WO2015122532A1 - 電気モジュール及び電気モジュールの製造方法 - Google Patents
電気モジュール及び電気モジュールの製造方法 Download PDFInfo
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- WO2015122532A1 WO2015122532A1 PCT/JP2015/054268 JP2015054268W WO2015122532A1 WO 2015122532 A1 WO2015122532 A1 WO 2015122532A1 JP 2015054268 W JP2015054268 W JP 2015054268W WO 2015122532 A1 WO2015122532 A1 WO 2015122532A1
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- conductive film
- conductive
- photoelectrode
- internal space
- counter electrode
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/20—Light-sensitive devices
- H01G9/2068—Panels or arrays of photoelectrochemical cells, e.g. photovoltaic modules based on photoelectrochemical cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/20—Light-sensitive devices
- H01G9/2027—Light-sensitive devices comprising an oxide semiconductor electrode
- H01G9/2031—Light-sensitive devices comprising an oxide semiconductor electrode comprising titanium oxide, e.g. TiO2
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/20—Light-sensitive devices
- H01G9/2059—Light-sensitive devices comprising an organic dye as the active light absorbing material, e.g. adsorbed on an electrode or dissolved in solution
-
- 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
- Y02E10/542—Dye sensitized solar cells
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to an electric module and a method for manufacturing the electric module.
- This application claims priority based on Japanese Patent Application No. 2014-027962 for which it applied to Japan on February 17, 2014, and uses the content here.
- the dye-sensitized solar cell described in Patent Document 1 includes one conductive metal layer on one plate surface of the first substrate.
- a porous insulating material (member for preventing a short circuit between the conductive metal layer and the conductive substrate) is disposed on the surface of the conductive metal layer, and the first conductive material is disposed on the surface of the porous insulating material.
- Another conductive metal layer disposed opposite to the metal layer is provided, and a semiconductor layer is further provided on the upper surface of the other conductive metal layer.
- a transparent substrate is disposed opposite to the first substrate, and outer peripheral portions of the opposed substrates are bonded together with a sealing material to form an internal space.
- an internal electrode is filled with an electrolytic solution, and a takeout electrode in which a metal conductive layer is formed on the surface of an insulating layer is connected to the conductive metal layer of the first electrode of the solar cell and the conductivity of other electrodes.
- positioning so that it may contact with a conductive metal layer is employ
- the present invention provides a high-quality electric module with improved current collection efficiency and reduced resistance, and a method for manufacturing the same.
- An electrical module includes a photoelectrode in which a semiconductor layer is formed on a first substrate on which a first conductive film is formed, and a second substrate on which a second conductive film is formed.
- An electrode and an electrolyte, the photoelectrode and the counter electrode are sealed and formed so as to form an internal space therebetween, and the electrolyte is filled in the internal space
- the at least part of the sealing portion between the photoelectrode and the counter electrode is formed by adhering the first conductive film and the second conductive film with a sealing material, and the first conductive film
- at least one of the second conductive films is extended to the outside of the internal space beyond the sealing material in a state of being electrically continuous from the internal space, and the extended portion
- a conductive material is disposed on the surface of the substrate so as to be conductive with the portion.
- electrolyte includes an electrolytic solution, a gel electrolyte, and a solid electrolyte. According to this configuration, at the time of current collection, at least one of the photoelectrode and the counter electrode can have low resistance and can conduct electricity in a wide region, thereby collecting current efficiently.
- a terminal is connected to the conductive material of the present invention, and at least one of the photoelectrode and the counter electrode may be formed with one or more openings that expose the terminal. According to 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. Further, when a plurality of openings are formed, current can be taken out from an arbitrary terminal.
- a terminal is connected to the conductive material of the present invention, and the terminal is provided so as to protrude from between the photoelectrode and the counter electrode and from the outer edge of the photoelectrode or the counter electrode. Also good. According to this configuration, the terminal can be easily taken out between the photoelectrode and the counter electrode at an arbitrary position of the conductive material.
- the conductive material of the present invention is preferably fixed to at least one of the first conductive film and the second conductive film by the terminal. According to this configuration, the conductive material can be stably fixed to the photoelectrode or the counter electrode.
- both the first conductive film and the second conductive film extend beyond the inner space beyond the sealing material in a state of being electrically continuous from the inner space.
- the first conductive film and the second conductive film are extended to opposite sides across the internal space, and the first conductive film and the second conductive film It is preferable that a conductive material is disposed on the surface of each of the extended portions so as to be conductive with the portion. According to this configuration, at the time of current collection, both the photoelectrode and the counter electrode can have low resistance and can conduct electricity in a wide region, thereby enabling more efficient current collection.
- the electrical module manufacturing method of the present invention includes a photoelectrode in which a semiconductor layer is formed on a first substrate on which a first conductive film is formed, and a second substrate on which a second conductive film is formed.
- the sealing material of the present invention is preferably extended in the one direction on at least one end side in the direction crossing the one direction, and the conductive material is preferably arranged in parallel to the one direction. According to this configuration, it is possible to easily perform continuous production such as roll-to-roll production in which any one of the above electric modules is continuously produced while being conveyed in one direction.
- the resistance value at the time of current collection can be reduced to improve the current collection efficiency and the quality of the electric module can be improved.
- the manufacturing method of the electrical module of this invention there exists an effect that the electrical module of this invention can be manufactured simply and efficiently by continuous production.
- FIG. 2 is a cross-sectional view taken along the line X1-X1 in FIG. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention.
- FIG. 3C is a cross-sectional view taken along the line X2-X2 in FIG. 3A. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention.
- FIG. 4B is a cross-sectional view taken along the line X3-X3 in FIG. 4A.
- FIG. 5B is a sectional view taken along line X4-X4 in FIG. 5A. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention.
- FIG. 6B is a cross-sectional view taken along line X5-X5 in FIG. 6A. It is the perspective sectional view showing typically a part of manufacturing process of the electric module of a 1st embodiment of the present invention.
- FIG. 7B is a cross-sectional view taken along the line X6-X6 in FIG. 7A.
- FIG. 11B is a cross-sectional view taken along line X8-X8 in FIG. 11A. It is sectional drawing which showed typically the modification of the electric module of 2nd Embodiment of this invention. It is the perspective sectional view showing typically the modification of the electric module of a 2nd embodiment of the present invention.
- 13B is a cross-sectional view taken along line X9-X9 in FIG. 13A. It is sectional drawing which showed typically the modification of the electric module of 2nd Embodiment of this invention. It is sectional drawing which showed typically the electric module of 3rd Embodiment of this invention.
