WO2015174219A1 - Module de production d'énergie solaire et procédé de fabrication de module de production d'énergie solaire - Google Patents

Module de production d'énergie solaire et procédé de fabrication de module de production d'énergie solaire Download PDF

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Publication number
WO2015174219A1
WO2015174219A1 PCT/JP2015/062034 JP2015062034W WO2015174219A1 WO 2015174219 A1 WO2015174219 A1 WO 2015174219A1 JP 2015062034 W JP2015062034 W JP 2015062034W WO 2015174219 A1 WO2015174219 A1 WO 2015174219A1
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Prior art keywords
electrode substrate
thermosetting
conductive material
conductive film
ultraviolet curable
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PCT/JP2015/062034
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English (en)
Japanese (ja)
Inventor
中井康晴
和田好史
三好正子
倉谷康浩
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株式会社村田製作所
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Publication of WO2015174219A1 publication Critical patent/WO2015174219A1/fr

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    • 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
    • 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 a photovoltaic module that generates power by irradiated light and a method for manufacturing the photovoltaic module.
  • a conventional dye-sensitized photovoltaic module has a structure as shown in Patent Document 1, for example.
  • a conventional dye-sensitized photovoltaic module uses a first substrate on which a porous semiconductor film carrying a dye is formed and a second substrate on which a catalyst layer is formed.
  • the first substrate and the second substrate are bonded using a sealing material so that the porous semiconductor film side and the catalyst layer side face each other and the porous semiconductor film and the catalyst layer are separated from each other.
  • An electrolytic solution is sealed in a hollow portion formed by bonding the first and second substrates.
  • Electrodes for taking out the current generated by the photovoltaic module are formed on the surface of the first substrate on which the porous semiconductor film is formed and on the surface of the second substrate on which the catalyst layer is formed. .
  • an ultraviolet curable material is often used as the sealing material without using a thermosetting material.
  • substrate to the exterior as needed is inside. May have.
  • the ultraviolet curable material has a lower adhesive strength of the sealing material to the substrate than the thermosetting material, and the adhesion reliability is reduced as compared to the case where the thermosetting material is used. .
  • each electrode of the first substrate formed inside the photovoltaic module and the conductor pattern extending in the thickness direction drawn to the second substrate side are made of an ultraviolet curable material, each electrode is formed as in the case of the sealing material. The adhesive strength of the conductor pattern with respect to is reduced.
  • an object of the present invention is to provide a photovoltaic module having higher reliability than the conventional configuration and a method for manufacturing the photovoltaic module.
  • the photovoltaic module of the present invention includes a working electrode substrate, a counter electrode substrate, a sealing material, and an electrolyte layer.
  • the working electrode substrate includes a first conductive film formed on at least a part of the surface of the first insulating substrate, and a photoelectric conversion layer formed on at least a part of the surface of the first conductive film.
  • the counter electrode substrate includes a second conductive film formed on at least a part of the surface of the second insulating substrate, and a catalyst layer formed on at least a part of the surface of the second conductive film.
  • the sealing material bonds the working electrode substrate and the counter electrode substrate in a state where the photoelectric conversion layer and the catalyst layer face each other with a space therebetween.
  • the sealing material is disposed so as to surround at least a part of the photoelectric conversion layer and the catalyst layer in plan view.
  • the electrolyte layer is sealed with a working electrode substrate, a counter electrode substrate, and a sealing material.
  • the sealing material has at least two layers of a thermosetting insulating material and an ultraviolet curable insulating material in the height direction orthogonal to the flat plate surfaces of the working electrode substrate and the counter electrode substrate.
  • thermosetting insulating material an effect of suppressing deterioration in characteristics of the electrolyte layer and the photoelectric conversion layer by using an ultraviolet curable insulating material.
  • an ultraviolet curable insulating material an ultraviolet curable insulating material
  • the photovoltaic module of the present invention preferably has the following configuration.
  • the photovoltaic module sealing material is orthogonal to the first thermosetting insulating material that contacts the working electrode substrate, the second thermosetting insulating material that contacts the counter electrode substrate, and the flat surfaces of the working electrode substrate and the counter electrode substrate.
  • An ultraviolet curable insulating material sandwiched between a first thermosetting insulating material and a second thermosetting insulating material is provided along the height direction.
  • the adhesion between the sealing material, the working electrode substrate and the counter electrode substrate can be further improved.
  • the photovoltaic module of the present invention preferably has the following configuration.
  • the photovoltaic module electrically connects the second conductive film for wiring formed on the surface of the second insulating substrate and the first conductive film, or the first formed on the surface of the first insulating substrate.
  • An internal wiring conductor that conducts the conductive film for wiring and the second conductive film.
  • the internal wiring conductor has at least two layers of a thermosetting conductive material and an ultraviolet curable conductive material in the height direction.
  • the adhesiveness is improved by using the thermosetting insulating material and the thermosetting conductive material, and the characteristics of the electrolyte layer and the photoelectric conversion layer are deteriorated by using the ultraviolet curable insulating material and the ultraviolet curable conductive material. Together with the suppression effect. Thereby, the reliability of the photovoltaic module can be improved.
