Environmental power generator and method for manufacturing same

Abstract

An environmental power generator, which has a first conductive substrate layer (2), a current collector layer (3), a sealing material layer (4), and a second conductive substrate layer (5) in this order, is provided with: a power generation unit that has a peripheral edge section (6a) formed by the first conductive substrate layer (2), the current collector layer (3), the sealing material layer (4), and the second conductive substrate layer (5); the energy of the external environment is converted into electric power; and an output unit (7) provided on the outside of the power generation unit and formed from the first conductive substrate layer and the current collector layer, the output unit having: a first portion (3a) of the current collector layer to which the power is supplied from the power generation unit; a second portion (3b) of the current collector layer, separated from the first portion; an electronic component (8) electrically connecting the first portion and the second portion; and a sealing member (9) that seals the electronic component.

Description

Technical Field

[0001] The present invention relates to an environmental power generator and a method for manufacturing the same. Background Art

[0002] An environmental power generator that sequentially includes a first conductive substrate layer, a current collector layer, a seal layer, and a second conductive substrate layer is known. It has: a power generation unit that has a peripheral portion formed by the first conductive substrate layer, the current collector layer, the seal layer, and the second conductive substrate layer, and converts the energy of the external environment into electric power; and an output unit that is provided outside the power generation unit and is formed by the first conductive substrate layer and the current collector layer (for example, refer to Patent Document 1).

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: International Publication No. 2019 / 188433. Summary of the Invention

[0006] Problems to be Solved by the Invention

[0007] When an electronic component is provided in the output unit for the purpose of suppressing the reverse flow of current or the like, an environmental power generator as described above preferably adopts a structure that can suppress the thickness of the environmental power generator as much as possible.

[0008] An object of the present invention is to provide an environmental power generator that can suppress the thickness of the environmental power generator and has an electronic component provided in the output unit, and a method for manufacturing the same.

[0009] Solutions to the Problems

[0010] One aspect of the present invention is as follows.

[0011] [1] An environmental power generator that sequentially includes a first conductive substrate layer, a current collector layer, a seal layer, and a second conductive substrate layer, characterized in that it has:

[0012] A power generation unit that has a peripheral portion formed by the first conductive substrate layer, the current collector layer, the seal layer, and the second conductive substrate layer, and converts the energy of the external environment into electric power; and

[0013] An output unit that is provided outside the power generation unit and is formed by the first conductive substrate layer and the current collector layer,

[0014] The output unit has: a first part of the current collector layer, which is supplied with the electric power by the power generation unit; a second part of the current collector layer, which is separated from the first part; an electronic component, which electrically connects the first part and the second part; and a sealant, which seals the electronic component.

[0015] [2] The ambient power generator according to [1], wherein the second conductive substrate layer is arranged not to overlap with the electronic component in the stacking direction.

[0016] [3] The ambient power generator according to [1] or [2], wherein the electronic component suppresses the reverse flow of current between the first part and the second part of the current collector layer.

[0017] [4] The ambient power generator according to [3], wherein the electronic component is a diode.

[0018] [5] The ambient power generator according to any one of [1] to [4], wherein the sealant is continuously formed of the same material in the sealant layer.

[0019] [6] The ambient power generator according to any one of [1] to [5], wherein the output unit has a pair of output electrodes formed of the current collector layer,

[0020] At least one of the output electrodes is formed of the second part of the current collector layer and a metal layer, and the metal layer is stacked on the opposite side of the first conductive substrate layer with respect to the second part of the current collector layer.

[0021] [7] The ambient power generator according to [6], wherein the power generation unit has a power generation unit group composed of a plurality of power generation units that electrically connect the pair of output electrodes to each other.

[0022] [8] The ambient power generator according to [7], wherein the power generation unit group has a first power generation unit row composed of a plurality of the power generation units electrically connected in series with each other, and a second power generation unit row composed of a plurality of the power generation units electrically connected in series with each other,

[0023] The power generation unit has a current collector that electrically connects the first power generation unit row and the second power generation unit row to each other.

