WO2023144866A1 - 太陽電池および太陽電池の製造方法 - Google Patents

太陽電池および太陽電池の製造方法 Download PDF

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Publication number
WO2023144866A1
WO2023144866A1 PCT/JP2022/002578 JP2022002578W WO2023144866A1 WO 2023144866 A1 WO2023144866 A1 WO 2023144866A1 JP 2022002578 W JP2022002578 W JP 2022002578W WO 2023144866 A1 WO2023144866 A1 WO 2023144866A1
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WO
WIPO (PCT)
Prior art keywords
solar cell
panel
cell panel
thickness
solar
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2022/002578
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English (en)
French (fr)
Japanese (ja)
Inventor
美雪 塩川
勝也 山下
武志 五反田
智博 戸張
穣 齊田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toshiba Corp
Toshiba Energy Systems and Solutions Corp
Original Assignee
Toshiba Corp
Toshiba Energy Systems and Solutions Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toshiba Corp, Toshiba Energy Systems and Solutions Corp filed Critical Toshiba Corp
Priority to CN202280089028.XA priority Critical patent/CN118591892A/zh
Priority to PCT/JP2022/002578 priority patent/WO2023144866A1/ja
Priority to DE112022006511.7T priority patent/DE112022006511T5/de
Priority to JP2023576269A priority patent/JP7789096B2/ja
Publication of WO2023144866A1 publication Critical patent/WO2023144866A1/ja
Priority to US18/780,579 priority patent/US20240379887A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F10/00—Individual photovoltaic cells, e.g. solar cells
    • H10F10/10—Individual photovoltaic cells, e.g. solar cells having potential barriers
    • H10F10/19—Photovoltaic cells having multiple potential barriers of different types, e.g. tandem cells having both PN and PIN junctions
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/40—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules comprising photovoltaic cells in a mechanically stacked configuration
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/804—Materials of encapsulations
    • 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

Definitions

  • Embodiments of the present invention relate to solar cells and methods for manufacturing solar cells.
  • a tandem-type solar cell in which solar cell panels are stacked.
  • a tandem solar cell includes a first solar cell panel and a light-transmissive second solar cell panel stacked on the light receiving surface side of the first solar cell panel.
  • the first solar cell panel and the second solar cell panel are made of semiconductor materials having absorption wavelength ranges different from each other. Tandem-type solar cells can convert light with a wider range of wavelengths into electrical energy compared to conventional solar cells, and have high energy conversion efficiency. Therefore, the tandem solar cell is suitable as a power source for mobile objects such as flying objects and mobility vehicles.
  • tandem solar cell when a tandem solar cell is mounted on a mobile object or the like, it is subject to weight restrictions depending on the equipment on which it is mounted. Since a tandem solar cell is formed by laminating a sealing material and a protective material on a solar cell panel, there is room for improvement in the structure of the sealing material and the protective material from the viewpoint of weight reduction. However, if the tandem-type solar cell is made thinner for the purpose of weight reduction, there is a possibility that the power generation efficiency will decrease due to, for example, irregularities occurring on the surface.
  • the problem to be solved by the present invention is to provide a highly efficient and lightweight solar cell and a method for manufacturing the solar cell.
  • a solar cell of an embodiment has a first solar cell panel, a second solar cell panel, a first sealing layer, a second sealing layer, a third sealing layer, and a first protective material.
  • the second solar cell panel is of a transmissive type arranged so as to face the light receiving surface of the first solar cell panel.
  • the first sealing layer is laminated to the second solar panel from the side opposite to the first solar panel.
  • the thickness of the first sealing layer is 50 ⁇ m or more and 400 ⁇ m or less.
  • a second encapsulant layer is disposed between the first solar panel and the second solar panel.
  • the second sealing layer is laminated so as to be in direct contact with the first solar panel and the second solar panel.
  • the thickness of the second sealing layer is 30 ⁇ m or more and 400 ⁇ m or less.
  • the third encapsulation layer is laminated to the first solar cell panel from the opposite side of the second encapsulation layer.
  • the thickness of the third sealing layer is 50 ⁇ m or more and 400 ⁇ m or less.
  • the first protective material is laminated on the first sealing layer from the side opposite to the second solar cell panel.
  • the thickness of the first protective material is 25 ⁇ m or more and 200 ⁇ m or less.
  • the thickness of the solar cell is 350 ⁇ m or more and 1140 ⁇ m or less at the portion where the first solar cell panel and the second solar cell panel overlap when viewed from the normal direction of the light receiving surface of the first solar cell panel.
  • FIG. 2 is a plan view showing the layer structure of the tandem solar cell of the embodiment;
  • FIG. 2 is an exploded view of the tandem solar cell of the embodiment;
  • the top view which shows the bottom module of embodiment.
  • the top view which shows the top module of embodiment.
  • the top view which shows the positional relationship of the bottom module of embodiment, and a top module.
  • FIG. 2 is a cross-sectional view of the tandem solar cell along line VI-VI of FIG. 1; The figure which shows an example of the heating process of embodiment.
  • a solar cell and a method for manufacturing a solar cell according to embodiments will be described below with reference to the drawings.
  • the same reference numerals are given to components having the same or similar functions. Duplicate descriptions of these configurations may be omitted.
  • FIG. 1 is a plan view showing the layer structure of a tandem solar cell according to an embodiment.
  • FIG. 2 is a development view of the tandem solar cell of the embodiment.
  • the tandem solar cell 1 in order to show the laminated structure of the tandem solar cell 1, some layers are cut away.
  • the tandem solar cell 1 is formed in a rectangular plate shape.
  • the thickness direction of the tandem solar cell 1 is simply referred to as "thickness direction”.
  • the +X direction, ⁇ X direction, +Y direction, and ⁇ Y direction orthogonal to the thickness direction are defined.
