JP2018098509A - 光起電力モジュールの製造方法およびそれによって得られた光起電力モジュール - Google Patents
光起電力モジュールの製造方法およびそれによって得られた光起電力モジュール Download PDFInfo
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Abstract
Description
第1の電導性材料の層で覆われた電気絶縁性基材を準備する工程、
次いで、前記層の上に、第1および第2の下部電極を画定する少なくとも1つの溝を形成する工程、第1および第2の下部電極は、前記溝によって互いに電気的に絶縁されている、
次いで、前記下部電極のそれぞれの上に、第2の電導性材料の層によって形成された少なくとも1つの上部電極と、前記下部電極と前記上部電極との間に配置された光活性材料の層とを含む積層体を形成する工程、前記第1及び第2の下部電極のそれぞれは、対応する積層体で第1および第2の光起電力セルをそれぞれ形成する、
次いで、第1の光起電力セルの上部電極と第2の下部電極との間に電気的接続を形成する工程、
を含んでいる。
− 非活性領域の幅は、0.1mm〜2mmの範囲である。
− 本方法は、溝を形成する工程と、積層工程の間に、以下の工程、第1の下部電極の上に第3の電気絶縁細片を形成する工程、第1および第3の電気絶縁細片は、実質的に平行であり、第1の下部電極の上に次に形成される積層体は、第1および第3の電気絶縁細片の間に配置される、を更に含んでいる。
− 少なくとも第1の電気絶縁細片は、溝の上および第1の電導材料の上への、絶縁材料の第1の液体配合物の堆積、それに続くその第1の配合物の固体状態への移行、によって形成される。
− 電気的接続を形成する工程は、第1の光起電力セルの上部電極と、第2の光起電力セルの第2の下部電極との間で、第1の電気絶縁細片の上に、第3の電導性材料の層を堆積させることを含んでいる。
− 絶縁材料の第1の液体配合物は、少なくとも1種のポリマーおよび少なくとも1種の界面活性剤を含んでおり、この少なくとも1種のポリマーは、好ましくは、アミン、アクリレート、エポキシド、ウレタンおよびそれらの混合物から選択された化合物を基に調製され、そしてこの少なくとも1種の界面活性剤は、好ましくはフッ素化化合物である。
− 電気的接続の形成工程が、第2の電導性材料の層の堆積と同時に行われ、第3の電導性材料は、第2の電導性材料と同じである。
− 上部電極および電気的接続が、可視光を透過する電導性材料から形成される。
− 第3の電導性材料の層の厚さは、1μmよりも小さく、そして好ましくは600nmよりも小さい。
例1:第1の絶縁細片22Aの配合
基材12は、ポリエチレンテレフタレートプラスチックフィルムである。下部電極18A、18Bは、第1の電導性材料19としてのインジウム錫酸化物(ITO)の微細層の、前記基材上への堆積、それに続く溝20A、20Bのエッチングによって形成される。
第2の液体配合物が、第1の電気的接続17Aを生成するように得られる。第2の液体配合物は、銀系のインクタイプの伝導性材料を含んでいる。
配合物GおよびHの第1の表面張力TS1は、(γS1−25mN/m)〜(γS1−15mN/m)の値の範囲にはない。同様に、絶縁細片GおよびHの第2の表面エネルギーγS2は、(Ts2+15mN/m)の値未満である。
Claims (12)
- 少なくとも2つの電気的に接続された光起電力セル(16A、16B)を含む光起電力モジュール(10)の製造方法であって、以下の工程、
a)第1の電導性材料(19)の層で被覆された電気絶縁性基材(12)を準備する工程、次いで、
b)前記層の上に、第1の下部電極(18A)および第2の下部電極(18B)を画定する少なくとも1つの溝(20A)を形成する工程、第1の下部電極(18A)および第2の下部電極(18B)は、該溝によって互いに電気的に絶縁されている、次いで、
c)該下部電極のそれぞれの上に、少なくとも、第2の電導性材料(40)の層よって形成された上部電極(36)ならびに該下部電極と該上部電極との間に配置された光活性材料の層(38)を含む積層体(34)を形成する工程、該第1の下部電極および第2の下部電極のそれぞれは、それぞれ対応する該積層体と、第1の光起電力セル(16A)および第2の光起電力セル(16B)を形成する、
