Solar cell and method for manufacturing the same

Abstract

The present invention was devised to solve the problems of the prior art, and an object of the present invention is to provide a solar cell with excellent visibility and a method for manufacturing the same by using a thin-film solar cell deposited on a glass substrate and a sealing member having a similar refractive index. 【Means for solving the problem】 The present invention relates to a solar cell and a method for manufacturing the same. The method for manufacturing a solar cell according to the present invention includes: a first step of forming a lower transparent resin layer on a lower cover glass; a second step of arranging a plurality of thin-film solar cells and a plurality of glass blocks on the lower transparent resin layer; a third step of forming an upper transparent resin layer on the upper portions of the plurality of thin-film solar cells and the plurality of glass blocks; and a fourth step of arranging an upper cover glass on the upper transparent resin layer to form a solar cell. In the second step, a plurality of glass blocks are respectively arranged between the plurality of thin-film solar cells on the lower transparent resin layer.

Description

Technical Field

[0001] The present invention relates to a solar cell and a method for manufacturing the same, and more particularly to a transparent solar cell having an improved light transmission function simultaneously with the electrical production of the solar cell.

Background Art

[0002] Due to problems such as global environmental issues, depletion of fossil energy, waste treatment of nuclear power generation, and site selection for the construction of new power plants, there is a growing interest in renewable energy. Therefore, the interest in solar cells, which are clean and sustainable energy friendly to the environment, is increasing day by day.

[0003] In addition, based on recent environmental issues and carbon neutral policies, the solar cell market is expected to grow steadily. From the fact that the movements of countries around the world to address climate crises such as the obligation of zero-energy buildings are accelerating, the BIPV market is a market that should be noted in the future. Along with this, the need for transparent solar cells is expected to increase day by day.

[0004] Currently, research on transparent solar cells applying thin-film solar cells is actively underway. However, solar cells having a transmittance of 50% or more show an energy conversion efficiency of only about 5%.

[0005] Therefore, the demand for solar cells with high transmittance and excellent energy conversion efficiency and a method for manufacturing the same is increasing.

Summary of the Invention

Problems to be Solved by the Invention

[0006] The present invention has been devised to solve the above-described problems, and an object of the present invention is to provide a solar cell with excellent visibility and a method for manufacturing the same by using a thin-film solar cell deposited on a glass substrate and a sealing member having a refractive index similar thereto.

[0007] Furthermore, the present invention provides a solar cell and a manufacturing method thereof in which image distortion is minimized, transmittance is high, and energy conversion efficiency is excellent.

Means for Solving the Problems

[0008] A method for manufacturing a solar cell according to an embodiment of the present invention for solving the above-described problems includes a first step of forming a lower transparent resin layer on a lower cover glass, a second step of arranging a plurality of thin-film solar cells and a plurality of glass blocks on the lower transparent resin layer, a third step of forming an upper transparent resin layer on the upper portions of the plurality of thin-film solar cells and the plurality of glass blocks, and a fourth step of arranging an upper cover glass on the upper transparent resin layer to constitute a solar cell. In the second step, a plurality of glass blocks are respectively arranged between the plurality of thin-film solar cells on the lower transparent resin layer.

[0009] According to another embodiment of the present invention, the second step may further include a step of additionally inserting a transparent resin between the glass block and the thin-film solar cell.

[0010] According to another embodiment of the present invention, the lower cover glass or the upper cover glass has irregularities formed on its surface.

[0011] According to another embodiment of the present invention, the thin-film solar cell may be configured such that electrodes having a conductive tape structure are joined to both ends, and the electrodes may be joined by ultrasonic bonding or thermal bonding.

[0012] According to another embodiment of the present invention, in the second step, the electrodes at both ends of the aligned thin-film solar cells may be connected to each other in parallel or in series.

[0013] According to another embodiment of the present invention, the second step may further include a step of fixing the lower cover glass on which the plurality of thin-film solar cells and the plurality of glass blocks are arranged using a high-temperature tape, a fixing housing, or a bracket.

[0014] According to another embodiment of the present invention, the thin-film solar cell is composed of a CIGS (Copper, Indium, Galium, Selenium Thin Film Solar Cell), a perovskite solar cell, or a perovskite-CIGS tandem solar cell.