[0024] [9] The ambient power generator according to [8], wherein the current collector is formed of the current collector layer.

[0025]

[10] The ambient power generator according to any one of [6] to [9] has, in order, a first barrier layer, the first conductive substrate layer, the current collector layer, the sealant layer, the second conductive substrate layer, and a second barrier layer.

[0026] The seal, the second conductive substrate layer, and the second barrier layer are arranged such that at least a part of the metal layer of each of the output electrodes does not overlap in the stacking direction.

[0027]

[11] The environmental power generator according to any one of [1] to

[10] , wherein the power generation unit converts light energy in the external environment into the electric power.

[0028]

[12] The environmental power generator according to any one of [1] to

[11] , which has an adhesive layer that is stacked between the electronic component and the first part of the current collector layer and between the electronic component and the second part of the current collector layer.

[0029] The adhesive layer electrically connects the electronic component to the first part of the current collector layer and the second part of the current collector layer, respectively.

[0030]

[13] The environmental power generator according to

[12] , wherein the adhesive layer is formed of an anisotropic conductive film.

[0031]

[14] The environmental power generator according to any one of [1] to

[13] , wherein the environmental power generator has a planar or curved outer shape.

[0032]

[15] The manufacturing method of the environmental power generator according to any one of [1] to

[14] , comprising:

[0033] A sealing step of continuously forming the seal layer and the seal with the same material.

[0034]

[16] The manufacturing method of the environmental power generator according to

[15] , comprising:

[0035] An electronic component arranging step of electrically connecting the electronic component to the first part of the current collector layer and the second part of the current collector layer, respectively,

[0036] The sealing step is performed after the electronic component arranging step.

[0037]

[17] The manufacturing method of the environmental power generator according to

[15] or

[16] , comprising:

[0038] A first barrier layer stacking step of stacking the first barrier layer on the first conductive substrate layer; and

[0039] A second barrier layer stacking step of stacking the second barrier layer on the second conductive substrate layer,

[0040] The sealing step is performed after the first barrier layer laminating step and after the second barrier layer laminating step.

[0041] The ambient power generation body sequentially has the first barrier layer, the first conductive substrate layer, the current collector layer, the sealant layer, the second conductive substrate layer, and the second barrier layer.

[0042] Advantages of the Invention

[0043] According to the present invention, it is possible to provide an ambient power generation body capable of suppressing the thickness of the ambient power generation body and arranging electronic components at the output part, and a manufacturing method thereof. Description of the Drawings

[0044] Figure 1 is a top view showing an ambient power generation body according to an embodiment of the present invention;

[0045] Figure 2 is Figure 1 a cross-sectional view taken along line A-A of Detailed Embodiments

[0046] Hereinafter, embodiments of the present invention will be illustrated with reference to the drawings.

[0047] As Figures 1 to 2 shown, in an embodiment of the present invention, an ambient power generation body 1 sequentially has a first conductive substrate layer 2, a current collector layer 3, a sealant layer 4, and a second conductive substrate layer 5. The ambient power generation body 1 has: a power generation part 6, which has a peripheral part 6a formed by the first conductive substrate layer 2, the current collector layer 3, the sealant layer 4, and the second conductive substrate layer 5, and converts the energy of the external environment into electric power; and an output part 7, which is provided outside the power generation part 6 and is formed by the first conductive substrate layer 2 and the current collector layer 3. The output part 7 has: a first part 3a of the current collector layer 3, which is supplied with electric power from the power generation part 6; a second part 3b of the current collector layer 3, which is separated from the first part 3a; an electronic component 8, which electrically connects the first part 3a and the second part 3b; and a sealant 9, which seals the electronic component 8.

