1. Introduction
Minimizing optical reflection at dielectric interfaces is a fundamental challenge,
and is vital for many applications in optics. It is well known that normal-incidence
reflection at a specific wavelength can be minimized using a single layer coating
with quarter-wavelength optical thickness and refractive index , where n
1 and n
2 are the refractive indices of the ambient and substrate, respectively.
However, a material with the required refractive index may not exist, and
additionally, omni-directional and broadband antireflection characteristics are
often required for applications such as solar cells or image sensors.
Several methods exist that allow the tuning of refractive index for optical thin
films. Alternating layers of a high-index and low-index material, each with
thickness much less than the wavelength, produces a film that can be treated as
homogenous with refractive index approximated by the volume ratio of the two
constituent materials [
1
W. H. Southwell, “Coating design using very thin high-
and low-index layers,” Appl. Opt.
24, 457–460
(1985). [CrossRef] [PubMed]
]. By changing the relative thickness of each layer, the
effective refractive index of the film can be varied between that of the two
materials. Oblique-angle deposition can also be used to control the refractive
index; in oblique-angle deposition, self-shadowing results in the formation of a
nano-porous film of high optical quality [
2–4
J.-Q. Xi, J. K. Kim, and E. F. Schubert, “Silica nanorod-array films with very
low refractive indices,” Nano Lett.
5, 1385 (2005). [CrossRef] [PubMed]
]. The refractive index is related to the
porosity of the film, and can be varied by changing the deposition angle. At
deposition angles close to 90°, the porosity becomes large and the index
decreases to low values. The nano-porous material is termed low-refractive-index
(low-
n) material. Using SiO
2, refractive indices as
low as 1.05 have been reported [
4
J.-Q. Xi, M. F. Schubert, J. K. Kim, M. Chen, S.-Y. Lin, W. Liu, and J. A. Smart, “Optical thin-film materials with low
refractive index for broadband elimination of Fresnel
reflection,” Nature Photon.
1, 176–179
(2007).
]. A third method to create a film with specific refractive
index is co-sputtering, in which two materials such as SiO
2 and
TiO
2 are simultaneously deposited. The refractive index can be tuned by
varying the relative deposition rates of the two materials.
The ability to tune the refractive index is crucial in enabling broadband and
omni-directional antireflection coatings. Such coatings generally consist of
multilayer stacks in which the refractive index is graded between substrate value
and that of air. Using the appropriate refractive index is critical in achieving the
best performance. In addition, the inclusion of layers with refractive index close
to that of air can greatly reduce reflection, and is impossible using bulk materials [
4
J.-Q. Xi, M. F. Schubert, J. K. Kim, M. Chen, S.-Y. Lin, W. Liu, and J. A. Smart, “Optical thin-film materials with low
refractive index for broadband elimination of Fresnel
reflection,” Nature Photon.
1, 176–179
(2007).
]. Well-known refractive index profiles for antireflection
coatings include the quintic or modified-quintic profiles, which are continuous
functions that vary between the substrate refractive index and the index of the
ambient material [
5
W. H. Southwell, “Gradient-index antireflection
coatings,” Opt. Lett.
8, 584–583
(1983). [CrossRef] [PubMed]
,
6
D. Poitras and J. A. Dobrowolski, “Toward perfect antireflection
coatings: 2. Theory,” Appl. Opt.
43, 1286–1295
(2004). [CrossRef] [PubMed]
]. However, these profiles do not give the optimum profile
when a finite number of layers is used. Additionally, these profiles require
high-refractive-index transparent materials - which often do not exist - to be
matched to high-refractive-index substrates, such as silicon. Finally, material
dispersion is not considered although it may play a significant role, particularly
for broadband applications.
Optimization of multilayer antireflection coatings is difficult because of the high
cost of evaluating the performance for a given structure. In addition, the parameter
space generally includes many local minima, which makes deterministic optimization
schemes that find the local minima unsuitable [
7
H. Greiner, “Robust optical coating design with
evolutionary strategies,” Appl. Opt.
35, 5477–5483
(1996). [CrossRef] [PubMed]
]. To meet these challenges, genetic algorithms have
previously been applied in order to optimize a variety of optical coatings [
7–10
H. Greiner, “Robust optical coating design with
evolutionary strategies,” Appl. Opt.
