JP5938695B2 - Solar cell and solar cell module - Google Patents

Description

  The present invention relates to a solar cell and a solar cell module.

  The solar cell includes an electrode on the main surface of the photoelectric conversion unit in order to collect carriers generated by light reception. Such electrodes typically include fingers that collect carriers from a wide range of photoelectric conversion units, and bus bars that are connected to the fingers and collect carriers from the fingers.

  The finger is required to have a low resistance loss in order to efficiently collect carriers. On the other hand, since the wiring material which connects a solar cell in modularization is attached to a bus bar, the favorable connection property with a wiring material is requested | required. For example, Patent Document 1 discloses a solar cell including a finger formed using a sintered conductive material and a bus bar formed using a thermosetting conductive material.

JP 2008-205137 A

  According to the above prior art, it is possible to efficiently collect carriers and realize good connectivity between the bus bar and the wiring material. However, in the current situation where the spread of solar cells is rapidly progressing, further improvement in photoelectric conversion efficiency is required.

  A solar cell according to one embodiment of the present invention includes a photoelectric conversion unit and an electrode provided on a main surface of the photoelectric conversion unit, and the electrode includes a bus bar including a binder resin and a conductive filler. And the Young's modulus (25 ° C.) of the bus bar is 0.05 to 1 GPa.

  ADVANTAGE OF THE INVENTION According to this invention, the solar cell which has a favorable photoelectric conversion characteristic can be provided.

It is sectional drawing which shows the solar cell module which is an example of embodiment of this invention. It is the top view which looked at the solar cell which is an example of embodiment of this invention from the light-receiving surface side. It is a figure which shows the AA line cross section of FIG. FIG. 4 is a diagram illustrating a state in which a wiring member is attached to a bus bar in an enlarged view of a portion B in FIG. 3. It is a figure which shows the modification of the solar cell which is an example of embodiment of this invention.

Embodiments of the present invention will be described in detail with reference to the drawings.
The present invention is not limited to the following embodiments. The drawings referred to in the embodiments are schematically described, and the dimensional ratios of the components drawn in the drawings may be different from the actual products. Specific dimensional ratios and the like should be determined in consideration of the following description.

FIG. 1 is a cross-sectional view showing a part of the solar cell module 10.
The solar cell module 10 includes a plurality of solar cells 11, a first protective member 12 disposed on the light receiving surface side of the solar cell 11, and a second protective member 13 disposed on the back surface side of the solar cell 11. The plurality of solar cells 11 are sandwiched between the first protective member 12 and the second protective member 13 and sealed in a layer of a filler 14 made of a resin such as ethylene vinyl acetate copolymer (EVA). Yes.

  The solar cell module 10 further includes a wiring member 15 that electrically connects the solar cells 11. Moreover, the solar cell module 10 is normally provided with the transition wiring material which connects the wiring materials 15 mutually, a flame | frame, a terminal box (all are not shown), etc.

  Here, the “light receiving surface” means a main surface on which light mainly enters from the outside of the solar cell 11. For example, more than 50% to 100% of light incident on the photoelectric conversion element 11 enters from the light receiving surface side. The “back surface” means a surface opposite to the light receiving surface. In other words, of the main surfaces, the one with the electrode area described later is the back surface.

  The solar cell 11 includes a photoelectric conversion unit 20 that generates carriers by receiving light such as sunlight, a first electrode 30 that is a light-receiving surface electrode provided on the light-receiving surface of the photoelectric conversion unit 20, and photoelectric conversion. And a second electrode 40 that is a back surface electrode provided on the back surface of the unit 20. In the solar cell module 10, carriers generated by the photoelectric conversion unit 20 are collected by the first electrode 30 and the second electrode 40, and are output to the outside via the wiring member 15. Note that, on the back surface of the solar cell 11, the influence of the light-shielding loss on the photoelectric conversion characteristics is less than that of the light receiving surface, so that the second electrode 40 can be formed in a larger area than the first electrode 30.

  For the first protective member 12, for example, a light transmissive member such as a glass substrate, a resin substrate, or a resin film can be used, but a glass substrate is preferable from the viewpoint of durability and the like. Although the same member as the first protective member 12 can be used for the second protective member 13, a resin substrate or a resin film made of polyethylene terephthalate (PET) or the like is preferable from the viewpoint of cost reduction or weight reduction. It is. When light reception from the back side is not assumed, the second protective member 13 may be an opaque substrate or a resin film, for example, a laminated base material laminated with an aluminum foil.

