Passivating contacts based on poly-Si/SiO x structures also known as TOPCon (tunnel oxide passivated contacts) have a great potential to improve the efficiency of crystalline silicon solar cells, resulting in more than 26% and 24% for laboratory and industrial cells, respectively. This publication gives an overview of the historical development of such contact structures which have started already in the 1980s and describes the current state-of-the-art in laboratory and industry. In order to demonstrate the great variety of scientific and technological research, four different research topics are addressed in more detail: (i) the superior passivation quality of TOPCon structures made it necessary to re-parametrize intrinsic recombination in silicon, (ii) the control of diffusion of dopants through the intermediate SiO x layer is essential to optimize passivation and transport properties, (iii) single-sided deposition of the poly-Si layer would reduce process complexity for industrial TOPCon cells, and (iv) silicon-based tunnel junctions for perovskite-silicon tandem cells can be fabricated using the TOPCon technology.

Plasma-enhanced chemical vapour deposition (PECVD) SiNx is the typical choice as anti-reflection coating (ARC) for Silicon based solar cells. However, there still exists a room for improvement in passivation quality of SiNx while maintaining good optics for the front side of a solar cell. In this paper, we studied in detail the optical and electrical properties of SiNx layers by varying the chamber pressure and substrate temperature in an industrially used inline PECVD tool. Both the optical as well as electrical properties of SiNx layers were found to be significantly influenced by the chamber pressure and substrate temperature. A trade-off between excellent optics and low surface recombination is observed with an increase in chamber pressure, whereas higher substrate temperature generally led to better passivation quality. The Si-H bond density, which is expected to directly influence the quality of surface passivation, increased at high pressure and at low substrate temperature. Based on our investigations, a good compromise between optics and surface passivation is struck to prepare optimized SiNx layers and apply them as passivation layers for the front side of passivated emitter and rear cell (PERC) solar cells. The best solar cells show high short-circuit current density (jSC) of 39.9 mA/cm2 corresponding to the SiNx layers with low parasitic absorption, good antireflection property, and excellent passivation of the surface and bulk silicon. The current-voltage (I-V) results are found to be in agreement with internal quantum efficiency (IQE) measurements of the solar cells.

Silicon oxide (SiOx) has many applications, including as a low-refractive index material. Plasma enhanced chemical vapor deposition (PECVD) processes are facile, low temperature routes to produce thin SiOx layers. A route to decrease the refractive index of SiOx films is to increase the layer porosity although maintaining structural and optical stability remains challenging. Organic carbon-containing sacrificial layers have been shown to modify the growth and resulting structure of PECVD SiOx layers. In this work, we study the effect of adding methane (CH4) to the standard SiOx process gas mixture (silane and nitrous oxide) and varying deposition temperatures and microwave power in an industrial-scale, microwave PECVD reactor. Spectral ellipsometry was used to measure the optical properties of deposited layers, Fourier-transformed infrared (FTIR) spectroscopy to determine bonding and the layer porosity, and optical emission spectroscopy to characterize the plasma. We propose two regimes characterized by whether adding CH4 increases or decreases the refractive index and porosity of deposited layers compared to SiOx layers grown under standard conditions. However, the magnitude of the effect of adding CH4 was not large and would not find industrial application. Furthermore, the deposited layers’ refractive indices increased over time, indicating that the effects of adding CH4 to the process gas mixture were not stable. To help explain our results and to provide guidance for future efforts to better control the refractive index of PECVD SiOx layers via carbon incorporation while maintaining layer stability, we propose possible growth pathways for our layers considering both plasma reactions and surface processes.