JP2009194177A - Power generating body, connector and method for manufacturing the connector - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connector which ensures connection strength by a plurality of power generating bodies while being connected in series. <P>SOLUTION: This connector is a connector A which connects a plurality of power generating bodies I<SB>i</SB>, I<SB>i+1</SB>, ... which generate power by light irradiation, and includes: a first power generating body I<SB>i</SB>which includes at least a rear electrode 3<SB>i</SB>, a light absorbing layer 4<SB>i</SB>and a front electrode 6<SB>i</SB>in turn on a glass substrate 1<SB>i</SB>; and a second generating body I<SB>i+1</SB>which is connected in series with the first power generating body I<SB>i</SB>, and includes at least a rear electrode 3<SB>i+1</SB>, a light absorbing layer 4<SB>i+1</SB>, and a front electrode 6<SB>i+1</SB>in turn on a glass substrate 1<SB>i+1</SB>. In the connector A, the first power generating body I<SB>i</SB>has a conductive film 20<SB>i</SB>which coats a surface on the light incident side of the glass substrate 1<SB>i</SB>, and has an exposure part 20a<SB>i</SB>in which the rear electrode 3<SB>i</SB>is not laminated on a face on the opposite side to a contact face with the first glass substrate 1<SB>i</SB>, and the exposure part 20a<SB>i</SB>of the conductive film 20<SB>i</SB>is connected with the front electrode 6<SB>i+1</SB>of the second generating body I<SB>i+1</SB>by a solder 9<SB>i</SB>. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a power generator and the like, and more particularly to a power generator that generates power by light irradiation.

In recent years, environmental concerns such as global warming prevention and waste reduction have been increasing worldwide. In particular, power generation is attracting attention because it may cause various pollution such as air and water quality while consuming a large amount of resources. In particular, solar power generation is highly expected in that it has inexhaustible resources and does not produce any harmful emissions.
Photovoltaic power generation is still not efficient enough to convert light into electricity, and in order to obtain the required amount of power generation, for example, it is indispensable to use an integrated structure to electrically connect multiple power generators in series. Yes (see Patent Document 1).

Japanese Patent Publication No. 06-009253

  By the way, an integrated structure for obtaining a necessary power generation amount by solar power generation requires complicated patterning, and thus there is a problem that manufacturing cost becomes high, such as complicated manufacturing process. Further, for example, a structure having a back surface as an electrode like a crystalline silicon type solar cell does not require complicated patterning like an integrated structure, but requires a new wiring processing step. Further, in connection by wiring, there is a problem that it is difficult to ensure sufficient coupling strength.

  The present invention has been made to solve such problems. That is, an object of the present invention is to provide a connection body in which a plurality of power generators are connected in series while ensuring sufficient coupling strength.

Thus, according to the present invention, a power generator that generates power when irradiated with light, comprising: an insulating substrate; a conductive film that covers the surface of the insulating substrate on the light incident side; and a portion laminated on the conductive film. And a conductive film covering at least the back surface electrode on the back surface electrode, the exposed portion where the back surface electrode is not laminated on the surface opposite to the contact surface with the insulating substrate. There is provided a power generator characterized by comprising:
Here, in the power generator to which the present invention is applied, it is preferable that the conductive film further covers at least a part of the end portion of the insulating substrate and the surface opposite to the light incident surface side.

Next, according to the present invention, there is provided a connection body in which a plurality of power generation bodies that generate power by light irradiation are connected, and at least a first back electrode, a first light absorption layer, and a first light absorption layer are formed on a first insulating substrate. A first power generation body having a first surface electrode in order, and a first power generation body connected in series with the first power generation body, and at least a second back electrode, a second light absorption layer, and a second on the second insulating substrate A first power generation body that covers the surface of the first insulating substrate on the light incident side and that is in contact with the first insulating substrate. A first conductive film provided with an exposed portion where the first back electrode is not laminated on a surface opposite to the first surface electrode, and the exposed portion of the first conductive film and the second surface electrode of the second power generator are A connection body characterized by being connected by a predetermined conductor is provided.
The connection body to which the present invention is applied can be manufactured without requiring a complicated manufacturing process such as patterning, and the connection strength between the power generation bodies is sufficiently higher than the connection method using wire wiring or the like. Can be secured.

