JP4993333B2 - Photovoltaic panel manufacturing method - Google Patents

Description

The present invention is an invention relating to a manufacturing method of multiple granular photovoltaic element lattice points photovoltaic panel which is integrally molded into panel-like transparent resin is arranged in (an array).

  In recent years, for example, Patent Document 1 (Japanese Patent Publication No. 7-54855) and Patent Document 2 (Japanese Patent Application Laid-Open No. 2002-164554) have been proposed in order to increase the power generation efficiency of photovoltaic panels that convert solar energy into electrical energy. As shown, a photovoltaic device is formed in a granular form. Granular photovoltaic elements have the advantage that the element projected area (light receiving amount) seen from the light incident direction is almost constant with respect to sunlight incident from various directions, so that it is possible to generate power efficiently even when the solar altitude is low. There is.

In the techniques of these Patent Documents 1 and 2, granular silicon is fitted into each of a large number of circular holes formed in the base plate that also serves as a surface electrode, and the granular silicon exposed portion protruding to the lower surface side of the base plate is interposed via an insulating layer. An electrode is formed.
Japanese Patent Publication No. 7-54855 JP 2002-164554 A

  In the techniques of Patent Documents 1 and 2, the area of the granular silicon light receiving region exposed on the upper surface side of the base plate and the size (height) of the electrode forming region on the lower surface side are the inner diameter of the circular hole formed in the base plate. Since it is determined by the relationship with the outer diameter of the granular silicon, in order to make the area of the granular silicon light receiving region and the size (height) of the electrode forming region uniform, the outer diameter size, shape and true sphere of the granular silicon High uniformity is required for accuracy. Further, high spherical accuracy is required for granular silicon in order to form a good electrical connection between the base plate that also serves as a surface electrode and granular silicon. For this reason, the management of the granular silicon manufacturing process is complicated, the productivity of the granular silicon is lowered, the yield of the granular silicon is deteriorated, and the manufacturing cost is increased.

  Therefore, the present applicant has applied for two inventions (Japanese Patent Application No. 2003-345292 and Japanese Patent Application No. 2004-190590) that solve this problem by different methods. Neither of these two patent applications has been published.

  Japanese Patent Application No. 2003-345292 discloses a method of forming a condensing lens one by one in a photovoltaic element. Specifically, each photovoltaic device is dipped in a resin solution and pulled up, and the resin solution adhering to the surface of each photovoltaic device is cured into a spherical convex shape by surface tension and cured to a resin on the surface of each photovoltaic device. A condensing lens made of this method is formed, and a photovoltaic panel is formed by arranging a large number of photovoltaic elements with a condensing lens formed in this manner in a planar shape. However, in this method, it is inevitable that the outer diameter of the condensing lens varies due to variations in the outer diameter and shape of the photovoltaic elements. Therefore, a large number of photovoltaic elements with condensing lenses are arranged in a plane. In the process of forming the photovoltaic panel, a gap is created around some condensing lenses, and the light incident on this gap no longer contributes to photovoltaic power generation. ing.

  In Japanese Patent Application No. 2004-190590, a spherical reflecting surface is formed on the lower side of each photovoltaic element, and light is condensed on this reflecting surface. Since this reflecting surface also serves as an electrode of the photovoltaic device, the reflecting surface material is required to have adhesion (bondability) with the photovoltaic device (granular silicon) in addition to high light reflectance. However, in reality, it is difficult to satisfy these two requirements, and it has been found that one of the functions is sacrificed and the power generation efficiency is lowered.

The present invention has been made in consideration of such circumstances. Therefore, the object of the present invention is to satisfy the required quality level of the photovoltaic panel, while maintaining the outer diameter size, shape and true spherical accuracy of the photovoltaic element (granular silicon). to be able to widen the allowable range for the productivity of the photovoltaic device improves, it is possible to realize the improved yield without reducing product quality, to provide a method for manufacturing a photovoltaic panel which can improve the power generation efficiency It is in.

