、「三フッ化塩素を用いたシリコンのテクスチャ化と光学的評価」、電子情報通信学会論文誌、1997年、vol.J80−C−11、No.11、p.412−413
S.Saitou、O.Ymaoka、A.Yoshida、"Plasmaless Cleaning Process of Silicon Surface Using Chlorine Trifluoride"、Appl.Phys.Lett.、1990、vol.56、p.1119−1121
特開2000−101111号公報
特開2005−150614号公報
上述したClF3ガスエッチング法によって、シリコン基板表面に凹凸形状を形成すると、特許文献1、および、特許文献2に記載されているように、基板表面の凹凸形状の先端部が鋭くなる。太陽電池セルの作製では、そのような凹凸形状を形成したシリコン基板表面に銀電極を形成・焼成して、太陽電池セルの受光面を作製する。しかしながら、シリコン基板表面の凹凸形状部が鋭く脆弱となっているため、その基板表面に銀電極を形成・焼成すると、電極直下のpn接合部が電気的に劣化・破壊されるという問題がある。
また、ClF3ガスエッチング法では、シリコン表面のエッチングが等方的に進行するため、基板表面の凹凸形状のアスペクト比(=深さ/直径)を大きくすることが非常に困難である。そのため、表面の光反射率を充分に低減することができず、太陽電池セルの受光面として、光の閉じ込め効果が不充分であるといった問題点があった。
さらに、ClF3ガスエッチング法では、シリコン表面の自然酸化膜がマイクロマスクとして作用するが、この自然酸化膜の厚みや膜質は基板間でバラツキがあり、大量のシリコン基板を処理する際、再現よく凹凸形状を形成するのは困難であった。
本発明は、上記のような問題点を解決するためになされたものであり、太陽電池セルにとって良好な凹凸形状をシリコン表面に再現よく形成することを目的とする。
本発明に係る請求項1に係る表面処理方法は、半導体基板の表面を処理する表面処理方法であって、(a)反応容器内に設けられた電極間に前記半導体基板を配置する工程と、(b)前記反応容器内にエッチングガスを導入する工程と、(c)前記電極間に高周波電力を間欠的に印加する工程とを備える。
本発明の表面処理方法によれば、太陽電池セルにとって良好な凹凸形状をシリコン半導体基板表面に形成することができる。
<実施の形態1>
図1は、本実施の形態に係る表面処理方法を行う基板処理装置を示す図である。図1に示すように、基板処理装置は、石英、アルミニウム、あるいはステンレス製の反応容器1を備える。基板処理装置は、反応容器1内に設けた電極を備える。本実施の形態では、この電極は、シリコン基板2を保持するためのステージ電極3と、それに対向して設けられた接地電極4で構成されている。半導体基板であるシリコン基板2は、反応容器1内に収容されて、表面に所定の処理が施される。
図1は、本実施の形態に係る表面処理方法を行う基板処理装置を示す図である。図1に示すように、基板処理装置は、石英、アルミニウム、あるいはステンレス製の反応容器1を備える。基板処理装置は、反応容器1内に設けた電極を備える。本実施の形態では、この電極は、シリコン基板2を保持するためのステージ電極3と、それに対向して設けられた接地電極4で構成されている。半導体基板であるシリコン基板2は、反応容器1内に収容されて、表面に所定の処理が施される。
基板処理装置は、反応容器1の外部に、13.56MHzの高周波電力を発生するRF電源5を備えており、RF電源5からの高周波電力は、整合器6を介して、ステージ電極3に供給される。基板処理装置は、RF電源5の出力をオン・オフ制御するための制御部7を備える。また、反応容器1には、反応容器1内にエッチングガスを供給するガス供給管8と、反応容器1内のガスを所定の排気速度で外部に排気するガス排気管9がそれぞれ接続されている。このエッチングガスは、ClF3ガスを含む。本実施の形態では、エッチングガスはArガスで希釈したClF3ガス、すなわち、ClF3/Arの混合ガスであるものとして、以下、説明する。
上記の基板処理装置による表面処理方法を図2を用いて説明する。まず、反応容器1内に設けられたステージ電極3上に半導体基板であるシリコン基板2を設置する。反応容器1は、ガス排気管9を通じて真空排気されている。そして、処理時間tが0<t<T1の範囲にある場合には、ガス供給管8から反応容器1内にエッチングガスであるClF3/Arの混合ガスを導入する。
この時、シリコン基板2は一定圧力の下、様々な方向から到来するClF3ガスに曝されることとなる。こうして、ClF3と化学反応させて、シリコン基板2に等方性エッチングを施す。エッチングに伴って生じたガスは、未反応の一部のエッチングガスとともに、ガス排気管9を通じて排気される。ここで、シリコン基板2表面に自然酸化膜が存在すると、ClF3ではこの自然酸化膜をエッチングすることが困難であるため、自然酸化膜はマイクロマスクとして働く。その結果、自然酸化膜が形成されていない部分がエッチングされ、表面に凹凸形状が形成される。
