JP6568479B2 - Electric module and method of manufacturing electric module - Google Patents

Description

The present invention relates to an electric module and a method for manufacturing the electric module.
This application claims priority based on Japanese Patent Application No. 2014-027962 for which it applied to Japan on February 17, 2014, and uses the content here.

In recent years, solar cells have attracted attention as clean energy power generation devices that replace fossil fuels, and silicon (Si) solar cells and dye-sensitized solar cells have been developed. In particular, dye-sensitized solar cells have been widely researched and developed for their structures and manufacturing methods as being inexpensive and easy to mass-produce (for example, Patent Document 1 below).
As shown in FIG. 1 of Patent Document 1, the dye-sensitized solar cell described in Patent Document 1 includes one conductive metal layer on one plate surface of the first substrate. A porous insulating material (member for preventing a short circuit between the conductive metal layer and the conductive substrate) is disposed on the surface of the conductive metal layer, and the first conductive material is disposed on the surface of the porous insulating material. Another conductive metal layer disposed opposite to the metal layer is provided, and a semiconductor layer is further provided on the upper surface of the other conductive metal layer. In the dye-sensitized solar cell, a transparent substrate is disposed opposite to the first substrate, and outer peripheral portions of the opposed substrates are bonded together with a sealing material to form an internal space.
In this solar cell, an internal electrode is filled with an electrolytic solution, and a takeout electrode in which a metal conductive layer is formed on the surface of an insulating layer is connected to the conductive metal layer of the first electrode of the solar cell and the conductivity of other electrodes. The structure which protruded from the sealing material after arrange | positioning so that it may contact with a conductive metal layer is employ | adopted.

JP 2011-249258 A

By the way, in the conventional solar cell, since the extraction electrode is only in local contact with the conductive metal layer of the first electrode of the solar cell and the conductive metal layer of the other electrode, the electron is a conductive material. It must move to the extraction electrode via the conductive metal layer having a higher resistance value. That is, the conventional solar cell has a problem that the resistance value during current collection is high and the quality is poor.
Moreover, since the said solar cell employ | adopted the structure which inserts the end of an extraction electrode in the internal space of one electrical module, and protrudes the other end outward from a sealing material, it is necessary to manufacture for every module There was a problem that it was not suitable for continuous production.
Therefore, in view of the above problems, the present invention provides a high-quality electric module with improved current collection efficiency and reduced resistance, and a method for manufacturing the same.

An electrical module according to the present invention includes a photoelectrode in which a semiconductor layer is formed on a first substrate on which a first conductive film is formed, and a second substrate on which a second conductive film is formed. An electrode and an electrolyte, the photoelectrode and the counter electrode are bonded and sealed so as to form a plurality of internal spaces therebetween, and the electrolyte is filled in each of the plurality of internal spaces. Thus, a plurality of power generation elements connected in series are formed, and at least one of the first conductive film and the second conductive film is formed with an insulating band serving as a partition between the plurality of power generation elements. And at least a part of the sealing portion between the photoelectrode and the counter electrode is formed by adhering the first conductive film and the second conductive film with a sealing material, At least one of the conductive film and the second conductive film is the inside The insulating band is not continuously formed in an electrically continuous manner, and extends beyond the inner space beyond the sealing material, and on the surface of the extended portion, A conductive material is disposed in a state capable of being electrically connected to a portion, and a terminal is connected to the conductive material, and the terminal is between the photoelectrode and the counter electrode and the photoelectrode or the counter electrode. It is provided so that it may protrude from the outer edge of an electrode .
In the present application, “electrolyte” includes an electrolytic solution, a gel electrolyte, and a solid electrolyte.
According to this configuration, at the time of current collection, at least one of the photoelectrode and the counter electrode can have low resistance and can conduct electricity in a wide region, thereby collecting current efficiently.
Further, according to this configuration, the terminal can be easily taken out between the photoelectrode and the counter electrode at an arbitrary position of the conductive material.

The conductive material of the present invention is preferably fixed to at least one of the first conductive film and the second conductive film by the terminal.

According to this configuration, the conductive material can be stably fixed to the photoelectrode or the counter electrode.

In the electric module of the present invention, the first conductive film and the second conductive film are both electrically sealed from the inner space, and the sealing material is not formed in the insulating band. And extending outside the internal space, wherein the first conductive film and the second conductive film extend to opposite sides across the internal space, and the first conductive film It is preferable that the conductive material is disposed on the surface of each of the extended portions of the conductive film and the second conductive film so as to be electrically connected to the portion.
According to this configuration, at the time of current collection, both the photoelectrode and the counter electrode can have low resistance and can conduct electricity in a wide region, thereby enabling more efficient current collection.

Method of manufacturing an electro-module of the present invention is a manufacturing method of the electrical module, comprising the steps of continuously feeding to extend the said photoelectrode and the counter electrode in one direction, respectively, the counter and the photoelectrode an electrode sealed bonded to form a plurality of interior space between them, this time, the at least a portion of formation of the sealing portion between said counter electrode and the photoelectrode the plurality of power generating elements formed I line with sealant, of the first conductive film and the second conductive film, the insulating band electrically continuous at least one from the internal space distribution but a sealing step of a state of being extended to the outside of the inner space in a state of not being formed over the encapsulant, the electrically conductive material on the surface of the extended portion of the conductive layer And a conductive material arranging step.
According to this configuration, it is possible to easily manufacture the electric module without considering the terminal extraction position in advance in bonding the photoelectrode and the counter electrode.