[0048] According to the above structure, the electronic component 8 is arranged so as to electrically connect the first part 3a of the current collector layer 3 and the second part 3b of the current collector layer 3, thereby suppressing the thickness of the ambient power generation body 1. By sealing the electronic component 8 with the sealant 9, the stable operation of the electronic component 8 can be ensured. Therefore, according to the above structure, it is possible to realize an ambient power generation body 1 that can arrange the electronic component 8 at the output part 7 while suppressing the thickness of the ambient power generation body 1. In addition, according to the above structure, by suppressing the thickness of the peripheral part of the ambient power generation body 1, the intrusion of moisture and the like into the inside of the power generation part 6 can be suppressed. The current collector layer 3 is formed of, for example, silver paste.

[0049] The second conductive substrate layer 5 is arranged not to overlap with the electronic component 8 in the stacking direction. According to the above structure, the thickness of the environmental power generation body 1 can be further suppressed.

[0050] The electronic component 8 suppresses the countercurrent of the current between the first part 3a and the second part 3b of the current collector layer 3. According to the above structure, the countercurrent of the current at the output part 7 can be suppressed by the electronic component 8.

[0051] The anode of the electronic component 8 is electrically connected to the power generation part 6 via the first part 3a of the current collector layer 3, and the cathode of the electronic component 8 is electrically connected to the external device of the environmental power generation body 1 via the second part 3b of the current collector layer 3. According to the above structure, the working stability of the electronic component 8 can be improved.

[0052] The electronic component 8 is a diode. According to the above structure, the structure of the electronic component 8 for suppressing the countercurrent of the current can be simplified.

[0053] The seal 9 is continuously formed of the same material in the seal layer 4. According to the above structure, the sealing performance against moisture and the like at the peripheral part of the power generation part 6 can be improved. In addition, according to the above structure, the seal layer 4 and the seal 9 can be formed by the same process, so the manufacturing process can be simplified. The seal 9 and / or the seal layer 4 preferably has light transmissivity. The seal 9 and / or the seal layer 4 can be formed of, for example, a thermoplastic resin, a thermosetting resin, or a radiation (light, electron beam) curable resin, and more specifically, can be formed of an acrylic resin, a methacrylic resin, a fluororesin, a silicone resin, an olefin resin, or a polyamide resin, etc. In addition, these materials can be used alone or in combination of two or more.

[0054] The output part 7 has a pair of output electrodes 10 formed of the current collector layer 3, and at least one output electrode 10 is formed of the second part 3b of the current collector layer 3 and the metal layer 11, and the metal layer 11 is laminated so as to be on the opposite side of the first conductive substrate layer 2 with respect to the second part 3b of the current collector layer 3. According to the above structure, by using the metal layer 11 as the contact of the output part 7, the resistance of the contact of the output part 7 can be reduced and the output performance can be improved.

[0055] The power generation part 6 has a power generation unit group 12 composed of a plurality of power generation units that electrically connect the pair of output electrodes 10 to each other. According to the above structure, the required power generation performance can be efficiently achieved.

[0056] The power generation unit group 12 has a first power generation unit row 12a composed of a plurality of power generation units electrically connected in series with each other and a second power generation unit row 12b composed of a plurality of power generation units electrically connected in series with each other. The power generation section 6 has a current collector 13 that electrically connects the first power generation unit row 12a and the second power generation unit row 12b to each other. With the above structure, the power generation voltage can be efficiently increased.

[0057] The power generation units of the power generation unit group 12 are solar cell units. With the above structure, the environmental power generation body 1 can be configured as a solar cell.

[0058] The power generation units of the power generation unit group 12 are, for example, dye-sensitized solar cells. The dye-sensitized solar cells generate electricity, for example, by absorbing light with a dye adsorbed on porous titanium dioxide to generate electrons.

[0059] The current collector 13 is formed by the current collector layer 3. With the above structure, the structure of the current collector 13 can be simplified. In addition, with the above structure, the manufacturing process can be simplified.