In order to achieve the above object, the invention according to claim 1 is a method of manufacturing a photovoltaic panel in which a large number of granular photovoltaic elements are arrayed in a lattice point shape (array shape) and integrally formed into a panel shape with a transparent resin. A temporary holding step of temporarily holding the plurality of photovoltaic elements arranged in a lattice point on one side of the temporary holding plate, a condensing lens covering each of the photovoltaic elements from the light receiving surface side, and each of the photovoltaic generators A resin solution of the transparent resin is injected into a mold for forming a transparent resin layer for holding the element, and the numerous photovoltaic elements temporarily held on one side of the temporary holding plate are added to the resin liquid. A molding step of molding a photovoltaic panel in which the condensing lens and the transparent resin layer holding the photovoltaic elements are integrated by immersing the resin liquid, and molding the photovoltaic panel The photovoltaic panel is removed from the mold Is characterized in that a step of peeling the al the temporary holding plate. In this manufacturing method, since a large number of condensing lenses can be integrally formed with a molding die, even if there is a slight variation in the size (diameter dimension) and shape (sphericity) of each photovoltaic element, Spherical convex convex condenser lens can be formed on the surface, and the tolerance level for the outer diameter size, shape and true spherical accuracy of photovoltaic element (granular silicon) can be expanded while meeting the required quality level of photovoltaic panel As a result, it is possible to improve the productivity and yield of photovoltaic devices without degrading product quality. In addition, since the condensing lens can be formed without gaps over the entire light receiving surface of the photovoltaic panel by the molding die, the light received by the photovoltaic panel can be efficiently contributed to photovoltaic power generation, and the power generation efficiency can be improved. This can be expected to reduce the cost by reducing the size of the photovoltaic panel and reducing the number of photovoltaic elements used.
In the manufacturing method of the present invention, it is possible to easily perform the operation of positioning a large number of photovoltaic elements with respect to the mold and immersing them in a resin liquid in the molding step. It is possible to efficiently form a photovoltaic panel in which the above is integrated. In addition, by adjusting the amount of a large number of photovoltaic elements temporarily held on one side of the temporary holding plate in the resin liquid in the molding process, the photovoltaic power generation is at an arbitrary height position with respect to the focal point of the condenser lens. Elements can be placed.

In this case, as in claim 2 , the temporary holding plate is formed of a transparent material, and in the molding step, an ultraviolet curable resin liquid is used, and ultraviolet rays are transmitted through the temporary holding plate to the resin liquid. It is preferable to cure the resin liquid by irradiation. If it does in this way, a condensing lens and a transparent resin layer can be hardened in a molding process by ultraviolet irradiation in a short time, and productivity can be improved. The same effect can be obtained by forming the mold with a transparent material and allowing the resin liquid to cure by transmitting ultraviolet rays through the mold.

In the case of manufacturing a photovoltaic panel having a configuration in which the light receiving surface of the condenser lens is covered with a transparent lens protective cover that also serves as a mold for molding the condenser lens, the condenser lens as in claim 3. Forming a transparent lens protective cover that also serves as a mold for molding the resin, injecting a resin liquid of the transparent resin into the lens protective cover, and arranging the plurality of photovoltaic elements in a lattice point form A photovoltaic panel in which the condensing lens, the transparent resin layer holding each photovoltaic element and the lens protective cover are integrated is formed by positioning and immersing in the resin liquid to cure the resin liquid. It is preferable to execute the molding process. In this way, a photovoltaic panel with a lens protective cover can be efficiently manufactured.

Further, as described in claim 4 , after the molding step is completed, a back cover is covered on the back surface of the photovoltaic panel, and the peripheral edge portion of the back cover and the peripheral edge portion of the lens protective cover are combined. In this way, the photovoltaic panel wrapped with the lens protective cover and the back cover can be efficiently manufactured.

Also in this case, as in claim 5 , after the large number of photovoltaic elements are preliminarily arranged in a lattice point form on one side of the temporary holding plate and then temporarily held in the molding step, The photovoltaic elements temporarily held in the substrate are immersed in the resin liquid to cure the resin liquid to form the photovoltaic panel, and after the molding process, the temporary holding plate is peeled off from the photovoltaic panel. It is good to do. In this way, in the molding process, it is possible to easily perform the operation of positioning a large number of photovoltaic elements with respect to the lens protective cover that also serves as a mold and immersing them in the resin liquid. A photovoltaic panel in which the condenser lens and the lens protective cover are integrated can be efficiently molded.

  Hereinafter, two Examples 1 and 2, which embody the best mode for carrying out the present invention, will be described.

A first embodiment of the present invention will be described with reference to FIGS.
First, the structure of the photovoltaic panel 10 manufactured by the manufacturing method of the first embodiment will be described with reference to FIG.

  The photovoltaic panel 10 includes a large number of granular photovoltaic elements 11 arranged in a lattice point (array) and integrated with a transparent resin layer 12. As the transparent resin layer 12, for example, an ultraviolet curable transparent resin may be used.

  Each photovoltaic element 11 is formed with a thin n-type semiconductor layer 11a on the outer peripheral portion, and a p-type semiconductor layer 11b on the inner peripheral side. The method for producing the photovoltaic element 11 is not particularly limited. For example, as shown in International Publication WO99 / 10935, a silicon droplet that has been heated and melted is freely dropped, and the silicon droplet is subjected to surface tension. Manufacturing a granular photovoltaic device by depositing Si over the entire surface of the core material in a plasma CVD apparatus as shown in Japanese Patent Application Laid-Open No. 2002-60943, or a free fall method in which it is deformed into a spherical shape and solidified The plasma CVD method may be used, or other manufacturing methods may be used.