The sealing material of the present invention is preferably extended in the one direction on at least one end side in the direction crossing the one direction, and the conductive material is preferably arranged in parallel to the one direction.
According to this configuration, it is possible to easily perform continuous production such as roll-to-roll production in which any one of the above electric modules is continuously produced while being conveyed in one direction.

According to the present invention, there is an effect that the resistance value at the time of current collection can be reduced to improve the current collection efficiency and the quality of the electric module can be improved.
Moreover, according to the manufacturing method of the electrical module of this invention, there exists an effect that the electrical module of this invention can be manufactured simply and efficiently by continuous production.

It is the perspective view which showed typically the state cut | disconnected by the X1-X1 line | wire of the electric module of 1st Embodiment of this invention. It is sectional drawing which looked at FIG. 1 at the X1-X1 line. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention. It is sectional drawing which looked at FIG. 3A at the X2-X2 line. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention. It is sectional drawing which looked at FIG. 4A at the X3-X3 line | wire. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention. It is sectional drawing which looked at FIG. 5A at the X4-X4 line. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention. It is sectional drawing which looked at FIG. 6A at the X5-X5 line. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention. FIG. 7B is a cross-sectional view taken along line X6-X6 in FIG. 7A. It is sectional drawing which showed typically the other example of the electric module of 1st Embodiment of this invention. It is sectional drawing which showed typically the other example of the electric module of 1st Embodiment of this invention. It is sectional drawing which showed typically the other example of the electric module of 1st Embodiment of this invention. It is the perspective sectional view showing typically the electric module of a 2nd embodiment of the present invention. It is sectional drawing which looked at FIG. 11A at the X8-X8 line. It is sectional drawing which showed typically the modification of the electric module of 2nd Embodiment of this invention. It is the perspective sectional view showing typically the modification of the electric module of a 2nd embodiment of the present invention. It is sectional drawing which looked at FIG. 13A at the X9-X9 line. It is sectional drawing which showed typically the modification of the electric module of 2nd Embodiment of this invention. It is sectional drawing which showed typically the electric module of 3rd Embodiment of this invention.

Hereinafter, embodiments of the electric module of the present invention will be described with reference to the drawings, taking as an example the case where the electric module of the present invention is a dye-sensitized solar cell (hereinafter referred to as “solar cell”).
Further, a case where an electric module is manufactured using a gel electrolyte as an electrolyte will be described as an example.

(First embodiment)
As shown in FIG. 1 or 2, the solar cell 1A according to the first embodiment of the present invention is a photoelectrode in which a semiconductor layer 8 is formed on a first substrate 7 on which a first conductive film 4 is formed. 2, a counter electrode 3 including a second substrate 11 on which a second conductive film 10 is formed, and an electrolyte 12, and the photoelectrode 2 and the counter electrode 3 have an internal space S therebetween. The electrolyte 12 is provided with a plurality of power generation elements (also referred to as cells) C filled in the internal space S, and is sealed to form the sealing portion P. The portion extending in the direction of the arrow L1 is formed by adhering the first conductive film 4 and the second conductive film 10 with the sealing material 9, and is sealed in an electrically continuous state from the internal space S. The first conductive film 4 and / or the second conductive film 1 extended in opposite directions to the outside of the internal space S beyond the material 9 On each surface of, it is characterized in that the conductive material 5 in a conductible state and is connected thereto. And in this embodiment, each electric power generation element C is connected in series.
Specifically, the solar cell 1A is configured as follows.

The photoelectrode 2 has a plurality of (three in this embodiment) strips extending in parallel to each other in the direction of arrow L1 (the depth direction in the drawing in FIG. 2) on the first conductive film 4 formed on the first substrate 7. The semiconductor layer 8 is provided. These semiconductor layers 8, 8,... Are formed with an interval in which the sealing materials 9, 9 and the conductive material 5 are arranged in the direction of the arrow L2 crossing the direction of the arrow L1.
In the first conductive film 4, strip-like insulating bands 15 extending in the direction of the arrow L <b> 1 and serving as cell separators are formed on both sides of the semiconductor layer 8 in the width direction at regular intervals so as to sandwich the semiconductor layer 8. Yes.

The counter electrode 3 includes a second substrate 11 on which a second conductive film 10 is formed.
The second conductive film 10 has a strip-shaped insulating band 15 extending in the direction of the arrow L1 and serving as a cell separator. The insulating band 15 formed on the first conductive film 4 is closer to the one side in the direction of the arrow L2. They are formed on both sides of the semiconductor layer 8 in the width direction at regular intervals so that the position is shifted to the right (in the present embodiment, to the right) and the semiconductor layer 8 is sandwiched therebetween.

  As a material of the first substrate 7 and the second substrate 11, for example, a resin material mainly composed of a transparent thermoplastic resin material such as polyethylene naphthalate (PEN) or polyethylene terephthalate (PET), or a glass substrate, respectively. Etc. are preferably used. In addition, the 1st board | substrate 7 and the 2nd board | substrate 11 may be formed in the flexible film form. At least one of the first substrate 7 and the second substrate 11 is a transparent substrate.

Examples of the material of the first conductive film 4 or the second conductive film 10 include tin-doped indium oxide (ITO), zinc oxide, fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), and tin oxide (SnO). ), Antimony-doped tin oxide (ATO), indium oxide / zinc oxide (IZO), gallium-doped zinc oxide (GZO), and the like are used.
At least one of the first conductive film 4 and the second conductive film 10 is formed of a transparent conductive film.
Further, in at least one of the combination of the first substrate 7 and the first conductive film 4 and the combination of the second substrate 11 and the second conductive film 10, the substrate and the conductive film are both It is desirable to be transparent.