  • the photovoltaic module of the present invention may have the following configuration.
  • the photovoltaic module includes a working electrode substrate, a counter electrode substrate, a sealing material, an electrolyte layer, and an internal wiring conductor.
  • the working electrode substrate includes a first conductive film formed on at least a part of the surface of the first insulating substrate, and a photoelectric conversion layer formed on at least a part of the surface of the first conductive film.
  • the counter electrode substrate includes a second conductive film formed on at least a part of the surface of the second insulating substrate, and a catalyst layer formed on at least a part of the surface of the second conductive film.
  • the sealing material bonds the working electrode substrate and the counter electrode substrate in a state where the photoelectric conversion layer and the catalyst layer face each other with a space therebetween.
  • the sealing material is disposed so as to surround at least a part of the photoelectric conversion layer and the catalyst layer in plan view.
  • the electrolyte layer is sealed with a working electrode substrate, a counter electrode substrate, and a sealing material.
  • the internal wiring conductor conducts a conductive film different from the second conductive film formed on the surface of the second insulating substrate and the first conductive film. Alternatively, the internal wiring conductor conducts a conductive film different from the first conductive film formed on the surface of the first insulating substrate and the second conductive film.
  • the internal wiring conductor has at least two layers of a thermosetting conductive material and an ultraviolet curable conductive material in a height direction orthogonal to the flat plate surfaces of the working electrode substrate and the counter electrode substrate.
  • thermosetting conductive material an effect of suppressing deterioration in characteristics of the electrolyte layer and the photoelectric conversion layer by using an ultraviolet curable conductive material.
  • an ultraviolet curable conductive material an ultraviolet curable conductive material
  • the internal wiring conductor preferably has the following configuration.
  • the internal wiring conductor includes a first thermosetting conductive material that adheres to the working electrode substrate, a second thermosetting conductive material that adheres to the counter electrode substrate, a first thermosetting conductive material, and a second thermosetting conductive material. And an ultraviolet curable conductive material provided between the two.
  • thermosetting conductive material and the second thermosetting conductive material is narrower than the ultraviolet curable conductive material.
  • the manufacturing method of the photovoltaic module of this invention has the following processes.
  • This method of manufacturing a photovoltaic module has a step of forming and curing a thermosetting conductive material on at least one of the surface of the working electrode substrate and the surface of the counter electrode substrate.
  • This method for manufacturing a photovoltaic module includes a step of forming an ultraviolet curable conductive material at a position where the working electrode substrate and the counter electrode substrate are bonded to the thermosetting conductive material.
  • This method of manufacturing a photovoltaic module has a step of forming an ultraviolet curable insulating material in conformity with the shape of the sealing material on at least one of the working electrode substrate and the counter electrode substrate.
  • This method of manufacturing a photovoltaic module includes a step of bonding a working electrode substrate and a counter electrode substrate together with a thermosetting conductive material, an ultraviolet curable conductive material, and an ultraviolet curable insulating material.
  • This method for manufacturing a photovoltaic module includes a step of irradiating ultraviolet rays to an ultraviolet curable insulating material and an ultraviolet curable conductive material.
  • thermosetting conductive material in this manufacturing method, it is possible to achieve both the improvement in adhesion by using a thermosetting conductive material and the effect of suppressing deterioration of characteristics of the electrolyte layer and the photoelectric conversion layer by using an ultraviolet curable conductive material. Thereby, a photovoltaic module with high reliability can be manufactured.
  • the manufacturing method of the photovoltaic module of this invention has the following processes.
  • the step of forming and curing the thermosetting conductive material includes the step of forming and curing the first thermosetting conductive material on the surface of the working electrode substrate, and the formation of the second thermosetting conductive material on the surface of the counter electrode substrate. And curing.
  • the ultraviolet curable conductive material is formed at the tip of the cured first thermosetting conductive material or the second thermosetting conductive material.
  • thermosetting conductive material is bonded to both surfaces of the working electrode substrate and the counter electrode substrate, the reliability of bonding between the substrate and the conductive material can be improved.
  • the photovoltaic module manufacturing method of the present invention may include the following steps.
  • the step of forming and curing the thermosetting conductive material includes the step of forming and curing the first thermosetting conductive material on the surface of the working electrode substrate, and the step of forming the ultraviolet curable conductive material on the surface of the counter electrode substrate. And having.
  • the photovoltaic module manufacturing method of the present invention may include the following steps.
  • the step of forming and curing the thermosetting conductive material includes the step of forming and curing the second thermosetting conductive material on the surface of the counter electrode substrate, and the step of forming the ultraviolet curable conductive material on the surface of the working electrode substrate. And having.
  • the manufacturing method of the photovoltaic module of this invention has the following processes.
  • the thermosetting conductive material and the ultraviolet curable conductive material are layered between the working electrode substrate and the counter electrode substrate.
  • a step of forming a thermosetting conductive material and an ultraviolet curable conductive material when the working electrode substrate and the counter electrode substrate are bonded together, the thermosetting insulating material and the ultraviolet curable insulating material are layered between the working electrode substrate and the counter electrode substrate.
