Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting....

Polymers for 3D Printing and Customized Additive Manufacturing

The efficiency of silicon solar cells has a large influence on the cost of most photovoltaics panels. Here, researchers from Kaneka present a silicon heterojunction with interdigitated back contacts reaching an efficiency of 26.3% and provide a detailed loss analysis to guide further developments.

Silicon heterojunction solar cell with interdigitated back contacts for a photoconversion efficiency over 26

The photovoltaics of organic–inorganic lead halide perovskite materials have shown rapid improvements in solar cell performance, surpassing the top efficiency of semiconductor compounds such as CdTe and CIGS (copper indium gallium selenide) used in solar cells in just about a decade. Perovskite preparation via simple and inexpensive solution processes demonstrates the immense potential of this thin-film solar cell technology to become a low-cost alternative to the presently commercially available photovoltaic technologies. Significant developments in almost all aspects of perovskite solar cells and discoveries of some fascinating properties of such hybrid perovskites have been made recently. This Review describes the fundamentals, recent research progress, present status, and our views on future prospects of perovskite-based photovoltaics, with discussions focused on strategies to improve both intrinsic and extrinsic (environmental) stabilities of high-efficiency devices. Strategies and challenges regardi...

Halide Perovskite Photovoltaics: Background, Status, and Future Prospects

Perovskite solar cells typically comprise electron- and hole-transport materials deposited on each side of a perovskite active layer. So far, only two organic hole-transport materials have led to state-of-the-art performance in these solar cells1: poly(triarylamine) (PTAA)2–5 and 2,2ʹ,7,7ʹ-tetrakis(N,N-di-p-methoxyphenylamine)-9,9ʹ-spirobifluorene (spiro-OMeTAD)6,7. However, these materials have several drawbacks in terms of commercialization, including high cost8, the need for hygroscopic dopants that trigger degradation of the perovskite layer9 and limitations in their deposition processes10. Poly(3-hexylthiophene) (P3HT) is an alternative hole-transport material with excellent optoelectronic properties11–13, low cost8,14 and ease of fabrication15–18, but so far the efficiencies of perovskite solar cells using P3HT have reached only around 16 per cent19. Here we propose a device architecture for highly efficient perovskite solar cells that use P3HT as a hole-transport material without any dopants. A thin layer of wide-bandgap halide perovskite is formed on top of the narrow-bandgap light-absorbing layer by an in situ reaction of n-hexyl trimethyl ammonium bromide on the perovskite surface. Our device has a certified power conversion efficiency of 22.7 per cent with hysteresis of ±0.51 per cent; exhibits good stability at 85 per cent relative humidity without encapsulation; and upon encapsulation demonstrates long-term operational stability for 1,370 hours under 1-Sun illumination at room temperature, maintaining 95 per cent of the initial efficiency. We extend our platform to large-area modules (24.97 square centimetres)—which are fabricated using a scalable bar-coating method for the deposition of P3HT—and achieve a power conversion efficiency of 16.0 per cent. Realizing the potential of P3HT as a hole-transport material by using a wide-bandgap halide could be a valuable direction for perovskite solar-cell research. A double-layered halide architecture for perovskite solar cells enables the use of dopant-free poly(3-hexylthiophene) as a hole-transport material, forming stable and scalable devices with a certified power conversion efficiency of 22.7 per cent.

Efficient, stable and scalable perovskite solar cells using poly(3-hexylthiophene)

Recent developments in photovoltaic materials have led to continual improvements in their efficiency. We review the electrical characteristics of 16 widely studied geometries of photovoltaic materials with efficiencies of 10 to 29%. Comparison of these characteristics to the fundamental limits based on the Shockley-Queisser detailed-balance model provides a basis for identifying the key limiting factors, related to efficient light management and charge carrier collection, for these materials. Prospects for practical application and large-area fabrication are discussed for each material.

