TWI650785B - Electrical module and method of manufacturing the same - Google Patents

Abstract

An electrical module, comprising: a photoelectrode having a semiconductor layer formed on a first substrate having a first conductive film formed thereon; and a counter electrode having a second substrate having a second conductive film formed thereon; And electrolyte; the photoelectrode and the counter electrode are bonded and sealed so as to form an internal space therebetween, the electrolyte is filled in the internal space, and a sealing portion between the photoelectrode and the counter electrode is sealed. At least a part of the first conductive film and the second conductive film are formed by bonding a sealing material, and at least one of the first conductive film and the second conductive film is electrically connected from the internal space to pass over the above. A sealing material is provided on the outside of the internal space, and a conductive material is disposed on the surface of the extended portion so as to be conductive with the above portion.

Description

Electric module and manufacturing method of electric module

The invention relates to an electric module and a method for manufacturing the electric module.

This case claims priority based on Japanese Patent Application No. 2014-027962 filed in Japan on February 17, 2014, and the contents are incorporated herein by reference.

In recent years, solar cells have attracted much attention as a power generation device for replacing clean energy with fossil fuels. The development of silicon (Si) solar cells and dye-sensitized solar cells has gradually developed. In particular, a dye-sensitized solar cell has been widely researched and developed as a cheap and easily mass-produced structure and manufacturing method (for example, the following Patent Document 1).

The dye-sensitized solar cell described in Patent Document 1 has a structure as shown in FIG. 1 of Patent Document 1. A plate surface on one side of the first substrate is provided with a first conductive metal layer, and the first conductive metal A porous insulating material (a member for preventing a short circuit between the conductive metal layer and the conductive substrate) is disposed on the surface of the layer, and another conductive material disposed opposite to the first conductive metal layer is provided on the surface of the porous insulating material. The metal layer further includes a semiconductor layer on the upper surface of the other conductive metal layer. In the dye-sensitized solar cell, a transparent substrate is arranged opposite to the first substrate, and an outer space of the opposed substrates is bonded to each other with a sealing material to form an internal space.

The solar cell has the following structure: an internal space is filled with an electrolyte, and a lead electrode with a metal conductive layer is formed on the surface of the insulating layer to contact the conductive metal layer of the first electrode of the solar cell and the conductivity of the other electrode The metal layer is arranged so that the lead-out electrode protrudes from the sealing material.

[Patent Document 1] Japanese Patent Laid-Open No. 2011-249258

However, in the conventional solar cell, since the lead-out electrode only partially touches the conductive metal layer of the first electrode of the solar cell and the conductive metal layer of the other electrode, the electrons must pass through a higher resistance value than the conductive material. The conductive metal layer moves to the lead-out electrode. That is, the conventional solar cell has the problems of high resistance value and poor quality at the time of current collection.

In addition, the above-mentioned solar cell adopts a structure in which one end of the lead-out electrode is inserted into the internal space of an electrical module, and the other end of the lead-out electrode protrudes more outward than the sealing material. Therefore, it is necessary to manufacture each module individually. Not suitable for continuous production.

Therefore, in view of the above-mentioned problems, the present invention provides a high-quality electrical module that improves current collection efficiency and reduces resistance value, and a method for manufacturing the same.

The electrical module of the present invention is characterized by comprising: a photoelectrode: a semiconductor layer is formed on a first substrate on which a first conductive film is formed; a counter electrode: a second substrate on which a second conductive film is formed; and Electrolyte; the photoelectrode and the counter electrode are adhered and sealed in such a manner as to form an internal space therebetween, the electrolyte is filled in the internal space, and a seal portion between the photoelectrode and the counter electrode is sealed. At least a part is formed by bonding the first conductive film and the second conductive film with a sealing material. At least one of the first conductive film and the second conductive film is electrically connected from the internal space, and passes over. The sealing material is extended on the outer side of the internal space, and on the surface of the extended portion, the sealing material is the same as the above. A conductive material is disposed in a partially conductive state.

In addition, in this case, "electrolyte" includes an electrolytic solution, a gel-like electrolyte, and a solid-state electrolyte.

According to this configuration, at the time of current collection, it is possible to achieve low resistance in at least one of the photoelectrode or the counter electrode, and to realize conduction in a wide area, thereby efficiently collecting electricity.

The terminal may be connected to the conductive material of the present invention, and at least one of the photoelectrode and the counter electrode may have one or more openings for exposing the terminal.

With this configuration, the terminal can be easily taken out from the plate surface of the first substrate of the photoelectrode and / or the plate surface of the second substrate of the counter electrode.

When a plurality of openings are formed, a current can be taken out from an arbitrary terminal.

The terminal may be connected to the conductive material of the present invention, and the terminal is provided to protrude from between the photoelectrode and the counter electrode and from the outer edge of the photoelectrode or the counter electrode.

According to this configuration, the terminal can be easily taken out between the photoelectrode and the counter electrode at any 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.

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

In the electrical module of the present invention, it is preferable that both the first conductive film and the second conductive film are electrically connected from the internal space to the outside of the internal space and extend beyond the sealing material. The first conductive film and the second conductive film are extended and disposed on opposite sides with the internal space interposed therebetween, and are provided on the extensions of the first conductive film and the second conductive film. A conductive material is disposed on a surface of each of the disposed portions so as to be electrically conductive with the above-mentioned portion.

According to this configuration, at the time of current collection, low resistance can be achieved in both the photoelectrode and the counter electrode, and conduction in a wide area can be realized, thereby allowing more efficient current collection.

