Method to form a photovoltaic cell comprising a thin lamina

Abstract

A very thin photovoltaic cell is formed by implanting gas ions below the surface of a donor body such as a semiconductor wafer. Ion implantation defines a cleave plane, and a subsequent step exfoliates a thin lamina from the wafer at the cleave plane. A photovoltaic cell, or all or a portion of the base or emitter of a photovoltaic cell, is formed within the lamina. In preferred embodiments, the wafer is affixed to a receiver before the cleaving step. Electrical contact can be formed to both surfaces of the lamina, or to one surface only.

1 . A photovoltaic module comprising:
 a receiver; and   a plurality of semiconductor laminae bonded to the receiver, wherein each semiconductor lamina is between about 1 and about 100 microns thick, wherein each semiconductor lamina comprises at least a portion of a base, or of an emitter, of a photovoltaic cell.   
     
     
         2 . The photovoltaic module of  claim 1  wherein each semiconductor lamina is between about 1 and about 20 microns thick. 
     
     
         3 . The photovoltaic module of  claim 2  wherein each semiconductor lamina is between about 1 and about 5 microns thick 
     
     
         4 . The photovoltaic module of  claim 1  wherein each semiconductor lamina is monocrystalline silicon. 
     
     
         5 . The photovoltaic module of  claim 1  wherein each semiconductor lamina is polycrystalline or multicrystalline semiconductor material. 
     
     
         6 . The photovoltaic module of  claim 1  wherein the plurality of semiconductor laminae comprises at least 12 laminae. 
     
     
         7 . The photovoltaic module of  claim 1  wherein the plurality of semiconductor laminae comprises at least 36 laminae. 
     
     
         8 . The photovoltaic module of  claim 1  wherein the receiver is a substrate. 
     
     
         9 . The photovoltaic module of  claim 1  wherein the receiver is a superstrate. 
     
     
         10 . The photovoltaic module of  claim 1  wherein each semiconductor lamina comprises a base of a photovoltaic cell. 
     
     
         11 . The photovoltaic module of  claim 1  wherein each semiconductor lamina comprises a base and an emitter of a photovoltaic cell. 
     
     
         12 . The photovoltaic module of  claim 11  wherein each semiconductor lamina consists essentially of monocrystalline silicon. 
     
     
         13 . The photovoltaic module of  claim 11  wherein each semiconductor lamina is less than about 5 microns thick. 
     
     
         14 . The photovoltaic module of  claim 1  wherein the receiver comprises glass. 
     
     
         15 . The photovoltaic module of  claim 1  wherein the receiver comprises metal. 
     
     
         16 . The photovoltaic module of  claim 1  wherein the receiver comprises a polymer.