WO2013088621A1 - 太陽電池及びその製造方法 - Google Patents
太陽電池及びその製造方法 Download PDFInfo
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- WO2013088621A1 WO2013088621A1 PCT/JP2012/006696 JP2012006696W WO2013088621A1 WO 2013088621 A1 WO2013088621 A1 WO 2013088621A1 JP 2012006696 W JP2012006696 W JP 2012006696W WO 2013088621 A1 WO2013088621 A1 WO 2013088621A1
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/02—Details
- H01L31/024—Arrangements for cooling, heating, ventilating or temperature compensation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/052—Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the PV cells
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/06—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices characterised by potential barriers
- H01L31/072—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices characterised by potential barriers the potential barriers being only of the PN heterojunction type
- H01L31/0725—Multiple junction or tandem solar cells
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/548—Amorphous silicon PV cells
Definitions
- the present invention relates to a solar cell and a manufacturing method thereof.
- FIG. 11 is a first example of a conventional solar cell (see Patent Document 1).
- a solar cell 100 shown in FIG. 11 includes an optical component 110 that collects sunlight and a back sheet 140.
- the optical component 110 is composed of a Cassegrain type glass lens.
- a concave portion 113 for inserting the solar battery cell 120 is formed in a part of the glass lens.
- the back sheet 140 is bonded to the optical component 110.
- the back sheet 140 includes a circuit board 150 and an adhesive layer 155.
- the circuit board 150 includes an insulator 153 and a conductor 154.
- the solar cells 120 are electrically and physically connected to the electrode portions 154A and 154B of the conductor 154 by the first connection portion 124A and the second connection portion 124B.
- FIG. 12 is a second example of a conventional solar cell (see Patent Document 2).
- a solar cell 200 shown in FIG. 12 includes an optical component that collects sunlight and a primary mirror 230 that is integrated with the optical component.
- the optical component is composed of a Cassegrain type glass lens.
- the primary mirror 230 is composed of two metal films 231 and 234 arranged with a gap 237 therebetween.
- the primary mirror 230 is formed in a bowl shape.
- the flat part at the bottom of the primary mirror 230 has an opening 239.
- the opening 239 is a passage of the concentrated sunlight.
- a solar battery cell 220 that receives sunlight that has passed through the opening 239 is fixed to the outside of the bottom of the primary mirror 230.
- one of the double-sided electrodes is connected to the wiring by a die bonding method, and the other electrode is connected to the wiring by a wire bonding method.
- FIG. 13 shows a solid transparent optical panel 300 that is an assembly of the solar cells 200 shown in FIG.
- the optical component 210 of the solar cell 200 has a hexagonal shape.
- the optical components 210 are adjacent to each other to form a single panel-like assembly.
- FIG. 14 shows a concentrating light energy collecting unit 400C that is an assembly of the solar cells 200 shown in FIG.
- the solar cell 200 includes two electrodes, a P-side electrode and an N-side electrode, by the two metal films 231 and 234 described above.
- One P-side electrode and the other N-side electrode of two adjacent solar cells 200 are electrically connected.
- the concentrating light energy collecting unit 400C is configured by connecting such a pair of solar cells 200 in series.
- the electric power generated by the concentrating optical energy collecting unit 400C is taken out by the socket connector 420.
- various related techniques are disclosed (for example, refer to Patent Documents 3 to 6).
- Patent Documents 3 to 5 describe solar cells in which sunlight condensed by a lens is incident on a multi-junction solar cell element fixed to a heat-radiating substrate.
- Patent Document 6 a U-shaped first electrode having one end attached to the surface of a P-type semiconductor is disposed on an insulating film covering the side surface and the back end of the N-type semiconductor and is connected to a bus bar on the surface.
- a solar cell is disclosed.
- problems remain in heat dissipation and the like.
- a conventional solar cell has a condensing lens and a metal film that is disposed facing the condensing lens and serves as both a reflecting mirror and a wiring portion.
- the thin metal film is a heat dissipation path from the solar battery cell that condenses sunlight and generates heat. For this reason, heat dissipation is low.
- the heat sink for heat dissipation was attached suitably.
- the solar battery cell has a double-sided electrode structure having a front electrode and a back electrode.
- the mounting of the back electrode is performed in the die bonding process from the viewpoint of productivity, for example, and the mounting of the front electrode is different from that in the mounting of the back electrode such as a wire bonding process from the viewpoint of securing the incident surface, for example.
- two mounting processes that is, mounting of the back surface electrode and mounting of the front surface electrode are required in order to achieve electrical connection with the outside. As a result, production lead time becomes longer.
- a solar cell with a double-sided electrode structure can be a single-sided electrode surface-mount package.
- a packaging process is required to make the double-sided solar cell into a single-sided electrode package. For this reason, production lead time becomes long and heat dissipation also deteriorates. Therefore, a solar cell with a shorter production lead time has been demanded.
- An object of the present invention is to provide a solar cell having excellent heat dissipation and a shorter production lead time.
- the present invention provides the following solar cell as means for solving the above-described problems.
- a plate-like base having heat dissipation, a substrate having a first conductive wire and a second conductive wire disposed on the base, First electrode electrically connected to first conductive line, bottom cell layer disposed on first electrode, top cell layer disposed on bottom cell layer, transparent electrode disposed on top cell layer, bottom cell layer And an insulating layer disposed on the side surface of the cell stack including the top cell layer, a transparent electrode disposed on the side surface of the cell stack via the insulating layer, and a second electrode electrically connected to the second conductive line
- a multi-junction solar cell A solar cell having a lens disposed in close contact with the transparent electrode and having a condensing point on the transparent electrode.
- the lens further includes a column portion protruding from the surface of the lens opposite to the light incident surface, and a tapered portion disposed at the tip of the column portion, and the substrate is fitted into the tapered portion.
- this invention provides the manufacturing method of the solar cell shown below as a means for solving the subject of.
- [8] preparing a lens having a condensing point on a surface opposite to the light incident surface; A first electrode; a bottom cell layer disposed on the first electrode; a top cell layer disposed on the bottom cell layer; a transparent electrode disposed on the top cell layer; and a bottom cell layer and a top cell layer
- a multi-junction solar cell having an insulating layer disposed on a side surface of a cell stack and a second electrode electrically connected to a transparent electrode and disposed on a side surface of the cell stack via the insulating layer A preparation process; Preparing a substrate having a plate-like base having heat dissipation, and a first conductive line and a second conductive line disposed on the base; Bonding a multi-junction solar cell to the lens so that a transparent electrode is disposed at the condensing point of the lens;
- the multijunction solar cell is configured such that the first
- a step of bonding the battery cell and the substrate [9]
- the lens further includes a column part protruding from the surface opposite to the light incident surface, and a tapered part arranged at the tip of the column part, and the substrate is a multijunction solar cell in the substrate.
- a step of determining a bonding position of the multi-junction solar cell with respect to the substrate by further having a tapered hole portion that fits into the tapered portion, and fitting the tapered portion into the tapered hole portion.
- the manufacturing method of the solar cell as described in [8].
- the lens is a compound eye lens having a plurality of condensing points on the surface opposite to the light incident surface, and the substrate has a first conductive line and a second conductive line at positions corresponding to the condensing points, respectively.
- the multijunction solar cell is bonded to each of the condensing points of the compound eye lens, and each of the multijunction solar cell bonded to the compound eye lens is bonded to the substrate.
- the solar cell of the present invention has a second electrode and a base. Heat on the incident surface side (for example, a lens) of the solar battery cell is transmitted to the base via the second electrode. Since the base has heat dissipation properties, the transmitted heat is quickly released to the outside. Therefore, the solar cell of this invention has the outstanding heat dissipation.
- the solar cell of the present invention has a second electrode. For this reason, in the solar battery cell, the conductive path of the transparent electrode on the sunlight incident surface side is formed up to the side opposite to the sunlight incident surface. Therefore, the process (single-sided electrode packaging process) which guides the electrodes on both sides of the cell stack to one side of the cell stack is unnecessary. Therefore, the production lead time can be shortened by at least the single-sided electrode packaging process as compared with the conventional solar cell.
- FIG. 5A to 5D are views showing a first part of the manufacturing process of the solar battery cell of the present embodiment.
- 6A to 6C are diagrams showing a second part of the manufacturing process of the solar battery cell of the present embodiment.
- 7A to 7C are diagrams showing a third part of the manufacturing process of the solar battery cell of the present embodiment.
- 8A to 8C are diagrams showing a fourth part of the manufacturing process of the solar battery cell of the present embodiment.
- 9A to 9D are diagrams showing a fifth part of the manufacturing process of the solar battery cell of the present embodiment. It is a figure showing roughly the whole solar cell of this embodiment. It is a figure which shows schematically the structure of the 1st example of the structure of the conventional solar cell. It is a figure which shows schematically the structure of the 2nd example of the structure of the conventional solar cell. It is a figure which shows schematically the structure of the 3rd example of the structure of the conventional solar cell. It is a figure which shows schematically the structure of the 4th example of the structure of the conventional solar cell.
- the solar cell of the present embodiment includes a substrate 24 having heat dissipation, a plurality of multi-junction solar cells 10 disposed on the substrate 24, and the respective solar cells 10. And a lens 31 that collects light in each of the solar cells 10. Between each of the solar cells 10 and the substrate 24, an ACF 36 that is an anisotropic conductive film that electrically connects the solar cells 10 and the substrate 24 is disposed.