  On the light-receiving surface side (upper surface side in FIG. 1) of the photovoltaic panel 10, a spherical convex condensing lens 13 is formed by a molding die 25 (see FIG. 5) so as to cover each photovoltaic element 11 with a transparent resin. It is integrally formed with the layer 12. In the first embodiment, the photovoltaic element 11 is arranged at the center of the spherical convex condenser lens 13, and the ratio D / d between the diameter D of each condenser lens 13 and the diameter d of the photovoltaic element 11 is approximately n2. / N1 or more (where n1 is the refractive index of the medium outside the condenser lens 13, and n2 is the refractive index of the condenser lens 13).

  For example, if the medium outside the condenser lens 13 is air, the refractive index n1 is 1.0, and if it is water, the refractive index n1 is approximately 1.3. If the condenser lens 13 is made of a transparent resin as in the first embodiment, the refractive index n2 is approximately 1.5. For reference, in the case of a glass lens, the refractive index n2 is approximately 1.5. In general, since the medium outside the condenser lens 13 is air, when the condenser lens 13 is formed of a transparent resin as in the first embodiment, n2 / n1 is approximately 1.5. .

  In this case, if D / d is smaller than n2 / n1, the parallel light incident on the surface of the condenser lens 13 is refracted by the condenser lens 13 and is all condensed on the surface of the photovoltaic element 11, so that the light A light reflecting film is not required on the back side of the power generation panel 10. Therefore, the present invention may be formed so that D / d is smaller than n2 / n1, but when D / d is smaller, the number of photovoltaic elements 11 used is increased and the cost is increased.

  On the other hand, when D / d is larger than n2 / n1, a part of the parallel light incident on the surface of the condenser lens 13 passes through the surface of the photovoltaic element 13 without being condensed. If light is reflected by the light reflecting film (electrode 14) and received by the photovoltaic element 11, the power generation efficiency can be increased. From this point of view, in the first embodiment, D / d is formed to be approximately n2 / n1 or more. Thereby, high power generation efficiency is realizable, reducing the number of the photovoltaic elements 11 used, and satisfy | filling the request | requirement of cost property.

  Further, the photovoltaic panel 10 of the present invention may have a small gap between the condenser lenses 13, but in the first embodiment, the condenser lenses 13 are formed in contact with each other. . Thereby, the clearance gap between each condensing lens 13 can be minimized, and the condensing efficiency by the condensing lens 13 can be maximized.

  On the back surface side of the photovoltaic panel 10 (on the lower surface side in FIG. 1), an n-electrode 14 that is electrically connected to the n-type semiconductor layer 11 a on the outer periphery of each photovoltaic device 11 is formed so as to cover the entire back surface of the transparent resin layer 12. Has been. The n-electrode 14 also functions as a light reflecting film that reflects the light transmitted through the transparent resin layer 12 toward the photovoltaic elements 11. The n electrode 14 is completely covered with two insulating resin layers 15 and 16. The first insulating resin layer 15 functions as a protective layer (mask) during etching described later, and the second insulating resin layer 16 is an insulating layer that insulates between the n electrode 14 and the p electrode 17. Function as.

  A portion where the n-type semiconductor layer 11a is partially removed by polishing or the like to expose the p-type semiconductor layer 11b is formed at the rear end of each photovoltaic element 11, and the p-electrode 17 is formed on the p-type semiconductor layer 11b. Is formed to be conductive. The p-electrode 17 is completely covered and protected and insulated by a protective insulating layer 18 formed of an insulating resin or the like.

  A method for manufacturing the photovoltaic panel 10 configured as described above will be described. As described above, the method for manufacturing the granular photovoltaic element 11 is not particularly limited, and the granular photovoltaic element 11 may be manufactured by any method. The process up to the production of the photovoltaic panel 10 may be performed consistently, or the photovoltaic panel 10 may be produced by purchasing photovoltaic elements 11 produced by other manufacturers. Hereinafter, each process which manufactures the photovoltaic panel 10 using the granular photovoltaic element 11 manufactured with the some method is demonstrated in order.

[1] Photovoltaic Element Alignment Step First, as shown in FIG. 2, an element alignment jig 21 in which a large number of element positioning recesses 22 into which the photovoltaic elements 11 are fitted one by one is formed in a lattice point shape is used. A large number of photovoltaic elements 11 are aligned in lattice points by fitting one photovoltaic element 11 into each element positioning recess 22 of the element alignment jig 21. At this time, the arrangement pitch of the photovoltaic elements 11 (element positioning recesses 22) aligned on the element alignment jig 21 matches the arrangement pitch of the photovoltaic elements 11 of the photovoltaic panel 10 to be manufactured.

