Patent Application
20160276503
1. Technical Field
The present disclosure relates to a photovoltaic cell and a manufacturing method of a photovoltaic cell.
2. Description of Related Art
A concentrating photovoltaic cell in which a condenser lens and a photoelectric conversion element are integrally formed is disclosed in Japanese Patent No. 5120524 (hereinafter referred to as “Patent Literature 1”), for example.
The above concentrating photovoltaic cell includes a photoelectric conversion element and a condenser lens. The condenser lens transmits and focuses sunlight. The converged sunlight is emitted on the photoelectric conversion element. The photoelectric conversion element then converts optical energy of the emitted sunlight to generate power.
A photovoltaic cell according to the present disclosure includes a translucent substrate; a photoelectric conversion element disposed on a light emission surface of the substrate; and a light guide member disposed on a light incidence surface of the substrate, at a position opposite the photoelectric conversion element across the substrate.
A manufacturing method of a photovoltaic cell according to the present disclosure includes: forming a first hydrophilic region on a light incidence surface of a translucent substrate; disposing a light guide member within the first hydrophilic region; forming a second hydrophilic region on a light emission surface of the substrate; and disposing a photoelectric conversion element in the second hydrophilic region.
Hereinafter, an exemplary embodiment will be described in detail with reference to the accompanying drawings. It is noted, however, that descriptions in more detail than necessary will sometimes be omitted. For example, detailed descriptions of well-known items and duplicate descriptions of substantially the same configuration will sometimes be omitted. This is to avoid unnecessary redundancy in the following description and to facilitate understanding by those skilled in the art.
Note that the accompanying drawings and the following descriptions are provided so as to facilitate full understanding of the present disclosure by those skilled in the art, and these are not intended to limit the subject matter defined by the claims.
In the drawings, hatching may be omitted in some cases for facilitating understanding of the present disclosure.
A configuration of a photovoltaic cell according to the present exemplary embodiment will be described below with reference to
As illustrated in
Substrate 100 supports photoelectric conversion element 400 and light guide member 300. Later-described water-repellant region 120 is formed on a surface of substrate 100. Note that substrate 100 may be made of a material that can transmit sunlight, and it may be made of translucent materials other than glass.
Light guide member 300 is formed into a shape of an inverted truncated square pyramid, and constitutes an optical element which allows emission light from condenser lens 810 to be efficiently incident on photoelectric conversion element 400. Light guide member 300 includes a rod integrator or a microlens, or a combination thereof.
Condenser lens 810 and light guide member 300 are made of glass or resin, for example. Specifically, they are made of glass, or polymethylmethacrylate or polycarbonate with weather resistance, which is used for a photovoltaic power generation module. Condenser lens 810 and light guide member 300 may contain the above materials in a multilayer structure. Note that materials for condenser lens 810 and light guide member 300 are not particularly limited to the above materials, and any material can be used, so long as they have property of transmitting sunlight.
In addition, condenser lens 810, light guide member 300, and other members may contain an appropriate ultraviolet absorber in their constituent materials. With this, deterioration of each member due to ultraviolet rays can be prevented.
Further, an appropriate antireflection film may be formed on a surface of light guide member 300. With this, optical reflectivity of light guide member 300 in a sensitivity wavelength region of photoelectric conversion element 400 can be reduced. Examples of the antireflection film include an inorganic film of silicon oxide, silicon nitride, or magnesium fluoride, and a layered composite film of these materials.
In addition, an ultraviolet reflection film or an infrared reflection film may be formed on a surface of light guide member 300. With this, light having a wavelength out of the sensitivity wavelength region can be reflected on light guide member 300.
Condenser lens 810 condenses light, such as sunlight, incident on light incidence surface 810a, and emits this light to light guide member 300. The size of condenser lens 810 is appropriately determined according to the size of light guide member 300 to be used and focal length.
Photoelectric conversion element 400 converts incident light energy through light guide member 300 and substrate 100 to generate power. For example, a semiconductor material selected from Si, GaAs, InGaP, AlInGaAs, AlGaAs, InGaAs, InGaAsN, Ge, CuInGaSe, and CdTe or a combination thereof can be used for photoelectric conversion element 400. Specifically, photoelectric conversion element 400 can be configured as a high-power condenser by using inorganic materials such as a Group IV semiconductor, a Group III-V compound semiconductor, and a Group II-VI compound semiconductor. Further, photoelectric conversion element 400 can employ various types of structures such as a single-junction cell or multi-junction cell. In the present exemplary embodiment, the material of photoelectric conversion element 400 is GaAs as one example.