- the substrate 24 further has a plurality of tapered holes 28.
- the tapered hole portion 28 has a shape in which the opening area gradually decreases from the upper surface to the lower surface of the substrate 24.
- the shape and size of the tapered hole portion 28 are formed in accordance with the tapered portion of the convex portion of the lens described later.
- the diameter of the tapered hole portion 28 is, for example, 20 to 50 ⁇ m, and the taper angle of the tapered hole portion 28 is, for example, 30 to 60 °.
- the tapered hole portions 28 are arranged at a constant interval (for example, an interval of 10 to 150 mm) such as four corners of a square region on the substrate 24 for arranging one solar battery cell 10.
- FIG. 2 is an enlarged view of part A in FIG.
- the substrate 24 includes a plate-like base 27 having heat dissipation, and a first conductive line 25 a and a second conductive line 25 b disposed on the base 27.
- the heat dissipation represents the ease of heat release from the base 27.
- the heat dissipation of the base 27 is expressed by, for example, thermal conductivity.
- the thermal conductivity of the base 27 is preferably 1.0 W / (m ⁇ K) or more and more preferably 2.0 W / (m ⁇ K) or more from the viewpoint of effectively releasing the heat of the lens. More preferred.
- Examples of the base 27 include a metal plate and the above-described ceramic plate having heat dissipation.
- an aluminum base substrate or an iron base substrate can be used.
- the thermal conductivity of the base 27 is preferably 2 to 8 W / (m ⁇ K), for example.
- the thickness of the base 27 is preferably 1.0 to 1.5 mm, for
- the first conductive line 25a and the second conductive line 25b are electrically independent from each other.
- the first conductive line and the second conductive line can be formed on the base by an ordinary method of forming a conductive layer such as a metal layer in a desired shape.
- the thickness of the first conductive line and the second conductive line is preferably 18 to 36 ⁇ m from the viewpoint of voltage resistance.
- the first conductive wire 25 a is disposed at a position that is electrically connected to a later-described center electrode 16 b in the solar battery cell 10.
- the second conductive line 25b is disposed at a position that is electrically connected to a later-described second electrode 16a in the solar battery cell 10.
- the first conductive line 25a and the second conductive line 25b are composed of a copper layer having an intended planar shape and a Ni—Au layer formed thereon by Ni and Au plating.
- the copper layer has a thickness of 10 to 50 ⁇ m, for example.
- the Ni—Au layer is formed by flash Au plating or electrolytic Au plating.
- the maximum thickness of the Ni—Au layer is, for example, 0.5 ⁇ m.
- the substrate 24 may further include an insulating layer (hereinafter also referred to as “first insulating layer”) 26 on the surface of the base 27 when the base 27 has conductivity.
- the first insulating layer 26 may be formed on the entire surface of the base from the viewpoint of easy formation of the layer, and from the viewpoint of enhancing heat dissipation, the first conductive line and the second conductive line. It may be formed only around.
- the first insulating layer can be formed by a normal method of forming a desired planar layer on the plate-like member. Examples of the material for the first insulating layer include an epoxy resin, a phenol resin, a fluorine resin, a polyimide resin, a silicone resin, and an acrylic resin.
- the thickness of the first insulating layer is preferably 15 to 300 ⁇ m from the viewpoint of sufficiently ensuring the insulation and heat transfer between the conductive wire and the base.
- both the first conductive line 25 a and the second conductive line 25 b are disposed on the first insulating layer 26.
- the first insulating layer 26 is formed by applying an insulating layer material paint to the metal plate 27.
- the first insulating layer 26 is formed to prevent air from entering and to prevent defects such as pinhole defects in order to maintain electrical insulation.
- the thickness of the first insulating layer 26 is, for example, 0.1 to 0.2 mm.
- the first insulating layer 26 is, for example, an epoxy resin layer.
- the base member 37 may be disposed on the lower surface of the substrate 24 via the heat radiation resin 44.
- the base member 37 is a member for arranging the plurality of substrates 24 under sunlight.
- the base member 37 is formed of a material having a high heat dissipation property such as an aluminum base material. Examples of the base member 37 include a metal plate or a ceramic plate having heat dissipation properties.
- the base member 37 may have a shape having a larger surface area in order to improve heat dissipation.
- the solar battery cell 10 is a multi-junction solar battery cell.
- the solar battery cell 10 includes a first electrode 9a, a bottom cell layer B disposed on the first electrode 9a, a middle cell layer M disposed on the bottom cell layer B, and a top cell layer disposed on the middle cell layer M.
- T the transparent electrode 12 disposed on the top cell layer T
- the second insulating layer 17 disposed on the side surface of the cell stack 50 including the bottom cell layer B, the middle cell layer M, and the top cell layer T;
- the second electrode 16a is disposed on the side surface of the cell stack 50 via the two insulating layers 17, and is electrically connected to the transparent electrode 12 and the second conductive line 25b.
- the utilization efficiency of sunlight is improved.
- the 1st electrode 9a is electrically connected to the 1st conductive wire 25a, even if it arrange
- the second electrode 16a is also electrically connected to the second conductive line 25b, the second electrode 16a is disposed above the second conductive line 25b via the conductive member even if it is directly disposed on the second conductive line 25b. It may be arranged.
- a first contact layer 2b is provided between the first electrode 9a and the bottom cell layer B.
- a central electrode 16b is disposed on the opposite side of the first electrode 9a from the first contact layer 2b.
- the second contact layer 2a is disposed between the top cell layer T and the transparent electrode 12.
- a third electrode 9b is disposed between the transparent electrode 12 and the second electrode 16a.
- An Au / Ti laminated film 16c is disposed between the second insulating layer 17 and the second electrode 16a.
- the second contact layer 2a, the top cell layer T, the middle cell layer M, the bottom cell layer B, and the first contact layer 2b constitute the cell stack 50.
- the lower surface of the second electrode 16a is disposed below the lower surface of the first electrode 9a. More preferably, the lower surface of the second electrode 16a and the lower surface of the central electrode 16b are coincident with each other by a broken line LL. This is because, in the step of joining the solar battery cell 10 and the substrate 24 described later, the solar battery cell 10 can be prevented from being damaged by applying pressure evenly to the solar battery cell 10. In this way, the second electrode 16a having the potential generated in the top cell layer T and the central electrode 16b having the potential generated in the bottom cell layer B are arranged on the same plane.
- connection electrodes the electrode having the potential of the top cell and the electrode having the potential of the bottom cell
- the production process of mounting with the external electrode Is required only once. Therefore, production lead time is shortened.
- the lower surface of the second electrode 16a and the lower surface of the central electrode 16b arranged on the same surface are electrically connected to the first and second conductive lines 25a and 25b of the substrate 24 through conductive members, respectively. Note that the second electrode 16a and the center electrode 16b are arranged electrically independently of each other.
- the first electrode 9a and the third electrode 9b are, for example, Au plating films having a thickness of about 10 ⁇ m.
- the center electrode 16b and the second electrode 16a are, for example, Au plating films having a thickness of about 10 to 50 ⁇ m.
- the center electrode 16b and the second electrode 16a are formed thicker than the first electrode 9a and the third electrode 9b.
- the second insulating layer 17 is, for example, a SiN film having a thickness of about 1 ⁇ m.
- the transparent electrode 12 is, for example, a ZnO layer having a thickness of about 0.5 ⁇ m.
- the thickness of the Au / Ti laminated film 16c is about 0.5 ⁇ m.
- the width of the transparent electrode 12 is, for example, 500 ⁇ m.
- the width of the second contact layer 2a is, for example, 470 ⁇ m.
- the width of the peripheral edge of the transparent electrode 12 is, for example, 15 ⁇ m.
- the width of the third electrode 9b disposed at the center of the peripheral edge is, for example, 5 ⁇ m.
- the width of the gap between the third electrode 9b and the cell stack is, for example, 5 ⁇ m.
- the width between the third electrode 9b and the edge of the transparent electrode 12 is, for example, 5 ⁇ m.
- the thickness of the cell stack is, for example, 10 ⁇ m.
- the thickness of the solar battery cell 10 is, for example, 25 ⁇ m.
- the cell stack includes a first contact layer 2b, a bottom cell layer B, a buffer layer 21, a grid layer 20, a tunnel layer 19b, a middle cell layer M, a tunnel layer 19a, a top cell layer T, and The second contact layer 2a.
- the forbidden bandwidth of the top cell layer T is 1.87 eV, and the wavelength that can be absorbed in the sunlight spectrum is a region of 650 nm or less.
- the forbidden band width of the middle cell layer M is 1.41 eV, and the wavelength that can be absorbed in the sunlight spectrum is in the region of 650 nm to 900 nm.
- the forbidden band width of the bottom cell layer B is 1.0 eV, and the wavelength that can be absorbed in the sunlight spectrum is in the range of 900 nm to 1,200 nm.
- the multi-junction solar cell includes a first electrode electrically connected to the first conductive wire, a bottom cell layer disposed on the first electrode, a top cell layer disposed on the bottom cell layer, and a top cell A transparent electrode disposed on the layer, an insulating layer disposed on a side surface of the cell stack including the bottom cell layer and the top cell layer, and disposed on a side surface of the cell stack via the insulating layer. And a second electrode electrically connected to the two conductive lines.
