JP2006041289A - Light emitting module and system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a light emitting module in which output from a solar cell can be prevented from lowering without causing declination in incident light on the solar cell, and manufacture thereof can be facilitated. <P>SOLUTION: The light emitting module is manufactured by laminating at least a solar cell part 1, a first adhesive layer 16, a second translucent insulating substrate (transparent PET) 17, a second metal layer (circuit pattern) 18, a light emitting part 2 consisting of a light emitting element (chip LED) 19, a second adhesive layer 20, and a third translucent insulating substrate 21 sequentially. When the light emitting part 2 is fabricated, a transparent PET 17 having a thickness of 50-500 μm on which a circuit pattern 18 is formed previously is employed. Silver paste hardening through heating at 150°C for 30 min is employed as the circuit pattern material and the circuit pattern 18 is formed on the transparent PET 17 by screen printing and thermally set. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a light emitting module and a light emitting system, and more particularly, to a light emitting module combined with a visible light transmissive solar cell and a light emitting system including such a light emitting module.

  Conventionally, as this type of light emitting module, as described in Patent Document 1, a light emitting device in which a light transmitting part and a solar cell are stacked on a light transmitting substrate, or Patent Document 2 is described. Such a lighting panel in which the light-receiving surface of the solar cell is disposed in the vicinity of the panel-like light emitter having the light-emitting surface so that the light-emitting surface and the light-receiving surface are located on the same surface, or Patent Document 3 Such a photovoltaic power generation light emitting module in which a photovoltaic power generation unit and a light emitting unit that emits light by electromotive force of the photovoltaic power generation unit are mounted on a single flat plate substrate has been known.

JP 59-217991 A JP 60-78477 A Japanese Patent Laid-Open No. 2001-351418

  However, the light-emitting device described in Patent Document 1 is laminated in the order of the light-transmitting light emitting unit and the solar cell from the sunlight receiving surface side, and light incident on the solar cell is attenuated by the light-transmitting light emitting unit. For this reason, there is a drawback that the output of the solar cell cannot be avoided. In addition, the lighting panel described in Patent Document 2 includes a solar cell having a light receiving surface in the vicinity of a panel-shaped light emitter having a light emitting surface, and the light emitting surface and the light receiving surface are on the same plane. Due to the above restrictions, there was a drawback that the output of the solar cell was unavoidable. Furthermore, the light emitting module described in Patent Document 3 has a through-hole on a single flat board on which a photovoltaic power generation unit is mounted on the front surface and a light emitting unit that emits light by the electromotive force of the solar power generation unit is mounted on the back surface. And a circuit and a device group using the printed wiring and the electromotive force of the solar cell module are mounted on the back surface, and thus there are disadvantages such as restrictions on the mounting location of the light emitting unit.

  The object of the present invention is to solve such problems of the prior art, prevent the light incident on the solar cell from attenuating, prevent a decrease in the output of the solar cell, and easily produce light emission. It is to provide a light emitting system including the module and such a light emitting module.

  According to one aspect of the present invention, at least a first translucent insulating substrate, a transparent conductive layer, a photoelectric conversion layer, a solar cell unit composed of a first metal layer, a first adhesive layer, and a second A light-transmitting insulating substrate, a second metal layer, a light-emitting portion made of a light-emitting element, a second adhesive layer, and a protective portion made of a third light-transmitting insulating substrate. A featured light emitting module is provided.

  According to another aspect of the present invention, there is provided a light emitting system including the light emitting module according to one aspect of the present invention, a storage battery, and a control unit.

  In the light emitting module according to one aspect of the present invention, since the light emitting surface and the light receiving surface are not on the same plane, there is a risk of attenuation by all or part of the light emitting portion of the light incident on the solar cell, or the sun. There is no restriction on the area occupied by the battery, and a decrease in the output of the solar battery can be prevented.

  In the light emitting system according to another aspect of the present invention, the generated voltage of the solar cell unit is monitored by the control unit, and by comparing the magnitude of this generated voltage with the threshold voltage for determining whether it is daytime or nighttime, It is possible to determine whether the charging mode is from the solar battery to the storage battery or the discharging mode from the storage battery to the light emitting module as a load, and the light emitting module can automatically emit light at night.

  In the light emitting module according to one aspect of the present invention, a third adhesive layer and a fourth light-transmitting insulating substrate are sequentially further provided on the opposite side of the first light-transmitting insulating substrate from the transparent conductive layer. It may be laminated. With this configuration, when it is necessary to consider the strength of the light emitting module, the strength of the light emitting module is further increased by overlapping the fourth light-transmitting insulating substrate via the third adhesive layer. can do.

