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    10 views22 pages

    US10593820B2

    Uploaded by

    EL OUARGUI El Mehdi

    Copyright:

    © All Rights Reserved
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    «2 United States Patent Nakano et al. 1US010S93820B2 IS 10,593,820 B2 Mar. 17, 2020 20) Patent No.: 4s) Date of Patent: (4) om m™ 3) w a @) (86) «n) (6) (0) Mar. 31, 2014 1) (2) SOLAR CELL MODULE AND METHOD FOR MANUFACTURING SAME Applicant: KANEKA CORPORATION, ‘Osak-shi, Osaka (IP) Inventors: Kunihiro Nakano, Setsu (JP); Kunta Yoshikawa, Sets JP}; Torw Terashita, Setsu (3P); Masafumi Hiraishi, Setsu (1P); Kenji Yamamoto, Settsu (JP) KANEKA CORPORATION, ‘Osaka-shi, Osaka (1D) Assignee "Notice: Subject ro any disluimer, the term of this patent is extended or adjusted under 35 USC. 154(b) by 68 days Appl. No. 15/128,360 PCT Filed PCT No, §371 ©), (2) Date: PCTIIP20151089516 Sep. 22, 2016 PCT Pulp, No: WO2018/152020 PCT Pub, Date: Oet. 8, 2018 Prior Publication Data US 201710125619 AL May 4, 2017 Foreign Application Priority Data ) 2014074692 Int. Cl HORN 600 HOLL 31/082 (2006.01) (01401) (Continued) us. cl. CPC. HOM, 31/043 (2014.12); HOLL 31/0201 2013.01); HOLL 31702167 (2013.01); (Continued) (68) Fleld of Classification Search crc HOI 31/043; HOLS 5/0202 See application file for complete search history 66) References Cited US, PATENT DOCUMENTS 7825329 B2* 112010 Basel OIL 3103028 136282 $129.12 BZ ¥2012 Wijekoon et al (Continued) FOREIGN PATENT DOCUMENTS ® SsLIZ2S74 U—o11976 Ss93080 A “11984 (Continued) OTHER PUBLICATIONS International Buea of WIPO, lternational Preliminary Report on Patentability [sue in Application No, PCT IP201S059816, Ot 13, 2016, WIPO, 7 pages (Continued) Primary Examiner (74) Attorney & Tule LLP Angelo Trivisonno {gent or Firm — Alleman Hall Creasman 7) Inthe solar cell module, a first solar cell and a second solar cell are stacked together with an electrocondoctive member interposed therebetwoen, such that a cleaved surfaceside periphery on a light-receiving surface of the first solar cell ‘overlaps a periphery on a back surface ofthe second solar cell. The first solar cell and the second solar cell each have: photoelectric conversion section including a crystalline sil «on substrate; collecting electrode; and back electrode. Ata section where the frst solr cell andthe sevond solar eel are stacked, the collecting eloctrode of the first solar cell and the back eleciode of the second solar cell are electrically connected to each other by coming into contact with the cleetrconductive member. An insulating member is pro vided on a pat of the cleaved sueface-side periphery on the (Continued) ABSTRACT US 10,593,820 B2 Page 2 light-roveiving surface of the first solar oell, where the collecting electrode is not provided. 15 Claims, 9 Drawing Sheets (51) Int. Cl HOL 31/043 (2014.01) HOLL 31224 (2006.01) HOIL 31905 (2014.01) HOLL 3192 (2006.01), HOLL 31216 (201401) HOLL 310382 (2006.01) HOI 3107 (2012.01) HOWL 3120 (2006.01), (2) US.cL cre HOLL 31022433 (2013.01), HOM, [310022466 (2013.01): HOIL 31/035281 (201301), HOLL 31/0504 (2013.01), HOI 1/077 (2013.01); HOLL 31/20 (2013.01), YORE 1030 (2013.01) (56) References Cited US. PATENT DOCUMENTS: 20060260673 A1* 11/2006 Takayama .... HOLL 302242 6/282 20100059790 A1* 32010 Takswoki Bary 20°00 257/105, 2OILULISAS AL S2D11 Kashkoush eta 2011008570 AL* 122011 Lach Hou 31 02008 62a 20120128391 AL* 52012 Pinabasi ooo. HOM 1/0808 6248 201310182996 AL® 62013. DeGroot OIL 31/0508 62a 2013/0269912 AL 102013 wade eal 20150078601 AL "32013 Adachi etal FOREIGN PATENT DOCUMENTS P ooianest A si1904 @ HIO2TOT3S A 1011998 » 200dliv6s7 A 42008 @ 2005123485 852005 ® 2oq0130103 § 62000 » 20121302 A 72012 @ 2oIDWSA6L A 102012 » 2013171503 492013 » Sa2SM9 BL 22014 (OTHER PUBLICATIONS ISA Japan Patt Ofice, Intemational Search Report Issved in Application No. PCTJP2018059516, May 26, 2015, WIPO, 4 pages Japanese Pate Office, Ofice Action Isted in Application No, 2016511607, dated Jun. 28,2019. 3 pag. Hooper A. eal, Review of Wafer Diving Techaigues for Via- ‘Mille Process 3D1TSV Uitthin Silicon Device War, hips so rescarchgate.nt publication 284 4062>, ticle ia Procead= ings Heston Components and Techaclogy Confrence, Jl 2015, 12 pages, * cited by examiner US 10,593,820 B2 Sheet 1 of 9 Mar. 17, 2020 USS. Patent FIG. 1 80 202 1190 190 FIG. 2 US. Patent Mar. 17,2020 Sheet 2 of 9 US 10,593,820 B2 FIG.3 1 FIG. 4 n/ US. Patent Mar. 17,2020 Sheet 3 of 9 US 10,593,820 B2 FIG. 5 US. Patent Mar. 17,2020 Sheet 4 of 9 US 10,593,820 B2 FIG. 7A FIG. 7B US. Patent Mar. 17,2020 Sheet 5 of 9 US 10,593,820 B2 FIG. 8A FIG. 8B. “20a 80 US. Patent Mar. 17,2020 Sheet 6 of 9 US 10,593,820 B2 FIG.9 (a) -80 -150a USS. Patent Mar. 17, 2020 FIG. 10 110b+ FIG. 11 Sheet 7 of 9 US 10,593,820 B2 10a US. Patent Mar. 17,2020 Sheet 8 of 9 US 10,593,820 B2 FIG. 13 FIG. 14 10a — FIG. 15, US. Patent Mar. 17,2020 Sheet 9 