- the first electrode is composed of a conductive layer such as a metal layer.
- the cell stack includes a bottom cell layer and a top cell layer.
- the bottom cell layer is a layer having photovoltaic power, and has the lowest forbidden band width in the cell stack.
- the top cell layer is a layer having photovoltaic power and has the highest forbidden band width in the cell stack.
- the cell stack may further include one or more middle cell layers having a forbidden band width between the forbidden band widths of these layers between the bottom cell layer and the top cell layer.
- the transparent electrode is formed on the top cell layer of the cell stack.
- the transparent electrode can be formed by an ordinary method of forming a transparent electrode at a desired position.
- Examples of the material for the transparent electrode include zinc oxide (ZnO), ITO, IZO, and a graphene transparent conductive film.
- the insulating layer (hereinafter also referred to as “second insulating layer”) in the multi-junction solar cell is formed on the side surface of the cell stack.
- the second insulating layer may be formed from the side surface of the cell stack to the side surface of the first electrode.
- Examples of the material of the second insulating layer include SiN, BN, SiO, and the same material as the first insulating layer.
- the second electrode is formed on the second insulating layer on the side of the cell stack.
- the second electrode may be formed away from the second insulating layer.
- the material of the first electrode can be used as the material of the second electrode.
- the second electrode is preferably formed to the side of the first electrode (but away from the first electrode) from the viewpoint of more easily electrically connecting to the conductive wire on the substrate surface.
- the multi-junction solar cell may have further components as long as the effects of the present invention are obtained.
- additional components include, for example, a third electrode that electrically connects the transparent electrode and the second electrode, a first contact layer for enhancing electrical contact between the bottom cell layer and the first electrode, Examples thereof include a second contact layer for enhancing electrical contact between the top cell layer and the transparent electrode, a center electrode for enhancing electrical contact between the first electrode and the first conductive line, and the like.
- the contact layer can be appropriately selected according to the material of the top cell layer and the bottom cell layer.
- the lens 31 is made of a resin having lower heat resistance than glass.
- the resin is a transparent resin such as an acrylic resin or a silicone resin.
- the lens 31 is, for example, a compound eye lens including a plurality of plano-convex lens portions arranged on a plane.
- the lens 31 is a molded product of transparent resin.
- Each plano-convex lens part has a condensing point 32 having the same planar shape as the transparent electrode 12 of the solar battery cell 10 on the surface opposite to the light incident surface, for example.
- the planar shape of the lens 31 (the shape seen from the direction of the arrow X in FIG. 1) is a square having a side length of about 50 mm.
- the thickness Tc of the lens 31 is 17 mm, for example.
- the number of individual lenses and condensing points 32 in the lens 31 can be determined by the condensing magnification of the individual lenses. For example, when the condensing magnification of each lens is 400 times, the size of each lens is 10 mm square. Therefore, the lens 31 has 25 (5 ⁇ 5) lenses. When the condensing magnification of each lens is 1,000 times, the size of each lens is 16 mm square. Therefore, the lens 31 has nine (3 ⁇ 3) lenses.
- the transparent resin contains, for example, an ultraviolet absorber. For this reason, even if the lens 31 is left under sunlight for a long period of time, the lens 31 does not turn yellow and can ensure transparency.
- the lens of the present embodiment is a plano-convex lens, but the present invention can also be implemented with a Fresnel lens or a Cassegrain type condenser lens.
- the lens is placed in close contact with the transparent electrode.
- the lens has a condensing point on the transparent electrode.
- the “condensing point” is a cross-sectional area with respect to the focal length direction in the optical path of sunlight that converges on the cell stack.
- the condensing point may be an area at any position other than the position of the cell stack as long as it is in the optical path.
- the condensing point may be, for example, the surface of the transparent electrode, or may be a portion through which light passes or a focal point on the surface opposite to the incident surface of the lens.
- the lens is usually a plano-convex lens having a curved surface on the sun side.
- the lens is made of a transparent material.
- the material for the lens include glass and transparent resin.
- the transparent resin include acrylic resins and silicone resins. From the viewpoint of heat resistance, a lens made of an inorganic material such as glass is preferable. From the viewpoint of weight reduction, a transparent resin lens is preferable. Among these, an acrylic resin lens is more preferable from the viewpoint of productivity and economy.
- the lens 31 has a plurality of convex portions 33 arranged corresponding to each of the tapered hole portions 28 of the substrate 24.
- the convex portions 33 are arranged at regular intervals in the same manner as the tapered hole portion 28.
- the convex portion 33 is formed by integral molding with the lens 31.
- the convex portion 33 includes a column portion 33 a that protrudes from the back surface of the lens 31 and a tapered portion 33 b that is disposed at the tip thereof.
- the taper angle of the taper portion 33 b is the same as the taper angle of the taper hole portion 28.
- the taper angle in the taper part and the taper hole part is determined from the viewpoint of easily fitting the taper part and the taper hole part, the viewpoint of workability of the taper hole, and the workability when the lens and the convex part are formed of resin. From the viewpoint, it is preferably 30 to 60 °.
- the diameter of the pillar portion 33a is 20 to 50 ⁇ m
- the height of the pillar portion 33a is 20 to 30 ⁇ m
- the height of the tapered portion 33b is 20 to 70 ⁇ m.
- the height of the pillar 33a is determined by the thickness (height) of the solar battery cell 10. For example, when the thickness of the solar battery cell 10 is 25 ⁇ m, the height of the column portion 33a is also 25 ⁇ m.
- the substrate, the multijunction solar cell, and the lens are arranged such that the column portion, the taper portion, and the taper hole are respectively arranged at positions where the lens is to be arranged on the substrate via the multijunction solar cell. Is more preferable from the viewpoint of easily performing proper alignment.
- the transparent electrode 12 of the solar battery cell 10 is bonded by a transparent adhesive 35 at a condensing point in the lens 31.
- the transparent adhesive 35 is made of an epoxy material or a silicone material.
- a two-component adhesive composed of a main agent made of a resin material and a curing agent made of a resin material and mixed with the main agent, or a resin material that is cured by ultraviolet rays is used.
- the gap between the substrate 24 and the lens 31 is sealed with a sealing resin 22 in order to reinforce mechanical strength and improve chemical resistance.
- the substrate 24, the solar battery cell 10, and the lens 31 are integrally configured by the sealing resin 22.
- the sealing resin is preferable from the viewpoint of suppressing stress concentration due to heating of the lens under sunlight.
- the sealing resin include an epoxy resin, a phenol resin, a fluorine resin, a polyimide resin, a silicone resin, and an acrylic resin.
- the solar cell of the present invention may have a further configuration as long as the effects of the present invention are obtained.
- the solar cell of the present invention may further include a spacer that supports the lens on the substrate.
- the spacer has a lens at a distance similar to the height of the multi-junction solar cell on the substrate (for example, H 0 ⁇ 10% when the height of the multi-junction solar cell on the substrate is H 0 ).
- a member supported on the substrate can be used.
- Examples of such a spacer include columnar portions that are arranged on one or both of the lens and the substrate and project from the surface of the lens or the substrate, and spherical particles that are scattered between the substrate and the lens.
- the spacer may be a member interposed while maintaining the shape between the lens and the substrate when the lens is supported on the substrate, or may be a member interposed in a collapsed state. Considering the latter member, the spacer can be used spherical particles having a particle size of 30H 0 from H 0 -10 ⁇ m.
- the spacer is a column protruding from the surface of the lens, from the viewpoint of improving productivity when the lens is manufactured by resin molding, and from the viewpoint of relaxation of thermal stress by the lens heated by sunlight.
- the column portion is disposed on the surface of the lens opposite to the light incident surface. It is more preferable that a plurality of column portions are arranged with respect to one lens from the viewpoint of relaxation of thermal stress.
- the solar cell of the present invention may further include an anisotropic conductive film interposed between the first electrode and the first conductive line and between the second electrode and the second conductive line.
- an anisotropic conductive film for example, a thermosetting resin film in which conductive fine particles are dispersed is used. It is preferable that the solar battery of the present invention further has an anisotropic conductive film from the viewpoint of simultaneously and easily performing electrical connection and adhesion between the substrate and the multi-junction solar battery cell.
- the solar cell of the present invention may have a configuration in which a plurality of the single structures described above are integrated.
- the solar cell of the present invention may be a compound eye lens in which a plurality of multi-junction solar cells are arranged on a single substrate, and the lens has a condensing point on each of the plurality of transparent electrodes in close contact.
- a substrate on which a plurality of multi-junction solar cells are arranged has a first conductive line and a second conductivity at an arrangement position of each multi-junction solar cell.
- the compound eye lens can be configured by, for example, a frame assembly in which a plurality of cylindrical frames are bundled, and a plano-convex lens disposed in each frame.
- a compound eye lens can be comprised by the resin lens formed in the shape where the some plano-convex lens was paralleled, for example.
- the solar cell of the present invention may further include a preliminary condensing lens that is arranged apart from the lens that is in close contact with the transparent electrode and collects sunlight toward the lens. According to the preliminary condensing lens, it is expected to reduce the thickness of the lens that is in close contact with the transparent electrode and to suppress the temperature rise of the lens.
- the solar cell of the present invention can be produced by the following method.