  In the light emitting module according to one aspect of the present invention, the light emitting unit may be composed of a plurality of light emitting units. If comprised in this way, the light emission area of a light emission part can be made wider.

  In a light emitting system according to another aspect of the present invention, a light emitting module is fitted into a frame, a storage battery and a control unit are housed in the frame, and the light emitting module and the storage battery are electrically connected via the control unit. It may be connected. If comprised in this way, the light-emitting system with a solar cell can be packaged in one unit body.

  A light emitting system according to another aspect of the present invention includes a terminal box for taking out the output of the solar cell unit, and a terminal box for applying a voltage to the light emitting unit, and these terminal boxes are provided on the side surfaces of the light emitting module. It may be attached to. If comprised in this way, when a solar cell part is a see-through type, the taken-in sunlight can be prevented from being interrupted by a terminal box or wiring accompanying it.

  In the light emitting system according to another aspect of the present invention, the second metal layer adjacent to the light emitting element is a circuit pattern for causing the light emitting element to emit light, and the circuit pattern is formed of a conductive paste. It may be. When configured in this way, using a conductive paste that can be cured at a temperature of 150 ° C. or less, a cost-effective PET film can be used as the second light-transmissive insulating substrate, A circuit pattern can be formed on the substrate.

  In the light emitting system according to another aspect of the present invention, the light emitting element may be a chip LED. If comprised in this way, compared with the case where lead type LED is used, the thickness of a light emitting module can be made thinner.

  In a light emitting system according to another aspect of the present invention, the chip LED may be attached to a circuit pattern with a conductive paste. When configured in this way, using a conductive paste that can be cured at a temperature of 150 ° C. or less, a cost-effective PET film can be used as the second light-transmissive insulating substrate, A light emitting element can be mounted on a circuit pattern formed on the substrate.

  In the light emitting system according to another aspect of the present invention, all the adhesive layers may be made of a low-temperature cross-linked EVA film. If comprised in this way, the plastic substrate which does not have heat resistance, such as a polycarbonate, can be used for the 1st-4th translucent insulated substrate.

  In the light emitting system according to another aspect of the present invention, at least a part of the solar cell unit may be a see-through solar cell. If comprised in this way, when this light-emitting system is used for the glass window of a room, sunlight can be taken in indoors from a solar cell part.

  In the following, for exemplary purposes only, three embodiments of the present invention will be described with reference to the accompanying drawings.

Embodiment 1

  An embodiment (Embodiment 1) of a light emitting module according to one aspect of the present invention will be described with reference to FIGS. The light emitting module includes at least a solar cell unit 1, a light emitting unit 2, and a protection unit 3.

  In the production of the solar cell unit 1 shown in FIGS. 1 and 2, a glass substrate 4 as a first translucent insulating substrate on which a transparent conductive film 5 is formed in advance is used. A transparent conductive film 5 as a transparent conductive layer is formed on the glass substrate 4 on one side surface and the entire peripheral end surface of the glass substrate 4.

  Next, the transparent conductive film 5 is patterned using laser light. At this time, for example, YAG fundamental wave laser light that is well absorbed by the transparent conductive film 5 is used. By making laser light enter from the glass substrate 4 side, the transparent conductive film 5 is separated into strips, and the separation line 6 of the transparent conductive film 5 is formed.

  Next, the glass substrate 4 on which the transparent conductive film 5 is formed is washed with pure water to form a photoelectric conversion film 7-1 as a photoelectric conversion layer. The photoelectric conversion film 7-1 includes an a-Si: Hp layer, an a-Si: Hi layer, and an a-Si: Hn layer, and has a total thickness of 100 nm to 300 nm.

  Next, the transparent conductive film 8 is formed. For the transparent conductive film 8, for example, ZnO or ITO having good contact with the a-Si: Hn layer is used. The total thickness of the transparent conductive film 8 is 5 nm to 100 nm.

  Next, the photoelectric conversion film 7-1 is patterned using laser light. At this time, in order to avoid damage to the transparent conductive film 5 due to laser light, for example, a YAG SHG laser having wavelength selectivity is used. By making the laser light incident from the glass substrate 4 side, the photoelectric conversion film 7-1 is separated into strips, and at the same time, the transparent conductive film 8 is also removed to form a separation line 9 of the photoelectric conversion film 7-1. . The separation line 9 is formed with a width of about 50 μm to 200 μm at a position separated by about 1 to 50 μm so as to overlap with the separation line 6 of the transparent conductive film 8 by about 50 μm.