[0015] According to another embodiment of the present invention, the solar cell is vacuum heat-treated, and further includes a fifth step in which the lower cover glass, the thin-film solar cell, the glass block, and the upper cover glass are mutually joined by the lower transparent resin layer, the upper transparent resin layer, and the transparent resin.

[0016] Also, a solar cell according to an embodiment of the present invention includes a lower cover glass, a lower transparent resin layer formed on the lower cover glass, a plurality of thin-film solar cells disposed on the lower transparent resin layer, a plurality of glass blocks respectively disposed between the plurality of thin-film solar cells on the lower transparent resin layer, an upper transparent resin layer formed on the plurality of thin-film solar cells and the plurality of glass blocks, and an upper cover glass disposed on the upper transparent resin layer.

Advantages of the Invention

[0017] According to the present invention, by using a sealing member having a refractive index similar to that of a thin-film solar cell deposited on a glass substrate, a solar cell with excellent visibility and a method for manufacturing the same can be provided.

[0018] Also, according to the present invention, a solar cell and a manufacturing method with minimized image distortion, high transmittance, and excellent energy conversion efficiency can be provided.

Brief Description of the Drawings

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Mode for Carrying Out the Invention

[0020] The present invention can be subjected to various transformations and can have various embodiments. Therefore, specific embodiments are illustrated in the drawings and will be described in detail in the detailed description. However, this is not intended to limit the present invention to specific embodiments, and it should be understood that it includes all transformations, equivalents, and alternatives included in the technical idea and technical scope of the present invention.

[0021] However, when it is determined that a specific description of a related known function or configuration can unnecessarily obscure the gist of the present invention in explaining the embodiment, the detailed description thereof will be omitted. Note that the size of each component in the drawings may be exaggerated for the purpose of explanation and does not mean the size actually applied.

[0022] In the entire specification, when a component is referred to as being "connected" or "joined" to another component, the former component may be directly connected or joined to the latter component. However, unless otherwise stated, it should be understood that they may also be connected or joined with another component intervening therebetween. Further, in the entire specification, when a part "includes" a certain component, this means that, unless otherwise stated, it does not exclude other components, but may further include other components.

[0023] FIG. 1 is an exploded perspective view of a solar cell according to an embodiment of the present invention, FIG. 2 is a side view of the solar cell according to an embodiment of the present invention, and FIG. 3 is a top view of the solar cell according to an embodiment of the present invention.

[0024] Hereinafter, the configuration of a solar cell according to an embodiment of the present invention will be described with reference to FIGS. 1 to 3.

[0025] A solar cell according to an embodiment of the present invention includes a lower cover glass 110, a lower transparent resin layer 120, a thin film solar cell 130, a glass block 140, a transparent resin 150, an upper transparent resin layer 160, and an upper cover glass 170.

[0026] The lower transparent resin layer 120 is formed on the lower cover glass 110.

[0027] At this time, the lower transparent resin layer 120 may be composed of a photocurable resin or a thermosetting resin. More specifically, the lower transparent resin layer 120 may be composed of EVA (Ethylene Vinyl Acetate), and may be configured to adhere the thin film solar cell 130 and the glass block 140 to the lower cover glass 110, and may be disposed on the lower cover glass 110 with a thickness of 0.1 to 1 mm.

[0028] At this time, the lower cover glass 110 may be tempered glass and may be further configured to include an antireflection film.

[0029] Note that the lower cover glass 110 may have irregularities formed on the surface that joins the lower transparent resin layer 120 in order to minimize light reflection. On the other hand, the thickness of the lower cover glass 110 may be configured to be 0.5 to 10 mm.

[0030] A plurality of thin-film solar cells 130 are disposed on the lower transparent resin layer 120.

[0031] At this time, the thin-film solar cell 130 may be configured such that electrodes having a conductive tape structure are joined to both ends, or may be configured such that the electrodes are joined by ultrasonic bonding or thermal bonding. The electrodes at both ends of the aligned thin-film solar cells 130 can be connected in parallel or in series with each other.