35, 5477–5483
(1996). [CrossRef] [PubMed]
]. Genetic algorithms mirror biological
evolution in which the fitness of a population is increased by the processes of
selection, crossover, and mutation. In the work presented here, we apply a genetic
algorithm to optimize antireflection coatings for silicon image sensors, silicon
solar cells, and triple-junction Ge/GaAs/GaInP solar cells with air as the ambient
medium. The calculations consider coatings composed of co-sputtered and
low-
n materials and take material dispersion into account.
2. Numerical approach
Calculations begin with the generation of a population of antireflection coatings
with a fixed number of layers whose thicknesses and compositions are randomly
generated. A layer may be composed of either nano-porous SiO
2 or any
combination of SiO
2/TiO
2, corresponding to low-n and
co-sputtered films, respectively. The porosity of SiO
2 is limited to 90%,
corresponding to a refractive index of 1.05, which has previously been demonstrated [
4
J.-Q. Xi, M. F. Schubert, J. K. Kim, M. Chen, S.-Y. Lin, W. Liu, and J. A. Smart, “Optical thin-film materials with low
refractive index for broadband elimination of Fresnel
reflection,” Nature Photon.
1, 176–179
(2007).
]. For each member of the population, the largest thicknesses
are matched to compositions with the lowest refractive index, and then sorted so
that the high-index layers are adjacent to the substrate. This increases the
population near the optimum antireflection coating - which is also expected to have
monotonically decreasing refractive index and increasing thickness when moving away
from the substrate - and reduces the computation time.
After the population has been formed, the fitness of each member is evaluated. The
fitness is determined by the reflection coefficient averaged over the wavelength
range and angle range of interest, Rave
, which is given by,
where
RTE
and
RTM
are the TE and TM reflection coefficients. In practice, the fitness
function may easily be modified to give greater weight to certain angles of
incidence or to certain wavelengths to take into account the responsivity of a
particular solar cell, the solar spectrum, or the orientation of a solar cell with
respect to the sun, in order to maximize the power produced by a solar cell, for
example. The fittest member of the population is the one with lowest average
reflection coefficient. The method for calculating the reflection coefficients of a
multilayer stack was described by Born and Wolf [
11
M. Born and E. Wolf, Principles of Optics
(Pergamon, Oxford,
1980).
]. The population is sorted by fitness, and a percentage of
the worst members are then discarded. These are replaced by the offspring of two
other antireflection coatings, which are selected at random from the remaining
members of the population. Offspring antireflection coatings are generated by a
process of crossover and mutation. In crossover, a set of layers for the new
offspring is taken from one parent, and the remainder is taken from the second
parent. In mutation, the composition and thickness of each layer is given a random
perturbation. Once the worst members of the population have been replaced by new
offspring, the fitness of each is evaluated, and the process repeats until good
convergence is achieved. Finally, using a deterministic algorithm, the local minima
near the fittest member of the population is found.
3. Silicon image sensor
Silicon image sensors are widespread in digital cameras, and generally capture light
in the visible wavelength range. Low reflection from the sensor surface is desirable
to increase the absorbed light and decrease the noise in the resultant image. The
reflection coefficient should also be low over a wide range of incident angles;
depending upon lens configuration, the angle of incidence of light on the sensor
surface can vary. Strong angular dependence of reflection can produce undesirable
vignetting. Finally, the reflection coefficient must be consistently low across the
entire visible wavelength range of 400 to 700 nm.
Figure 1 shows the reflection coefficient of bare silicon and
optimized one- and three-layer antireflection coatings as a function of wavelength
and incident angle. The reflection for bare silicon is high throughout the range of
wavelengths and angles. The single-layer coating has a minimum near
λ=540 nm at small angles of incidence, where the
reflection coefficient is below 0.5%, and reduced reflection coefficient values
throughout the range compared to bare silicon. The three-layer coating has three
distinct minima which combine to give reflection coefficients less than 2% for the
majority of wavelengths and incident angles; for optimized antireflection coatings
for the silicon image sensor, the number of local minima in reflection is equal to
the number of layers used. The layer compositions and thicknesses of these optimized
coatings are listed in
Table 1. Layer thicknesses and compositions should be within
several percent of the specified values in order to achieve performance similar to
the given structure. In the optimized antireflection structures for the silicon
image sensor, generally about half of the layers are composed of nano-porous
low-
n SiO
2. The same is true for antireflection
coatings optimized for other applications, as will be shown later. This finding
underscores the importance of low-
n materials in achieving high
performance antireflection coatings.