  Next, a photoelectric conversion film 7-2 as a photoelectric conversion layer is formed. The photoelectric conversion film 7-2 includes a μc-Si: Hp layer, a μc-Si: Hi layer, and a μc-Si: Hn layer, and has a total thickness of 1000 nm to 3000 nm.

  Next, the photoelectric conversion film 7-2 is patterned using a laser beam. At this time, in order to avoid damage to the transparent conductive film 5 due to laser light, for example, a YAG SHG laser having wavelength selectivity is used. By making laser light enter from the glass substrate 4 side, the photoelectric conversion film 7-2 is separated into strips, and at the same time, the photoelectric conversion film 7-1 and the transparent conductive film 8 are also removed, and the photoelectric conversion film 7-2 A separation line 10 is formed. The separation line 10 is formed with a width of about 50 μm to 200 μm at a position about 1 to 50 μm apart from the separation line 9 by about 50 μm.

  Subsequently, the back electrode film 13 as the first metal layer is formed by laminating the transparent conductive film 11 and the metal electrode film 12. For the transparent conductive film 11, for example, ZnO, ITO, or the like having a small specific resistance and high translucency is used. On the other hand, the metal electrode film 12 is made of, for example, Al or Ag having a high reflectance. The film thickness of the transparent electrode film 11 is about 50 nm to 200 nm, and the film thickness of the metal electrode film 12 is about 500 nm to 1 μm. However, the transparent electrode film 11 may be omitted.

  Next, patterning of the back electrode film 13 is performed using laser light. At this time, in order to avoid damage to the transparent conductive film 5 due to laser light, and at the same time, in order to remove the photoelectric conversion film 7-1, the transparent conductive film 8, and the photoelectric conversion film 7-2, there is wavelength selectivity. For example, a YAG SHG laser is used. By making laser light enter from the glass substrate 4 side, the back electrode film 13 is separated into strips, and at the same time, the photoelectric conversion film 7-1, the transparent conductive film 8 and the photoelectric conversion film 7-2 are also removed, and the back electrode A separation line 14 for the membrane 13 is formed. The separation line 14 is formed with a width of about 50 μm to 200 μm at a position about 1 to 150 μm apart from the separation line 10 of the photoelectric conversion film 7-2 by about 50 μm.

  Thus, at least the glass substrate 4, the transparent conductive film 5, the photoelectric conversion film 7-1 made of an amorphous silicon semiconductor, the transparent conductive film 8, the photoelectric conversion film 7-2 made of a crystalline silicon semiconductor, and the back surface. An integrated thin-film solar cell that includes an electrode film 13 and is divided into a plurality of power generation regions on the glass substrate 4 and connected in series. The separation line 14 of the back electrode film 13 includes the back electrode film 13 and photoelectric conversion. A solar cell patterned through substantially the same shape through the film 7-2, the transparent conductive film 8, and the photoelectric conversion film 7-1 can be obtained.

  Next, the translucent opening 15 is patterned in the power generation region. At this time, in order to avoid damage to the transparent conductive film 5 due to laser light, and at the same time, in order to remove the photoelectric conversion film 7-1, the transparent conductive film 8, and the photoelectric conversion film 7-2, there is wavelength selectivity. For example, a YAG SHG laser is used. The laser beam is processed by being incident from the glass substrate 4 side, and the light-transmitting opening 15 is formed. The translucent opening 15 is formed in a direction perpendicular to the separation line 14 of the back electrode film 13.

  Here, in the power generation region divided into strips having a width of 11.09 mm, a total of 704 light transmissions with a width of 0.08 mm and a pitch of about 1.27 mm perpendicular to the separation lines 14 of the back electrode film 13 are obtained. The opening 15 is formed.

  Therefore, by patterning 704 translucent openings 15 in a 48-stage solar cell, it becomes possible to obtain an aperture ratio of approximately 10%, the substrate size is 560 mm × 930 mm, and the power generation output is Solar cells that are about 50 watts [W] can be made.

  In this example, the photoelectric conversion layer has a tandem structure of a-Si: H and μc-Si: H, but a single structure of a-Si: H, a tandem structure, a triple structure, or a single structure of μc-Si: H. A structure, a tandem structure, a triple structure, or a combination of these, a tandem structure or a triple structure may be used. In this example, a see-through solar cell has been described as an example of the solar cell. However, the solar cell may be any solar cell that can perform daylighting, such as a daylighting solar cell.