- the manufacturing method of the solar cell in the present invention includes a step of preparing a lens, a step of preparing a multi-junction solar cell, and a step of preparing a substrate.
- a lens having a condensing point on the surface opposite to the light incident surface is prepared.
- the condensing point is, for example, a portion to which the transparent electrode is bonded on the surface of the lens, or a smaller region included in the portion.
- Such a lens can be prepared by mounting the plano-convex lens on the frame or molding a transparent resin.
- the step of preparing the multi-junction solar cell includes, for example, a step of forming a cell stack on a sacrificial layer on a growth substrate, a step of forming a first electrode on the formed cell stack. Forming a second insulating layer on the side of the cell stack and forming a second electrode on the second insulating layer.
- the step of forming the cell stack can be performed by sequentially epitaxially growing the material of each cell layer (for example, a III-V compound) in the order of the top cell layer to the bottom cell layer on the sacrifice layer on the growth substrate. .
- the step of forming the first electrode and the step of forming the second electrode can be performed by an appropriate method according to the size of the cell stack and the material of the layer to be formed, among ordinary layer forming methods. For example, when the thickness of the cell stack is several ⁇ m to several tens of ⁇ m, the step of forming the first electrode and the step of forming the second electrode are ordinary methods for forming a conductive layer having a desired shape. (For example, photolithography, plating, etching, etc.) can be used.
- the step of forming the second insulating layer is a normal method for forming an insulating layer having a desired shape according to the material of the second insulating layer (for example, plasma CVD method, dry etching method, photolithography, etc.) Can be done by.
- the step of preparing the multi-junction solar cell includes the step of separating the product on the growth substrate obtained in the above step from the sacrificial layer and the step of forming a transparent electrode on the top cell layer of the separated product. And further including.
- a normal method of separating the semiconductor stack on the growth substrate through the sacrificial layer from the sacrificial layer can be employed.
- the process of forming a transparent electrode can be performed by the normal method of forming a transparent electrode in a desired position according to the material of the transparent electrode.
- the step of preparing the multi-junction solar cell may include further steps such as a step of forming the third electrode and a step of forming the central electrode. These further steps can be performed by conventional methods depending on the size of the cell stack and the material of the layer to be formed.
- the step of preparing the substrate can be performed, for example, by arranging a first conductive line and a second conductive line that are electrically independent from each other on the base.
- the conductive line can be formed by an ordinary method for forming a metal layer having a desired planar shape.
- a first insulating layer is further formed between the base and the conductive wire.
- the first insulating layer can be formed by photolithography.
- the method for manufacturing a solar cell in the present invention further includes a step of bonding the multi-junction solar cell to the lens and a step of bonding the multi-junction solar cell bonded to the lens and the substrate.
- the multi-junction solar cell is bonded to the lens so that a transparent electrode is disposed at the condensing point of the lens.
- Adhesion of the multi-junction solar cell to the lens can be performed using a normal liquid transparent adhesive according to the material of the adhesion surface. It is preferable from the viewpoint of easily adjusting the adhesion position of the multi-junction solar cell to the condensing point, by subjecting the lens surface other than the condensing point to a liquid repellent treatment and applying a transparent adhesive only to the condensing point .
- the first electrode is electrically connected to the first conductive wire
- the second electrode is electrically connected to the second conductive wire.
- the multi-junction solar cell bonded to the lens and the substrate can be bonded with a transparent adhesive.
- Adhesion between the multi-junction solar cell bonded to the lens and the substrate is performed by thermosetting a thermosetting transparent adhesive, and is adjusted from the viewpoint of adjusting the bonding position after applying the transparent adhesive. From the viewpoint of performing bonding at the bonding position.
- the method for manufacturing a solar cell in the present invention may include further steps.
- the manufacturing method of the present invention may further include a step of supporting a lens to which a multi-junction solar cell is bonded on a substrate with a spacer.
- the support of the lens on the substrate by the spacer can be performed, for example, by dispersing spherical particles before bonding the multi-junction solar cell and the substrate.
- the support of the lens on the substrate by the spacer can be performed by using a lens or a substrate having a column part. Furthermore, in the case of using a lens having a pillar portion and a tapered portion and a substrate having a tapered hole portion, the fitting of the tapered portion and the tapered hole portion is used to adjust the bonding position between the multi-junction solar cell and the substrate. Can be used.
- a column part and a taper part are formed on the surface of the lens opposite to the light incident surface.
- a taper hole is formed at a position where the multi-junction solar cell is to be disposed on the substrate.
- the bonding position of the multi-junction solar cell to the substrate can be appropriately determined by fitting the tapered portion into the tapered hole portion.
- the tapered portion and the tapered hole portion are formed on the same substrate and the same lens from the viewpoint of alignment of the bonding position of the multi-junction solar cell to the substrate and from the viewpoint of supporting the lens at an appropriate interval on the substrate. It is preferable to arrange three or more. From the viewpoint of alleviating the thermal stress due to the heat of the lens, the tapered portion and the tapered hole portion are preferably arranged at 4 pieces / 100 mm square, and more preferably at 4 to 16 pieces / 5 cm square. The tapered portion and the tapered hole portion are preferably arranged more densely from the viewpoint of increasing the accuracy of alignment between the lens and the substrate, in addition to relaxing thermal stress.
- the accuracy of alignment can be determined according to the condensing magnification of the lens and the size of the multi-junction solar cell (for example, the size of the condensing point). For example, when the condensing magnification of the lens is 500 times and the size of the multi-junction solar cell is 0.5 mm square, the tapered portion and the tapered hole portion should be arranged at 1 to 4 pieces / cm 2. Is preferred.
- the method for manufacturing a solar cell in the present invention may further include a step of sandwiching an anisotropic conductive film between the multi-junction solar cell and the substrate.
- This step is preferable from the viewpoint of simultaneously and easily performing electrical connection and adhesion between the substrate and the multi-junction solar cell.
- the step of sandwiching the anisotropic conductive film includes, for example, a step of placing the anisotropic conductive film on the first conductive line and the second conductive line of the substrate, and a lens on the substrate on which the anisotropic conductive film is disposed. And bonding the bonded multi-junction solar cells by thermocompression bonding.
- the manufacturing method of the solar cell in the present invention uses a compound eye lens as a lens, and uses a substrate having a first conductive line and a second conductivity at each of the positions corresponding to the respective condensing points. It can be set as the form of the aggregate
- a multi-junction solar cell is bonded to each of the condensing points of the compound eye lens and electrically connected to the first conductive line and the second conductive line corresponding to the condensing point.
- the cell stack is obtained by forming a metal layer constituting each cell layer on the GaAs substrate 1.
- Each metal layer can be formed by putting the metal layer material into a vertical MOCVD (Metal Organic Chemical Vapor Deposition) apparatus and growing each metal material by an epitaxial growth method.
- MOCVD Metal Organic Chemical Vapor Deposition
- each metal layer can be performed using a normal method.
- the epitaxial growth of each metal layer can be performed at an ambient temperature of about 700 ° C., for example.
- TMG trimethylgallium
- AsH 3 arsine
- TMI trimethylindium
- TMG trimethylindium
- PH 3 phosphine
- SiH 4 monosilane
- DEZn diethyl zinc
- DEZn diethyl zinc
- an AlAs layer having a thickness of about 100 nm is formed as a sacrificial layer 4 on a GaAs substrate 1 as a growth substrate by an epitaxial growth method.
- an n-type InGaP layer having a thickness of about 0.1 ⁇ m is formed by an epitaxial growth method (see FIG. 4).
- the top cell layer T is formed.
- An n-type InAlP layer of about 25 nm thickness as a window; an n-type InGaP layer of about 0.1 ⁇ m thickness as an emitter; a p-type 1 + InGaP layer of about 0.9 ⁇ m thickness as a base; And a p-type InGaP layer having a thickness of about 0.1 ⁇ m are formed by an epitaxial growth method. As a result, a top cell layer T having a thickness of about 1 ⁇ m is formed.
- a p-type AlGaAs layer having a thickness of about 12 nm and an n-type GaAs having a thickness of about 20 nm are formed as a tunnel layer by an epitaxial growth method.
- a tunnel layer 19a having a thickness of about 30 nm is formed.
- the middle cell layer M is formed.
- a p-type AlGaAs layer having a thickness of about 12 nm, an n-type GaAs layer having a thickness of about 20 nm, a tapered portion, and a tapered hole portion are formed as the tunnel layer 19b by an epitaxial growth method.
- a tunnel layer 19b having a thickness of about 30 nm is formed.
- the grid layer 20 suppresses the occurrence of dislocations, defects, and the like due to lattice constant mismatch.
- Eight n-type InGaP layers having a thickness of about 0.25 ⁇ m are formed, and a grid layer 20 having a thickness of about 2 ⁇ m is formed. Further, an n-type InGaP layer having a thickness of about 1 ⁇ m is formed as the buffer layer 21.
- the bottom cell layer B is formed.
- a p-type InGaP layer having a thickness of about 50 nm is formed as a passivation film by an epitaxial growth method.
- a bottom cell layer B having a thickness of about 3 ⁇ m is formed.
- a p-type InGaAs layer having a thickness of about 0.1 ⁇ m is formed as the first contact layer 2b by an epitaxial growth method.
- ⁇ Solar cell manufacturing method> A manufacturing flow of the compound solar cell will be described with reference to FIGS. 5A to 9D.