次に、処理時間tがT1<t<T2の範囲にある場合には、制御部7からの信号を受けてRF電源5がオンされ、ステージ電極3に高周波電力が供給される。そうすると、ステージ電極3と接地電極4との間に直ちに放電が起こり、ガス供給管8から供給されたClF3/Ar混合ガスがプラズマ化される。プラズマ中ではClF3が解離・電離され、塩素イオン(Cl+)やフッ素イオン(F+)が生成される。これらのイオンは、シリコン基板2の表面に形成されるシースと呼ばれる電界領域を通過する際、シリコン基板2に向かって加速され、高エネルギー状態でシリコン基板2表面と略垂直に入射する。その結果、シリコン基板2の表面と略垂直方向に進むエッチングとなる。こうして、ClF3をプラズマ化して、シリコン基板2に異方性エッチングを施す。エッチングに伴って生じたガスは、エッチングガスとともに、ガス排気管9を通じて排気される。
この時、Cl+やF+は、シリコン基板2表面の自然酸化膜をある程度エッチングするが、自然酸化膜に覆われていないシリコンのほうがそれ以上にエッチングされるため、選択的に異方性エッチングが施される。そのため、表面の凹凸形状は等方性エッチングのみよる凹凸形状より深くなる。また、それとともに、凹凸形状の先端部の鋭角部分もエッチングされ、ある程度平坦化される。
次に、処理時間tがT2<t<T3の範囲にある場合には、制御部7からの信号を受けてRF電源5がオフされ、プラズマ中のCl+やF+のイオンは直ちに消滅し、処理時間が0<t<T1の時と同様に、ClF3ガスによる等方性エッチングが再開するようになる。
このように、RF電源5をオン/オフしてプラズマの発生を間欠的に行うことにより、等方性エッチング→異方性エッチング→等方性エッチング→・・・というように、シリコン基板2に等方性エッチングを施す工程と、シリコン基板2に異方性エッチングを施す工程とを交互に繰り返す。その際、RF電源5をオンしている期間Ton(=T2−T1)と、RF電源5をオフしている期間Toff(=T1=T3−T2)とを調整することにより、シリコン基板2表面の凹凸形状を変化させることが可能になる。
図5は、従来のエッチング方法の後に、シリコン基板2にn型半導体層2aと、p型半導体層2bと、反射防止膜12と、裏面電極13と、表面電極14を形成したものを示す図である。この図に示すように、従来のClF3ガスエッチング法では、エッチングは全て等方的に起こるので、シリコン基板2表面に形成される凹凸形状の先端部が鋭く、また凹凸形状のアスペクト比が小さかった。それに対し、本発明では、等方性エッチングと異方性エッチングとを交互に行うので、凹凸形状の先端部の鋭角部分を丸くしたり、凹凸形状を深くしたりすることができる。
次に、本実施の形態に係る処理、または、従来処理が施された多結晶シリコン基板で形成された受光面を備える太陽電池セルの性能を比較する。ただし、本発明は、以下の処理条件に制限されるものではない。
<実施例1>
本実施の形態に係る処理の具体的な一例を実施例1として説明する。導入するガスを、ClF3流量:10sccm、Ar流量:490sccm、圧力:5Torrに設定した。また、プラズマ生成するための電力を、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)に設定した。そして、表面処理を行う時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。この場合、高周波電力の全オン時間は1分30秒、全オフ時間は4分30秒となる。
本実施の形態に係る処理の具体的な一例を実施例1として説明する。導入するガスを、ClF3流量:10sccm、Ar流量:490sccm、圧力:5Torrに設定した。また、プラズマ生成するための電力を、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)に設定した。そして、表面処理を行う時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。この場合、高周波電力の全オン時間は1分30秒、全オフ時間は4分30秒となる。
<比較例1>
比較例1として、従来から広く用いられてきたウェットエッチング法(エッチング液:イソプロピルアルコールを添加した10%のKOH水溶液、液温:90℃、浸漬時間:20分)により、多結晶シリコン基板に等方性エッチングのみを施した。
