Crystalline silicon thin-film solar cells are promising candidates to reduce the watt-peak prices of photovoltaic energy, thanks to a much smaller use of high purity silicon. In our case, the active layers of silicon are supported by substrates. These substrates have low production costs and are compatible with the high temperature process steps, which are necessary to a rapid and high-quality crystalline growth. The company S’TILE develops these substrates, by sintering silicon powders and recrystallizing the obtained wafers. The objective of this PhD thesis is to pinpoint the relevance of this substrate for the photovoltaics industry and demonstrate that it is adapted to the fabrication of solar cells with low cost and high efficiency. This work uses the epitaxy process, which is central to fabricate these thin-film cells. It is organized in two main axes. The first one is the fabrication of solar cells and their optimization on monocrystalline reference substrates. Several optimization pathways have been tested: the use of porous silicon Bragg reflectors, the optimization of emitter doping, the base variable doping and the use of rear emitter structures. The studies permitted to unveil the potential of each pathway; promising results were obtained for the improvement of thin-film solar cell conversion efficiency. The second axis of the thesis is the cell fabrication on the substrates prepared by S’TILE and the application of the means developed in the first axis to improve these cells. Encouraging efficiencies have demonstrated the feasibility of solar cells on the substrates made by the low-cost process developed by S’TILE.