[0032] Further, the thin-film solar cell 130 is composed of CIGS (Copper, Indium, Gallium, Selenium Thin Film Solar Cell), a perovskite solar cell, or a perovskite-CIGS tandem solar cell.

[0033] Moreover, the thin-film solar cell 130 according to an embodiment of the present invention can be configured by connecting thin-film solar cells 130 having a monolithic structure in series or in parallel with each other and joining electrode ribbons to both ends for connecting the electrodes. As the joining method, methods such as joining using a conductive tape, ultrasonic bonding, and thermal bonding are used. Further, in order to minimize the contact resistance during joining, a part of the thin film can be removed so as to contact the electrode.

[0034] At this time, in order to prevent joining defects and bubbles due to steps from occurring when joining with the upper cover glass 170, the step at the electrode connection part can be minimized and configured to be thinner than the thickness of the EVA (lower transparent resin layer 120, transparent resin 150, and upper transparent resin layer 160).

[0035] On the other hand, a plurality of the glass blocks 140 are respectively disposed between the plurality of thin-film solar cells 130 on the lower transparent resin layer 120.

[0036] At this time, the glass block 140 is formed to have the same height as the thin-film solar cell 130.

[0037] At the same time, for the interface bonding between the thin-film solar cell 130 and the glass block 140, a transparent resin 150 of EVA material can be additionally inserted between each of them.

[0038] In addition, the glass block 140 is configured with a width of 10 to 50 mm and a height of 5 to 20 mm, and its width and height can be adjusted according to the aperture ratio and the capacity of the thin-film solar cell 130.

[0039] On the other hand, in order to minimize the refractive index and the sense of heterogeneity, the glass block 140 can use the same material as the lower cover glass 110 and the upper cover glass 170.

[0040] The upper transparent resin layer 160 is formed on the upper parts of the plurality of thin-film solar cells 130 and the plurality of glass blocks 140, and the upper cover glass 170 is disposed on the upper transparent resin layer 160.

[0041] That is, after protecting the fixed module and additionally disposing an upper transparent resin layer 160 of EVA material on the upper part for smooth bonding with the glass block, the upper cover glass 170 is disposed to cover it.

[0042] At this time, the upper transparent resin layer 160 is composed of EVA (Ethylene Vinyl Acetate), and is configured to adhere the thin-film solar cell 130 and the glass block 140 to the lower cover glass 110, and may be configured to have a thickness of 0.1 to 1 mm.

[0043] Further, the upper cover glass 170 may be configured in the same manner as the lower cover glass 110.

[0044] More specifically, the upper cover glass 170 has unevenness formed on the surface that joins the upper transparent resin layer 160 to minimize light reflection, and the thickness of the upper cover glass 170 may be configured to be 0.5 to 10 mm.

[0045] In this way, the solar cell in which the upper cover glass 170 is disposed on the upper transparent resin layer 160 is completely joined through a vacuum heat treatment process.

[0046] FIG. 4 is a flowchart for explaining a method of manufacturing a solar cell according to an embodiment of the present invention, and FIG. 5 is a diagram for explaining a method of fixing a solar cell according to an embodiment of the present invention.

[0047] Hereinafter, a method of manufacturing a solar cell according to an embodiment of the present invention will be described with reference to FIGS. 4 and 5.

[0048] First, a lower transparent resin layer 120 is formed on the lower cover glass 110 (S410).

[0049] At this time, the lower transparent resin layer 120 may be composed of EVA (Ethylene Vinyl Acetate) and may be configured to adhere the thin-film solar cell 130 and the glass block 140 to the lower cover glass 110, and may be disposed on the lower cover glass 110 with a thickness of 0.1 to 1 mm.

[0050] At this time, the lower cover glass 110 may be tempered glass and may be further configured to include an antireflection film.

[0051] Further, the lower cover glass 110 has unevenness formed on the surface that joins the lower transparent resin layer 120 to minimize light reflection. On the other hand, the thickness of the lower cover glass 110 is configured to be 0.5 to 10 mm.

[0052] Thereafter, a plurality of thin-film solar cells 130 and a plurality of glass blocks 140 are arranged on the lower transparent resin layer 120 (S420).