Here, in the connection body to which the present invention is applied, a first insulating film that covers at least a part of the end face of the first power generation body on the second power generation body side, and the first power generation body are connected in series. And a second insulating film that covers at least a part of the end face of the second power generation body on the first power generation body side.
Thus, by covering the side surfaces of the two power generators connected to each other with the insulating film, current leakage to the conductors connecting these power generators is prevented, and the efficiency of converting light into electricity is improved. .
Moreover, it is preferable that the conductor which connects the exposed part of the first conductive film and the second surface electrode of the second power generator is made of a flexible material.

According to the present invention, there is also provided a method of manufacturing a connection body in which a plurality of power generation bodies that generate power by light irradiation are connected, wherein at least a first back electrode and a first light absorption layer are formed on a first insulating substrate. And a first surface electrode in order, further covering the light incident side surface of the first insulating substrate, and a first back electrode on the surface opposite to the contact surface with the first insulating substrate Forming a first power generation body having a first conductive film provided with an exposed portion on which no layer is laminated, and at least a second back electrode, a second light absorption layer, and a second surface electrode on a second insulating substrate A second power generation body including the exposed portion of the first conductive film included in the first power generation body and the second surface electrode of the second power generation body with a predetermined conductor. Provided is a method of manufacturing a connection body, wherein the first power generation body and the second power generation body are coupled by using the connection. That.
Here, in the connection body manufacturing method to which the present invention is applied, at least a part of the end face of the first power generation body on the second power generation body side is covered with the first insulating film, and further, It is preferable to cover at least a part of the end face of the second power generator connected in series on the first power generator side with the second insulating film.

  According to the present invention, it is possible to obtain a connection body in which a plurality of power generation bodies are connected in series while ensuring sufficient coupling strength.

  Hereinafter, embodiments of the present invention will be described in detail. The present invention is not limited to the following embodiments, and various modifications can be made within the scope of the invention. The drawings used are for explaining the present embodiment and do not represent the actual size.

(Embodiment 1: Power generator I)
FIG. 1 is a diagram illustrating a power generator I according to the first embodiment. FIG. 2 is a diagram for explaining a mask used when the power generator I is formed by a sputtering method. A power generator I shown in FIG. 1 is laminated on a glass substrate 1 as an insulating substrate, a conductive film 20 covering at least a part of the surface of the glass substrate 1 on which light L is incident, and a conductive film 20. A back electrode 3 having a portion, a light absorption layer 4 and a transparent conductive film 5 laminated on the back electrode 3, and a surface electrode 6 formed on the transparent conductive film 5 are provided.
The conductive film 20 that covers the glass substrate 1 that is an insulating substrate is provided with an exposed portion 20a on the surface opposite to the contact surface with the glass substrate 1 where the back electrode 3 and other layers are not laminated.

  In the present embodiment, a glass plate having a side of 138 mm square and a thickness of 0.55 mm is used as the glass substrate 1. The conductive film 20 covers the entire surface of the light L incident side on the glass substrate 1 using aluminum (Al). The back electrode 3 is formed using molybdenum (Mo). The light absorption layer 4 is formed using a chalcopyrite type compound (Cu—In—Se compound). Here, in the present embodiment, the transparent conductive film 5 is formed on the light absorption layer 4 using zinc oxide (ZnO). The surface electrode 6 is formed using aluminum (Al).

Each layer of the power generator I is formed as follows by a sputtering method using a predetermined sputtering apparatus. First, the conductive film 20 having a thickness of 400 nm is formed by sputtering on the entire surface of the light incident side of the glass substrate 1 using Al. Next, as shown in FIG. 2 (a), one side of the conductive film 20 formed on the surface of the glass substrate ₁ is covered with a mask M1 having a width of 1.5 mm, and then using Mo, a sputtering method. The back electrode 3 having a thickness of 500 nm is formed to a thickness of 500 nm. As a result, the conductive film 20 is provided with an exposed portion 20a where the back electrode 3 is not laminated.

