U.S. patent application number 16/890005 was filed with the patent office on 2020-12-03 for high efficiency graphene/wide band-gap semiconductor heterojunction solar cells.
The applicant listed for this patent is Dimerond Technologies, LLC. Invention is credited to Dieter M. Gruen.
Application Number | 20200381645 16/890005 |
Document ID | / |
Family ID | 1000005218666 |
Filed Date | 2020-12-03 |
![](/patent/app/20200381645/US20200381645A1-20201203-D00000.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00001.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00002.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00003.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00004.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00005.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00006.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00007.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00008.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00009.png)
![](/patent/app/20200381645/US20200381645A1-20201203-D00010.png)
View All Diagrams
United States Patent
Application |
20200381645 |
Kind Code |
A1 |
Gruen; Dieter M. |
December 3, 2020 |
High Efficiency Graphene/Wide Band-Gap Semiconductor Heterojunction
Solar Cells
Abstract
A photovoltaic solar cell apparatus is described herein
combining the advantages of several discoveries that address the
previously unsolved problem of creating high conversion efficiency
solar cells at a low cost. The solar cell designs and underlying
principals disclosed herein may be applied in any type of
photovoltaic solar power application, such as large scale
photovoltaic solar plants, rooftop panels, solar powered electronic
devices, and many others.
Inventors: |
Gruen; Dieter M.; (Downers
Grove, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dimerond Technologies, LLC |
Downers Grove |
IL |
US |
|
|
Family ID: |
1000005218666 |
Appl. No.: |
16/890005 |
Filed: |
June 2, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62937938 |
Nov 20, 2019 |
|
|
|
62924805 |
Oct 23, 2019 |
|
|
|
62856698 |
Jun 3, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 51/0045 20130101;
H01L 51/4266 20130101; H01L 51/442 20130101 |
International
Class: |
H01L 51/42 20060101
H01L051/42; H01L 51/00 20060101 H01L051/00; H01L 51/44 20060101
H01L051/44 |
Claims
1.-38. (canceled)
39. A photovoltaic solar cell apparatus comprising: a foil
substrate consisting essentially of zinc; a plurality of nanowire
cores on the foil substrate, the nanowire cores comprising zinc
oxide, wherein at least a majority of the nanowire cores are
substantially aligned to one another and extend generally
perpendicular to the foil substrate and electrically connected to
the foil substrate at a first end of the nanowire cores; a
substantially continuous coating of zinc oxide on the foil
substrate between the nanowire cores; a plurality of shells, each
comprising graphene, and each shell being conformally disposed
about a portion of a respective nanowire core to form a plurality
of nanowire core/shell structures; a first conducting electrode
electrically connected to the foil substrate and providing a first
electrical pathway to facilitate a movement of electrons away from
the nanowire cores; a second conducting electrode connected to
shells at a second end of the nanowire core/shell structures and
providing a second electrical pathway to facilitate a movement of
positive charges away from the shells; and the second conducting
electrode comprising a material that is at least partially
transparent to sunlight and at least one metal effective to reduce
the work function of the shells within at least a portion of the
partially transparent material.
40. The photovoltaic solar cell apparatus of according to claim 39,
wherein the shells are formed from at least one polyaromatic
hydrocarbon comprising at least one of coronene, naphthalene, and
terphenyl.
41. (canceled)
42. The photovoltaic solar cell apparatus according to claim 39,
characterized in that the photovoltaic solar cell has an
open-circuit voltage of between about 1.5 V and 3.6 V when
illuminated with 1 KW/m.sup.2 of AM 1.5G irradiation.
43. The photovoltaic solar cell apparatus according to claim 42,
characterized in that the photovoltaic solar cell has a short
circuit current density of at least 1 mA/cm.sup.2 when illuminated
with 1 KW/m.sup.2 of AM 1.5G irradiation.
44.-45. (canceled)
46. The photovoltaic solar cell apparatus according to claim 39,
wherein the shells comprise a substantially uniform single layer of
graphene.
47.-50. (canceled)
51. The photovoltaic solar cell apparatus according to claim 39,
wherein the nanowire cores include a dopant along at least a
portion of the longitudinal surface thereof.
52.-58. (canceled)
59. The photovoltaic solar cell apparatus according to claim 39,
wherein the at least one metal effective to reduce the work
function of graphene comprises one or more of silver, aluminum and
copper.
60. The photovoltaic solar cell apparatus according to claim 39,
wherein the material forming the second conducting electrode is
interspersed between the nanowire cores.
61. The photovoltaic solar cell apparatus according to claim 39,
wherein second conducting electrode comprises indium tin oxide
containing particles of silver.
62.-191. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional
Application No. 62/856,698, filed Jun. 3, 2019, U.S. Provisional
Application No. 62/924,805, filed Oct. 23, 2019, and U.S.
Provisional Application No. 62/937,938, filed Nov. 20, 2019, each
of which is hereby incorporated herein by reference in its
entirety.
FIELD
[0002] This application relates generally to the generation of
electricity using solar energy.
BACKGROUND
[0003] Various modalities of solar energy conversion are used in
the art. For example, prior systems employ photovoltaic junctions
in favor of converting sunlight directly into electricity. It is
also known to convert sunlight into heat and to then utilize that
heat to generate electricity. Conversion efficiency, for example,
varies amongst different modalities with many posited modalities
performing quite poorly and none achieving high conversion
efficiency. Those relative conversion efficiencies, in turn, quite
directly impact the return on investment an enterprise can expect
to receive for pursuing a given solar energy conversion system.
[0004] Photovoltaic production of electricity, now more than 600
gigawatts globally, is increasing exponentially and will reach one
terawatt in two or three years. Solar cells are made of a
semiconductor material, typically silicon in crystalline solar
cells. Traditionally, a solar cell has two layers: an n-type with a
high concentration of electrons, and a p-type with a relatively low
concentration of electrons. One side of a solar cell is "doped"
with a p type material such as boron, and the other side with an
n-type material such as phosphorous, creating a single p-n
junction. When sunlight hits the n-type layer, electrons are
dislodged from the n-region and flow through a circuit to the
p-region, creating an electrical current that can be captured and
used for power. Although non-equilibrium thermodynamic theory
predicts that solar cell conversion efficiencies could potentially
be as high as 86%, actually achieving higher efficiencies presents
difficult technical challenges, and solar cells approaching such
efficiencies are not now available.
[0005] Most solar cells in commercial production today are based on
this architecture of a single p-n junction of doped silicon sheets,
either monocrystalline or polycrystalline silicon. The solar
frequency spectrum approximates that of a black body at 5,800 K.
Much of the solar radiation reaching the Earth is composed of
photons with energies greater than the 1 V band gap of silicon,
which represents the minimum energy required to excite an electron
up to a state where it can participate in conduction. These photons
are absorbed by silicon, but their excess energy is converted to
heat rather than electrical energy. On the other hand, much of the
solar radiation is composed of photons in the infrared region of
the solar spectrum whose energies are below the band gap of
silicon. These cannot be absorbed by silicon thus further
decreasing the conversion efficiency of silicon solar cells. Due to
these limitations, today's solar cells consisting primarily of
silicon typically convert only about 15%-20% of the energy in
sunlight to electricity. Silicon solar panels are also less
effective at high temperatures. Heterojunction solar cells
consisting of a crystalline silicon cell sandwiched between two
layers of amorphous thin film silicon have been developed. The
additional layers allow more sunlight to be absorbed, allowing
efficiencies of 21% or slightly higher to be achieved.
[0006] Significant effort has been devoted to the development of
solar cells other than silicon that can overcome the deficiencies
discussed above. For example, multijunction solar cells are
reported to have the potential to reach conversion efficiencies of
about 45%. Such multi-junction solar cells are not made using
silicon as a semiconductor. Instead, materials like gallium indium
phosphide, indium gallium arsenide, and germanium are used to
create separate layers of semiconductors that all respond to
different wavelengths of incoming sunlight, making them more
efficient at converting sunlight into electricity than
single-junction cells. While they have the potential to be several
times more efficient than traditional solar cells, such designs are
complex and difficult to manufacture and, up to now, high
fabrication costs have prevented their being used for large scale
commercialization such as in roof-top or solar electric power plant
applications.