The manufacturing method of the electrical module of the present invention is characterized by including the steps of continuously rolling out the photoelectrode and the counter electrode in a unidirectionally extending manner, respectively. The photoelectrode has a first conductive film formed thereon. A semiconductor layer is formed on the first substrate, and the counter electrode includes a second substrate on which a second conductive film is formed; the photoelectrode and the counter electrode are bonded and sealed in such a manner as to form an internal space therebetween. At this time, at least a part of the sealing portion between the photoelectrode and the counter electrode is formed using a sealing material, and it is set that at least one of the first conductive film and the second conductive film is electrically connected from the internal space. A step of sealing in a state where the state extends beyond the sealing material and is provided outside the internal space; and a conductive material arrangement in which the conductive material is disposed on the surface of the portion where the conductive film is extended to be conductive with the portion step.

According to this configuration, in the bonding of the photoelectrode and the counter electrode, the electrical module can be easily manufactured without considering the taking-out position of the terminal in advance.

Preferably, the sealing material according to the present invention extends along the unidirectionally at least one end side in a direction intersecting the unidirectionally, and the conductive material is disposed parallel to the unidirectionally.

According to this configuration, it is possible to easily perform continuous production such as roll-to-roll production in which one of the electrical modules described above is transported in one direction and continuously manufactured.

According to the present invention, the following effects are exerted: the resistance value at the time of power collection can be reduced, the power collection efficiency can be improved, and the quality of the electrical module can be improved.

In addition, according to the manufacturing method of the electrical module of the present invention, it is possible to make continuous production simple and convenient. The effect of efficiently manufacturing the electrical module of the present invention.

1A ~ 1F‧‧‧solar battery (electric module)

2‧‧‧photoelectrode

3‧‧‧ counter electrode

4‧‧‧ the first conductive film

5‧‧‧ conductive material

6‧‧‧terminal

7‧‧‧ the first substrate

8‧‧‧ semiconductor layer

9‧‧‧sealing material

10‧‧‧Second conductive film

11‧‧‧ second substrate

12‧‧‧ Electrolyte

16‧‧‧ opening

P‧‧‧Sealing Department

FIG. 1 is a perspective view schematically showing a state in which the electrical module according to the first embodiment of the present invention is cut along the line X1-X1.

FIG. 2 is a cross-sectional view of FIG. 1 viewed along the direction of the arrow at the line X1-X1.

3A is a perspective cross-sectional view schematically showing a part of a manufacturing process of the electrical module according to the first embodiment of the present invention.

FIG. 3B is a cross-sectional view of FIG. 3A viewed along the direction of the arrow at the line X2-X2.

FIG. 4A is a perspective cross-sectional view schematically showing a part of a manufacturing process of the electrical module according to the first embodiment of the present invention. FIG.

FIG. 4B is a cross-sectional view of FIG. 4A viewed along the direction of the arrow at the line X3-X3.

5A is a perspective cross-sectional view schematically showing a part of a manufacturing process of the electrical module according to the first embodiment of the present invention.

FIG. 5B is a cross-sectional view of FIG. 5A viewed along the direction of the arrow at the line X4-X4.

6A is a perspective cross-sectional view schematically showing a part of a manufacturing process of the electrical module according to the first embodiment of the present invention.

FIG. 6B is a cross-sectional view of FIG. 6A viewed along the direction of the arrow at the line X5-X5.

FIG. 7A is a perspective cross-sectional view schematically showing a part of a manufacturing process of the electrical module according to the first embodiment of the present invention. FIG.

FIG. 7B is a cross-sectional view of FIG. 7A viewed along the direction of the arrow at the line X6-X6.

FIG. 8 is a cross-sectional view schematically showing another example of the electric module according to the first embodiment of the present invention.

FIG. 9 is a cross-sectional view schematically showing another example of the electric module according to the first embodiment of the present invention.

FIG. 10 is a cross-sectional view schematically showing another example of the electric module according to the first embodiment of the present invention.

11A is a perspective sectional view schematically showing an electric module according to a second embodiment of the present invention.

FIG. 11B is a cross-sectional view of FIG. 11A viewed along the direction of the arrow at the line X8-X8.

FIG. 12 is a cross-sectional view schematically showing a modification example of the electric module according to the second embodiment of the present invention.

FIG. 13A is a perspective cross-sectional view schematically showing a modification example of the electric module according to the second embodiment of the present invention.

FIG. 13B is a cross-sectional view of FIG. 13A viewed along the direction of the arrow at the line X9-X9.

FIG. 14 is a cross-sectional view schematically showing a modification example of the electric module according to the second embodiment of the present invention.

15 is a cross-sectional view schematically showing an electric module according to a third embodiment of the present invention.

Hereinafter, with reference to the drawings, an embodiment of the electrical module of the present invention will be described by taking a case where the electrical module of the present invention is a dye-sensitized solar cell (hereinafter referred to as a "solar cell") as an example.

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 FIG. 2, the solar cell 1A according to the first embodiment of the present invention is characterized in that The photoelectrode 2 includes a semiconductor layer 8 formed on a first substrate 7 on which a first conductive film 4 is formed; and the counter electrode 3 includes a second substrate 11 on which a second conductive film 10 is formed; and Electrolyte 12; the photoelectrode 2 and the counter electrode 3 are bonded to each other so as to form an internal space S therebetween (a sealed portion P is formed), and the electrolyte 12 includes a plurality of power generators filled in the internal space S. The element (also referred to as a unit) C. The portion of the sealing portion P extending in the direction of the arrow L1 is formed by bonding the first conductive film 4 and the second conductive film 10 with a sealing material 9. In the connected state, the conductive material 5 is connected to the surface of each of the first conductive film 4 and / or the second conductive film 10 extending in opposite directions from each other on the outside of the internal space S beyond the sealing material 9. . In the present embodiment, the power generating elements C are connected in series.

