The present invention relates to a solar cell, a solar cell module, and a method for manufacturing the solar cell.
A solar cell has a photoelectric conversion unit and an electrode formed on a main surface of the photoelectric conversion unit (see, for example, Patent Document 1). The electrode includes fine-line finger portions. Patent document 1 discloses a structure in which finger portions having different widths are combined.
Patent Document 1: Japanese Registered Utility Model No. 3154145
In order to modularize the solar cell, wiring members for electrically connecting a plurality of solar cells to each other are attached to the finger portions. Although the wiring members are thermally compressed onto the finger portion using, for example, an adhesive, typically, there are irregularities on the finger portion, and thus a convex portion contacts the wiring member to thereby function as a collecting point. However, because these irregularities exist at random, the collecting points occur randomly, and this may cause a longer current path and thus output loss.
A solar cell according the present invention has current collecting finger portions formed on a main surface of a photoelectric conversion unit, and in this solar cell a separation region is formed on the main surface so as to extend in a direction intersecting with the current collecting finger portions to thereby separate the current collecting finger portions, and the current collecting finger portions arranged on both sides of the separation region with the separation region therebetween are electrically separated from each other.
A solar cell module according to the present invention has a plurality of the solar cells and a wiring member for connecting the solar cells, and in this module, the wiring member is provided so as to extend across ends of current collecting finger portions arranged on both sides of the separation region with the separation region therebetween.
A method of manufacturing a solar cell according to the present invention has the step of forming current collecting finger portions on a main surface of a photoelectric conversion unit by screen printing, and in this step, the current collecting finger portions are formed while a separation region extending in a direction intersecting with the current collecting finger portions to separate the current collecting finger portions remains on the main surface, and the current collecting finger portions arranged on both sides of the separation region with the separation region therebetween are electrically separated.
With the present invention, it is possible to increase output of the solar cell.
The embodiment of the present invention, that is, a solar cell 10, will be described in detail by reference to the drawings. The present invention is not limited to the below-described embodiment. In addition, because the figures referred to in the embodiment are drawn schematically, the size and the ratio of the components drawn in the figures may differ from those of actual components. The specific size and ratio should be decided in consideration of the following description.
In the present embodiment, the direction in which semiconductor layers and electrodes are layered in the photoelectric conversion unit will be referred to as the “thickness direction”.
The structure of the solar cell 10 will be described in detail by reference to
The solar cell 10 has a photoelectric conversion unit 11 which generates carriers (electrons and electron holes) by receiving solar light, a light receiving surface electrode 12 formed on a light receiving surface of the photoelectric conversion unit 11, and a back surface electrode 13 formed on the back surface of the photoelectric conversion unit 11. In the solar cell 10, the carriers generated in the photoelectric conversion unit 11 are collected by the light receiving surface electrode 12 and the back surface electrode 13. The solar cell 10 has current collecting finger portions 32 and 42 to which the wiring members 54 are connected during modularization. In the present embodiment, the solar cell 10 further has connecting finger portions 33 and 43, and these finger portions will be collectively referred to as finger portions 31 and 41 for explanation.
Here, the “light receiving surface” means a main surface onto which solar light is mainly incident from outside the solar cell 10. For example, 50% to 100% of solar light entering the solar cell 10 enters from the light receiving surface side. The “back surface” means a main surface on the opposite side of the light receiving surface. The surfaces which are provided along the thickness direction of the solar cell 10 and are vertical to the main surface are side surfaces.
The photoelectric conversion unit 11 has, for example, a semiconductor substrate 20, an amorphous semiconductor layer 21 formed on the light receiving surface side of the substrate 20, and an amorphous semiconductor layer 22 formed on the back surface side of the substrate 20. The amorphous semiconductor layers 21 and 22 are formed so as to cover the entire areas of the light receiving surface and the back surface, respectively (including when the entire area is considered to be substantially covered, such as, for example, 95% of the light receiving surface is covered. The same shall apply hereafter).