  • the -X direction is the opposite direction to the +X direction. When the +X direction and the -X direction are not distinguished, they are simply referred to as "X direction".
  • the +Y direction and -Y direction are directions orthogonal to the X direction.
  • the -Y direction is the opposite direction to the +Y direction.
  • the +Y direction and the -Y direction are not distinguished, they are simply referred to as the "Y direction”.
  • one direction in the thickness direction is defined as “front side”, and the direction opposite to the front side is defined as “back side”.
  • the tandem solar cell 1 includes a bottom module 10 having solar cells 12 forming back cells, a top module 50 having solar cells 52 arranged on the front side of the bottom module 10 and forming front cells, and a package 80 that houses the bottom module 10 and the top module 50 .
  • the tandem solar cell 1 is a four-terminal solar cell that draws current from each of the bottom module 10 and the top module 50 .
  • FIG. 3 is a plan view showing the bottom module of the embodiment.
  • the outer shape of the package 80 is indicated by phantom lines.
  • the bottom module 10 includes a plurality of series-connected bottom solar panels 11 (first solar panel, other solar panels). All bottom solar panels 11 are arranged along a common XY plane. At least one solar cell 12 is formed in the bottom solar cell panel 11 .
  • a single solar cell 12 may be formed in the bottom solar cell panel 11, or a plurality of solar cells 12 connected in series and parallel may be formed.
  • the solar cell 12 is a silicon-based solar cell using Si, which is an indirect transition type semiconductor, for the light absorption layer.
  • the solar cell 12 is, for example, a back contact type crystalline silicon solar cell having an n-type electrode and a p-type electrode on the back side of the light absorbing layer.
  • the solar cells 12 may be other forms of solar cells such as crystalline silicon solar cells.
  • As the solar cell 12 for example, a monocrystalline, polycrystalline, heterojunction, or amorphous silicon-based solar cell, or a CIS-based or CIGS-based compound solar cell is employed.
  • a metal wrap-through structure and a double-sided light receiving structure may be combined as the cell electrode structure (p-electrode, n-electrode) of the solar cell 12 .
  • the bottom solar cell panel 11 is arranged with the light receiving surface facing the front side.
  • each bottom solar cell panel 11 is formed in a rectangular shape with a pair of sides extending in the X direction and the remaining pair of sides extending in the Y direction when viewed from above in the thickness direction.
  • each bottom solar cell panel 11 is formed in a rectangular shape with the X direction as the longitudinal direction in plan view.
  • the bottom module 10 includes a plurality of bottom panel rows 11R (at least one first solar panel) formed by a plurality of bottom solar panels 11 connected in series.
  • the bottom solar cell panels 11 are arranged in the X direction at intervals.
  • the entire outer shape of each bottom panel row 11R is formed in a rectangular shape with the X direction as the longitudinal direction in plan view.
  • the bottom panel rows 11R are arranged in the Y direction at intervals. Thereby, the plurality of bottom solar cell panels 11 are aligned in the X direction and the Y direction.
  • the entire outer shape of the aligned bottom solar cell panels 11 is formed in a rectangular shape with the X direction as the longitudinal direction.
  • the bottom module 10 includes five bottom panel rows 11R formed by four bottom solar panels 11 .
  • the number of bottom solar panels 11 is not particularly limited.
  • the bottom panel row 11R positioned most in the +Y direction among the plurality of bottom panel rows 11R the bottom panel row 11R positioned Nth in the -Y direction is referred to as the "Nth bottom panel row 11R". called.
  • the top panel row 51R which will be described later.
  • the bottom solar cell panel 11 includes a negative terminal 13 electrically connected to the n-type electrode and a positive terminal 14 electrically connected to the p-type electrode.
  • the negative electrode terminal 13 and the positive electrode terminal 14 are provided on the back surface of the bottom solar cell panel 11 when the solar cell 12 is a back-contact type solar cell.
  • the negative terminal 13 is provided at the +X direction end of the bottom solar cell panel 11 in the odd-numbered bottom panel rows 11R, and is provided at the ⁇ X-direction end of the bottom solar cell panel 11 in the even-numbered bottom panel row 11R. It is
  • the positive terminal 14 is provided at the end of each bottom solar cell panel 11 opposite to the negative terminal 13 .
  • the bottom module 10 includes interconnectors 16 , panel row end connectors 17 and bottom busbars 20 .
  • the interconnector 16 serially connects adjacent bottom solar panels 11 in the bottom panel row 11R.
  • the interconnector 16 is made of a metal plate.
  • the interconnector 16 is formed of a copper plate, copper wire, or copper foil having solder plating layers on both main surfaces.
  • the interconnector 16 extends across the space between a pair of bottom solar cell panels 11 adjacent in the X direction in plan view.
  • the interconnector 16 connects to the negative terminal 13 of one bottom solar panel 11 and the positive terminal 14 of the other bottom solar panel 11 .
  • the panel row end connector 17 is connected to a terminal to which the interconnector 16 is not connected among the negative terminal 13 and positive terminal 14 of the bottom solar cell panel 11 of each bottom panel row 11R. That is, the panel row end connector 17 is connected to the negative terminal 13 and the positive terminal 14 that are the electrical ends of the bottom panel row 11R.
  • the panel row end connector 17 is made of a metal plate.
  • the panel row end connector 17 is made of the same material as the interconnector 16 .
  • the panel row end connector 17 protrudes in the X direction from the bottom panel row 11R in plan view.
  • the bottom bus bar 20 is arranged around the entire plurality of bottom solar cell panels 11 in plan view.
  • the entire perimeter of the plurality of bottom solar cell panels 11 means the perimeter of the panel when the plurality of bottom solar cell panels 11 are regarded as a single rectangular panel.
  • Bottom bus bar 20 is formed of a metal plate.
  • the bottom bus bar 20 is made of a copper plate having solder plating layers on both main surfaces.