d)該第1の光起電力セルの該上部電極と該第2の下部電極との間に電気的接続(17A)を形成する工程、を含んでなり、該方法は、工程b)とc)との間に以下の工程を含むことを特徴としている、
e)該溝(20A)の中および該溝の上に第1の電気絶縁細片(22A)を形成する工程、該細片は、第1の下部電極および第2の下部電極に対して盛り上がりを形成する、ならびに、
f)該第2の下部電極の上に、第2の電気絶縁細片(24B)を形成する工程、該第1の電気絶縁細片および該第2の電気絶縁細片は、実質的に平行であり、そして該第2の下部電極上に非活性領域(28B)の境界を画定する、工程c)で該第2の光起電力セル上に形成された該積層体は、該非活性領域の外に配置される、
方法。 - 前記非活性領域(28B)の幅(32)が、0.1mm〜2mmの範囲である、請求項1記載の方法。
- − 少なくとも前記第1の電気絶縁性細片(22A、22B)が、前記溝(20A、20B)の上および前記第1の電導性材料の上に、絶縁材料の第1の液体配合物の堆積、それに続く該第1の配合物の固体状態への移行によって形成され、
− 前記基材(12)を被覆する前記第1の電導性材料(19)の前記層が、第1の表面エネルギー(γS1)を有しており、
− 該第1の液体配合物の前記堆積が、該第1の電導性材料と第1の界面(60)を生成し、該第1の界面の第1の表面張力(TS1)が、該第1の表面エネルギー(γS1)よりも小さい、
− 該第1の表面エネルギーと該第1の表面張力との間の差異が、好ましくは0.015Nm−1〜0.025Nm−1の範囲である、
請求項1または2記載の方法。 - 工程d)が、前記第1の電気絶縁細片(22A、22B)の上で、前記第1の光起電力セル(16A、16B)の前記上部電極(36)と前記第2の光起電力セル(16B、16C)の第2の下部電極との間に、第3の電導性材料(52)の層を堆積させる工程を含む、請求項1〜3のいずれか1項記載の方法。
- − 前記第1の電気絶縁細片(22A、22B)が、第2の表面エネルギー(γS2)を有しており、
− 電導性材料の前記第3の層が、第2の液体配合物を堆積することによって形成され、前記第1の電気絶縁細片と第2の界面(62)を生成させ、該第2の界面の第2の表面張力(TS2)が該第2の表面エネルギー(γS2)よりも小さく、
該第2の表面エネルギーと該第2の表面張力との間の差異が、好ましくは0.015Nm−1より大きい、請求項4記載の方法。 - 絶縁材料の前記第1の液体配合物が、少なくとも1種のポリマーおよび少なくとも1種の界面活性剤を含み、
該少なくとも1種のポリマーが、好ましくはアミン、アクリレート、エポキシド、ウレタンおよびそれらの混合物から選択された化合物を基に調製され、そして、
該少なくとも1種の界面活性剤が、好ましくはフッ素化化合物である、
請求項3〜5のいずれか1項記載の方法。 - 第2の電導性材料および光活性材料の前記層(36、38)の少なくとも1つが、連続湿式法を用いた、好ましくはスロットダイ、グラビア印刷およびフレキソ印刷から選択された、コーティング技術または印刷技術によって形成される、請求項1〜6のいずれか1項記載の方法。
- 工程d)が、工程c)の前記第2の電導性材料(36)の前記層の前記堆積と同時に行われ、前記第3の電導性材料(52)が前記第2の電導性材料(40)と同じである、請求項1〜7のいずれか1項記載の方法。
- 前記上部電極(36)および前記電気的接続(17A、17B)が、可視光を透過する電導性材料(40)から形成される、請求項1〜8のいずれか1項記載の方法。
- 第3の電導性材料の前記層の厚さ(54)が、1μm未満、そして好ましくは600nm未満である、請求項4〜9のいずれか1項記載の方法。
- 請求項1〜10のいずれか1項記載の方法から製造された光起電力モジュール(10)。
- 光活性材料の層を含む前記積層体(34)の面積の合計と、前記基材(12)の合計面積との比が、80%超、そして好ましくは85%超である、請求項11記載の光起電力モジュール。
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