[2] Temporary holding step After the photovoltaic element alignment step, the process proceeds to a temporary holding step. In this temporary holding step, as shown in FIG. 3, an adhesive is applied to one side of the temporary holding plate 23 using a temporary holding plate 23 formed of a transparent material such as transparent glass capable of transmitting ultraviolet rays. An adhesive layer is formed on one side of the temporary holding plate 23 by coating or by sticking a double-sided adhesive sheet. The thickness of the adhesive layer is desirably set to a thickness that can absorb the variation in the diameter of the photovoltaic element 11.

  Then, with the adhesive layer of the temporary holding plate 23 facing downward, the temporary holding plate 23 is lowered from above the element alignment jig 21, and the adhesive layer of the temporary holding plate 23 is placed on each of the element alignment jigs 21. Press against the photovoltaic element 11. As a result, the photovoltaic elements 11 are adhered (temporarily held) to the adhesive layer of the temporary holding plate 23 in a state where the photovoltaic elements 11 are arranged in a lattice point form.

[3] Molding process After the temporary holding process is completed, the process proceeds to the molding process. First, as shown in FIG. 4, a resin liquid of an ultraviolet curable transparent resin is formed in a mold 25 in which a large number of condensing lens molding cavities 24 are formed. 26 is injected. Thereafter, with the photovoltaic elements 11 adhered to the adhesive layer of the temporary holding plate 23 aligned with the condensing lens molding cavities 24 of the mold 25, the temporary holding plate 23 is lowered, as shown in FIG. As described above, the photovoltaic elements 11 adhered to the adhesive layer of the temporary holding plate 23 are immersed in the resin liquid 26 of the condenser lens molding cavities 24. At this time, if the amount of immersion of the photovoltaic element 11 in the resin liquid 26 is adjusted, the photovoltaic element 11 can be arranged at an arbitrary height position with respect to the focal point of the condenser lens 13. When the photovoltaic device 11 is immersed in the resin liquid 26, a gap is provided between the lower surface (adhesive layer) of the temporary holding plate 23 and the resin liquid 26 so that the lower surface (adhesive layer) of the temporary holding plate 23. The resin liquid 26 is prevented from adhering to the surface.

  Thereafter, as shown in FIG. 6, ultraviolet rays are irradiated downward from above the temporary holding plate 23. Thereby, the condensing lens 13 and the transparent resin layer 12 that holds each photovoltaic element 11 are integrated by passing ultraviolet rays through the temporary holding plate 23 and irradiating the resin liquid 26 to cure the resin liquid 26. The converted photovoltaic panel 10 is molded. Alternatively, the mold 25 may be formed of a transparent material, and the resin liquid 26 may be cured by allowing ultraviolet rays to pass through the mold 25.

[4] Mold Release Process After the molding process is completed, the process proceeds to the mold release process. As shown in FIG. 7, the molded photovoltaic panel 10 is taken out from the molding mold 25 and temporarily held from the back side of the photovoltaic panel 10. The plate 23 is peeled off. At this time, if the resin liquid 26 is not attached to the lower surface of the temporary holding plate 23, the temporary holding plate 23 can be easily peeled from the back surface side of the photovoltaic panel 10.

[5] n-electrode formation process After the mold release process, the process proceeds to the n-electrode formation process. As shown in FIG. 8, conductors such as vapor deposition, plating, CVD, sputtering, coating, and printing are formed on the entire back surface of the photovoltaic panel 10. An n-electrode 14 is formed using a film forming technique. As the conductor forming the n-electrode 14, it is preferable to use a conductor that has a small electrical resistance value such as Ag or an Ag-based conductor and easily reflects light (to function as a reflection surface of incident light). The n-electrode 14 is electrically connected to the n-type semiconductor layer 11 a on the outer peripheral portion of each photovoltaic element 11 and covers the entire back surface of the transparent resin layer 12 to function as a light reflecting film for incident light. . In addition, since a part of n electrode 14 is removed so that a part of photovoltaic device 11 may be exposed by the sandblast process mentioned later, the part which does not form the n electrode 14 may exist in the part.