Specifically, the solar cell 1A is configured as described below.

The photoelectrode 2 includes a plurality of (three in this embodiment) strip-shaped semiconductor layers 8 formed on the first conductive film 4 of the first substrate 7 in the direction of the arrow L1 (shown in FIG. 2 (the depth direction on the paper surface) extends parallel to each other. The semiconductor layers 8, 8, and ‧ are formed at intervals in the direction of the arrow L2 that intersects with the direction of the arrow L1 and are used to arrange the interval between the sealing materials 9 and 9 and the conductive material 5.

On the first conductive film 4, strip-shaped insulating tapes 15 extending in the direction of the arrow L1 to form a unit interval are formed on both sides of the semiconductor layer 8 in the width direction at a fixed interval so as to sandwich the semiconductor layer 8.

The counter electrode 3 includes a second substrate 11 on which a second conductive film 10 is formed.

On the second conductive film 10, a strip-shaped insulating tape 15 extending in the direction of the arrow L1 to become a unit is oriented toward one side of the direction of the arrow L2 (to the right in this embodiment), and is formed on the first conductive film The insulating tape 15 of 4 is staggered and the semiconductor layer 8 is sandwiched therebetween Fixed intervals are formed on both sides in the width direction of the semiconductor layer 8.

As the material of the first substrate 7 and the second substrate 11, respectively, transparent thermoplastic resin materials such as polyethylene naphthalate (PEN) and polyethylene terephthalate (PET) can be preferably used. Materials such as resin materials or glass substrates. The first substrate 7 and the second substrate 11 may be formed in a flexible film shape. At least one of the first substrate 7 and the second substrate 11 is a transparent substrate.

In the material of the first conductive film 4 or the second conductive film 10, for example, indium tin oxide (ITO), zinc oxide, fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), tin oxide ( SnO), antimony-doped tin oxide (ATO), indium oxide / zinc oxide (IZO), gallium-doped zinc oxide (GZO), and the like.

At least one of the first conductive film 4 and the second conductive film 10 is formed of a transparent conductive film.

In addition, it is preferable that 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 is transparent.

The semiconductor layer 8 has a function of receiving and transporting electrons from the sensitizing dye described below, and a semiconductor composed 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 dioxide (SnO ₂ ), or the like can be used.

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

As the second conductive film 10, any material that does not have a role as a catalyst layer and has a role as a conductive film, or any material that can serve both a catalyst layer and a conductive film may be used. One. 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.

As the catalyst layer formed on the surface of the second conductive film 10, carbon paste, platinum, or the like can be used.

The photoelectrode 2 and the counter electrode 3 are bonded to the sealing portion P. As a result, an internal space S for sealing the electrolyte 12 is formed on each of the semiconductor layers 8 continuously provided in a band shape.

In the sealing portion P, the sealing material 9 is arranged in two rows and two rows in the direction of the arrow L1 between the adjacent semiconductor layers 8 and 8 and both ends 1a and 1b in the direction of the arrow L2. The film 4 and the second conductive film 10 are formed next, and are formed by fusing the first substrate 7 and the second substrate 11 in the direction of arrow L2 by ultrasonic welding or the like.

The sealing material 9 is disposed at a position that covers the insulating tape 15 formed on the first conductive film 4 or the insulating tape 15 formed on the second conductive film 10 one by one. Furthermore, at both ends of one end 1a and the other end 1b, a sealing material 9 (P) is provided so as to cover the two insulating tapes 15 and 15 facing each other.

Furthermore, as the sealing material 9, an adhesive agent of a material that does not impair the functions of the first conductive film 4 and the second conductive film 10, such as a hot-melt resin, can be preferably used.

The wiring space 20 is formed between the sealing materials 9 and 9 arranged between the semiconductor layers 8 and 8. In this wiring space 20, a conductive material 5 is arranged in the direction of the arrow L1 so that adjacent cells C and C are connected to each other in series. That is, the conductive material 5 in the wiring space 20 contacts both the first conductive film 4 and the second conductive film 10 across the direction of the arrow L1. The first conductive film 4 is located in the internal space S of a unit C adjacent to the right side. The second conductive film 10 is continuously extended beyond the sealing material 9, and the second conductive film 10 is continuously extended from the internal space S of the other unit C adjacent to the left side across the sealing material 9. At this time, it is preferable that the first conductive film 4 and the conductive material 5 are continuously extended from the internal space S of one unit C and the internal space S of the other unit C One or both of the second conductive film 10 and the conductive material 5 that are continuously extended are provided with an auxiliary conductive material 5a such as a conductive material paste that assists the electrical connection between the two.

Summarizing the above configuration, between the cells C and C, the internal space S filled with the electrolyte 12 and the wiring space 20 which is liquid-tightly separated are formed by the sealing portions P containing the sealing materials 9 and 9. Furthermore, in the wiring space 20, a conductive material 5 is connected across the direction of the arrow L1 to the first conductive film 4 and the second conductive film 10 continuously extending from the adjacent internal space S in the wiring space 20, A series connection is formed between units C and C‧‧.