  • the bottom busbar 20 extends along the Y direction.
  • the bottom bus bars 20 are arranged so as not to contact each other.
  • the bottom bus bar 20 includes an inter-panel bus bar 21 and a terminal bus bar 22 .
  • the inter-panel bus bar 21 connects the adjacent bottom panel rows 11R in series via the panel row end connectors 17 .
  • the inter-panel bus bars 21 are arranged on both sides of the bottom panel row 11R in the +X direction and the -X direction in plan view.
  • the inter-panel bus bar 21 in the +X direction connects the n-th bottom panel row 11R and the (n+1)-th bottom panel row 11R in series, where n is an even number.
  • the +X-direction inter-panel bus bar 21 includes a +X-direction panel row end connector 17 connected to the n-th bottom panel row 11R and a +X-direction panel row end connector 17 connected to the (n+1)th bottom panel row 11R. are connected to the panel row end connector 17 of the .
  • the inter-panel bus bar 21 in the -X direction connects the m-th bottom panel row 11R and the (m+1)-th bottom panel row 11R in series, where m is an odd number.
  • the ⁇ X direction inter-panel bus bar 21 is connected to the ⁇ X direction panel row end connector 17 connected to the m-th bottom panel row 11R and the (m+1)th bottom panel row 11R. and the panel row end connector 17 in the -X direction.
  • the terminal bus bar 22 is connected to the panel row end connector 17 that is not connected to the inter-panel bus bar 21 among the panel row end connectors 17 .
  • the terminal bus bar 22 is connected to the negative electrode terminal 13 and the positive electrode terminal 14 which are the electrical ends of one solar cell. They are connected via panel row end connectors 17 .
  • the terminal bus bars 22 are arranged on both sides of the bottom panel row 11R in the +X direction and the -X direction in a plan view.
  • the +X direction terminal bus bar 22 is connected to the +X direction panel row end connector 17 connected to the first bottom panel row 11R.
  • the +X direction terminal bus bar 22 extends in the +Y direction from the connecting portion with the panel row end connector 17 and is drawn out of the package 80 .
  • the ⁇ X direction terminal bus bar 22 is connected to the ⁇ X direction panel row end connector 17 connected to the N-th bottom panel row 11R.
  • the -X direction terminal bus bar 22 extends in the -Y direction from the connection with the panel row end connector 17 and is drawn out of the package 80 .
  • the bottom bus bar 20 extends in the +Y direction from each bottom panel row 11R connected to the bottom bus bar 20 .
  • the inter-panel bus bar 21 in the +X direction extends in the +Y direction beyond the m-th bottom panel row 11R from the connection with the m-th bottom panel row 11R, and the (m-1)th bottom panel row 11R.
  • the +X direction inter-panel bus bar 21 extends in the +Y direction from the connection portion with the (m ⁇ 1)th bottom panel row 11R beyond the (m ⁇ 1)th bottom panel row 11R.
  • the bottom module 10 includes a flexible substrate 30 and bypass diodes 40 .
  • a flexible substrate 30 is provided for each bottom panel row 11R.
  • the flexible substrate 30 is connected in parallel to the bottom panel row 11R to form a bypass line for the bottom panel row 11R.
  • the flexible substrate 30 is connected to the negative terminal 13 and the positive terminal 14, which are the electrical ends of the bottom panel row 11R, via the bottom bus bar 20 and the panel row end connector 17.
  • the flexible substrate 30 is arranged on the back side of the bottom solar cell panel 11 and overlaps the bottom solar cell panel 11 in plan view.
  • the flexible substrate 30 extends along the longitudinal direction (that is, the X direction) of the bottom panel row 11R with a constant width in plan view.
  • the flexible substrate 30 is arranged with both main surfaces facing in the thickness direction.
  • the flexible substrate 30 includes wiring 31 and a base material 32 that supports the wiring 31 .
  • the wiring 31 is made of copper foil or the like.
  • the wiring 31 extends over substantially the entire length of the flexible substrate 30 .
  • the base material 32 is formed in a sheet shape from an insulating material such as polyimide.
  • the substrate 32 exposes the wiring 31 to the front side at both ends of the flexible substrate 30 .
  • the wiring 31 is exposed to the front side from the base material 32 at both ends of the flexible substrate 30 .
  • a configuration in which flying leads are used near both ends of the flexible substrate 30 and the wirings 31 are exposed on both the front side and the back side from the base material 32 may be employed.
  • the wiring 31 is connected to the back surface of the bottom bus bar 20 at both ends of the flexible substrate 30 .
  • the bypass diode 40 is mounted on the flexible substrate 30.
  • a bypass diode 40 is connected to the middle of the wiring 31 .
  • a bypass diode 40 rectifies the wiring 31 .
  • the bypass diode 40 is connected to the back surface of the wiring 31 and protrudes from the flexible substrate 30 to the back surface.
  • FIG. 4 is a plan view showing the top module of the embodiment.
  • the outer shape of the package 80 is indicated by imaginary lines.
  • the top module 50 has a plurality of top solar panels 51 (second solar panels). All top solar panels 51 are arranged along a common XY plane.
  • the top solar cell panels 51 are provided in the same number as the bottom solar cell panels 11 .
  • One solar battery cell 52 is formed in the top solar battery panel 51 .
  • the top solar cell panel 51 may have a plurality of solar cells connected in series and parallel.
  • the photovoltaic cell 52 is a transmissive photovoltaic cell using a direct transition semiconductor for the light absorption layer.
  • the photovoltaic cell 52 has a light absorption layer with a wider bandgap than the photoabsorption layer of the photovoltaic cell 12 of the bottom module 10 .
  • the light absorbing layer of the solar cell 52 contains cuprous oxide (Cu 2 O) as a direct transition semiconductor.