[0060] The current collector layer 3 is formed, for example, by a conductive paste. The conductive paste is, for example, a mixture of conductive particles and a resin. There is no particular limitation on the conductive particles of the conductive paste constituting the current collector layer 3, and for example, they are copper, silver, carbon, etc. The current collector layer 3 can also be formed by pasting a metal foil with a conductive adhesive or the like.

[0061] The environmental power generation body 1 sequentially has a first barrier layer 14, a first conductive substrate layer 2, a current collector layer 3, a sealant layer 4, a second conductive substrate layer 5, and a second barrier layer 15. Among them, the sealant 9, the second conductive substrate layer 5, and the second barrier layer 15 are arranged so as not to overlap at least a part of the metal layer 11 of each output electrode 10 in the stacking direction. With the above structure, the metal layer 11 provided on each output electrode 10 can be used as a contact of the output section 7, and moisture and the like can be inhibited from invading the inside of the power generation section 6 through the first barrier layer 14 and the second barrier layer 15. In an environment with a temperature of 40 °C and a relative humidity of 90% (90% RH), the water vapor transmission rate of the first barrier layer 14 and the second barrier layer 15 is preferably 0.1 g / m 2 / day or less, more preferably 0.01 g / m 2 / day or less, further preferably 0.0005 g / m 2 / day or less, particularly preferably 0.0001 g / m 2 / day or less. The total light transmittance of the first barrier layer 14 and the second barrier layer 15 is preferably 50% or more, more preferably 70% or more, and further preferably 85% or more. Such total light transmittance can be measured, for example, in accordance with JIS K7361-1. The first barrier layer 14 and the second barrier layer 15 may be a film or a sheet having a barrier layer with low water vapor and gas permeability provided on a plastic support. Examples of the barrier film with low water vapor and gas permeability include materials vapor-deposited with silicon oxide and aluminum oxide, materials having an organic-inorganic hybrid coating layer, materials having an inorganic layered compound, materials laminated with inorganic materials, materials having organic layers and inorganic layers alternately laminated, materials having organic layers and inorganic layers continuously laminated, and the like. As needed, the first barrier layer 14 and the second barrier layer 15 may also be given a barrier function for blocking specific wavelengths such as ultraviolet rays, an antifouling function for preventing surface fouling, a hard coating function for preventing surface damage, and the like.

[0062] The environmental power generation body 1 may also be configured to have a pair of holes 16, for example. The pair of holes 16 is composed of one hole 16 that exposes at least a part of the metal layer 11 of one output electrode 10 and another hole 16 that exposes at least a part of the metal layer 11 of the other output electrode 10. According to the above structure, through the pair of holes 16, the metal layers 11 provided on the respective output electrodes 10 can be used as the contacts of the output portion 7. For example, a notch may be provided instead of the hole 16.

[0063] The power generation unit 6 converts the light energy of the external environment into electricity. According to the above structure, the environmental power generation body 1 can be configured as a photovoltaic power generation body.

[0064] The environmental power generation body 1 has an adhesive layer 17 laminated between the electronic component 8 and the first part 3a of the current collector layer 3 and between the electronic component 8 and the second part 3b of the current collector layer 3. The adhesive layer 17 is in contact with the electronic component 8, the first part 3a, and the second part 3b respectively. The adhesive layer 17 electrically connects the electronic component 8 to the first part 3a and the second part 3b of the current collector layer 3 respectively. According to the above structure, the thickness of the environmental power generation body 1 can be further reduced. In addition, the arrangement of the electronic component 8 is not limited to this. For example, the following structure may also be adopted: the adhesive layer 17 is not laminated on either the first part 3a or the second part 3b of the current collector layer 3, but is laminated on the first conductive substrate layer 2. The adhesive layer 17 is in contact with the electronic component 8, the first conductive substrate layer 2, the first part 3a, and the second part 3b respectively. The electronic component 8 is electrically connected to the first part 3a through the adhesive layer 17, and the electronic component 8 is electrically connected to the second part 3b through the adhesive layer 17.

