JP3904559B2 - 発光又は受光用半導体モジュールおよびその製造方法 - Google Patents
発光又は受光用半導体モジュールおよびその製造方法 Download PDFInfo
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- JP3904559B2 JP3904559B2 JP2003539112A JP2003539112A JP3904559B2 JP 3904559 B2 JP3904559 B2 JP 3904559B2 JP 2003539112 A JP2003539112 A JP 2003539112A JP 2003539112 A JP2003539112 A JP 2003539112A JP 3904559 B2 JP3904559 B2 JP 3904559B2
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Description
(1)前記各半導体セルが光電変換を伴う受光機能を有し、前記第1シート体の受光側の外表面に微細なピラミッドカット叉は凹凸を形成する。
(2)前記各半導体セルが電光変換を伴う発光機能を有する。
(3)前記粒状の半導体セルが球状の半導体セルである。
(4)前記粒状の半導体セルが円柱状の半導体セルである。
(5)前記第2シート体が光透過性のシート体からなる。
(7)前記1対のシート体は合成樹脂製のフレキシブルなシート体からなる。
(8)前記1対のシート体の間の複数の半導体セルの間の空間に絶縁性の透明合成樹脂が充填されている。
(10)(9) のものにおいて、前記第2シート体の内面の第1,第2導電膜は透明な金属酸化物製導電膜からなる。
(11)(9) のものにおいて、前記第2シート体の内面の第1,第2導電膜は、光反射膜として機能する金属製導電膜からなる。
(14)(13)のものにおいて、前記半導体セル同士間に所定の間隔が設けられ、前記1対のシート体の表面側から裏面側又は裏面側から表面側を部分的に透視可能に構成した。
(15)(2)のものにおいて、前記第2シート体が光透過性のシート体で構成され、前記1対のシート体の表面側と裏面側へ光を放射可能に構成した。
図1、図2には粒状の受光用半導体セルとしての球状ソーラセル1,11が示されている。図1に示す球状ソーラセル1は、抵抗率が1Ωm程度のp形シリコン単結晶からなる直径が約0.6〜2.0mmの球状結晶2を素材として形成される。この球状結晶2の下端に直径約0.6mmの平坦面3が形成され、この球状結晶2の表面部にリン(P)を拡散したn+ 形拡散層4(厚さ約0.4〜0.5μm)とpn接合5が形成されている。尚、前記平坦面3の直径0.6mmは直径2.0mmの球状結晶2の場合の大きさである。
ソーラモジュール20は、1対のシート体21,22の間に多数の球状ソーラセル11を多数行多数列のマトリックス状に組み込んだ構造のものであり、ソーラモジュール20の縦横のサイズが例えば10cm×20cmで、球状ソーラセル11の配列ピッチが例えば4mmであるとすると、多数の球状ソーラセル11が例えば25行50列のマトリックス状に配置されることになる。そのような細かい構造は図示することが難しいので、本実施形態では、理解しやすいように50個の球状ソーラセル11を5行10列に配設した場合を例として拡大図示して説明する。
最初に、第1,第2シート体21,22と、25個の球状ソーラセル1と50個の球状ソーラセル11を予め準備する。第1,第2シート体21,22は、厚さ0.1〜0.5mmの透明なフレキシブルなプリント基板であり、透明な電気絶縁性の合成樹脂材料(ポリカーボネイト、アクリル、ポリアリレート、メタクリル、シリコーン、ポリエステル等)で構成されている。第1シート体21の外面(上面)には、ソーラモジュール20に入射する光お反射損失を少なくする為に、多数行多数列のドーム状の小さな凸部25(これが凹凸に相当する)が形成されている。この多数行多数列の凸部25は、第1シート体21をロール成形する際に形成することができる。
このソーラモジュール20においては、各列(各群)の5個の球状ソーラセル11が並列接続され、各列の5個の球状ソーラセル11とそれに隣接する列の5個の球状ソーラセル11とが直列接続されているため、何れかの球状ソーラセル11が故障や日陰により機能低下や機能停止した場合でも、それらの球状ソーラセル11による光起電力が低下したり停止するだけで、正常な球状ソーラセル11の出力は並列接続関係にあるその他の球状ソーラセルを介して分流出力されるため、一部の球状ソーラセルの故障や機能低下による悪影響は殆ど生じず、信頼性と耐久性に優れたソーラモジュール20となる。