- the electric module of the present invention is a dye-sensitized solar cell (hereinafter referred to as “solar cell”). Further, a case where an electric module is manufactured using a gel electrolyte as an electrolyte will be described as an example.
- the solar cell 1A As shown in FIG. 1 or 2, the solar cell 1A according to the first embodiment of the present invention is a photoelectrode in which a semiconductor layer 8 is formed on a first substrate 7 on which a first conductive film 4 is formed. 2, a counter electrode 3 including a second substrate 11 on which a second conductive film 10 is formed, and an electrolyte 12, and the photoelectrode 2 and the counter electrode 3 have an internal space S therebetween.
- the electrolyte 12 is provided with a plurality of power generation elements (also referred to as cells) C filled in the internal space S, and is sealed to form the sealing portion P.
- the portion extending in the direction of the arrow L1 is formed by adhering the first conductive film 4 and the second conductive film 10 with the sealing material 9, and is sealed in an electrically continuous state from the internal space S.
- the first conductive film 4 and / or the second conductive film 1 extended in opposite directions to the outside of the internal space S beyond the material 9
- the conductive material 5 in a conductible state and is connected thereto.
- each electric power generation element C is connected in series.
- the solar cell 1A is configured as follows.
- the photoelectrode 2 has a plurality of (three in this embodiment) strips extending in parallel to each other in the direction of arrow L1 (the depth direction in the drawing in FIG. 2) on the first conductive film 4 formed on the first substrate 7.
- the semiconductor layer 8 is provided. These semiconductor layers 8, 8,... Are formed with an interval in which the sealing materials 9, 9 and the conductive material 5 are arranged in the direction of the arrow L2 crossing the direction of the arrow L1.
- strip-like insulating bands 15 extending in the direction of the arrow L ⁇ b> 1 and serving as cell separators are formed on both sides of the semiconductor layer 8 in the width direction at regular intervals so as to sandwich the semiconductor layer 8. Yes.
- the counter electrode 3 includes a second substrate 11 on which a second conductive film 10 is formed.
- the second conductive film 10 has a strip-shaped insulating band 15 extending in the direction of the arrow L1 and serving as a cell separator.
- the insulating band 15 formed on the first conductive film 4 is closer to the one side in the direction of the arrow L2. They are formed on both sides of the semiconductor layer 8 in the width direction at regular intervals so that the position is shifted to the right (in the present embodiment, to the right) and the semiconductor layer 8 is sandwiched therebetween.
- the first substrate 7 and the second substrate 11 for example, a resin material mainly composed of a transparent thermoplastic resin material such as polyethylene naphthalate (PEN) or polyethylene terephthalate (PET), or a glass substrate, respectively. Etc. are preferably used.
- substrate 11 may be formed in the flexible film form. At least one of the first substrate 7 and the second substrate 11 is a transparent substrate.
- Examples of the material of the first conductive film 4 or the second conductive film 10 include tin-doped indium oxide (ITO), zinc oxide, fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), and tin oxide (SnO). ), Antimony-doped tin oxide (ATO), indium oxide / zinc oxide (IZO), gallium-doped zinc oxide (GZO), and the like are used.
- At least one of the first conductive film 4 and the second conductive film 10 is formed of a transparent conductive film. Further, in at least one of the combination of the first substrate 7 and the first conductive film 4 and the combination of the second substrate 11 and the second conductive film 10, the substrate and the conductive film are both It is desirable to be transparent.
- the semiconductor layer 8 has a function of receiving and transporting electrons from a sensitizing dye described later, and a semiconductor made of a metal oxide is formed on the surface of the conductive film.
- a metal oxide for example, titanium oxide (TiO 2 ), zinc oxide (ZnO), tin oxide (SnO 2 ) or the like is used.
- the semiconductor layer 8 carries a sensitizing dye.
- the sensitizing dye is composed of an organic dye or a metal complex dye.
- organic dye for example, various organic dyes such as coumarin, polyene, cyanine, hemicyanine, and thiophene can be used.
- metal complex dye for example, a ruthenium complex is preferably used.
- the second conductive film 10 either a material that does not serve as a catalyst layer and serves as a conductive film, or a material that can serve as both a catalyst layer and a conductive film is employed.
- a catalyst layer (not shown) is further formed on the second conductive film 10.
- only the second conductive film 10 is formed on the second substrate 11. .
- the catalyst layer formed on the surface of the second conductive film carbon paste, platinum, or the like is employed.
- the photoelectrode 2 and the counter electrode 3 are bonded together at the sealing portion P, and as a result, an internal space S for sealing the electrolyte 12 is formed for each semiconductor layer 8 provided continuously in a band shape.
- the sealing part P includes the first conductive film 4 and the second conductive film 4 between the adjacent semiconductor layers 8 and 8 and the two ends 1a and 1b in the direction of the arrow L2 with two rows of sealing materials 9 in the direction of the arrow L1. Is formed by adhering the conductive film 10 to the first substrate 7 and the second substrate 11 in the direction of the arrow L2 by ultrasonic fusion or the like. Has been.
- the sealing material 9 is arranged at a position covering the insulating band 15 formed on the first conductive film 4 or the insulating band 15 formed on the second conductive film 10 one by one. Note that, at both ends of the one end 1a and the other end 1b, the sealing material 9 (P) is provided so as to cover the two insulating bands 15, 15 facing each other.
- the adhesive agent of the material which does not impair the function of the 1st electrically conductive film 4 and the 2nd electrically conductive film 10, for example, hot-melt resin etc. is used suitably.
- a wiring space 20 is formed between the sealing materials 9 and 9 disposed between the semiconductor layers 8 and 8.
- a conductive material 5 for connecting adjacent cells C and C in series is arranged in the direction of the arrow L1. That is, the conductive material 5 in the wiring space 20 is adjacent to the left side of the first conductive film 4 continuously extending from the internal space S of one cell C adjacent to the right side beyond the sealing material 9.
- the second conductive film 10 continuously extending from the internal space S of the other cell C beyond the sealing material 9 in the direction of the arrow L1.
- the first conductive film 4 and the conductive material 5 continuously extending from the inner space S of one cell C and the inner space S of the other cell C are continuously extended.
- one or both of the second conductive film 10 and the conductive material 5 is provided with an auxiliary conductive material 5a such as a conductive material paste for assisting electrical connection therebetween.
- the internal space S filled with the electrolyte 12 and the wiring space 20 separated in a liquid-tight manner are formed between the cells C and C by the sealing portion P including the sealing materials 9 and 9. Is formed.
- the conductive material 5 has an arrow L ⁇ b> 1 on the first conductive film 4 and the second conductive film 10 that are continuously extended from the adjacent internal space S into the wiring space 20.
