The study investigates the fabrication and characterization of tunnel oxynitride (TON) layers produced using Plasma-Enhanced Chemical Vapor Deposition (PECVD) at different pressure and power variations. The aim is to explore TON layers as potential substitutes for conventional SiO2 in Tunnel Oxide Passivated Contact (TOPCon) solar cells. Foe this purpose, an effective oxide thickness (EOT) of 1.1–1.2 nm and 1.5–1.6 nm has been achieved by treating the TON samples with NH3 and N2 gas plasma, respectively. Fourier Transform Infrared Spectroscopy (FTIR) analysis revealed critical variations in the chemical bonding within TON layers, which exhibit different properties based on the deposition conditions. The presence of nitrogen-nitrogen and nitrogen–hydrogen bonds is prominently influenced by changes in the PECVD parameters, directly affecting the layer’s optical and electronic properties. Notably, the presence of hydroxyl (O–H) and amino (NH2) groups within the TON structure suggests an improvement in surface passivation, essential for optimizing solar cell performance and durability. A lifetime of 737 and 823 μs has been recorded for N2 and NH3 samples, compared to the NAOS 710 μs reference sample. NH3 plasma-treated samples show an improved iVoc of 736 mV, indicating better phase transformation and passivation quality than N2 plasma treatment and the NAOS reference sample.
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