  • a step of forming a thermosetting insulating material and an ultraviolet curable insulating material when the working electrode substrate and the counter electrode substrate are bonded together.
  • This method for manufacturing a photovoltaic module includes a step of bonding a working electrode substrate and a counter electrode substrate together with a thermosetting conductive material and an ultraviolet curable conductive material, and a thermosetting insulating material and an ultraviolet curable insulating material.
  • This method for manufacturing a photovoltaic module includes a step of irradiating ultraviolet rays to an ultraviolet curable insulating material and an ultraviolet curable conductive material.
  • thermosetting insulating material an effect of suppressing deterioration of characteristics of an electrolyte layer and a photoelectric conversion layer by using an ultraviolet curable insulating material.
  • an ultraviolet curable insulating material an ultraviolet curable insulating material
  • the manufacturing method of the photovoltaic module of this invention has the following processes.
  • the step of forming the thermosetting insulating material and the ultraviolet curable insulating material includes the step of forming and curing the first thermosetting insulating material on the surface of the working electrode substrate, and the counter electrode substrate. Forming a second thermosetting insulating material on the surface of the substrate and curing it.
  • the step of forming the thermosetting insulating material and the ultraviolet curable insulating material includes a step of forming the ultraviolet curable conductive material at the tip of the cured first thermosetting conductive material or second thermosetting conductive material.
  • thermosetting insulating material is bonded to both surfaces of the working electrode substrate and the counter electrode substrate, the reliability of bonding between the substrate and the conductive material can be improved.
  • the photovoltaic module manufacturing method of the present invention may include the following steps.
  • the step of forming the thermosetting insulating material and the ultraviolet curable insulating material includes a step of forming and curing a first thermosetting insulating material on the surface of the working electrode substrate, and an ultraviolet curable insulating material on the surface of the counter electrode substrate. Forming.
  • the photovoltaic module manufacturing method of the present invention may include the following steps.
  • the step of forming the thermosetting insulating material and the ultraviolet curable insulating material includes a step of forming and curing a second thermosetting insulating material on the surface of the counter electrode substrate, and an ultraviolet curable insulating material on the surface of the working electrode substrate. Forming.
  • the width of at least one of the first thermosetting conductive material and the second thermosetting conductive material is narrower than the ultraviolet curable conductive material. It is preferable.
  • the irradiation efficiency of ultraviolet rays with respect to the ultraviolet curable conductive material can be improved.
  • a photovoltaic module with higher reliability than the conventional configuration can be realized.
  • the photovoltaic module concerning the 4th Embodiment of this invention it is side sectional drawing which shows the state before affixing the working electrode board
  • the photovoltaic module which concerns on the 5th Embodiment of this invention it is side sectional drawing which shows the state before affixing the working electrode board
  • FIG. 1A is a side sectional view showing the configuration of the photovoltaic module according to the first embodiment of the present invention.
  • FIG. 1B is a side sectional view showing a state before the conductive material and the insulating material of the photovoltaic module according to the first embodiment of the present invention are cured.
  • the photovoltaic module 10 includes a substantially flat working electrode substrate 21 and a counter electrode substrate 22 having a pair of main surfaces facing each other.
  • the working electrode substrate 21 and the counter electrode substrate 22 have the same outer shape (the outer peripheral shape of a flat plate in plan view in the direction orthogonal to the main surface).
  • the working electrode substrate 21 and the counter electrode substrate 22 are disposed so as to face each other so that the flat plate surfaces thereof are parallel to each other and the end sides thereof coincide with each other in plan view.
  • the working electrode substrate 21 and the counter electrode substrate 22 are bonded together by a sealing material 60.
  • the sealing material 60 is formed in an annular shape having a predetermined width along the end sides of the working electrode substrate 21 and the counter electrode substrate 22.
  • the sealing material 60 is made of an insulating material.
  • the sealing material 60 is made of UV curable resin (corresponding to “ultraviolet curable insulating material” of the present invention).
  • the working electrode substrate 21 includes a first insulating substrate 211, a first conductive film 212, and a photoelectric conversion layer 213.
  • the first insulating substrate 211 is made of a material having insulating properties and translucency.
  • the first insulating substrate 211 is made of, for example, glass, PET, or PEN.
  • the first conductive film 212 is formed on the surface of the first insulating substrate 211.
  • the first conductive film 212 is made of a material having conductivity and translucency.
  • the first conductive film 212 is made of FTO, ITO, metal mesh, or the like.
  • the first conductive film 212 is formed on substantially the entire surface of the first insulating base material 211, but is not formed in a region in contact with the first sealing wall 61 on one side of the sealing material 60. In other words, the first sealing wall 61 is in contact with a region where the first conductive film 212 is not formed in the working electrode substrate 21. Note that the first conductive film 212 has a shape that abuts against the first sealing wall 61 (a shape that overlaps in the height direction of the photovoltaic module 10) as long as the first conductive film 212 has a shape excluding at least a region where an opening 901 described later is formed. ). In this case, the bonding strength between the first sealing wall 61 and the working electrode substrate 21 can be improved.
  • the photoelectric conversion layer 213 is formed on the surface of the first conductive film 212.