- the cells C, C,... Are connected in series and constitute a series connection.
- one conductive film 4 extends continuously from the internal space S to the outside beyond the sealing material 9 that seals the internal space S.
- the conductive film 10 is insulated in the direction of the arrow L1 at the position of the sealing material 9 that seals the internal space S.
- a sealing material 9 is further provided with a space in the direction of the arrow L2 from the sealing material 9 that seals the internal space S, and a wiring space 20 is formed by these sealing materials 9 and 9.
- the first conductive film 4 and the second conductive film 10 are further insulated in the arrow L1 direction.
- Openings 16 are formed in the first substrate 7 and the first conductive film 4 in the wiring space 20 provided at one end 1a in the direction of the arrow L2 with a gap in the direction of the arrow L1.
- the linear conductive material 5 is connected to the first conductive film 4 continuously extending into the wiring space 20 provided at the one end 1a through the auxiliary conductive material 5a in the direction of the arrow L1.
- the current can be efficiently collected while ensuring conduction in a wide region of the first conductive film 4.
- a terminal 6 is inserted into the opening 16 formed in the wiring space 20 so that one end is in contact with the auxiliary conductive material 5 a and the conductive material 5 and the other end protrudes (exposes) from the opening 16. Yes.
- the wiring space 20 at the one end 1a in the direction of the arrow L2 is liquid-tightly separated from the adjacent internal space S.
- the conductive material 5 in the wiring space 20 is arranged over the direction of the arrow L1, so that the first conductive film extends continuously from the internal space S to the outside beyond the sealing material 9.
- the current is collected while securing conduction throughout the direction of the arrow L1 in FIG. 4, and a current can be taken out from any of the terminals 6, 6,.
- the second conductive film 10 at the one end 1a is insulated from the other conductive film 10 in the cell C at the position of the sealing material 9 sealing the internal space S. Even if it is in contact with the second conductive film 10 in the wiring space 20, it does not conduct with the second conductive film 10. In this way, the conductive material 5 in the wiring space 20 at the one end 1a forms a series connection with the adjacent cell C.
- the auxiliary conductive material 5a is not essential as long as the conductive material 5 and the terminal 6 are in reliable contact with the first conductive film 4 and can be electrically connected, but the connection reliability and the conductive material 5 and In order to securely fix the terminal 6 to the first conductive film 4, the conductive material 5 and the terminal 6 are preferably disposed between the first conductive film 4.
- the second conductive film 10 at the one end 1a is insulated from the other conductive film 10 in the internal space S by the insulating band 15 at the position of the sealing material 9 provided at the one end 1a as described above. Therefore, the conductive material 5 at the one end 1a does not cause a short circuit problem even if it is in contact with the second conductive film 10, but in order to prevent unnecessary conduction with the second conductive film 10, It is desirable to ensure separation from the membrane 10. Therefore, it is more desirable that an insulating material (not shown) is disposed between the conductive material 5 and the second conductive film 10.
- a sealing material (not shown) is disposed in the opening 16 in order to prevent moisture and the like from entering. Since the sealing material (not shown) for sealing the opening 16 is preferably as close as possible to the terminal 6 at one end 1a and the first conductive film 4 to be opened to achieve good conduction, The opening 16 on the one end 1a side is preferably made of a conductive material.
- the other end 1b in the direction of the arrow L2 has a structure substantially similar to the structure of the one end 1a.
- the conductive material 5 provided at the other end 1b is a second conductive film continuously extended from the adjacent internal space S so as to match the series connection structure formed between the cells C and C. 10 and is electrically connected to form a serial connection with the adjacent cell C.
- the first conductive film 4 in the wiring space 20 at the other end 1b is insulated from the one conductive film 4 in the internal space S at the position of the sealing material 9 sealing the internal space S. Therefore, the conductive material 5 provided at the other end 1 b is not electrically connected to the first conductive film 4 even if it is in contact with the first conductive film 4.
- the auxiliary conductive material 5a is not essential at the other end 1b for the same reason as the one at the end 1a, but is preferably disposed between the conductive material 5 and the terminal 6 and the other conductive film 10. Further, like the one end 1 a, it is desirable that the conductive material 5 at the other end 1 b be reliably separated from the first conductive film 4. For this purpose, it is more desirable to provide an insulating material (not shown) between the conductive material 5 and the first conductive film 4. Moreover, since it is preferable that the terminal 6 of the other end 1b does not conduct
- the linear conductive material 5 is not particularly limited as long as it is formed of a low-resistance metal.
- a conductive wire formed of copper, silver, a copper alloy, or the like can be used, and cost and availability are easy. In view of the above, it is preferable to use a copper wire.
- the linear conductive material 5 is arranged on the surface of the first conductive film 4 or the second conductive film 10 and can collect electricity generated in the cell C.
- the conductive material 5 is preferably disposed with a larger contact area with respect to the first conductive film 4 or the second conductive film 10 via the paste-like auxiliary conductive material 5a.
- the solar cell 1 ⁇ / b> A has a reduced resistance to movement of electrons in the photoelectrode 2 and the counter electrode 3.
- the efficiency of current collection work is shortened by shortening the distance.
- the electrolyte 12 penetrates into the semiconductor layer 8 and is coated on almost the entire surface thereof.
- the electrolyte 12 is, for example, a nonaqueous solvent such as acetonitrile or propionitrile, or a liquid component such as ionic liquid such as dimethylpropylimidazolium iodide or butylmethylimidazolium iodide, and a supporting electrolyte such as lithium iodide.
- a solution in which a liquid and iodine are mixed is used.
- the electrolyte 12 may contain t-butylpyridine in order to prevent reverse electron transfer reaction.
- the solar cell 1A includes the wiring space 20 separated from the internal space S between the cells C and C, and the first conductive film 4 is connected to the wiring space 20 in series with each other. And the second conductive film 10 are continuously extended, or the first conductive film 4 or the second conductive film 10 is patterned (insulated).
- the terminal 6 is connected to the conductive material 5 at both ends 1a and 1b in the direction of the arrow L2, and the terminal 6 protrudes from the plate surface of the photoelectrode 2 through the opening 16, and current is supplied to the arbitrary terminal 6 It can be easily removed from.
- an opening 16 may be formed in the wiring space 20 between the semiconductor layers 8 and 8 similarly to the one end 1 a and the other end 1 b, and a terminal may be inserted into the opening 16. According to this configuration, the number of power generating elements connected in series can be increased or decreased.
- One embodiment of the manufacturing method of the solar cell 1 ⁇ / b> A includes (I) a photoelectrode 2 in which a semiconductor layer 8 is formed on a first substrate 7 on which a first conductive film 4 is formed, and a second conductive film 10.