The reflection coefficient as a function of layer number for optimized coatings is
shown in
Fig. 2. The reflection coefficient initially decreases
rapidly as more layers are added, and then becomes almost constant. The angle- and
wavelength-averaged reflectivity of the three- and four-layer antireflection
coatings are similar at 4.4% and 3.9%, respectively; the top layers of the three-
and four-layer antireflection coatings each are composed of 90% porous
SiO
2 - which gives the lowest allowed refractive index, while the bottom
layers of both coatings are pure or nearly-pure TiO
2 - which gives the
highest achievable refractive index. As mentioned above, the three- and four-layer
coatings also have similar reflection coefficients. This is a general characteristic
for antireflection coatings: once a sufficient number of layers is used so that the
optimum stack contains layers with both the highest and lowest allowed refractive
index, increasing the layer number further has only a small effect on the reflection
coefficient.
Fig. 1. Reflection coefficient of (left) silicon and optimized (center) one- and
(right) three-layer antireflection coatings for silicon image sensors versus
wavelength and incident angle.
Table 1. Thickness t (in nm) and composition c of
individual layers for optimized silicon image sensor antireflection
coatings. (CS=co-sputtered layer, NP=nano-porous low-n
layer)
| 1-layer | 2-layer | 3-layer | 4-layer |
|---|
|
t
1
| 68.4 | 327.7 | 362.8 | 293.4 |
|
t
2
| - | 65.6 | 91.9 | 115.6 |
|
t
3
| - | - | 42.7 | 75.4 |
|
t
4
| - | - | - | 41.7 |
|
c
1
| CS, 36% TiO2
| NP, 14% SiO2
| NP, 10% SiO2
| NP, 10% SiO2
|
|
c
2
| - | CS, 42% TiO2
| CS, 4% TiO2
| NP, 35% SiO2
|
|
c
3
| - | - | CS, 98% TiO2
| CS, 15% TiO2
|
|
c
4
| - | - | - | CS, 100% TiO2
|
Fig. 2. Angle- and wavelength-averaged reflection coefficient as a function of the
number of layers for optimized antireflection coatings for a silicon image
sensor.
4. Silicon solar cell
The silicon solar cell is one of the most widespread technologies for photovoltaics;
the relevant spectral range for this application is 400 to 1100 nm. One or two-layer
antireflection coatings and surface texturing are common methods used to reduce
reflection from the surface and increase efficiency [
12
H. Nagel, A. G. Aberle, and R. Hezel, “Optimized antireflection coatings
for planar silicon solar cells using remote PECVD silicon nitride and porous
silicon dioxide,” Prog. Photovolt: Res.
Appl.
7, 245–260
(1999). [CrossRef]
,
13
E. Vazsonya, K. De Clercq, R. Einhaus, E. Van Kerschaver, K. Said, J. Poortsmans, J. Szlufcik, and J. Nijs, “Improved anisotropic etching process
for industrial texturing of silicon solar cells,”
Sol. Energy Mater. Sol. Cells
57, 179–188
(1999). [CrossRef]
]. Using the genetic algorithm approach, antireflection
coatings for silicon solar cells with up to five layers are optimized. The
reflection coefficient as a function of wavelength and incident angle is shown in
Fig. 3 for optimized one-, two-, and four-layer
antireflection coatings. As before, the number of minima in reflection is equal to
the number of layers in the antireflection coating. The compositions of optimized
coatings are shown in
Table 2. Again, nano-porous layers compose roughly half of
the layers in an antireflection coating with a given number of layers.
Compared to the one- and two-layer coatings, the four-layer coating yields
substantially reduced reflection, particularly at the largest incident angles and
shortest wavelengths. Note that the one- and two-layer coatings feature one
co-sputtered layer and both nano-porous low-
n and co-sputtered
layers, respectively, which will give enhanced performance compared to conventional
one- and two-layer coatings. The angle- and wavelength-averaged reflection
coefficients are plotted in
Fig. 4 as a function of the number of layers. As discussed
above, when an optimized antireflection coating includes layers with both the lowest
allowed and highest allowed refractive index, adding additional layers generally
provides little benefit. In the case of the silicon solar cell, which is identical
to the image sensor with the exception that the relevant wavelength range is
broader, a larger number of layers is needed to reach this threshold. In the image
sensor, going from three to four layers reduces average reflectivity by 11.1%, while
for the solar cell, reflectivity is reduced by 31.1%. Adding an fifth layer to the
solar cell antireflection coating reduces reflection by an additional 5.6%.
