Solar cell

Abstract

To reduce a curvature radius of a bent part of a film-like substrate in a solar cell using the substrate.SOLUTION: A solar cell 100 includes: a film-like substrate 10 including a main area 10A and a terminal area 10B and having a surface 11 and a surface 12 located on a side opposite to the surface 11; photoelectric conversion layers 21-24 provided on the surface 11 of the main area 10A of the substrate 10; an electrode layer 31 provided on the surface 12 of the terminal area 10B of the substrate 10; and a via conductor 51 provided to penetrate through the substrate 10 and connecting the photoelectric conversion layer 21 with the electrode layer 31. On the surface 11 of the substrate 10, a half-cut groove 71 is provided at a position overlapping with the electrode layer 31.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a solar cell, and more particularly to a solar cell using a film-shaped substrate.

Background Art

[0002] Patent Document 1 discloses a solar cell using a film-shaped substrate. In the solar cell described in Patent Document 1, the end of the substrate is bent 180° so that the terminal electrode faces the back side.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when a material that is difficult to elastically deform is used as the substrate material, there is a problem that when the substrate is bent, the radius of curvature of the bent portion becomes large.

[0005] In the present disclosure, a technique for reducing the radius of curvature of the bent portion of a substrate in a solar cell using a film-shaped substrate is described.

Means for Solving the Problems

[0006] A solar cell according to one aspect of the present disclosure includes a film-shaped substrate having a main region and a terminal region and having a first surface and a second surface located on the opposite side of the first surface, a photoelectric conversion layer provided on the first surface of the main region of the substrate, a first electrode layer provided on the second surface of the terminal region of the substrate, and a first via conductor provided through the substrate and connecting the photoelectric conversion layer and the first electrode layer. A first half-cut groove is provided on the first surface of the substrate at a position overlapping the first electrode layer.

Effects of the Invention

[0007] According to the present disclosure, in a solar cell using a film-like substrate, a technique for reducing the radius of curvature of a bent portion of the substrate is provided.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

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Figure 9

Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments of the technique according to the present disclosure will be described in detail with reference to the accompanying drawings.

[0010] FIG. 1(a) is a schematic plan view showing the appearance of a solar cell 100 according to an embodiment of the technology related to the present disclosure. Further, FIG. 1(b) is a schematic cross-sectional view taken along line A-A shown in FIG. 1(a).

[0011] As shown in FIG. 1(a), the solar cell 100 according to this embodiment has a film-like substrate 10 and photovoltaic conversion layers 21 to 24 provided on the surface 11 of the substrate 10. The substrate 10 is a flexible film-like member made of an insulating material such as polyethylene naphthalate and functions as a support for the photovoltaic conversion layers 21 to 24. The thickness of the substrate 10 is, for example, 75 to 90 μm. The substrate 10 includes a main region 10A and terminal regions 10B and 10C. The photovoltaic conversion layers 21 to 24 are provided on the surface 11 of the main region 10A of the substrate 10.

[0012] FIG. 2 is a schematic cross-sectional view of the solar cell 100.

[0013] As shown in FIG. 2, on the surface 11 of the substrate 10, there are provided photovoltaic conversion layers 21 to 24 and a sealing resin layer 80 that covers the photovoltaic conversion layers 21 to 24. In FIG. 1(b), the photovoltaic conversion layers 21 to 24 and the sealing resin layer 80 are omitted. The photovoltaic conversion layers 21 to 24 are semiconductor elements that convert incident light into electric power and are formed on substantially the entire surface of the main region 10A of the substrate 10 except for the outer peripheral portion. The sealing resin layer 80 is a protective member for protecting the light-receiving surface of the photovoltaic conversion layers 21 to 24 and is made of a thermosetting resin material such as polyimide.

[0014] The photovoltaic conversion layers 21 to 24 are, for example, connected in series in this order. The terminal 50 of the photovoltaic conversion layer 21 is connected to a via conductor 51 provided through the substrate 10. For the terminals (not shown) of the photovoltaic conversion layer 24, they are also connected to a via conductor (not shown) provided through the substrate 10. The terminals of the photovoltaic conversion layers 21 and 24 are concealed by being covered with colored resins 61 and 62. The connection portions connecting the photovoltaic conversion layer 21 and the photovoltaic conversion layer 22 and the connection portions connecting the photovoltaic conversion layer 23 and the photovoltaic conversion layer 24 may also be concealed by colored resins 63 and 64.

