JPS62203387A - Manufacture of amorphous photovoltaic power generation element module - Google Patents

Abstract

PURPOSE:To eliminate the need for connecting leads, equip a photovoltaic power generation element with an enlarged effective area, and to realize a high-efficiency module by a method wherein a single-body amorphous photovoltaic power generation element including a multiplicity of comb-type collecting electrodes is separated into individual pieces and the resultant photovoltaic power generation elements are piled one upon another. CONSTITUTION:An amorphous film 13 provided with a PIN junction is formed on a wide, lengthy stainless steel substrate 12 and, on the amorphous film 13, a transparent electrode film 14 is formed. Next, on the transparent electrode film 14, numerous comb-type collecting electrodes 15 are formed one after another at a prescribed interval along the direction of length, for the formation of a single-body amorphous photovoltaic power generation element 11. Further, the power generation element 11 is separated into individual amorphous photovoltaic power generation elements 11A, 11B, etc., each containing an electrode 15. Stacking is so accomplished that the electrode 15 of each of the separated power generation elements 11A, 11B, etc., may be in contact with a substrate 11 of a next power generation element 11. This results in an enlarged power generation element module effective area without using connecting leads.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing an amorphous photovoltaic device module using a metal substrate. [Prior Art] FIG. This figure shows a 10 cm x 10 cm metal substrate type amorphous photovoltaic device used in the amorphous original device module, in which Figure 3 (fat) is a front view and Figure 3 (+bl) is a cross-sectional view. In the figure, (C) is an amorphous photovoltaic device, (=) is a stainless steel substrate as a metal substrate for this photovoltaic device (C), and (3) is a non-crystalline photovoltaic device formed on this stainless steel substrate (C). Crystalline photovoltaic element (PIN of HA)
The junction part (ql) is a transparent electrode formed on this PIN junction part (3), and (51 is a collector electrode formed on this transparent electrode (ri) and having the shape shown in FIG. 3 fat).

Such an amorphous starting material 1 is used as an element (C is a stainless steel substrate (2) cut to a predetermined size in advance. (Co a) is a part of the stainless steel substrate L21.

Figure 9 is a diagram showing the arrangement and connection of amorphous photovoltaic elements (C) in a power amorphous photovoltaic element module made using a large number of amorphous photovoltaic elements (C) shown in Figure 3. It is.

For example, the seven amorphous photovoltaic device modules shown in the figure have a total of ≠ S amorphous photovoltaic devices (
The amorphous photovoltaic elements in two rows on the right (C) and the amorphous photovoltaic elements (C) in two rows on the left are arranged in opposite directions. (41 is the collector electrode Ctl and the stainless steel substrate (2
) is a thin rectangular lead wire used for connection with the part (Ua) of the wire, and is called a tab lead.

Next, we will explain how to electrically connect the ur photovoltaic elements in FIG. (not shown) to prevent the above-mentioned P-N junction and transparent electrode from forming a film.
l has opposite polarity.

In the power amorphous photovoltaic device module configured as described above, the amorphous photovoltaic devices at the top of the right column and left column are connected in parallel with each other with lead wires (6), and The amorphous photovoltaic elements (in C) with different polarities adjacent to each other are connected in series as shown, and the lowest ψ amorphous photovoltaic elements (in C, the two central By connecting two amorphous photovoltaic devices (C) in series, a crystalline photovoltaic device (C) and two amorphous photovoltaic devices (C) on both sides will be connected in parallel, so the amorphous photovoltaic device module is [Problem to be solved by the invention] Amorphous photovoltaic elements are constructed so that when light from the sun or other sources is irradiated onto the light-receiving surface, an electric output can be taken out between the θ terminals. However, one of the seven characteristics of this device is that it can be manufactured into a large-area device using, for example, plasma C'VD method, unlike a crystal device.

Since it is a thin film element, it is not possible to increase the area and flow a large current with a single element. Therefore, conventional metal substrate type amorphous photovoltaic elements and their modules are constructed as described above, and a large number of non-crystalline photovoltaic elements are used. Crystalline photovoltaic elements must be arranged with a predetermined insulation interval so that adjacent ones do not come into contact with each other, and lead wires must be used to connect the amorphous photovoltaic elements. Assembling a power generation element module requires manpower and a lot of time, and the area ratio of the amorphous photovoltaic element in the module, which is effective for photovoltaic power generation, is poor, and the dimensions of the amorphous photovoltaic element are not predetermined. Therefore, there is a problem in that when it is desired to produce 7 joules with a size suitable for the application, there is a restriction due to the size of the amorphous photovoltaic element.

This invention was made to solve the above-mentioned problems, and it is possible to process the substrate on which the amorphous photovoltaic element is formed into a size suitable for the application, and also to process the substrate on which the amorphous photovoltaic element is formed into a non-crystalline photovoltaic device without using lead wires. Provided is a method for manufacturing an amorphous photovoltaic device module that enables electrical connection between crystalline photovoltaic devices and improves the ratio of the area occupied by the amorphous photovoltaic device to the surface area of the module. The purpose is to

[Means for solving problems]

The method for manufacturing an amorphous photovoltaic device module according to the present invention includes first forming an amorphous photovoltaic device film on a long jointed end substrate, then forming a transparent electrode film thereon, and then forming a transparent electrode film on the transparent electrode film. The process includes forming a large number of comb-shaped collector electrodes according to the required dimensions to form an integrated amorphous photovoltaic element, and cutting this integrated amorphous photovoltaic element into predetermined dimensions to form individual non-crystalline photovoltaic elements. The step of forming a crystalline photovoltaic device and the comb-shaped collector electrode of one cut amorphous photovoltaic device and the metal substrate of the next amorphous photovoltaic device are overlapped and electrically connected. This method includes the step of electrically connecting individual amorphous photovoltaic elements in series.