Fig. 3. Reflection coefficient of (left) one-, (center) two-, and (right) four-layer
antireflection coatings optimized for silicon solar cells versus wavelength
and incident angle.
Table 2. Thickness t (in nm) and composition c of
individual layers for optimized silicon solar cell antireflection coatings.
(CS=co-sputtered layer, NP=nano-porous low-n layer)
| 1-layer | 2-layer | 3-layer | 4-layer | 5-layer |
|---|
|
t
1
| 91.2 | 133.1 | 432.8 | 432.6 | 388.7 |
|
t
2
| - | 64.0 | 113.3 | 145.8 | 159.3 |
|
t
3
| - | - | 58.6 | 79.7 | 107.8 |
|
t
4
| - | - | - | 51.2 | 70.1 |
|
t
5
| - | - | - | - | 50.5 |
|
c
1
| CS, 36% TiO2
| NP, 78% SiO2
| NP, 11% SiO2
| NP, 10% SiO2
| NP, 10% SiO2
|
|
c
2
| - | CS, 70% TiO2
| CS, 3% TiO2
| NP, 54% SiO2
| NP, 29% SiO2
|
|
c
3
| - | - | CS, 82% TiO2
| CS, 28% TiO2
| NP, 81% SiO2
|
|
c
4
| - | - | - | CS, 100% TiO2
| CS, 37% TiO2
|
|
c
5
| - | - | - | - | CS, 100% TiO2
|
Fig. 4. Angle- and wavelength-averaged reflection coefficient as a function of the
number of layers for optimized antireflection coatings for silicon solar
cells.
5. GaInP/GaAs/Ge triple-junction solar cell
Multi-junction solar cells have achieved the highest efficiency of any photovoltaic
technology available [
14–16
N. H. Karam, R. R. King, M. Haddad, J. H. Ermer, H. Yoon, H. L. Cotal, R. Sudharsanan, J. W. Eldredge, K. Edmondson, D. E. Joslin, D. D. Krut, M. Takahashi, W. Nishikawa, M. Gillanders, J. Granata, P. Hebert, B. T. Cavicchi, and D. R. Lillingron, “Recent developments in
high-efficiency Ga0.5In0.5P/GaAs/Ge dual- and
triple-junction solar cells: steps to next-generation PV
cells,” Sol. Energy Mater. Sol. Cells
66, 453–466
(2001). [CrossRef]
]. Because of the higher cost associated with
fabrication, a primary intended use is in concentrator systems, where lenses or
reflectors are used to collect sunlight over a large area and focus it on a small
active area where the solar cell is located. Because of the nature of concentrator
systems, generally there is always some light incident upon the solar cell at
oblique angles, which makes broadband and omni-directional antireflection coatings
especially important in this application.
The structure used in calculations consists of a GaInP/GaAs/Ge stack with thicknesses
as given in [
16
Z. Q. Li, Y. G. Xiao, and Z. M. Simon Li, “Modeling of multi-junction solar
cells by Crosslight APSYS,” Proc. SPIE
6339, 633909 (2006). [CrossRef]
]. The bottom germanium layer is assumed to be infinitely
thick. The structure in [
16
Z. Q. Li, Y. G. Xiao, and Z. M. Simon Li, “Modeling of multi-junction solar
cells by Crosslight APSYS,” Proc. SPIE
6339, 633909 (2006). [CrossRef]
] also includes intermediate layers which act as tunnel
junctions or back surface field structures; however, the refractive indices of
materials used in some of these layers are not well reported. Therefore, the
triple-junction solar cell is treated as a simple three-layer stack, although in
principle any number of layers could be included in the calculation. The wavelength
range considered in for the antireflection coatings is 400 nm to 1500 nm.
Table 3 shows the composition and thickness of each layer for
optimized antireflection coatings with up to six layers.
Figure 5 shows the reflectivity as a function of angle for
the bare triple-junction solar cell, as well as the solar cell with optimized one-,
three-, and five-layer antireflection coatings.
Fig. 5. Reflectivity of (top to bottom) a bare GaInP/GaAs/Ge triple-junction solar
cell, and triple-junction solar cells with optimized one-, three-, and
five-layer antireflection coatings.