[0015] In the terminal region 10B of the substrate 10, an electrode layer 41 is provided on the surface 11 side, and an electrode layer 31 is provided on the surface 12 side located on the opposite side of the surface 11. Similarly, in the terminal region 10C of the substrate 10, an electrode layer 42 is provided on the surface 11 side, and an electrode layer 32 is provided on the surface 12 side. One end of the electrode layer 31 reaches the main region 10A and is connected to the terminal 50 of the photoelectric conversion layer 21 via the via conductor 51. Similarly, one end of the electrode layer 32 reaches the main region 10A and is connected to a terminal (not shown) of the photoelectric conversion layer 24 via a via conductor (not shown). Further, the other end of the electrode layer 31 is connected to the electrode layer 41 via the via conductor 52 provided through the substrate 10. Similarly, the other end of the electrode layer 32 is connected to the electrode layer 42 via a via conductor (not shown) provided through the substrate 10.

[0016] As the materials of the electrode layers 31, 32, 41, and 42, a flexible conductive paste may be used, or as shown in FIG. 3, a laminate of a conductive adhesive 91 and a metal foil 92 may be used.

[0017] In the present embodiment, half-cut grooves 71 and 72 are provided on the surface 11 of the substrate 10. The half-cut groove 71 is provided between the photoelectric conversion layer 21 and the electrode layer 41, and the half-cut groove 72 is provided between the photoelectric conversion layer 24 and the electrode layer 42. In the example shown in FIG. 1(a), the half-cut groove 71 is provided along the boundary between the main region 10A and the terminal region 10B, and the half-cut groove 72 is provided along the boundary between the main region 10A and the terminal region 10C. The depths of the half-cut grooves 71 and 72 are within a range where the strength of the substrate 10 in the portion where the half-cut grooves 71 and 72 are provided is ensured, and for example, are about half of the thickness of the substrate 10.

[0018] By providing such half-cut grooves 71 and 72, even when a material that is difficult to elastically deform, such as polyethylene naphthalate, is used as the material of the substrate 10, the substrate 10 can be easily bent along the half-cut grooves 71 and 72. That is, if the substrate 10 is bent along the half-cut grooves 71 and 72, the radius of curvature of the bent portion can be significantly reduced. Further, even if the substrate 10 is bent along the half-cut grooves 71 and 72, since the main region 10A hardly deforms, damage is less likely to be applied to the photoelectric conversion layers 21 to 24.

[0019] FIG. 4 is a schematic cross-sectional view showing a state in which the solar cell 100 according to the present embodiment is bent.

[0020] In the example shown in FIG. 4, a terminal region 10B bent by about 90° along the half-cut groove 71 is inserted between the substrate 210 and the substrate 220. Then, the electrode layer 31 of the solar cell 100 is connected to the electrode pattern 211 provided on the substrate 210, and the electrode layer 41 of the solar cell 100 is connected to the electrode pattern 221 provided on the substrate 220. Thus, the solar cell 100 according to the embodiment can be connected from both sides of the terminal region 10B. However, this point is not essential in the present invention, and the electrode layers 41 and 42 on the surface 11 side of the substrate 10 may be omitted. Also, regarding the half-cut grooves 71 and 72, it is not essential that they are provided along the boundaries between the main region 10A and the terminal regions 10B and 10C, and it is sufficient if they are provided at positions overlapping at least the electrode layers 31 and 32. Therefore, the half-cut grooves 71 and 72 may be provided in the terminal regions 10B and 10C, respectively.

[0021] FIG. 5(a) is a schematic plan view showing the appearance of the solar cell 101 according to the first modification. FIG. 5(b) is a schematic cross-sectional view taken along the line A-A shown in FIG. 5(a).