  The wiring member 15 connects the solar cells 11 arranged adjacent to each other. One end side of the wiring member 15 is attached to the first electrode 30 of one solar cell 11 among the solar cells 11 arranged adjacent to each other. The other end side of the wiring member 15 is connected to the second electrode 40 of the other solar cell 11. That is, the wiring member 15 is bent in the thickness direction of the solar cell module 10 between the adjacent solar cells 11, and the adjacent solar cells 11 are electrically connected in series. In the solar cell module 10, the bus bars 32 and 42 and the wiring member 15 are connected using an adhesive 16 as described later. The adhesive 16 can be a non-conductive resin adhesive or a conductive resin adhesive containing a conductive filler such as silver (Ag), but the non-conductive or anisotropic conductive resin bond can be used. Agents are preferred.

Hereinafter, the configuration of the solar cell 11 will be further described in detail with reference to FIGS.
FIG. 2 is a plan view of the solar cell 11 as seen from the light receiving surface side. FIG. 3 is a cross-sectional view taken along the line AA of FIG. 2 and shows a cross section of the solar cell 11 cut in the thickness direction along the direction in which the fingers 31 extend. FIG. 4 shows a connection form of the wiring member 15 in the enlarged view of part B of FIG.

  The photoelectric conversion unit 20 includes a substrate made of a semiconductor material such as crystalline silicon (c-Si), gallium arsenide (GaAs), or indium phosphorus (InP). The photoelectric conversion unit 20 is, for example, a translucent conductive material mainly composed of an i-type amorphous silicon layer, a p-type amorphous silicon layer, indium oxide, and the like on a light-receiving surface of an n-type single crystal silicon substrate. And a transparent conductive layer made of an oxide (TCO: Transparent Conductive Oxide). In addition, an i-type amorphous silicon layer, an n-type amorphous silicon layer, and a transparent conductive layer are sequentially provided on the back surface of the n-type single crystal silicon substrate. Note that the photoelectric conversion unit 20 is not limited to this configuration, and can have various configurations.

  The light receiving surface of the photoelectric conversion unit 20 preferably has a texture structure 21 (see FIG. 4). The texture structure 21 is a surface uneven structure that suppresses surface reflection and increases the light absorption amount of the photoelectric conversion unit 20. The unevenness height of the texture structure 21, that is, the depth of the recess is preferably 1 μm to 15 μm, and particularly preferably 5 μm to 10 μm. As a specific example of the texture structure 21, a pyramidal (quadrangular pyramid or quadrangular frustum-shaped) concavo-convex structure obtained by performing anisotropic etching on the light-receiving surface of a substrate made of single crystal silicon having a (100) plane Can be illustrated. Or the uneven structure obtained by performing isotropic etching on the light-receiving surface of the substrate made of crystalline silicon can be exemplified. The texture structure 21 is preferably provided also on the back surface.

  The first electrode 30 includes, for example, a plurality (for example, 50) of fingers 31 and a plurality of (for example, two) bus bars 32. The finger 31 is a carrier collecting electrode that collects the carriers generated by the photoelectric conversion unit 20, and is a thin wire electrode formed over a wide range on the light receiving surface. The bus bar 32 is an electrode that collects carriers from the fingers 31, and is electrically connected to all the fingers 31. The bus bar 32 is also an electrode for connection to which the wiring material 15 is connected.

  In the solar cell 11, two bus bars 32 are arranged in parallel to each other with a predetermined interval, and a plurality of fingers 31 are arranged so as to intersect with each other. The plurality of fingers 31 are arranged so that a part thereof extends from each of the bus bars 32 to the edge side of the light receiving surface, and the rest connects the two bus bars 32. In the present embodiment, the second electrode 40 also includes a plurality of (for example, 250) fingers 41 and a plurality of (for example, two) bus bars 42, and is the same electrode as the first electrode 30. Have an arrangement.