[For production]

In this invention, an integrated amorphous photovoltaic device is directly formed on a long metal substrate, and the amorphous photovoltaic device is later processed into dimensions according to the purpose. Not only does it save you the trouble of arranging and mounting the substrates, but it also allows you to connect the amorphous photovoltaic elements using an extremely simple method, which reduces the number of electrical connections between the amorphous photovoltaic elements and saves you time. is significantly reduced. Furthermore, since no insulation space is required between the amorphous photovoltaic elements, the photovoltaic conversion efficiency per module is also improved.

〔Example〕

An embodiment of the present invention will be described below with reference to FIGS. 1 and 2. FIG. FIG. 1 is a front view of an integrated amorphous photovoltaic device fabricated on a long metal substrate according to the present invention.

The integrated amorphous photovoltaic device (/l) in FIG. 7 first has a thickness of, for example, 0. /m wide long metal substrate, such as a stainless steel substrate (/co), using a plasma CVD device.
An amorphous film (tJ) with an IN junction (see Figure 2) is formed, and a transparent electrode film (/3) is formed on this amorphous film (/3) using a sputtering device. This transparent electrode film (Ha・
It is made by printing a large number of comb-shaped collector electrodes (t!r) on top of the t!r. Note that the amorphous film with PIN junction (/3) is a long stainless steel substrate (/, 2).
and the transparent layer are present between the polar membrane (/q), so they are not shown in FIG. Further, as shown in the figure, a large number of comb-shaped collector electrodes (/left) are printed one after another in the same pattern on a long stainless steel substrate (12) at predetermined intervals in the longitudinal direction.

Fig. 2 shows the integrated amorphous photovoltaic device (l/) constructed as shown in Fig. 1, along lines AA' and BB' in Fig. 1.

Individual amorphous photovoltaic elements formed by cutting along the CC' line //A, //B, //C... are stacked and electrically connected in series. This is a perspective view showing an amorphous photovoltaic element module, in which (13) is an amorphous film with a PIN junction, (/λ), (c) and (l) are the same as those shown in Figure 1. be.

The amorphous photovoltaic device configured as shown in Figure 1 is connected to the stainless steel substrate (lco) which serves as the lower electrode of the adjacent amorphous photovoltaic device (llB) by soldering, pressure bonding, crimping or spot bonding. Individual amorphous photovoltaic elements (/lA), (llB), (/l
C)... can be connected in series. Therefore, there is no need to provide an insulating interval between the amorphous photovoltaic elements, unlike in the case of the conventional module shown in FIG.

In the above example, a case was described in which wide individual amorphous photovoltaic devices cut from an integrated amorphous photovoltaic device using a wide long metal substrate were connected in series. It goes without saying that the shape and dimensions of the amorphous photovoltaic element cut out from the crystalline photovoltaic element can be arbitrarily set depending on the use of the module.

〔Effect of the invention〕

As described above, according to the present invention, individual amorphous photovoltaic devices formed by cutting an integrated amorphous photovoltaic device in which a large number of comb-shaped collector electrodes are formed are stacked and electrically connected in series. Since the module is constructed by connecting the amorphous photovoltaic elements, there is no need to use lead wires to connect the amorphous photovoltaic elements, and the connection can therefore be easily performed. Furthermore, since no insulation interval is required between the amorphous photovoltaic elements, the effective area of the amorphous photovoltaic elements can be increased, and a highly efficient module can be obtained.

[Brief explanation of drawings]

FIG. 1 is a front view showing an integrated amorphous photovoltaic device according to an embodiment of the present invention, FIG. 2 is a perspective view showing the structure of an amorphous photovoltaic device module according to an embodiment of the present invention, and FIG. 3
Figures (at and fbl are a front view and a cross-sectional view of a conventional amorphous photovoltaic device, and FIG. 9 is a front view of a conventional amorphous photovoltaic device module. In the figure, (11) is an integrated non- Crystalline photovoltaic device, (/
/A), (llB), (//C)... are individual amorphous photovoltaic elements, (is) is a long stainless steel substrate, (
/3) is an amorphous film with a PIN junction, (19) is a transparent 'lit electrode film, and (15) is a comb-shaped collector electrode. In each figure, the same reference numerals indicate the same or corresponding parts. 1 figure death 2 figure %3 figure (0) (b) soil 2G t.

Claims (3)

[Claims] (1) First, an amorphous film having a PIN junction is formed on a long metal substrate, and then a transparent electrode film is formed thereon, and then a large number of comb-shaped collector electrodes are arranged on the transparent electrode film in a predetermined direction in the longitudinal direction. forming an integrated amorphous photovoltaic device one after another at intervals, and cutting the integrated amorphous photovoltaic device into pieces that always include one of the plurality of comb-shaped collector electrodes. Steps of forming individual amorphous photovoltaic elements, and stacking so that the comb-shaped collector electrode of one cut amorphous photovoltaic element and the metal substrate of the next amorphous photovoltaic element are in contact with each other. A method for manufacturing an amorphous photovoltaic device module, comprising the step of electrically connecting the individual amorphous photovoltaic devices in series. (2) The method for manufacturing an amorphous photovoltaic device module according to claim 1, wherein the series connection is performed by soldering, pressure bonding, crimping, or discharge welding. (3) The method for manufacturing an amorphous photovoltaic device module according to claim 1, wherein the long metal substrate also serves as one electrode of the amorphous photovoltaic device.