- a disk-shaped GaAs substrate 1 (wafer) is prepared.
- the size of the GaAs substrate 1 is, for example, 4 inches (10.16 cm) in diameter and 500 ⁇ m in thickness.
- a plurality of solar cells 10 are formed on one GaAs substrate 1.
- the cell stack 50 is formed on the GaAs substrate 1.
- the cell stack 50 includes, for example, the second contact layer 2a, the top cell layer T, the tunnel layers 19a and 19b, the middle cell layer M, the grid layer 20, the buffer layer 21, and the bottom cell layer.
- B and the first contact layer 2b are obtained by forming the sacrificial layer 4 by epitaxial growth.
- the height of the obtained cell stack is, for example, 10 ⁇ m.
- the first contact layer 2b having a thickness of about 0.1 ⁇ m is patterned into a desired planar shape.
- the patterning is preferably performed by a dry etching process.
- the cell stack 50 having a thickness of 10 ⁇ m is patterned into a predetermined planar shape.
- the size of the planar shape by patterning (for example, a circular diameter or a rectangular length) is, for example, 500 ⁇ m.
- the patterning is preferably performed by a dry etching process.
- the structure obtained by etching the cell stack at the edge portion may be referred to as a “Ledge structure”. “J. Vac. Sci. Technol. B, Vol. 11, No. 1, Jan / Feb 1993” and “The Institute of Electronics, Information and Communication Engineers IEICE Technical Report IEICE Technical Report ED2007-217, MW2007-148 (2008-1)” As shown in the above, it is known that the carrier disappears easily at the end of the PN junction. On the other hand, by adopting the “Ledge structure”, carriers are concentrated inside the substrate, and the disappearance of carriers at the end portion is suppressed.
- an Au plated electrode is formed as the third electrode 9b and the first electrode 9a.
- an Au plating film having a thickness of about 10 ⁇ m or less is formed on the entire upper surface of the cell stack shown in FIG. 5D by electroplating.
- the Au plating film is patterned to form the third electrode 9b and the first electrode 9a. The patterning is performed using a photolithography method and wet etching.
- a SiN film is formed as the second insulating layer 17.
- a SiN film is formed on the entire upper surface of the cell stack using a plasma CVD method.
- an Au / Ti laminated film 16c is formed on the entire upper surface of the cell laminated body obtained in FIG. 6C by using a metal sputtering method.
- the Au / Ti laminated film 16c is a pretreatment film for performing electrolytic Au plating in the next step.
- a resist 18 is formed in a portion where it is not necessary to form an electrolytic Au plating film.
- a resist material is applied on the Au / Ti laminated film 16c.
- the resist material is exposed through a predetermined resist pattern for mesa etching.
- unnecessary portions are removed by etching with an aqueous alkali solution or an aqueous acid solution. In this way, a resist 18 is formed.
- the central electrode 16b and the second electrode 16a are formed by electrolytic Au plating.
- the thicknesses of the central electrode 16b and the second electrode 16a made of an Au plating film are thicker than the thickness of 10 ⁇ m of the cell stack of the solar battery cells, and are formed with a thickness of about 10 to 50 ⁇ m.
- a Ti film 16d for protecting the Au plating is formed.
- the Ti film 16d is formed on the entire upper surface of the stacked body obtained in FIG. 7B.
- the Ti film 16d is formed by a metal sputtering method.
- the resist 18 shown in FIG. 7C is removed.
- the resist 18 is removed by wet processing.
- the resist 18 is removed, for example, by etching with an alkaline aqueous solution and an acid solution.
- the Au / Ti film 16c on the second insulating layer 17 and the Ti film 16d on the Au plating electrodes are removed. These removals are performed using a dry edge method. In this way, the outermost surface of the Au-plated electrode is a clean surface free from organic contamination.
- a sacrificial layer recess 4a is formed on the side surface of the sacrificial layer 4 in order to peel off the GaAs substrate 1. Since the solar cell 10 is very fragile, it may be destroyed by stress when the GaAs substrate 1 is peeled off. For this reason, the sacrificial layer recess 4a is formed as a starting point for reliably breaking the sacrificial layer 4 internally.
- the sacrificial layer recess 4a is mechanically provided with a “scratch” recess, ground with a blade, or ground with a water jet so that the sacrificial layer 4 becomes a starting point of destruction of the sacrificial layer 4. What is necessary is just to provide. Since the solar cell 10 is fixed on the working substrate 29, the solar cell 10 is not destroyed when the sacrificial layer recess 4a is formed.
- the sacrificial layer 4 is internally broken and the GaAs substrate 1 is peeled off.
- methods for internally breaking the sacrificial layer 4 include many SOI (silicon on insulator) related techniques such as dicing, roller peeling, water jet, and ultrasonic destruction. Therefore, the GaAs substrate 1 is easily peeled off.
- the lattice constant of GaAs constituting the GaAs substrate 1 is 5.653 angstroms
- the lattice constant of AlAs constituting the sacrificial layer 4 is 5.661 angstroms, which are almost the same. Therefore, the sacrificial layer 4 is a stable film and can be internally broken stably.
- the sacrificial layer 4 remaining in the solar battery cell 10 is removed by wet etching.
- the wet etching of the sacrificial layer 4 can be performed by melting and removing the remaining sacrificial layer 4 in contact with hydrofluoric acid for 2 to 3 minutes.
- the transparent electrode 12 is formed on the second contact layer 2a.
- the transparent electrode 12 constitutes a sunlight incident surface in the solar battery cell 10.
- the transparent electrode 12 is a ZnO layer, an ITO layer, or the like, and can be formed by a sputtering method.
- the transparent electrode 12 is formed on the entire upper surface of the solar battery cell 10, and electrically connects the second contact layer 2a and the third electrode 9b.
- the conductivity can be further improved by adding 0.1% by mass or more of Al or Ga to the ZnO layer.
- the solar battery cell 10 is taken out from the wax 40.
- the solar battery cell 10 of FIG. 10 obtained in this way does not have an electrode that blocks sunlight on the sunlight incident surface. Therefore, the amount of sunlight incident on the solar battery cell 10 is increased, and the power generation efficiency of the solar battery cell 10 is improved.
- the lens 31 is formed by molding a transparent acrylic resin or a transparent silicone resin material.
- the molding process can be performed by injection molding or transfer molding using a mold.
- the convex portion 33 is formed at the same time as the lens 31 at the time of molding by further forming a portion for forming the convex portion 33 on the mold for the lens 31 and using this mold.
- the substrate 24 is provided with the first insulating layer 26, the first conductive wire 25 a, and the second conductive wire 25 b in accordance with the arrangement of the solar cells 10 and the condensing point of the lens 31 to form the tapered hole 28. Manufactured by.
- the substrate 24 can be manufactured by an ordinary method for manufacturing a substrate having wiring on the surface.
- a liquid repellent process is applied to the back surface of the lens 31, which is the surface to which the transparent electrode of the solar battery cell 10 is bonded.
- a liquid repellent treatment is performed on the back surface of the lens 31 except for the focal point.
- the liquid repellent treatment is a silane coupling agent having a fluorocarbon chain such as CF 3 (CF 2 ) 7 C 2 H 4 SiCl 3 or a hydrocarbon chain such as CH 3 (CH 2 ) 17 SiCl 3.
- the condensing point has a surface made of a resin material of the lens 31.
- the focal point remains as it is and exhibits lyophilicity with respect to the transparent adhesive.
- the condensing point becomes a lyophilic region, and the region other than the condensing point becomes a liquid repellent region.
- the condensing point may be subjected to a lyophilic treatment for improving the wettability of the transparent adhesive according to the type of the transparent adhesive.
- the transparent adhesive 35 is transferred and applied to a condensing point having a lyophilic surface.
- a transfer pin having a hemispherical shape with a tip shape of 20 to 50 ⁇ mR is brought into contact with the transparent adhesive on the transfer table adjusted to a uniform film thickness of 20 to 100 ⁇ m. Then, the transparent adhesive is once transferred to the tip of the transfer pin by surface tension.
- the transfer pin is brought into contact with the condensing point of the lens 31, and the transparent adhesive transferred to the tip of the transfer pin is retransferred to the condensing point. In this way, a predetermined amount of the transparent adhesive 35 is applied to the condensing point.
- the transparent adhesive 35 gets wet in the lyophilic area that is the condensing point, but is repelled in the other liquid-repellent areas, and thus does not protrude from the condensing point.
- the thickness of the solar battery cell 10 is as very thin as 5 to 50 ⁇ m.
- the solar battery cell 10 uses a compound semiconductor such as GaAs or Ge.
- the photovoltaic cell 10 is very fragile.
- the solar battery cell 10 is lightly adsorbed with a flat vacuum tweezers and mounted on the liquid transparent adhesive 35.
- the mount load is about 10 to 50 gf (9.81 ⁇ 10 ⁇ 2 to 4.90 ⁇ 10 ⁇ 1 N).
- the solar battery cell 10 mounted on the liquid transparent adhesive 35 is aligned with the lyophilic region (that is, the condensing point) by being wetted with the transparent adhesive.
- the lyophilic region that is, the condensing point
- the solar cell 10 has the surface tension of the transparent adhesive 35. Due to the balance, it automatically moves in the XY directions, and finally is aligned within the square of 900 ⁇ m square.
