J. Semicond. > 2019, Volume 40 > Issue 4 > 042601, doi: 10.1088/1674-4926/40/4/042601
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ARTICLES

Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics

Lei Tang1, 2, Kwong-Hoi Tsui1, 2, Siu-Fung Leung3, Qianpeng Zhang1, 2, Matthew Kam1, 2, Hsin-Ping Wang3, Jr-Hau He3 and Zhiyong Fan1, 2,

+ Author Affiliations

 Corresponding author: Zhiyong Fan, E-mail: eezfan@ust.hk

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Abstract: An effective and low-cost front-side anti-reflection (AR) technique has long been sought to enhance the performance of highly efficient photovoltaic devices due to its capability of maximizing the light absorption in photovoltaic devices. In order to achieve high throughput fabrication of nanostructured flexible and anti-reflection films, large-scale, nano-engineered wafer molds were fabricated in this work. Additionally, to gain in-depth understanding of the optical and electrical performance enhancement with AR films on polycrystalline Si solar cells, both theoretical and experimental studies were performed. Intriguingly, the nanocone structures demonstrated an efficient light trapping effect which reduced the surface reflection of a solar cell by 17.7% and therefore enhanced the overall electric output power of photovoltaic devices by 6% at normal light incidence. Notably, the output power improvement is even more significant at a larger light incident angle which is practically meaningful for daily operation of solar panels. The application of the developed AR films is not only limited to crystalline Si solar cells explored here, but also compatible with any types of photovoltaic technology for performance enhancement.

Key words: antireflection, crystalline Si solar cells, flexible film



[1]
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[2]
Pern F J, Glick D H, Czanderna A W. Review of the photothermal stability of EVA pottants: effects of formulation on the discoloration rate and mitigation methods. AIP Conference Proceedings, 1996, 353, 1 doi: 10.1063/1.58004
[3]
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[4]
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[5]
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[6]
Eisele C, Nebel C E, Stutzmann M. Periodic light coupler gratings in amorphous thin film solar cells. J Appl Phys, 2001, 89, 7722 doi: 10.1063/1.1370996
[7]
Nelson J. The physics of solar cells. London: Imperial College Press, 2003
[8]
Gwon H, Park Y, Moon C, et al. Superhydrophobic and antireflective nanograss-coated glass for high performance solar cells Nano Research, 2014, 7, 670 doi: 10.1007/s12274-014-0427-x
[9]
Deubener J, Helsch G, Moiseev A, et al. Glasses for solar energy conversion systems. J Eur Ceram Soc, 2009, 29, 1203 doi: 10.1016/j.jeurceramsoc.2008.08.009
[10]
Li X, He J, Liu W. Broadband anti-reflective and water-repellent coatings on glass substrates for self-cleaning photovoltaic cells. Mater Res Bull, 2013, 48, 2522 doi: 10.1016/j.materresbull.2013.03.017
[11]
Wang H, Periyanagounder D, Li A, et al. Fabrication of silicon hierarchical structures for solar cell applications. IEEE Access, 2019, 7, 19395 doi: 10.1109/ACCESS.2018.2885169
[12]
Lim S, Um D, Ha M, et al. Broadband omnidirectional light detection in flexible and hierarchical ZnO/Si heterojunction photodiodes. Nano Res, 2017, 10, 22 doi: 10.1007/s12274-016-1263-y
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[14]
Zheng X, Wei Z, Chen H, et al. Designing nanobowl arrays of mesoporous TiO2 as an alternative electron transporting layer for carbon cathode-based perovskite solar cells. Nanoscale, 2016, 8, 6393 doi: 10.1039/C5NR06715D
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Fan Z, Ruebusch D, Rathore A, et al. Challenges and prospects of nanopillar-based solar cells. Nano Res, 2009, 2, 829 doi: 10.1007/s12274-009-9091-y
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Yu M, Long Y, Sun B, et al. Recent advances in solar cells based on one-dimensional nanostructure arrays. Nanoscale, 2012, 4, 9 doi: 10.1039/c2nr30437f
[17]
Das S, Hossain M J, Leung S, et al. A leaf-inspired photon management scheme using optically tuned bilayer nanoparticles for ultra-thin and highly efficient photovoltaic devices Nano Energy, 2019, 58, 47 doi: 10.1016/j.nanoen.2018.12.072
[18]
Jiang S, Wang K, Zhang H, et al. Macromolecular Reaction Engineering, 2015, 9, 5 doi: 10.1002/mren.201400065
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Tsui K H, Lin Q, Chou H, et al. Low-cost, flexible and self-cleaning three-dimensional anti-reflection nanocone arrays for high efficiency photovoltaics. Adv Mater, 2014, 26, 2805 doi: 10.1002/adma.v26.18
[20]
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[21]
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[22]
Qiu Y, Leung S, Zhang Q, et al. Efficient photoelectrochemical water splitting with ultrathin films of hematite on three-dimensional nanophotonic structures. Nano Lett, 2014, 14, 2123 doi: 10.1021/nl500359e
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[24]
Leung S, Yu M, Lin Q, et al. Efficient photon capturing with ordered three-dimensional nanowell arrays. Nano Lett, 2012, 12, 3682 doi: 10.1021/nl3014567
[25]
Choi J, Wehrspohn R B, Gösele U. Moiré pattern formation on porous alumina arrays using nanoimprint lithography. Adv Mater. 2003, 15, 1531 doi: 10.1002/(ISSN)1521-4095
[26]
Galliano A, Bistac S, Schultz J. Adhesion and friction of PDMS networks: molecular weight effects. J Colloid Interface Sci. 2003, 265, 372 doi: 10.1016/S0021-9797(03)00458-2
[27]
Crawford R J, Ivanova E P. Superhydrophobic surfaces. Amsterdam, Netherlands: Elsevier, 2015
[28]
Tsui K, Li X, Tsoi J K H, et al. Low-cost, flexible, disinfectant-free and regular-array three-dimensional nanopyramid antibacterial films for clinical applications. Nanoscale. 2018, 10, 10436. doi: 10.1039/C8NR01968A
[29]
Tsai M, Tu W, Tang L, et al. Efficiency enhancement of silicon heterojunction solar cells via photon management using graphene quantum dot as downconverters. Nano Lett, 2016, 16, 309 doi: 10.1021/acs.nanolett.5b03814
[30]
Lin Y, Lai K Y, Wang H, et al. Slope-tunable sinanorod arrays with enhanced antireflection and self-cleaning properties. Nanoscale. 2010, 2, 2765 doi: 10.1039/c0nr00402b
[31]
Cai J, Qi L. Recent advances in antireflective surfaces based on nanostructure arrays. Mater Horiz, 2014, 2, 37 doi: 10.1039/c4mh00140k
Fig. 1.  (Color online) Schematic diagram of fabrication process of i-cone mold and AR film, and SEM images of Au-coated mold and PDMS nanocone. (a) A 4-inch glass wafer with sputtered 5 μm pure aluminum on the surface underwent photolithography of 1 μm hexagonal array pattern. (b) The pattern wafer underwent dry etching to form 50 nm-depth nanoindentation. (c) The wafer underwent anodization to form i-nanocone arrays. (d) The replication and peeloff process of AR film. (e) SEM of Au-coated mold with 1 μm pitch and 1 μm depth. (f) SEM of nanocone with 1 μm pitch and 1 μm depth.

