Electrospun ZnO Nanofibers as Functional Interlayer in CdS/PbS-Based n–p Thin Film Solar Cells

We introduce a fully solution-processed interlayer strategy for n–p CdS/PbS thin film solar cells that combines a sol–gel ZnO compact coating with an electrospun ZnO nanofiber network. The synthesis and characterization of ZnO, CdS, and PbS thin films, complemented by electrospun ZnO nanofibers, are aimed at low-cost photovoltaic applications. Sol–gel ZnO films exhibited a hexagonal wurtzite structure with a bandgap (Eg) of approximately 3.28 eV, functioning effectively as electron transport and hole-blocking layers. CdS films prepared by chemical bath deposition (CBD) showed mixed cubic and hexagonal phases with an Eg of about 2.44 eV. PbS films deposited at low temperature displayed a cubic galena structure with a bandgap of approximately 0.40 eV. Scanning Electron Microscopy revealed uniform ZnO and CdS surface coatings and a conformal 1D ZnO network with nanofibers measuring about 50 nm in diameter (ranging from 49.9 to 53.4 nm), which enhances interfacial contact coverage. PbS films exhibited dense grains ranging from 50 to 150 nm, and EDS confirmed the expected stoichiometries. Electrical characterization indicated low carrier densities and high resistivities consistent with low-temperature processing, while mobilities remained within reported ranges. The incorporation of ZnO layers and nanofibers significantly improved device performance, particularly at the CdS/PbS heterojunction. The device achieved a Voc of 0.26 V, an Jsc of 3.242 mA/cm2, and an efficiency of 0.187%. These improvements are attributed to enhanced electron transport selectivity and reduced interfacial recombination provided by the percolated 1D ZnO network, along with effective hole blocking by the compact film and increased surface area. Fill-factor limitations are linked to series resistance losses, suggesting potential improvements through fiber densification, sintering, and control of the compact layer thickness. This work is a proof-of-concept of a fully solution-processed and low-temperature CdS/PbS architecture. Efficiencies remain modest due to low carrier concentrations typical of low-temperature CBD films and the deliberate omission of high-temperature annealing/ligand exchange. Overall, this non-vacuum, low-temperature coating method establishes electrospun ZnO as a tunable functional interlayer for CdS/PbS devices and offers a practical pathway to elevate power output in scalable productions. These findings highlight the potential of nanostructured intermediate layers to optimize charge separation and transport in low-cost PbS/CdS/ZnO solar cell architectures.