[6] Protection Layer (First Insulating Resin Layer) Formation Process After the n electrode formation process is completed, the process proceeds to the protection layer formation process, and as shown in FIG. Then, an insulating resin such as an epoxy resin is applied and cured to form a protective layer (first insulating resin layer) 15, and the entire surface of the n electrode 14 is covered with the protective layer 15. The resin for forming the protective layer 15 may be any of thermosetting resin, ultraviolet curable resin, anaerobic curable resin, etc., but has insulation, chemical resistance and acid resistance (used as a mask during etching). For that). In addition, since a part of the protective layer 15 is removed so as to expose a part of the photovoltaic element 11 in the next sandblasting step, there may be a part where the protective layer 15 is not formed.

[7] Sandblasting process After the protective layer forming process is completed, the process proceeds to the sandblasting process. As shown in FIG. 10, the protective layer 15 and the n-electrode 14 at the rear end of each photovoltaic element 11 are partially removed by sandblasting. The n-type semiconductor layer 11a at the rear end of each photovoltaic element 11 is exposed. Instead of sandblasting, the protective layer 15 and the n-electrode 14 may be partially removed by polishing, laser processing, electric discharge processing, or the like.

[8] Etching Step After the sandblasting step, the process proceeds to the etching step, and the protective layer 15 is used as a mask (etching resist), and the n-type semiconductor layer 11a at the rear end of the photovoltaic element 11 exposed from the protective layer 15 is removed. Chemical etching is partially removed to expose the p-type semiconductor layer 11b inside. Note that dry etching may be used instead of chemical etching.

[9] Insulating layer (second insulating resin layer) forming step After the etching step is completed, the process proceeds to an insulating layer (second insulating resin layer) forming step, and as shown in FIG. An insulating resin (second insulating resin layer) 16 is formed by applying and curing an insulating resin such as an epoxy resin on the entire back surface of the n-type electrode, and the n-electrode 14 partially exposed in the sandblasting process. Completely covered and insulated. As the resin forming the insulating layer 16, any of the same type or different types of insulating resin as the protective layer 15 thereunder may be used, and any of thermosetting resin, ultraviolet curable resin, anaerobic curable resin, etc. may be used. It may be used. Since a part of the insulating layer 16 is removed so as to expose a part of the photovoltaic element 11 in the next polishing step, there may be a part where the insulating layer 16 is not formed.

[10] Polishing Step After the insulating layer forming step is completed, the process proceeds to the polishing step. As shown in FIG. 12, the insulating layer 16 on the back surface of the photovoltaic panel 10 is polished and planarized by a polishing apparatus, and the photovoltaic element 11 The p-type semiconductor layer 11b at the rear end is exposed from the insulating layer 16, and the exposed surface of the p-type semiconductor layer 11b is planarized. In addition, you may make it grind | polish by sandblasting.

[11] p-electrode forming process After the polishing process is completed, the process proceeds to the p-electrode forming process. As shown in FIG. 13, the p-electrode 17 is placed on the entire back surface of the photovoltaic panel 10. It is formed so as to be in close contact with the exposed surface. The conductor forming the p-electrode 17 may be the same conductor as the n-electrode 14 described above, or a different conductor may be used. The p-electrode 17 may be formed by the same method as the n-electrode 14 or by a different method. For example, a conductor such as Al is rubbed against the entire back surface of the photovoltaic panel 10, and the conductor such as Al is applied to the exposed surface of the p-type semiconductor layer 11 b of each photovoltaic element 11 and the insulating layer 16 by the frictional force and frictional heat. The p electrode 17 may be formed by adhering. Alternatively, the p-electrode 17 may be formed by attaching a conductive foil such as an aluminum foil to the entire back surface of the photovoltaic panel 10.

[12] Laser sintering process After the p electrode forming process is completed, the laser sintering process is performed, and laser light is spotted at the center of the junction between the p electrode 17 and the p-type semiconductor layer 11b at the rear end of each photovoltaic element 11. The p electrode 17 is heat-treated (sintered) to form an ohmic contact.

[13] Protective insulating layer forming process After the laser sintering process, the process proceeds to the protective insulating layer forming process, and as shown in FIG. 14, an insulating resin is applied to the entire surface of the p-electrode 17 on the back surface of the photovoltaic panel 10 and cured. Thus, the protective insulating layer 18 is formed, and the entire surface of the p electrode 17 is covered with the protective insulating layer 18. As the resin forming the protective insulating layer 18, any of thermosetting resin, ultraviolet curable resin, anaerobic curable resin, and the like may be used. If each process [1]-[13] demonstrated above is performed one by one, manufacture of the photovoltaic panel 10 will be completed.