  • the photoelectric conversion layer 213 is formed in a region between a region where the first sealing wall 61 is in contact with the working electrode substrate 21 and a region where the second sealing wall 62 is in contact with the first conductive film 212.
  • the photoelectric conversion layer 213 is made of a porous oxide semiconductor that has adsorbed a sensitizing dye.
  • the porous oxide semiconductor is made of, for example, titanium oxide (TiO 2 ), zinc oxide (ZnO), tin oxide (SnO), or the like.
  • the sensitizing dye includes a Ru complex dye, an indoline dye, a coumarin dye, and the like.
  • the counter electrode substrate 22 includes a second insulating substrate 221, a second conductive film 222, a conductive film 232 for wiring, and a catalyst layer 223.
  • the second insulating substrate 221 is made of a material having insulating properties and translucency.
  • the second insulating substrate 221 is made of, for example, glass, PET, or PEN. Note that at least one of the counter electrode substrate 22 and the working electrode substrate 21 may be made of a light-transmitting material.
  • the second conductive film 222 is formed on the surface of the second insulating substrate 221.
  • the second conductive film 222 and the conductive film 232 for wiring are made of a material having conductivity and translucency.
  • the second conductive film 222 and the conductive film 232 for wiring are made of FTO, ITO, metal mesh, or the like.
  • the second conductive film 222 is formed on substantially the entire surface of the second insulating substrate 221 except for a partial region including a region in contact with the second sealing wall 62.
  • the wiring conductive film 232 is formed in a partial region of the second insulating substrate 221 excluding the formation region of the second conductive film 222.
  • the conductive film 232 for wiring is separated from the second conductive film 222.
  • the catalyst layer 223 is formed on the surface of the second conductive film 222.
  • the catalyst layer 223 is formed in a region between a region where the first sealing wall 61 is in contact with the second conductive film 222 and a region where the second sealing wall 62 is in contact with the counter electrode substrate 22.
  • the catalyst layer 223 is made of a material that promotes the reduction reaction of elements of the electrolyte layer 51 (described later). For example, it is made of platinum (Pt), carbon, PEDOT or the like.
  • the electrolyte layer 51 is disposed so as to fill a hollow surrounded by the sealing material 60, the photoelectric conversion layer 213, and the catalyst layer 223. In other words, the electrolyte layer 51 is enclosed by the working electrode substrate 21, the counter electrode substrate 22, and the sealing material 60.
  • the electrolyte layer 51 is made of a solvent containing redox for reducing the dye that has been oxidized by the photoelectric effect of the photoelectric conversion layer 213.
  • redox used here is iodine redox (I ⁇ / I 3 ⁇ ), and examples of the solvent include organic solvents such as acetonitrile and propylene carbonate, and ionic liquids.
  • An opening 901 (corresponding to the “first opening” of the present invention) is formed in a region where the working electrode substrate 21 and the counter electrode substrate 22 are bonded by the first sealing wall 61 (overlapping region). Has been.
  • the opening 901 has a shape that penetrates the working electrode substrate 21 and the first sealing wall 61.
  • the second conductive film 222 is exposed on the bottom surface of the opening 901.
  • An external connection conductor 91 is formed on the surface of the second conductive film 222 constituting the bottom surface of the opening 901.
  • An opening 902 (corresponding to the “second opening” in the present invention) is formed in a region where the working electrode substrate 21 and the counter electrode substrate 22 are bonded by the second sealing wall 62 (overlapping region). Has been.
  • the opening 902 has a shape that penetrates the working electrode substrate 21 and the second sealing wall 62.
  • a conductive film 232 for wiring is exposed on the bottom surface of the opening 902.
  • An external connection conductor 92 is formed on the surface of the conductive film 232 for wiring that constitutes the bottom surface of the opening 902.
  • An internal wiring conductor 922 is formed on the photoelectric conversion layer 213, the catalyst layer 223, and the electrolyte layer 51 side of the second sealing wall 62.
  • the internal wiring conductor 922 has a shape extending in the height direction of the photovoltaic module 10 (a direction perpendicular to the flat surfaces of the working electrode substrate 21 and the counter electrode substrate 22), and the first conductive film 212, the conductive film 232 for wiring, Is connected.
  • the internal wiring conductor 922 includes thermosetting conductive materials 9221 and 9222 and an ultraviolet curable conductive material 9223.
  • One end of the thermosetting conductive material 9221 in the height direction is in contact with the working electrode substrate 21.
  • One end of the thermosetting conductive material 9222 in the height direction is in contact with the counter electrode substrate 22.
  • the ultraviolet curable conductive material 9223 is disposed between the thermosetting conductive material 9221 and the thermosetting conductive material 9222 along the height direction.
  • the ultraviolet curable conductive material 9223 is connected to the other end of the thermosetting conductive material 9221 and the other end of the thermosetting conductive material 9222.
  • thermosetting conductive materials 9221 and 9222 and the ultraviolet curable conductive material 9223 are integrated through an after-mentioned bonding process and ultraviolet irradiation process to be an internal wiring conductor 922.
  • the internal sealing wall 63 is formed on the photoelectric conversion layer 213, the catalyst layer 223, and the electrolyte layer 51 side of the internal wiring conductor 922.