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

The first substrate 7 and the first conductive film 4 are provided in the wiring space 20 provided at one end 1a in the direction of the arrow L2, and openings 16 are formed at intervals in the direction of the arrow L1. Further, the linear conductive material 5 is connected to the first conductive film 4 continuously extending into the wiring space 20 provided at one end 1a through the auxiliary conductive material 5a across the direction of the arrow L1, thereby ensuring the first conductive film. It can conduct electricity in a wide area and can collect electricity efficiently. Further, a terminal 6 is inserted into the opening 16 formed in the wiring space 20 such that one end of the terminal 6 is connected to the auxiliary conductive material 5a and the conductive material 5 and the other end protrudes (exposed) from the opening 16.

With the above configuration, the wiring space 20 at one end 1a in the direction of the arrow L2 and the adjacent space The internal space S and the liquid-tight separation are connected. In addition, the conductive material 5 of the wiring space 20 is arranged across the direction of the arrow L1, thereby being able to straddle the sealing material 9 in the direction of the arrow L1 of the first conductive film 4 continuously extending from the internal space S to the outside thereof. As a whole, it is ensured to conduct and collect electricity, and it is possible to draw current from any terminal 6, 6‧‧. On the other hand, the second conductive film 10 at one end 1a is insulated from the conductive film 10 on the other side in the unit C at the position of the sealing material 9 that seals the internal space S. Therefore, the conductive material 5 is electrically isolated from the first conductive film 5 in the wiring space 20. The two conductive films 10 are not in contact with the second conductive film 10, either.

In this way, the conductive material 5 in the wiring space 20 at one end 1a and the adjacent unit C are connected in series.

In addition, regarding the auxiliary conductive material 5a, it is not necessary if the conductive material 5 and the terminal 6 are in contact with the first conductive film 4 to obtain electrical connection, but for the reliability of the connection and the conductive material 5 and the terminal 6 are reliably It is fixed on the first conductive film 4, and the auxiliary conductive material 5 a is preferably arranged between the conductive material 5 and the terminal 6 and the first conductive film 4.

The second conductive film 10 on one end 1a is insulated from the conductive film 10 on the other side of the internal space S by the insulating tape 15 at the position of the sealing material 9 provided on the one end 1a as described above. Therefore, even if the conductive material 5 at one end 1a is in contact with the second conductive film 10, a short circuit problem does not occur, but in order to prevent unnecessary conduction with the second conductive film 10, it is desirable to make the conductive material 5 at one end 1a and the first conductive film 5 The two conductive films 10 are surely separated. Therefore, it is more desirable to arrange an insulating material (not shown) between the conductive material 5 and the second conductive film 10.

Furthermore, it is more preferable that a sealing material (not shown) be disposed in the opening portion 16 to prevent entry of moisture and the like.

The sealing material (not shown) for sealing the opening portion 16 preferably has the terminal 6 at one end 1a and the opening The first conductive film 4 is as close as possible to achieve good conduction. Therefore, a sealing material having a conductive material can be preferably used for the opening 16 on the side of the one end 1a.

The other end 1b in the direction of the arrow L2 has a structure substantially the same as that of the one end 1a. However, the conductive material 5 provided at the other end 1b is aligned with the series connection structure formed between the cells C and C, and is in contact with the second conductive film 10 extending continuously from the adjacent internal space S. It is arranged and electrically connected to form a series connection with the adjacent unit C. Further, the position of the first conductive film 4 in the wiring space 20 at the other end 1b at the position of the sealing material 9 that seals the internal space S is insulated from the conductive film 4 on one side of the internal space S. Therefore, even if the conductive material 5 provided on the other end 1 b is in contact with the first conductive film 4, it will not be conductive with the first conductive film 4.

Furthermore, at the other end 1b, for the same reason as the one end 1a, the auxiliary conductive material 5a is not necessary, but is preferably disposed between the conductive material 5 and the terminal 6 and the conductive film 10 on the other side.

Also, like the one end 1a, the conductive material 5 at the other end 1b is preferably separated from the first conductive film 4 surely. Therefore, it is more desirable to arrange an insulating material (not shown) between the conductive material 5 and the first conductive film 4.

In addition, since the terminal 6 on the other end 1b is preferably not conductive with the first conductive film 4, the sealing material (not shown) for sealing the opening 16 can be preferably used on the opening 16 on the other end 1b side. Conductive materials.

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, copper alloy, or the like can be used, and copper wires are preferably used from the viewpoint of cost or ease of starting.

The linear conductive material 5 is arranged on the surface of the first conductive film 4 or the second conductive film 10 so that the electricity generated in the cell C can be collected. The conductive material 5 is preferably arranged to extend the contact area with respect to the first conductive film 4 or the second conductive film 10 via a paste-shaped auxiliary conductive material 5 a. Furthermore, by increasing the contact area and disposing a conductive material 5 having a lower resistance than a conductive film such as ITO, the solar cell 1A can be caused by the low resistance and short distance caused by the movement of electrons in the photoelectrode 2 and the counter electrode 3. Efficiency of current collection operations.

The electrolyte 12 penetrates inside the semiconductor layer 8 and is applied to substantially the entire surface thereof.

Further, as the electrolyte 12, for example, a nonaqueous solvent such as acetonitrile, propionitrile, or a liquid component such as ionic liquid such as dimethylpropylimidazolium iodide or butylmethylimidazolium iodide can be mixed with lithium iodide, Supports electrolyte and iodine solutions. In addition, in order to prevent the reverse electron transfer reaction, the electrolyte 12 may be one containing a third butylpyridine.

In this way, the solar cell 1A is provided with the wiring space 20 separated between the cells C and C from the internal space S, and the first conductive film 4 and the second conductive layer are made conductive so that the cells C and C are connected to the wiring space 20 in series with each other. The film 10 is formed by continuously extending or patterning (insulating) the first conductive film 4 or the second conductive film 10.