[0065] The adhesive layer 17 is formed of an anisotropic conductive film such as an ACF (Anisotropic Conductive Film). According to the above structure, the manufacturing process can be simplified. The adhesive layer 17 can also be formed of silver paste, for example.

[0066] The outer shape of the ambient power generator 1 is not particularly limited. The ambient power generator 1 can adopt a structure with a planar outer shape, or can adopt a structure with a curved outer shape, for example. The thickness of the ambient power generator 1 is 0.3 mm to 5 mm, preferably 0.5 mm to 3 mm, and more preferably 0.6 mm to 1.5 mm.

[0067] In the case where vibration is used as the energy of the external environment, the ambient power generator 1 can also be configured such that the power generation unit 6 has a piezoelectric element that converts vibration into electricity, for example. In the case where geothermal energy is used as the energy of the external environment, the ambient power generator 1 can also be configured such that the power generation unit 6 has a heat exchange element that converts heat into electricity, for example.

[0068] The ambient power generator 1 can also be manufactured by a manufacturing method having a sealing step in which the sealant layer 4 and the sealant 9 are continuously formed of the same material. According to the above structure, a manufacturing method that can suppress the thickness of the ambient power generator 1 and dispose the electronic component 8 in the output unit 7 can be realized. In addition, according to the above structure, the sealant layer 4 and the sealant 9 can be formed by the same process, so the manufacturing process can be simplified.

[0069] The manufacturing method of the ambient power generator 1 can also be configured to have: an electronic component 8 arranging step of electrically connecting the electronic component 8 to the first part 3a of the current collector layer 3 and the second part 3b of the current collector layer 3 respectively, and the sealing step is performed after the electronic component 8 arranging step. According to the above structure, the manufacturing process can be simplified.

[0070] The manufacturing method of the ambient power generator 1 can also be configured to have: a first barrier layer 14 laminating step of laminating the first barrier layer 14 with the first conductive substrate layer 2; and a second barrier layer 15 laminating step of laminating the second barrier layer 15 with the second conductive substrate layer 5, and the sealing step is performed after the first barrier layer 14 laminating step and after the second barrier layer 15 laminating step. The ambient power generator 1 sequentially has the first barrier layer 14, the first conductive substrate layer 2, the current collector layer 3, the sealant layer 4, the second conductive substrate layer 5, and the second barrier layer 15. According to the above structure, the manufacturing process can be simplified.

[0071] The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist thereof.

[0072] Therefore, the environmental power generator 1 of the foregoing embodiment sequentially includes a first conductive substrate layer 2, a current collector layer 3, a seal layer 4, and a second conductive substrate layer 5, and has: a power generation unit 6, which has a peripheral portion 6a formed by the first conductive substrate layer 2, the current collector layer 3, the seal layer 4, and the second conductive substrate layer 5, and converts the energy of the external environment into electricity; and an output unit 7, which is disposed outside the power generation unit 6 and is formed by the first conductive substrate layer 2 and the current collector layer 3. The output unit 7 has: a first portion 3a of the current collector layer 3, which is supplied with electricity by the power generation unit 6; a second portion 3b of the current collector layer 3, which is separated from the first portion 3a; an electronic component 8, which electrically connects the first portion 3a and the second portion 3b; and a seal 9, which seals the electronic component 8. As long as it is such an environmental power generator 1, it can be changed.

[0073] Industrial applicability

[0074] According to the present invention, it is possible to provide an environmental power generator 1 and a manufacturing method thereof that can suppress the thickness of the environmental power generator 1 while providing an electronic component 8 in the output unit 7.