Next, in a state of covering the one side of the conductive film 20 in the mask _{M 1,} on the back electrode 3, by a sputtering _method, each layer is formed of _{CuSe 2 / In / CuSe 2 /} In 2 Se 3 in this order, respectively The film is formed so that the film thickness is 100 nm / 150 nm / 100 nm / 200 nm.
Subsequently, on these thin films, using ZnO, by sputtering, to form a transparent conductive film 5 having a film thickness of 800 nm, then remove the mask _{M 1.}
Next, as shown in FIG. 2 (b), covering the transparent conductive film 5 in the mask _{M 2.} The mask M _2, a square portion m ₁ corresponding to the surface electrode 6 is hollowed out at four. The upper transparent conductive film 5 in a state covered with a mask _{M 2,} with Al, by sputtering, to form a surface electrode 6 having a thickness of 500 nm, then remove the mask _{M 2.}

Finally, the glass substrate 1 is heated at 400 ° C. for 30 minutes with a predetermined heating device, and the light absorbing layer 4 is formed by melting and crystallizing each layer of CuSe ₂ / In / CuSe ₂ / In ₂ Se ₃ , Complete the power generator I.
In addition, the process which heats the glass substrate 1 and melts and crystallizes each layer of CuSe ₂ / In / CuSe ₂ / In ₂ Se ₃ is performed after connecting a plurality of power generators I in series as will be described later. May be.

(Connector A)
Next, the connection body A using the power generation body I will be described.
FIG. 3 is a diagram illustrating a connection body A in which a plurality of power generation bodies I are connected in series. About the same structure as the electric power generation body I shown in FIG. 1, the same code | symbol is used and the description is abbreviate | omitted.
As shown in FIG. 3, the connection body A includes a plurality of conductive films 20 _i , a back electrode 3 _i , a light absorption layer 4 _i , a transparent conductive film 5 _i, and a front electrode 6 _i in order on a glass substrate 1. The power generators (I _i , I _{i + 1} , I _{i + 2} ,...) Are connected by solders 9 _i−1 , 9 _i , 9 _{i + 1} ,. Note that i is an integer of 1 or more.

Here, two adjacent power generators (I _i , I _{i + 1} ) include a side surface on the side having the exposed portion 20 a _i provided on the conductive film 20 _i of the first power generator (I _i ), The power generators (I _{i + 1} ) are arranged so as to be in contact with the side surface on which the surface electrode 6 _{i + 1} is provided. Then, formed in the surface electrode _{6 i + 1} a provided with side side of the back electrode _{3 i} like are not laminated area and the second power generator of the exposed portion 20a _{i (I i + 1)} in the first power generating element _{(I i)} The solder 9 _i is poured so as to fill the space portion to be covered and to cover the surface electrode 6 _{i + 1} of the second power generation body (I _{i + 1} ). As a result, the first power generating element _{(I i)} and the surface electrode _{6 i + 1} of the exposed portion provided on the conductive film 20 _i 20a _i and second generators _{(I i + 1)} in is a conductor solder _{9 i} The two power generators (I _i , I _{i + 1} ) are electrically connected in series.
The solder 9 is usually a Pb—Sn alloy and an alloy soft solder containing a small amount of a low melting metal such as bismuth (Bi).

In the present embodiment, the end faces on the surface side of the two adjacent power generators (I _i , I _{i + 1} ) that are in contact with each other are each covered with an insulating film. Thereby, slight current leakage from each layer having a very thin film thickness as compared with the glass substrate 1 _i can be prevented.
That is, as shown in FIG. 3, in the connection body A, the glass substrate 1 _i and the conductive film 20 _i are formed on the end face of the first power generation body (I _i ) on the second power generation body (I _{i + 1} ) side. A first insulating film 10a _i covering the formed portion, and a first insulating film 10b _i covering the portion where the back electrode 3 _i , the light absorption layer 4 _i, and the transparent conductive film 5 _i are formed, respectively. Yes. Further, the second insulating film 11 _{i + 1} covering the end faces of all the layers other than the surface electrode 6 _{i + 1} is formed on the end face of the second power generating body (I _{i + 1} ) on the first power generating body (I _i ) side. Is formed.