The semiconductor layer 8 has a function of receiving and transporting electrons from a sensitizing dye described later, and a semiconductor made of a metal oxide is formed on the surface of the conductive film. As the metal oxide, for example, titanium oxide (TiO ₂ ), zinc oxide (ZnO), tin oxide (SnO ₂ ) or the like is used.

  The semiconductor layer 8 carries a sensitizing dye. The sensitizing dye is composed of an organic dye or a metal complex dye. As the organic dye, for example, various organic dyes such as coumarin, polyene, cyanine, hemicyanine, and thiophene can be used. As the metal complex dye, for example, a ruthenium complex is preferably used.

As the second conductive film 10, either a material that does not serve as a catalyst layer and serves as a conductive film, or a material that can serve as both a catalyst layer and a conductive film is employed. In the former case, a catalyst layer (not shown) is further formed on the second conductive film 10. In the latter case, only the second conductive film 10 is formed on the second substrate 11. .
In addition, as the catalyst layer formed on the surface of the second conductive film 10, carbon paste, platinum, or the like is employed.

The photoelectrode 2 and the counter electrode 3 are bonded together at the sealing portion P, and as a result, an internal space S for sealing the electrolyte 12 is formed for each semiconductor layer 8 provided continuously in a band shape.
The sealing part P includes the first conductive film 4 and the second conductive film 4 between the adjacent semiconductor layers 8 and 8 and the two ends 1a and 1b in the direction of the arrow L2 with two rows of sealing materials 9 in the direction of the arrow L1. Is formed by adhering the conductive film 10 to the first substrate 7 and the second substrate 11 in the direction of the arrow L2 by ultrasonic fusion or the like. Has been.

The sealing material 9 is arranged at a position covering the insulating band 15 formed on the first conductive film 4 or the insulating band 15 formed on the second conductive film 10 one by one. Note that, at both ends of the one end 1a and the other end 1b, the sealing material 9 (P) is provided so as to cover the two insulating bands 15, 15 facing each other.
In addition, as the sealing material 9, the adhesive agent of the material which does not impair the function of the 1st electrically conductive film 4 and the 2nd electrically conductive film 10, for example, hot-melt resin etc. is used suitably.

  A wiring space 20 is formed between the sealing materials 9 and 9 disposed between the semiconductor layers 8 and 8. In the wiring space 20, a conductive material 5 for connecting adjacent cells C and C in series is arranged in the direction of the arrow L1. That is, the conductive material 5 in the wiring space 20 is adjacent to the left side of the first conductive film 4 continuously extending from the internal space S of one cell C adjacent to the right side beyond the sealing material 9. In contact with the second conductive film 10 continuously extending from the internal space S of the other cell C beyond the sealing material 9 in the direction of the arrow L1. At this time, the first conductive film 4 and the conductive material 5 continuously extending from the inner space S of one cell C and the inner space S of the other cell C are continuously extended. It is preferable that one or both of the second conductive film 10 and the conductive material 5 is provided with an auxiliary conductive material 5a such as a conductive material paste for assisting electrical connection therebetween.

  To summarize the above configuration, between the cells C 1 and C 2, the internal space S filled with the electrolyte 12 and the wiring space 20 separated liquid-tightly are formed by the sealing portion P including the sealing materials 9 and 9. Is formed. In the wiring space 20, the conductive material 5 has an arrow L <b> 1 on the first conductive film 4 and the second conductive film 10 that are continuously extended from the adjacent internal space S into the wiring space 20. The cells C, C,... Are connected in series and constitute a series connection.

  At one end 1a in the direction of the arrow L2, one conductive film 4 extends continuously from the internal space S to the outside beyond the sealing material 9 that seals the internal space S. The conductive film 10 is insulated in the direction of the arrow L1 at the position of the sealing material 9 that seals the internal space S. Further, a sealing material 9 is further provided with a space in the direction of the arrow L2 from the sealing material 9 that seals the internal space S, and a wiring space 20 is formed by these sealing materials 9 and 9. At the position of the sealing material 9 located on the outermost side in the arrow L2 direction, the first conductive film 4 and the second conductive film 10 are further insulated in the arrow L1 direction.

  Openings 16 are formed in the first substrate 7 and the first conductive film 4 in the wiring space 20 provided at one end 1a in the direction of the arrow L2 with a gap in the direction of the arrow L1. The linear conductive material 5 is connected to the first conductive film 4 continuously extending into the wiring space 20 provided at the one end 1a through the auxiliary conductive material 5a in the direction of the arrow L1. The current can be efficiently collected while ensuring conduction in a wide region of the first conductive film 4. In addition, a terminal 6 is inserted into the opening 16 formed in the wiring space 20 so that one end is in contact with the auxiliary conductive material 5 a and the conductive material 5 and the other end protrudes (exposes) from the opening 16. Yes.