[0007] Another prior approach resulting from prior work of the
inventor hereof and disclosed in U.S. Pat. Nos. 8,586,999,
8,829,331, and 9,040,395 contemplates an array of nanowires
comprising a wide band gap material core coated with thin graphene
shells grown on a foil substrate and disposed with their
longitudinal axes oriented substantially coaxial and parallel to
anticipated light beams. These patents postulate that the solar
energy conversion efficiency is enhanced in the nanostructured
radial coaxial shell/core nanowire configuration over conventional
planar solar cell configurations clue to the strong light
absorption properties of the graphene and because electron
diffusion lengths are much shorter. Techniques for growing titanium
oxide or silicon carbide nanowire cores are also disclosed, as are
methods for coating such nanowires by high temperature treatment of
silicon carbide nanowires or by chemical vapor deposition using a
methane environment. These patents report an expected cell voltage
of the disclosed silicon carbide/graphene photovoltaic junction
solar cell of about 1 V under standard sunlight intensities, which
is only marginally higher than the voltage of conventional silicon
solar cells. Because a graphene-based photovoltaic junction can be
expected to maintain photovoltaic functionality at a useful level
of energy conversion at high temperatures that are inhospitable to
the functioning of photovoltaic deices that employ silicon or other
materials such as gallium arsenide, the patents focus on
co-generation applications in which such cells are deployed
adjacent a second high temperature second modality of solar energy
conversion.
[0008] The solar cell technology based on graphene coated nanowire
cores disclosed in the previously referenced patents does not fully
address the needs of the vast potential market for single modality
photovoltaic solar power generation, such as in photovoltaic solar
plants and rooftop solar panels. To overcome the shortcomings of
the conventional silicon based solar cell technology in those
applications, even greater conversion efficiencies are needed, as
are cost effective manufacturing procedures using readily available
materials. Therefore, the invention of affordable solar cells with
conversion efficiencies significantly higher than provided by
present day technology, and that can be economically manufactured
on a large scale, would substantially lower solar electricity costs
and facilitate a technological solution to the detrimental
environmental impact resulting from overreliance on fossil fuel
energy sources.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above needs are at least partially met through an
apparatus pertaining to high efficiency solar cells having nanowire
cores of a wide band gap material and graphene exteriors described
in the following detailed description, particularly when studied in
conjunction with the drawings, wherein:
[0010] FIG. 1 is a perspective view of a portion of a photovoltaic
solar cell having a plurality of nanowires;
[0011] FIG. 1A is a perspective view of one nanowire coated with a
shell, as found in FIG. 1;
[0012] FIG. 2 is a cross-sectional view of one form of a
photovoltaic solar cell;
[0013] FIG. 3 is a cross-sectional view of another form of a
photovoltaic solar cell having a masking layer;
[0014] FIG. 4 is a cross-sectional view of another form of a
photovoltaic solar cell having a multi-component electrode;
[0015] FIG. 5 is a top view of one form of a photovoltaic solar
cell;
[0016] FIG. 6 is a scanning electron microscope image of ZnO
nanowire cores grown on a foil substrate;
[0017] FIG. 7 is a scanning electron microscope image of ZnO
nanowire cores that have been coated with reduced graphene
oxide;
[0018] FIG. 8 is a scanning electron microscope image of ZnO
nanowire cores that have been coated with graphene using a
polyaromatic hydrocarbon;
[0019] FIG. 9 is Raman spectroscopy results for ZnO nanowire cores
that have been coated with reduced graphene oxide;
[0020] FIG. 10 is Raman spectroscopy results for ZnO nanowire cores
that have been coated with graphene using a polyaromatic
hydrocarbon;
[0021] FIG. 11 is a current versus voltage graph for a photovoltaic
solar cell having ZnO nanowire cores coated with reduced graphene
oxide and using a silver electrode in contact with the reduced
graphene oxide;
[0022] FIG. 12 is a current versus voltage graph for a photovoltaic
solar cell having ZnO nanowire cores coated with graphene from a
polyaromatic hydrocarbon and using an indium tin oxide electrode in
contact with the graphene;
[0023] FIG. 13 is a current versus voltage graph for a photovoltaic
solar cell having ZnO nanowire cores coated with graphene from a
polyaromatic hydrocarbon and using a silver electrode in contact
with the graphene;
[0024] FIG. 14 is a current versus voltage graph for a photovoltaic
solar cell having ZnO nanowire cores coated with graphene from a
polyaromatic hydrocarbon and using an electrode including silver
and indium tin oxide in contact with the graphene;
[0025] FIG. 15 is graph showing the results of annealing in an
oxygen environment on the sheet resistance of ZnO nanowires;
[0026] FIG. 16 is a graph of normalized current versus illumination
wavelength illustrating wavelength independence of the graphene
light absorption coefficient;
[0027] FIG. 17 is a graph of photo current versus two light
intensities differing by three orders of magnitude for a
photovoltaic solar cell having ZnO nanowire cores coated with
graphene; and
[0028] FIG. 18 is a scanning electron microscope image of ZnO
nanowire cores grown on a foil substrate showing both aligned and
"flower" type growth.
[0029] Elements in the figures are illustrated for simplicity and
clarity and have not necessarily been drawn to scale. For example,
the dimensions and/or relative positioning of some of the elements
in the figures may be exaggerated relative to other elements to
help to improve understanding of various embodiments of the present
invention. Also, common but well-understood elements that are
useful or necessary in a commercially feasible embodiment are often
not depicted in order to facilitate a less obstructed view of these
various embodiments of the present invention. Certain actions
and/or steps may be described or depicted in a particular order of
occurrence while those skilled in the art will understand that such
specificity with respect to sequence is not actually required. The
terms and expressions used herein have the ordinary technical
meaning as is accorded to such terms and expressions by persons
skilled in the technical field as set forth above except where
different specific meanings have otherwise been set forth
herein.
DETAILED DESCRIPTION
[0030] A photovoltaic solar cell apparatus is described herein
combining the advantages of several discoveries that address the
previously unsolved problem of creating high conversion efficiency
solar cells at a low cost. The solar cell designs and underlying
principals disclosed herein may be applied in any type of
photovoltaic solar power application, such as large scale
photovoltaic solar plants, rooftop panels, solar powered electronic
devices, solar powered satellites, outdoor lighting, and many
others.
[0031] The photovoltaic effect results in the production of
electricity measured in watts, the product of current and voltage.
The higher the current.times.voltage product, the higher the cell
conversion efficiency. Energy conversion efficiency is measured by
dividing the electrical power output by the incident light power.
Factors influencing output include spectral distribution, spatial
distribution of power, temperature, and resistive load. IEC
standard 61215 is used to compare the performance of cells at
terrestrial temperature: irradiance of 1 kW/m2. Specifically, a
spectral distribution close to that of solar radiation through AM
(airmass) of 1.5 and a cell temperature 25.degree. C. is taken.
[0032] The magnitude of the cell current is primarily due to the
light absorption properties of the cell material and the
illumination intensity. On the other hand, the measured cell
voltage is primarily due to the difference in what are called the
"quasi Fermi levels" of the majority charge carriers. In this
regard, the work function of a material is the minimum
thermodynamic energy needed to remove an electron from a solid to a
point in the vacuum immediately outside the solid surface. Work
functions can be measured experimentally and can be shown to be
directly related to the Fermi levels of the majority carriers. The
measured cell voltage is attributed to the effective work function
of the solar cell, which is the difference in the "work functions"
of the materials that constitute the photovoltaic junction of solar
cell.
[0033] New insights derived by the applicant based on an intensive
and prolonged study of the scientific principles of photovoltaics,
led the applicant to conclude that high conversion efficiency solar
cells should absorb the total solar spectrum to provide sizeable
short circuit currents while constituting materials capable of
exhibiting large differences in work function so as to be capable
of furnishing large open circuit potentials. The cell materials
should also allow effective charge separation at the heterojunction
to set the stage for a solar cell having conversion efficiencies
several times higher than offered by current technology. Although
these conclusions are far from self-evident, they are not a panacea
in and of themselves, for the choice of materials that would
constitute such cells and the elucidation of economical methods for
their fabrication present formidable challenges whose solutions are
not at all apparent. The solar cell apparatuses disclosed herein
are composed of materials chosen in such a way as to provide large
photocurrents at high photovoltages and possessing three or more
times the conversion efficiency of currently available solar cells.
The structure and performance of these novel cells as well as the
fabrication techniques required for their effective functioning are
described here in detail.