  • One end in the height direction of the internal sealing wall 63 is in contact with the surface of the first conductive film 212.
  • the other end in the height direction of the inner sealing wall 63 is in contact with the surface of the second insulating substrate 221 where the second conductive film 222 and the conductive film 232 for wiring are separated.
  • the internal sealing wall 63 physically separates the wiring conductive film 232 and the internal wiring conductor 922 from the photoelectric conversion layer 213, the catalyst layer 223, and the electrolyte layer 51.
  • the second conductive film 222 may be formed so that at least a part thereof overlaps with the inner sealing wall 63 and the photovoltaic module 10 in the height direction as long as the second conductive film 222 does not contact the conductive film 232 for wiring. In this case, the bonding strength between the internal sealing wall 63 and the counter electrode substrate 22 can be improved.
  • the bonding strength of the internal wiring conductor 922 to the working electrode substrate 21 and the counter electrode substrate 22 can be kept high. Further, the connection reliability of the internal wiring conductor 922 can be kept high. Thereby, the photovoltaic module 10 with high reliability is realizable.
  • FIG. 2 is a flowchart showing a method for manufacturing a photovoltaic module according to the first embodiment of the present invention.
  • FIG. 3 is a side cross-sectional view showing a state in each manufacturing process of the working electrode substrate of the photovoltaic module according to the first embodiment of the present invention.
  • FIG. 4 is a side cross-sectional view showing a state in each manufacturing process of the counter electrode substrate of the photovoltaic module according to the first embodiment of the present invention.
  • FIG. 5 is a side cross-sectional view showing a state in each manufacturing process of making the photovoltaic module according to the first embodiment of the present invention into a cell.
  • a first insulating substrate 211 is prepared, and a transparent conductive film 212 ⁇ / b> P that becomes the first conductive film 212 is formed on the surface of the first insulating substrate 211.
  • the transparent conductive film 212P is made of, for example, ITO.
  • thermosetting conductive material 9221 is formed on the surface of the transparent conductive film 212P.
  • the thermosetting conductive material 9221 is made of, for example, a silver paste (Ag paste).
  • the thermosetting conductive material 9221 is heat-treated under a desired heating condition and cured from a paste.
  • the heating condition is, for example, 130 ° C. ⁇ 30 minutes.
  • the transparent conductive film 212P is patterned by a known method to form the first conductive film 212.
  • the conductive film non-forming portion 610 is provided in a region where the conductive film is not formed in the region where the first sealing wall 61 is disposed on the surface of the first insulating base material 211.
  • a photoelectric conversion layer 213 is formed on the surface of the first conductive film 212.
  • the photoelectric conversion layer 213 is formed by the following method, for example.
  • a zinc oxide (ZnO) paste containing ethanol as a main solvent is applied to the surface of the first conductive film 212 to form a ZnO porous layer.
  • the ZnO porous layer is immersed in a staining solution obtained by dissolving the dye D149 in ethanol for 2 hours in a room temperature atmosphere. Thereafter, excess pigment and staining solution are washed with ethanol and dried.
  • thermosetting conductive material 9221 is cured and formed is formed.
  • step S103 as shown in FIG. 4A, a second insulating substrate 221 is prepared, and a transparent conductive film 222P to be the second conductive film 222 is formed on the surface of the second insulating substrate 221. .
  • thermosetting conductive material 9222 is formed on the surface of the transparent conductive film 222P.
  • the thermosetting conductive material 9222 is also made of, for example, a silver paste (Ag paste).
  • the transparent conductive film 222P is patterned by a known method to form the second conductive film 222 and the conductive film 232 for wiring.
  • the conductive film non-formation part 630 is provided in a region where the conductive film is not formed in a region where the internal sealing wall 63 is disposed on the surface of the second insulating substrate 221.
  • a catalyst layer 223 is formed on the surface of the second conductive film 222 as shown in FIG.
  • the catalyst layer 223 is formed, for example, by sputtering platinum Pt on the surface of the second conductive film 222.
  • thermosetting conductive material 9222 is cured
  • step S105 as shown in FIG. 5A, the ultraviolet curable insulating materials 61P and 62P that become the sealing material 60 (the first sealing wall 61 and the second sealing wall 62), and the internal sealing are performed.
  • An ultraviolet curable insulating material 63 ⁇ / b> P that forms the stop wall 63 is formed on the surface of the working electrode substrate 21.
  • a material that is cured by ultraviolet irradiation and has an insulating property may be used.
  • “Toyo Ink trade name: REXWIN UA-A1” is used.
  • an ultraviolet curable conductive material is attached to the tip in the height direction (the other end in the extending direction) of the thermosetting conductive material 9222 formed on the counter electrode substrate 22.
  • 9223 is formed.
  • the ultraviolet curable conductive material 9223 a material that is cured by ultraviolet irradiation and has conductivity may be used.
  • “Hisol trade name: Elecolit 3063” is used.
  • step S107 as shown in FIG. 5C, the electrolytic layer 51 is electrolyzed in a space surrounded by a frame-shaped wall including the ultraviolet curable insulating materials 61P and 63P on the surface of the working electrode substrate 21.