With the above configuration, the wiring space 20 at the one end 1a in the direction of the arrow L2 is liquid-tightly separated from the adjacent internal space S. Then, the conductive material 5 in the wiring space 20 is arranged over the direction of the arrow L1, so that the first conductive film extends continuously from the internal space S to the outside beyond the sealing material 9. The current is collected while securing conduction throughout the direction of the arrow L1 in FIG. 4, and a current can be taken out from any of the terminals 6, 6,. On the other hand, the second conductive film 10 at the one end 1a is insulated from the other conductive film 10 in the cell C at the position of the sealing material 9 sealing the internal space S. Even if it is in contact with the second conductive film 10 in the wiring space 20, it does not conduct with the second conductive film 10.
In this way, the conductive material 5 in the wiring space 20 at the one end 1a forms a series connection with the adjacent cell C.

  The auxiliary conductive material 5a is not essential as long as the conductive material 5 and the terminal 6 are in reliable contact with the first conductive film 4 and can be electrically connected, but the connection reliability and the conductive material 5 and In order to securely fix the terminal 6 to the first conductive film 4, the conductive material 5 and the terminal 6 are preferably disposed between the first conductive film 4.

  The second conductive film 10 at the one end 1a is insulated from the other conductive film 10 in the internal space S by the insulating band 15 at the position of the sealing material 9 provided at the one end 1a as described above. Therefore, the conductive material 5 at the one end 1a does not cause a short circuit problem even if it is in contact with the second conductive film 10, but in order to prevent unnecessary conduction with the second conductive film 10, It is desirable to ensure separation from the membrane 10. Therefore, it is more desirable that an insulating material (not shown) is disposed between the conductive material 5 and the second conductive film 10.

Furthermore, it is preferable that a sealing material (not shown) is disposed in the opening 16 in order to prevent moisture and the like from entering.
Since the sealing material (not shown) for sealing the opening 16 is preferably as close as possible to the terminal 6 at one end 1a and the first conductive film 4 to be opened to achieve good conduction, The opening 16 on the one end 1a side is preferably made of a conductive material.

  The other end 1b in the direction of the arrow L2 forms a structure substantially similar to the structure of the one end 1a. However, the conductive material 5 provided at the other end 1b is a second conductive film continuously extended from the adjacent internal space S so as to match the series connection structure formed between the cells C and C. 10 and is electrically connected to form a serial connection with the adjacent cell C. The first conductive film 4 in the wiring space 20 at the other end 1b is insulated from the one conductive film 4 in the internal space S at the position of the sealing material 9 sealing the internal space S. Therefore, the conductive material 5 provided at the other end 1 b is not electrically connected to the first conductive film 4 even if it is in contact with the first conductive film 4.

The auxiliary conductive material 5a is not essential at the other end 1b for the same reason as the one at the end 1a, but is preferably disposed between the conductive material 5 and the terminal 6 and the other conductive film 10.
Further, like the one end 1 a, it is desirable that the conductive material 5 at the other end 1 b be reliably separated from the first conductive film 4. For this purpose, it is more desirable to provide an insulating material (not shown) between the conductive material 5 and the first conductive film 4.
Moreover, since it is preferable that the terminal 6 of the other end 1b does not conduct | electrically_connect with the 1st electrically conductive film 4, the sealing material (not shown) which seals the opening part 16 is in the opening part 16 by the side of the other end 1b. A material having no electrical conductivity is preferably used.

The linear conductive material 5 is not particularly limited as long as it is formed of a low-resistance metal. For example, a conductive wire formed of copper, silver, a copper alloy, or the like can be used, and cost and availability are easy. In view of the above, it is preferable to use a copper wire.
The linear conductive material 5 is arranged on the surface of the first conductive film 4 or the second conductive film 10 and can collect electricity generated in the cell C. The conductive material 5 is preferably disposed with a larger contact area with respect to the first conductive film 4 or the second conductive film 10 via the paste-like auxiliary conductive material 5a. Then, by increasing the contact area and providing the conductive material 5 having a lower resistance than the conductive film such as ITO, the solar cell 1 </ b> A has a reduced resistance to movement of electrons in the photoelectrode 2 and the counter electrode 3. The efficiency of current collection work is shortened by shortening the distance.

The electrolyte 12 penetrates into the semiconductor layer 8 and is coated on almost the entire surface thereof.
The electrolyte 12 is, for example, a nonaqueous solvent such as acetonitrile or propionitrile, or a liquid component such as ionic liquid such as dimethylpropylimidazolium iodide or butylmethylimidazolium iodide, and a supporting electrolyte such as lithium iodide. A solution in which a liquid and iodine are mixed is used. The electrolyte 12 may contain t-butylpyridine in order to prevent reverse electron transfer reaction.

As described above, the solar cell 1A includes the wiring space 20 separated from the internal space S between the cells C and C, and the first conductive film 4 is connected to the wiring space 20 in series with each other. And the second conductive film 10 are continuously extended, or the first conductive film 4 or the second conductive film 10 is patterned (insulated).
In the solar cell 1A, the terminal 6 is connected to the conductive material 5 at both ends 1a and 1b in the direction of the arrow L2, and the terminal 6 protrudes from the plate surface of the photoelectrode 2 through the opening 16, and current is supplied to the arbitrary terminal 6 It can be easily removed from.
Note that an opening 16 may be formed in the wiring space 20 between the semiconductor layers 8 and 8 similarly to the one end 1 a and the other end 1 b, and a terminal may be inserted into the opening 16. According to this configuration, the number of power generating elements connected in series can be increased or decreased.