比較例1として、従来から広く用いられてきたウェットエッチング法(エッチング液:イソプロピルアルコールを添加した10%のKOH水溶液、液温:90℃、浸漬時間:20分)により、多結晶シリコン基板に等方性エッチングのみを施した。
<比較例2>
比較例2として、ClF3/Ar混合ガス(ガスの流量および圧力は実施例1と同じ)中で、高周波電力を印加せずに、5分間、多結晶シリコン基板に等方性エッチングのみを施した。
比較例2として、ClF3/Ar混合ガス(ガスの流量および圧力は実施例1と同じ)中で、高周波電力を印加せずに、5分間、多結晶シリコン基板に等方性エッチングのみを施した。
以上の各処理条件により処理したシリコン基板2を受光面とする太陽電池セルを試作し、その特性を測定した結果を図3に示す。図3に示されているように、本実施の形態の表面処理方法に相当する実施例1の太陽電池セルは、開放電圧Voc、短絡電流Jsc、曲線因子F.F.、変換効率Effi.が、従来処理の比較例1や比較例2に比べ大きくなっており、良好な太陽電池セルが実現された。これは、シリコン基板2に形成される凹凸形状の先端部の鋭角部分が丸くなるとともに、凹凸形状が従来よりも深くなったためである。それに対し、エッチングガスを用いて等方性エッチングのみを行った比較例2では、表面に形成された凹凸形状の先端部が鋭く、pn接合部に劣化が生じているため、太陽電池セルの特性は比較例1よりも悪くなっている。
このように、本実施の形態に係る表面処理方法は、高周波電力を間欠的にオン/オフして印加し、ClF3ガスを間欠的にプラズマ化すると、シリコン基板2に等方性エッチングと異方性エッチングが交互に繰り返し施される。そのため、シリコン基板2に形成される凹凸形状の先端部の鋭角部分を丸くしたり、凹凸形状を深くしたりすることができた。そして、開放電圧Voc、短絡電流Jsc、曲線因子F.F.、変換効率Effi.が大きい良好な太陽電池セルを実現することができた。
なお、本実施の形態では、ClF3の希釈ガスとしてArを用いたが、必ずしも希釈する必要はなく、また、希釈ガスもArに限定されるものではない。例えば、その他の希釈ガスとして、不活性ガス(He、Ne、Kr、・・・)を用いることができる。また、本実施の形態に相当する実施例では、高周波電力のオン時間をTon=5秒、オフ時間をToff=15秒としたが、Ton、Toffを変化させて同様の実験を行った結果、ほとんどの時間の組み合わせにおいて、本実施例と同様の効果を得ることができた。例えば、高周波電力のオン/オフを高速化し、Ton=50ms、Toff=150ms(繰返し周期:200ms、デューティ比:25%)の場合でも、同様の結果を得ることができた。
<実施の形態2>
実施の形態1では、プラズマを間欠的に発生させ、ClF3ガスによる等方性エッチングとF+イオンとCl+イオンによる異方性エッチングを交互に行うことについて説明した。しかし、イオンによる異方性エッチングが強すぎると、シリコン基板2表面に存在する自然酸化膜を全てエッチングしてしまうことがある。この場合において、シリコン基板2表面のマイクロマスクが無くなってしまうと、全ての場所が同じ速度でエッチングされてしまうため、それ以降は凹凸形状の成長が止まってしまう。
実施の形態1では、プラズマを間欠的に発生させ、ClF3ガスによる等方性エッチングとF+イオンとCl+イオンによる異方性エッチングを交互に行うことについて説明した。しかし、イオンによる異方性エッチングが強すぎると、シリコン基板2表面に存在する自然酸化膜を全てエッチングしてしまうことがある。この場合において、シリコン基板2表面のマイクロマスクが無くなってしまうと、全ての場所が同じ速度でエッチングされてしまうため、それ以降は凹凸形状の成長が止まってしまう。
そこで、本実施の形態では、反応容器1内にエッチングガスを導入する工程において、エッチングガスに加えて窒素または酸素を含むガスを導入する。窒素を含むガスに、窒素(N2)そのものを用いてもよく、酸素を含むガスに、酸素(O2)そのものを用いてもよい。そして、図4に示されるように、エッチングガスをプラズマ化するとともに、酸素または窒素をプラズマ化して、シリコン基板2の表面を酸化または窒化させる。酸化または窒化された部分は、上述したマイクロマスクの役割を果たす。こうして、シリコン基板2表面にマイクロマスクを再形成し、凹凸形状をさらに成長させる。以下、エッチングガスに加えて導入するガスはO2であるものとして説明する。
高周波電力をオンして、エッチングガスとO2をプラズマ化すると、Cl+イオンおよびF+イオンに加えて、酸素原子(O)や酸素イオン(O+)も生成される。これらO原子やO+イオンはシリコン基板2表面に入射すると、シリコンを酸化させることができるので、表面に薄いSiOx層を形成する。