[0022] As shown in FIGS. 5(a) and 5(b), the solar cell 101 according to the first modification is different from the solar cell 100 shown in FIGS. 1(a) and 1(b) in that additional half-cut grooves 73 and 75 are provided on the surface 11 of the terminal region 10B, and additional half-cut grooves 74 and 76 are provided on the surface 11 of the terminal region 10C. Since other basic configurations are the same as those of the solar cell 100 shown in FIGS. 1(a) and 1(b), the same elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0023] The half-cut grooves 71, 73, and 75 extend parallel to each other, and the half-cut grooves 72, 74, and 76 extend parallel to each other. This enables the terminal regions 10B and 10C to be bent in multiple stages in the same direction. As a result, not only can the terminal regions 10B and 10C be bent more greatly, but it is also possible to relax the bending angle of each of the half-cut grooves 71 to 76.

[0024] FIG. 6 is a schematic plan view showing the appearance of the solar cell 102 according to the second modification.

[0025] As shown in FIG. 6, the solar cell 102 according to the second modification is different from the solar cell 100 shown in FIGS. 1(a) and 1(b) in that an additional half-cut groove 77 is provided on the surface 11 of the terminal region 10B. Since other basic configurations are the same as those of the solar cell 100 shown in FIGS. 1(a) and 1(b), the same elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0026] The half-cut groove 71 and the half-cut groove 77 extend perpendicular to each other. The symbol S shown in FIG. 6 is a slit, and at this portion, the substrate 10 is cut. This enables the terminal region 10B to be bent in multiple stages in different directions.

[0027] FIG. 7 is a schematic plan view showing the appearance of the solar cell 103 according to the third modification.

[0028] As shown in FIG. 7, the solar cell 103 according to the third modification is different from the solar cell 102 shown in FIG. 6 in that another half-cut groove 78 is further provided on the surface 11 of the terminal region 10B. Since the other basic configuration is the same as that of the solar cell 102 shown in FIG. 6, the same elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0029] The half-cut groove 77 and the half-cut groove 78 extend parallel to each other. This enables the terminal region 10B to be bent in multiple stages along the half-cut grooves 71, 77, 78.

[0030] FIG. 8 is a schematic plan view showing the appearance of the solar cell 104 according to the fourth modification.

[0031] As shown in FIG. 8, the solar cell 104 according to the fourth modification is different from the solar cell 100 shown in FIGS. 1(a) and (b) in that the terminal region 10B is surrounded by the main region 10A and a half-cut groove 79 is provided along the boundary between the terminal region 10B and the main region 10A. Since the other basic configuration is the same as that of the solar cell 100 shown in FIGS. 1(a) and (b), the same elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0032] The symbol S shown in FIG. 8 is a slit, and the substrate 10 is cut at this portion. That is, the terminal region 10B surrounded by the main region 10A has three sides separated from the main region 10A by the slit S and one side connected to the main region 10A via the half-cut groove 79. This enables the terminal region 10B to be bent along the half-cut groove 79.

[0033] FIG. 9 is a schematic plan view showing the appearance of the solar cell 105 according to the fifth modification.

[0034] As shown in FIG. 9, the solar cell 105 according to the fifth modification is different from the solar cell 100 shown in FIGS. 1(a) and 1(b) in that a slit S is provided in a part of the main region 10A located on the extension line of the edge of the terminal regions 10B and 10C. Since the other basic configurations are the same as those of the solar cell 100 shown in FIGS. 1(a) and 1(b), the same elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0035] The slit S is formed from the ends of the half-cut grooves 71 and 72 located at the boundary between the main region 10A and the terminal regions 10B and 10C toward the main region 10A side. Thus, when the substrate 10 is bent along the half-cut grooves 71 and 72, the bent portion of the substrate 10 moves inward by the amount of the slit S formed, so that the protrusion in the plan view of the bent portion is suppressed.

[0036] The length of the slit S is preferably equal to or greater than the thickness of the substrate 10. This is because if the length of the slit S is shorter than the thickness of the substrate 10, even when bent at a substantially right angle, the bent portion protrudes from the main region 10A in the plan view. Further, the length of the slit S is more preferably 1.1 times to 1.5 times the thickness of the substrate 10. This is because by making the length of the slit S 1.1 times or more the thickness of the substrate 10, the bent portion hardly protrudes, and by making the length of the slit S 1.5 times or less the thickness of the substrate 10, it is possible to minimize the reduction in the area of the photoelectric conversion layer.

[0037] Although the embodiments of the technology according to the present disclosure have been described above, the technology according to the present disclosure is not limited to the above embodiments, and various modifications can be made without departing from the gist thereof, and it goes without saying that those are also included within the scope of the technology according to the present disclosure.