Next, the manufacturing method of 1 A of solar cells is demonstrated using FIGS.
One embodiment of the manufacturing method of the solar cell 1 </ b> A includes (I) a photoelectrode 2 in which a semiconductor layer 8 is formed on a first substrate 7 on which a first conductive film 4 is formed, and a second conductive film 10. A feeding step of continuously feeding the counter electrode 3 provided with the second substrate 11 on which the film is formed to extend in the direction of the arrow L1, and (II) the photoelectrode 2 and the counter electrode 3, In order to form an internal space S therebetween, sealing is performed. At this time, at least a part of the sealing portion P between the photoelectrode 2 and the counter electrode 3 is formed by the sealing material 9, The conductive material 5 is applied to the surface of either the first conductive film 4 or the second conductive film 10 that extends beyond the inner space S beyond the sealing material 9 in an electrically continuous state from the space S. It is characterized by providing a sealing step and a conductive material placement step.
Hereinafter, each step will be described.

<Preparation of photoelectrode 2 and counter electrode 3>
As shown in FIGS. 3A and 3B, before the unwinding step, first, for example, the first substrate 7 wound in a roll shape is drawn out in one direction (in the direction of the arrow L1), and the first substrate surface is placed on one plate surface. One photoconductive film 4 is formed, a semiconductor layer 8 is further formed on the surface of the first conductive film 4, and a photoelectrode 2 carrying a dye is prepared. In addition, you may use the roll-shaped base material in which the 1st electrically conductive film 4 was previously formed in one board surface of the 1st board | substrate 7. FIG.
Similarly, the counter electrode 3 in which the second conductive film 10 is formed on the second substrate 11 wound in a roll shape, for example, is prepared. A roll-shaped base material in which the second conductive film 10 is formed on one plate surface of the second substrate 11 in advance may be used.

(I) <Feeding process>
In the feeding process, the photoelectrode 2 and the counter electrode 3 are fed so as to continuously extend in the direction of the arrow L1 (one direction) in a strip shape.
As shown in FIGS. 3A and 3B, it is preferable to arrange a paste-like auxiliary conductive material 5 a in a band shape on one end 1 a side in the width direction (arrow L <b> 2 direction) of the photoelectrode 2.

Further, in the first conductive film 4 on the first substrate 7, it is preferable that a strip-shaped insulating band 15 parallel to the arrow L <b> 1 direction is formed between the semiconductor layers 8 by a laser or the like.
Furthermore, as shown in FIGS. 4A and 4B, it is preferable that openings 16 are formed at both ends 1a and 1b in the width direction of the photoelectrode 2 with an interval in the direction of the arrow L1.
Then, as shown in FIGS. 5A and 5B, the terminal 6 is allowed to penetrate the opening 16 (see FIG. 4A).

(II) Sealing Step and Conductive Material Arrangement Step Next, as shown in FIGS. 6A and 6B, the linear conductive material 5 is in contact with the terminal 6 and the auxiliary conductive material 5 a on the first conductive film 4. Is arranged in the direction of the arrow L1, and the linear conductive material 5 is also arranged in the direction of the arrow L1 between the semiconductor layers 8 and 8. The sealing materials 9, 9 are continuously arranged in the direction of the arrow L1 so as to sandwich the conductive material 5 on each line. At this time, a paste-like auxiliary conductive material 5a is arranged in a strip shape on the conductive material 5 on the other end 1b side in the width direction (arrow L2 direction) of the photoelectrode 2. By providing the sealing materials 9, a wiring space 20 separated from the internal space S is formed when the photoelectrode 2 and the counter electrode 3 are bonded together.
Then, the electrolyte 12 is applied or dropped onto the surface of the semiconductor layer 8.

In addition, the order of arrangement | positioning of the electrically conductive material 5 and the sealing material 9, and application | coating or dripping of the electrolyte 12 is not specifically limited.
As for the counter electrode 3, the insulation formed on the first conductive film 4 between the semiconductor layers 8 when the counter electrode 3 is bonded to the photoelectrode 2 as shown in FIGS. 7A and 7B. A strip-shaped insulating band 15 is formed in advance on the second conductive film 10 so as to be shifted in one direction of the band 15 and the arrow L2 and continuously extending in the direction of the arrow L1.

7A and 7B, the photoelectrode 2 and the counter electrode 3 are laminated with the first conductive film 4 and the second conductive film 10 facing each other. Then, the position where the sealing material 9 is disposed is heated and pressurized to adhere the sealing portion P of each cell C in the direction of the arrow L1, and at a predetermined interval in the direction of the arrow L1, ultrasonic welding, etc. As a result, the photoelectrode 2 and the counter electrode 3 are fused and cut in the direction of the arrow L2.
Through the above steps, the internal space S including the semiconductor layer 8 and the electrolyte 12 shown in FIG. 1 or FIG. 2 and the wiring space 20 including the conductive material 5 are formed. The first conductive film 4 of the cell C and the second conductive film 10 of the other cell C are connected to obtain a solar cell 1A having a series connection structure.

  In the solar cell 1A thus obtained, as shown in FIG. 2, all the conductive materials 5 are continuously arranged in the direction of the arrow L1 in the wiring space 20. Therefore, the solar cell 1A can shorten the electron moving distance and efficiently collect current from the entire direction of the arrow L1 of each cell C, and an effect of high quality is obtained. In the present invention, the conductive material 5 is continuously disposed in the direction of the arrow L1 in the wiring space 20 (that is, the conductive material 5 is disposed over the entire length of the conductive films 4 and 10 of the solar cell 1A. However, the conductive material 5 is preferably disposed over 10 to 100% of the entire length of the conductive films 4 and 10, and 50 to 100 % Is more preferable.