(Connector B)
FIG. 4 is a diagram for explaining another embodiment of a connection body in which a plurality of power generation bodies I are connected in series. The same components as those of the power generator I and the connector A shown in FIGS. 1 and 3 are denoted by the same reference numerals, and the description thereof is omitted. Connector B shown in FIG. 4, the conductive film 20 _i on a glass substrate _{1 i,} respectively, the back electrode _{3 i,} the light-absorbing layer _{4 i,} a plurality of power generation comprising in sequence a transparent conductive film _{5 i} and the surface electrode _{6 i} The bodies (I _i , I _{i + 1} , I _{i + 2} ,...) Have a structure in which the conductors 12 _i , 12 _{i + 1} , 12 _{i + 2} ,... And the solders 13 _i−1 , 13 _i , 13 _{i + 1} ,. Yes.

Here, as shown in FIG. 4, the conductor 12 _i includes the surface electrode 6 _{i of} the first power generation body (I _i ) and the side surface on which the surface electrode 6 _i is provided, and the glass substrate 1 _i . It is formed so as to continuously cover a part of the surface opposite to the light incident surface side. Then, a region in which the back electrode _{3 i} like are not stacked in the exposed portion 20a _i provided on the conductive film 20 _i of the first power generation element _{(I i),} formed on the side surface of the second generator bodies adjacent _{(I i + 1)} The portion of the lower surface of the glass substrate 1 _{i + 1} of the conductor 12 _{i + 1} is overlapped. Furthermore, with the solder 13 _i , the exposed portion 20 a _i provided on the conductive film 20 _i of the first power generation body (I _i ) and the conductor 12 _{i + 1} formed on the side surface of the second power generation body (I _{i + 1} ) By coupling, two adjacent power generators (I _i , I _{i + 1} ) are electrically connected in series.
In the present embodiment, after the surface electrode 6 _i is formed on the glass substrate 1 _i , the conductor 12 _i is formed by Al using a sputtering method so as to have a film thickness of 800 nm, and the surface electrode 6 _{i is formed.} In addition, it is formed by continuously covering the side surface on which the surface electrode 6 _i is provided and a part of the lower surface of the glass substrate 1 _i .

Further, in the present embodiment, the first power generation body (I _i ) is covered with an insulating film at the end face that contacts the conductors 12 _i and 12 _{i + 1} that electrically connect the adjacent power generation bodies.
Namely, as illustrated in FIG 4, the first power generating body in (I _i), a side of the side provided with the surface electrode 6 _i may be conductors 12 _i and electrically insulated is covered by the insulating film 14 _i Yes. The adjacent second power generation body (I _{i + 1} ) side is covered with an insulating film 15 _i at the end surface where the back electrode 3 _i , the light absorption layer 4 _i, and the transparent conductive film 5 _i are formed. It is electrically insulated from the lower part of 12 _{i + 1} .

(Embodiment 2: Power generator II)
FIG. 5 is a diagram for explaining the power generation body II of the second embodiment. About the same structure as the electric power generation body I shown in FIG. 1, the same code | symbol is used and the description is abbreviate | omitted. 5 includes a glass substrate 1, a conductive film 21 that covers the surface of the glass substrate 1, a back electrode 3, a light absorption layer 4, a transparent conductive film 5, and a surface electrode 6. .
And in this Embodiment, the electrically conductive film 21 which coat | covers the surface of the glass substrate 1 is a glass substrate as a part in which the back surface electrode 3 and another layer are not laminated | stacked on the surface on the opposite side to a contact surface with the glass substrate 1. An exposed portion 21 a that covers one end portion of the glass substrate 1 and an exposed portion 21 b that covers at least a part of the surface of the glass substrate 1 opposite to the light incident surface side are formed.

(Connector C)
Next, a connection body using the power generation body II will be described.
FIG. 6 is a diagram illustrating a connection body C in which a plurality of power generation bodies II are connected in series. About the same structure as the electric power generation body II shown in FIG. 5, the same code | symbol is used and the description is abbreviate | omitted.
Connector C shown in FIG. 6, a conductive film 21 on the glass substrate _{1 i i,} the back electrode _{3 i,} a plurality of power generating body comprising the light absorbing layer _{4 i,} the transparent conductive film _{5 i} and the surface electrode _{6 i} in order (II _i , II _{i + 1} , II _{i + 2} ,...) Are connected by solders 16 _i−1 , 16 _i , 16 _{i + 1} ,.