A specific example of the substrate 20 includes an n-type single crystal silicon substrate. The amorphous semiconductor layer 21 has a layered structure in which, for example, an i-type amorphous silicon layer and a p-type amorphous silicon layer are formed sequentially. The amorphous semiconductor layer 22 has a layered structure in which, for example, an i-type amorphous silicon layer and an n-type amorphous silicon layer are formed sequentially. The photoelectric conversion unit 11 may have a structure in which an i-type amorphous silicon layer and an n-type amorphous silicon layer are sequentially formed on the light receiving surface of the n-type single crystal silicon substrate, while an i-type amorphous silicon layer and a p-type amorphous silicon layer are sequentially formed on the back surface of the n-type single crystal silicon substrate. The photoelectric conversion units 11 can be formed by known methods.
It is preferable to form a texture structure on the light receiving surface and the back surface of the substrate 20. The texture structure is an irregular surface structure for suppressing surface reflectance and increasing light absorption amount by the photoelectric conversion unit 11. The irregularity height of the texture structure is approximately 1 μm to 15 μm. Because the thicknesses of the amorphous semiconductor layers 21 and 22 and transparent conductive layer 30 and 40 are several nm to several tens nm, the irregularity of the texture structure also appears on the transparent conductive layer 30 and 40. The texture structure may also affect the surface shape of the finger units 31 and 41.
The light receiving surface electrode 12 preferably includes the transparent conductive layer 30 formed on the light receiving surface of the photoelectric conversion unit 11. A transparent conductive oxide (TCO) obtained by doping metal oxide, such as indium oxide (In2O3) and zinc oxide (ZnO), with tin (Sn) or antimony (Sb) can be adopted as the transparent conductive layer 30. The transparent conductive layer 30 can be formed by sputtering. Although the transparent conductive layer 30 may be formed on the entire area of the amorphous semiconductor layer 21, in the embodiment shown in
Further, the light receiving surface electrode 12 preferably includes a plurality of (for example, 50) finger portions 31 formed on the transparent conductive layer 30 and a plurality of (for example, two) bus bar portions 34 formed on the transparent conductive layer 30 so as to extend in the direction intersecting with the finger portion 31. The finger portions 31 are fine-line electrodes formed on a broad area of the transparent conductive layer 30. The bus bars 34 are electrodes which are smaller in number than the finger portions 31 and collect carriers from the finger portions 31.
In the present embodiment, two bus bar portions 34 are arranged in parallel to each other with a predetermined interval therebetween, and the plurality of finger portions 31 are arranged orthogonal to them (including when the finger portions 31 can be regarded as substantially orthogonal to the two bas bars 34, such as when the angle between the finger portions 31 and the bus bar portions 34 is 90°±5°. The same shall apply hereafter).
Like the light receiving surface electrode 12, the back surface electrode 13 preferably includes a transparent conductive electrode 40, a plurality of finger portions 41, and a plurality of bus bar portions 44. However, because, compared to the finger portions 31 on the light receiving surface side, the finger portions 41 are less affected by shadow loss, it is preferable to install more finger portions 41 than the finger portions 31 with narrower intervals (for example, 250 finger portions 41 with an interval of 0.5 mm). In other words, the main surface on which more finger portions are formed is the back surface. If light receiving loss from the back surface side is not a problem, a metal film, such as a silver (Ag) film, may be formed on the approximately entire area of the back surface of the photoelectric conversion unit 11, instead of the finger portions 41.
Although the finger portions 31 and 41 and the bus bar portions 34 and 44 can be formed by plating or sputtering, they are preferably formed by screen printing in terms of productivity, etc. In the screen printing, after a conductive paste (for example, a silver paste) is screen printed on the transparent conductive layer 30 in a desired pattern, a solvent contained in the paste is allowed to volatilize, and the finger portions 31 and the bus bar portions 34 are formed. The conductive paste may include, for example, a binder resin such as an epoxy resin, conductive fillers such as silver and carbon dispersed in the binder resin, and a solvent such as butyl carbitol acetate (BCA). That is, the finger portions 31 and 34 and the bus bar portions 34 and 44 are made of a binder resin in which conductive fillers are dispersed.