  Moreover, since the conductive material 5 and the terminal 6 are installed in the wiring space 20 formed outside the internal space S having the electrolyte 12, the solar cell 1A can easily form a gap such as the terminal 6 as in the prior art. Is prevented from being leaked out of the cell C, and the effect of high quality can be obtained.

Moreover, since the solar cell 1A is provided with the conductive material 5 in the direction of the arrow L1 in the wiring space 20 provided outside the internal space S having the electrolyte 12, the opening 16 is easily formed at an arbitrary position. Thus, an effect that current can be taken out from an arbitrary position via the terminal 6 is obtained. Further, for the same reason, the solar cell 1 </ b> A has an effect of preventing the deterioration of the battery performance by preventing the conductive material 5 and the terminal 6 from being corroded by the electrolyte 12.
In addition, the solar cell 1A has an effect that the size or design freedom of the solar cell 1A is high for the above reason.

  In addition, the solar cell 1A is identical to the first conductive film 4 or the second conductive film 10 that is physically and electrically continuous from the internal space S in the wiring space 20 and the same as described above in the insulating band 15. Either the second conductive film 10 or the first conductive film 4 insulated from the internal space S is extended to the outside of the same sealing material 9. Therefore, the solar cell 1A can be easily used without considering the short-circuit caused by the contact between the conductive material 5 and the terminal 6 and both the first conductive film 4 and the second conductive film 10 facing each other. The effect that 6 can be arranged is obtained. Therefore, an effect that the manufacturing of the solar cell 1A can be facilitated is obtained.

  Furthermore, in the manufacturing method of the solar cell 1A of the present invention, the photoelectrode 2 and the counter electrode 3 are bonded in the direction of the arrow L1 by the sealing material 9 while being fed in the direction of the arrow L1, and cross over the sealing material 9. Sealing in the direction of the arrow L2 can be performed by ultrasonic fusion or the like at an arbitrary position of the solar cell 1A. That is, the manufacturing method of the solar cell 1A of the present invention uses, for example, the Roll to Roll manufacturing method in which the photoelectrode 2 and the counter electrode 3 are formed in a strip shape and continuously manufactured while being conveyed in the direction of the arrow L1 (ie, the longitudinal direction) Thus, an advantageous effect that the solar cell 1A can be manufactured extremely simply, efficiently and speedily is obtained.

  In the above embodiment, the solar cell 1A is configured to form the opening 16 in the photoelectrode 2 and take out the terminal 6 from the opening 16, but the formation of the opening 16 is limited to the photoelectrode 2. It is not something. That is, since the opening 16 is only an option for the direction of taking out the terminal 6, if the conductive material 5 and the terminal 6 are appropriately connected to the electrode (that is, the first conductive film 4 or the second conductive film 10). The opening 16 may be formed in the counter electrode 3 as shown in FIG. 8, or the opening 16 on the one end 1a side is formed in the counter electrode 3 as shown in FIG. The opening 16 on the other end 1b side may be formed in the photoelectrode 2 or vice versa (not shown). Alternatively, the opening 16 may be formed in both the photoelectrode 2 and the counter electrode 3.

  Furthermore, as shown in FIG. 10, the terminal 6 is projected from the outer edge (that is, one end 1a and the other end 1b) of the photoelectrode 2 or the counter electrode 3 from between the photoelectrode 2 and the counter electrode 3. There may be. In this case, the wiring space 20 in which the conductive material 5 for connecting the terminal 6 is arranged is opened to the side so that the terminal 6 can easily protrude at any position of the conductive material 5. May be.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with reference to FIGS. 11A and 11B. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.
As shown in FIGS. 11A and 11B, the solar cell 1B of the present embodiment forms a current collection structure by arranging a plurality of conductive materials 5 in the internal space S of one cell C, and the current collection structures are arranged in parallel. It differs from the first embodiment in that it is provided.

The first conductive film 4 and the second conductive film 10 are not patterned in the internal space S and are formed on the entire surfaces of the first substrate 7 and the second substrate 11.
The conductive material 5 is arranged at one end 1a, between the semiconductor layers 8 and 8, and the other end 1b. At the one end 1a and the other end 1b, an auxiliary conductive material 5a is interposed between the semiconductor layers 8 and 8. It arrange | positions so that only the electrically conductive film 4 side may be contacted without passing through the electrically conductive material 5a. It is more preferable that the auxiliary conductive material 5 a is provided below the conductive material 5 between the semiconductor layers 8 and 8.

Openings 16 are formed in the photoelectrode 2 at intervals in the direction of the arrow L1 (the depth direction in FIG. 11B), and the terminal 6 is inserted through each of them, and the conductive material 5, the terminal 6, and the first electrode The conductive film 4 is in contact with each other.
A protective material 35 is provided on the surface of the conductive material 5 between the semiconductor layers 8 and 8 so that the entire surface including the terminal 6 does not contact the electrolyte 12.

Between the conductive material 5 on the one end 1a side and the second conductive film 10 and between the conductive material 5 on the other end 1b side and the first conductive film 4 in order to ensure insulation, it is between these An insulating material 31 is interposed between the two.
By adopting such a configuration, the solar cell 1 </ b> B efficiently collects electric power while connecting the electric wires 30 to the respective terminals 6 and ensuring conduction throughout the first conductive film 4 in one cell C. The effect that it can do is acquired.