[0038] The technology according to the present disclosure includes, but is not limited to, the following configuration examples.

[0039] The solar cell according to one aspect of the present disclosure includes a main region and a terminal region, and has a film-shaped substrate having a first surface and a second surface located on the opposite side of the first surface, a photoelectric conversion layer provided on the first surface of the main region of the substrate, a first electrode layer provided on the second surface of the terminal region of the substrate, and a first via conductor provided through the substrate to connect the photoelectric conversion layer and the first electrode layer. A first half-cut groove is provided on the first surface of the substrate at a position overlapping the first electrode layer. According to this, by bending the substrate along the first half-cut groove, it becomes possible to reduce the radius of curvature of the bent portion.

[0040] In the above solar cell, the first half-cut groove may be provided along the boundary between the main region and the terminal region. According to this, by bending the substrate along the first half-cut groove, it becomes possible to reduce the planar size of the substrate.

[0041] The above solar cell may further include a second electrode layer provided on the first surface of the terminal region of the substrate, and a second via conductor provided through the substrate to connect the first electrode layer and the second electrode layer. According to this, connection is possible from both sides of the substrate.

[0042] In the above solar cell, the first half-cut groove may be provided between the photoelectric conversion layer and the second electrode layer. According to this, the second electrode layer is not divided by the first half-cut groove.

[0043] In the above solar cell, a second half-cut groove may be further provided on the first surface of the terminal region of the substrate. According to this, it becomes possible to bend the substrate in multiple steps. In this case, the first half-cut groove and the second half-cut groove may extend parallel to each other, or may extend in different directions. According to the former, not only can the terminal region be bent more greatly, but also the bending angles of the first and second half-cut grooves can be relaxed. According to the latter, it becomes possible to bend the terminal region in multiple steps in different directions.

[0044] In the above solar cell, the terminal region may be surrounded by the main region. According to this, it becomes possible to dispose the electrode layer directly below the photoelectric conversion layer.

[0045] In the above solar cell, the substrate may have a slit formed on the extension line of the edge of the terminal region toward the main region side from the boundary between the main region and the terminal region. According to this, when the substrate is bent along the half-cut groove, it becomes possible to suppress the protrusion in the plan view of the bent portion.

Explanation of reference numerals

[0046] 10 Substrate 10A Main region 10B, 10C Terminal region 11, 12 Surfaces of the substrate 21~24 Photoelectric conversion layer 31, 32, 41, 42 Electrode layer 50 Terminal 51, 52 Via conductor 61~64 Resin 71~79 Half-cut groove 80 Encapsulation resin layer 91 Conductive adhesive 92 Metal foil 100~105 Solar cell 210, 220 Substrate 211, 221 Electrode pattern S Slit

Claims

1. A film-like substrate including a main region and a terminal region, and having a first surface and a second surface located on the opposite side of the first surface; A photoelectric conversion layer provided on the first surface of the main region of the substrate; A first electrode layer provided on the second surface of the terminal region of the substrate; A first via conductor provided through the substrate to connect the photoelectric conversion layer and the first electrode layer; Comprising; On the first surface of the substrate, a first half-cut groove is provided at a position overlapping the first electrode layer. A solar cell.

2. The first half-cut groove is provided along the boundary between the main region and the terminal region. The solar cell according to Claim 1.

3. A second electrode layer provided on the first surface of the terminal region of the substrate; A second via conductor provided through the substrate to connect the first electrode layer and the second electrode layer; Further comprising; The solar cell according to Claim 1.

4. The first half-cut groove is provided between the photoelectric conversion layer and the second electrode layer. The solar cell according to Claim 3.

5. On the first surface of the terminal region of the substrate, a second half-cut groove is further provided. The solar cell according to any one of Claims 1 to 4.

6. The first half-cut groove and the second half-cut groove extend parallel to each other. The solar cell according to Claim 5.

7. The first half-cut groove and the second half-cut groove extend in different directions from each other. The solar cell according to Claim 5.

8. The terminal region is surrounded by the main region. The solar cell according to any one of Claims 1 to 4.

9. The substrate has a slit formed on the extension line of the edge of the terminal region toward the main region side from the boundary between the main region and the terminal region. The solar cell according to any one of Claims 1 to 4.

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