- the solar cells 10 are aligned on the lens 31 using a metal mask having a hole at a position corresponding to the condensing point. It is also possible to mount all at once by arrangement. It is also possible to apply a liquid in which the solar cells 10 are dispersed on the lens 31 and arrange the solar cells 10 at a condensing point that is a lyophilic region.
- the transparent adhesive 35 is cured.
- a two-component mixed room temperature curable resin is used for the transparent adhesive 35.
- a room temperature curable resin for example, when left at room temperature, curing starts after about 90 minutes, and curing ends in 24 hours.
- an ultraviolet curable resin can be used for the transparent adhesive 35.
- ultraviolet rays are irradiated after alignment and mounting of the solar battery cell 10 to the condensing point.
- the transparent electrode 12 of the solar battery cell 10 is appropriately fixed to the condensing point of the lens 31.
- ACF pasting method on substrate On the other hand, the ACF 36 is attached to the surface of the substrate 24.
- ACF 36 is an anisotropic conductive film in which conductive particles are dispersed in an epoxy resin film.
- the ACF 36 is mainly used to mount a driver for driving a liquid crystal display. In the present embodiment, the ACF 36 for such applications can be used.
- the ACF 36 is cut into a shape larger than the arrangement area of the solar cells 10 on the substrate 24, for example, a shape surrounding the second conductive line.
- the ACF 36 needs to have a sufficiently large thickness as compared to the gap between the electrode of the solar battery cell 10 and the conductive line on the substrate 24. For this reason, the ACF 36 is thicker than the first conductive line 25a and the second conductive line 25b.
- an ACF having a thickness of 40 to 60 ⁇ m is used for the ACF 36.
- the cut ACF 36 is attached to the arrangement area of the substrate 24 by heating and pressing.
- the ACF 36 is aligned with the arrangement region of the substrate 24, and the whole ACF 36 is pressurized in 5 seconds or less with a flat tool heated to 60 to 100 ° C. from above.
- the ACF 36 is attached to the arrangement region under a condition that the epoxy resin inside the ACF 36 does not undergo a curing reaction (temporary pressure bonding step).
- the mounting position of the solar battery cell 10 and the positions of the first conductive line 25a and the second conductive line 25b of the substrate 24 are confirmed by the recognition camera of the mounting apparatus.
- the solar battery cell 10 is mounted according to a predetermined position of the first conductive line 25a and the second conductive line 25b.
- a temporary pressure-bonded product obtained by the above-described temporary pressure-bonding process is placed on the substrate 24 with the substrate 24 facing upward on a metal stage having polytetrafluoroethylene or polyimide bonded to the surface.
- a metal pressure plate heated to about 180 to 220 ° C. from above the substrate 24 is applied for 5 to 20 seconds with a load of about 50 to 200 gf (0.49 to 1.96 N) per solar cell. Press. By this pressurization, the epoxy resin inside the ACF 36 is melted and cured.
- the central electrode 16b of the solar battery cell 10 and the first conductive wire 25a of the substrate, and the second electrode 16a of the solar battery cell 10 and the second conductive wire 25b of the substrate 24 are respectively separated by the conductive particles in the intervening ACF 36. It communicates electrically.
- the solar battery cell 10 is electrically connected to the first conductive wire 25a and the second conductive wire 25b, and the solar battery cell 10 and the substrate are physically fixed (main press bonding step).
- the lens 31 When the lens 31 has the convex portion 33, the lens 31 is supported on the substrate 24 at the height of the column portion 33a. For this reason, it is possible to prevent an excessive load from being applied to the solar battery cell 10, and thus it is possible to prevent the solar battery cell 10 from being damaged in the main press bonding step.
- the sealing resin 22 is disposed in the gap between the substrate 24 and the lens 31 (FIGS. 1 and 2).
- Filling the gap between the substrate 24 and the lens 31 with the sealing resin 22 is usually performed by placing the substrate 24 on a metal stage heated to 50 to 80 ° C. It is performed by the method of pouring using.
- the sealing resin 22 is applied onto the substrate 24 before the temporary press-bonding step, the gap is filled with the sealing resin 22 by heating and pressurization in the main press-bonding step, and the sealing resin 22 is heated by heating in the main press-bonding step. Is cured. According to this method, the electrical connection between the solar battery cell 10 and the first conductive wire 25a and the second conductive wire 25b and the sealing of the gap with the sealing resin 22 can be simultaneously performed.
- the sealing resin 22 is made of an epoxy or silicone material.
- examples of the sealing resin 22 include a resin material used as a main agent and a curing agent as a two-component adhesive, a resin material that is cured by ultraviolet rays, and a resin material that is cured by heating.
- the sealing resin 22 When the sealing resin 22 is filled in the gap between the substrate 24 and the lens 31, the sealing resin 22 is naturally cured at a temperature of 80 ° C. or lower (for example, normal temperature (20 ⁇ 15 ° C.)). Alternatively, the sealing resin 22 is cured by irradiating ultraviolet rays.
- the solar cell of the present embodiment is placed under sunlight.
- Sunlight irradiates the lens 31 along the arrow X direction.
- Sunlight incident on the lens 31 is collected by the lens 31 toward the cell stack, for example, on the transparent electrode 12.
- the light that has passed through the transparent electrode 12 passes through the top cell layer T, middle cell layer M, and bottom cell layer B in the cell stack.
- the light according to the absorption wavelength of each cell layer in sunlight is converted into an electromotive force in each cell layer.
- the conversion efficiency in the solar battery cell 10 is about 30 to 50%.
- the lens 31 Under sunlight, the lens 31 is heated by infrared rays contained in sunlight. In the solar cell of the present embodiment, the heat of the lens 31 is quickly transmitted from the transparent electrode 12 to the substrate 24 through the third electrode 9b and the second electrode 16a. Then, it is discharged from the substrate 24 to the outside.
- the electrodes arranged on the sunlight incident surface are transparent, sunlight can be collected in the cell stack with high translucency.
- the cell stack of the solar battery cells 10 has a three-layer stacked structure including the top cell layer T, the middle cell layer M, and the bottom cell layer B.
- Light in the wavelength region can be used effectively for power generation. Therefore, a highly efficient solar cell can be realized.
- the lens 31 is in close contact with the solar battery cell 10.
- the thickness of the solar cell which is the distance from the bottom surface of the substrate 24 to the top of the lens 31, is about 20 mm.
- the solar battery of this embodiment can be configured with a thickness of about 10%.
- the solar cell of this Embodiment has the lens 31 closely_contact
- fever of the lens 31 in the incident surface side of sunlight can be discharge
- the metal plate 27 of the substrate 24 has a very large surface area compared to the electrodes. Therefore, the heat of the lens 31 released to the substrate 24 is released from the metal plate 27 to the outside. Therefore, the temperature of the lens 31 can be lowered as compared with a conventional solar cell of the type that releases the heat of the lens from the lens side. Therefore, a weak heat-resistant transparent resin can be used as the material of the lens 31.
- the cost of the material of the lens 31 can be further reduced as compared with the case where a glass lens is used.
- the solar cell can be made lighter than when a glass lens is used, and in particular, the workability in installing the solar cell under sunlight can be further improved. it can.
- both the electrode having the potential of the top cell layer T and the electrode having the potential of the bottom cell layer B are opposite to the sunlight incident surface. Is arranged. For this reason, by using the ACF 36, the solar battery cell 10 can be mounted on the substrate 24 in one process called a thermocompression bonding process. Therefore, the production lead time of the solar cell is shortened.
- the gap between the substrate 24 and the lens 31 can be made uniform by forming the convex portion 33 provided with the tapered portion 33b on the lens 31. For this reason, an excessive load on the solar battery cell 10 is prevented. Further, by arranging the tapered portion 33 b and the tapered hole portion 28 according to the mounting positions of the lens 31, the solar battery cell 10, and the substrate 24, the lens 31 and the substrate 24 can be easily aligned. Further, the stress due to the heat of the lens 31 can be dispersed along the plane direction of the substrate 24.
- a light, thin and small solar cell can be easily manufactured with high temperature cycle resistance, high humidity resistance, and high impact resistance.
- no wiring is required for the lens.
- the electrode on the light receiving part side of sunlight passes through the side part of the solar battery cell 10 and is electrically connected to the second conductive wire 25b on the heat radiating substrate 24, the conductive path is a heat transfer path. Can be used. For this reason, the high heat dissipation of a solar cell is realizable.
- a damageless mounting method can be provided for a fragile solar cell.
- the solar cell of the present invention can be used for a concentrating solar cell on the earth from a conventional use in space. And the conversion efficiency of sunlight can be improved greatly compared with the conventional silicon solar cell. Therefore, it is particularly suitable for a large-scale power generation system in an area with a large amount of sunlight.