A plurality of solar cells 10 are, for example, arranged on the same plane and modularized by means of a first protection member 51 for covering the light receiving surface side, a second protection member 52 for covering the back surface side, and a encapsulant 53 provided between the first protection member 51 and the second protection member 52 (see
The structure near the bus bar portion 34 of the light receiving surface electrode 12 will be further described in detail by reference to
In the present embodiment, the finger portion 31 is configured to include the current collecting finger portion 32 and the connecting finger portion 33. On the light receiving surface, a separation region R extending in the direction intersecting with the current collecting finger portions 32 to separate the current collecting finger portions 32 (see
The current collecting finger portions 32 and the connecting finger portions 33 are formed, for example, on the same straight line orthogonal to the bus bar portion 34. One end of the connecting finger 33 is connected to the current collecting finger portion 32, and the other end is connected to the bus bar portion 34. That is, some of the carriers collected in the current collecting finger portions 32 are transported to the bus bar portion 34 via the connecting finger portion 33. The connecting finger portions 33 are formed so as to extend outward from both ends of the bus bar portion 34 in the width direction in a region near the bus bar portion 34.
The lengths of the connecting finger portions 33 are equal to each other (including when they can be considered to be substantially equal to each other, such as when a difference in the lengths is within 5%). That is, a pair of connecting finger portions 33a and 33b extending outward from both ends of the bus bar portion 34 in the width direction have equal lengths. It is then preferable to position the bus bar portion 34 in the center position between the pair of current collecting finger portions 32a and 32b (i.e. separation region R) connected to the bus bar portion 34 via the connecting finger portions 33a and 33b.
The connecting finger portion 33 is preferably formed within a range of approximately 2.0 mm from the end of the bus bar portion 34. In other words, the length Lf of the connecting finger portion 32 is preferably 2.0 mm or less. Although the length Lf is preferably changed according to the width Wb of the bus bar portion 34 and the width Wt of the wiring member 54, typically, a length is preferably from 0.1 mm to 1.0 mm, and more preferably, from 0.2 mm to 0.7 mm. In the present embodiment, {Lf×2+Wb} is equal to the distance Ld between the current collecting finger portions 32a and 32b (that is, the width of the separation region R).
The wiring member 54 is provided across the ends of the current collecting finger portions 32a and 32b located on both sides of the separation region R with the separation region R therebetween (see
The connecting finger portions 33a and 33b are entirely covered by the wiring member 54. Regarding the current collecting finger portions 32a and 32b, only their ends on the separation region R side are covered by the wiring member 54. The wiring member 54 is located such that the center portion of the wiring member 54 in the width direction matches the center portion of the bus bar portion 34 in the width direction, and the lengths Le of the ends of the current collecting finger portions 32a and 32b covered by the wiring member 54 are preferably equal to each other. The length Le is preferably from 0.05 mm to 1.0 mm, and more preferably, 0.1 mm to 0.5 mm, in consideration of shortening of the current path and installation tolerance of the wiring member 54.