[0075] Description of reference numerals

[0076] 1: Environmental power generator;

[0077] 2: First conductive substrate layer;

[0078] 3: Current collector layer;

[0079] 3a: First portion;

[0080] 3b: Second portion;

[0081] 4: Seal layer;

[0082] 5: Second conductive substrate layer;

[0083] 6: Power generation unit;

[0084] 6a: Peripheral portion;

[0085] 7: Output unit;

[0086] 8: Electronic component;

[0087] 9: Seal;

[0088] 10: Output electrode;

[0089] 11: Metal layer;

[0090] 12: Power generation unit group;

[0091] 12a: First power generation unit row;

[0092] 12b: Second power generation unit column;

[0093] 13: Current collector;

[0094] 14: First barrier layer;

[0095] 15: Second barrier layer;

[0096] 16: Hole;

[0097] 17: Adhesive layer.

Claims

1. An environmental power generator, comprising a first conductive substrate layer, a current collector layer, a sealing layer, and a second conductive substrate layer in sequence, characterized in that: have: a power generation section having a peripheral portion formed by the first conductive substrate layer, the current collector layer, the sealant layer, and the second conductive substrate layer, and converting energy of an external environment into electric power; and an output portion, which is disposed outside the power generation portion and is formed by the first conductive substrate layer and the current collector layer, The output unit includes: a first portion of the current collector layer to which the power is supplied from the power generation unit; and a second portion of the current collector layer separated from the first portion. an electronic component electrically connecting the first portion with the second portion; and a sealing member that seals the electronic component.

2. The environmental power generator according to claim 1, wherein: The second conductive substrate layer is provided so as not to overlap with the electronic component in a stacking direction.

3. The environmental power generator according to claim 1, wherein: The electronic component suppresses reverse flow of current between the first portion and the second portion of the current collector layer.

4. The environmental power generator according to claim 3, wherein: The electronic component is a diode.

5. The environmental power generator according to claim 1, wherein: The seal is continuously formed of the same material in the seal layer.

6. The environmental power generator according to claim 1, wherein: The output portion has a pair of output electrodes formed by the current collector layer, At least one of the output electrodes is formed of the second portion of the current collector layer and a metal layer, and the metal layer is stacked so as to be located on the opposite side of the first conductive substrate layer with respect to the second portion of the current collector layer.

7. The environmental power generator according to claim 6, It comprises a first barrier layer, the first conductive substrate layer, the current collector layer, the sealing layer, the second conductive substrate layer, and a second barrier layer in sequence. The sealing member, the second conductive substrate layer, and the second barrier layer are provided so as not to overlap with at least a portion of the metal layer of each of the output electrodes in a stacking direction.

8. The environmental power generator according to claim 1, wherein: The power generation unit converts light energy of the external environment into the electric power.

9. The environmental power generator according to claim 1, comprising an adhesive layer. The adhesive layer is stacked between the electronic component and the first portion of the current collector layer and between the electronic component and the second portion of the current collector layer. The adhesive layer electrically connects the electronic component to the first portion of the current collector layer and the second portion of the current collector layer, respectively.

10. The environmental power generator according to claim 9, wherein: The adhesive layer is formed of an anisotropic conductive film.

11. The method for producing an environmentally friendly power generator according to any one of claims 1 to 10, comprising: The sealing step is to continuously form the sealing member layer and the sealing member with the same material.

12. The method for manufacturing an environmentally friendly power generator according to claim 10, comprising: an electronic component configuration step of electrically connecting the electronic component to the first portion of the current collector layer and the second portion of the current collector layer, respectively; The sealing step is performed after the electronic component arrangement step.

13. The method for manufacturing an environmentally friendly power generator according to claim 11, comprising: a first barrier layer lamination step of laminating the first barrier layer and the first conductive substrate layer; and a second barrier layer lamination step, laminating the second barrier layer and the second conductive substrate layer, The sealing step is performed after the first barrier layer lamination step and after the second barrier layer lamination step, The environmental power generator includes the first barrier layer, the first conductive substrate layer, the current collector layer, the sealing layer, the second conductive substrate layer, and the second barrier layer in this order.

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