JP2008085225A - 太陽電池モジュール - Google Patents
太陽電池モジュール Download PDFInfo
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- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
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Abstract
【解決手段】太陽電池モジュールは、表面保護材と裏面保護材との間に、複数の太陽電池セルが配設され、太陽電池セルのバスバー電極20同士をタブにより互いに電気的に接続して構成される。太陽電池モジュールは、バスバー電極20とタブ40との間に、複数の導電性粒子70を含む樹脂60からなる接着層を備え、バスバー電極20とタブ40は、導電性粒子70を介して電気的に接続し、樹脂60は、バスバー電極20の側面まで覆い、タブ40と光電変換部10の表面を接着する。
【選択図】図3
Description
本実施形態に係る太陽電池セルとして、HIT構造を有する太陽電池セルを例に挙げ、以下について説明する。図1は、本実施形態に係る太陽電池セルの断面図であり、図2は、上面図である。
本実施形態に係る太陽電池モジュールによると、柔軟性の高い樹脂60によってバスバー電極20とタブ40を接着し、光電変換部10とタブ40までも接着しているので、タブ40と光電変換部10との線膨張係数の違いから生じていたストレスを樹脂60により緩和することができる。このため、導電性ペースト(バスバー電極)の破壊、導電性ペーストと光電変換部の界面の剥離、及び導電性ペーストと合金層の界面の剥離を抑制することができる。このため、導電性ペースト部の破壊による接触抵抗の増加を防止し、モジュール出力の低下を抑制することができる。この結果、太陽電池モジュールの信頼性を向上させることができる。
次に、本実施形態に係る太陽電池モジュールの製造方法について説明する。
本発明は上記の実施形態によって記載したが、この開示の一部をなす論述及び図面はこの発明を限定するものであると理解すべきではない。この開示から当業者には様々な代替実施形態、実施例及び運用技術が明らかとなろう。
本発明の実施例1に係る太陽電池セルとして、図1、図2及び図4に示す太陽電池セルを以下のように作製した。以下の作製方法では、工程を工程1〜4に分けて説明する。
まず、図1に示すように、洗浄することにより、不純物が除去された約1Ω・cmの抵抗率と約300μmの厚みとを有するn型単結晶シリコン基板10dを準備した。次に、RFプラズマCVD法を用いて、n型単結晶シリコン基板10dの上面上に、約5nmの厚みを有するi型非晶質シリコン層10cと、約5nmの厚みを有するp型非晶質シリコン層10bとをこの順番で形成した。尚、RFプラズマCVD法によるi型非晶質シリコン層10c及びp型非晶質シリコン層10bの具体的な形成条件は、周波数:約13.65MHz、形成温度:約100〜250℃、反応圧力:約26・6〜80.0Pa、RFパワー:約10〜100Wであった。
スクリーン印刷法を用いて、エポキシ系熱硬化型の銀ペーストを受光面側の透明導電膜の所定領域上に転写した後、150℃で5分間加熱し、仮硬化させ、200℃で1時間加熱することにより、完全に硬化させることで、集電極を形成した。これにより、図2に示すように、透明導電膜の上面上に、所定の間隔を隔てて互いに平行に延びるように形成された複数のフィンガー電極30と、フィンガー電極30により収集された電流を集合させるバスバー電極20とからなる集電極を形成した。ここでは、バスバー電極20の幅が約1.0mm、高さが約50μmであった。
まず、バスバー電極20上に、ディスペンサーで、エポキシ系熱硬化型のニッケルペーストを塗布した。具体的には、図8に示すように、バスバー電極20上に、約30μmの厚みとなるように塗布するとともに、バスバー電極20の側面外側を約100μmずつ覆うように塗布した。又、図9に示すように、フィンガー電極30の根元の部分も同時に覆うように塗布した。尚、ニッケルペースト中のニッケル粒子の含有量は、体積率約5%のものを使用した。
ガラス基板からなる表面保護材の上に、EVAシートからなる充填材を載せた後、タブにより接続した複数の太陽電池セルを配置した。そして、その上に、更にEVAシートからなる充填材を載せた後、PET/アルミニウム箔/PETの3層構造を有する裏面保護材を配置した。これらを、真空にした後、150℃で10分間加熱圧着することで駆り圧着した後、150℃で1時間加熱することで、完全に硬化させた。これに、端子ボックス、金属フレームを取り付け、実施例1に係る太陽電池モジュールを作製した。
比較例1に係る太陽電池セルとして、図12に示す太陽電池セルを以下のように作製した。
比較例2に係る太陽電池セルとして、従来のハンダ付けによる接着を行った太陽電池セルを以下のように作製した。
実施例1及び比較例1、2に係る太陽電池モジュールについて、それぞれ温度サイクル試験(JIS C8917)を行い、試験前後の太陽電池モジュールの出力を比較し、タブ接続部の断面観察、エレクトロルミネッセンス法による発光比較を行った。JIS規格では、200サイクル後の出力変化率にて規定されているが、今回は、更に長期の耐久性を評価するため、400サイクルの試験を行った。太陽電池モジュールの出力は、AM1.5、100mW/cm2の光照射下で測定した。