The height h1 of the connecting finger portion 33 is set to be lower than the height h2 of the end of the current collecting finger portion 32 on the separation region R side (see
While contact between the wiring member 54 and the connecting finger portions 33 is prevented or suppressed by setting the height h1 to be lower than h2, the collecting finger portions 32 contact the wiring member 54. The ends of the current collecting finger portions 32a and 32b on the separation region R side contact the ends of the wiring member 54 in the width direction, respectively. Meanwhile, the portion near the middle portion of the wiring member 54, which is away from the both end portions of the wiring member 54 in the width direction, does not contact the finger portions 31. The contact portions between the wiring member 54 and the collecting finger portions 32 become collecting points P (see
The difference Hd in the heights (that is, h2−h1) between the current collecting finger portion 32 on which the collecting point P is provided and the connecting finger portion 33 is preferably made greater than the height h3 which is the surface irregularity of the current collecting finger portion 32. In particular, when the finger portions 31 are formed by screen printing, this structure is preferable because irregularity tends to be formed on the electrode surface. By making the height difference Hd greater than the surface irregularity height h3, it is possible to prevent the wiring member 54 from contacting the connecting finger portions 33 and enable the collecting points P to be arranged at the ends of the current collecting finger portions 32 on the separation region R side in a more reliable manner. Here, the height h3 of the surface irregularity is an average that can be calculated by three-dimensional measurement SEM.
More specifically, the height h2 of the current collecting finger portion 32 is preferably from 15 μm to 50 μm, and more preferably from 20 μm to 40 μm. The height h1 of the connecting finger portion 33 is preferably from 5 μm to 30 μm, and more preferably, from 10 μm mm to 20 μm, within a range that satisfies the condition height h2>height h1. For example, the height h1 is preferably set to be approximately ½ of the height h2. Adopting such heights h1 and h2 enables the collecting points P to be positioned at the ends of the current collecting finger portions 32 on the separation region R side in a more reliable manner.
By forming the line width of the connecting finger portion 33 so as to be smaller than that of the current collecting finger portion 32 based on the experiment results shown in
In the present embodiment, the height of the bus bar portion 34 is set to be equal to that of the current collecting finger portion 32, and the collecting points are also formed on the bus bar portions 34.
Next, the functions and the effects of the solar cell 10 and solar cell module 50 will be described in detail by reference to
In the solar cell module 50, the wiring member 54 is connected onto the bus bar portion 34 and the current collecting finger portion 32 using, for example, an adhesive 55. The adhesive 55 is a non-conductive adhesive or a conductive adhesive in which conductive fillers, such as silver, are dispersed in a resin. The wiring member 54 is thermally compressed to the current collecting finger portion 32, etc. with the film type adhesive 55 therebetween. In this thermal compression, convex portions on the surface of the current collecting finger portion 32, etc. are pressed by the wiring member 54 and compressed, and, for example, the wiring member 54 and those convex portions contact each other. The adhesive 55 mainly exists in concave portions on the electrode surface and strongly bond the wiring member 54 to the electrode. Thus, the collecting point P is formed.
Because, in the embodiment illustrated in
Further, if the collecting point P at the end of the current collecting finger portion 32 is lost due to, for example, an impact while in use, carriers collected in the current collecting finger portion 32 are transported to the bus bar portion 34 via the connecting finger portion 33 and extracted from the collecting point of the bus bar portion 34.
Further because a contact surface between the wiring member 54 and the electrode is small in the solar cell module 50, it is also possible to reduce pressure for thermal compression. Thus, it is possible to suppress cracks in the solar cell 10 during thermal compression, even if the thickness of the substrate 20 is thin.
The back surface electrode 13 can also achieve the same functions and effects if it is configured to have the same structure as the light receiving surface electrode 12.
The design of the above embodiment can be changed as desired within a scope without departing from the objective of the invention.
In
In other words, in both of the solar cell 10 and its variant, a plurality of current collecting finger portions 32, which intersect with the separation region R, are formed on both sides of the separation region R with the separation region R therebetween. Therefore, the ends of the plurality of current collecting finger portions 32 which are set as the collecting points are arranged along the separation region R, and it is possible to concentrate the collecting points on both sides of the separation region R. As such, with the solar cell 10 and its variant, it is possible to form the current path effectively and reduce output loss. In other words, it is possible to reduce variations in the collecting points, thereby increasing output.
The present application is a continuation under 35 U.S.C. §120 of PCT/JP2011/072312, filed Sep. 29, 2011, which is incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
Parent | PCT/JP2011/072312 | Sep 2011 | US |
Child | 14218185 | US |