一方、Cl+やF+はSiのみならず、SiOxもある程度エッチングすることができるので、シリコン基板2表面では酸化とエッチングが競合するようになる。エッチングガス中のClF3濃度が大きい場合にはエッチング反応が勝り、逆にO2濃度が大きい場合には酸化反応が勝るようになる。こうして、ClF3とO2との混合比を適当に選ぶことにより、シリコン基板2表面にSiOx層を部分的に形成することができる。すなわち、シリコン基板の表面では、F+やCl+イオンによる異方性エッチングに加え、マイクロマスクの形成が同時に行われる。
高周波電力がオフの状態では、化学的に活性なOやO+は消滅しており、ガス中にはClF3とO2のみが存在するようになる。このうち、ClF3はSiOxをエッチングすることが困難であるため、SiOxに覆われていないシリコンが選択的にかつ等方的にエッチングされる。
このように、O2を含むエッチングガスに間欠的に高周波電力を印加すると、表面のマイクロマスクの消失を抑えながら、等方性エッチングと異方性エッチングを交互に行うことが可能となる。その結果、シリコン基板2表面の凹凸形状の孔を深くすることができ、アスペクト比が大きい凹凸形状を形成することができる。
<実施例2>
本実施の形態に係る処理の具体的な一例を実施例2として説明する。導入するガスを、ClF3流量:10sccm、Ar流量:480sccm、そして、O2流量:10sccmを加え、圧力:5Torrに設定した。また、プラズマ生成するための電力を、実施例1と同じ、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)と設定にした。そして、表面処理を施す時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。
本実施の形態に係る処理の具体的な一例を実施例2として説明する。導入するガスを、ClF3流量:10sccm、Ar流量:480sccm、そして、O2流量:10sccmを加え、圧力:5Torrに設定した。また、プラズマ生成するための電力を、実施例1と同じ、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)と設定にした。そして、表面処理を施す時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。
O2を含まずに処理した実施例1の多結晶シリコン基板では、アスペクト比は最大で1程度であった。それに対し、O2を含む実施例2で処理したシリコン基板では、表面の凹凸形状のアスペクト比を1〜2程度にまで大きくすることができた。そのため、実施例1よりもさらに、光反射率が小さい受光面を有する太陽電池セルが形成されるはずである。そこで、実際に、実施例2の処理を施したシリコン基板2を受光面とする太陽電池セルを試作し、その特性を測定すると、図3の実施例2に示される結果が得られた。この結果に示されるように、実施例2の表面処理方法によれば、実施例1よりも、開放電圧Voc、短絡電流Jsc、変換効率Effi.を大きくすることができ、光閉じ込め効果の大きい良好な太陽電池セルを得ることができた。
なお、本実施例ではO2を混合したが、シリコン基板2表面を窒化させるN2を混合しても同様の結果を得ることができた。その他、エッチングガスに加えるガスは、プラズマ環境下でシリコンの表面を酸化あるいは窒化させることができるガスであればよく、オゾン(O3)、一酸化炭素(CO2)、二酸化炭素(CO2)、一酸化窒素(NO)、二酸化窒素(NO2)などを用いてもよい。また、本実施例では、希釈ガスとしてArを用いたが、実施例1と同様これに限ったものではない。
<実施の形態3>
実施の形態2では、エッチングガスにシリコン基板2表面を酸素または窒素を含むガスを混合し、マイクロマスクを再形成して、凹凸形状をさらに成長させた。本実施の形態では、酸素または窒素を含むガスの代わりに、反応容器1内にエッチングガスを導入する工程において、エッチングガスに加えてシリコン基板2の表面上に膜を形成する堆積性のガスを導入する。ここで、堆積性のガスとは、プラズマ化していないときはシリコン基板2の表面上にほとんど影響を与えないが、プラズマ化したときにシリコン基板2の表面上に堆積して膜を形成するガスである。このような堆積性のガスは、C3H8,C2H6,CH4,CHF3,CH2F2,CH3F,CF4,C2F6,C3F8,C4F8の少なくとも一つが含まれる。つまり、堆積性のガスは、上記のガスのいずれか1種類であってもよく、複数のガス種を組み合わせたものであってもよい。本実施の形態では、堆積性のガスとして、C3F8を用いる。