  • the solar cell 52 has a configuration in which a p-electrode, a p-light absorption layer, an n-compound layer, and an n-electrode are laminated in this order on the front side of a glass substrate. The p-electrode is exposed to the front side at the +Y-direction end of the top solar cell panel 51 .
  • the n-electrode is exposed on the front side at the edge of the top solar cell panel 51 in the -Y direction.
  • the p-electrode and n-electrode function as terminals for taking out current on the front surface of the top solar cell panel 51 .
  • the top solar cell panel 51 is arranged with the light receiving surface facing the front side. That is, the normal direction of the light receiving surface of the top solar cell panel 51 is along the thickness direction.
  • the top module 50 includes a plurality of top panel rows 51R formed by a plurality of top solar cell panels 51 connected in parallel.
  • the top solar cell panels 51 are arranged in the X direction at intervals.
  • the entire outer shape of each top panel row 51R is formed in a rectangular shape with the X direction as the longitudinal direction in plan view.
  • the top panel rows 51R are connected in series with each other.
  • the top panel rows 51R are arranged in the Y direction at intervals.
  • the plurality of top solar cell panels 51 are aligned in the X direction and the Y direction.
  • the entire outer shape of the aligned top solar cell panels 51 is formed in a rectangular shape with the X direction as the longitudinal direction.
  • the top solar panel 51 is arranged so as to overlap each bottom solar panel 11 .
  • the top module 50 includes five top panel rows 51R formed by four top solar cell panels 51. As shown in FIG.
  • FIG. 5 is a plan view showing the positional relationship between the bottom module and top module of the embodiment.
  • each top solar cell panel 51 is arranged so as to face the light receiving surface (front surface) of the bottom solar cell panel 11 of the bottom module 10 .
  • the top solar cell panel 51 is formed to have a size equal to or greater than that of the bottom solar cell panel 11 .
  • the top solar panel 51 overlaps the entire bottom solar panel 11 in plan view.
  • the photovoltaic cells 52 of the top photovoltaic panel 51 entirely overlap the photovoltaic cells 12 of the bottom photovoltaic panel 11 in plan view. In other words, the entire solar battery cell 12 of the bottom solar battery panel 11 is arranged inside the outline of the solar battery cell 52 of the top solar battery panel 51 in plan view.
  • the top module 50 includes an interconnector 60 and a top busbar 70.
  • the interconnector 60 is formed of a copper wire, a copper plate, a copper foil, or a conductive tape having solder plating layers on both main surfaces.
  • a pair of interconnectors 60 are provided for each top panel row 51R.
  • the interconnector 60 includes a first interconnector 61 electrically connected to the p-electrode of the top solar cell panel 51 and a second interconnector 62 electrically connected to the n-electrode of the top solar cell panel 51 for each top panel row 51R.
  • Each interconnector 60 has a constant width in plan view and extends along the alignment direction of the top solar cell panels 51 in the top panel row 51R (that is, the X direction).
  • the first interconnector 61 is joined to the surface of the +Y-direction end of the top solar cell panel 51 of each top panel row 51R.
  • the first interconnector 61 commonly connects the p-electrodes of the top solar cell panels 51 of each top panel row 51R.
  • the second interconnector 62 is joined to the surface of the -Y direction end of the top solar cell panel 51 of each top panel row 51R.
  • the second interconnector 62 commonly connects the n-electrodes of the top solar cell panels 51 of each top panel row 51R.
  • the interconnector 60 is desirably arranged so as not to overlap the solar battery cells 12 of the bottom solar battery panel 11 in plan view.
  • the interconnector 60 extends in the +X direction or the -X direction from the top panel row 51R.
  • the first interconnector 61 joined to the odd-numbered top panel row 51R extends in the -X direction beyond the top panel row 51R.
  • the first interconnectors 61 joined to the even-numbered top panel rows 51R extend in the +X direction beyond the top panel rows 51R.
  • the second interconnector 62 joined to the odd-numbered top panel row 51R extends in the +X direction beyond the top panel row 51R.
  • the second interconnector 62 joined to the even-numbered top panel row 51R extends in the -X direction beyond the top panel row 51R.
  • the interconnector 60 is connected to the top bus bar 70 at a location that protrudes in the X direction from the top panel row 51R.
  • the top bus bars 70 are arranged on both sides of the top panel row 51R in the +X direction and the -X direction in plan view.
  • the top bus bar 70 is arranged around the entire plurality of top solar cell panels 51 in plan view.
  • the entire perimeter of the plurality of top solar cell panels 51 means the perimeter of the panel when the plurality of top solar cell panels 51 are regarded as a single rectangular panel.
  • the top bus bar 70 is arranged at the same position in the X direction as the bottom bus bar 20 .
  • Top bus bar 70 is formed of a metal plate.
  • the top busbar 70 is made of the same material as the bottom busbar 20 .
  • Top bus bar 70 extends along the Y direction.
  • the top busbars 70 are arranged so as not to contact each other.
  • the top bus bar 70 includes an inter-panel bus bar 71 and a terminal bus bar 72 .
  • the inter-panel bus bar 71 connects the adjacent top panel rows 51R in series via the interconnector 60 .
  • the inter-panel bus bars 71 are arranged on both sides of the top panel row 51R in the +X direction and the -X direction in a plan view.
  • the +X-direction inter-panel bus bar 71 connects between the +X-direction end of the second interconnector 62 connected to the m-th top panel row 51R and the (m+1)-th top panel row 51R. and the +X-direction end of the connected first interconnector 61 .
  • the -X direction inter-panel bus bar 71 is connected to the -X direction end of the second interconnector 62 connected to the nth top panel row 51R and the (n+1)th top panel row. and the -X direction end of the first interconnector 61 connected to 51R.
  • the terminal bus bar 72 is connected to the p-electrode and the n-electrode which are the electrical ends of one solar cell. connected via The terminal bus bars 72 are arranged on both sides of the top panel row 51R in the +X direction and the -X direction in a plan view.