  The width of the finger 31 is not particularly limited, but is preferably 30 μm to 150 μm from the viewpoint of reducing the light shielding loss. As the distance from the bus bar 32 increases, the width may be narrowed. In this case, the finest width is preferably 30 μm to 80 μm. The width of the bus bar 32 is preferably 0.5 mm to 1.5 mm, for example, and is 80 to 100% (equivalent) of the width of the wiring material 15 from the viewpoint of relaxation of stress generated by the connection of the wiring material 15. It is particularly preferred to do this. In the second electrode 40, it is preferable that the width of the finger 41 is larger than that of the finger 31, and is set to 60 μm to 250 μm, for example.

  The height of the finger 31 and the bus bar 32 is not particularly limited, but is preferably 40 μm to 150 μm from the viewpoint of reducing resistance loss. In addition, the height h2 of the bus bar 32 is preferably equal to or higher than the height h1 of the finger 31 in order to improve electrical connection with the wiring member 15 (see FIG. 4). Here, the heights h1 and h2 are the lengths from the uppermost surface of the photoelectric conversion unit 20 (the convex portion of the texture structure 21) to the uppermost surface of each electrode, and use a scanning electron microscope (SEM). It is an average value of values measured by cross-sectional observation. Since the second electrode 40 has a larger electrode area than the first electrode 30, the electrode height can be made lower than that of the first electrode 30. As in the case of the first electrode 30, the height of the bus bar 42 is preferably equal to the height of the finger 41 or higher than h1.

  The fingers 31 and 41 and the bus bars 32 and 42 include a binder resin and a conductive filler. As the conductive filler, for example, metal particles such as silver (Ag), copper (Cu), nickel (Ni), carbon, or a mixture thereof is used. Of these, silver particles are preferred. The shape of the silver particles is not particularly limited, and may be spherical, spindle shape, needle shape, flake shape, iga chestnut shape, or the like. Conductive fillers such as silver particles are dispersed in the binder resin, and the content thereof is preferably 70 to 95% by weight, more preferably 75 to 92% by weight, based on the total weight of the electrode constituent components. 80 to 90% by weight is particularly preferred. The content of the binder resin is preferably 5 to 30% by weight, more preferably 8 to 25% by weight, and particularly preferably 10 to 20% by weight based on the total weight of the electrode constituent components. The electrode component may contain a small amount of an additive such as a filler dispersant.

  The fingers 31 and 41 and the bus bars 32 and 42 are preferably formed by a screen printing method. In the screen printing method for the fingers 31 and the like, for example, using a screen plate having an opening corresponding to the shape of the fingers 31 and the like, and a squeegee, ink containing electrode components is transferred onto the main surface of the photoelectric conversion unit 20. . Then, the transferred ink is solidified by heating or the like to form the fingers 31 and the like. As the ink, a thermosetting type conductive paste in which the binder resin and the conductive filler are mixed is preferable. A small amount of solvent (for example, an organic solvent such as an alcohol, glycol ether, or hydrocarbon, or a mixed solvent thereof) may be added to the conductive paste for the purpose of adjusting the viscosity. The finger and the bus bar are printed in different printing processes, and different conductive pastes are used in each printing process.

  In the solar cell 11, the Young's modulus (25 ° C.) of the fingers 31 and 41 is 1 to 50 GPa, and the Young's modulus (25 ° C.) of the bus bars 32 and 42 is 0.05 to 1 GPa.

The Young's modulus is measured using a TMA (thermal mechanical analysis) method. The Young's modulus is obtained by measuring the amount of strain with respect to compressive stress at room temperature (25 ° C.). These relational expressions are shown below.
σ = E · ε (σ: stress, E: Young's modulus, ε: strain)

  The content of the conductive filler in the bus bars 32 and 42 (relative to the total weight of the electrode constituent components) is preferably lower than the content of the conductive filler in the fingers 31 and 41. That is, it is preferable to change the content of the conductive filler in accordance with the function of each electrode. Preferably, the former is less than 85% by weight and the latter is 85% by weight or more. By increasing the content of the conductive filler in the fingers 31 and 41, the resistance loss of the fingers 31 and 41 can be reduced. When the content of the conductive filler is lowered, the flexibility of the electrode is increased and the Young's modulus tends to be lowered.