[0034] In one aspect, the apparatus can comprise, at least in part,
a foil substrate having a plurality of the coated nanowire cores
disposed thereon. The nanowire cores, such as including zinc oxide,
are capable of exhibiting large differences in work function
relative to the work function of the graphene or reduced graphene
oxide shells so as to be capable of furnishing large open circuit
potentials. To facilitate charge separation at the graphene-based
photovoltaic junction, a substantially continuous coating of a
nonconductive material, such as an insulator, is formed on the foil
substrate between the nanowire cores. The first conducting
electrode is electrically connected to the foil substrate to
provide an electrical pathway to facilitate a movement of electrons
away from the nanowire cores, and a second conducting electrode
connected to the shells at a second end of the nanowire core/shell
structures provides an electrical pathway to facilitate a movement
of positive charges away from the shells.
[0035] In another aspect, the photovoltaic solar cell apparatuses
herein are prepared by a method that utilizes a hydrothermal
synthesis process to form a plurality of nanowire cores, such as of
zinc oxide, on a foil substrate. In some approaches, at least a
majority of the nanowire cores are substantially aligned with one
another and generally perpendicular to the foil substrate. In one
form, the hydrothermal synthesis process forms a substantially
continuous insulator coating, such as of nonconductive zinc oxide
material, on the foil substrate between the nanowire cores. The
nanowire cores so formed may be subjected to a post-growth
annealing process to reduce structural defects at the surface of
the nanowires cores, which may be effective to improve the diode
properties of the nanowire array while also reducing its electrical
resistance.
[0036] In yet other aspects, efficient and effective methods are
provided for cladding a graphene-based material about a portion of
a respective nanowire core to form a photovoltaic junction. In a
preferred form of the solar cell apparatus disclosed herein, a
single layer of graphene, or no more than a few layers, surrounds
the zinc oxide nanowires. The outstanding performance of the solar
cell apparatus of this embodiment requires high quality and
uniformity of the ultrathin graphene cladding the zinc oxide
nanowires. A novel methodology is disclosed to accomplish this,
which involves forming the graphene shells by thermal conversion
from at least one polyaromatic hydrocarbon precursor. In another
approach, the cladding technique comprises surrounding the nanowire
cores with a solution containing graphene oxide followed by
thermally reducing the graphene oxide to form shells of reduced
graphene oxide conformally disposed about a portion of a respective
nanowire cores.
[0037] In one aspect, the graphene side facing away from zinc oxide
is in contact with a material that is effective to further lower
graphene's work function. In this manner, the difference in work
functions of the materials constituting the solar cells is
increased so as to increase the built-in potential that determines
the open cell voltage. Techniques for implementing this enhancement
are also disclosed herein. For example, the electrode in contact
with the graphene-based shells can be formed of a metal, such as
silver, that reduces the graphene work function when in contact
with graphene. In another form, such a metal is provided as a
colloidal suspension within a partially transparent conductive
material such as indium tin oxide, to form an electrode that serves
the dual functions of transferring electrical current and enhancing
the cell potential by reducing the graphene work function. So
configured, the solar cell apparatuses according to the invention
can achieve open circuit cell voltages significantly greater than
are attainable using conventional silicon based solar cell
designs.
[0038] These and other cladding methodologies are described in
detail below as are the unique and uniquely important
optoelectronic properties of the cells. Fabrication techniques,
contact doping of graphene, lowering of cell series resistance,
increasing work function differences and other matters pertaining
to maximizing the performance parameters of the new generation of
solar cells disclosed herein are detailed below. Further, while
reference may be made to zinc oxide in many areas herein, it should
be appreciated that other wide band-gap materials may be used in
the alternative and/or in combination with zinc oxide in certain
forms.
[0039] Turning to more of the details and as generally shown in
FIGS. 1-4, a schematic of a nanowire core-shell radial
heterojunction solar cell is shown. Referring more specifically to
FIG. 1, one illustrative example of a solar cell device 20 is
provided. The device 20 includes a plurality of nanowire cores 22
having a coating 24 thereon. In one form, the coating 24 extends
over the tops of the nanowire cores 22, such as illustrated at
reference 26. FIG. 1A shows an enlarged view of a portion of one
nanowire core 22 and coating 24.
[0040] The device 20 also includes a first electrode 30 and a
second electrode 32. In one form, the first electrode 30 includes a
substrate 34, which may be provided for growing the nanowire cores
22. The first electrode may include any number of additional
materials and layers so as to improve overall electron transport
and/or decrease resistance. For example, the first electrode 30 may
include a contact layer 36 for providing suitable contact between
the substrate 34 and other components in the first electrode 30 or
elsewhere in the solar cell 20. The first electrode may also
include a collector 38, such as used to collect and transfer
electrons at the first electrode 30.
[0041] The second electrode 32 may similarly include one or more
different materials and/or layers. The second electrode 32 is
generally provided so as to allow light and/or photons to pass
through at least a portion of the electrode 32. As shown in FIG. 1,
the second electrode 32 is in the form of strips or other
interconnected designs so as to allow light and/or photons to pass
in-between. In other forms, the second electrode can include at
least a portion that is transparent, translucent, and the like.
[0042] In one form, the device 20 includes an insulating layer 40
at the ends of the nanowire cores adjacent the first electrode 30.
The insulating layer 40 generally prevents the coating 24 from
contacting the substrate 34 and/or portions of the first electrode
30. If the coating 24 were to contact the first electrode, it could
cause a short circuit in the solar cell.
[0043] FIG. 2 illustrates a side view of the solar cell device 20.
As shown in this figure, light, as represented by arrow 50, passes
at least partially through the second electrode 32 to interact with
the coating 24.
[0044] FIG. 3 illustrates a similar solar cell device 52 as shown
in FIG. 2. In device 52, the substrate 34 and/or first electrode 30
include a masking layer 54. Masking layer 54 may be used
temporarily, such as during manufacture, or permanently, to prevent
nanowire cores 22 from growing on all sides of the substrate. The
specifics of masking layer 54 and use thereof will be discussed in
further detail below.
[0045] FIG. 4 illustrates another form of solar cell device 60.
This device 60 includes an electrode component 62 that can be used
as part of and/or in conjunction with the second electrode 32. The
electrode component 62 can include a material that is at least
partially transparent and/or translucent. The electrode component
62 can be placed on the second electrode 32, below the second
electrode 32 and/or at least partially extend beyond the second
electrode 32 to contact the coating 24. For example, in the form of
a masked second electrode 32 as shown in FIG. 1, the electrode
component 62 can pass between the spaces in the second electrode
32. Further, the electrode component 62 can extend along the length
of the nanowire 22 and coating 24 to provide further contact
therebetween. The electrode component 62 and use thereof will be
discuss in more detail below.
[0046] There are a variety of different materials that may be used
in the solar cells described herein. In general, the coating(s)
comprise graphene and graphene related materials. For example, the
coating may comprise generally a single layer of graphene or a few
layers of graphene. In other forms, the coating material may
comprise reduced graphene oxide. In this regard, depending on the
application method, multiple layers of reduced graphene oxide
typically result as the coating.
[0047] Graphene consists of a single layer of carbon infinitely
extended in two dimensions. The chemical bonds between the carbon
atoms are very similar to those in graphite. Graphene has an
electronic structure that imparts unique optical and electrical
properties not found in any other material. Importantly, graphene
absorbs light more strongly than any other material and does so
independent of wavelength throughout the entire solar spectrum.
Unsupported graphene has no bandgap and electrons behave as if they
were massless fermions. At the so-called Dirac point, coincident
with the Fermi level, the density of quantum states is zero.
Because electrons move with a velocity that is a sizeable fraction
of the velocity of light, graphene follows the dictates of quantum
electrodynamics rather than quantum mechanics.
[0048] The nanowire cores may also include a variety of different
materials. For example, a variety of wide bandgap materials may be
used. Such wide bandgap materials may include, but are not limited
to, zinc oxide, boron, titanium, silicon borides, carbides,
nitrides, oxides, or sulfides, combinations thereof, and the like.
Wide band-gap material will be understood to refer to a material
having a valence band and a conduction band that differ by at least
two volts. In one form, zinc oxide may be especially suitable for
at least some of the techniques and combinations of materials
discussed herein.
[0049] Zinc oxide possesses outstanding optoelectronic properties.
For example, density functional calculations have shown that there
is a strong attractive potential, enhanced with nanowires, between
zinc oxide and graphene due to a dipole induced dipole
electrostatic interaction accompanied by only a small degree of
electron transfer. This "contact" interaction profoundly changes
certain of graphene's electronic properties such as the work
function while leaving the desirable electronic structure and other
electronic properties such as the Dirac point of graphene intact.