  According to the first embodiment described above, in the photovoltaic panel 10 in which a large number of granular photovoltaic elements 11 are arranged in lattice points and integrally formed in a panel shape with the transparent resin layer 12, the photovoltaic panel 10 receives light. Since the condenser lens 13 that covers each photovoltaic element 11 is integrally formed on the surface side by the molding die 25, the size (diameter dimension) and shape (sphericity) of each photovoltaic element 11 are somewhat different. Can be formed on the surface of each photovoltaic element 11, and the outer diameter dimension and shape of the photovoltaic element 11 can be satisfied while satisfying the required quality level of the photovoltaic panel 10. -The allowable range for the true spherical accuracy can be expanded, and the productivity improvement and the yield improvement of the photovoltaic device 11 can be realized without deteriorating the product quality. Moreover, since the condensing lens 13 can be formed without gaps over the entire light receiving surface of the photovoltaic panel 10 by the molding die 25, the light received by the photovoltaic panel 10 can be efficiently contributed to photovoltaic power generation, and the power generation efficiency can be improved. Can be improved. Thereby, cost reduction by size reduction of the photovoltaic panel 10 and reduction of the number of the photovoltaic elements 11 used can also be expected.

  Moreover, in the first embodiment, the temporary holding plate 23 is formed of a transparent material, and in the molding process, an ultraviolet curable resin liquid 26 is used, and ultraviolet rays are transmitted through the temporary holding plate 23 to irradiate the resin liquid 26. By doing so, the resin liquid 26 is cured, so that in the molding process, the condenser lens 13 and the transparent resin layer 12 can be cured in a short time by ultraviolet irradiation, and productivity can be improved.

  In the first embodiment, one photovoltaic element 11 is fitted into each element positioning recess 22 of the element aligning jig 21 so that a large number of photovoltaic elements 11 are aligned in a lattice point state. Then, a large number of photovoltaic elements 11 are arranged and adhered to the adhesive layer of the temporary holding plate 23 in the form of lattice points, but in addition to this, the following alignment method of the photovoltaic elements 11 is adopted. Also good. For example, instead of the element positioning recess 22 in the element alignment jig, through holes having a diameter slightly larger than the diameter of the photovoltaic element 11 are formed in a lattice point shape, and this element alignment jig is attached to the temporary holding plate 23. By pressing the photovoltaic device 11 one by one from each through hole of the element alignment jig and pressing it against the adhesive layer of the temporary holding plate 23 with the adhesive layer on the upper surface facing a slight gap, A large number of photovoltaic elements 11 may be arranged and adhered to the adhesive layer of the temporary holding plate 23 in the form of lattice points.

  Next, a second embodiment of the present invention will be described with reference to FIGS. In the following description, parts that are substantially the same as those in the first embodiment are denoted by the same reference numerals, and the description is simplified.

  As shown in FIG. 19, the photovoltaic panel 30 of the second embodiment covers the light receiving surface of the condenser lens 13 with a transparent lens protective cover 31 that also serves as a mold for molding the condenser lens 13, and The back surface of the power generation panel 30 is covered with an insulating back cover 32, the peripheral edge portion of the back cover 32 and the peripheral edge portion of the lens protection cover 31 are joined together by a sealing material 33, and the entire photovoltaic power generation panel 30 is connected to the lens protection cover 31. And the back cover 32 and are sealed (sealed) in a sealed state.

  In this case, the lens protective cover 31 is formed of a transparent resin excellent in weather resistance, wear resistance, and ultraviolet ray cut-off property (preventing ultraviolet ray deterioration of the condenser lens 13). On the other hand, the back cover 32 is formed of a resin excellent in weather resistance, wear resistance, and insulation. Since the back cover 32 is not required to be transparent or UV cut, it may be formed of an opaque or translucent resin or a resin that transmits ultraviolet light. In addition, the material for forming the lens protection cover 31 and the back cover 32 is not limited to resin, and it goes without saying that it may be formed of a material other than resin, such as glass.

  In the second embodiment, the insulating back cover 32 that covers the entire back surface of the photovoltaic panel 30 plays a role corresponding to the protective insulating layer 18 of the first embodiment. Therefore, the protective insulating layer 18 is formed on the p-electrode 17. However, it goes without saying that the protective insulating layer 18 may be formed on the p-electrode 17 in order to further enhance the sealing effect.

  Alternatively, the protective insulating layer 18 formed on the p-electrode 17 on the back surface of the photovoltaic panel 30 by the same method as in the first embodiment is used as a back cover, and the peripheral portion of the protective insulating layer 18 (back cover) and lens protection are used. You may make it join with the peripheral part of the cover 31 by adhesion | attachment, heat sealing | fusion, etc. FIG.

The photovoltaic panel 30 of Example 2 configured as described above is manufactured through the following steps.
First, a transparent lens protective cover 31 (see FIG. 15) that also serves as a mold for forming the condenser lens 13 and a back cover 32 are prepared. When these are formed of resin, they may be formed by a vacuum forming method, an injection forming method, a compression forming method or the like. Inside the lens protective cover 31, a cavity 31a having the same shape as the cavity 24 of the mold 25 used in the first embodiment is formed.