[0053] At this time, the thin-film solar cell 130 may be configured such that electrodes having a conductive tape structure are joined to both ends, or may be configured such that the electrodes are joined by ultrasonic bonding or thermal bonding. The electrodes at both ends of the aligned thin-film solar cells 130 can be connected in parallel or in series with each other.

[0054] The thin-film solar cell 130 is composed of CIGS (Copper, Indium, Gallium, Selenium Thin Film Solar Cell), a perovskite solar cell, or a perovskite-CIGS tandem solar cell.

[0055] On the other hand, the thin-film solar cell 130 and the glass block 140 can be sequentially arranged on the arranged lower transparent resin layer 120. At this time, a transparent resin 150 made of an EVA material can be additionally inserted between them for interfacial bonding between the thin-film solar cell 130 and the glass block 140.

[0056] The glass block 140 has a width of 10 to 50 mm and a height of 5 to 20 mm, and its width and height can be adjusted according to the aperture ratio and the capacity of the thin-film solar cell 130.

[0057] At this time, the glass block 140 can use the same material as the lower cover glass 110 and the upper cover glass 170 in order to minimize the refractive index and the sense of heterogeneity.

[0058] Thereafter, the electrodes of the thin-film solar cell 130 are connected (S430).

[0059] That is, in order to connect the electrodes of the thin-film solar cell 130, electrode ribbons can be joined to both ends of the thin-film solar cell 130 having a monolithic structure. As the joining method, methods such as joining using a conductive tape, ultrasonic joining, and thermal joining are used. Further, in order to minimize the contact resistance during joining, a part of the thin film can be removed so as to contact the electrode.

[0060] At this time, in order to prevent joining defects and bubbles due to steps from occurring when joining with the upper cover glass 170, the step at the electrode connection portion can be minimized and configured to be thinner than the thickness of the EVA (lower transparent resin layer 120, transparent resin 150, and upper transparent resin layer 160).

[0061] Thereafter, the lower cover glass 110 on which the thin-film solar cell 130 and the glass block 140 are disposed can be fixed using a high-temperature tape, a fixing housing, or a bracket (S440).

[0062] That is, as shown in FIG. 5, in order to prevent deformation of the solar cell 100 that may occur during the working process, it can be fixed using fixing means 201 such as a high-temperature tape, a fixing housing, or a bracket.

[0063] Thereafter, an upper transparent resin layer 160 is formed on the upper portions of the plurality of thin-film solar cells 130 and the plurality of glass blocks 140, and the upper cover glass 170 is disposed on the upper transparent resin layer 160 to form a solar cell (S450).

[0064] That is, after additionally disposing the upper transparent resin layer 160 of the EVA material on the upper portion to protect the fixed module and for smooth joining with the glass block, the upper cover glass 170 is covered.

[0065] At this time, the upper transparent resin layer 160 may be made of EVA (Ethylene Vinyl Acetate), and may be configured to adhere the thin-film solar cell 130 and the glass block 140 to the lower cover glass 110, and may be configured to have a thickness of 0.1 to 1 mm.

[0066] Also, the upper cover glass 170 may be configured in the same manner as the lower cover glass 110.

[0067] More specifically, the upper cover glass 170 has unevenness formed on the surface that joins the upper transparent resin layer 160 to minimize light reflection, and the thickness of the upper cover glass 170 is configured to be 0.5 to 10 mm.

[0068] Thereafter, lamination processing is performed (S460).

[0069] More specifically, the solar cell is vacuum heat-treated, and the lower cover glass 110, the thin-film solar cell 130, the glass block 140, and the upper cover glass 170 are joined to each other by the lower transparent resin layer 120, the upper transparent resin layer 160, and the transparent resin 150.

[0070] That is, a vacuum heat treatment process may be performed so that the lower cover glass 110, the thin-film solar cell 130, the glass block 140, and the upper cover glass 170 are perfectly joined by EVA. The vacuum heat treatment temperature at this time is 50 to 200 °C, and more specifically, 150 °C is the optimal temperature.

[0071] FIG. 6 is a diagram showing a solar cell according to an embodiment of the present invention, FIG. 7 is a diagram showing an image distortion phenomenon generated from a conventional solar cell, and FIG. 8 is a diagram showing the visibility of a solar cell according to an embodiment of the present invention.