(Modification 1)
Next, Modification 1 of the second embodiment will be described with reference to FIG.
A solar cell 1C according to Modification 1 includes a semiconductor layer 8 as shown in FIG. 12 in place of the conductive material 5 between the semiconductor layers 8 and 8 shown in FIGS. 11A and 11B and the protective material 35 provided on the terminal 6. , 8 and sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2) to form a wiring space 20. An insulating material 31 is interposed between the conductive material 5 and the second conductive film 10.

By setting it as such a structure, the solar cell 1C of the modification 1 is efficient, connecting the electric wire 30 to each terminal 6, and ensuring conduction | electrical_connection over the whole 1st electrically conductive film 4 in one cell C. The effect that current can be collected is obtained.
Further, in the solar cell 1C of the first modification, the conductive material 5 is arranged in the wiring space 20 separated from the internal space S, so that the terminals 6, 6,... And the conductive material 5 are reliably separated from the electrolyte 12. Can be protected.

Moreover, since the solar cell 1C of the modification 1 can be isolated from the electrolyte 12 only by installing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be simplified is obtained.
Further, in the solar cell 1 </ b> C of the first modification, the treatment of the opening 16 in the wiring space 20 between the semiconductor layers 8 and 8 is easy, and the electrolyte 12 leaks from the opening 16 formed on the photoelectrode 2 side. The effect that it can prevent reliably is acquired.

(Modification 2)
Next, Modification 2 of the second embodiment will be described with reference to FIGS. 13A and 13B. In the second modification, the same components as those in the second embodiment shown in FIGS. 11A and 11B are denoted by the same reference numerals, and the description thereof is omitted.
Unlike the second embodiment of FIGS. 11A and 11B in which a plurality of conductive materials 5 are provided only on the photoelectrode 2 side, the solar cell 1D of Modification 2 includes a protective material 35 as shown in FIGS. 13A and 13B. The plurality of conductive materials 5 provided are provided on both the first conductive film 4 and the second conductive film 10.

In the solar cell 1D of Modification 2, the openings 16, 16,... Are also formed in the second substrate 11 and the second conductive film 10, and the second conductive film is formed in these openings 16, 16,. Terminals 6, 6... Connected to 10 are inserted. The terminals 6, 6... Connected to the first conductive film 4 and the conductive material 5 are connected to the electric wire 30 and collected, and the terminals 6 connected to the second conductive film 10 and the conductive material 5. , 6... Are connected to the electric wire 30 for current collection, and a current collecting structure is formed in parallel.
The solar cell 1D of the second modification can obtain an effect that current can be collected using both the photoelectrode 2 and the counter electrode 3 efficiently.

(Modification 3)
Next, Modification 3 of the second embodiment will be described with reference to FIG. In the third modification, the same components as those in the first and second modifications are denoted by the same reference numerals, and the description thereof is omitted.
The solar cell 1E of Modification 3 includes a semiconductor layer 8, as shown in FIG. 14, instead of the conductive material 5 between the semiconductor layers 8, 8 shown in FIGS. 13A and 13B and the protective material 35 provided on the terminal 6. Sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2) between the eight and the wiring space 20 is formed.

In this case, since the conductive material 5 connected to the first conductive film 4 in the wiring space 20 and the conductive material 5 connected to the second conductive film 10 are disposed to face each other, the conductive material 5 between these conductive materials 5 and 5 is disposed. An insulating material 31 is interposed between the two.
Even in the case of such a configuration, the solar cell 1E is efficiently collected from the first conductive film 4 and the second conductive film 10 in one cell C by connecting the electric wire 30 to each terminal 6. The effect that it can be electrified is acquired.

  In addition, since the conductive material 5 is arranged in the wiring space 20 separated from the internal space S, the solar cell 1E of Modification 3 is reliably separated from the terminals 6, 6,. can do. Moreover, since the solar cell 1E of the modification 3 can be isolated from the electrolyte 12 only by installing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be simplified is obtained.

  Further, in the solar cell 1E of the modification 3, the processing of the opening 16 in the wiring space 20 between the semiconductor layers 8 and 8 is simplified, and it is possible to reliably prevent the electrolyte 12 from leaking from the opening 16. The effect that it can be obtained.

Next, a third embodiment of the present invention will be described with reference to FIG. In the present embodiment, the same components as those of Modification 3 of the second embodiment are denoted by the same reference numerals, and the description thereof is omitted.
In the solar cell 1F of the present embodiment, a part of the solar cell 1E of Modification 3 of the second embodiment shown in FIG. 14 is deformed to connect a plurality of power generation elements (cells) C, C,. .

That is, in the solar cell 1F, the sealing materials 9 and 9 are arranged on both sides of the semiconductor layer 8 to form a plurality of internal spaces S and wiring spaces 20, and the internal spaces S and the wiring spaces 20 are set as a pair. An insulating band 15 is provided in one conductive film 4 and the second conductive film 10 to form a plurality of cells C, C,.
The insulating band 15 is located on one side (left side in the present embodiment) of the sealing materials 9 and 9 forming each wiring space 20, and the first conductive film 4 and the second conductive film 10 Is formed.

  The quality of the solar cell 1 </ b> F can be improved by adopting a configuration that can reliably prevent the electrolyte 12 from leaking into the wiring space 20. Moreover, although it is desirable for the structure of the solar cell 1F to seal the opening part 16, since it is not necessary to seal strictly, the effect that manufacturing efficiency can be improved is acquired.