- the sealing material 9 is formed by the sealing material 9,
- the conductive material 5 is applied to the surface of either the first conductive film 4 or the second conductive film 10 that extends beyond the inner space S beyond the sealing material 9 in an electrically continuous state from the space S. It is characterized by providing a sealing step and a conductive material placement step. Hereinafter, each step will be described.
- the counter electrode 3 in which the second conductive film 10 is formed on the second substrate 11 wound in a roll shape is prepared.
- a roll-shaped base material in which the second conductive film 10 is formed on one plate surface of the second substrate 11 in advance may be used.
- a strip-shaped insulating band 15 parallel to the arrow L ⁇ b> 1 direction is formed between the semiconductor layers 8 by a laser or the like.
- openings 16 are formed at both ends 1a and 1b in the width direction of the photoelectrode 2 with an interval in the direction of the arrow L1. Then, as shown in FIGS. 5A and 5B, the terminal 6 is allowed to penetrate the opening 16 (see FIG. 4A).
- coating or dripping of the electrolyte 12 is not specifically limited.
- a strip-shaped insulating band 15 is formed in advance on the second conductive film 10 so as to be shifted in one direction of the band 15 and the arrow L2 and continuously extending in the direction of the arrow L1.
- the photoelectrode 2 and the counter electrode 3 are laminated with the first conductive film 4 and the second conductive film 10 facing each other. Then, the position where the sealing material 9 is disposed is heated and pressurized to adhere the sealing portion P of each cell C in the direction of the arrow L1, and at a predetermined interval in the direction of the arrow L1, ultrasonic welding, etc. As a result, the photoelectrode 2 and the counter electrode 3 are fused and cut in the direction of the arrow L2.
- the internal space S including the semiconductor layer 8 and the electrolyte 12 shown in FIG. 1 or FIG. 2 and the wiring space 20 including the conductive material 5 are formed.
- the first conductive film 4 of the cell C and the second conductive film 10 of the other cell C are connected to obtain a solar cell 1A having a series connection structure.
- the solar cell 1A can shorten the electron moving distance and efficiently collect current from the entire direction of the arrow L1 of each cell C, and an effect of high quality is obtained.
- the conductive material 5 is continuously disposed in the direction of the arrow L1 in the wiring space 20 (that is, the conductive material 5 is disposed over the entire length of the conductive films 4 and 10 of the solar cell 1A.
- the conductive material 5 is preferably provided over 10 to 100% of the entire length of the conductive films 4 and 10, and 50 to 100. % Is more preferable.
- the solar cell 1A can easily form a gap such as the terminal 6 as in the prior art. Is prevented from being leaked out of the cell C, and the effect of high quality can be obtained.
- the solar cell 1A is provided with the conductive material 5 in the direction of the arrow L1 in the wiring space 20 provided outside the internal space S having the electrolyte 12, the opening 16 is easily formed at an arbitrary position. Thus, an effect that current can be taken out from an arbitrary position via the terminal 6 is obtained. Further, for the same reason, the solar cell 1 ⁇ / b> A has an effect of preventing the deterioration of the battery performance by preventing the conductive material 5 and the terminal 6 from being corroded by the electrolyte 12. In addition, the solar cell 1A has an effect that the size or design freedom of the solar cell 1A is high for the above reason.
- the solar cell 1A is identical to the first conductive film 4 or the second conductive film 10 that is physically and electrically continuous from the internal space S in the wiring space 20 and the same as described above in the insulating band 15. Either the second conductive film 10 or the first conductive film 4 insulated from the internal space S is extended to the outside of the same sealing material 9. Therefore, the solar cell 1A can be easily used without considering the short-circuit caused by the contact between the conductive material 5 and the terminal 6 and both the first conductive film 4 and the second conductive film 10 facing each other. The effect that 6 can be arranged is obtained. Therefore, an effect that the manufacturing of the solar cell 1A can be facilitated is obtained.
- the photoelectrode 2 and the counter electrode 3 are bonded in the direction of the arrow L1 by the sealing material 9 while being fed in the direction of the arrow L1, and cross over the sealing material 9. Sealing in the direction of the arrow L2 can be performed by ultrasonic fusion or the like at any position of the solar cell 1A. That is, the manufacturing method of the solar cell 1A of the present invention uses, for example, the Roll to Roll manufacturing method in which the photoelectrode 2 and the counter electrode 3 are formed in a strip shape and continuously manufactured while being conveyed in the direction of the arrow L1 (that is, the longitudinal direction).
- the manufacturing method of the solar cell 1A of the present invention uses, for example, the Roll to Roll manufacturing method in which the photoelectrode 2 and the counter electrode 3 are formed in a strip shape and continuously manufactured while being conveyed in the direction of the arrow L1 (that is, the longitudinal direction).
- the solar cell 1A is configured to form the opening 16 in the photoelectrode 2 and take out the terminal 6 from the opening 16, but the formation of the opening 16 is limited to the photoelectrode 2. It is not something. That is, since the opening 16 is only an option for the direction of taking out the terminal 6, if the conductive material 5 and the terminal 6 are appropriately connected to the electrode (that is, the first conductive film 4 or the second conductive film 10).
- the opening 16 may be formed in the counter electrode 3 as shown in FIG. 8, or the opening 16 on the one end 1a side is formed in the counter electrode 3 as shown in FIG.
- the opening 16 on the other end 1b side may be formed in the photoelectrode 2 or vice versa (not shown).
- the opening 16 may be formed in both the photoelectrode 2 and the counter electrode 3.
- the terminal 6 is projected from the outer edge (that is, one end 1a and the other end 1b) of the photoelectrode 2 or the counter electrode 3 from between the photoelectrode 2 and the counter electrode 3.
- the wiring space 20 in which the conductive material 5 for connecting the terminal 6 is arranged is opened to the side so that the terminal 6 can easily protrude at any position of the conductive material 5. May be.
- the solar cell 1B of the present embodiment forms a current collection structure by arranging a plurality of conductive materials 5 in the internal space S of one cell C, and the current collection structures are arranged in parallel. It differs from the first embodiment in that it is provided.
- the first conductive film 4 and the second conductive film 10 are not patterned in the internal space S and are formed on the entire surfaces of the first substrate 7 and the second substrate 11.
- the conductive material 5 is arranged at one end 1a, between the semiconductor layers 8 and 8, and the other end 1b. At the one end 1a and the other end 1b, an auxiliary conductive material 5a is interposed between the semiconductor layers 8 and 8. It arrange
- Openings 16 are formed in the photoelectrode 2 at intervals in the direction of the arrow L1 (the depth direction in FIG. 11B), and the terminal 6 is inserted through each of them, and the conductive material 5, the terminal 6, and the first electrode The conductive film 4 is in contact with each other.