  • the ⁇ X direction terminal bus bar 72 is connected to the ⁇ X direction end of the first interconnector 61 connected to the first top panel row 51R.
  • the -X direction terminal bus bar 72 extends in the +Y direction from the connecting portion with the first interconnector 61 and is drawn out of the package 80 .
  • the +X-direction terminal bus bar 72 is connected to the +X-direction end of the second interconnector 62 connected to the N-th top panel row 51R, where N is the number of top panel rows 51R.
  • the +X-direction terminal bus bar 72 extends in the -Y direction from the connecting portion with the second interconnector 62 and is drawn out of the package 80 .
  • each top solar panel 51 may have a bypass diode connected in parallel.
  • one bypass diode can be provided for each top panel row 51R.
  • the bypass diodes may be connected to the first interconnector 61 and the second interconnector 62 at positions in the +X direction or -X direction of the top panel row 51R.
  • the package 80 accommodates the bottom module 10 with the terminal busbars 22 of the bottom busbar 20 pulled out, and accommodates the top module 50 with the top busbar 70 pulled out.
  • the package 80 includes a front cover 81 (first protective material) and a back cover 82 (second protective material).
  • the front cover 81 is arranged on the front sides of the bottom module 10 and the top module 50 .
  • the back cover 82 is arranged behind the bottom module 10 and the top module 50 .
  • the front cover 81 is a translucent single-layer film made of fluorine-based resin.
  • the fluororesin is a tetrafluoroethylene/ethylene copolymer (ETFE), a chlorotrifluoroethylene/ethylene copolymer (ECTFE), or the like.
  • the front cover 81 is formed in a rectangular shape with a pair of sides extending in the X direction and the remaining pair of sides extending in the Y direction in plan view.
  • the front cover 81 is arranged so as to overlap the entire portion of the bottom module 10 excluding the tips of the terminal busbars 22 and the portion of the top module 50 excluding the tips of the top busbars 70 in plan view.
  • each of the bottom module 10 and the top module 50 that overlaps the front cover 81 in plan view will be referred to as a main portion.
  • the surface on the front side of the front cover 81 forms the light incident surface of the tandem solar cell 1 .
  • the back cover 82 is a translucent single-layer film made of a fluororesin.
  • the back cover 82 is formed to have the same shape and size as the front cover 81 in plan view.
  • the back cover 82 is arranged so as to completely overlap the front cover 81 in plan view.
  • the package 80 includes a sealing material 83.
  • the sealing material 83 is arranged between the front cover 81 and the back cover 82 .
  • the sealing material 83 is made of a translucent and insulating resin material.
  • the sealing material 83 is formed by laminating a plurality of insulating films 90 between the front cover 81 and the back cover 82 and integrating them with each other by heat treatment.
  • Each insulating film 90 is a single-layer film containing at least one of an ethylene-vinyl acetate copolymer, a polyolefin-based resin, and an ionomer-based resin.
  • FIG. 6 is a cross-sectional view of the tandem solar cell along line VI-VI of FIG.
  • the plurality of insulating films 90 are composed of a first insulating film 91 (first sealing material) arranged between the top module 50 and the front cover 81, a bottom a second insulating film 92 (second sealing material) arranged between the module 50 and a third insulating film 93 (third sealing material) arranged between the bottom module 10 and the back cover 82; ,including.
  • the bottom module 10 and the top module 50 are arranged between the layers of the insulating film 90 .
  • a flexible substrate 30 is embedded in the third insulating film 93 .
  • each insulating film 90 overlaps the entire major portions of the bottom module 10 and the top module 50 in plan view. Furthermore, the insulating films 90 overlap each other outside the bottom module 10 and the top module 50 in a plan view.
  • the sealing material 83 includes a first sealing layer 84, a second sealing layer 85, and a third sealing layer 86.
  • the first sealing layer 84 is laminated so as to be in direct contact with the top solar cell panel 51 from the side opposite to the bottom solar cell panel 11 .
  • the first sealing layer 84 is a portion of the first insulating film 91 that overlaps the top solar cell panel 51 in plan view.
  • a second encapsulation layer 85 is disposed between the bottom solar panel 11 and the top solar panel 51 .
  • the second sealing layer 85 is laminated so as to be in direct contact with the bottom solar cell panel 11 and the top solar cell panel 51 .
  • the second sealing layer 85 is a portion of the second insulating film 92 that overlaps the bottom solar cell panel 11 and the top solar cell panel 51 in plan view. Thereby, only the second sealing layer 85 is arranged between the bottom solar cell panel 11 and the top solar cell panel 51 .
  • the third sealing layer 86 is laminated so as to be in direct contact with the bottom solar cell panel 11 from the side opposite to the second sealing layer 85 .
  • the third sealing layer 86 is a portion of the third insulating film 93 that overlaps the bottom solar cell panel 11 in plan view.
  • the thickness of each component of the tandem solar cell 1 will be described with reference to FIG.
  • the thickness of the front cover 81 is 25 ⁇ m or more and 200 ⁇ m or less, preferably 50 ⁇ m or more and 150 ⁇ m or less, more preferably 50 ⁇ m or more and 100 ⁇ m or less.
  • the thickness of the first sealing layer 84 is 50 ⁇ m or more and 400 ⁇ m or less, preferably 50 ⁇ m or more and 200 ⁇ m or less, more preferably 100 ⁇ m or more and 200 ⁇ m or less.
  • the thickness of the top solar cell panel 51 is 30 ⁇ m or more and 150 ⁇ m or less, preferably 35 ⁇ m or more and 80 ⁇ m or less. For example, the thickness of the top solar panel 51 is the thickness of the glass substrate.