It turns out that the work function of wide bandgap ZnO (3.37 eV)
is also very surface sensitive and increases by up to 2.8 eV when
placed in contact with selected substances. Thus, the work function
of graphene decreases while that of zinc oxide increases as a
result of contact between the two materials allowing graphene to
function as a photoactive material. The work function changes are
due to a redistribution of charge that occurs when graphene comes
into contact with ZnO, with the graphene interacting with ZnO in
just the requisite manner, perhaps because its ambipolarity allows
it to act as an electron acceptor.
[0050] The solar cell devices disclosed herein were developed to
test the conjecture that, based on these theoretical
considerations, the resulting large difference in work functions
might make the graphene/ZnO junction favorable for charge
separation. The results disclosed herein of the experimental tests
undertaken to test those conjectures confirm that graphene/ZnO
heterojunctions are in fact capable of giving rise to large
photocurrents as well as photovoltages and are good candidate
materials for a new generation of high conversion efficiency solar
cells.
[0051] As elucidated more fully in the discussion below, the
applicant has developed a novel heterojunction solar cell
architecture and related fabrication methods based on a p-n
junction, such as in the form of zinc oxide nanowires radially clad
with a single layer or up to a few layers of graphene or reduced
graphene oxide. The ZnO nanowires provide for a high voltage and
facilitate current transport, and the graphene material absorbs the
entire spectrum of sunlight and creates the current as electrons
are accelerated into the ZnO nanowire cores. The graphene material
is contact charged by the redistribution of electric charge at the
graphene-ZnO interface, resulting in an increase of the work
function of ZnO and a decrease of the work function of graphene.
The "effective work function" of the solar cell, constituting the
difference in the work functions of the materials forming the p-n
junction of the cell, is therefore increased and consequently the
solar cells operate at significantly higher voltage levels than
have previously been achieved in silicon based or other prior solar
cell architectures.
[0052] As further described and demonstrated below, the present
teachings enable the production of photovoltaic solar cells
displaying an open cell voltage in excess of 2.4 V and as high as
at least 3.5 V. With optimizations related to improve series
resistance, coating uniformity and recombination kinetics, the
disclosed architecture should provide photocurrent levels resulting
in conversion efficiencies that far surpass that of cells used in
present day photovoltaic installations.
[0053] In one approach, the nanowire cores are formed of a material
that effectively distributes charge to graphene upon contact,
resulting in increasing the material's work function while reducing
the work function of graphene. Suitable core materials may also
have an attractive potential with graphene causing them to be
catalysts for the thermal decomposition and simultaneous conversion
of one or more aromatic hydrocarbon precursors to form one or more
layers of the graphene shell cladding the nanowires. The
shells/coating 24 comprise a graphene material, which, in a
preferred form, comprises graphene or reduced graphene oxide, and
are preferably conformally disposed about at least a substantial
portion of the cores 22. As used herein this reference to
"substantial portion" will be understood to refer to an amount
disposed about more than fifty percent of the nanowire surface
area. Generally speaking, a viable solar cell will comprise a
plurality of such nanowire cores 22 that each have a shell 24 of a
graphene material disposed thereabout.
[0054] In one approach, the nanowire cores comprise zinc oxide. In
other forms, zinc oxide constitutes about 50 to about 100% of the
nanowire cores. As used herein, "consist substantially of" a
material will be understood to refer to an amount in excess of
fifty percent. In one form, the nanowire cores consist
substantially of zinc oxide such that at least fifty percent of the
nanowire cores is zinc oxide. The reference to the core 22
consisting essentially of a material will be understood to refer to
a core 22 that is largely pure in these regards but which can
include trace impurities and dopants, for example,
purposefully-introduced n-type or p-type dopants designed to elicit
desired electrical properties.
[0055] The nanowires are generally arranged on the foil such that
they extend therefrom in a generally transverse manner. In a
preferred form, the nanowires can be disposed so that at least a
majority of the nanowires have their longitudinal axes
substantially aligned to one another and extend generally
perpendicular to the foil. As used in these regards, "substantially
aligned" will be understood to mean within twenty-five degrees and
"generally perpendicular" will be understood to mean extending at
an angle of between 70 degrees to about 110 degrees relative to the
substrate. In particular, by one approach these longitudinal axes
are also oriented substantially coaxial and parallel to anticipated
light beams.
[0056] The bottoms of the resulting nanowire nanostructures are
attached to the foil substrate 34, thus electrically connecting all
of the cores 22. The tops of the nanowires carry layers of a
coating, such as the graphene material, that are in electrical
contact with all of the coaxial shells 24 surrounding the nanowire
cores 22. The growth process thus automatically creates a solar
cell nanostructure that provides separate electrical connections to
cores 22 and shells/coatings 24.
[0057] The thickness of these shells/coating of graphene material
24 can vary with the application setting. To maximize the cell
voltage, however, the thickness is preferably from about one layer
to a few layers. Accordingly, for many purposes the thickness of
the shell 24 is very thin. Generally speaking, when employed in a
photovoltaic setting, the number of layers need be no more than are
required to achieve a particular amount of light absorption. It
will be presumed herein that the shell 24 has an essentially
uniform thickness for a given object but these teachings will
accommodate variations in these regards if desired and/or as
appropriate to the needs of a given application setting. For
example, in some application settings it can be useful if the shell
24 has no more than about ten layers of the graphene material. In a
preferred form the graphene material is graphene that is
substantially 1 atom thick and in other forms the thickness ranges
from 1-3 layers thick along the length of a nanowire. When the
graphene material is reduced graphene oxide (r-GO), the preferred
thickness is 2-10 layers thick.
[0058] By one approach, dark current and majority carrier transport
can be minimized by preventing contact of the coaxial graphene
material shells 24 with the foil substrate 34. This can be
accomplished, for example, by chemical vapor deposition of a
monolayer or multilayers of an insulator 40 in the spaces between
the nanowire cores 22 prior to depositing the graphene material
shells 24. Alternatively, the insulator layer 40 may be formed
during hydrothermal growth of the nanowire cores themselves, as is
described further below.
[0059] A solar cell apparatus in accordance with the design
illustrated in FIG. 1 and utilizing an array of ZnO nanowires can
take advantage of the unique optoelectronic properties of ZnO
nanowires. Bulk ZnO is an insulator and although it is possessed of
a quite sizeable electron mobility, it has generally been
considered unsuitable as a solar cell material due to its
relatively high resistivity. Nonetheless, bulk ZnO displays a very
limited electron transport due to surface electrical conductivity.
By structuring the ZnO in the form of nanowires, the surface
electrical conductivity is vastly enhanced, presumably because the
surface to volume ratio of the nanowire form is orders of magnitude
larger than that of the bulk form. Compared to bulk ZnO, nanowires
of this material are quite good electrical conductors.
[0060] Single layer graphene absorbs 2.3% of solar radiation and
does so independent of wavelength from the infrared to the
ultraviolet regions of the spectrum. The ZnO nanowires are
preferably clad uniformly along their entire length with graphene
to insure optimal absorption of solar radiation. In order for
single layer graphene cladding to absorb all of the incident solar
radiation, the graphene clad area must exceed the linear area by at
least a factor of 43. By cladding nanowires with graphene, the
graphene area exposed to sunlight is easily increased by two orders
of magnitude compared to the "linear" area of the cell itself. In
one aspect, the nanowire diameters and aspect ratios are chosen so
as to fulfill this requirement. Thus, the nanowires that comprise
the nanowire cores may have a longitudinal length in excess of many
hundreds of nanometers. For example, the length of the nanowires
can range from about 5 to about to about 25 micrometers, and the
length of the individual nanowires may vary somewhat in a given
solar cell. The length of the nanowires can be adjusted by changing
the concentration of the starting materials. The cross-sectional
diameters of the nanowires are preferably from about 40 to about
500 nanometers, although these teachings will accommodate nanowires
of other diameters. The nanowire cores may be characterized by an
aspect ratio (length divided by diameter) of from about 10 to about
250.
[0061] The creation of such core/shell axial heterostructures
allows absorption of the total solar flux on a substantially
reduced "linear" area of solar cell material. Each one of the vast
numbers of such nanowires present in such a photovoltaic device
comprises a unique structure that individually acts as an effective
nantenna and optical rectifier. Calculations for cylindrical
nanowires of radius twenty nanometers show that total light
absorption occurs for nanowire lengths of about four hundred
nanometers (which is, in turn, in the range of the wavelengths of
visible light). Each nanowire can therefore be seen to
simultaneously possess both the light (electromagnetic wave)
gathering power of an antenna and the rectifying properties of a
photovoltaic device.