Furthermore, regarding the solar cell 1A, at both ends 1a, 1b in the direction of the arrow L2, the terminal 6 is connected to the conductive material 5, and the terminal 6 protrudes from the plate surface of the photoelectrode 2 through the opening 16 so that it can be easily from any terminal 6 Take out the current.

Further, an opening 16 may be formed in the wiring space 20 between the semiconductor layers 8 and 8 in the same manner as one end 1a and the other end 1b, and a terminal may be inserted into the opening 16. With this configuration, it is possible to increase or decrease the power generating elements connected in series.

Next, a manufacturing method of the solar cell 1A will be described using FIGS. 3 to 7.

An embodiment of a method for manufacturing a solar cell 1A is characterized by having: (I) a rolling-out step, which forms a photoelectrode 2 having a semiconductor layer 8 on a first substrate 7 having a first conductive film 4 formed thereon, and The counter electrode 3 of the second substrate 11 with the second conductive film 10 formed thereon is continuously rolled out so as to extend in the direction of the arrow L1, respectively; (II) a sealing step and a conductive material arrangement step, etc. 2 and the counter electrode 3 are bonded and sealed in such a manner as to form an internal space S therebetween. 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. A conductive material 5 is disposed on the surface of any one of the first conductive film 4 or the second conductive film 10 extending beyond the sealing material 9 in an electrically connected state from the internal space S to the outside of the internal space S.

Each step will be described below.

<Preparation of Photoelectrode 2 and Counter Electrode 3>

As shown in FIG. 3A and FIG. 3B, before the unwinding step, firstly, the first substrate 7 wound into a roll shape is pulled out unidirectionally (in the direction of arrow L1), and a film is formed on one side of the plate surface. A conductive film 4 further forms a semiconductor layer 8 on the surface of the first conductive film 4 to prepare a photoelectrode 2 carrying a dye. Furthermore, a roll-shaped base material in which the first conductive film 4 is formed on a plate surface of one side of the first substrate 7 in advance may be used.

In the same manner, the counter electrode 3 is prepared on the second substrate 11, which is previously wound into a roll shape, to form a second conductive film 10. A roll-shaped base material having a second conductive film 10 formed on a plate surface on one side of the second substrate 11 in advance may be used.

(I) <Unrolling steps>

In the unrolling step, the photoelectrode 2 and the counter electrode 3 are aligned in the direction of the arrow L1 (unidirectional) in advance. Continuously rolled out in a strip-like manner.

It is preferable to arrange the pasted auxiliary conductive material 5a in a strip shape in advance as shown in FIGS. 3A and 3B on one end 1a side in the width direction (direction of arrow L2) of the photoelectrode 2.

Further, it is preferable that a strip-shaped insulating tape 15 parallel to the direction of the arrow L1 is formed in advance between the semiconductor layers 8 by laser or the like on the first conductive film 4 on the first substrate 7 in advance.

Furthermore, as shown in FIG. 4A and FIG. 4B, it is preferable that the openings 16 be formed in advance in the width direction both ends 1 a and 1 b of the photoelectrode 2 at intervals in the direction of the arrow L1.

As shown in FIGS. 5A and 5B, the terminal 6 is passed through the opening 16 in advance (see FIG. 4A).

(II) Sealing step and conductive material configuration step

Next, as shown in FIG. 6A and FIG. 6B, the linear conductive material 5 is arranged in the direction of the arrow L1 so as to contact the terminal 6 and the auxiliary conductive material 5a on the first conductive film 4, and is placed on the semiconductor layers 8, 8 The linear conductive materials 5 are also arranged between each other in the direction of the arrow L1. The sealing materials 9 and 9 are continuously arranged in the direction of the arrow L1 so as to sandwich the linear conductive materials 5 therebetween. At this time, the pasty auxiliary conductive material 5 a is arranged in a strip shape on the conductive material 5 on the other end 1 b side in the width direction (the direction of the arrow L2) of the photoelectrode 2. By disposing the sealing materials 9 and 9, a wiring space 20 separated from the internal space S can be formed when the photoelectrode 2 and the counter electrode 3 are bonded together.

Then, the electrolyte 12 is applied or dropped on the surface of the semiconductor layer 8.

The arrangement of the conductive material 5 and the sealing material 9 and the order of applying or dropping the electrolyte 12 are not particularly limited.

As for the counter electrode 3, when the counter electrode 3 is bonded to the photoelectrode 2 as shown in FIGS. 7A and 7B, the semiconductor layer 8 is formed in advance on the second conductive film 10 in advance. Strip Insulating tape 15, the strip-shaped insulating tape 15 and the insulating tape 15 formed on the first conductive film 4 are continuously shifted in the direction of arrow L1 in a unidirectionally offset position from arrow L2.

Then, as shown in FIGS. 7A and 7B, the first conductive film 4 and the second conductive film 10 are opposed to each other, and the photoelectrode 2 and the opposite electrode 3 are laminated. Then, the position where the sealing material 9 is disposed is heated and pressurized, so that the sealing portion P of each unit C is continued in the direction of the arrow L1, and a certain interval is spaced in the direction of the arrow L1, and the light is ultrasonically welded or the like. The electrode 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 provided with the semiconductor layer 8 and the electrolyte 12 and the wiring space 20 provided with the conductive material 5 as shown in FIG. 1 or FIG. 2 can be formed. The wiring space 20 is connected with the conductive material 5 The first conductive film 4 of one cell C and the second conductive film 10 of the same another cell C can obtain a solar cell 1A having a series connection structure.