  • the thickness of the second sealing layer 85 is 30 ⁇ m or more and 400 ⁇ m or less, preferably 35 ⁇ m or more and 200 ⁇ m or less, more preferably 100 ⁇ m or more and 200 ⁇ m or less.
  • the thickness of the bottom solar cell panel 11 is 100 ⁇ m or more and 150 ⁇ m or less.
  • the thickness of the bottom solar cell panel 11 is the thickness of a silicon wafer (silicon substrate).
  • the thickness of the third sealing layer 86 is 50 ⁇ m or more and 400 ⁇ m or less, preferably 50 ⁇ m or more and 200 ⁇ m or less, more preferably 100 ⁇ m or more and 200 ⁇ m or less.
  • the thickness of the third sealing layer 86 is the thickness including the flexible substrate 30 .
  • the thickness of the back cover 82 is 25 ⁇ m or more and 200 ⁇ m or less, preferably 50 ⁇ m or more and 150 ⁇ m or less, more preferably 50 ⁇ m or more and 100 ⁇ m or less.
  • the thickness of the tandem solar cell 1 is 375 ⁇ m or more and 1290 ⁇ m or less at the portion where the bottom solar cell panel 11 and the top solar cell panel 51 overlap in plan view. For example, the thickness of each part of the tandem solar cell 1 is measured by cross-sectional SEM or the like.
  • the tandem solar cell 1 is formed by heating and integrating the laminate 2 in which the front cover 81, the back cover 82, the bottom module 10, the top module 50, and the insulating film 90 are laminated.
  • the manufacturing method of this embodiment includes a preheating step, a laminating step, and a heating step.
  • the preheating step at least one of the first insulating film 91, the second insulating film 92, and the third insulating film 93 is heated alone to shrink the insulating film in advance.
  • the preheating step when the thickness of the protective material on the heating surface side of the first protective material and the second protective material exceeds 100 ⁇ m (preferably 150 ⁇ m or more), and the thickness of the insulating film If the thickness exceeds 100 ⁇ m, the preheating step may not be performed.
  • the lamination process is performed.
  • the laminate 2 is formed by laminating the front cover 81, the first insulation film 91, the top module 50, the second insulation film 92, the bottom module 10, the third insulation film 93 and the back cover 82 in this order.
  • the top module 50 is arranged such that the top solar cell panel 51 faces the light receiving surface of the bottom solar cell panel 11 .
  • a first insulating film 91 is overlaid on the top module 50 from the opposite side of the bottom module 10 .
  • a second insulating film 92 is overlaid on the bottom module 10 and the top module 50 between the bottom solar panel 11 and the top solar panel 51 .
  • a third insulating film 93 is overlaid on the bottom module 10 from the side opposite to the second insulating film 92 .
  • the back cover 82 is placed on the third insulating film 93 from the opposite side of the bottom module 10 .
  • the front cover 81 is placed on the first insulating film 91 from the side opposite to the top module 50 .
  • the laminated body 2 is formed by the above.
  • the order in which the steps of stacking the members are performed is not particularly limited as long as the laminate 2 can be formed by stacking the members in the order described above.
  • the laminate 2 is formed by stacking the front cover 81, the first insulating film 91, the top module 50, the second insulating film 92, the bottom module 10, the third insulating film 93, and the back cover 82 in this order.
  • the insulating films 90 overlap each other outside the bottom module 10 and the top module 50 in plan view. Thereby, the first insulating film 91 and the second insulating film 92 directly overlap each other outside the top module 50 . Also, the second insulating film 92 and the third insulating film 93 overlap each other outside the bottom module 10 .
  • each insulating film 90 is 50 ⁇ m or more and 400 ⁇ m or less, preferably 50 ⁇ m or more and 200 ⁇ m or less, more preferably 100 ⁇ m or more and 200 ⁇ m or less.
  • the thickness of each insulating film 90 is the thickness before the preheating process.
  • the thicknesses of the front cover 81 , the back cover 82 , the bottom solar cell panel 11 and the top solar cell panel 51 are the same as the thicknesses of the finished tandem solar cell 1 .
  • the heating process is performed.
  • the laminate 2 is heated to melt the insulating film 90 .
  • the melted insulating film 90 is bonded to the member overlapping the insulating film 90 .
  • the bottom module 10, the top module 50, the front cover 81, the back cover 82, the first insulation film 91, the second insulation film 92, and the third insulation film 93 are bonded together.
  • the first insulating film 91 and the second insulating film 92 are welded and integrated with each other on the outer side of the top module 50 in plan view.
  • the second insulating film 92 and the third insulating film 93 are welded and integrated with each other outside the bottom module 10 in plan view.
  • the first insulating film 91, the second insulating film 92, and the third insulating film 93 are integrated so as to have continuity to form the sealing material 83. As shown in FIG.
  • FIG. 7 is a diagram showing an example of the heating process of the embodiment.
  • the laminate 2 is heated by directly contacting the laminate 2 with a high-temperature heating device 100 .
  • the heating device 100 includes a glass body 101 that is in direct contact with the laminate 2 and a heater 102 that heats the glass body 101 .
  • the glass body 101 is made of silicate glass.
  • the glass body 101 is, for example, a glass plate.
  • the glass body 101 has a flat heating surface 103 in contact with the front cover 81 or the back cover 82 (the back cover 82 in the illustrated example) of the laminate 2, and a flat heated surface 104 facing away from the heating surface 103.
  • the heating surface 103 is sized to contact the entire surface of the front cover 81 or the back cover 82 .
  • the heater 102 is made of metal.
  • the heater 102 is in contact with the heated surface 104 of the glass body 101 . It is desirable that the heater 102 is in contact with at least the entire area of the surface to be heated 104 that coincides with the contact portion between the heating surface 103 and the laminate 2 when viewed from the normal direction of the heating surface 103 . For example, the heater 102 contacts the entire heated surface 104 .