  Then, as in the first embodiment, [1] photovoltaic element alignment step and [2] temporary holding step are performed, and each photovoltaic element 11 is latticed on the adhesive layer on the lower surface of the temporary holding plate 23 as shown in FIG. Adhesion (temporary holding) is performed in the state of being arranged in the form of dots.

  Thereafter, the process proceeds to a molding step, and as shown in FIG. 16, a resin liquid 26 of an ultraviolet curable transparent resin is injected into the cavity 31a of the lens protective cover 31 that also serves as a mold. Thereafter, in a state where the photovoltaic elements 11 adhered to the adhesive layer of the temporary holding plate 23 are aligned with the cavities 31a of the lens protective cover 31, the temporary holding plate 23 is lowered, as shown in FIG. Each photovoltaic device 11 adhered to the adhesive layer of the temporary holding plate 23 is immersed in the resin liquid 26 in the cavity 13a of the lens protective cover 31. At this time, if the amount of immersion of the photovoltaic element 11 in the resin liquid 26 is adjusted, the photovoltaic element 11 can be arranged at an arbitrary height position with respect to the focal point of the condenser lens 13. When the photovoltaic device 11 is immersed in the resin liquid 26, a gap is provided between the lower surface (adhesive layer) of the temporary holding plate 23 and the resin liquid 26 so that the lower surface (adhesive layer) of the temporary holding plate 23. The resin liquid 26 is prevented from adhering to the surface.

  Thereafter, ultraviolet rays are irradiated downward from above the temporary holding plate 23. Thus, the transparent resin that holds the lens protective cover 31, the condensing lens 13, and each photovoltaic device 11 by irradiating the resin liquid 26 with the ultraviolet light transmitted through the temporary holding plate 23 and curing the resin liquid 26. The photovoltaic panel 30 integrated with the layer 12 is molded.

  After completion of the molding process, the temporary holding plate 23 is peeled from the rear surface side of the photovoltaic panel 30 after molding, as shown in FIG.

  Thereafter, as in Example 1, [5] n-electrode forming step, [6] protective layer (first insulating resin layer) forming step, [7] sandblasting step, [8] etching step, [ 9) An insulating layer (second insulating resin layer) forming step, [10] polishing step, [11] p-electrode forming step, and [12] laser sintering step are sequentially executed.

  Thereafter, as shown in FIG. 18, the back cover 32 is put on the p-electrode 17 on the back surface of the photovoltaic panel 30, and the peripheral portion of the back cover 32 and the peripheral portion of the lens protective cover 31 are joined by the sealing material 33. Then, the entire photovoltaic panel 30 is wrapped with the lens protection cover 31 and the back cover 32 and sealed (sealed) in a sealed state. As the sealing method, an appropriate method such as heat fusion or adhesive may be used. Further, the sealing material 33 is omitted, and the peripheral edge of the back cover 32 and the peripheral edge of the lens protective cover 31 are thermally fused. You may make it join by adhesion | attachment, adhesion | attachment, etc.

  In the second embodiment described above, the condensing lens 13 is formed using the lens protective cover 31 of the condensing lens 13 as a molding die, and the photovoltaic panel 30 with the lens protective cover 31 is formed. A mold release step after molding becomes unnecessary, and a step of attaching the lens protection cover 31 to the photovoltaic panel 30 becomes unnecessary, so that productivity can be improved. In addition, since the condensing lens 13 and the lens protective cover 31 can be formed of different materials, the selection range of materials for forming these can be expanded. For example, the condensing lens 13 is formed of a highly transparent resin, and the lens The protective lens 31 and the lens protective cover are formed such that the protective cover 31 is formed of a transparent resin (or glass) excellent in weather resistance, abrasion resistance, and ultraviolet ray cut-off property (preventing ultraviolet ray deterioration of the condenser lens 13). 31 can be formed of a suitable material in accordance with the intended use, and the power generation efficiency, durability, and cost can be improved.

  In addition, since the entire photovoltaic panel 30 is wrapped with the lens protective cover 31 and the back cover 32 and sealed (sealed) in a sealed state, the waterproof property of the photovoltaic panel 30 can be improved. In addition, also in the second embodiment, the same effects as in the first embodiment can be obtained.

  In each of Examples 1 and 2, the outer peripheral side of the photovoltaic element 11 is an n-type semiconductor layer and the inner peripheral side is a p-type semiconductor layer. The peripheral side may be an n-type semiconductor layer. In this case, the positions of the n electrode and the p electrode are also reversed, and an ohmic contact resistance portion may be formed at the junction between the n electrode and the photovoltaic element 11 by laser beam sintering.