比較例1及び2においては、温度サイクル試験後にバスバー電極20内の亀裂が観察され、又、温度サイクル試験後のエレクトロルミネッセンス法による発光試験で暗部が見られている。この暗部について、図16のA部に示すようなフィンガー電極30に沿って見られる暗部は、フィンガー電極30の根元(バスバー電極との接続部)で断線が生じたため、根元から先まで電流が流れにくいことにより、エレクトロルミネッセンス法による発光が弱いものと考えられる。又、B部に示すようなバスバー電極20に沿って見られる暗部は、断面SEMでも観察されたバスバー電極20内の亀裂によるものと考えられる。このような亀裂は、温度サイクル試験が繰り返されたことにより、線膨張係数の大きく異なるタブとシリコン基板の間に位置するバスバー電極にダメージが蓄積されたために生じたものと考えられる。即ち、比較例1及び2において、温度サイクル試験により、上述した2種類の集電極損傷が起こっているものと考えられ、このような集電極の損傷により、出力の低下を招いていると考えられる。
次に、導電性粒子の粒子量を変化させた場合の影響について調査した。
図17に、横軸を樹脂成分の断面SEMから観察される導電性粒子の面積率、縦軸を規格化出力低下率とし、表示したグラフを示す。導電性粒子の面積率は、断面SEMから観察されるバスバー電極の側面外側領域(図4のX部分)における、導電性粒子断面の占める割合を算出した。出力低下率は、(1−試験後出力/試験前出力)×100(%)の式より算出し、比較例2における出力低下率を1.00として規格化した。
10a…ITO膜
10b…p型非晶質シリコン層
10c…i型非晶質シリコン層
10d…n型単結晶シリコン基板
10e…i型非晶質シリコン層
10f…n型非晶質シリコン層
10g…ITO膜
20…バスバー電極
30…フィンガー電極
40…タブ
50…合金部
60…樹脂
70…導電性粒子
80…加熱部
90…メッキ
Claims (6)
- 表面保護材と裏面保護材との間に、複数の太陽電池セルが配設され、前記太陽電池セルの接続用電極同士をタブにより互いに電気的に接続してなる太陽電池モジュールであって、
前記接続用電極と前記タブとの間に、複数の導電性粒子を含む樹脂からなる接着層を備え、
前記接続用電極と前記タブとは、前記導電性粒子を介して電気的に接続され、
前記樹脂は、前記接続用電極の側面まで覆い、前記タブと前記太陽電池セルの表面を接着することを特徴とする太陽電池モジュール。 - 前記接続用電極は、バスバー電極であり、
前記接着層は、前記バスバー電極に接続されたフィンガー電極の当該バスバー電極との接続部分と前記タブとの間に配置されることを特徴とする請求項1に記載の太陽電池モジュール。 - 前記フィンガー電極と前記タブは、前記導電性粒子を介して電気的に接続することを特徴とする請求項2に記載の太陽電池モジュール。
- 前記導電性粒子は、前記接続用電極の側面に配置された樹脂中において、体積率3〜20%の割合で含有されていることを特徴とする請求項1〜3のいずれか1項に記載の太陽電池モジュール。
- 前記接続用電極の表面は、凹凸形状を有し、凸形状の部分は、前記タブに接することを特徴とする請求項1〜4のいずれか1項に記載の太陽電池モジュール。
- 前記接着層に含まれる樹脂は、前記接続用電極に使用されている樹脂材料と同種の樹脂であることを特徴とする請求項1〜5のいずれか1項に記載の太陽電池モジュール。
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US20100084001A1 (en) | 2010-04-08 |
TW200816502A (en) | 2008-04-01 |
KR101568048B1 (ko) | 2015-11-10 |
KR20090079909A (ko) | 2009-07-22 |
ES2698120T3 (es) | 2019-01-31 |
CN101523617A (zh) | 2009-09-02 |
US9748413B2 (en) | 2017-08-29 |
CN102157583A (zh) | 2011-08-17 |
CN101937942A (zh) | 2011-01-05 |
WO2008041487A1 (en) | 2008-04-10 |
TWI429093B (zh) | 2014-03-01 |
EP2068372A1 (en) | 2009-06-10 |
TR201815209T4 (tr) | 2018-11-21 |
EP2068372B1 (en) | 2018-08-08 |
JP5230089B2 (ja) | 2013-07-10 |
CN101523617B (zh) | 2011-03-30 |
CN102157583B (zh) | 2016-08-03 |
EP2068372A4 (en) | 2012-12-19 |
CN101937942B (zh) | 2014-10-29 |
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