Table 3. Thickness t (in nm) and composition c of
individual layers for optimized GaInP/GaAs/Ge triple-junction solar cell
antireflection coatings. (CS=co-sputtered layer, NP=nano-porous
low-n layer)
| 1-layer | 2-layer | 3-layer | 4-layer | 5-layer | 6-layer |
|---|
|
t
1
| 162.7 | 294.9 | 544.4 | 550.9 | 525.0 | 489.8 |
|
t
2
| - | 132.0 | 137.5 | 168.1 | 195.8 | 206.5 |
|
t
3
| - | - | 78.3 | 94.0 | 108.9 | 127.7 |
|
t
4
| - | - | - | 63.0 | 74.1 | 90.1 |
|
t
5
| - | - | - | - | 53.2 | 66.5 |
|
t
6
| - | - | - | - | - | 52.2 |
|
c
1
| CS, 27% TiO2
| NP, 36% SiO2
| NP, 11% SiO2
| NP, 10% SiO2
| NP, 10% SiO2
| NP, 10% SiO2
|
|
c
2
| - | CS, 44% TiO2
| CS, 0% TiO2
| NP, 58% SiO2
| NP, 39% SiO2
| NP, 28% SiO2
|
|
c
3
| - | - | CS, 61% TiO2
| CS, 25% TiO2
| CS, 5% TiO2
| NP, 69% SiO2
|
|
c
4
| - | - | - | CS, 82% TiO2
| CS, 48% TiO2
| CS, 17% TiO2
|
|
c
5
| - | - | - | - | CS, 100% TiO2
| CS, 57% TiO2
|
|
c
6
| - | - | - | - | - | CS, 100% TiO2
|
Fig. 6. Angle- and wavelength-averaged reflection coefficient as a function of the
number of layers for optimized antireflection coatings for GaInP/GaAs/Ge
triple-junction solar cells.
For each case shown in
Fig. 5, the reflectivity at wavelengths longer than 700 nm,
and particularly longer than 900 nm shows pronounced fringing. These longer
wavelengths pass through the top junction or both the top and middle junctions of
the solar cell without being absorbed; interference of light within these layers
produces the reflectivity fringes. When a single-layer antireflection coating is
added, reflectivity is initially reduced at longer wavelengths. As more layers are
added, reflectivity across the entire range of wavelengths and incident angles is
reduced.
Figure 6 plots the reflectivity of the optimized
antireflection coatings as a function of total number of layers.
6. Conclusion
We have described a method for optimizing antireflection coatings made of
co-sputtered and nano-porous low-refractive-index coatings. The method is based on a
genetic algorithm which is well suited for the task of optimizing optical thin-film
coatings, given the fact that the design space of multi-layered optical coatings
includes many local minima of the fitness function, i.e., the average reflectivity.
The optimization method was applied to silicon image sensors and solar cells, as
well as a triple-junction GaInP/GaAs/Ge solar cell. In each case, nano-porous layers
constitute roughly half of the total number of layers in optimized antireflection
coatings, which underscores the importance of low-refractive-index materials for
high-performance antireflection coatings.
Acknowledgments
The authors gratefully acknowledge support by the National Science Foundation, the
Department of Energy, Sandia National Laboratories, New York State, Samsung
Electro-Mechanics Company, Crystal IS Corporation, and Troy Research
Corporation.
References and links
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(1985). [CrossRef] [PubMed] |
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reflection,” Nature Photon.
1, 176–179
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8, 584–583
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7, 245–260
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E. Vazsonya, K. De Clercq, R. Einhaus, E. Van Kerschaver, K. Said, J. Poortsmans, J. Szlufcik, and J. Nijs, “Improved anisotropic etching process
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Sol. Energy Mater. Sol. Cells
57, 179–188
(1999). [CrossRef] |
14. |
N. H. Karam, R. R. King, M. Haddad, J. H. Ermer, H. Yoon, H. L. Cotal, R. Sudharsanan, J. W. Eldredge, K. Edmondson, D. E. Joslin, D. D. Krut, M. Takahashi, W. Nishikawa, M. Gillanders, J. Granata, P. Hebert, B. T. Cavicchi, and D. R. Lillingron, “Recent developments in
high-efficiency Ga0.5In0.5P/GaAs/Ge dual- and
triple-junction solar cells: steps to next-generation PV
cells,” Sol. Energy Mater. Sol. Cells
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