The structure of photoelectric conversion element 400 composing photovoltaic cell 1 according to the present exemplary embodiment will be described with reference to
As illustrated in
Substrate 100 of photovoltaic cell 1 according to the present exemplary embodiment will be described below with reference to
As illustrated in
A manufacturing method of the photovoltaic cell according to the present exemplary embodiment will be described in detail for each step.
[2-1. Alignment of Condenser Lens and Substrate]
<Step A>
Firstly, alignment step A for determining relative positions of condenser lens 810 and substrate 100 will be described in step A1 and step A2 with reference to
<Step A1>
As illustrated in
Corners of light incidence surface 101 of substrate 100 facing light emission surface 810b of condenser lens 810 are beveled to form corner faces 103.
<Step A2>
Next, as illustrated in
Next, epoxy putty 830, for example, is filled between condenser lens 810 and corner faces 103 of substrate 100 to which mold release agent 811 is applied. Filled epoxy putty 830 cures after a certain period of time.
Then, as illustrated in
[2-2. Placement of Light Guide Member]
[2-2-1. Formation of First Hydrophilic Region and First Water-Repellant Region]
Steps B1 to B8 for forming first hydrophilic regions 110a and first water-repellant region 120a on light incidence surface 101 of substrate 100 will be described in detail with reference to
Specifically,
<Step B1>
As illustrated in
Then, substrate 100 is immersed in a solution in which alkyl trichlorosilane or alkyl trialkoxysilane is dissolved. With this, the entire surface of substrate 100 is covered with an alkylsilane compound, and alkylsilane film 801 illustrated in
<Step B2>
Subsequently, alkylsilane film 801 covering light incidence surface 101 of substrate 100 is removed as illustrated in
<Step B3>
Then, substrate 100 having exposed light incidence surface 101 is immersed in a solution in which fluoroalkyl trichlorosilane or fluoroalkyl trialkoxysilane is dissolved. An example of fluoroalkyl trichlorosilane is heptadecafluorooctyl ethyl trichlorosilane. An example of fluoroalkyl trialkoxysilane is heptadecafluorooctyl ethyl trimethoxysilane or heptadecafluorooctyl ethyl triethoxysilane. With these steps, light incidence surface 101 of substrate 100 is covered with fluoroalkylsilane film 802 as illustrated in
In this case, the surfaces, including light emission surface 102, other than light incidence surface 101 of substrate 100 are not covered with fluoroalkylsilane film 802. This is because surfaces such as light emission surface 102 of substrate 100 are covered with alkylsilane film 801 (see step B2). In other words, active hydrogen that can react with a fluoroalkylsilane compound is not present on substrate 100 covered with alkylsilane film 801, so that fluoroalkylsilane film 802 is not formed.
<Step B4>
Next, substrate 100 in the state illustrated in
On the other hand, surfaces such as light emission surface 102 of substrate 100 covered with alkylsilane film 801 made of an alkylsilane compound are not hydrophilized. In other words, only light incidence surface 101 covered with fluoroalkylsilane film 802 is hydrophilized with fluoroalkylsilane film 802.
With the above process, aminoalkylsilane film 803 is further formed only on light incidence surface 101 of substrate 100. Specifically, a multilayer film of fluoroalkylsilane film 802 and aminoalkylsilane film 803 is formed on light incidence surface 101 of substrate 100. With this, fluoroalkylsilane film 802 is formed as sandwiched between substrate 100 and aminoalkylsilane film 803.
Aminoalkylsilane film 803 provides an effect of enabling uniform application of positive photoresist to light incidence surface 101 side of substrate 100 in step B5 described below. In addition, surfaces of substrate 100 such as light emission surface 102 side keep water-repellant property, because they are covered with alkylsilane film 801. Accordingly, an effect of inhibiting deposition of positive photoresist on the surfaces of substrate 100 such as light emission surface 102 is also provided.
<Step B5>
Next, as illustrated in
<Step B6>
Then, condenser lens 810 is again disposed at the light incidence surface 101 side of substrate 100 as illustrated in
Then, nearly parallel light 805 (including parallel light) in an ultraviolet wavelength region, for example, is made incident from a light incidence surface 810a side of condenser lens 810. Incident nearly parallel light 805 is converged on quadrilateral condenser lens 810, for example, in a plan view. Converged nearly parallel light 805 is emitted on positive photoresist layer 804. With this, positive photoresist layer 804 which covers the vicinity of the focal point of condenser lens 810 and formed on substrate 100 is exposed in a rectangular shape, for example.