  In order to further enhance flexibility while suppressing a significant increase in the resistance of the bus bars 32 and 42, it is preferable to change the composition of the binder resin in accordance with the function of each electrode. In the present embodiment, the finger 31 and the bus bar 32 have different binder resin compositions, the finger 41 has the same composition as the finger 31, and the bus bar 42 has the same composition as the bus bar 32. The bus bars 32 and 42 have a conductive filler content of 70 to 85% by weight, preferably 80 to 85% by weight, and a Young's modulus of 0.07 to 0.7 GPa, preferably 0.1 to 0. .5 GPa is particularly preferable. In addition, the Young's modulus (25 degreeC) of the fingers 31 and 41 has preferable 10-40GPa, and 15-35GPa is especially preferable.

Hereinafter, the composition of the binder resin will be described in detail.
The binder resin constituting the fingers 31 and 41 preferably contains 90 to 100% by weight of thermosetting resin. As the thermosetting resin, for example, at least one selected from the group consisting of epoxy resins, urethane resins, urea resins, acrylic resins, imide resins, and phenol resins can be used. Among these, an epoxy resin and a urethane resin are preferable, and an epoxy resin as a main component (50% by weight or more) is particularly preferable. Further, a small amount of silicone resin or the like may be added to epoxy resin or the like. The thermosetting resin may be a resin classified into a plurality of groups (for example, a resin that can be classified into both an epoxy resin and a urethane resin).

  Examples of the epoxy resins include alicyclic epoxy resins, chain epoxy resins, bisphenol A type epoxy resins, epoxy phenol novolac type resins, polyglycidyl ether type epoxy resins, polyalkylene ether type epoxy resins, epoxy acrylate resins, and fatty acid-modified resins. Examples include epoxy resins and urethane-modified epoxy resins.

  The binder resin constituting the bus bars 32 and 42 contains 50 to 90% by weight of the thermosetting resin and 10 to 50% by weight of rubber or elastomer having a glass transition temperature (hereinafter referred to as Tg) of 25 ° C. or less. Is preferred. More preferably, the former is 60 to 85% by weight and the latter is 15 to 40% by weight, and particularly preferably, the former is 70 to 80% by weight and the latter is 20 to 30% by weight. Tg is a value measured with a differential scanning calorimeter (DSC). The elastomer may be a thermoplastic elastomer or a crosslinked elastomer.

  The rubber means a crosslinkable polymer having a Tg of 25 ° C. or lower, preferably 0 ° C. or lower, particularly preferably −20 ° C. or lower. The crosslinked structure can be formed by vulcanization or the like. As the rubber, for example, at least one selected from the group consisting of diene rubber, olefin rubber, urethane rubber, acrylic rubber, silicon-containing rubber, halogen-containing rubber, and modified products thereof may be used. it can. The rubber may be classified into a plurality of groups.

  Diene rubbers include natural rubber, butadiene rubber, isoprene rubber, methyl rubber, butyl rubber, polypentadiene rubber, norbornene rubber, nitrile rubber (acrylonitrile-butadiene copolymer, acrylonitrile-isoprene copolymer, etc.), styrene-butadiene copolymer. An example is a united rubber.

  Examples of the olefin rubber include ethylene-propylene rubber, ethylene-propylene-diene copolymer rubber, polyisobutylene rubber, polyisobutyl ether rubber, polycyclopentene rubber, maleic acid-modified ethylene-propylene copolymer rubber, and the like.

  Examples of the urethane rubber include polyether urethane rubber and polyester urethane rubber.

  Examples of the acrylic rubber include acrylic ester-acrylonitrile copolymer rubber, acrylic ester-chloroethyl vinyl ether copolymer rubber, and acrylic ester-butadiene copolymer rubber.

  Examples of the silicon-containing rubber include silicone rubber (methyl vinyl silicone rubber, methyl phenyl vinyl silicone rubber, etc.).

  Examples of halogen-containing rubbers include chloroprene rubber, brominated butyl rubber, chlorinated butyl rubber, hydrin rubber (such as epichlorohydrin rubber), chlorosulfonated polyethylene rubber, chlorinated polyethylene rubber, maleic acid-modified chlorinated polyethylene rubber, and fluororubber (vinylidene fluoro). Ride rubber, fluorine-containing vinyl ether rubber, fluorine-containing phosphazene rubber) and the like.