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Fig. 2.  (Color online) (a) The photograph of 4-inch Au-coated mold. (b) The photograph of flexible AR film attached on polycarbonate film. (c) Schematic diagram of the c-Si solar cell device with nanocone AR film attached on the top. (d) Real 8 cm by 8 cm AR film attached on c-Si device.

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Fig. 3.  (Color online) (a) The reflectance spectra of c-Si solar cell device with and without epoxy layer and nanocone AR film in optical wavelength from 400 to 900 nm. (b) Simulations of reflectance spectra in optical wavelength from 400 to 900 nm of c-Si solar cell device with and without epoxy layer and nanocone AR film. (c) Simulated |E|2 distribution of electromagnetic wave at 650 nm wavelength for the bare c-Si device. (d) Simulated |E|2 distribution of electromagnetic wave at 650 nm wavelength for the epoxy-encapsulated c-Si device. (e) Simulated |E|2 distribution of electromagnetic wave at 650 nm wavelength for the AR film-attached c-Si device. (f) QE measurement of c-Si solar cell device with and without epoxy layer and nanocone AR film.

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Fig. 4.  (Color online) (a) Reflectance spectra of a c-Si solar cell device with and without epoxy layer and AR film obtained for the light incident angles tuning from 0° (normal incident) to 60° at 10° intervals. (b) Jsc of a c-Si device with and without epoxy layer and AR film obtained at different incident angles, together with the angular-dependent relative improvement of Jsc. (c) Power output of a c-Si device with and without epoxy layer and AR film against daytime. (d) Power output improvement of a c-Si device with and without epoxy layer and nanostructure AR film against daytime, with their daily energy output in the inset.