As shown in FIG. 2, in the solar cell 1A obtained in this manner, 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 moving distance of the electrons and efficiently collect electricity from the entire direction of the arrow L1 of each unit C, thereby obtaining a high-quality effect. In the present invention, the conductive material 5 is preferably arranged continuously in the direction of the arrow L1 in the wiring space 20 (that is, the conductive material 5 is arranged across the entire length of the conductive films 4 and 10 of the solar cell 1A), but it may also be intermittent In this case, the conductive material 5 is preferably disposed across 10 to 100% of the total length of the conductive films 4 and 10, and is more preferably disposed across 50 to 100%.

In addition, regarding the solar cell 1A, since the conductive material 5 and the terminals 6 are provided in the wiring space 20 formed outside the internal space S having the electrolyte 12, it is possible to avoid being caught by those who easily form gaps such as the terminals 6 as is known in the art. Into the sealing material 9, the electrolyte 12 can be more surely prevented from leaking out of the cell C, and a high-quality effect can be obtained.

In the solar cell 1A, since the conductive material 5 is provided in the wiring space 20 provided outside the internal space S having the electrolyte 12 in the direction of the arrow L1, the opening portion 16 can be easily formed at any position, thereby The effect that a current can be taken out from an arbitrary position via the terminal 6 can be obtained. In addition, for the solar cell 1A, for the same reason, the following effects can be obtained: the conductive material 5 and the terminal 6 can be prevented from being corroded by the electrolyte 12, and the deterioration of the battery performance can be effectively prevented.

Further, regarding the solar cell 1A, for the reasons described above, it is possible to obtain the effect that the size and design of the solar cell 1A are high.

In addition, the solar cell 1A extends either of the first conductive film 4 or the second conductive film 10 that is physically and electrically connected from the internal space S in the wiring space 20 to the outside of the same sealing material 9, And any one of the second conductive film 10 or the first conductive film 4 which is insulated from the same internal space S as described above in the insulating tape 15. Therefore, the solar cell 1A can obtain the following effect: the conductive material 5 and the conductive material 5 and the terminal 6 can be easily disposed without considering the short circuit caused by the contact between the conductive material 5 and the terminal 6 and the first conductive film 4 and the second conductive film 10 facing each other. Terminal 6. Therefore, the effect that the solar cell 1A can be easily manufactured can be obtained.

Furthermore, regarding the manufacturing method of the solar cell 1A of the present invention, the photoelectrode 2 and the counter electrode 3 can be sent out in the direction of the arrow L1 while the photoelectrode 2 and the counter electrode 3 are sent out in the direction of the arrow L1 by the sealing material 9 and then applied to the solar cell 1A. At any position, sealing is performed by ultrasonic welding or the like crossing the direction of the arrow L2 of the sealing material 9. That is, the manufacturing method of the solar cell 1A of the present invention can obtain the following advantageous effects: the photoelectrode 2 and the counter electrode 3 can be formed into a strip shape on one side, and can be continuously manufactured while being conveyed in the direction of the arrow L1 (that is, the length). For example, a roll-to-roll method is extremely simple, efficient, and fast for manufacturing a solar cell 1A.

Furthermore, in the above-mentioned embodiment, the solar cell 1A has a configuration in which the opening 16 is formed in the photoelectrode 2 and the terminal 6 is taken out from the opening 16. However, the formation of the opening 16 is not limited to the photoelectrode 2. That is, the opening 16 is only an option for the direction of taking out the terminal 6. Therefore, if the conductive material 5 and the terminal 6 are properly connected to the electrode (ie, the first conductive film 4 or the second conductive film 10), the opening 16 may be As shown in FIG. 8, it is formed on the counter electrode 3, or as shown in FIG. 9, the opening 16 on the one end 1a side can be formed on the counter electrode 3, and the opening 16 on the other end 1b side can be formed on the photoelectrode. 2. (Although not shown), it can also be the opposite. 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 may protrude between the photoelectrode 2 and the counter electrode 3 and protrude from the outer edge of the photoelectrode 2 or the counter electrode 3 (that is, one end 1a and the other end 1b). . In this case, the wiring space 20 configured to connect the conductive material 5 of the terminal 6 may be opened to the side, and the terminal 6 can be easily protruded at any position of the conductive material 5.

(Second Embodiment)

Next, a second embodiment of the present invention will be described with reference to Figs. 11A and 11B. In this embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and descriptions thereof will be omitted.

As shown in FIGS. 11A and 11B, the solar cell 1B of this embodiment is different from the first embodiment in the following aspects: a plurality of conductive materials 5 are arranged in the internal space S of a unit C to form a current collecting structure, and the current collecting Structures are placed side by side.

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 each of the first substrate 7 and the second substrate 11.

The conductive material 5 is arranged between one end 1a, the semiconductor layers 8, 8 and the other end 1b, and is arranged as follows: at one end 1a and the other end 1b, between the semiconductor layers 8, 8 through the auxiliary conductive material 5a It is connected only to the conductive film 4 side without passing through the auxiliary conductive material 5a. The auxiliary conductive material 5a is also preferably disposed below the conductive material 5 between the semiconductor layers 8,8.

On the photoelectrode 2, openings 16 are formed at intervals along the direction of the arrow L1 (the depth direction of the paper surface in FIG. 11B), and terminals 6 are inserted through each of them. Touch 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 terminals 6 are included and the whole is not in contact with the electrolyte 12.

An insulating material 31 is provided 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 to ensure insulation.