  The properties required for the rubber material to be used include a low Tg in order to maintain adhesion and flexibility at low temperatures, and degradation at the highest temperature (about 120 ° C.) of the solar cell module 10 (thermal decomposition, oxidation degradation) , Fluidization) is low, and the heat resistance is high. In addition, the rubber material needs to have appropriate compatibility and dispersibility with the thermosetting resin from the viewpoint of the stability of the conductive paste. If such characteristics are satisfied, it is possible to maintain functions such as cell protection and adhesion.

  The thermoplastic elastomer means a non-crosslinkable polymer having a Tg of 25 ° C. or lower, preferably 0 ° C. or lower, particularly preferably −20 ° C. or lower. Examples of the thermoplastic elastomer include a styrene thermoplastic elastomer, an olefin thermoplastic elastomer, a urethane thermoplastic elastomer, an ester thermoplastic elastomer, an acrylic thermoplastic elastomer, a silicone thermoplastic elastomer, and modified products thereof. At least one selected from the group consisting of can be used. Of these, styrene-based thermoplastic elastomers, urethane-based thermoplastic elastomers, and silicone-based thermoplastic elastomers are preferable, and silicone-based thermoplastic elastomers and urethane-based thermoplastic elastomers are particularly preferable. The thermoplastic elastomer may be classified into a plurality of groups.

  Styrenic thermoplastic elastomers include styrene-based AB diblock copolymers such as styrene-ethylene-butylene copolymer (SEB), styrene-butadiene-styrene copolymer (SBS), and hydrogenated SBS (SEBS). ), Styrene-isoprene-styrene copolymer (SIS), hydrogenated product of SIS (SEPS), styrene-based ABA type triblock copolymer such as styrene-isobutylene-styrene copolymer (SIBS), styrene-butadiene- Examples thereof include styrene-based ABAB type tetrablock copolymers such as styrene-butadiene (SBSB).

Examples of the urethane-based thermoplastic elastomer include polymers having a hard segment composed of a low molecular diol and diisocyanate and a soft segment composed of a high molecular diol.
As the low-molecular diol, for example, an aliphatic dihydric alcohol having 2 to 15 carbon atoms, an alicyclic dihydric alcohol having 5 to 15 carbon atoms, an aromatic dihydric alcohol having 6 to 15 carbon atoms, or the like can be used. . Of these, dihydric alcohols and dihydric phenols are preferable, and ethylene glycol, hydroquinone, and bisphenol A are particularly preferable.
Examples of the diisocyanate include aromatic diisocyanates having 6 to 20 carbon atoms, aliphatic diisocyanates having 2 to 18 carbon atoms, alicyclic diisocyanates having 4 to 15 carbon atoms, and aromatic aliphatic diisocyanates having 8 to 15 carbon atoms. be able to. Of these, aromatic diisocyanates and aliphatic diisocyanates are preferable, and TDI (tolylene diisocyanate), MDI (diphenylmethane diisocyanate), and HDI (hexamethylene diisocyanate) are particularly preferable.
Polyether having a weight average molecular weight of 500 to 10,000, a polyester having a weight average molecular weight of 500 to 10,000, a polycarbonate having a weight average molecular weight of 500 to 10,000, etc. should be used as the polymer diol. Can do. Among these, an alkylene oxide adduct of a dihydric alcohol and an alkylene oxide adduct of a dihydric phenol are preferable, and an alkylene oxide adduct of ethylene glycol and an alkylene oxide adduct of bisphenol A are particularly preferable.

  Examples of the silicone-based thermoplastic elastomer include polydimethylsiloxane (PDMS), polymethylphenylsiloxane, and polydiphenylsiloxane.

  The weight average molecular weight (Mw) of the thermoplastic elastomer is somewhat different depending on the composition, etc., but is preferably 20,000 to 500,000, more preferably 30,000 to 300,000, and particularly preferably 40,000 to 150,000. preferable. Here, the weight average molecular weight (Mw) is a relative value in terms of polystyrene, and is measured by the GPC method.