[0072] As shown in FIG. 6, it can be confirmed that the solar cell according to an embodiment of the present invention is very excellent in visibility.

[0073] In addition, as shown in FIG. 7, in the conventional solar cell, an image distortion phenomenon occurs due to light distortion, whereas, as shown in FIG. 8, in the solar cell according to the present invention, by using a thin-film solar cell deposited on a glass substrate and a sealing member having a refractive index similar thereto, it can be confirmed that the visibility is extremely excellent.

[0074] In the detailed description of the present invention as described above, specific embodiments have been described. However, various modifications are possible without departing from the scope of the present invention. The technical idea of the present invention should not be defined as being limited to the foregoing embodiments of the present invention, but should be defined by not only the claims but also those equivalent to the claims.

Claims

1. A first step of forming a lower transparent resin layer on a lower cover glass; A second step of arranging a plurality of thin-film solar cells and a plurality of glass blocks on the lower transparent resin layer; A third step of forming an upper transparent resin layer on top of the plurality of thin-film solar cells and the plurality of glass blocks; A fourth step of arranging an upper cover glass on the upper transparent resin layer to form a solar cell, comprising: In the second step, the plurality of glass blocks are respectively arranged between the plurality of thin-film solar cells on the lower transparent resin layer. A method for manufacturing a solar cell.

2. The method for manufacturing a solar cell according to claim 1, wherein the second step further includes a step of additionally inserting a transparent resin between the glass block and the thin-film solar cell.

3. The method for manufacturing a solar cell according to claim 1, wherein the lower cover glass or the upper cover glass has irregularities formed on its surface.

4. The method for manufacturing a solar cell according to claim 1, wherein the thin-film solar cell is configured such that electrodes with a conductive tape structure are joined to both ends, or the electrodes are joined by ultrasonic bonding or thermal bonding.

5. The method for manufacturing a solar cell according to claim 4, wherein in the second step, the electrodes at both ends of the aligned thin-film solar cells are connected in parallel or in series with each other.

6. The method for manufacturing a solar cell according to claim 1, wherein the second step further includes a step of fixing the lower cover glass on which the plurality of thin-film solar cells and the plurality of glass blocks are arranged, using a high-temperature tape, a fixing housing, or a bracket.

7. The method for manufacturing a solar cell according to claim 1, wherein the thin-film solar cell is composed of CIGS (Copper, Indium, Gallium, Selenium Thin Film Solar Cell), a perovskite solar cell, or a perovskite-CIGS tandem solar cell.

8. The method for manufacturing a solar cell according to claim 2, further comprising a fifth step of subjecting the solar cell to vacuum heat treatment, and joining the lower cover glass, the thin-film solar cell, the glass block, and the upper cover glass to each other by the lower transparent resin layer, the upper transparent resin layer, and the transparent resin.

9. A lower cover glass, a lower transparent resin layer formed on the lower cover glass, a plurality of thin film solar cells disposed on the lower transparent resin layer, a plurality of glass blocks respectively disposed between the plurality of thin film solar cells on the lower transparent resin layer, an upper transparent resin layer formed on the upper portions of the plurality of thin film solar cells and the plurality of glass blocks, an upper cover glass disposed on the upper transparent resin layer, and a solar cell comprising the same.

10. The solar cell according to claim 9, wherein the lower cover glass or the upper cover glass has irregularities formed on its surface.

11. The solar cell according to claim 9, wherein the lower transparent resin layer and the upper transparent resin layer are made of a photocurable resin or a thermosetting resin.

12. The thin film solar cell is configured such that electrodes having a conductive tape structure are joined to both ends thereof, or the electrodes are joined by ultrasonic bonding or thermal bonding, and the electrodes at both ends of the aligned thin film solar cells are connected in parallel or in series to each other. The solar cell according to claim 9.

13. The thin film solar cell is composed of CIGS (Copper, Indium, Gallium, Selenium Thin Film Solar Cell), a perovskite solar cell (Perovskite Solar Cell) or a perovskite-CIGS tandem solar cell (Perovskite-CIGS Tandem Solar Cell). The solar cell according to claim 9.

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