In the first to third embodiments and the first to third modifications of the second embodiment, the conductive material 5 disposed between the semiconductor layers 8 is a linear example. Although mentioned, the conductive material 5 may use a paste-like conductive material.
The conductive material 5 is preferably fixed to the first conductive film 4 or the second conductive film 10 with a terminal 6 or a conductive paste. With such a configuration, the conductive material 5 is stably fixed to the photoelectrode 2 or the counter electrode 3, and the effect that the quality of the solar cell 1A can be improved is obtained.

Further, in the first to third embodiments and the first to third modifications of the second embodiment, the solar cells 1A to 1F are provided between the semiconductor layers 8 and 8 and on one end 1a and the other end 1b. The conductive material 5 is continuously arranged in the direction of the arrow L1, but this configuration is not essential in the present invention, and a part of the one end 1a and the other end 1b are formed between the semiconductor layers 8 and 8 described above. Even if it has this structure, the effect of the present invention can be obtained.
In the present invention, it is not essential that the conductive material 5 is continuous in the direction of the arrow L1, and the conductive material 5 is locally disposed at one place where the terminal 6 is disposed. For example, the conductive material 5 may be partially arranged, or the conductive material 5 may be interrupted in the arrow L1 direction.

Moreover, in the said embodiment, although this invention was demonstrated using the example which has arrange | positioned the gel-like electrolyte 12 between the photoelectrode 2 and the counter electrode 3, this invention uses the electrolyte 12 of a liquid or solid state. Can also be implemented.
Moreover, in the said embodiment, although it is set as the structure which sealed the arrow L2 direction which crosses in the arrow L1 direction which the sealing material 9 extends by ultrasonic welding, it seals suitably with sealing methods other than ultrasonic welding. It may stop.

Furthermore, although the said embodiment demonstrated as an example the structure by which the semiconductor layer 8 was formed into a film by arranging 3 rows in the width direction of the 1st board | substrate 7, the structure of this invention is limited to such a structure. Instead, the semiconductor layer 8 may be formed in one or more rows.
In addition, the solar cells 1A to 1F shown in the first to third embodiments and the first to third modifications of the second embodiment are connected to the solar cells 1A to 1F or in combination with each other. An electrical structure may be formed.

  In the above embodiment, a plurality of openings 16 are formed at intervals in the direction of the arrow L1, but one opening 16 is formed because it can be easily formed at an arbitrary position. It may be made, or a plurality of pieces other than those shown in the embodiment may be formed.

  In addition, the solar cell 1 </ b> A preferably has a configuration in which the conductive material 5 is installed on the first conductive film 4 or the second conductive film 10 that extends outside the sealing material 9 at both ends in the width direction. The effect of the present invention can be obtained even if the above configuration is adopted only at one end in the width direction.

1A-1F Solar cell (electric module)
2 Photoelectrode 3 Counter electrode 4 First conductive film 5 Conductive material 6 Terminal 7 First substrate 8 Semiconductor layer 9 Sealing material 10 Second conductive film 11 Second substrate 12 Electrolyte 16 Opening P Sealing portion

Claims (5)

A photoelectrode in which a semiconductor layer is formed on a first substrate on which a first conductive film is formed, a counter electrode including a second substrate on which a second conductive film is formed, and an electrolyte The photoelectrode and the counter electrode are bonded and sealed so as to form a plurality of internal spaces therebetween, and the electrolyte is filled in each of the plurality of internal spaces, thereby being connected in series. A plurality of power generation elements are formed,
At least one of the first conductive film and the second conductive film is formed with an insulating band serving as a separator between the plurality of power generation elements,
At least a part of the sealing portion between the photoelectrode and the counter electrode is formed by adhering the first conductive film and the second conductive film with a sealing material,
Of the first conductive film and the second conductive film, at least one of the first conductive film and the second conductive film is electrically continuous from the inner space and the insulating band is not formed. A conductive material is arranged on the surface of the extended part, and is electrically connected to the part, on the surface of the extended part ,
A terminal is connected to the conductive material,
The electrical module , wherein the terminal is provided so as to protrude from between the photoelectrode and the counter electrode and from an outer edge of the photoelectrode or the counter electrode . The electric module according to claim 1 , wherein the conductive material is fixed to at least one of the first conductive film and the second conductive film by the terminal. Both the first conductive film and the second conductive film are outside the internal space beyond the sealing material in a state where the insulating band is not formed electrically continuously from the internal space. Here, the first conductive film and the second conductive film are extended to the opposite side across the internal space, and the first conductive film and the second conductive film on the respective surfaces of the extended portions of the film, wherein the conductive material in a conductible state is arranged between the partial electrical module according to claim 1 or 2. It is a manufacturing method of an electric module given in any 1 paragraph of Claims 1-3 ,
A step of continuously extending the photoelectrode and the counter electrode so as to extend in one direction,
The photoelectrode and the counter electrode are bonded and sealed so as to form the plurality of internal spaces therebetween, and at this time, at least the sealing portion between the photoelectrode and the counter electrode Partial formation is performed using the sealing material to form the plurality of power generation elements, and at least one of the first conductive film and the second conductive film is electrically continuous from the internal space. And a sealing step in which the insulating band is not formed and in a state of extending outside the internal space beyond the sealing material,
And a conductive material arranging step of arranging the conductive material on the surface of the extended portion of the conductive film. The sealing material extends in the one direction on at least one end side in the direction crossing the one direction,
The method of manufacturing an electric module according to claim 4 , wherein the conductive material is arranged in parallel with the one direction.

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