- a protective material 35 is provided on the surface of the conductive material 5 between the semiconductor layers 8 and 8 so that the entire surface including the terminal 6 does not contact the electrolyte 12.
- the solar cell 1 ⁇ / b> B efficiently collects electric power while connecting the electric wires 30 to the respective terminals 6 and ensuring conduction throughout the first conductive film 4 in one cell C. The effect that it can do is acquired.
- a solar cell 1C according to Modification 1 includes a semiconductor layer 8 as shown in FIG. 12 in place of the conductive material 5 between the semiconductor layers 8 and 8 shown in FIGS. 11A and 11B and the protective material 35 provided on the terminal 6. , 8 and sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2) to form a wiring space 20. An insulating material 31 is interposed between the conductive material 5 and the second conductive film 10.
- the solar cell 1C of the modification 1 is efficient, connecting the electric wire 30 to each terminal 6, and ensuring conduction
- the effect that current can be collected is obtained.
- the conductive material 5 is arranged in the wiring space 20 separated from the internal space S, so that the terminals 6, 6,... And the conductive material 5 are reliably separated from the electrolyte 12. Can be protected.
- the solar cell 1C of the modification 1 can be isolated from the electrolyte 12 only by installing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be simplified is obtained. Further, in the solar cell 1 ⁇ / b> C of the first modification, the treatment of the opening 16 in the wiring space 20 between the semiconductor layers 8 and 8 is easy, and the electrolyte 12 leaks from the opening 16 formed on the photoelectrode 2 side. The effect that it can prevent reliably is acquired.
- Modification 2 of the second embodiment will be described with reference to FIGS. 13A and 13B.
- the same components as those in the second embodiment shown in FIGS. 11A and 11B are denoted by the same reference numerals, and the description thereof is omitted.
- the solar cell 1D of Modification 2 includes a protective material 35 as shown in FIGS. 13A and 13B.
- the plurality of conductive materials 5 provided are provided on both the first conductive film 4 and the second conductive film 10.
- the openings 16, 16,... are also formed in the second substrate 11 and the second conductive film 10, and the second conductive film is formed in these openings 16, 16,.
- Terminals 6, 6... Connected to 10 are inserted.
- the terminals 6, 6... Connected to the first conductive film 4 and the conductive material 5 are connected to the electric wire 30 and collected, and the terminals 6 connected to the second conductive film 10 and the conductive material 5.
- 6... Are connected to the electric wire 30 for current collection, and a current collecting structure is formed in parallel.
- the solar cell 1D of the second modification can obtain an effect that current can be collected using both the photoelectrode 2 and the counter electrode 3 efficiently.
- the solar cell 1E of Modification 3 includes a semiconductor layer 8, as shown in FIG. 14, instead of the conductive material 5 between the semiconductor layers 8, 8 shown in FIGS. 13A and 13B and the protective material 35 provided on the terminal 6. Sealing materials 9 and 9 are provided on both sides of the conductive material 5 (in the direction of the arrow L2) between the eight and the wiring space 20 is formed.
- the conductive material 5 connected to the first conductive film 4 in the wiring space 20 and the conductive material 5 connected to the second conductive film 10 are disposed to face each other, the conductive material 5 between these conductive materials 5 and 5 is disposed. An insulating material 31 is interposed between the two. Even in the case of such a configuration, the solar cell 1E is efficiently collected from the first conductive film 4 and the second conductive film 10 in one cell C by connecting the electric wire 30 to each terminal 6. The effect that it can be electrified is acquired.
- the solar cell 1E of Modification 3 is reliably separated from the terminals 6, 6,. can do. Moreover, since the solar cell 1E of the modification 3 can be isolated from the electrolyte 12 only by installing the conductive material 5 in the wiring space 20, an effect that the manufacturing can be simplified is obtained.
- the processing of the opening 16 in the wiring space 20 between the semiconductor layers 8 and 8 is simplified, and it is possible to reliably prevent the electrolyte 12 from leaking from the opening 16. The effect that it can be obtained.
- the sealing materials 9 and 9 are arranged on both sides of the semiconductor layer 8 to form a plurality of internal spaces S and wiring spaces 20, and the internal spaces S and the wiring spaces 20 are set as a pair.
- An insulating band 15 is provided in one conductive film 4 and the second conductive film 10 to form a plurality of cells C, C,.
- the insulating band 15 is located on one side (left side in the present embodiment) of the sealing materials 9 and 9 forming each wiring space 20, and the first conductive film 4 and the second conductive film 10 Is formed.
- the quality of the solar cell 1F can be improved by adopting a configuration that can reliably prevent the electrolyte 12 from leaking into the wiring space 20. Moreover, although it is desirable for the structure of the solar cell 1F to seal the opening part 16, since it is not necessary to seal strictly, the effect that manufacturing efficiency can be improved is acquired.
- the conductive material 5 disposed between the semiconductor layers 8 is a linear one.
- the conductive material 5 may use a paste-like conductive material.
- the conductive material 5 is preferably fixed to the first conductive film 4 or the second conductive film 10 with a terminal 6 or a conductive paste. With such a configuration, the conductive material 5 is stably fixed to the photoelectrode 2 or the counter electrode 3, and the effect that the quality of the solar cell 1A can be improved is obtained.
- the solar cells 1A to 1F are provided between the semiconductor layers 8 and 8, at one end 1a and the other end 1b.
- the conductive material 5 is continuously arranged in the direction of the arrow L1, but this configuration is not essential in the present invention, and a part of the one end 1a and the other end 1b are formed between the semiconductor layers 8 and 8 described above. Even if it has this structure, the effect of the present invention can be obtained.
- the conductive material 5 it is not essential that the conductive material 5 is continuous in the direction of the arrow L1, and the conductive material 5 is locally disposed at one place where the terminal 6 is disposed.
- the conductive material 5 may be partially arranged, or the conductive material 5 may be interrupted in the arrow L1 direction.
- this invention uses the electrolyte 12 of a liquid or solid state. Can also be implemented.
- it is set as the structure which sealed the arrow L2 direction which crosses in the arrow L1 direction which the sealing material 9 extends by ultrasonic welding, it seals suitably with sealing methods other than ultrasonic welding. It may stop.
- the structure of this invention is limited to such a structure.
- the semiconductor layer 8 may be formed in one or more rows.
- the solar cells 1A to 1F shown in the first to third embodiments and the first to third modifications of the second embodiment are connected to the solar cells 1A to 1F or in combination with each other.