Next, as illustrated in
<Step B7>
Next, as illustrated in
<Step B8>
Next, as illustrated in
By the processes in steps B1 to B8 described above, first hydrophilic regions 110a enclosed by fluoroalkylsilane film 802 are formed on the focal point or in the vicinity of the focal point of condenser lens 810. Fluoroalkylsilane film 802 functions as first water-repellant region 120a.
First hydrophilic regions 110a formed by the above exposure process will be described below in detail.
Firstly, wettability of first hydrophilic regions 110a with respect to an adhesive is higher than wettability of first water-repellant region 120a with respect to an adhesive.
In addition, the shape of each of first hydrophilic regions 110a is determined depending on the shape of light guide member 300 mounted on first hydrophilic region 110a. A rectangular shape has been described above as one example. However, the shape is not limited thereto. The shape of first hydrophilic regions 110a may be a polygon such as triangle, quadrilateral, or hexagon, or circle or ellipse, according to the shape of light guide member 300.
In addition, each first hydrophilic region 110a preferably has a shape same as the shape of the surface (specifically, the surface of light guide member 300 facing substrate 100 in the state in which light guide member 300 is mounted on substrate 100) of light guide member 300 to be mounted. Herein, “the same shape” means that the shape of each first hydrophilic region 110a and the surface of light guide member 300 to be mounted are in a congruence relation or a similarity relation in a mathematical concept.
Here, the surface area of the surface, which is adhered to substrate 100, of light guide member 300 mounted on substrate 100 is defined as S1. The area of one of first hydrophilic regions 110a is defined as S2. In this case, the value of S2/S1 is preferably from 0.64 to 1.44 both inclusive. When the value of S2/S1 is smaller than 0.64, an amount of an adhesive used to bond light guide member 300 to first hydrophilic region 110a is significantly small. Therefore, positional precision of light guide member 300 might be deteriorated. On the other hand, when the value of S2/S1 is larger than 1.44, an amount of an adhesive used to bond light guide member 300 to first hydrophilic region 110a is significantly large. Therefore, positional precision of light guide member 300 might also be deteriorated as in the above case.
The shape of each first hydrophilic region 110a is determined according to quadrilateral condenser lens 810, for example, in a plan view. It is to be noted that, when a light-shielding filter is provided between an exposure light source emitting nearly parallel light 805 and substrate 100, the shape is determined according to the shape of the light-shielding filter. In addition, the area of first hydrophilic regions 110a is determined by a distance between an exposure light source exposing positive photoresist layer 804 and substrate 100, and integrated exposure quantity of nearly parallel light 805.
The above condition may be different or same during formation of later-described second hydrophilic regions 110b on which photoelectric conversion elements 400 are disposed.
The case where positive photoresist layer 804 is exposed to form first hydrophilic regions 110a has been described above. However, it is not limited thereto. For example, first water-repellant region 120a enclosing a plurality of first hydrophilic regions 110a may be formed by an ink jet method, a screen printing method, a relief printing method, an intaglio printing method, or a microcontact printing method.
[2-2-2. Application of Adhesive]
Next, step C for applying an adhesive to first hydrophilic regions 110a will be described with reference to
<Step C>
Specifically, in step C, adhesive 200 for adhering light guide members 300 to substrate 100 is applied to first hydrophilic regions 110a on light incidence surface 101 of substrate 100.
Firstly, as illustrated in
In this case, adhesive 200 is applied using squeegee 510, for example, as illustrated in
Specifically, hydrophilic adhesive 200 containing water as a main component is applied to light incidence surface 101 side of substrate 100, for example. Applied adhesive 200 is disposed in first hydrophilic regions 110a with the movement of squeegee 510. Adhesive 211 illustrated in
In this case, first water-repellant region 120a is formed to enclose first hydrophilic regions 110a. Therefore, hydrophilic adhesive 200 disposed in first hydrophilic regions 110a does not stick out onto first water-repellant region 120a.
In step C illustrated in
In step C, after adhesive 200 is applied to one end of substrate 100, substrate 100 is tilted to raise the one end. Adhesive 200 flowing downward along the tilt may be sequentially poured into first hydrophilic regions 110a. In this case, squeegee 510 does not have to be particularly used.
Instead of the relative movement of squeegee 510 and substrate 100, an adhesive may be individually applied to each of first hydrophilic regions 110a using a dispenser.
[2-2-3. Mounting of Light Guide Member]
<Step D>
Next, step D for mounting light guide members 300 will be described with reference to
As illustrated in
In this case, interface tension (surface tension) of adhesive 211 is exerted on light guide member 300 which is mounted. With this, light guide member 300 moves to the center of adhesive 211 applied to each of first hydrophilic regions 110a. As a result, light guide member 300 is disposed at the center of each of first hydrophilic regions 110a by a self-alignment effect due to adhesive 211.