DownLoad: Full-Size Img PowerPoint
[1]
Klampaftis E, Richards B S. Improvement in multi-crystalline silicon solar cell efficiency via addition of luminescent material to EVA encapsulation layer. Prog Photovoltaics Res Appl, 2011, 19, 345 doi: 10.1002/pip.1019
[2]
Pern F J, Glick D H, Czanderna A W. Review of the photothermal stability of EVA pottants: effects of formulation on the discoloration rate and mitigation methods. AIP Conference Proceedings, 1996, 353, 1 doi: 10.1063/1.58004
[3]
Miller D C, Muller M T, Kempe M D, et al. Durability of polymeric encapsulation materials for concentrating photovoltaic systems. Prog Photovoltaics Res Appl, 2013, 21, 631 doi: 10.1002/pip.1241
[4]
Ramrakhiani M. Recent advances in photovoltaics. Millersville, PA: Materials Research Forum, 2017
[5]
Chen J, Zhou L, Ou Q, et al. Enhanced light harvesting in organic solar cells featuring a biomimetic active layer and a self‐cleaning antireflective coating. Adv Energy Mater, 2014, 4, 1301777 doi: 10.1002/aenm.201301777
[6]
Eisele C, Nebel C E, Stutzmann M. Periodic light coupler gratings in amorphous thin film solar cells. J Appl Phys, 2001, 89, 7722 doi: 10.1063/1.1370996
[7]
Nelson J. The physics of solar cells. London: Imperial College Press, 2003
[8]
Gwon H, Park Y, Moon C, et al. Superhydrophobic and antireflective nanograss-coated glass for high performance solar cells Nano Research, 2014, 7, 670 doi: 10.1007/s12274-014-0427-x
[9]
Deubener J, Helsch G, Moiseev A, et al. Glasses for solar energy conversion systems. J Eur Ceram Soc, 2009, 29, 1203 doi: 10.1016/j.jeurceramsoc.2008.08.009
[10]
Li X, He J, Liu W. Broadband anti-reflective and water-repellent coatings on glass substrates for self-cleaning photovoltaic cells. Mater Res Bull, 2013, 48, 2522 doi: 10.1016/j.materresbull.2013.03.017
[11]
Wang H, Periyanagounder D, Li A, et al. Fabrication of silicon hierarchical structures for solar cell applications. IEEE Access, 2019, 7, 19395 doi: 10.1109/ACCESS.2018.2885169
[12]
Lim S, Um D, Ha M, et al. Broadband omnidirectional light detection in flexible and hierarchical ZnO/Si heterojunction photodiodes. Nano Res, 2017, 10, 22 doi: 10.1007/s12274-016-1263-y
[13]
Tavakoli M M, Lin Q, Leung S, et al. Efficient, flexible and mechanically robust perovskite solar cells on inverted nanocone plastic substrates. Nanoscale, 2016, 8, 4276 doi: 10.1039/C5NR08836D
[14]
Zheng X, Wei Z, Chen H, et al. Designing nanobowl arrays of mesoporous TiO2 as an alternative electron transporting layer for carbon cathode-based perovskite solar cells. Nanoscale, 2016, 8, 6393 doi: 10.1039/C5NR06715D
[15]
Fan Z, Ruebusch D, Rathore A, et al. Challenges and prospects of nanopillar-based solar cells. Nano Res, 2009, 2, 829 doi: 10.1007/s12274-009-9091-y
[16]
Yu M, Long Y, Sun B, et al. Recent advances in solar cells based on one-dimensional nanostructure arrays. Nanoscale, 2012, 4, 9 doi: 10.1039/c2nr30437f
[17]
Das S, Hossain M J, Leung S, et al. A leaf-inspired photon management scheme using optically tuned bilayer nanoparticles for ultra-thin and highly efficient photovoltaic devices Nano Energy, 2019, 58, 47 doi: 10.1016/j.nanoen.2018.12.072
[18]
Jiang S, Wang K, Zhang H, et al. Macromolecular Reaction Engineering, 2015, 9, 5 doi: 10.1002/mren.201400065
[19]
Tsui K H, Lin Q, Chou H, et al. Low-cost, flexible and self-cleaning three-dimensional anti-reflection nanocone arrays for high efficiency photovoltaics. Adv Mater, 2014, 26, 2805 doi: 10.1002/adma.v26.18
[20]
Lin Q, Leung S, Tsui K, et al. Programmable nanoengineering templates for fabrication of three-dimensional nanophotonic structures. Nanoscale Res Lett, 2013, 8, 1 doi: 10.1186/1556-276X-8-1
[21]
McIntosh K R, Powell N E, Norris A W, et al. The effect of damp-heat and UV aging tests on the optical properties of silicone and EVA encapsulants. Prog Photovoltaics Res Appl, 2011, 19, 294 doi: 10.1002/pip.1025
[22]
Qiu Y, Leung S, Zhang Q, et al. Efficient photoelectrochemical water splitting with ultrathin films of hematite on three-dimensional nanophotonic structures. Nano Lett, 2014, 14, 2123 doi: 10.1021/nl500359e
[23]
Leung S F, Gu L, Zhang Q, et al. Roll-to-roll fabrication of large scale and regular arrays of three-dimensional nanospikes for high efficiency and flexible photovoltaics. Sci Rep, 2014, 4 doi: 10.1038/srep04243
[24]
Leung S, Yu M, Lin Q, et al. Efficient photon capturing with ordered three-dimensional nanowell arrays. Nano Lett, 2012, 12, 3682 doi: 10.1021/nl3014567
[25]
Choi J, Wehrspohn R B, Gösele U. Moiré pattern formation on porous alumina arrays using nanoimprint lithography. Adv Mater. 2003, 15, 1531 doi: 10.1002/(ISSN)1521-4095
[26]
Galliano A, Bistac S, Schultz J. Adhesion and friction of PDMS networks: molecular weight effects. J Colloid Interface Sci. 2003, 265, 372 doi: 10.1016/S0021-9797(03)00458-2
[27]
Crawford R J, Ivanova E P. Superhydrophobic surfaces. Amsterdam, Netherlands: Elsevier, 2015
[28]
Tsui K, Li X, Tsoi J K H, et al. Low-cost, flexible, disinfectant-free and regular-array three-dimensional nanopyramid antibacterial films for clinical applications. Nanoscale. 2018, 10, 10436. doi: 10.1039/C8NR01968A
[29]
Tsai M, Tu W, Tang L, et al. Efficiency enhancement of silicon heterojunction solar cells via photon management using graphene quantum dot as downconverters. Nano Lett, 2016, 16, 309 doi: 10.1021/acs.nanolett.5b03814
[30]
Lin Y, Lai K Y, Wang H, et al. Slope-tunable sinanorod arrays with enhanced antireflection and self-cleaning properties. Nanoscale. 2010, 2, 2765 doi: 10.1039/c0nr00402b
[31]
Cai J, Qi L. Recent advances in antireflective surfaces based on nanostructure arrays. Mater Horiz, 2014, 2, 37 doi: 10.1039/c4mh00140k