[0062] The areal density of the nanowires may also be optimized to
manipulate the optical and electrical performance of the solar cell
devices according to the teachings herein. In this regard, areal
density may be characterized as the number of nanowires per area of
substrate, or as the proportion of the substrate area occupied by
nanowires. The areal density may be determined, for example, from
measurements of nanowire diameter and distance between nanowires
obtained from SEM images of the nanowire array.
[0063] The areal density of the nanowires may be controlled by
manipulating factors such as the chemistry of the precursor
solution, temperature at which the nanowires are grown,
concentration of the nucleation species used, surface roughness and
crystallinity of the seed layer, and other conditions, as is
understood by those skilled in the art of hydrothermal growth of
nanowire arrays. In one form, the nanowires are grown such that
there is a high areal density of nanowires thereon. It is generally
preferable that the nanowire array be as dense as possible to
maximize the power output per area of the solar cell device.
However, if the areal density is too high, coating the nanowires
uniformly with graphene along a substantial portion of their
lengths becomes more difficult. The density and spacing of the
nanowires should be as high as possible while leaving sufficient
spacing to be able to coat with graphene and such that the adjacent
coated nanowires do not contact one another so as to prevent short
circuiting the solar cell. In one form, the areal density, in terms
of the percentage of the substrate area in contact with the grown
nanowires prior to coating with graphene, is approximately 10% to
about 80%, though it may be more, if appropriate.
[0064] Hydrothermal synthesis processes to form ZnO nanowire arrays
on many different metal foils are understood by those skilled in
the art. The foil substrate can thus comprise a variety of metals,
including, for example, zinc, aluminum, steel, or copper, to note
but a few examples in these regards. The thickness of the foil can
vary with the application setting. For many purposes, the thickness
of the foil is very thin to make the solar cell apparatus flexible
so that it can cover surfaces of a variety of shapes. Generally
speaking, however, a thicker foil will have greater strength. For
many applications, the foil is thin enough to be flexible yet thick
enough to avoid being torn or ruptured in use. These teachings will
accommodate variations in the selection of foil material and the
foil thickness if desired for cost or other reasons and/or as
appropriate to the needs of a given application setting.
[0065] By one approach, the substrate is provided as a zinc foil
and a hydrothermal synthesis process is used to form an array of
substantially aligned zinc oxide nanowires to serve as the nanowire
cores 22. The ZnO nanowires need to be in ohmic contact with the
first electrode. In one approach, this can be accomplished using
hydrothermal synthesis on zinc metal foil using an aqueous solution
of zinc acetate and hexamine. The presence of hexamine
(hexamethylenetetramine) promotes highly anisotropic growth
conditions because of selective capping of the non-polar ZnO
crystallographic planes. As one illustrative example in these
regards, but without intending to suggest any particular
limitations in these regards, aligned ZnO nanowires can be grown
using an aqueous solution of 50 mM zinc acetate and 50 mM hexamine
in contact with 100 micron thick zinc foil at 90 degrees centigrade
for 4 hours. Using this approach, nanowires were 100 to 200 nm in
diameter and 10 to 15 microns in length, and a substantially
continuous coating of a nonconductive zinc oxide formed on the foil
substrate between the ZnO nanowire cores.
[0066] In another approach, ZnO nanowires could be grown at
elevated temperatures using water as a source of oxygen, such as
used in the process of zinc galvanization. In yet another form, a
seed layer can be used to grow the nanowires.
[0067] FIG. 6 is a field emission scanning electron microscope
image taken from one end of a ZnO nanowire array formed in this
manner. The nanowires have a hexagonal cross-sectional geometry and
are substantially aligned along their longitudinal axis. Inelastic
scattering-based Raman vibrational spectroscopy analysis of such
ZnO nanowires is presented in the lower portion of FIG. 9. The E2
vibration mode peak at 438.78 cm.sup.-1 of the lower curve is
indicative of substantially pure ZnO.
[0068] If the hydrothermally grown nanowires are too long, their
ends may diverge outwardly in a characteristic "flower" growth
pattern shown in the center region of the FESEM image of FIG. 18.
Although not necessarily detrimental to the cell performance, this
is preferably avoided as it may increase the difficulty of coating
the nanowires uniformly with graphene.
[0069] In order for the foil to function as an electrode, one side
should be protected from nanowire growth. This can be accomplished
by protecting one side with a polymer film or coating, prior to
forming the nanowire array, such as shown as masking layer 54 in
FIG. 3. The protective polymer coating is subsequently removed,
typically after cladding of the nanowires with the graphene
material, such as by dissolution using one of a number of different
organic solvents. In one form, this technique was deployed using
polymethylmethacrylate (PMMA) to protect one side of a Zn foil from
ZnO nanowire growth. Any alternative plastic coating or film
capable of withstanding the temperature conditions of the nanowire
growth and cladding steps can be used.
[0070] An alternative method for preventing the growth of nanowires
on both sides of a foil is to double the foil so that two sides
touch. Growth solution is prevented from reaching the protected
sides allowing growth of nanowires to occur exclusively on the two
exposed sides. After cladding the nanowires with a graphene
material, the doubled foil is restored to its single foil form.
[0071] The power output of a solar cell being a function of
current, it is preferable to minimize the series resistance of the
cell. Series resistance in a solar cell is a combination of the
resistance to current flow through the emitter and base of the
solar cell, the contact resistance between the electrodes and the
materials of the photovoltaic junction, and the resistance of the
electrodes. The sheet resistance of the nanowire array is a
principal contributor to the series resistance of the solar cells
disclosed herein. Sheet resistance is used to characterize the
resistance to current flow along the surface of a sheet, not
perpendicular to it.
[0072] By one approach the nanowires 22 can be subject to a
post-growth annealing process to thereby reduce surface defects and
increase the surface conductivity thereof in a controlled way. The
annealing procedure may consist of heating the nanowire/foil
composites in an oxygen atmosphere or by using other conventional
techniques. FIG. 15 shows the effect of annealing of ZnO nanowire
arrays in an oxygen atmosphere at 350.degree. C. for up to eight
hours prior to cladding with graphene. The nanowire array of
approximately 1 cm.sup.2 was formed and its sheet resistance was
measured directly by using a conventional four-point probe
measuring device. The sheet resistance had decreased substantially
after 2 hours of annealing and by up to two orders of magnitude
after 8 hours.
[0073] Further decrease in series resistance will result in a
proportionate increase in photocurrent. It is believed that this
may be achieved by annealing at temperatures higher than
350.degree. C. For example, such higher temperature annealing can
be performed despite zinc's relatively low melting point (about
420.degree. C.) by contacting the zinc foil substrate with copper
foil to form brass by diffusion raising the melting point and
allowing the further reduction of surface defects on the zinc oxide
nanowires at the higher temperature conditions.
[0074] Post-growth annealing may also improve the diode properties
of the nanowires. As will be appreciated, the p-n junction formed
by cladding graphene radially about a ZnO nanowire functions as a
diode that conducts current primarily in one direction. The ZnO
starts out as an n-type semiconductor, but when in contact with
graphene material the ZnO transfers excess electrons to the
graphene and the graphene becomes an n-type region that contains
negatively charged electrons and ZnO becomes a p-type region that
contains positive charge carriers. As is confirmed by experimental
investigations presented in more detail below, the graphene coating
absorbs photons of sunlight and a flow of electrons occurs from the
graphene to the ZnO.
[0075] The impact of oxygen annealing has also been shown to
significantly improve the cell rectification factor. In this
regard, the cell rectification factor is understood to refer to the
ratio of the forward to the reverse current. In one study performed
for the r-GO/ZnO heterostructure before and after 02 annealing for
8 hours at 400.degree. C., the rectification factor increased from
0.52 to 1.82 (4-fold increase), indicating a much higher forward
current than the reverse saturation current. Having a good
rectification factor influences the ideality of the fabricated
diode for optoelectronic applications. Lower reverse saturation
currents are preferred to avoid leakage current and less observed
voltage under solar insolation.