  According to the solar cell module 10 including the solar cell 11, by controlling the Young's modulus of the bus bars 32 and 42 to 0.05 to 1 GPa, without impairing the conductivity necessary for transmitting the carrier to the wiring member 15, Adhesion between the bus bars 32 and 42 and the wiring member 15 can be improved. Furthermore, the influence of the stress generated due to the connection of the wiring member 15 can be reduced. Examples of the stress include stress generated due to the difference in coefficient of linear expansion between the bus bars 32 and 42 and the wiring material 15, stress applied when the wiring material 15 is crimped, and a resin film that is the second protective member 13. There are stresses caused by expansion and contraction. The stress is likely to occur at the interface between the bus bars 32 and 42 and the wiring member 15 and at the interface between the bus bars 32 and 42 and the photoelectric conversion unit 20.

  That is, since the bus bars 32 and 42 have flexibility suitable as a connection portion of the wiring member 15, the bus bars 32 and 42 are easily deformed by the pressure applied when the wiring member 15 is crimped, and the contact area with the wiring member 15 can be improved. Thereby, adhesiveness with the wiring material 15 improves, for example, peeling of the wiring material 15 can be suppressed also in a high temperature or cold environment. And since the bus-bars 32 and 42 are flexible and easy to elastically deform, the said stress can be absorbed and the influence can be relieved. Thereby, damages, such as a crack of a photoelectric conversion part 20, a crack, and a brittle fracture, can be controlled. The bus bars 32 and 42 can sufficiently suppress damage such as cracks even when the photoelectric conversion unit 20 is thin.

Moreover, not only the softness | flexibility of an electrode improves but manufacturing cost can be reduced by making the content rate of the electroconductive filler in the bus bars 32 and 42 lower than the fingers 31 and 41. FIG. Alternatively, while suppressing an increase in manufacturing cost, the width of the bus bars 32 and 42 can be increased to disperse the stress, thereby further improving the stress relaxation performance.
However, if the content of the conductive filler in the bus bars 32 and 42 is too low, the conductivity necessary for transmitting the carrier to the wiring member 15 is impaired. Therefore, by adding rubber or thermoplastic elastomer having rubber elasticity at room temperature or lower to the binder resin of the bus bars 32 and 42, the flexibility of the electrode can be further improved without impairing the conductivity.
If the rubber or thermoplastic elastomer is excessively increased, the mechanical strength of the bus bars 32 and 42 is reduced, and micro-cracks are generated in the bus bars 32 and 42 due to the stress from the wiring material 15, thereby inhibiting the collection of carriers. there's a possibility that.

On the other hand, the fingers 31 and 41 increase the content rate of the conductive filler more than the bus bars 32 and 42, and control the Young's modulus to more than 1 to 50 GPa. Thereby, carriers can be efficiently collected from a wide range of the photoelectric conversion unit 20.
As described above, the solar cell module 10 having good photoelectric conversion characteristics can be provided by controlling the Young's modulus of the electrode within an appropriate range in accordance with the function of each electrode.

It should be noted that the design of this embodiment can be changed as appropriate without departing from the object of the present invention.
For example, as shown in FIG. 5, a metal thin film 41 x such as silver may be formed on the back surface of the photoelectric conversion unit 20 instead of the fingers 41. In the solar cell 11x illustrated in FIG. 5, the second electrode 40x includes a metal thin film 41x and a bus bar 42x formed thereon. The metal thin film 41x collects the carriers generated by the photoelectric conversion unit 20, and the bus bar 42x collects the carriers collected by the metal thin film 41x. The bus bar 42x may be formed on a part of the metal thin film 41x.

Further, the Young's modulus may be different between the bus bar 32 and the bus bar 42. For example, it is preferable to make the Young's modulus of the bus bar 42 lower than the Young's modulus of the bus bar 32. This is because a glass substrate is usually applied to the first protective member 12 and a resin film such as a PET film is usually applied to the second protective member 13, so that the second protective member 12 is more second than the first electrode 30 side. This is because the stress is likely to occur on the electrode 40 side.
Alternatively, the first electrode 30 is formed using the same conductive paste without changing the Young's modulus of the finger 31 and the bus bar 32, and the Young's modulus of the finger 31 and the bus bar 32 is changed only with the second electrode 40. May be.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further, this invention is not limited to these Examples.