- An electrical structure may be formed.
- a plurality of openings 16 are formed at intervals in the direction of the arrow L1, but one opening 16 is formed because it can be easily formed at an arbitrary position. It may be made, or a plurality of pieces other than those shown in the embodiment may be formed.
- the solar cell 1 ⁇ / b> A preferably has a configuration in which the conductive material 5 is installed on the first conductive film 4 or the second conductive film 10 that extends outside the sealing material 9 at both ends in the width direction.
- the effect of the present invention can be obtained even if the above configuration is adopted only at one end in the width direction.
Abstract
Description
本願は、2014年2月17日に日本に出願された特願2014-027962号に基づき優先権を主張し、その内容をここに援用する。
特許文献1に記載された色素増感太陽電池は、特許文献1の図1に示されているように、第一の基板の一方の板面に一の導電性金属層を備え、この第一の導電性金属層の表面に多孔質の絶縁材(導電性金属層と導電性基板との短絡を防止する部材)を配し、前記多孔質の絶縁材の表面に、前記第一の導電性金属層に対向配置させる他の導電性金属層を設け、更に前記他の導電性金属層の上面に半導体層を備えた構成となっている。そして、前記色素増感太陽電池は、前記第一の基板に透明基板を対向配置させ、対向配置させた基板の外周部同士を封止材により貼り合わせて内部空間を形成している。
この太陽電池は、内部空間に電解液を充填するとともに、絶縁層の表面に金属導電層を成膜させた取り出し電極を、太陽電池の第一の電極の導電性金属層と他の電極の導電性金属層とに接触するように配した上で、封止材から突出させた構成を採用している。
また、上記太陽電池は、取り出し電極の一端を一電気モジュールの内部空間に挿入し、同他端を封止材よりも外方に突出させる構成を採用していたため、一モジュールごとに製造する必要があり、連続生産に不向きであるという問題があった。
そこで、本発明は、上記課題に鑑み、集電効率を向上させて抵抗値を低減させた高品質な電気モジュール及びその製造方法を提供する。
なお、本願において「電解質」には、電解液、ゲル状の電解質及び固体状の電解質が含まれる。
この構成によれば、集電時に光電極又は対向電極の少なくとも一方において低抵抗、かつ、広い領域での導電が可能となり、それにより効率的に集電することができる。
この構成によれば、端子を光電極の第一の基板の板面及び/又は対向電極の第二の基板の板面から容易に取り出すことができる。
また、開口部が複数形成されている場合には、任意の端子から電流を取り出すことができる。
この構成によれば、導電材の任意の位置において端子を光電極と対向電極との間から容易に取り出すことができる。
この構成によれば、導電材を安定的に光電極又は対向電極に固定することができる。
本発明の電気モジュールにおいては、前記第一の導電膜及び前記第二の導電膜の両方が、前記内部空間から電気的に連続した状態で前記封止材を越えて前記内部空間の外側に延設され、ここで前記第一の導電膜及び前記第二の導電膜は、前記内部空間を挟んで反対側に延設されており、かつ、前記第一の導電膜及び前記第二の導電膜の延設された部分のそれぞれの表面上に、前記部分と導通可能な状態で導電材が配されていることが好ましい。
この構成によれば、集電時に光電極及び対向電極の両方において低抵抗、かつ、広い領域での導電が可能となり、それによりより一層効率的に集電することが可能になる。
この構成によれば、光電極と対向電極との貼り合せにおいて端子の取出し位置を予め考慮することなく、容易に電気モジュールを製造することができる。
この構成によれば、上記いずれかの電気モジュールを一方向に搬送しつつ連続して製造する、例えばRoll to Roll生産等の連続生産を容易に行うことができる。
また、本発明の電気モジュールの製造方法によれば、本発明の電気モジュールを連続生産で簡便かつ効率的に製造することができるという効果を奏する。
また、電解質としてゲル電解質を用いて電気モジュールが製造された場合を例として説明する。
図1又は図2に示すように、本発明の第1実施形態である太陽電池1Aは、第一の導電膜4が成膜された第一の基板7に半導体層8が形成された光電極2と、第二の導電膜10が成膜された第二の基板11を備えた対向電極3と、電解質12とを備え、光電極2と対向電極3とが、これらの間に内部空間Sを形成するように貼り合わされて封止され(封止部Pを形成)、前記電解質12は前記内部空間Sに充填されている発電素子(セルともいう)Cを複数備え、封止部Pのうち矢印L1方向に延在する部分は、第一の導電膜4と第二の導電膜10とを封止材9によって接着させて形成され、内部空間Sから電気的に連続した状態で封止材9を越えて内部空間Sの外側に互いに反対方向に延設させた第一の導電膜4及び/又は第二の導電膜10のそれぞれの表面に、これと導通可能な状態で導電材5が接続されていることを特徴としている。そして、本実施形態では、各発電素子Cが直列接続されている。
詳細には、太陽電池1Aは、以下のように構成されている。
第一の導電膜4には、矢印L1方向に延びて一つのセルの区切りとなる条状の絶縁帯15が半導体層8を挟むようにして一定間隔で半導体層8の幅方向の両側に形成されている。
第二の導電膜10には、矢印L1方向に延びて一つのセルの区切りとなる条状の絶縁帯15が、第一の導電膜4に形成された絶縁帯15と矢印L2方向の一方寄り(本実施形態では右寄り)に位置をずらして、かつ、半導体層8を間に挟むように一定間隔で半導体層8の幅方向両側に形成されている。
第一の導電膜4及び第二の導電膜10の少なくともいずれかは、透明導電膜により形成されている。
また、第一の基板7と第一の導電膜4との組み合わせ、及び第二の基板11と第二の導電膜10との組み合わせのうち、少なくとも一方の組み合わせにおいては、基板と導電膜が共に透明であることが望ましい。
また、第二の導電膜10の表面に成膜される触媒層としては、カーボンペースト、プラチナ等が採用されている。