of 9 US 10,593,820 B2 FIG. 16 FIG.17 FIG. 18 < Conventional Art > 270 US 10,593,820 B2 1 SOLAR CELL MODULE AND METHOD FOR -MANUEACTURING SAME. ‘TECHNICAL FIELD ‘The invention relates to solar cell module and method for ‘manufacturing thereof, BACKGROUND ART Since energy issues and global environmental isues are becoming more serious, solar cells are receiving more attention a an alternative energy source for replacing fossil fies. Inthe solar cell carrier (electrons and holes) gener- ated by photo imadiation 10 a photoelectric conversion section composed ofa semiondvctor junction or the like are extracted to an external circuit to generate electricity. Solar cell having a collecting electrode on the photoelectric con- version section is utilized for efciently extracting carriers, ‘generated at the photoelectric conversion section to the 2 extemal circuit Solar cells are casted broad iat thin-film-based solar cells in which a photoslectric conversion layer is deposited ‘on a plass substrate oF aa eleetroconductive substrate, and crystalline solar ells using a single-crystallne silicon sub- strate or a polyerystallne silicon substrate Generally, a plurality of soar cells are connected in series cor in parallel throogh a wiring member to form. a module, ‘and put into practical use, Solar cells are modularzed by an appropriate method. For example, the collecting electrode of the solar cell is electrically connected to a wiring member, and adjacent solar cell are connected to each other with & ‘gap section provided therebetween so thatthe solar cells are ‘hot in contact with each other. However, in a solar cell ‘module prepared in this way, the gap section is a region ‘hich does not contbute to passer generation, and there- fore module power generation elficiency is insuliien. Pateat Documents 1 t0 3 each propose a method for ‘manufacturing a solar cell module in which a plurality of solar cells are stacked together with an elecroconduetive ‘member interposed therebetween in such a manner that the peripheries of adjacent solar cells overlap each other ‘According to this method, the area of a region which does not contribute to power generation is reduced. Pateat Document I describes a method for manufacturing «a solar cell module in which a plurality of solar cells each hhaving a small area are connected 10 one another. The peripheries of solar ells are superimposed one another, and then cleaved, Patent Document 2 describes a solar cel module in which ‘2 plurality of solar ells each including an electroconductive substrate are connected to one another using a specific clectroconductive adhesive. In Patent Document 2, a thin- film-based solar cel is used in which an amorphous silicon thin-film ee. is deposited asa photoelectric conversion layer ‘on a flexible eleetrocondnetive substrate such as stainless stoe] substrate. Solar cells prepared by the above-mentioned method are cleaved to a predetermined size, and the periph cries of the solar cells are superimposed on each other. Patent Document 2 desribes thatthe et end surface ofthe solar cells covered with an insulating material for prevent- ing a front electrode layer and a back electrode layer being short-circuited Patent Document 3 describes a solar cell module in which solar cells each having a solar cell element formed on a rial flare stacked in such » manner thatthe ends ofthe solar cells overlap one another. Patent Document 3 deseribes 4s 2 that the ends of solar eels are connected by’ solder that is covered with an insulating member, so that stress concen: teation on the connection part can be relieved 10 prevent damage to the coaneetion part, ete. Patent Documeat 3 describes that an amomphous silicon thin-film ete. is depos ited on a metal Lilt prepare a solar cell shee, the solar cell, sheets cut toa predetermined size, and the ends ofthe solar cells are then superimposed on each other PRIOR ART DOCUMENTS: Patent Documents Patent Document I: Japanese Patent Lsidhopen Publica- tion No. $9.003980 Patent Document 2: Japanese Patent Lid-open Publica- tion No, 6-140651 Patent Document 3: Japanese Patent Laid-open Publica- tion No, 2009-130193 SUMMARY OF THE INVENTION Problems to be Solved by the Invention As described in Patent Documents 1 ta 3, the peripheries of solar cells are superimposed on one another with an clectroconductive member interposed hetween the solar cells, and thus the area of region which does not contribute to power generation can be reduced, so that the power eneraton ofa solar cell module can be increased, So far, studies have been conducted ona method in which thin-flm-based solar cells, patcularlythin-flm-based solar cells including a flexible substrate are stacked to be modu favized a8 described in Patest Document 2 and. Patent Document 3. For thin-flm-based solar eels, the following method is preferable from the viewpoint of manufacturing elliceney: a method in which a photoelectric