Here, as shown in FIG. 6, two adjacent power generators (II _i , II _{i + 1} ) include a surface electrode 6 _i in the first power generator (II _i ) and a second power generator (II _{i + 1).} The exposed portion 21b _{i + 1} which covers a part of the surface opposite to the light incident surface side of the glass substrate 1 _{i + 1} in FIG. Then, the surface electrode 6 _{i of} the first power generation body (II _i ) and the exposed portion 21 b _{i + 1} provided on the conductive film 21 _{i + 1} of the second power generation body (II _{i + 1} ) are joined by the solder 16 _i . Two adjacent power generators (II _i , II _{i + 1} ) are electrically connected in series.

(Connector D)
FIG. 7 is a diagram for explaining another embodiment of a connection body in which a plurality of power generation bodies II are connected in series. About the same structure as the electric power generation body II and the connection body C shown in FIG.5 and FIG.6, the same code | symbol is used and the description is abbreviate | omitted. The connection body D shown in FIG. 7A includes a plurality of conductive films 21 _i , a back electrode 3 _i , a light absorption layer 4 _i , a transparent conductive film 5 _i, and a front electrode 6 _i in order on a glass substrate 1 _i. Has a structure in which a plurality of power generators (II _i , II _{i + 1} ,...) Are connected by conductors 17 _i−1 , 17 _i ,... And solders 18 a _i−1 , 18 b _i , 18 a _i , 18 b _{i + 1} ,. is doing.

As shown in FIG. 7A, the conductor 17 _i includes a surface of the first power generation body (II _i ) on the side where the surface electrode 6 _i and the surface electrode 6 _i are provided, and a surface electrode 6 _i . It is formed so as to continuously cover the exposed portion 21b _{i + 1} of the conductive film 21 _{i + 1} of the second power generation body (II _{i + 1} ) adjacent to the side surface on the provided side. Then, the first power generating body by soldering 18a _i (II _i) combining the surface electrode _{6 i} and the conductor 17 _i of at solder _{18b i + 1} conductors 17 _i and second generators _{(II i +} 1) The two adjacent power generation bodies (II _i , II _{i + 1} ) are electrically connected in series by coupling the exposed portions 21b _{i + 1 of} the two.

Further, in this embodiment, the end face of the first power generating element in contact with the conductor 17 _i for electrically connecting the adjacent two generators (II _i) is covered with an insulating film.
That is, as shown in FIG. 7A, in the first power generator (II _i ), the side surface on the side where the surface electrode 6 _i is provided is covered with the insulating film 19 a _i . Further, the side surface opposite to the side on which the front surface electrode 6 _i is provided, and the end surface of the portion where the back surface electrode 3 _i , the light absorption layer 4 _i and the transparent conductive film 5 _i are formed is covered with an insulating film 19 b _i . It has been broken.

In this embodiment, an exposed portion _{21b i + 1} of the first power generation surface electrode _{6 i} and the second power generating body _{(II i) (II i +} 1) attached, adjacent two generators (II _i , II i + ₁₎ conductors 17 are electrically connected in series _i is composed of a flexible material.
Here, the flexible material is not particularly limited as long as it is a material that has conductivity, deforms softly with respect to external force, and has a property of returning to its original shape when the external force is removed. Examples of the tape include a tape encapsulating a conductive wire used for tape automated bonding (TAB) and TCP (Tape Carrier Package).
Since the conductor 17 _i is made of a flexible material, for example, as shown in FIG. 7B, even when an external force is applied to the connection body D, the power generation bodies move flexibly, The mutual positional relationship can be flexibly adjusted. As a result, the stress applied to the connecting portion between the power generators and the strain based on the applied stress are reduced, and the connection strength is increased.