  • the laminate 2 may be sandwiched from both sides in the thickness direction by the glass body 101 and the pressing member 105 .
  • the pressing member 105 is preferably in contact with the entire surface of the front cover 81 or the back cover 82 (the front cover 81 in the illustrated example).
  • the pressing member 105 presses the laminate 2 by its own weight.
  • an external force that presses the laminate 2 may be applied to the pressing member 105 .
  • the laminate 2 may be heated by the high-temperature pressing member 105 .
  • the pressing member 105 may be made of a glass body and a heater as in the heating device 100 .
  • tandem solar cell 1 is formed. Further, by performing the heating process of this embodiment, the insulating film 90 is melted to form the respective sealing layers 84, 85, 86 having the thicknesses described above.
  • the tandem solar cell 1 of the present embodiment heats the first insulating film 91, the second insulating film 92 and the third insulating film 93 to heat the bottom module 10, the top module 50 and the first insulating film.
  • the insulation film 91, the second insulation film 92, the third insulation film 93, the front cover 81 and the back cover 82 are joined together.
  • the thickness of each insulating film 90 is set to 50 ⁇ m to 400 ⁇ m
  • the thickness of the front cover 81 is set to 25 ⁇ m to 200 ⁇ m
  • the thickness of the back cover 82 is set to 25 ⁇ m to 200 ⁇ m.
  • the thickness of the first sealing layer 84 is 50 ⁇ m or more and 400 ⁇ m or less
  • the thickness of the second sealing layer 85 is 30 ⁇ m or more and 400 ⁇ m or less
  • the third sealing layer 86 has a thickness of 50 ⁇ m or more and 400 ⁇ m or less.
  • the thickness of the portion where the bottom solar cell panel 11 and the top solar cell panel 51 overlap in plan view in the tandem solar cell 1 is 375 ⁇ m or more and 1290 ⁇ m. It was confirmed that the tandem solar cell 1 with no wrinkles in the front cover 81 and no defects in the sealing layers 84, 85, and 86 can be formed by setting the conditions below. Therefore, the tandem solar cell 1 can be thinned while suppressing a decrease in power generation efficiency. Therefore, a highly efficient and lightweight tandem solar cell 1 can be obtained.
  • the second sealing layer 85 when the thickness of the second sealing layer 85 is 30 ⁇ m or more, when a material having a volume resistivity of 1.0 ⁇ 10 14 [ ⁇ cm] or more is used as the second sealing layer 85, the second sealing layer 85 has a thickness of 30 ⁇ m or more.
  • the resistance value in the thickness direction of the sealing layer 85 becomes 3.0 ⁇ 10 11 [ ⁇ ] or more. Therefore, by setting the thickness of the second sealing layer 85 to 30 ⁇ m or more as in the present embodiment, in the thinned tandem solar cell 1, the bottom solar cell panel 11 and the top solar cell panel 51 are separated from each other. Insulation can be ensured between
  • the thickness of the bottom solar cell panel 11 is set to 100 ⁇ m or more and 150 ⁇ m or less
  • the thickness of the top solar cell panel 51 is set to 30 ⁇ m or more and 150 ⁇ m or less.
  • the front cover 81 is a translucent film containing fluorine-based resin. According to this configuration, the solar cell panels 51 and 11 can be sealed while suppressing attenuation of light incident on the top solar cell panel 51 and the bottom solar cell panel 11 and ensuring electrical insulation.
  • the front cover 81 of this embodiment is a single-layer film, it can be made lighter than when the front cover is a multi-layer film. Therefore, the tandem solar cell 1 can be made lightweight.
  • the bottom solar cell panel 11 has an indirect transition type semiconductor layer.
  • the top solar panel 51 has direct bandgap semiconductor layers. According to this configuration, the absorption wavelength range in the bottom solar cell panel 11 and the absorption wavelength range in the top solar cell panel 51 can be made different. Therefore, it is possible to form a highly efficient solar cell as compared with a solar cell having a solar cell panel having one type of semiconductor layer.
  • the top solar cell panel 51 a p-electrode and an n-electrode are formed on the front side of the glass substrate. According to this configuration, even if the second encapsulating layer 85 between the top solar panel 51 and the bottom solar panel 11 is thin, the glass substrate provides electrical insulation between the top solar panel 51 and the bottom solar panel 11 . can be ensured. Therefore, by thinning the second sealing layer 85, the tandem solar cell 1 can be made lightweight.
  • the thickness of the glass substrate of the top solar cell panel 51 is 30 ⁇ m or more, and the volume resistivity of the glass substrate is 7.9 ⁇ 10 11 [ ⁇ cm] or more, the thickness of the glass substrate in the thickness direction The resistance value becomes 2.0 ⁇ 10 9 [ ⁇ ] or more. Therefore, in the thinned tandem solar cell 1, the insulation between the bottom solar cell panel 11 and the top solar cell panel 51 can be ensured more reliably.
  • the method for manufacturing the tandem solar cell 1 of this embodiment includes the bottom solar cell panel 11, the top solar cell panel 51, the first insulating film 91, the second insulating film 92, the third insulating film 93, the back cover 82 and the A heating step is provided in which the laminated body 2 formed by the front cover 81 is brought into contact with the heated glass body 101 to be heated.
  • the glass has a sufficiently lower thermal conductivity than the metal material, the heat is rapidly transferred to the laminate 2 as compared with the method in which the laminate is heated by bringing the laminate into contact with the heated metal body. can be suppressed. Therefore, since the laminate 2 can be heated evenly, the occurrence of local defects in the tandem solar cell 1 can be suppressed.
  • the method for manufacturing the tandem solar cell 1 of the present embodiment includes a preheating step of heating at least one of the first insulating film 91, the second insulating film 92, and the third insulating film 93 alone. Prepare.