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Abstract
Description
その他にも、種々の関連技術が開示されている(例えば、特許文献3~6参照)。例えば特許文献3~5には、放熱性を有する基板に固定された多接合型太陽電池素子にレンズで集光した太陽光を入射する太陽電池が記載されている。特許文献6には、P型半導体表面に一端が取付けられたコの字状の第一の電極が、N型半導体側面と裏面端部を覆う絶縁膜上に配置されて表面のブズバーに接続された太陽電池セルが開示されている。なお、特許文献3~6の発明にあっては放熱性等に課題が残されていた。
[1]放熱性を有する板状のベース、ベース上に配置される第一導電線及び第二導電線を有する基板と、
第一導電線に電気的に接続される第一電極、第一電極上に配置されたボトムセル層、ボトムセル層上に配置されたトップセル層、トップセル層上に配置された透明電極、ボトムセル層およびトップセル層を含むセル積層体の側面に配置された絶縁層、絶縁層を介してセル積層体の側面に配置され透明電極及び第二導電線に電気的に接続される第二電極を有する多接合型太陽電池セルと、
透明電極に密着して配置され、透明電極に集光点を有するレンズと、を有する太陽電池。
[2] レンズが、レンズにおける光の入射面とは反対側の表面から突出する柱部と、柱部の先端に配置されるテーパ部とをさらに有し、基板が、テーパ部に嵌合するテーパ穴部をさらに有する、[1]に記載の太陽電池。
[3] 基板上にレンズを支持するスペーサをさらに有する、[1]に記載の太陽電池。
[4] 第一電極と第一導電線との間、及び、第二電極と第二導電線との間、に介在する異方性導電フィルムをさらに有する、[1]に記載の太陽電池。
[5] 複数の多接合型太陽電池セルが一枚の基板に配置され、レンズが、密着する複数の透明電極のそれぞれに集光点を有する複眼レンズである、[1]に記載の太陽電池。
[6] 第二電極の下面は、第三電極の下面よりも下方に配置されている、[1]に記載の太陽電池。
[7] 太陽電池は、第三電極の下面側にさらに中央電極を有し、第二電極の下面と中央電極の下面とが同一面に配置されている、[1]に記載の太陽電池。
[8] 光の入射面とは反対側の表面に集光点を有するレンズを準備する工程と、
第一電極と、第一電極上に配置されたボトムセル層と、ボトムセル層上に配置されたトップセル層と、トップセル層上に配置された透明電極と、ボトムセル層とトップセル層とを含むセル積層体の側面に配置された絶縁層と、透明電極に電気的に接続され、絶縁層を介してセル積層体の側面に配置される第二電極と、を有する多接合型太陽電池セルを準備する工程と、
放熱性を有する板状のベースと、ベース上に配置される第一導電線及び第二導電線とを有する基板を準備する工程と、
レンズの集光点に透明電極が配置されるように、レンズに多接合型太陽電池セルを接着する工程と、
レンズに接着された多接合型太陽電池セルの第一電極を第一導電線に電気的に接続し、かつ第二電極を第二の導電線に電気的に接続するように、多接合型太陽電池セルと基板とを接着する工程と、を含む、太陽電池の製造方法。
[9] 多接合型太陽電池セルが接着されたレンズを基板上にスペーサによって支持する工程をさらに含む、[8]に記載の太陽電池の製造方法。
[10] レンズが、光の入射面とは反対側の表面から突出する柱部と、柱部の先端に配置されるテーパ部とをさらに有し、基板が、基板における多接合型太陽電池セルが配置されるべき位置で、テーパ部に嵌合するテーパ穴部をさらに有し、テーパ部をテーパ穴部に嵌合させて、基板に対する多接合型太陽電池セルの接着位置を決める工程、をさらに含む、[8]に記載の太陽電池の製造方法。
[11] 多接合型太陽電池セルと基板との間に異方性導電フィルムを挟む、[8]のいずれか一項に記載の太陽電池の製造方法。
[12] レンズが、光の入射面とは反対側の表面に複数の集光点を有する複眼レンズであり、基板が、集光点に対応する位置のそれぞれに第一導電線及び第二導電性を有し、複眼レンズの集光点のそれぞれに多接合型太陽電池セルを接着し、複眼レンズに接着された多接合型太陽電池セルのそれぞれを基板に接着する、[8]に記載の太陽電池の製造方法。
≪太陽電池≫
図1に示すように、本実施の形態の太陽電池は、放熱性を有する基板24と、基板24上に配置される複数の多接合型の太陽電池セル10と、それぞれの太陽電池セル10上に配置され、それぞれの太陽電池セル10に光を集めるレンズ31と、を有する。それぞれの太陽電池セル10と基板24との間には、太陽電池セル10と基板24とを電気的に接続する異方性導電フィルムであるACF36が配置されている。
図1に示すように、基板24は、複数のテーパ穴部28をさらに有する。テーパ穴部28は、基板24の上面から下面に向けて開口面積が漸次縮小する形状を有する。テーパ穴部28の形状や大きさは、後述するレンズの凸部のテーパ部に合わせて形成されている。テーパ穴部28の口径は、例えば20~50μmであり、テーパ穴部28のテーパ角は、例えば30~60°である。テーパ穴部28は、例えば基板24上における、一つの太陽電池セル10を配置するための正方形の領域の四隅等、一定の間隔(例えば10~150mm間隔)で配置されている。
第一導電線25aは、太陽電池セル10における後述の中央電極16bと電気的に接続される位置に配置されている。第二導電線25bは、太陽電池セル10における後述の第二電極16aと電気的に接続される位置に配置されている。第一導電線25a及び第二導電線25bは、所期の平面形状を有する銅の層と、その上に配置される、Ni、Auメッキ処理によるNi-Au層とからなる。銅の層は、例えば10~50μmの厚さを有する。Ni-Au層は、フラッシュAuメッキや、電解Auメッキ工法によって形成される。Ni-Au層の厚さは、例えば最大0.5μmである。
図3に示すように、太陽電池セル10は、多接合型太陽電池セルである。太陽電池セル10は、第一電極9aと、第一電極9a上に配置されたボトムセル層Bと、ボトムセル層B上に配置されたミドルセル層Mと、ミドルセル層M上に配置されたトップセル層Tと、トップセル層T上に配置された透明電極12と、ボトムセル層B、ミドルセル層M、及びトップセル層Tを含むセル積層体50の側面に配置された第二絶縁層17と、第二絶縁層17を介してセル積層体50の側面に配置され、透明電極12及び第二導電線25bに電気的に接続される第二電極16aと、を有する。太陽電池セル10によれば、太陽光の受光面に透明電極12以外の電極を有しないため、太陽光の利用効率が向上する。
なお、第一電極9aは、第一導電線25aに電気的に接続されるのであれば、第一導電線25a上に直接配置されても、導電性部材を介して第一導電線25aの上方に配置されても構わない。また第二電極16aも、第二導電線25bに電気的に接続されるのであれば、第二導電線25b上に直接配置されても、導電性部材を介して第二導電線25bの上方に配置されても構わない。
レンズ31は、ガラスに比べて低い耐熱性を有する樹脂で構成されている。樹脂は、アクリル樹脂やシリコーン樹脂などの透明な樹脂である。レンズ31は、例えば、平面上に配列する複数の平凸レンズ部からなる複眼レンズである。レンズ31は、透明樹脂の成形品である。各平凸レンズ部は、例えば光の入射面とは反対側の表面に、太陽電池セル10の透明電極12と同じ平面形状の集光点32を有する。レンズ31の平面形状(図1の矢印X方向から見た形状)は一辺の長さが約50mmの正方形である。レンズ31の厚さTcは例えば17mmである。レンズ31における個々のレンズ及び集光点32の数は、個々のレンズの集光倍率により決めることができる。例えば、個々のレンズの集光倍率が400倍である場合では、個々のレンズの大きさは10mm角となる。よってレンズ31は25個(5個×5個)のレンズを有する。個々のレンズの集光倍率が1,000倍である場合では、個々のレンズの大きさは16mm角となる。よってレンズ31は9個(3個×3個)のレンズを有する。透明樹脂は、例えば紫外線吸収剤を含有している。このためレンズ31は、長期間、日射下に置かれても、黄色に変色することがなく、透明性を確保することが可能である。
レンズ31は、基板24のテーパ穴部28のそれぞれに対応して配置される複数の凸部33を有する。凸部33は、テーパ穴部28と同様に一定の間隔で配置されている。凸部33は、レンズ31と一体成形で形成されている。
図1に示されるように、凸部33は、レンズ31の裏面から突出する柱部33aと、その先端に配置されるテーパ部33bとを有する。テーパ部33bのテーパ角は、テーパ穴部28のテーパ角と同じである。テーパ部及びテーパ穴部におけるテーパ角は、テーパ部及びテーパ穴部の嵌合を容易に行う観点、テーパ穴の加工性の観点、及び、レンズと凸部を樹脂で成形する場合の加工性の観点から、30~60°であることが好ましい。一例として、凸部33は、柱部33aの直径が20~50μm、柱部33aの高さが20~30μm、テーパ部33bの高さが20~70μmである。柱部33aの高さは、太陽電池セル10の厚み(高さ)により決まる。例えば太陽電池セル10の厚さが25μmである場合、柱部33aの高さも25μmになる。
太陽電池セル10の透明電極12は、レンズ31における集光点で、透明接着剤35によって接着されている。透明接着剤35は、エポキシ系の材料やシリコーン系の材料で構成されている。透明接着剤35には、例えば、樹脂材料からなる主剤と、樹脂材料からなり、主剤に混合される硬化剤と、からなる二液性の接着剤や、紫外線で硬化する樹脂材料が用いられる。