[2-2-4. Fixation of Light Guide Member]
<Step E>
Next, step E for fixing light guide members 300 will be described with reference to
As illustrated in
By each step described above, light guide members 300 can precisely be disposed in first hydrophilic regions 110a formed on the focal point or in the vicinity of the focal point of condenser lens 810 (see
[2-3. Placement of Photoelectric Conversion Element]
Next, a step for placing photoelectric conversion elements 400 on light emission surface 102 side of substrate 100 to which light guide members 300 are adhered will be described with reference to
[2-3-1. Formation of Second Hydrophilic Region and Second Water-Repellant Region]
<Step F1>
As illustrated in
Then, substrate 100 in the above state is immersed in a solution in which alkyl trichlorosilane or alkyl trialkoxysilane is dissolved. With this, alkylsilane film 801 is formed on the entire surface of substrate 100 other than the portion covered with fluoroalkylsilane film 802 having water-repellant property as illustrated in
<Step F2>
Subsequently, alkylsilane film 801 covering light emission surface 102 of substrate 100 is removed as illustrated in
<Step F3>
Then, substrate 100 having exposed light emission surface 102 is immersed in a solution in which fluoroalkyl trichlorosilane or fluoroalkyl trialkoxysilane is dissolved. An example of fluoroalkyl trichlorosilane is heptadecafluorooctyl ethyl trichlorosilane. An example of fluoroalkyl trialkoxysilane is heptadecafluorooctyl ethyl trimethoxysilane or heptadecafluorooctyl ethyl triethoxysilane. With these steps, light emission surface 102 of substrate 100 is covered with fluoroalkylsilane film 802 as illustrated in
In this case, the surfaces, including light incidence surface 101, other than light emission surface 102 of substrate 100 are not covered with fluoroalkylsilane film 802. This is because surfaces such as light incidence surface 101 of substrate 100 are covered with alkylsilane film 801 (see step F2). In other words, active hydrogen that can react with a fluoroalkylsilane compound is not present on substrate 100 covered with alkylsilane film 801, so that fluoroalkylsilane film 802 is not formed.
<Step F4>
Next, substrate 100 in the state illustrated in
On the other hand, surfaces such as light incidence surface 101 of substrate 100 covered with alkylsilane film 801 made of an alkylsilane compound are not hydrophilized. In other words, only light emission surface 102 covered with fluoroalkylsilane film 802 is hydrophilized with fluoroalkylsilane film 802.
With this, aminoalkylsilane film 803 provides an effect of enabling uniform application of positive photoresist to light emission surface 102 side of substrate 100 in step F5 described below. In addition, surfaces of substrate 100 such as light incidence surface 101 side keep water-repellant property, because they are covered with alkylsilane film 801. Accordingly, an effect of inhibiting deposition of positive photoresist on the surfaces of substrate 100 such as light incidence surface 101 side is also provided.
<Step F5>
Next, as illustrated in
<Step F6>
Then, condenser lens 810 is again disposed at the light incidence surface 101 side of substrate 100 as illustrated in
Then, nearly parallel light 805 (including parallel light) in an ultraviolet wavelength region, for example, is made incident from a light incidence surface 810a side of condenser lens 810. Incident nearly parallel light 805 is converged by condenser lens 810. Converged nearly parallel light 805 passes through light guide members 300 while being refracted, and is emitted from the surfaces of light guide members 300 facing light incidence surface 101 of substrate 100. The emitted light passes through substrate 100, and emitted on positive photoresist layer 804 at a light emission surface 102 side of substrate 100. With this, positive photoresist layer 804 which covers a condensing spot where light is condensed through condenser lens 810 and light guide members 300 or the vicinity of the condensing spot is exposed in a rectangular shape, for example.
Next, as illustrated in
<Step (F7)>
Next, as illustrated in
<Step F8>
Next, as illustrated in
By the processes in steps F1 to F8 described above, second hydrophilic regions 110b enclosed by fluoroalkylsilane film 802 are formed on the condensing spot of condenser lens 810 through light guide members 300 or in the vicinity of the condensing spot. Fluoroalkylsilane film 802 functions as second water-repellant region 120b.