As mentioned above, although embodiment of this invention was described concretely, this invention is not limited to this. For example, the material of the light absorption layer is not limited to a Cu—In—Se compound, and a silicon-based material, an organic material, or the like is appropriately selected. The insulating substrate is not limited to a glass substrate, and for example, a polymer material such as polyimide is appropriately selected.
The film forming means for each layer is not limited to the sputtering method, and an evaporation method, plating, or the like is appropriately selected. The conductor and the conductive adhesive for connecting the power generators are not limited to solder. For example, a conductive material such as indium (In) is appropriately selected, and a technique such as welding by ultrasonic vibration is used. Can be adopted.

It is a figure explaining the electric power generation body I of Embodiment 1. FIG. It is a figure explaining the mask used when forming the electric power generation body I by sputtering method. It is a figure explaining the connection body which connected the several electric power generation body I in series. It is a figure explaining other embodiment of the connection body which connected the several electric power generation body I in series. It is a figure explaining the electric power generation body II of Embodiment 2. FIG. It is a figure explaining the connection body which connected the several electric power generation body II in series. It is a figure explaining other embodiment of the connection body which connected the several electric power generation body II in series.

Explanation of symbols

1 ... glass substrate, 20, 21 ... conductive film, 3 ... back electrode, 4 ... light absorbing layer, 5 ... transparent conductive film, 6 ... surface electrode, 20a, 21a, 21b ... exposed _portion, 9 _i, 13 i, 16 _i , 18 a _i , 18 b _i ... solder, 12 _i , 17 _i ... conductor, 10 a _i , 10 b _i ... first insulating film, 11 _i ... second insulating film, 14 _i , 15 _i , 19 a _i , 19 b _i ... Insulating film

Claims (7)

A power generator that generates power when irradiated with light,
An insulating substrate;
A conductive film covering the light incident side surface of the insulating substrate;
A back electrode having a portion laminated on the conductive film;
At least a light absorption layer and a surface electrode are provided on the back electrode,
The power generation body, wherein the conductive film covering the insulating substrate has an exposed portion where the back electrode is not laminated on a surface opposite to a contact surface with the insulating substrate.   2. The power generator according to claim 1, wherein the conductive film covering the insulating substrate further covers at least a part of an end portion of the insulating substrate and a surface opposite to the light incident surface side. A connection body in which a plurality of power generation bodies that generate power by light irradiation are connected,
A first power generation body comprising at least a first back electrode, a first light absorption layer, and a first front electrode in order on a first insulating substrate;
A second power generation body connected in series with the first power generation body, and comprising at least a second back electrode, a second light absorption layer, and a second surface electrode in order on a second insulating substrate; With
The first power generating body covers the light incident side surface of the first insulating substrate, and the first back electrode is not laminated on the surface opposite to the contact surface with the first insulating substrate. A first conductive film provided with an exposed portion;
The connection body, wherein the exposed portion of the first conductive film and the second surface electrode of the second power generation body are connected by a predetermined conductor. A first insulating film covering at least a part of an end face of the first power generator on the second power generator side;
4. A second insulating film that covers at least a part of an end surface of the second power generation body on the first power generation body side of the second power generation body connected in series with the first power generation body. Connected body described in 1.   4. The conductor that connects the exposed portion of the first conductive film and the second surface electrode of the second power generator is made of a flexible material. The connection body described. A method of manufacturing a connection body in which a plurality of power generation bodies that generate power by light irradiation are connected,
On the first insulating substrate, at least a first back electrode, a first light absorption layer, and a first surface electrode are provided in order, and further, a light incident side surface of the first insulating substrate is covered, And forming a first power generator having a first conductive film provided with an exposed portion on which the first back electrode is not laminated on the surface opposite to the contact surface with the first insulating substrate;
Forming a second power generation body including at least a second back electrode, a second light absorption layer, and a second front electrode in order on the second insulating substrate;
The first power generation is performed by connecting the exposed portion of the first conductive film of the first power generation body and the second surface electrode of the second power generation body using a predetermined conductor. A method of manufacturing a connection body, comprising: connecting a body and the second power generation body.   Covering at least a part of the end face of the first power generation body on the second power generation body side with a first insulating film, and further, the second power generation body connected in series with the first power generation body The method for manufacturing a connection body according to claim 6, wherein at least part of the end face on the first power generation body side is covered with a second insulating film.

Images