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    Received: 22 January 2019 Revised: 17 March 2019 Online: Uncorrected proof: 02 April 2019Published: 08 April 2019

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      Article Navigation >  Journal of Semiconductors  > 2019  >  40(4): 042601
      Lei Tang, Kwong-Hoi Tsui, Siu-Fung Leung, Qianpeng Zhang, Matthew Kam, Hsin-Ping Wang, Jr-Hau He, Zhiyong Fan. Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics[J]. Journal of Semiconductors, 2019, 40(4): 042601. doi: 10.1088/1674-4926/40/4/042601 L Tang, K H Tsui, S F Leung, Q P Zhang, M Kam, H P Wang, J H He, Z Y Fan, Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics[J]. J. Semicond., 2019, 40(4): 042601. doi: 10.1088/1674-4926/40/4/042601.Export: BibTex EndNote
      Citation:
      Lei Tang, Kwong-Hoi Tsui, Siu-Fung Leung, Qianpeng Zhang, Matthew Kam, Hsin-Ping Wang, Jr-Hau He, Zhiyong Fan. Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics[J]. Journal of Semiconductors, 2019, 40(4): 042601. doi: 10.1088/1674-4926/40/4/042601

      L Tang, K H Tsui, S F Leung, Q P Zhang, M Kam, H P Wang, J H He, Z Y Fan, Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics[J]. J. Semicond., 2019, 40(4): 042601. doi: 10.1088/1674-4926/40/4/042601.
      Export: BibTex EndNote
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      Large-scale, adhesive-free and omnidirectional 3D nanocone anti-reflection films for high performance photovoltaics

      doi: 10.1088/1674-4926/40/4/042601
      • 1.

        HKUST-Shenzhen Research Institute, Shenzhen 518057, China

      • 2.

        Department of Electronic and Computer Engineering, Hong Kong University of Science and Technology (HKUST), Hong Kong, China

      • 3.

        Computer, Electrical and Mathematical Sciences and Engineering, King Abdullah University of Science and Technology, Thuwai 23955-6900, Kingdom of Saudi Arabia

      More Information
      • Corresponding author: E-mail: eezfan@ust.hk
      • Received Date: 2019-01-22
      • Revised Date: 2019-03-17
      • Published Date: 2019-04-01

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