[0076] In another aspect, doping of the nanowire cores 22, such as
by addition of dopants to the growth solution, may be used to
increase the electrical conductivity thereof in a controlled way as
one technique for reducing the series resistance of the solar cell
apparatus. In one aspect, one or more dopants are included along at
least a portion of the longitudinal surface thereof. Dopants may
include, but are not limited to at least one of aluminum, indium,
chlorine, and gallium. Such an approach to doping can help to
optimize the characteristics of the junction between the nanowire
cores and the coating, such as the graphene-zinc oxide junction, to
yield a solar cell that displays maximum efficiency with respect to
converting light to electricity.
[0077] After formation and any subsequent annealing and/or doping
steps, the aligned zinc oxide nanowires 22 can be exposed to a
cladding procedure to deposit a graphene material along the
longitudinal surfaces in the spaces between the wires as well as on
the top surfaces of the nanowire cores 22 themselves. By one
approach, this coating or shell 24 may consist primarily of reduced
graphene oxide and/or graphene and comprises, for example, from a
few layers to no more than about ten layers in thickness. For
example, Hummers method (W. S. Hummers and R. E. Offeman, JACS
1958) can be used to synthesize few layer micrometer sized flakes
of graphene oxide (GO) to be used as a cladding for the ZnO
nanowires. Graphite is treated using well-known procedures
involving nitric and sulfuric acids together with KClO3 or KMnO4 as
oxidizing agents to make graphene oxide (GO).
[0078] Cladding of the ZnO nanowires may proceed by drop-casting an
aqueous suspension of graphene oxide onto an array of aligned ZnO
nanowires, followed by heating to a temperature of about
300.degree. C. in a hydrogen environment for about 2 hours. Various
other methods such as drop, dip and spin coating can alternatively
be used to surround the nanowires with graphene oxide. The GO
flakes are reduced thermally by heating in a hydrogen atmosphere.
Some oxygen remains in substitutional sites yielding reduced
graphene oxide, a disordered form of a few layers of graphene. The
uniformity of the cladding is enhanced by adding isopropyl alcohol
or acetone as wetting agents to the aqueous suspension prior to
drop-casting. In order to prevent short circuits from occurring, it
is desirable that the reduced graphene oxide does not come in
contact with the Zn foil or substrate carrying the ZnO
nanowires.
[0079] Other methods for surrounding the ZnO nanowires with a thin
coating of r-GO are also possible. For example, known methods for
solubilizing r-GO flakes to form a solution or to make a colloidal
suspension of r-GO flakes can be used so that the nanowire coating
process can be performed from a solution. In such an approach, the
solution or stable colloidal suspension of r-GO flakes is applied
to the nanowires and the solvent allowed to evaporate with optional
heating to remove impurities. Alternatively, such an approach can
be used to coat the nanowires with graphene from a solution of
graphene nanoflakes.
[0080] FIG. 7 is a field-emission scanning electron microscopy of
hydrothermally grown and oxygen annealed ZnO nanowires coated with
r-GO. The FESEM topography characterization showed an approximate
length of about 10 microns which were vertically aligned with some
horizontal wires residing on top of the parallel vertically ordered
ZnO nanowires. The cladding of r-GO is clearly observed as a
transparent thin layer wrapping around ZnO nanowires and covering
the top surface as well as yielding good interfacial contacts with
the semiconductor. The coated nanowires are more round compared to
the hexagonal uncoated nanowires, indicating that the r-GO coating
is several layers thick.
[0081] Raman vibrational spectroscopy analysis was also carried out
to illustrate the existence of both ZnO cores and r-GO shells in
the co-axial hetero-architecture. One such spectra is presented in
the top spectra in FIG. 9. The ZnO samples showed the corresponding
ZnO peaks E.sub.2.sup.low and E.sub.2.sup.high due to in-plane
vibrations of Zn--O bonds. The r-GO/ZnO heterostructure exhibited
the in-plane vibrations-based E peaks as well as the A peaks
attributed to out-of-plane vibrations of Zn--O bonds. Moreover, the
defect-induced "D" and graphitic "G" modes where observed in the
r-GO/ZnO nanocomposite indicating the presence of r-GO.
[0082] The r-GO clad ZnO nanowire heterojunction photovoltaic cells
with a silver electrode patterned as generally shown in FIG. 1 in
contact with the r-GO in accordance with the principles disclosed
have attained open circuit voltage of up to about 2.4 V, which is
significantly higher than that possessed by any previously single
junction solar cell of which the applicant is aware. By comparison,
the open cell voltage of silicon based solar cells typically does
not exceed 0.6 V. The current density vs. voltage profile of five
such cells illuminated with 1 KW/m.sup.2 of AM 1.5G irradiation is
presented in FIG. 11. As will be appreciated, AM 1.5G is a
standardized light spectrum that approximates overall yearly
average solar irradiance for mid-latitudes in the United States and
is used by the solar industry for standardized testing or rating of
terrestrial solar cells or modules. (The latest AM 1.5G standards
pertaining to photovoltaic applications are reflected in ASTM G-173
and IEC 60904.) The current and voltage profile was generated by
use of a standard Keithley Source Meter. The observed differences
between the current density and voltage profiles of the individual
cells are likely attributable to factors such as variance of the
r-GO coating uniformity and/or of the dimensions and density of the
nanowires.
[0083] The large open-circuit voltage (i.e., the voltage when
overall current flow through the solar cell is zero) observed can
be rationalized based on a very large work function increase
reaching 2.8 eV that occurs when ZnO is in intimate contact with a
strong electron acceptor. Graphene, because of its amphoteric
character, can serve in this capacity with ZnO acting as the
electron donor. Owing to the interfacial charge transfer between
r-GO and ZnO, the ZnO donates electrons to graphene. Therefore, the
work function of ZnO increases about 1 eV and for r-GO it
decreases. Upon illumination, photons generate excitons (bound
electron-hole pairs) in the exterior r-GO shell and exciton
dissociation take place at the heterojunction due to the existing
built-in electric potential. The electrons transport from the low
work function graphene to the large work function ZnO.
[0084] The investigations underlying the disclosure herein have
also confirmed that graphene functions as the photoactive element
by following the photocurrent as a function of wavelength. As shown
in FIG. 16, the normalized photocurrent (i.e., the current
corrected for sensitivity of the phototube measuring device)
generated from the heterostructure is substantially constant over a
broad wavelength range from 200 to 1100 nm. This indicates that
exciton generation takes place in r-GO since ZnO does not absorb
light in the visible region of the spectrum. The r-GO can absorb
all the sunlight energies corresponding to a UV-Vis-1R wavelength
ranging from 200 to 1100 nm and into the IR. The maximum absorption
for r-GO occurs at 290 nm which is located in a UV region; however,
most of sunlight energy is actually in the visible region and can
only be absorbed by r-GO in the ZnO/r-GO heterostructure.
[0085] Since the normalized current data shows a stable
photogenerated normalized current of 0.6-0.7 from 200 to 1100 nm,
one may conclude that uniform r-GO clad ZnO nanowires result in
solar energy absorption across the whole solar spectrum to generate
observed wavelength independent photocurrents. The use of ZnO
nanowires without graphene cladding would not yield a significant
photo current due to the fact that ZnO is a wide-band gap
semiconductor (3.37 eV) requiring sunlight in the ultraviolet part
of the spectrum to photoexcite ZnO orbital electrons from the
valence to the conduction band in order to generate electron-hole
pairs. Since essentially all of the solar spectrum lies at energies
lower than the ultraviolet, the electron excitation to form
electron/hole pairs occurs essentially only in graphene. Charge
separation occurs at the junction of graphene with ZnO yielding
photocurrent at a cell voltage up to 2.4 V.
[0086] The experimental results displayed in FIG. 17 show that the
magnitude of the photocurrent is linearly dependent on light
intensity over a range of three orders of magnitude. With the AM
1.5G light source a photocurrent of 4.14 pA is generated compared
to a photocurrent of 3.46 nA produced when using monochromatic
light. The AM 1.5G light source includes all wavelengths of the
solar spectrum. Its intensity was measured to be three orders of
magnitude higher than the light intensity of the monochromatized
source.