封止部Pは、隣り合う半導体層8,8の間及び矢印L2方向の両端1a,1bには封止材9を2列ずつ矢印L1方向に配して第一の導電膜4と第二の導電膜10とをこの封止材9を介して接着させることにより形成され、矢印L2方向には超音波融着等により第一の基板7と第二の基板11とを融着させて形成されている。
なお、封止材9としては、第一の導電膜4及び第二の導電膜10の機能を害さない材質の接着剤、例えばホットメルト樹脂等が好適に用いられる。
このようにして、一端1aの配線空間20内の導電材5は、隣り合うセルCと直列接続を構成している。
開口部16を封止する封止材(不図示)は、一端1aの端子6と開口される第一の導電膜4とを可及的に密着させて良好な導通を図ることが好ましいため、一端1a側の開口部16には、導電性のある材料のものが好適に用いられる。
また、一端1aと同様に、他端1bにおける導電材5は、第一の導電膜4と確実に離間させていることが望ましい。また、そのために、導電材5と第一の導電膜4との間に絶縁材(不図示)を配していることがより望ましい。
また、他端1bの端子6は第一の導電膜4と導通しないことが好ましいので、開口部16を封止する封止材(不図示)は、他端1b側の開口部16には、導電性を有しない材料のものが好適に用いられる。
線状の導電材5は、第一の導電膜4又は第二の導電膜10の表面に配されセルCにおいて生ずる電気を集電することができるようになっている。この導電材5は、ペースト状の補助導電材5aを介して第一の導電膜4又は第二の導電膜10に対し接触面積を大きくして配置されていることが好ましい。そして、接触面積を大きくしてITO等の導電膜よりも低抵抗の導電材5が配されていることにより、太陽電池1Aは、光電極2及び対向電極3における電子の移動が低抵抗化及び短距離化されることによる集電作業の効率化が図られている。
なお電解質12としては、例えば、アセトニトリル、プロピオニトリル等の非水系溶剤、又はヨウ化ジメチルプロピルイミダゾリウム若しくはヨウ化ブチルメチルイミダゾリウム等のイオン液体などの液体成分に、ヨウ化リチウム等の支持電解液とヨウ素とが混合された溶液等が用いられている。また、電解質12は、逆電子移動反応を防止するため、t-ブチルピリジンを含むものでもよい。
そして、太陽電池1Aは、矢印L2方向の両端1a,1bにおいて導電材5に端子6が接続され、端子6が開口部16を介して光電極2の板面から突出して電流を任意の端子6から容易に取り出せるようになっている。
なお、半導体層8,8間の配線空間20には、一端1a及び他端1bと同様に開口部16が形成され、この開口部16に端子が挿入されていてもよい。この構成によれば、直列接続させる発電素子を増減させることができる。
太陽電池1Aの製造方法の一実施形態は、(I)第一の導電膜4が成膜された第一の基板7に半導体層8が形成された光電極2と、第二の導電膜10が成膜された第二の基板11を備えた対向電極3とをそれぞれ矢印L1方向に延在するよう連続的に繰り出す繰り出し工程と、(II)光電極2と対向電極3とを、これらの間に内部空間Sを形成するように貼り合せて封止し、この際、前記光電極2と対向電極3と間の封止部Pの少なくとも一部の形成を封止材9により行い、内部空間Sから電気的に連続した状態で封止材9を越えて内部空間Sの外側に延設させた第一の導電膜4又は第二の導電膜10のいずれかの表面に導電材5を配する封止工程及び導電材配置工程を備えていることを特徴としている。
以下、各工程について説明する。
図3A、図3Bに示すように、繰り出し工程の前に、まず、例えばロール状に巻回しておいた第一の基板7を一方向(矢印L1方向)に引き出し、その一方の板面に第一の導電膜4を成膜し、更に第一の導電膜4の表面に半導体層8を形成し色素を担持させた光電極2を用意しておく。なお、予め、第一の基板7の一方の板面に第一の導電膜4が形成されたロール状の基材を使用してもよい。
また、同様にして、例えばロール状に巻回しておいた第二の基板11に第二の導電膜10を成膜した対向電極3を用意しておく。予め、第二の基板11の一方の板面に第二の導電膜10が形成されたロール状の基材を使用してもよい。
繰り出し工程では、光電極2と対向電極3とを矢印L1方向(一方向)に連続して帯状に延在するように繰り出しておく。
光電極2の幅方向(矢印L2方向)の一端1a側には、図3A、図3Bに示すように、ペースト状の補助導電材5aを帯状に配しておくことが好ましい。
また更に、図4A、図4Bに示すように、光電極2の幅方向の両端1a,1bに矢印L1方向に間隔を空けて開口部16を形成しておくことが好ましい。
そして、図5A、図5Bに示すように、開口部16(図4A参照)に端子6を貫通させておく。
次に、図6A、図6Bに示すように、端子6及び第一の導電膜4上の補助導電材5aに接触するように線状の導電材5を矢印L1方向に配置するとともに、半導体層8,8同士の間にも線状の導電材5を矢印L1方向に配置する。封止材9,9は、各線上の導電材5を間に挟むように矢印L1方向に連続して配置する。この際、光電極2の幅方向(矢印L2方向)の他端1b側の導電材5上にはペースト状の補助導電材5aを帯状に配しておく。この封止材9,9を配することにより、光電極2と対向電極3とを貼り合せた際に内部空間Sと分離した配線空間20が形成される。
そして、半導体層8の表面に電解質12を塗布又は滴下する。
また、対向電極3についても、この対向電極3を図7A、図7Bに示すように光電極2に貼り合せた際に、半導体層8同士の間で第一の導電膜4に形成された絶縁帯15と矢印L2の一方向に位置をずらして矢印L1方向に連続して延びる条状の絶縁帯15を、第二の導電膜10に予め形成しておく。
以上の工程により、図1又は図2に示す半導体層8及び電解質12を備えた内部空間Sと、導電材5を備えた配線空間20とが形成され、配線空間20で導電材5により一方のセルCの第一の導電膜4と同他方のセルCの第二の導電膜10とが接続されて、直列接続構造を有する太陽電池1Aが得られる。
また、太陽電池1Aは、更に上記理由から太陽電池1Aのサイズ又は設計の自由度が高いという効果が得られる。
次に、本発明の第2実施形態について図11A、図11Bを用いて説明する。本実施形態において、第1実施形態と同一の構成については同一の符号を付しその説明を省略する。
図11A、図11Bに示すように、本実施形態の太陽電池1Bは、一のセルCの内部空間Sに複数の導電材5を配して集電構造を形成し、この集電構造を並列に設けている点で第1実施形態と異なっている。
導電材5は、一端1a、半導体層8,8間及び他端1bに配されており、一端1a及び他端1bにおいては、補助導電材5aを介して、半導体層8,8間においては補助導電材5aを介さず導電膜4側のみに接するように配されている。補助導電材5aは、半導体層8,8間の導電材5の下方にも設けられているとなおよい。
半導体層8,8間の導電材5の表面には、端子6を含んで全体が電解質12に接触しないように保護材35が設けられている。