  • the thermal shrinkage of the insulating film in the heating process is suppressed, and defects such as wrinkles and defects are not generated in the sealing layers 84, 85, and 86. can be suppressed. This is particularly effective when the insulating film is made of a thermoplastic resin or a material having a relatively high heat shrinkage.
  • the insulating film (the third insulating film 93 in this embodiment) disposed closest to the heating device 100 in the heating process among the insulating films has a thickness of 100 ⁇ m or less, a step or a cavity may be formed after the heating process. A defect having a thickness of about 30 ⁇ m or less may occur. As a result, deterioration of the water vapor barrier property of the sealing layer, corrosion of the electrode, expansion of air in the defective portion due to changes in atmospheric pressure, and the like occur.
  • the thickness of the protective material on the heating surface side in the heating process is greater than 100 ⁇ m (preferably 150 ⁇ m or more), the shrinkage of the insulating film is suppressed by the hardness of the protective material, but the thickness of the protective material is 100 ⁇ m.
  • the insulating film tends to wrinkle in the following cases. Therefore, when the thickness of the protective material or insulating film on the heating surface side in the heating step is 100 ⁇ m or less, the preheating step is performed because the occurrence of the above-described problems can be effectively suppressed by performing the preheating step. is preferred.
  • FIG. 8 is an exploded view of a device provided with a tandem solar cell according to a modification of the embodiment.
  • the sealing material 83 is laminated on the back cover 82 .
  • the sealing material 83 may be laminated on a part of the device 200 on which the tandem solar cell 1A is mounted instead of the back cover .
  • the tandem solar cell 1A is fixed to the device 200 on which it is mounted by adhesion or the like.
  • the sealing material 83 is laminated on the upper surface of the wing of an aircraft, the roof of a mobility vehicle, or the like.
  • the thicknesses of the bottom solar cell panel 11, the top solar cell panel 51, the first sealing layer 84, the second sealing layer 85, the third sealing layer 86, and the front cover 81 are the same as those described above. Similar to morphology. Further, the thickness of the tandem solar cell 1A is 350 ⁇ m or more and 1140 ⁇ m or less at the portion where the bottom solar cell panel 11 and the top solar cell panel 51 overlap each other in plan view. Thereby, the tandem solar cell 1A has the same effect as the tandem solar cell 1 of the embodiment.
  • the tandem solar cell 1A of this modified example can be formed by a manufacturing method similar to that of the tandem solar cell 1 of the embodiment. In this case, in the heating process, it is desirable to bring the heating device 100 into contact with the front cover 81 of the laminated body in which the front cover 81 , the bottom module 10 , the top module 50 and the insulating film 90 are laminated.
  • the front cover 81 is a single-layer film made of fluorine-based resin, but is not limited to this configuration.
  • the front cover may be a single layer film made of weather resistant polyethylene terephthalate.
  • the front cover may have a structure in which any of the single-layer films described above is coated with a primer, a topcoat, or the like.
  • the front cover may be a multi-layer film containing at least one of fluororesin and weather-resistant polyethylene terephthalate.
  • the multilayer film is a film obtained by bonding a fluorine-based resin film on the light incident side and a weather-resistant polyethylene terephthalate film on the encapsulant side.
  • the front cover is a translucent film containing at least one of fluororesin and weather-resistant polyethylene terephthalate, light will enter the top solar panel 51 and the bottom solar panel 11.
  • Each solar cell panel 11, 51 can be sealed while suppressing the attenuation of the light emitted and ensuring electrical insulation.
  • the front cover may be made of a transparent resin material, glass, or the like other than the materials described above.
  • the back cover is similar to the front cover.
  • all the bottom solar cell panels 11 are connected in series, but the configuration is not limited to this. Multiple bottom solar panels may be connected together in parallel or a combination of series and parallel. Also, the bottom module may be provided with a single bottom solar panel.
  • the plurality of top solar cell panels 51 are connected to each other in a parallel and series combination, but the configuration is not limited to this. Multiple top solar panels may be connected in series or in parallel with each other. Also, the top module may be provided with a single top solar panel.
  • the tandem solar cell 1 is a four-terminal solar cell, but is not limited to this configuration.
  • a tandem solar cell may be a two-terminal solar cell in which a bottom module and a top module are connected together in series.
  • the positions of the positive electrode terminal and the negative electrode terminal in the tandem solar cell are not particularly limited.
  • the flexible substrate 30 of the bottom module 10 is arranged on the back side of the bottom solar cell panel 11, but the configuration is not limited to this.
  • the flexible substrate may be arranged around the bottom panel row 11R so as not to overlap the bottom solar panel 11 .
  • the flexible substrate may be arranged along the bottom panel row 11R at a position shifted in the Y direction with respect to the bottom panel row 11R connected in parallel to the flexible substrate.
  • the solar cell 12 of the bottom solar cell panel 11 is a back-contact solar cell having an n-type electrode and a p-type electrode on the back side, but is not limited to this configuration.
  • the solar cells of the bottom solar panel may have a structure with an n-electrode on the front side and a p-electrode on the back side.
  • the interconnector that connects the pair of bottom solar cell panels is a wire-shaped member, and includes a p-electrode on the back side of one bottom solar cell panel and an n-electrode on the front side of the other bottom solar cell panel. , may be connected.
  • the thickness of the portion where the bottom solar cell panel and the top solar cell panel overlap when viewed from the thickness direction is set to 350 ⁇ m or more and 1140 ⁇ m or less, so that the front cover has no wrinkles. Moreover, it is possible to form a tandem solar cell that does not have defects in the sealing layer. Therefore, it is possible to suppress a decrease in power generation efficiency while reducing the thickness of the tandem solar cell. Therefore, a highly efficient and lightweight tandem solar cell can be obtained.

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DE112022006511.7T DE112022006511T5 (de) 2022-01-25 2022-01-25 Solarzelle und verfahren zur herstellung von solarzellen
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