A new type of a-Si/c-Si heterojunction solar cell, called the HIT (Heterojunction with Intrinsic Thin-layer) solar cell, has been developed based on ACJ (Artificially Constructed Junction) technology. A conversion efficiency of more than 18% has been achieved, which is the highest ever value for solar cells in which the junction was fabricated at a low temperature (<200°C).

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Polycrystalline silicon (poly-Si) thin films prepared by the solid phase crystallization (SPC) method were investigated for application as photovoltaic materials. To improve the properties of the poly-Si thin film, two methods were developed to control crystallization. One is the partial doping method, in which starting material of a-Si consists of a doped layer and an undoped layer. We have succeeded in controlling nuclei generation using partial doping, and high mobility of 196 cm2/V·s was obtained at a carrier concentration of 1×1018 cm-3. SPC temperature can also be decreased to 500°C. The other is adoption, for the first time, of a textured substrate which exerted effects on the enlargement of grain size in poly-Si thin films prepared by the SPC method. By combining the partial doping method with the textured substrate, an n-type poly-Si thin-film with the grain size of 6 µm was fabricated which showed the Hall mobility of 623 cm2/V·s (n: 3.0\times1015 cm-3). In a solar cell (thickness: 12 µm) applying this film, a conversion efficiency of 6.2% was obtained and a collection efficiency of 50% was achieved at a wavelength of 900 nm.

For further improvement of conversion efficiency in a-Si solar cells, it is necessary to develop materials with high photosensitivity in the long-wavelength region. A new solid phase crystallization (SPC) method was developed to grow a Si crystal at temperatures as low as 600°C. Using this method, high-quality thin-film polycrystalline silicon (poly-Si) with a Hall mobility of 70 cm2/V·s was obtained. Quantum efficiency in the range of 800 nm ∼ 1000 nm was achieved up to 80% in an experimental solar cell using the n-type poly-Si with a grain size of about 1.5 µm. Therefore, it was found that our SPC method was suitable as a new technique to prepare high-quality solar cell materials.

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