In this case, the area of second hydrophilic regions 110b which are formed in step F and on which photoelectric conversion elements 400 are mounted is larger than the area of the first hydrophilic regions 110a which are formed in step B and on which light guide members 300 are mounted. The reason for this is as follows. Firstly, a second distance from photoresist layer 804 to condenser lens 810 during formation of second hydrophilic regions 110b is different from a first distance from photoresist layer 804 to condenser lens 810 during formation of first hydrophilic regions 110a. Specifically, the exposure process of positive photoresist in step F is performed by light after passing through substrate 100. Therefore, the second distance from photoresist layer 804 to condenser lens 810 is increased. With this, light incident on light incidence surface 101 of substrate 100 spreads when passing through substrate 100. Consequently, the area of second hydrophilic regions 110b is larger than the area of first hydrophilic regions 110a.
[2-3-2. Application of Adhesive]
<Step G>
Next, in step G, adhesive 211 is applied to and filled in second hydrophilic regions 110b as in step C described with reference to
[2-3-3. Mounting of Photoelectric Conversion Element]
<Step H>
Next, a method for mounting photoelectric conversion elements 400 will be described with reference to
As illustrated in
In this case, interface tension (surface tension) of adhesive 211 is exerted on photoelectric conversion element 400 which is mounted. With this, photoelectric conversion element 400 moves to the center of adhesive 211 applied to each of second hydrophilic regions 110b. As a result, photoelectric conversion element 400 is disposed at the center of each of second hydrophilic regions 110b by a self-alignment effect due to adhesive 211.
[2-3-4. Fixation of Photoelectric Conversion Element]
<Step I>
Finally, step I for fixing a photoelectric conversion element will be described with reference to
As illustrated in
Photovoltaic cell 1 according to the above exemplary embodiment includes translucent substrate 100; photoelectric conversion element 400 disposed on light emission surface 102 of substrate 100; and light guide member 300 disposed on a light incidence surface of substrate 100, at a position opposite photoelectric conversion element 400 across substrate 100. With this configuration, photovoltaic cell 1 is capable of efficiently guiding incident sunlight to photoelectric conversion element 400, whereby light use efficiency can be enhanced.
By each step described above, photoelectric conversion element 400 can precisely be disposed on a condensing spot formed by condenser lens 810 and light guide member 300 or the vicinity of the condensing spot (see
A manufacturing method of photovoltaic cell 1 according to the present disclosure includes: forming first hydrophilic region 110a on light incidence surface 101 of translucent substrate 100; disposing light guide member 300 within first hydrophilic region 110a; forming second hydrophilic region 110b on light emission surface 102 of substrate 100; and disposing photoelectric conversion element 400 in second hydrophilic region 110b. Second hydrophilic region 110b which is formed on light emission surface 102 of substrate 100 and on which photoelectric conversion element 400 is disposed is formed by an exposure process of positive photoresist layer 804 using light guide member 300. Therefore, relative alignment between condenser lens 810 and both light guide member 300 and photoelectric conversion element 400 can easily and precisely be performed. This can allow sunlight incident on light guide member 300 to be reliably incident on photoelectric conversion element 400. Consequently, light use efficiency can be enhanced, whereby a highly efficient photovoltaic cell can be implemented.
As presented above, the exemplary embodiment has been described as an example of the technique described in the present application. However, the technique in the present disclosure is not limited to these, and can be applied to embodiments in which various changes, replacements, additions, omissions, or the like are made. Moreover, constituent elements described in the above exemplary embodiment can be combined to provide a new embodiment.
Other exemplary embodiments will be illustrated below.
The present exemplary embodiment describes that light incidence surface 101 and light emission surface 102 of substrate 100 undergo the exposure process, one at a time, to form corresponding hydrophilic regions 110 and water-repellant regions 120. However, the configuration is not limited thereto. For example, light incidence surface 101 and light emission surface 102 of substrate 100 may simultaneously undergo the exposure process to form corresponding hydrophilic regions 110 and water-repellant regions 120. In this case, positive photoresist is applied to both surfaces of substrate 100 to form photoresist layer 804, and then, both surfaces are exposed by incidence of nearly parallel light 805 on both surfaces.
In addition, the present exemplary embodiment may be configured such that photovoltaic cell 1 is provided with a tracking device which detects the direction of the sun and allows sunlight to be vertically incident on an optical axis of condenser lens 810 according to the direction of the sun. With this configuration, a more efficient photovoltaic cell can be implemented.
Note that the above-described embodiments have been described to exemplify the technique according to the present disclosure, and therefore, various modifications, replacements, additions, and omissions may be made within the scope of the claims and the scope of the equivalents thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015-056718 | Mar 2015 | JP | national |
| 2016-002209 | Jan 2016 | JP | national |