It is a longitudinal cross-sectional view which shows the structure of the photovoltaic panel manufactured with the manufacturing method of Example 1 of this invention. It is a figure explaining the photovoltaic device alignment process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the temporary holding process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the formation process in the manufacturing method of the photovoltaic panel of Example 1 (the 1). It is a figure explaining the formation process in the manufacturing method of the photovoltaic panel of Example 1 (the 2). It is a figure explaining the formation process in the manufacturing method of the photovoltaic panel of Example 1 (the 3). It is a figure explaining the mold release process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the n electrode formation process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the protective layer (1st insulating resin layer) formation process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the sandblasting process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the insulating layer (2nd insulating resin layer) formation process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the grinding | polishing process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the p electrode formation process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is a figure explaining the protective insulating layer formation process in the manufacturing method of the photovoltaic panel of Example 1. FIG. It is sectional drawing which shows the lens protective cover used as a shaping | molding die used with the manufacturing method of the photovoltaic panel of Example 2. FIG. It is a figure explaining the formation process in the manufacturing method of the photovoltaic panel of Example 2 (the 1). It is a figure explaining the formation process in the manufacturing method of the photovoltaic panel of Example 2 (the 2). It is a figure which shows the state which peeled the temporary holding board from the photovoltaic panel after the shaping | molding of Example 2. FIG. It is sectional drawing which shows the structure of the photovoltaic panel manufactured with the manufacturing method of the photovoltaic panel of Example 2. FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Photovoltaic panel, 11 ... Photovoltaic element, 12 ... Transparent resin layer, 13 ... Condensing lens, 14 ... N electrode, 15 ... Protective layer (first insulating resin layer), 16 ... Insulating layer (2 Insulating resin layer), 17 ... p electrode, 18 ... protective insulating layer, 21 ... element alignment jig, 22 ... element positioning recess, 23 ... temporary holding plate, 24 ... condensing lens molding cavity, 25 ... molding Mold, 26 ... Resin liquid, 30 ... Photovoltaic panel, 31 ... Lens protection cover, 32 ... Back cover, 33 ... Sealing material

Claims (5)

In a method for manufacturing a photovoltaic panel in which a large number of granular photovoltaic elements are arranged in a lattice pattern and integrally molded into a panel shape with a transparent resin,
A temporary holding step of temporarily holding the plurality of photovoltaic elements arranged in a lattice point on one side of the temporary holding plate; and
A resin solution of the transparent resin is injected into a mold for molding a condensing lens that covers the photovoltaic elements from the light receiving surface side and a transparent resin layer that holds the photovoltaic elements. The condensing lens and the transparent resin layer for holding each photovoltaic element are obtained by immersing the numerous photovoltaic elements temporarily held on one side of the holding plate in the resin liquid and curing the resin liquid. A molding process for molding an integrated photovoltaic panel;
And a step of removing the photovoltaic panel from the mold and peeling the temporary holding plate from the photovoltaic panel. Forming the temporary holding plate with a transparent material;
2. The light according to claim 1 , wherein in the molding step, an ultraviolet curable resin liquid is used, and the resin liquid is cured by irradiating the resin liquid with ultraviolet rays transmitted through the temporary holding plate. A method for producing a power generation panel. In a method of manufacturing a photovoltaic panel in which a large number of granular photovoltaic elements are arranged in a grid and formed integrally with a transparent resin in a panel shape ,
Forming a transparent lens protective cover that also serves as a mold for forming a condensing lens that covers each photovoltaic element from the light-receiving surface side ;
Injecting a resin liquid of the transparent resin into the lens protective cover, positioning the large number of photovoltaic elements to be arranged in a lattice point, and immersing the resin liquid in the resin liquid to cure the resin liquid And a forming step of forming a photovoltaic panel in which the condensing lens, the transparent resin layer holding each photovoltaic element and the lens protective cover are integrated, and a method for producing a photovoltaic panel. 4. The photovoltaic power generation according to claim 3 , wherein after the molding step is finished, a back cover is put on a back surface of the photovoltaic power generation panel, and a peripheral edge portion of the back cover and a peripheral edge portion of the lens protective cover are combined. Panel manufacturing method. The large number of photovoltaic elements previously arranged on one side of the temporary holding plate and temporarily held on one side of the temporary holding plate in the molding step after the large number of photovoltaic elements are arranged in a lattice point and temporarily held Is immersed in the resin solution to cure the resin solution to form the photovoltaic panel,
The method of manufacturing a photovoltaic panel according to claim 3 or 4 , wherein the temporary holding plate is peeled off from the photovoltaic panel after the forming step.

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