  Next, the production of the light emitting unit 2 shown in FIGS. 1, 3, and 5 will be described. FIG. 5 shows an example of the arrangement of the light emitting unit 2, but the illustration of the electrodes of the solar cell unit 1 is omitted for the sake of convenience. For example, four light emitting units including the light emitting unit 2 are arranged. Shows things.

  When the light emitting unit 2 is manufactured, as shown in FIG. 1, transparent PET 17 as a second translucent insulating substrate on which a circuit pattern 18 as a second metal layer is formed in advance is used. For the circuit pattern material, a silver paste that is cured by heating at 150 ° C. for 30 minutes is used. For example, the circuit pattern 18 is formed by screen printing using a mask on transparent PET 17 having a thickness of about 50 to 500 μm, The light emitting part 2 is produced by curing.

  FIG. 3 is a plan view showing an example of the circuit pattern 18 of the light emitting unit 2 according to the present invention thus obtained. A light emitting unit in which 80 chip LEDs 19 as light emitting elements are mounted with the circuit pattern 18 of FIG. 3 is used, for example, 4 units as shown in FIG. A light emitting unit having a power consumption of 14.4 watts [W] was configured with a size of about 260 mm × about 300 mm.

  In these light emitting units, as shown in FIG. 3, land patterns 23 and 23 for mounting the chip LED 19 are formed, and silver which can be cured by heating the land patterns 23 and 23 at 150 ° C. for 30 minutes. Print and apply paste.

  Next, the two electrodes of the chip LED 19 are mounted so as to be conductive with the silver paste applied to the land patterns 23 and 23.

  Next, the circuit pattern on the transparent PET on which the chip LED 19 is mounted is allowed to stand in a heating furnace maintained at an atmospheric temperature of 150 ° C. and thermally cured.

  In this example, the printing process is used. However, the printing process is not limited as long as it is a process capable of controlling the coating amount of the silver paste. In this example, a method of curing the silver paste is used for bonding the chip LED 19 onto the circuit pattern. However, a solder solder may be used and soldered through a reflow process.

  When the solar cell unit 1 and the light emitting unit 2 thus manufactured are used as a module, an EVA (ethylene vinyl acetate) layer that is a first adhesive layer is formed between the solar cell unit 1 and the light emitting unit 2. 16 is sandwiched. In addition, a second adhesion which is thicker than the height of the chip LED 19 disposed in the light emitting unit 2 between the light emitting unit 2 and the glass substrate 21 as a third translucent insulating substrate for protecting the light emitting unit 2. The EVA layer 20 as a layer is sandwiched. And after hold | maintaining at 130 degreeC for 20 minutes and melt | dissolving EVA, it hold | maintains at 150 degreeC for 45 minutes, and EVA is bridge | crosslinked.

  In this example, the glass substrate 21 is used to protect the chip LED 19, but instead of this, a fluorine-based resin having high weather resistance may be used. Further, when a plastic substrate having no heat resistance such as polycarbonate is used for the first to third translucent insulating substrates, it is necessary to use low temperature EVA. In this case, after holding the EVA at 120 ° C. for 10 minutes to dissolve the EVA, the EVA may be cross-linked by holding at 130 ° C. for 45 minutes.

The light-emitting module manufactured as described above has a solar cell unit 1 that transmits a part of incident light while generating power during the daytime, and a light-emitting unit 2 that emits light when power is supplied. Since the light emitting module in which the region and the light emitting region overlap with each other, the securing of the light emitting part area and the securing of the power generating part area at the installation location are compatible, and the installation can be performed without being restricted by the installation area.
Moreover, it can be used for, for example, outdoor lighting or a guide sign in combination with a solar battery or other batteries.

Embodiment 2

  An embodiment (Embodiment 2) of a light emitting system according to another aspect of the present invention will be described with reference to FIGS. 1 and 4. FIG. 4 shows a configuration diagram of the light emitting system. The light emitting system includes at least a light emitting module 24, a storage battery 25, and a control unit 26.

  With this light emitting system, a part of incident light can be transmitted in the daytime, the storage battery 25 can be charged with the electric power generated by the solar cell unit 1, and the light emitting unit 2 can emit light by supplying power from the storage battery 25 at night. .

  The storage battery 25 may be a lead storage battery, a secondary battery such as a nickel-hydrogen battery, a lithium-ion battery, or a capacitor. For example, when a 10-series lithium ion battery is used as the storage battery and a battery capable of charging 4.2 V per battery is used, the battery can be charged up to 42 V in 10 series.