  • the liquid is dropped (injected).
  • step S108 as shown in FIG. 5D, the working electrode substrate 21 and the counter electrode substrate 22 are bonded together using ultraviolet curable insulating materials 61P, 62P, and 63P.
  • the thermosetting conductive materials 9221 and 9222 are connected using the ultraviolet curable conductive material 9223.
  • step S109 ultraviolet rays are irradiated to cure the ultraviolet curable insulating materials 61P, 62P, 63P and the ultraviolet curable conductive material 9223.
  • step S110 openings 901 and 902 and external connection conductors 91 and 92 are formed.
  • the photovoltaic module 10 is formed by the manufacturing process as described above.
  • thermosetting conductive materials 9221 and 9222 are hardened at the joining positions of the working electrode substrate 21 and the counter electrode substrate 22 and the internal wiring conductor 922. Therefore, the bonding strength between the working electrode substrate 21 and the counter electrode substrate 22 and the internal wiring conductor 922 can be kept high.
  • thermosetting conductive materials 9221 and 9222 are connected by an ultraviolet curable conductive material 9223. Therefore, the connection reliability of the internal wiring conductor 922 itself can be kept high.
  • the photovoltaic module 10 having excellent power generation efficiency and high reliability can be realized.
  • FIG. 6 is a side cross-sectional view showing a state before the conductive material and the insulating material are cured in the photovoltaic module according to the second embodiment of the present invention.
  • the photovoltaic module 10 according to the first embodiment described above is an aspect in which one photovoltaic cell including a working electrode substrate, an electrolyte layer, and a counter electrode substrate is arranged.
  • the module 10A has a mode in which a plurality of photovoltaic cells (four in FIG. 6) are arranged. Further, the photovoltaic module according to the present embodiment has a mode in which a plurality of photovoltaic cells are connected in series.
  • the basic configuration of each photovoltaic cell is substantially the same as the configuration of the photovoltaic module 10 of the first embodiment described above.
  • the photovoltaic module 10A includes photovoltaic cells 11A, 12A, 13A, and 14A in one casing.
  • Each photovoltaic cell 11A, 12A, 13A, 14A has a configuration sandwiched between the working electrode substrate 21A and the counter electrode substrate 22A, and has a configuration in which the first sealing wall 61 and the second sealing wall 62 are sequentially arranged. Become.
  • the first photovoltaic cell 11A is partitioned by internal sealing walls 631 and 632, and has a laminated structure of a first conductive film 2121, a photoelectric conversion layer 2131, an electrolyte layer 511, a catalyst layer 2231, and a second conductive film 2221. Become.
  • the second photovoltaic cell 12A is partitioned by internal sealing walls 633 and 634, and has a laminated structure of a first conductive film 2122, a photoelectric conversion layer 2132, an electrolyte layer 512, a catalyst layer 2232, and a second conductive film 2222. Become.
  • the third photovoltaic cell 13A is delimited by internal sealing walls 635 and 636, and has a laminated structure of a first conductive film 2123, a photoelectric conversion layer 2133, an electrolyte layer 513, a catalyst layer 2233, and a second conductive film 2223. Become.
  • the fourth photovoltaic cell 14A is partitioned by the inner sealing wall 637 and the second sealing wall 62, and the first conductive film 2124, the photoelectric conversion layer 2134, the electrolyte layer 514, the catalyst layer 2234, and the second conductive film. It consists of 2224 laminated structures.
  • the first conductive film 2121 of the first photovoltaic cell 11A is connected to the conductive film 2220 for wiring by the internal wiring conductor 922A surrounded by the first sealing wall 61 and the internal sealing wall 631.
  • the external connection conductor 91 is exposed to the outside through an opening 901 provided in the first sealing wall 61 and the working electrode substrate 21A.
  • the internal wiring conductor 922A includes thermosetting conductive materials 9221 and 9222 and an ultraviolet curable conductive material 9223.
  • the thermosetting conductive material 9221 is connected to the first conductive film 2121, and the thermosetting conductive material 9222 is connected to the conductive film 2220 for wiring.
  • the ultraviolet curable conductive material 9223 connects the thermosetting conductive material 9221 and the thermosetting conductive material 9222.
  • the second conductive film 2221 of the first photovoltaic cell 11A and the first conductive film 2122 of the second photovoltaic cell 12A are connected by the internal wiring conductor 922B surrounded by the internal sealing walls 632 and 633. Yes.
  • the internal wiring conductor 922B is also composed of thermosetting conductive materials 9221 and 9222 and an ultraviolet curable conductive material 9223.
  • the first conductive film 2122 corresponds to the “first wiring conductive film” of the present invention
  • the second conductive film 2221 corresponds to the “second wiring conductive film” of the present invention. .
  • the second conductive film 2222 of the second photovoltaic cell 12A and the first conductive film 2123 of the third photovoltaic cell 13A are connected by an internal wiring conductor 922C surrounded by the internal sealing walls 634 and 635. Yes.
  • the internal wiring conductor 922C is also composed of thermosetting conductive materials 9221 and 9222 and an ultraviolet curable conductive material 9223.