[0087] Yet another aspect of the invention involves enhancing the
open cell potential by contacting at least a portion of the outer
surface of the coating or shells, such as r-GO shells (i.e. the
surface facing away from the ZnO cores), with a material that
functions as an electron donor to graphene. In one preferred
aspect, the electron donor material may also function as a current
gathering electrode. Such an electrode may be formed, for example,
by depositing a paste of silver nanoparticles through a patterned
mask that had been placed on the r-GO terminated surface of the
cell. In the illustrated embodiment of FIG. 1, the metal is
patterned as a series of spaced, elongated fingers extending
perpendicularly from a bus bar, which allows for sufficient surface
contact between the metal and the r-GO shells. A prototype of a 1
cm.sup.2 cell is displayed as FIG. 5, which shows the top of the
cell with a silver layer contacting the top surface of the r-GO
coated ZnO nanowire array. Sunlight illuminates the graphene by
penetrating between the narrow silver fingers. The metal layer may
be provided in other geometries that can similarly function to
create a surface contact with the r-GO shells while allowing
sufficient sunlight penetration. In this way advantage is taken of
the substantial photon absorption characteristics of the nanowire
array clad with r-GO that constitutes important constituents of the
solar cell device.
[0088] Silver acts both as an n-type contact dopant and as an
electrode. The silver electrode was effective to increase in the
open circuit potential to about 2.4 V. While not wishing to be
limited to any theory, this effect may be the result of a similar
redistribution of charge between the metal and r-GO resulting in
contact charging that decreased the work function of the r-GO
shells by an amount that corresponds to the observed increase in
the cell open circuit potential. As discussed below, this effect
has also been demonstrated in alternative embodiments having shells
of substantially single layer pure phase graphene produced from
polyaromatic precursors. Indeed, by judicious contacting of the
single layer graphene/ZnO nanowire/silver composite the open
circuit voltage was found to have been increased to 3.5 V. Further,
it is believed similar improvements can be made with other nanowire
core materials as well as by using other electron donor contact
charging materials that can simultaneously function as
electrodes.
[0089] Thus, by one approach, both sides of the graphene-based
shells are used to lower the graphene work function and thereby
increase the open cell potential. In such embodiments, the graphene
coating or cladding is in essence being charged by two "plates" to
develop giant built-in potential. Although the significant
performance benefit of this important discovery has been
demonstrated using silver, other metals such as aluminum, copper,
and others in reducing the work function of graphene by donating
electrons to graphene. In addition, materials such as ZnO could
also be used as the contact charging material in the double contact
charging configuration disclosed herein. The teachings herein will
enable those skilled in the art to identify other suitable
alternative contact charging materials by comparison of cell
voltage measurements of solar cells made with and without the
candidate material in contact with the graphene material
shells.
[0090] The arrangements for implementation of double contact
charging are not limited to contacting the electron donor with the
ends of the nanowires as illustrated in FIG. 1. For example, the
electron donor may alternatively be arranged so as to contact
positions along the length of the nanowire. Combinations of these
approaches may also be effective. According to another aspect,
described in more detail below, the chosen charging material is
incorporated within another material, such as an organic or
inorganic transparent electrode conductive material, that functions
as the electrode for the graphene side of the photovoltaic
junction.
[0091] Turning back to approaches for cladding the ZnO nanowire
cores in accordance with the disclosure herein, in another
approach, the nanowires are clad with an ultra-thin coating,
consisting of single layer to no more than a few layers, of
graphene. Polyaromatic hydrocarbons (PAH) such as coronene,
pentacene, naphthalene and others thermally decompose on metals
such as copper to form single layer graphene at modest
temperatures. It was not known, however, whether similar results
could be obtained with ZnO nanowires. Additional investigations
have led to the discovery of techniques utilizing these precursors
that are effective to deposit one to a few layers of essentially
pure phase graphene substantially uniformly along substantial
portions of the outer surface of the ZnO nanowires.
[0092] As an illustrative example of this newly developed cladding
technique, coronene was dissolved in tetrahydrofuran and drop-cast
onto ZnO nanowire arrays hydrothermally grown on Zn foil. These
assemblies were heated in an argon atmosphere at temperatures
between 200.degree. C. and 400.degree. C. for one to two hours. A
thin layer of this solution in contact with ZnO decomposes to form
graphene and the remainder evaporates.
[0093] With reference to FIG. 10, Raman spectroscopic examination
revealed that thermal decomposition had indeed resulted in the
formation of high-quality graphene as evidenced by G/D band
intensity ratios of about 2.0. Electron microscopy images of the
clad nanowires, such as the image displayed in FIG. 8, show that
the hexagonal facets of the nanowires are preserved suggesting that
growth of single layer graphene has occurred. The discovery
disclosed herein of a solution to overcoming the difficult
challenge of cladding with graphene billions or even trillions of
densely packed nanowires has significant implications for the
commercial scale production of high efficiency solar cell devices.
It is believed that the very strong attractive potential of about 1
V that has been shown by theoretical density functional
calculations to exist between graphene and ZnO lowers the
activation energy for the transformation of PAHs to graphene and
becomes, in a sense, the driving force for the reaction. The ZnO
surface can be thought of as functioning as a catalytic surface for
the reaction enabling the formation of an ultrathin layer of
graphene on a nanowire structure, and at temperatures as low as
200.degree. C. The reaction is self-limiting because once the
graphene layer forms on the surface it remains there rather than
leaving the ZnO surface to allow the next PAH molecule to be
catalyzed. While the above description uses ZnO, it is believed
that other wide band gap nanowire core materials may also be
suitable for use in this manner.
[0094] Based on the insights derived from this work, other aromatic
molecules, such as substituted benzenes, are also believed to be
suitable precursors to clad ZnO nanowires with an ultrathin coating
of from one to a few layers of graphene according to the teachings
herein. This technique is also adaptable to nanowires formed of
other materials that exhibit attractive potential with graphene, as
can be identified by theoretical density functional
calculations.
[0095] This disclosure of a technique for coating high density
nanowire arrays with an ultrathin coating of graphene has
significant implications for the production of high efficiency
solar cells. The open circuit voltage of such graphene clad ZnO
nanowire solar cells was observed to be about 1.9 V under 1
KW/m.sup.2 of AM 1.5G illumination, even without contact charging
the graphene with a metal electrode to decrease its work function.
In combination with a silver electrode in contact with the graphene
shells, open cell potentials as high as 3.5 V were observed. The
higher cell potentials achieved in such solar cell devices compared
to those clad with r-GO are believed to be due to the higher
graphene quality of single or few layer graphene produced from
polyaromatic hydrocarbons. Since contact charging is an
electrostatic phenomenon, charges transferred from the metal layer
are distributed over a single rather than over several layers of
graphene. The transferred charge can therefore be expected to
result in a higher graphene charge density. In this way, the
built-in potential is increased resulting in the observed increase
in the open circuit potential.
[0096] The ultrathin graphene coating obtained by thermal
transformation of polyaromatic hydrocarbons decreases the width of
the junction to about 2-3 angstrom compared to about 8-9 angstrom
for ZnO nanowires clad with several layers of r-GO. This, in
addition to higher graphene quality, may be another reason for the
superior functioning of single layer graphene in this photovoltaic
device.
[0097] In yet another aspect, graphene shells may be doped to
further control the graphene work function. In particular, doping
the shells with n-type dopant such as nitrogen, by heating in an
ammonia atmosphere for example, or other n-type dopant, can further
reduce the work function of the graphene by at least 0.5 V, which
may enhance the open circuit potential even more. It should also be
kept in mind that it is unlikely that the open circuit voltage to
exceed the band-gap of the material constituting the nanowire
core.
[0098] The creation of a graphene-based nanocomposite photovoltaic
device displaying an open circuit voltage as high as 3.5 V enables
a new class of potentially high efficiency solar cells. In addition
to high open circuit voltage, high short circuit currents are
necessary to achieve high power conversion efficiency. As discussed
above, since current flows on the surface of the ZnO nanowires, the
current density can be enhanced by controlling the nanowire growth
conditions to increase the surface to volume ratio of the nanowires
by reducing their diameter.
[0099] Another factor believed to affect the short circuit currents
of devices fabricated in accordance with the disclosure herein
relates to electron/hole recombination kinetics. Exciton lifetimes
in have been reported to not exceed a few femtoseconds in pristine
graphene. Recombination kinetics could strongly compete with
electron transport across the heterojunction. To address this, an
appropriate dopant may be found which act to increase exciton
lifetimes and thus increase the photocurrent. The inclusion of one
or more of such dopants in the graphene or r-GO shells can result
in more favorable electron/hole recombination kinetics and increase
the photocurrent produced by the disclosed solar cell devices.
[0100] In another aspect, the photocurrent performance of the solar
cell device may be optimized by the inclusion of conductive
material to establish electrical contact between the nanowires.