このような構成とすることにより、太陽電池1Bは、各端子6に電線30を接続させて一つのセルCにおいて第一の導電膜4の全体に亘って導通を確保しつつ効率的に集電することができるという効果が得られる。
次に、第2実施形態の変形例1について図12を用いて説明する。
本変形例1の太陽電池1Cは、図11A、図11Bに示す半導体層8,8間の導電材5及び端子6に設けられた保護材35に代えて、図12に示すように半導体層8,8同士の間であって導電材5(矢印L2方向)の両側に封止材9,9を設け、配線空間20を形成している。また導電材5と第二の導電膜10との間に絶縁材31を介装させている。
また、変形例1の太陽電池1Cは、内部空間Sと分離した配線空間20に導電材5を配しているため、端子6,6・・及び導電材5を電解質12から確実に分離して保護することができる。
また、変形例1の太陽電池1Cは、半導体層8,8間の配線空間20における開口部16の処理も簡便となるとともに、光電極2側に形成された開口部16から電解質12が漏出することを確実に防止することができるという効果が得られる。
次に、第2実施形態の変形例2について図13A、図13Bを用いて説明する。本変形例2において図11A、図11Bに示す第2実施形態と同一の構成については同一の符号を付し、その説明を省略する。
変形例2の太陽電池1Dは、複数の導電材5を光電極2側にのみ設けた図11A、図11Bの第2実施形態と異なり、図13A、図13Bに示すように、保護材35を備えた複数の導電材5を第一の導電膜4と第二の導電膜10との双方に設けている。
本変形例2の太陽電池1Dは、光電極2及び対向電極3の双方を効率的に利用して集電することができるという効果が得られる。
次に、第2実施形態の変形例3について図14を用いて説明する。本変形例3において変形例1及び2と同一の構成については同一の符号を付し、その説明を省略する。
変形例3の太陽電池1Eは、図13A、図13Bに示す半導体層8,8間の導電材5及び端子6に設けられた保護材35に代えて、図14に示すように半導体層8,8同士の間であって導電材5(矢印L2方向)の両側に封止材9,9を設け、配線空間20を形成している。
このような構成とした場合であっても、太陽電池1Eは、各端子6に電線30を接続させて一つのセルCにおいて第一の導電膜4及び第二の導電膜10から効率的に集電することができるという効果が得られる。
本実施形態の太陽電池1Fは、図14に示す第2実施形態の変形例3の太陽電池1Eの一部を変形させて複数の発電素子(セル)C,C・・を並列接続させている。
絶縁帯15は、各配線空間20を形成している封止材9,9のいずれか一方側(本実施形態では左側)の位置で、第一の導電膜4と第二の導電膜10とに形成されている。
また、導電材5は、端子6又は導電ペースト等により、第一の導電膜4又は第二の導電膜10に固定されていることが好ましい。このような構成により、導電材5が光電極2又は対向電極3に安定的に固定され、太陽電池1Aの品質を向上させることができるという効果が得られる。
また、本発明において、導電材5が矢印L1方向の全体に連続していることは必須であるわけではなく、導電材5が端子6を配する一カ所に局所的に配されているのでなければ、導電材5が部分的に配されていたり、導電材5が矢印L1方向に途切れていてもよい。
また、上記実施形態においては封止材9が延設する矢印L1方向に交叉する矢印L2方向を超音波溶着で封止した構成とされているが、超音波溶着以外の封止方法により適宜封止するものであってもよい。
また、上記第1実施形態から第3の実施形態及び第2の実施形態の変形例1~3で示した太陽電池1A~1Fは、それぞれの太陽電池1A~1F又は互いに組み合わせて接続構造又は集電構造を形成してもよい。
2 光電極
3 対向電極
4 第一の導電膜
5 導電材
6 端子
7 第一の基板
8 半導体層
9 封止材
10 第二の導電膜
11 第二の基板
12 電解質
16 開口部
P 封止部
Claims (7)
- 第一の導電膜が成膜された第一の基板に半導体層が形成された光電極と、第二の導電膜が成膜された第二の基板を備えた対向電極と、電解質とを備え、前記光電極と前記対向電極とが、これらの間に内部空間を形成するように貼り合わされて封止され、前記電解質は前記内部空間に充填されており、
前記光電極と対向電極と間の封止部の少なくとも一部は、前記第一の導電膜と前記第二の導電膜とを封止材によって接着させて形成され、
前記第一の導電膜及び前記第二の導電膜のうち、少なくとも一方が前記内部空間から電気的に連続した状態で前記封止材を越えて前記内部空間の外側に延設されており、かつ、延設された部分の表面上に、前記部分と導通可能な状態で導電材が配されていることを特徴とする電気モジュール。 - 前記導電材には、端子が接続され、
前記光電極及び前記対向電極の少なくとも一方には前記端子を露出させる開口部が一以上形成されていることを特徴とする請求項1に記載の電気モジュール。 - 前記導電材には、端子が接続され、
前記端子は、前記光電極と前記対向電極との間から、かつ、前記光電極又は前記対向電極の外縁から突出するように設けられていることを特徴とする請求項1に記載の電気モジュール。 - 前記導電材は、前記端子により前記第一の導電膜及び前記第二の導電膜の少なくとも一方に固定されていることを特徴とする請求項2又は3に記載の電気モジュール。
- 前記第一の導電膜及び前記第二の導電膜の両方が、前記内部空間から電気的に連続した状態で前記封止材を越えて前記内部空間の外側に延設され、ここで前記第一の導電膜及び前記第二の導電膜は、前記内部空間を挟んで反対側に延設されており、かつ、前記第一の導電膜及び前記第二の導電膜の延設された部分のそれぞれの表面上に、前記部分と導通可能な状態で導電材が配されていることを特徴とする、請求項1~4のいずれかに記載の電気モジュール。
- 第一の導電膜が成膜された第一の基板に半導体層が形成された光電極と、第二の導電膜が成膜された第二の基板を備えた対向電極とをそれぞれ一方向に延在するよう連続的に繰り出す工程と、
前記光電極と前記対向電極とを、これらの間に内部空間を形成するように貼り合せて封止し、この際、前記光電極と対向電極と間の封止部の少なくとも一部の形成を封止材を用いて行い、前記第一の導電膜及び前記第二の導電膜のうち、少なくとも一方を前記内部空間から電気的に連続した状態で前記封止材を越えて前記内部空間の外側に延設させた状態とする封止工程と、
前記導電膜の延設された部分の表面上に導電材を配する導電材配置工程とを備えていることを特徴とする電気モジュールの製造方法。 - 前記封止材は、前記一方向に交叉する方向の少なくとも一端側に、前記一方向に延設させ、
前記導電材は、前記一方向に平行に配されていることを特徴とする請求項6に記載の電気モジュールの製造方法。
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