  • the first conductive film 2123 corresponds to the “first wiring conductive film” of the present invention
  • the second conductive film 2222 corresponds to the “second wiring conductive film” of the present invention. .
  • the second conductive film 2223 of the third photovoltaic cell 13A and the first conductive film 2124 of the fourth photovoltaic cell 14A are connected by an internal wiring conductor 922D surrounded by internal sealing walls 636 and 637. Yes.
  • the internal wiring conductor 922D is also composed of thermosetting conductive materials 9221 and 9222 and an ultraviolet curable conductive material 9223.
  • the first conductive film 2124 corresponds to the “first wiring conductive film” of the present invention
  • the second conductive film 2223 corresponds to the “second wiring conductive film” of the present invention. .
  • Part of the second conductive film 2224 of the fourth photovoltaic cell 14A is the bottom surface of the opening 902, and the external connection conductor 92 is formed on the surface.
  • the external connection conductor 92 is exposed to the outside through the opening 902 provided in the second sealing wall 62 and the working electrode substrate 21A.
  • FIG. 7A is a side sectional view showing a state before the working electrode substrate and the counter electrode substrate are attached to each other in the photovoltaic module according to the third embodiment of the present invention.
  • FIG. 7B is a side cross-sectional view showing a state before the conductive material and the insulating material are cured in the photovoltaic module according to the third embodiment of the present invention.
  • the photovoltaic module 10B according to the present embodiment is different from the photovoltaic module 10 according to the first embodiment in the shape of the thermosetting conductive material 9221B constituting the internal wiring conductor. Other configurations are the same as those of the photovoltaic module 10 according to the first embodiment.
  • the internal wiring conductor of the photovoltaic module 10B includes thermosetting conductive materials 9221 and 9222B and an ultraviolet curable conductive material 9223.
  • the width of the thermosetting conductive material 9222B is narrower than the width of the thermosetting conductive material 9221.
  • the ultraviolet curable conductive material 9223 can be effectively irradiated with ultraviolet rays even after the working electrode substrate 21 and the counter electrode substrate 22 are bonded together.
  • substrate 22 narrower than the width
  • thermosetting conductive material of the both sides may be made the thermosetting conductive material of the both sides of an ultraviolet curable conductive material thin.
  • the width of the thermosetting conductive material on both sides may be the same or different.
  • FIG. 8A is a side sectional view showing a state before the working electrode substrate and the counter electrode substrate are attached to each other in the photovoltaic module according to the fourth embodiment of the present invention.
  • FIG. 8B is a side cross-sectional view showing a state before the conductive material and the insulating material are cured in the photovoltaic module according to the fourth embodiment of the present invention.
  • the photovoltaic module 10C according to the present embodiment is different from the photovoltaic module 10 according to the first embodiment in the combination of the thermosetting conductive material and the ultraviolet curable conductive material constituting the internal wiring conductor. Other configurations are the same as those of the photovoltaic module 10 according to the first embodiment.
  • the internal wiring conductor has a two-layer structure of a thermosetting conductive material 9222 and an ultraviolet curable conductive material 9223. That is, the thermosetting conductive material 9221 is omitted.
  • the ultraviolet curable conductive material 9223 is formed on the surface of the working electrode substrate 21.
  • the bonding strength of the internal wiring conductor to one working electrode substrate 21 can be increased, and the reliability can be improved as compared with the case where all of the internal wiring conductor is formed of an ultraviolet curable conductive material.
  • the ultraviolet curable conductive material 9223 may be formed on the counter electrode substrate.
  • An ultraviolet curable conductive material 9223 may be formed on the light-transmitting substrate side.
  • FIG. 9A is a side sectional view showing a state before the working electrode substrate and the counter electrode substrate are attached to each other in the photovoltaic module according to the fifth embodiment of the present invention.
  • FIG. 9B is a side sectional view showing a state before the conductive material and the insulating material are cured in the photovoltaic module according to the fifth embodiment of the present invention.
  • the photovoltaic module 10D of this embodiment is a photovoltaic module 10 according to the first embodiment in that the sealing material and the internal sealing wall have a three-layer structure of a thermosetting insulating material and an ultraviolet curable insulating material. And different. Other configurations are the same as those of the photovoltaic module 10 according to the first embodiment.
  • the first sealing wall 61 of the photovoltaic module 10D is composed of thermosetting insulating materials 611P and 612P and an ultraviolet curable insulating material 613P.
  • the second sealing wall 62 is composed of thermosetting insulating materials 621P and 622P and an ultraviolet curable insulating material 623P.
  • the inner sealing wall 63 is composed of thermosetting insulating materials 631P and 632P and an ultraviolet curable insulating material 633P.
  • thermosetting insulating materials 611P, 621P, 631P are formed on the surface of the working electrode substrate 21.
  • the thermosetting insulating materials 612P, 622P, and 632P are formed on the surface of the counter electrode substrate 22.
  • the ultraviolet curable insulating materials 613P, 623P, and 633P are interposed between the thermosetting insulating materials 611P and 612P, between the thermosetting insulating materials 621P and 622P, and between the thermosetting insulating materials 631P and 632P, respectively. Yes.