conversion layer is formed om a substrate having a size that is as large as possible, the substrate is then divided cleaved to a predetermined siz, and the cleaved solar cells ate stacked, For thin-film solar cells, studies for improving a sola cell, ‘module manufactured by the method above have been conducted (On the other hand, for crystalline solar cells including a crystallin silicon substrate an attempt has not been made to prepare a solar cell module by superimposing the peripheries of solar cells oa one another. FIG. 18 is a plan view schematically showing one example of a collecting electrode to be used in a conven tional crystalline silicon-based solar cell. The collecting electrode 270 shown in FIG. 18 includes a finger electrode 271 for collecting a generated current, and a bus bar eloc- twode 272 which is substantially orthogonal to the finger electrode 271 and electrically connects solar eels. In modu Tarization, a wiring member is disposed on the bus bar electrode 272 to electrically connect solar cells, where solar cells are connected in series or in parallel ‘When solar cells each having a collecting electrode as described above are modularize, the finger electrode and the bus bar electrode provide a shading section. Particularly, the bus bar electrode has larger width, ax hence a lamer shading area as compared othe finger electrode. Therefore, even in crystalline solar cals itis effective to stack solar cells in such a manner thatthe peripheries of the solar cells ‘overlap one another in onder to reduce the shading area “Thus, the inventors have made-an attempt 1 cleavea solar cell having a crystalline silicon substrate toa predetermine US 10,593,820 B2 eS size, and stack the cleaved solar cells together with an cloctroconductive member interposed betwcon the solar cells, However, it bas been found that a sola cell module in ‘which solar cells are stacked by the abovesmentioned ‘method has lower conversion eficency and reliability as ‘compared to conventional solar cell modile in which solar cells are connected using a wiring member. Inview of the above-mentioned situation, an object of the present invention isto provide a solar ell module with high ‘conversion efficiency and reliability that can be prepared by stacking plurality of solar cells each including a crystalline silicon substrate cleaved to prodetermined size. “Means for Solving the Problems ‘The inventors have discovered that when a solar coll is cleaved to form a cleaved surféce on a lateral thereof, conversion eficiency and reliability ae deteriorated at the cleaved surlace. The reason for deterioration of module performance may be that a textured structure generally formed on a crystallin silicon substrate, ora structure of photoelectric conversion section (eg, semiconductor layer in a heterojunction solar cell) including the substrate is disordered due to cleavage of the subsite. The inventors have frst considered stacking solar cells in such a manner that the cleaved surface of a lower solar cell provides a shading section so that deterioration of module character ties in cleaved surface is suppress. However, it has been found that a cleaved surface is inferior in mechanical strength 1o a non-cleaved surface, and therefore when the cleaved surface ofa lower solar cell is covered with an upper solar cell, the lower solar cell is damaged at the cleaved surface during stacking the solar calls or modularizing the solar cells, and conversion ell- ciency and relsblity are deteriorated due to the damage. Accordingly, the inventors have considered providing an insulating member as a bulfer material on the cleaved surface-side periphery of the solar cel ‘The present invention relates to a solar coll module including a first solar cel, a second sola cel, an electo- conductive member, and an insulating member. The first solar cell and the second solr cell each have a photoelectric conversion section tht includes a erystalline silicon sub- strate of first concuctvity-type, a colleting electrode pro- ‘vided on a light-receiving surface of the photoelecteie con- version section, and a back electrode provided on a back surface of the photoelectic conversion section. In the fits, solar cell, the erystalline silicon substrate of first conduc~ tivity-¢ype has a frst principal surface on the light-eceiving side, a second principal surface on the back side, and a cleaved surface extending fom the frst prinepal surface the second principal surface. The first solar cell and the second solar cell are stacked together with an electrocon- ductive member inteposed therebetween in such & manner that the cleaved surface-side periphery on the light-receiving surface of the first soar cell overlaps the periphery on the ‘back surface ofthe second solar cell Ata stacked section of the first solar cell and the second solar eel, the collecting

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