  The control unit 26 only needs to have a circuit capable of switching between at least a charging mode and a discharging mode. In addition, the control unit 26 monitors the battery voltage of the solar cell unit 1 and switches between the charge mode and the discharge mode, monitors the battery level of the storage battery 25 and switches between the overdischarge mode and the overcharge mode, And the like, and the function of adjusting the output of the power supplied to the load in the discharge mode by the pulse voltage modulation output method.

Embodiment 3

  An embodiment (Embodiment 3) of a light emitting module according to one aspect of the present invention will be described with reference to FIG. 1, FIG. 5, and FIG. FIG. 6 is a cross-sectional view taken along the line A-A ′ in FIG. 5. FIG. 6 shows a light emitting module having the same configuration as that of the first embodiment except that a protective portion 28 as a fourth light-transmissive insulating substrate is formed on the power generation unit side in addition to the light emitting module of the first embodiment. is there.

  In this light emitting module, in addition to the configuration of FIG. 1, a protective portion 28, for example, glass, preferably tempered glass is disposed on the light receiving surface side of the solar cell portion 1 via a third adhesive layer 27. It is a feature. When the protection part 28 protrudes outside the solar cell part 1 and the light emitting part 2, it is filled with the first to third adhesive layers 16, 20, and 27 and the side surfaces are formed in a flush shape. It is preferable. Details of the power generation unit 1 and the light emitting unit 2 are omitted.

  The light-emitting module and the light-emitting system of the present invention can be widely applied to small or large-sized lighting, guide signs, and the like in combination with solar cells and other batteries.

FIG. 1 is a cross-sectional view showing one light emitting module according to the present invention. FIG. 2 is a plan view showing a solar cell portion in the light emitting module of FIG. FIG. 3 is a plan view illustrating an example of a circuit pattern of a light emitting unit in the light emitting module of FIG. FIG. 4 is a plan view schematically showing a light emitting system according to the present invention. FIG. 5 is a plan view showing another light emitting module according to the present invention. FIG. 6 is a cross-sectional view taken along the line AA ′ of FIG.

Explanation of symbols

1: Solar cell
2: Light emitting part
3: Protection part
4: Glass substrate (first translucent insulating substrate)
5: Transparent conductive film (transparent conductive layer)
6: Separation line 7-1: Photoelectric conversion film (photoelectric conversion layer)
7-2: Photoelectric conversion film (photoelectric conversion layer)
8: Transparent conductive film
9: Separation line 10: Separation line 11: Transparent conductive film 12: Metal electrode film 13: Back electrode film (first metal layer)
14: Separation line 15: Translucent opening 16: EVA layer (first adhesive layer)
17: Transparent PET (second translucent insulating substrate)
18: Circuit pattern (second metal layer)
19: Chip LED (light emitting device)
20: EVA layer (second adhesive layer)
21: Protective substrate (third translucent insulating substrate)
22: Gap 23: Land pattern 24: Light emitting module with solar cell 25: Storage battery 26: Control unit 27: Adhesive layer (third adhesive layer)
28: Protection part (fourth translucent insulating substrate)

Claims (9)

  At least a first translucent insulating substrate, a transparent conductive layer, a photoelectric conversion layer, a solar cell portion comprising a first metal layer, a first adhesive layer, a second translucent insulating substrate, a second A light emitting module comprising a metal layer, a light emitting portion made of a light emitting element, a second adhesive layer, and a protective portion made of a third light-transmitting insulating substrate, which are sequentially laminated.   2. The light emitting module according to claim 1, wherein a third adhesive layer and a fourth light transmissive insulating substrate are further sequentially laminated on the side opposite to the transparent conductive layer in the first light transmissive insulating substrate. .   The light-emitting module according to claim 1, wherein the light-emitting unit is composed of a plurality of light-emitting units.   A light emitting system comprising the light emitting module according to claim 1, a storage battery, and a control unit.   The light emitting system according to claim 4, wherein the second metal layer adjacent to the light emitting element has a circuit pattern for causing the light emitting element to emit light, and the circuit pattern is formed of a conductive paste.   The light emitting system according to claim 4, wherein the light emitting element is a chip LED.   The light emitting system according to claim 6, wherein the chip LED is attached to the circuit pattern with a conductive paste.   The light emitting system according to claim 4, wherein all of the adhesive layers are made of a low-temperature cross-linked EVA film.   The light emitting system according to claim 4, wherein at least a part of the solar cell unit is a see-through solar cell.

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