<Example 1>
A photoelectric conversion part for evaluation is produced by the following procedure. Note that the same photoelectric conversion unit is used in all examples and comparative examples.
First, a clean n-type single crystal silicon substrate (hereinafter referred to as a substrate) is prepared by anisotropically etching the (100) plane using an aqueous potassium hydroxide (KOH) solution to form a texture structure on the light receiving surface and the back surface. . Subsequently, the substrate is placed in a vacuum chamber, and an i-type amorphous silicon film and an n-type amorphous silicon film are sequentially formed on the back surface of the substrate by CVD. In the step of forming the i-type amorphous silicon film, silane gas (SiH ₄ ) is used as a source gas. In the step of forming the n-type amorphous silicon film, silane (SiH ₄ ), hydrogen (H ₂ ), and phosphine (PH ₃ ) are used as source gases. Also on the light receiving surface of the substrate, an i-type amorphous silicon film and a p-type amorphous silicon film are sequentially formed by CVD. In the step of forming the p-type amorphous silicon film, diborane (B ₂ H ₆ ) is used as a source gas instead of PH ₃ .
Subsequently, a TCO film containing indium oxide as a main component is formed on the n-type amorphous silicon film and the p-type amorphous silicon film by sputtering. Thus, the photoelectric conversion portion having the layer structure of TCO film / i-type amorphous silicon film / p-type amorphous silicon film / substrate / i-type amorphous silicon film / n-type amorphous silicon film / TCO film is obtained. Produced.

Next, a light receiving surface electrode is formed on the light receiving surface of the produced photoelectric conversion unit, and a back electrode is formed on the back surface of the photoelectric conversion unit.
The light-receiving surface electrode is formed of two bus bars and 50 fingers orthogonal thereto, both of which are formed by printing a conductive paste having the following composition on the light-receiving surface by screen printing. First, the finger is printed, and then the bus bar is printed. In each printing process, the printing conditions such as the squeegee angle and the printing pressure are the same. Subsequently, a part of the solvent of the conductive paste transferred by the temporary drying step (150 ° C. × 15 minutes) is removed.
The back electrode is made up of two bus bars and 250 fingers orthogonal thereto. The back electrode is printed in the same manner as in the case of the light receiving surface electrode, except that the pattern of the openings of the screen plate is different.
Thereafter, the solvent of the conductive paste transferred in the main drying step (200 ° C. × 60 minutes) is removed, and the binder resin is thermally cured. In this way, a solar cell including a light-receiving surface electrode and a back electrode having the following dimensions and the like was manufactured.
<Finger conductive paste>
[Binder resin] Bisphenol A type epoxy resin [Conductive filler] Silver particles (particle size: 1 to 10 μm, shape: mixed type of flake powder and spherical powder (mixing ratio is 50:50 wt%)
[Composition ratio] Solvent: Binder resin: Conductive filler = 1: 9: 90 wt%
<Conductive paste for bus bars>
[Conductive filler] Same as for finger [Binder resin]
Thermosetting resin (60 wt%); same as finger Elastomer A (40 wt%); Silicone rubber (Tg; -120 ° C.)
[Blending ratio] Solvent: Binder resin: Conductive filler = 1: 19: 80
<Light receiving surface electrode>
[Finger] height: 40 μm, Young's modulus: 30 GPa
[Bus bar] Height: 50 μm, Young's modulus: 0.05 GPa
<Back electrode>
[Finger] height: 30 μm, Young's modulus: 30 GPa
[Bus bar] Height: 40 μm, Young's modulus: 0.05 GPa

Next, the produced solar cells are arranged on the same plane, and adjacent solar cells are connected to each other with a wiring material to produce a solar cell module.
The wiring member is connected to the bus bar using a film adhesive (epoxy resin adhesive). First, a film adhesive is arranged on the bus bar, and then a wiring material is arranged on the adhesive. The wiring material covers the entire area on the bus bar and is arranged so as not to be applied to the fingers. And a wiring material and a bus-bar are connected by attaching a heat seal bar on a wiring material and carrying out thermocompression bonding.
Subsequently, the string of solar cells obtained by connecting the wiring materials is laminated using EVA (filler), a glass substrate (first protective member), and a PET film (second protective member). In the laminating apparatus, the module material is placed in a state of being superimposed on the heater. From the heater side, it arrange | positions in order of a glass substrate / EVA sheet / string / EVA sheet / PET film, and heats material at about 150 degreeC in a vacuum state. Thereafter, heating is continued while pressing the material on the heater side under atmospheric pressure to cross-link EVA. Finally, attach a frame or the like. In this way, a solar cell module was produced.