  • the bonding strength of the sealing material to the working electrode substrate 21 and the counter electrode substrate 22 can be increased. Thereby, reliability can be improved rather than forming a sealing material only with an ultraviolet curable insulating material.
  • FIG. 10 is a flowchart showing a method for manufacturing a photovoltaic module according to the fifth embodiment of the present invention.
  • steps S101 to S104 are the same as those in the first embodiment, description thereof will be omitted.
  • thermosetting insulating materials 611P and 621P that become part of the sealing material and thermosetting insulating material 631P that becomes the internal sealing material are formed on the surface of the working electrode substrate 21.
  • thermosetting insulating materials 612P and 622P that are part of the sealing material and thermosetting insulating material 632P that is the internal sealing material are formed on the surface of the counter electrode substrate 22.
  • step S105 ultraviolet curable insulating materials 613P, 623P, and 633P, which become a part of the sealing material, are formed at the tips in the height direction of the cured thermosetting resins 612P, 622P, and 632P, respectively.
  • step S106 an ultraviolet curable conductive material 9223 is formed at the tip in the height direction of the thermosetting conductive material 9222 formed on the counter electrode substrate 22.
  • step S107 includes a wall made of thermosetting insulating material 612P and ultraviolet curable insulating material 613P on the surface of counter electrode substrate 22, and a wall made of thermosetting insulating material 632P and ultraviolet curable insulating material 633P.
  • An electrolytic solution to be the electrolyte layer 51 is dropped (injected) into a space surrounded by the frame shape.
  • step S108 the working electrode substrate 21 and the counter electrode substrate 22 are bonded together using ultraviolet curable insulating materials 613P, 623P, and 633P.
  • the thermosetting conductive materials 9221 and 9222 are connected using the ultraviolet curable conductive material 9223.
  • step S109 ultraviolet rays are irradiated to cure the ultraviolet curable insulating materials 613P, 623P, 633P and the ultraviolet curable conductive material 9223.
  • the photovoltaic module 10D is formed by the manufacturing process as described above.
  • the sealing material may be formed by a two-layer structure of a thermosetting insulating material and an ultraviolet curable insulating material.
  • the thermosetting insulating material may be in contact with either the working electrode substrate 21 or the counter electrode substrate 22.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Hybrid Cells (AREA)
  • Photovoltaic Devices (AREA)

Abstract

Cette invention concerne un module de production d'énergie solaire (10), comprenant : un substrat d'électrode de travail (21), un substrat d'électrode auxiliaire (22), une couche d'électrolyte (51) et un élément d'encapsulation (60). Le substrat d'électrode de travail (21) et le substrat d'électrode auxiliaire (22) sont collés par l'élément d'encapsulation (60). La couche d'électrolyte (51) est entourée par le substrat d'électrode de travail (21), le substrat d'électrode auxiliaire (22), et l'élément d'encapsulation (60). Le substrat d'électrode de travail (21) comprend un premier film conducteur (212), et le substrat d'électrode auxiliaire (22) comprend un second film conducteur (222) et un film conducteur de câblage (232). Le premier film conducteur (212) et le film conducteur de câblage (232) sont connectés par un conducteur de câblage interne (922). Le conducteur de câblage interne (922) comprend un matériau conducteur de type thermodurcissable (9221) se connectant au premier film conducteur (212), un matériau conducteur thermodurcissable (9222) se connectant au second film conducteur (222), et un matériau conducteur durcissant sous UV (9223) connectant les matériaux conducteurs thermodurcissables (9221, 9222).
PCT/JP2015/062034 2014-05-12 2015-04-21 Module de production d'énergie solaire et procédé de fabrication de module de production d'énergie solaire WO2015174219A1 (fr)

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JP2014098444 2014-05-12

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008004556A1 (fr) * 2006-07-06 2008-01-10 Sharp Kabushiki Kaisha Module de cellule solaire sensible aux colorants et procédé de fabrication correspondant
JP2008226782A (ja) * 2007-03-15 2008-09-25 Fujikura Ltd 光電変換素子およびその製造方法
WO2011125843A1 (fr) * 2010-04-02 2011-10-13 株式会社フジクラ Dispositif électronique et procédé pour sa fabrication
WO2014038570A1 (fr) * 2012-09-07 2014-03-13 シャープ株式会社 Élément de conversion photoélectrique ainsi que procédé de fabrication de celui-ci, et module d'élément de conversion photoélectrique ainsi que procédé de fabrication de celui-ci

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008004556A1 (fr) * 2006-07-06 2008-01-10 Sharp Kabushiki Kaisha Module de cellule solaire sensible aux colorants et procédé de fabrication correspondant
JP2008226782A (ja) * 2007-03-15 2008-09-25 Fujikura Ltd 光電変換素子およびその製造方法
WO2011125843A1 (fr) * 2010-04-02 2011-10-13 株式会社フジクラ Dispositif électronique et procédé pour sa fabrication
WO2014038570A1 (fr) * 2012-09-07 2014-03-13 シャープ株式会社 Élément de conversion photoélectrique ainsi que procédé de fabrication de celui-ci, et module d'élément de conversion photoélectrique ainsi que procédé de fabrication de celui-ci

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