With such a configuration, the solar cell 1B can obtain the following effects: the electric wire 30 can be connected to each terminal 6 and the whole of the first conductive film 4 can be ensured through conduction in one unit C, and the current can be efficiently collected. .

(Modification 1)

Next, a modification 1 of the second embodiment will be described with reference to FIG. 12.

The solar cell 1C of this modification 1 replaces the conductive material 5 provided between the semiconductor layers 8 and 8 and the protective material 35 of the terminal 6 as shown in FIG. 11A and FIG. 11B, as shown in FIG. 12, on the semiconductor layers 8 and 8. Between each other, sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2), and a wiring space 20 is formed. An insulating material 31 is provided between the conductive material 5 and the second conductive film 10.

By having such a configuration, the solar cell 1C of the first modification can obtain the following effects: the electric wire 30 can be connected to each terminal 6 and a unit C spans the entire first conductive film 4 It ensures the continuity and collects electricity efficiently.

In addition, since the solar cell 1C of the modification 1 is provided with the conductive material 5 in the wiring space 20 separated from the internal space S, the terminals 6, 6‧, and the conductive material 5 can be reliably separated from the electrolyte 12 and protected.

In addition, since the solar cell 1C of the modification 1 can be isolated from the electrolyte 12 only by disposing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be simplified can be obtained.

In addition, the solar cell 1C of the modification 1 can achieve the following effects: the handling of the openings 16 in the wiring space 20 between the semiconductor layers 8 and 8 is also simplified, and the electrolyte 12 can be reliably prevented from openings formed on the photoelectrode 2 side. Section 16 leaks.

(Modification 2)

Next, a 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 descriptions thereof will be omitted.

The solar cell 1D of the second modification is different from the second embodiment shown in FIGS. 11A and 11B in which a plurality of conductive materials 5 are provided only on the photoelectrode 2 side, and as shown in FIGS. 13A and 13B, a protective material 35 is provided. The plurality of conductive materials 5 are disposed 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 openings 16, 16‧‧ are connected to the second conductive film 10 Terminals 6, 6‧‧. Furthermore, the terminals 6, 6‧‧ connected to the first conductive film 4 and the conductive material 5 are connected to each other to the electric wire 30 for current collection, and the terminals 6, 6‧‧ connected to the second conductive film 10 and the conductive material 5 are connected to each other Current is collected on the electric wires 30, and a current collecting structure is formed in parallel.

The solar cell 1D of the second modification can obtain the following effect: it is possible to efficiently use both the photoelectrode 2 and the counter electrode 3 to collect electricity.

(Modification 3)

Next, a modification 3 of the second embodiment will be described with reference to FIG. 14. In the third modification, the same components as those in the first and second modifications are denoted by the same reference numerals, and descriptions thereof are omitted.

The solar cell 1E of the modification 3 replaces the conductive material 5 provided between the semiconductor layers 8 and 8 and the protective material 35 of the terminal 6 as shown in FIGS. 13A and 13B, and is applied to the semiconductor layers 8 and 8 as shown in FIG. 14. Between each other, sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2), and a wiring space 20 is formed.

In this case, since the conductive material 5 connected to the first conductive film 4 and the conductive material 5 connected to the second conductive film 10 in the wiring space 20 are opposed to each other, it is installed between the conductive materials 5 and 5. There are 31 insulating materials.

In the case of such a configuration, the solar cell 1E can also obtain the following effects: the electric wire 30 can be connected to each terminal 6, and the first conductive film 4 and the second conductive film 10 can be efficiently performed in one unit C. Collect electricity.

In addition, since the solar cell 1E of the modification 3 has the conductive material 5 disposed in the wiring space 20 separated from the internal space S, the terminals 6, 6‧, and the conductive material 5 can be reliably separated from the electrolyte 12 and protected. In addition, since the solar cell 1E according to the third modification can be isolated from the electrolyte 12 only by disposing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be easily performed is obtained.

In addition, the solar cell 1E of the modification 3 can obtain the following effects: the handling of the opening 16 of the wiring space 20 between the semiconductor layers 8 and 8 is also simplified, and the electrolyte can be reliably prevented 12 leaks from the opening 16.

Next, a third embodiment of the present invention will be described using FIG. 15. In this embodiment, the same components as those in the third modification of the second embodiment are denoted by the same reference numerals, and descriptions thereof will be omitted.

The solar cell 1F of this embodiment deforms a part of the solar cell 1E of the modification 3 of the second embodiment shown in FIG. 14 and connects a plurality of power generating elements (cells) C and C‧‧ in parallel.

That is, the solar cell 1F arranges the sealing materials 9 and 9 on both sides of the semiconductor layer 8 to form a plurality of internal spaces S and wiring spaces 20, and uses the internal spaces S and the wiring spaces 20 as a group on the first conductive film 4 and The second conductive film 10 is provided with an insulating tape 15 so as to form a plurality of cells C, C‧‧ insulated from each other.

The insulating tape 15 is formed on the first conductive film 4 and the second conductive film 10 at a position on either side (left side in this embodiment) of the sealing materials 9 and 9 forming each wiring space 20.

The solar cell 1F has a structure capable of reliably preventing the electrolyte 12 from leaking out into the wiring space 20, thereby improving its quality. In addition, although the solar cell 1F preferably has a structure that seals the opening portion 16, it does not need to be tightly sealed, so that the effect of improving manufacturing efficiency can be obtained.

In the modified examples 1 to 3 from the first embodiment to the third embodiment and the second embodiment, the conductive material 5 disposed between the semiconductor layers 8 is exemplified by the use of a linear conductive material, but The conductive material 5 may be a paste-like conductive material.