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Photovoltaic materials: Present efficiencies and future challenges

The experimentally observed dependence of effective surface recombination velocity Seff at the Si‐SiO2 interface on light‐induced minority carrier excess concentration is compared with theoretical predictions of an ‘‘extended Shockley–Read–Hall (SRH) formalism.’’ The calculations of SRH‐recombination rates at the Si‐SiO2 interface are based on the theory of a surface space charge layer under nonequilibrium conditions and take into account the impact of illumination level, gate metal work function, fixed oxide charge density, and the energy dependence of capture cross sections σn, σp and interface state density Dit. Applying this theory to p‐type silicon surfaces covered by high quality thermal oxides, the experimentally observed strong increase of Seff with decreasing minority carrier excess concentration could quantitatively be attributed to the combined effect of the σn/σp ratio of about 1000 at midgap and the presence of a positive fixed oxide charge density Qf of about 1×1011 charges/cm2. Due to the f...

Impact of illumination level and oxide parameters on Shockley–Read–Hall recombination at the Si‐SiO2 interface

In order to utilize the full potential of solar cells fabricated on n-type silicon, it is necessary to achieve an excellent passivation on B-doped emitters. Experimental studies on test structures and theoretical considerations have shown that a negatively charged dielectric layer would be ideally suited for this purpose. Thus, in this work the negative-charge dielectric Al2O3 was applied as surface passivation layer on high-efficiency n-type silicon solar cells. With this front surface passivation layer, a confirmed conversion efficiency of 23.2% was achieved. For the open-circuit voltage Voc of 703.6mV, the upper limit for the emitter saturation current density J0e, including the metalized area, has been evaluated to be 29fA∕cm2. This clearly shows that an excellent passivation of highly doped p-type c-Si can be obtained at the device level by applying Al2O3.

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High efficiency n-type Si solar cells on Al2O3-passivated boron emitters

From today's viewpoint future solar cells will be thinner, of higher efficiency and produced in greater numbers. A solar cell concept able to fit these developments could be the passivated emitter and rear cell. With a new laser-based process (laser-fired contacts), the rear point contact pattern of this concept can be implemented industrially. After the deposition of a dielectric passivation layer and a metal layer on top, a Nd-YAG laser is used to alloy the contact points through the dielectric layer. Excellent efficiencies have been achieved which approach closely those of reference cells processed by photolithography. This demonstrates the high potential of the new laser-based technique. Copyright © 2002 John Wiley & Sons, Ltd.

Laser‐fired rear contacts for crystalline silicon solar cells

A method for spatially resolved measurement of the minority carrier diffusion length in silicon wafers and in silicon solar cells is introduced. The method, which is based on measuring the ratio of two luminescence images taken with two different spectral filters, is applicable, in principle, to both photoluminescence and electroluminescence measurements and is demonstrated experimentally by electroluminescence measurements on a multicrystalline silicon solar cell. Good agreement is observed with the diffusion length distribution obtained from a spectrally resolved light beam induced current map. In contrast to the determination of diffusion lengths from one single luminescence image, the method proposed here gives absolute values of the diffusion length and, in comparison, it is much less sensitive to lateral voltage variations across the cell area as caused by local variations of the series resistance. It is also shown that measuring the ratio of two luminescence images allows distinguishing shunts or surface defects from bulk defects.

Diffusion lengths of silicon solar cells from luminescence images

The minority carrier lifetime in boron-doped oxygen-contaminated Czochralski (Cz) silicon is strongly reduced under illumination or carrier injection. This process can be fully reversed by a 200 °C anneal step. In several recent studies it was shown that boron and oxygen are the major components of the underlying metastable Cz-specific defect. The energy level of the defect in its active state A was determined to be around midgap [Schmidt et al., J. Appl. Phys. 86, 3175 (1999)] while the energy level of the defect in its passive state P is very shallow. The Cz-specific defect in its passive state can be identified with the shallow thermal donor. The kinetics of the excess carrier-induced transformation from state P to state A can be described using recombination-enhanced defect reaction theory. On the basis of these experimental facts different solutions for the reduction or elimination of the metastable defect are suggested. Two promising solutions are discussed in more detail: the use of gallium-doped C...

Stefan W. Glunz

Papers

Impact of illumination level and oxide parameters on Shockley–Read–Hall recombination at the Si‐SiO2 interface

High efficiency n-type Si solar cells on Al2O3-passivated boron emitters

Laser‐fired rear contacts for crystalline silicon solar cells

Diffusion lengths of silicon solar cells from luminescence images

Minority carrier lifetime degradation in boron-doped Czochralski silicon