Transparent conducting oxides such as indium tin oxide (ITO), or
ZnO based conducting transparent oxides or sulfides, for example,
can be effective for this purpose and may be disposed between the
nanowires. Indium tin oxide was chosen because it is readily
available. It was deposited as a thin film by drop coating.
Alternatively, thin films of indium tin oxide can be deposited by
many other techniques such as spray coating, or spin coating,
physical vapor deposition, electron beam evaporation, or a range of
sputter deposition techniques. Other suitable optically transparent
conductors include conductive organic polymers such as
polyethylenedioxythiophene polystyrene sulfonate (PEDOT:PSS) and
many others, which may be deposited in organic solvents or in
aqueous suspensions.
[0101] The conducting material may be located on top of the cell to
form all or part of the counter electrode, and/or in the
interstitial space between the graphene or r-GO clad nanowires of
the array. In another study, a very substantial decrease in series
resistance was achieved by drop casting a suspension of nanometric
indium oxide/tin oxide in isopropanol on the top graphene
terminated surface of the nanowire array. In this way electrical
contact was established between graphene clad ZnO nanowires. The
resulting impact on cell performance is discussed with respect to
the experimental results described further below.
[0102] In another aspect, the transparent conductive electrode
material may include a metal effective to reduce the graphene work
function, to thereby enhance both the voltage and current density
performance of the cell. For example, a colloidal suspension of
nanoparticles of silver in ITO is applied to the graphene nanowire
array to form the electrode and improve the charge mobility within
the array. Alternatively, the silver or another metal may be
applied to the graphene coated nanowire array followed by drop
casting a suspension of ITO to fill the space between nanowires and
form a top conductive layer of the solar cell.
[0103] Additional experimental results demonstrating the
effectiveness of the principles disclosed herein in optimizing the
photovoltaic properties of the radial heterojunction solar cells
disclosed herein will now be discussed. FIG. 12 shows the current
density versus voltage profile for a cell having a core-shell
heterojunction of graphene wrapped ZnO wires grown on zinc foil and
coated by hydrothermal decomposition of coronene. In this
particular cell, a copper electrode was in electrical contact with
the zinc substrate. ITO was deposited between the nanowires and
over the top of the cell to increase the electrical contact between
the nanowires and provide the counter electrode for the graphene
coating. Each line represents measurements taken by contacting at
different points of the cell under 1 KW/m.sup.2 of AM 1.5G
illumination. The data shows that the cell displayed an open cell
voltage as high as about 1.9 V and a short circuit current density
in the low mA/cm.sup.2 range. These results show that the surface
interaction between the ZnO and the ultrathin substantially pure
phase graphene coating generates large cell potentials even without
contact doping the opposite side of the graphene.
[0104] FIG. 14 displays the corresponding current density versus
voltage profile for a photovoltaic cell of a construction similar
to that of the cell corresponding to FIG. 12, except that a silver
electrode was applied to the nanowire array and the ITO was
deposited over the silver electrode. The open cell voltage
increased significantly to about 3.5 V, owing at least in part to
the effect of silver in decreasing the work function of the
graphene shells and thereby increasing the difference between the
work functions of the graphene and ZnO components of the
heterojunction.
[0105] Further investigations of the effectiveness of the ITO in
increasing the photocurrent were performed by constructing a cell
having a graphene wrapped ZnO wire array supported on zinc foil,
and a patterned silver electrode in place of the ITO electrode of
the previously described embodiment. The current density versus
voltage profile for this cell is shown in FIG. 13. While the cell
displayed an open cell voltage of about 3.2 V, its short circuit
current density was significantly lower than that achieved in the
cell with ITO corresponding to FIG. 14. The significantly higher
current density shown in FIG. 14 is at least partially attributed
to the effect of the ITO.
[0106] While the principles disclosed herein have been demonstrated
with regard to solar cells using ZnO nanowire cores, these
teachings are extendable to other wide band gap nanowire materials,
for example, boron, titanium, silicon borides, carbides, nitrides,
oxides, or sulfides. Wide band-gap material will be understood to
refer to a material having a valence band and a conduction band
that differ by at least two volts. The materials best suited for
generating the highest solar cell potentials are those functioning
to contact charge graphene and exhibiting a large attractive
potential with graphene so as to catalyze the formation of single
layer graphene shells according to the disclosed aromatic
hydrocarbon decomposition method. By additionally contact charging
of the opposite surface of the graphene shell using an electron
donor material as disclosed herein, and the use of a transparent
conductive material as an electrode material for the graphene side
of the photovoltaic junction, a variety of high voltage solar cells
capable of significantly greater conversion efficiencies then
previously known designs may be provided.
[0107] In summary, energy favorable, surface-based, and radial
heterojunction solar cells made up of graphene 2D layer and ZnO 1D
nanowires have been disclosed. This novel solar cell architecture
has been experimentally shown to be capable of producing an open
circuit photovoltage in the range of 2.4 V to 3.5 V under AM 1.5G
illumination. While the reported experimental results show short
circuit currents in the low milliampere range, the broader
teachings herein will enable the production of solar cells having
short circuit currents of at least 10 mA, and likely as high as 25
mA. The creation of a solar cell structure displaying an open
circuit voltage as high as 3.5 V makes it feasible, with additional
optimizations directed to increasing the photocurrent into the
range just mentioned, to achieve solar cell energy conversion
efficiencies of at least 50%. The upper limit for the conversion
efficiency remains at 85% as found determined by non-equilibrium
thermo-dynamics. This is far superior to the maximum conversion
efficiency of about 20% for commercially available multicrystalline
silicon solar cells. Furthermore, the disclosed fabrication methods
can be readily deployed in full-scale commercial production at a
fraction of the cost of high efficiency multijunction cells based
on exotic materials such as gallium arsenide or indium selenide,
which are presently available only in low volumes at very high
price points.
[0108] Techniques to increase the photocurrent of solar cells are
known in the art, and other principles for generating higher
currents within the embodied solar cell devices have been disclosed
herein. For example, as demonstrated in FIGS. 13 and 14,
application of the transparent conductor ITO increased the
generated photocurrent by three orders of magnitude. Selecting the
optimum transparent conducting material, or adding colloidal metal
particles to increase the electrical conductivity of the ITO, can
yield even higher photocurrents. Optimizing the distribution of the
transparent conductive material throughout nanowire array can also
improve the results. Annealing of the nanowires to reduce surface
defects has also been shown to reduce the cell resistance.
Improvements to the annealing process, such as the higher
temperature annealing techniques described herein, are also
expected to reduce the resistance further and yield higher
photocurrents. In addition, controlling the diameter and areal
density of the nanowires to optimize the available electron
conducting ZnO surface area can increase the current density. One
or more of these techniques, or other generally known approaches
for enhancing the cell conductivity, will enable the production of
high voltage solar cells having comparatively high conversion
efficiencies, achieving significantly shorter energy payback times
than conventional solar energy systems.
[0109] The discovery of cost-effective high conversion efficiency
solar cells disclosed herein has enormous beneficial consequences
for humanity far into the future. The sun provides enough energy in
one hour to satisfy the energy requirements of the entire global
population for a year. Cheap solar power will hasten the day when
the sun fulfills its destiny to become the global energy
source.
[0110] In some forms, it was desired to devise a PV cell that lends
itself to large scale economical manufacture using non-resource
limited environmentally benign materials. In some forms, this may
be achieved by employing hydrothermal growth of ZnO nanowires clad
with graphene, a pure carbon material. Going from the laboratory
sized prototype to large scale development so as to satisfy the
world-wide multi-terawatt need for electricity is a challenging
engineering task that is not without precedent. In some forms, the
features described herein may be suitable for achieving these
goals.
[0111] The novel PV cells described herein can be flexible and
readily conform to surfaces of very complex shapes. It is believed
that extremely cost-effective retrofitting of the existing PV
plants soon to generate one terawatt of solar electricity can be
accomplished. Instead of one terawatt, between three and four
terawatts of solar electricity could be produced at very low cost
by taking advantage of trillions of dollars already invested in PV
installations both as central station plants and as distributed
power modules on roof tops.
[0112] The flexibility conferred by virtue of using a metal foil
substrate opens the door to new markets for PV power generation.
For example, the roofs of automobiles may be cited as an obvious
application. Other uses and implementations may also be
utilized.
[0113] Those skilled in the art will recognize that a wide variety
of modifications, alterations, and combinations can be made with
respect to the above described embodiments without departing from
the scope of the invention, and that such modifications,
alterations, and combinations are to be viewed as being within the
ambit of the inventive concept.
* * * * *