Energy efficient process for continuous production of thin semiconductor films on metallic substrates

#The present invention relates to semiconductor matrices which can be used in devices such as solar cells, diodes, electrifiers and transistors and the like and to methods of manufacturing such matrices from elemental semiconductors such as silicon and germanium.

#An extremely important use of the semiconductor matrices of the present invention is in a solar cell. Because of the rapid depletion of our natural energy sources, and the associated pollution problems with these sources, solar energy as a source of energy has become highly important. Solar energy is abundantly available in this country and can be utilized without ecological problems.

#Electricity can be directly generated from solar energy by the photovoltaic process whereby an electric current is generated when light is allowed to fall upon a rectifying contact or junction such as that contained in a solar cell. Photovoltaic solar cells are an expedient means of utilizing the virtually inexhaustable energy resource, incident solar radiation, to meet the growing worldwide demand for electric power.

#A detailed description of the invention will be made with the aid of the accompanying drawings wherein:

#FIG. 1 is a schematic view of a production line for fabricating a semiconductor matrix;

#FIG. 2 is a cross-sectional view of a semiconductor matrix.

#FIG. 1 shows a production line for the manufacture of a semiconductor matrix which could be used for solar cells, diodes, electrifiers, transistors and the like. The line begins with a thin metal sheet 10 of sufficient Young's Modulus and appropriate thickness to support its own weight in a half I Beam or channel-like configuration without excessive elastic deformation over the area of the desired semiconductor matrix and yet sufficient elastic limit to be coiled. The metal sheet is preferably steel or aluminum. This sheet is then continuously fed into the reaction system by a roller 12.

#If the substrate strip is steel, it should first be coated with aluminum. This aluminum may conveniently be applied with any of the techniques known to those of ordinary skill in the art. However, preferably an aluminum coating can be applied using the techniques of the present invention. In this embodiment, a hopper 14 containing aluminum trichloride electrolyte is used to apply the electrolyte to the surface of the substrate. The substrate coated with electrolyte is then contacted with an alkali metal anode 16 to deposite a layer of aluminum on the substrate.

#Strip 10 is then fed into the reaction system by rollers 18 and 20. The rollers are configured in a manner similar to a rolling mill operated with only sufficient force applied to the work piece to cause transport without plastic deformation although some elastic deformation may occur.