  About the produced solar cell module, the output correlation of the solar cell / solar cell module and the evaluation of the temperature cycle test were performed. The evaluation results are shown in Table 1 together with the Young's modulus of the electrode and the like. The output correlation is a value indicating a change in the fill factor (FF) before and after modularization, and is calculated by [FF immediately after modularization / FF of solar cell immediately after electrode formation] × 100 (%). The result of the temperature cycle test is the change in the maximum output Pmax before and after 400 cycles (holding at the minimum temperature (−40 ° C.) and the maximum temperature (90 ° C.) for 30 minutes and changing each temperature in 90 minutes). And is calculated by [Pmax after cycle test / Pmax before cycle test] × 100 (%).

<Examples 2-8, Comparative Examples 1-3>
A solar cell was produced and evaluated in the same manner as in Example 1 except that the composition of the binder resin constituting the bus bar was changed to that shown in Table 1.
Elastomer B: Urethane rubber (Tg; -30 ° C)
Elastomer C; Olefin rubber (Tg; -55 ° C)

As shown in Table 1, the solar cell modules of the examples all had an output correlation of 99.5% or higher, and the Pmax change rate by the temperature cycle test was 95.0% or higher. That is, the solar cell module of the example is excellent in initial output characteristics, and the characteristics are not easily deteriorated by long-term use. This excellent characteristic is that the Young's modulus (25 ° C) of the bus bar is controlled within the range of 0.05 to 1 GPa, and the Young's modulus (25 ° C) of the finger is controlled within the range of 1 to 50 GPa. It was obtained by.
On the other hand, the solar cell module of the comparative example had a high initial output characteristic but the characteristic was easily deteriorated (Comparative Example 1) or a low initial output characteristic (Comparative Examples 2 and 3).
Further, by setting the elastomer content to 10 to 30% by weight and controlling the Young's modulus (25 ° C.) of the bus bar within the range of 0.1 to 1 GPa, the output correlation is 99.5% or more and the temperature Particularly excellent characteristics are obtained in which the rate of change in Pmax by the cycle test is 99.1% or more.

  DESCRIPTION OF SYMBOLS 10 Solar cell module, 11 Solar cell, 12 1st protective member, 13 2nd protective member, 14 Filler, 15 Wiring material, 16 Adhesive, 20 Photoelectric conversion part, 21 Texture structure, 30 1st electrode, 31, 41 Finger, 32, 42 Busbar, 40 Second electrode.

Claims (7)

A photoelectric conversion unit;
Electrodes provided on the main surface of the photoelectric conversion unit;
With
The electrode has a finger and a bus bar configured to include a binder resin and a conductive filler,
Young's modulus of the bus bar (25 ° C.), the Ri 0.05~1GPa der,
The binder resin constituting the finger is a thermosetting resin that is at least one selected from the group consisting of an epoxy resin, a urethane resin, a urea resin, an acrylic resin, an imide resin, and a phenol resin. 90% to 100% by weight,
The said binder resin which comprises the said bus-bar is a solar cell which contains 50 to 90 weight% of the said thermosetting resin, and 10 to 50 weight% of rubber | gum or thermoplastic elastomer whose glass transition temperature is 25 degrees C or less . A solar cell according to claim 1,
The Young's modulus of the fingers (25 ° C.) is 1 exceeded ～50GPa. A solar cell according to claim 1 or 2,
The rubber is at least one selected from the group consisting of diene rubber, olefin rubber, urethane rubber, acrylic rubber, silicon-containing rubber, halogen-containing rubber, and modified products thereof. A solar cell according to claim 1 or 2,
The thermoplastic elastomer is a group consisting of a styrene thermoplastic elastomer, an olefin thermoplastic elastomer, a urethane thermoplastic elastomer, an ester thermoplastic elastomer, an acrylic thermoplastic elastomer, a silicone thermoplastic elastomer, and a modified product thereof. It is at least one selected from more. A solar cell according to any one of claims 1 to 4,
The content rate of the conductive filler in the bus bar is lower than the content rate of the conductive filler in the finger. A solar cell according to any one of claims 1 to 5,
The height of the bus bar is higher than the height of the fingers. A plurality of solar cells according to any one of claims 1 to 6 ,
A wiring material attached to the bus bar;
Solar cell module with

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