実施の形態2では、エッチングガスにシリコン基板2表面を酸素または窒素を含むガスを混合し、マイクロマスクを再形成して、凹凸形状をさらに成長させた。本実施の形態では、酸素または窒素を含むガスの代わりに、反応容器1内にエッチングガスを導入する工程において、エッチングガスに加えてシリコン基板2の表面上に膜を形成する堆積性のガスを導入する。ここで、堆積性のガスとは、プラズマ化していないときはシリコン基板2の表面上にほとんど影響を与えないが、プラズマ化したときにシリコン基板2の表面上に堆積して膜を形成するガスである。このような堆積性のガスは、C3H8,C2H6,CH4,CHF3,CH2F2,CH3F,CF4,C2F6,C3F8,C4F8の少なくとも一つが含まれる。つまり、堆積性のガスは、上記のガスのいずれか1種類であってもよく、複数のガス種を組み合わせたものであってもよい。本実施の形態では、堆積性のガスとして、C3F8を用いる。
実施の形態2の図4と同じように、エッチングガスをプラズマ化するとともに、堆積性のガスをプラズマ化して、シリコン基板2の表面上に膜を堆積させる。このようにして、F+やCl+イオンによる異方性エッチング中に、マイクロマスクの形成を同時に行う。
<実施例3>
本実施の形態に係る処理の具体的な一例を実施例3として説明する。導入するガスを、ClF3流量:15sccm、Ar流量:480sccm、そして、C3F8流量:5sccmを加え、圧力:5Torrに設定した。また、プラズマ生成するための電力を、実施例1と同じ、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)に設定した。そして、表面処理を施す時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。
本実施の形態に係る処理の具体的な一例を実施例3として説明する。導入するガスを、ClF3流量:15sccm、Ar流量:480sccm、そして、C3F8流量:5sccmを加え、圧力:5Torrに設定した。また、プラズマ生成するための電力を、実施例1と同じ、高周波電力(13.56MHz):100W、高周波電力のオン時間:Ton=5秒、高周波電力のオフ時間:Toff=15秒(繰り返し周期:20秒、デューティ比:25%)に設定した。そして、表面処理を施す時間を6分として、多結晶シリコン基板に等方性エッチングと異方性エッチングを施した。
堆積性のガスを追加した実施例3で処理したシリコン基板では、実施例2と同じく、表面の凹凸形状のアスペクト比を最大2程度にまで大きくすることができた。そのため、実施例1よりもさらに、光反射率が小さい受光面を有する太陽電池セルが形成されるはずである。そこで、実際に、実施例3の処理を施したシリコン基板2を受光面とする太陽電池セルを試作し、その特性を測定すると、図3の実施例3に示される結果が得られた。この結果に示されるように、実施例3の表面処理方法によれば、実施例1よりも、開放電圧Voc、短絡電流Jsc、変換効率Effi.を大きくすることができ、光閉じ込め効果の大きい良好な太陽電池セルを得ることができた。
1 反応容器、2 シリコン基板、2a n型半導体層、2b p型半導体層、3 ステージ電極、4 接地電極、5 RF電源、6 整合器、7 制御部、8 ガス供給管、9 ガス排気管、12 反射防止膜、13 裏面電極、14 表面電極。
Claims (6)
- 半導体基板の表面を処理する表面処理方法であって、
(a)反応容器内に設けられた電極間に前記半導体基板を配置する工程と、
(b)前記反応容器内にエッチングガスを導入する工程と、
(c)前記電極間に高周波電力を間欠的に印加する工程とを備え、
前記エッチングガスは、ClF3を含み、
前記半導体基板は、シリコン基板を含む、
表面処理方法。 - 前記工程(b)は、前記エッチングガスに加え、酸素または窒素を含むガスを導入する工程を含む、
請求項1に記載の表面処理方法。 - 前記工程(b)は、前記エッチングガスに加え、前記半導体基板の表面上に膜を形成する堆積性のガスを導入する工程を含む、
請求項1に記載の表面処理方法。 - 前記堆積性のガスは、
C3H8,C2H6,CH4,CHF3,CH2F2,CH3F,CF4,C2F6,C3F8,C4F8の少なくとも一つを含む、
請求項3に記載の表面処理方法。 - 半導体基板の表面を処理する表面処理方法であって、
(a)エッチングガスと化学反応させて、前記半導体基板の前記表面に等方性エッチングを施す工程と、
(b)前記エッチングガスをプラズマ化して、前記半導体基板の前記表面に異方性エッチングを施す工程とを備え、
前記工程(a)と前記工程(b)とを交互に繰り返す、
表面処理方法。 - 請求項1乃至請求項5のいずれかに記載の表面処理方法が施された前記半導体基板で形成された受光面を備える、
太陽電池セル。
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