このソーラモジュール20では、球状ソーラセル11同士の間に所定の間隔が設けられ、第1,第2シート体21,22が透明材料で構成され、採光性があるため、ソーラモジュール20を窓ガラスとして又は窓ガラスに貼りつけて使用することも可能である。但し、採光の必要がない場合には、球状ソーラセル11の配置ピッチを小さくして、発電能力を高めるように構成してもよい。
変更形態1・・(図10〜図12参照)
このソーラモジュール40は、第1,第2シート体41,42、これらシート体41,42の間に組み込んだ5行10列の球状ソーラセル1,11、各列の5個の球状ソーラセル1,11(各群の球状ソーラセル)を並列接続する並列接続機構、各群の球状ソーラセル1,11とそれに隣接する群の球状ソーラセル1,11を直列接続する直列接続機構などで構成されている。第1,第2シート体41,42は前記第1,第2シート体21,22と同様のものである。
第2シート体42の内面には、4つの導電膜47と、左右両端側の2つの導電膜48,49と、導電膜48と一体の正極端子43と、導電膜49と一体の負極端子44が形成され、これら導電膜47〜49は前記導電経路27〜29と同様に銅箔の表面に銀メッキを施した構造のものである。
最初に、第1,第2シート体41,42と、25個の球状ソーラセル1と、25個の球状ソーラセル11を予め準備する。次に、第1シート体41の内面に5組の導電経路46を形成すると共に、第2シート体42の内面に導電膜47〜49を形成する。次に、図11に示すように、第2シート体42において、各列の球状ソーラセル1の負極7を対応する導電膜47,49の所定の位置に合成樹脂製接着剤にて接着すると共に、各列の球状ソーラセル11の正極16を対応する導電膜47,48の所定の位置に導電性合成樹脂接着剤にて接着する。そして、これら球状ソーラセル1,11の周囲を囲繞するようにシーラント51を貼り付ける。そして、第2シート体42に接着された各列の球状ソーラセル1の正極6と、各列の球状ソーラセル11の負極17に導電性合成樹脂接着剤を夫々塗布する。
このソーラモジュール60は、前記球状ソーラセル1,11を適用したものであって、ソーラモジュール20,40とほぼ同様の構造のものであり、ほぼ同様に製作することができるので、このソーラモジュール60の構造と製造方法について簡単に説明する。
このソーラモジュール80は、第1,第2シート体81,82、これらのシート体81,82の間に組み込んだ3群の72個の球状ソーラセル11、各群の球状ソーラセル11を並列接続する並列接続機構、各群の24個の球状ソーラセル11とそれに隣接する群の24個の球状ソーラセル11を直列接続する直列接続機構などから構成されている。
更に、前記第1シート体81の代わりに、図23に示す第1シート体81Aを採用してもよい。この第1シート体81Aにおいては、3つの導電膜83の代わりに図示のような導電膜としての3組のプリント配線99が形成されている。
1〕図24,図25に示す粒状の球状ソーラセル100,110は、前記の球状ソーラセル1,11と同様の大きさで、同様の発電機能を有するものであるので、球状ソーラセル1,11と共に或いは球状ソーラセル1,11の代わりにソーラモジュールに適用することができる。
発光用半導体モジュールでは、透明な第1,第2シート体を用いて、両面から発光するモジュール、あるいは、透明な第1シート体と第1シート体の方へ光を反射する不透明な第2シート体を用いて片面へのみ発光するモジュール、などの形態が採用される。
或いは、発光用半導体セルを組み込んで発光用半導体モジュールを構成する場合には、GaAs及びその化合物、InP及びその化合物、GaP及びその化合物、GaN及びその化合物、SiC及びその化合物、などの半導体で電光変換機能のある発光用半導体セルを構成することもできる。
前記逆流防止用ダイオード68や、球状ダイオード90は必須のものではなく、省略してもよい。
1,11,90,100,110 球状ソーラセル
21,41,61,81 第1シート体
22,42,62,82 第2シート体
6,7,16,17 電極
25 凸部
63 ピラミッドカット
91,92,106,107 電極
120 円柱状ソーラセル
Claims (19)
- 光透過性の絶縁材料製の第1シート体とこの第1シート体に平行に対向させた絶縁材料製の第2シート体とを含む1対のシート体と、これらシート体の間に複数行複数列に配設された複数の粒状の半導体セルとを備え、
各半導体セルは、p形又はn形の半導体粒と、半導体粒の表層部に形成されたpn接合と、半導体粒の両端に相対向状に形成されpn接合の両端に接続された1対の電極を備えると共に発光又は受光機能を有し、
各半導体セルは、1対の電極を結ぶ導電方向が1対のシート体と直交する状態に配設され、
複数の粒状の半導体セルは、導電方向を揃えて配設されたグループをなす複数の半導体セルを単位として複数群にグループ化され、