図1及び図2に示すように、基板24とレンズ31との隙間は、機械的強度の補強と耐薬品性の向上とのために、封止樹脂22で封止されている。封止樹脂22によって、基板24、太陽電池セル10、及びレンズ31が一体的に構成されている。封止樹脂は、日射下のレンズの加熱による応力の集中を抑制する観点から好ましい。封止樹脂としては、例えば、エポキシ樹脂、フェノール樹脂、フッ素系樹脂、ポリイミド樹脂、シリコーン樹脂、及びアクリル樹脂が挙げられる。
本発明の太陽電池は、以下の方法によって製造することができる。本発明における太陽電池の製造方法は、レンズを準備する工程、多接合型太陽電池セルを準備する工程、及び基板を準備する工程、を含む。
まず、太陽電池セル10の準備について説明する。
セル積層体は、GaAs基板1の上に、各セル層を構成する金属層を形成することで得られる。各金属層は、縦型MOCVD(Metal Organic Chemical Vapor Deposition)装置に金属層の材料を投入し、各金属材料をエピタキシャル成長法によって成長させることによって形成されうる。
図5A~図9Dを用いて、化合物太陽電池の製造フローを説明する。図5Aの工程では、円板状のGaAs基板1(ウェハ)を用意する。GaAs基板1のサイズは、例えば、直径が4インチ(10.16cm)、厚さが500μmである。通常、1つのGaAs基板1に複数の太陽電池セル10を形成する。
レンズ31は、透明のアクリル樹脂や透明なシリコーン樹脂材料の成形加工で形成される。成形加工は、金型を用いた、インジェクション成形や、トランスファー成形で行われ得る。凸部33は、レンズ31用の金型に、凸部33を形成する部分をさらに形成し、この金型を用いることによって、成形時にレンズ31と同時に形成される。
基板24は、太陽電池セル10の配置やレンズ31の集光点に応じて、第一絶縁層26や第一導電線25a及び第二導電線25bを配置し、テーパ穴部28を形成することによって製造される。基板24の製造には、配線を表面に有する基板を製造するための通常の方法によって製造することができる。
レンズ31の表面のうち、太陽電池セル10の透明電極が接着される表面であるレンズ31の裏面に、撥液加工を施す。具体的には、レンズ31の裏面のうち、集光点以外の領域に撥液処理を施す。撥液処理は、例えば、CF3(CF2)7C2H4SiCl3のようなフッ化炭素鎖、またはCH3(CH2)17SiCl3のような炭化水素鎖を有するシランカップリング剤による化学修飾によって行われる。
次に、親液性の表面を有する集光点に、透明接着剤35を転写して塗布する。透明接着剤35を転写する方法は、20~100μmの均一な膜厚に調整された、転写台の上の透明接着剤に、先端形状が20~50μmRの半球形状である転写ピンを接触させる。そして、表面張力によって転写ピンの先端に透明接着剤を一度転写させる。
次に、図1に示すように、レンズ31の集光点に塗布された透明接着剤35上に、太陽電池セル10の透明電極12を、位置合わせしながら実装する。
一方で基板24の表面には、ACF36を貼り付ける。ACF36は異方性導電フィルムであり、エポキシ樹脂フィルムの中に、導電粒子が分散している。ACF36は、主に液晶ディスプレイの駆動用ドライバーを実装するのに使用されている。本実施の形態では、このような用途のACF36を用いることができる。
次に、太陽電池セル10が接着されたレンズ31を、ACF36が貼り付けられた基板24にマウントする。レンズ31の凸部33と基板24の凹部とを嵌合する。これにより、基板24、太陽電池セル10及びレンズ31が正しい位置で配置される。
次に、太陽電池セル10と基板24とを電気的に接続すると共に、太陽電池セル10と基板24とを物理的に固定する。
次に、基板24とレンズ31との間の隙間に封止樹脂22を配置する(図1及び図2)。
本出願は、同出願人により先にされた日本国特許出願、すなわち、特願2011-273742号(出願日2011年12月14日)に基づく優先権主張を伴うものであって、これらの明細書の内容を参照して本発明の一部としてここに組み込むものとする。
2a 第二コンタクト層
2b 第一コンタクト層
4 犠牲層
4a 犠牲層凹部
9a 第一電極
9b 第三電極
10、120、220 太陽電池セル
12 透明電極
16a 第二電極
16b 中央電極
16c Au/Ti積層膜
16d Ti膜
17 第二絶縁層
17a、17b 第二絶縁層の窓
18 レジスト
19a、19b トンネル層
20 グリッド層
21 バッファ層
22 封止樹脂
24 基板
25a 第一導電線
25b 第二導電線
26 第一絶縁層
27 金属板(ベース)
28 テーパ穴部
29 作業用基板
31 レンズ
32 集光点
33 凸部
33a 柱部
33b テーパ部
35 透明接着剤
36 ACF(異方性導電フィルム)
37 ベース部材
50 セル積層体
100、200 太陽電池
110、210 光学部品
113 凹部
124A 第1接続部
124B 第2接続部
140 バックシート
150 回路基板
153 絶縁体
154 導電体
154A、154B 電極部分
155 接着層
230 一次鏡
231、234 金属膜
237 隙間
239 開口
300 固体透明光学パネル
400C 集光型光エネルギ収集ユニット
420 ソケットコネクタ
A 図1の太陽電池における太陽電池セル10の周辺を囲む線
B ボトムセル層
M ミドルセル層
T トップセル層
X 太陽光の照射方向を示す矢印
Claims (12)
- 放熱性を有する板状のベース、前記ベース上に配置される第一導電線及び第二導電線を有する基板と、
前記第一導電線に電気的に接続される第一電極、前記第一電極上に配置されたボトムセル層、前記ボトムセル層上に配置されたトップセル層、前記トップセル層上に配置された透明電極、ボトムセル層およびトップセル層を含むセル積層体の側面に配置された絶縁層、前記絶縁層を介して前記セル積層体の側面に配置され前記透明電極及び前記第二導電線に電気的に接続される第二電極、を有する多接合型太陽電池セルと、
前記透明電極に密着して配置され、前記透明電極に集光点を有するレンズと、を有する太陽電池。 - 前記レンズが、前記レンズにおける光の入射面とは反対側の表面から突出する柱部と、前記柱部の先端に配置されるテーパ部とをさらに有し、
前記基板が、前記テーパ部に嵌合するテーパ穴部をさらに有する、請求項1に記載の太陽電池。 - 前記基板上に前記レンズを支持するスペーサをさらに有する、請求項1に記載の太陽電池。
- 前記第一電極と前記第一導電線との間、及び、前記第二電極と前記第二導電線との間、に介在する異方性導電フィルムをさらに有する、請求項1に記載の太陽電池。
- 複数の前記多接合型太陽電池セルが一枚の前記基板に配置され、
前記レンズが、密着する複数の前記透明電極のそれぞれに集光点を有する複眼レンズである、請求項1に記載の太陽電池。 - 前記第二電極の下面は、前記第三電極の下面よりも下方に配置されている、請求項1に記載の太陽電池。
- 前記太陽電池は、前記第三電極の下面側にさらに中央電極を有し、前記第二電極の下面と前記中央電極の下面とが同一面に配置されている、請求項1に記載の太陽電池。
- 光の入射面とは反対側の表面に集光点を有するレンズを準備する工程と、
第一電極と、前記第一電極上に配置されたボトムセル層と、前記ボトムセル層上に配置されたトップセル層と、前記トップセル層上に配置された透明電極と、前記ボトムセル層と前記トップセル層とを含むセル積層体の側面に配置された絶縁層と、前記透明電極に電気的に接続され、前記絶縁層を介して前記セル積層体の側面に配置される第二電極と、を有する多接合型太陽電池セルを準備する工程と、
放熱性を有する板状のベースと、前記ベース上に配置される第一導電線及び第二導電線とを有する基板を準備する工程と、
前記レンズの集光点に前記透明電極が配置されるように、前記レンズに前記多接合型太陽電池セルを接着する工程と、
前記レンズに接着された前記多接合型太陽電池セルの前記第一電極を前記第一導電線に電気的に接続し、かつ前記第二電極を前記第二の導電線に電気的に接続するように、前記前記多接合型太陽電池セルと前記基板とを接着する工程と、を含む、太陽電池の製造方法。 - 前記多接合型太陽電池セルが接着された前記レンズを前記基板上にスペーサによって支持する工程をさらに含む、請求項8に記載の太陽電池の製造方法。
- 前記レンズが、光の入射面とは反対側の表面から突出する柱部と、前記柱部の先端に配置されるテーパ部とをさらに有し、
前記基板が、前記基板における前記多接合型太陽電池セルが配置されるべき位置で、前記テーパ部に嵌合するテーパ穴部をさらに有し、
前記テーパ部を前記テーパ穴部に嵌合させて、前記基板に対する前記多接合型太陽電池セルの接着位置を決める工程、をさらに含む、請求項8に記載の太陽電池の製造方法。 - 前記多接合型太陽電池セルと前記基板との間に異方性導電フィルムを挟む、請求項8に記載の太陽電池の製造方法。
- 前記レンズが、光の入射面とは反対側の表面に複数の集光点を有する複眼レンズであり、
前記基板が、前記集光点に対応する位置のそれぞれに前記第一導電線及び前記第二導電性を有し、
前記複眼レンズの集光点のそれぞれに前記多接合型太陽電池セルを接着し、前記複眼レンズに接着された前記多接合型太陽電池セルのそれぞれを前記基板に接着する、請求項8に記載の太陽電池の製造方法。
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