The conductive material 5 is preferably fixed to the first conductive film 4 or the second conductive film 10 by a terminal 6 or a conductive paste. With this configuration, the following effects can be obtained: the conductive material 5 can be stably fixed to the photoelectrode 2 or the counter electrode 3, and the quality of the solar cell 1A can be improved.

In addition, in the modified examples 1 to 3 from the first embodiment to the third embodiment and the second embodiment, the solar cells 1A to 1F are interposed between the semiconductor layers 8 and 8 and are all straddled at one end 1a and the other end 1b. The conductive material 5 is continuously arranged in the direction of the arrow L1. However, this structure is not necessary in the present invention, and the effect of the present invention can be obtained even if the semiconductor layer 8 and 8 and a part of the one end 1a and the other end 1b have the above structure. .

Moreover, in the present invention, it is not necessary to make the conductive material 5 integrally continuous in the direction of the arrow L1. As long as the conductive material 5 is not locally disposed at one of the placement terminals 6, the conductive material 5 may be locally disposed, or The conductive material 5 is interrupted in the direction of the arrow L1.

Furthermore, in the above-mentioned embodiment, the present invention has been described using an example in which a gel-like electrolyte 12 is disposed between the photoelectrode 2 and the counter electrode 3, but the present invention can be implemented even if the liquid-state or solid-state electrolyte 12 is used. .

Further, in the above-mentioned embodiment, a configuration is adopted in which the direction of the arrow L2 crossing the direction of the arrow L1 extending to the sealing material 9 is sealed by ultrasonic welding, but sealing may be performed by a sealing method other than ultrasonic welding as appropriate. .

Furthermore, in the above-mentioned embodiment, the structure in which the semiconductor layers 8 are arranged in three rows in the width direction of the first substrate 7 has been described as an example, but the structure of the present invention is not limited to such a structure. The semiconductor layer 8 can also form several lines of more than one line.

In addition, regarding the solar cells 1A to 1F shown in the first to third embodiments and the second to third modification examples 1 to 3, each of the solar cells 1A to 1F or a combination of each other can be formed into a connection structure. Or collector structure.

In the above-mentioned embodiment, a plurality of openings 16 are formed at intervals in the direction of the arrow L1. However, since the openings 16 can be easily formed at arbitrary positions, they can be shaped. It may be one, or a plurality may be formed except as shown in the embodiment.

The solar cell 1A is preferably provided at both ends in the width direction. The conductive material 5 is provided on the first conductive film 4 or the second conductive film 10 extending outside the sealing material 9. However, even if only the above-mentioned The effect of the present invention can also be obtained by adopting the configuration at any one of the ends in the width direction.

Claims (7)

An electrical module includes: a photoelectrode: a semiconductor layer is formed on a first substrate on which a first conductive film is formed; a counter electrode: a second substrate on which a second conductive film is formed; and an electrolyte, the photoelectrode And the counter electrode system are adhered and sealed in such a manner as to form an internal space therebetween, the electrolyte system fills the internal space, and at least a part of a sealing portion between the photoelectrode and the counter electrode is formed by A sealing material is formed by bonding the first conductive film and the second conductive film. At least one of the first conductive film and the second conductive film is electrically connected from the internal space and extends across the sealing material. A conductive material is disposed on the outer side of the internal space, and a conductive material is arranged on the surface of the extended portion, and a conductive material is connected to the conductive material. A terminal is connected to the conductive material, and the conductive material and the terminal are connected to the first An auxiliary conductive material is arranged between a conductive film or the second conductive film. For example, the electrical module of the first patent application range, wherein the terminal is connected to the conductive material, and at least one of the photoelectrode and the counter electrode is formed with one or more openings for exposing the terminal. For example, the electrical module of the scope of patent application, wherein the terminal is connected to the conductive material, and the terminal is provided between the photoelectrode and the counter electrode and from the outer edge of the photoelectrode or the counter electrode protruding. For example, the electrical module of claim 2 or 3, wherein the conductive material is fixed to at least one of the first conductive film and the second conductive film through the terminal. For example, the electrical module of the first scope of the patent application, wherein both the first conductive film and the second conductive film are electrically connected from the internal space and extend beyond the sealing material and are disposed outside the internal space. Here, the first conductive film and the second conductive film are extended and disposed on opposite sides with the internal space interposed therebetween, and on respective surfaces of the extended portions of the first conductive film and the second conductive film, A conductive material is disposed in a state capable of conducting with the portion. An electrical module manufacturing method includes the steps of continuously rolling out a photoelectrode and a counter electrode in a unidirectionally extending manner, respectively. The photoelectrode is formed on a first substrate having a first conductive film. A semiconductor layer is formed, and the counter electrode includes a second substrate on which a second conductive film is formed. The photoelectrode and the counter electrode are bonded and sealed so as to form an internal space therebetween. At this time, use The sealing material forms at least a portion of a sealing portion between the photoelectrode and the counter electrode, and is configured to cause at least one of the first conductive film and the second conductive film to electrically pass from the internal space to the state of crossing the seal. A step of sealing in a state where the material is extended outside the internal space; a step of disposing a conductive material in which a conductive material is disposed on a surface of the portion where the conductive film is extended; and a terminal connected to the conductive material in the conductive material and A step of disposing an auxiliary conductive material between the terminal and the first conductive film or the second conductive film. For example, the manufacturing method of an electrical module according to item 6 of the patent application, wherein the sealing material extends along the unidirectionally at least one end side in a direction crossing the unidirectionally, and the conductive material is arranged parallel to the unidirectionally .