前記1対のシート体の相対向する内面に、各群の複数の半導体セルを並列接続する並列接続機構と、各群の半導体セルとそれに隣接する群の半導体セルを直列接続する直列接続機構が設けられ、
前記並列接続機構は第1,第2シート体の内面に夫々形成されたプリント配線からなる第1導電膜を有し、前記直列接続機構は第1,第2シート体の内面に夫々形成されたプリント配線からなる第2導電膜を有する、
ことを特徴とする発光又は受光用半導体モジュール。 - 前記各半導体セルが光電変換を伴う受光機能を有し、前記第1シート体の受光側の外表面に微細な多数のピラミッドカット又は凹凸を形成したことを特徴とする請求項1に記載の発光又は受光用半導体モジュール。
- 前記各半導体セルが電光変換を伴う発光機能を有することを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記粒状の半導体セルが球状の半導体セルであることを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記粒状の半導体セルが円柱状の半導体セルであることを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記第2シート体が光透過性のシート体からなることを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記第1シート体がガラス製のシート体からなることを特徴とする請求項2に記載の発光又は受光用半導体モジュール。
- 前記1対のシート体は合成樹脂製のフレキシブルなシート体からなることを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記1対のシート体の間の複数の半導体セルの間の空間に絶縁性の透明合成樹脂が充填されたことを特徴とする請求項1又は2に記載の発光又は受光用半導体モジュール。
- 前記第1シート体の内面の第1,第2導電膜は透明な金属酸化物製導電膜からなることを特徴とする請求項1に記載の発光又は受光用半導体モジュール。
- 前記第2シート体の内面の第1,第2導電膜は透明な金属酸化物製導電膜からなることを特徴とする請求項10に記載の発光又は受光用半導体モジュール。
- 前記第2シート体の内面の第1,第2導電膜は、光反射膜として機能する金属製導電膜からなることを特徴とする請求項10に記載の発光又は受光用半導体モジュール。
- 前記第2シート体の内面の第1,第2導電膜は、光反射膜として機能する金属製導電膜からなることを特徴とする請求項1に記載の発光又は受光用半導体モジュール。
- 前記第2シート体が光透過性のシート体で構成され、前記1対のシート体の表面側と裏面側から入射する外来光を受光可能に構成したことを特徴とする請求項2に記載の発光又は受光用半導体モジュール。
- 前記半導体セル同士間に所定の間隔が設けられ、前記1対のシート体の表面側から裏面側又は裏面側から表面側を部分的に透視可能に構成したことを特徴とする請求項14に記載の発光又は受光用半導体モジュール。
- 前記第2シート体が光透過性のシート体で構成され、前記1対のシート体の表面側と裏面側へ光を放射可能に構成したことを特徴とする請求項3に記載の発光又は受光用半導体モジュール。
- 光透過性の絶縁材料製の第1シート体とこの第1シート体に平行に対向可能な絶縁材料製の第2シート体と、発光又は受光機能を有し1対の電極を備えた複数の半導体セルを予め準備する第1工程と、
前記第1,第2シート体の内面に複数の導電膜を夫々形成する第2工程と、
前記第1シート体の各導電膜の一部分に複数の半導体セルの一方の電極を接着すると共に、第2シート体の各導電膜の一部分に複数の半導体セルの前記一方の電極と同じ一方の電極を接着する第3工程と、
前記第1,第2シート体を接近対向させ、第1シート体の各導電膜に固着された複数の半導体セルの他方の電極を第2シート体の対応する導電膜に接着すると共に、第2シート体の各導電膜に固着された複数の半導体セルの他方の電極を第1シート体の対応する導電膜に接着する第4工程と、
を有することを特徴とする発光又は受光用半導体モジュールの製造方法。 - 光透過性の絶縁材料製の第1シート体とこの第1シート体に平行に対向可能な絶縁材料製の第2シート体と、発光又は受光機能を有し1対の電極を備えた複数の半導体セルを予め準備する第1工程と、
前記第1,第2シート体の内面に複数の導電膜を夫々形成する第2工程と、
前記第2シート体の各導電膜に複数の半導体セルの一方の電極を接着する第3工程と、 前記第1,第2シート体を接近対向させ、第2シート体側に接着された複数の半導体セルの他方の電極を第1シート体の対応する導電膜に接着する第4工程とを有することを特徴とする発光又は受光用半導体モジュールの製造方法。 - 前記第4工程において、この第4工程にて並列接続される複数の半導体セルの群を、隣接する群に直列接続することを特徴とする請求項18に記載の発光又は受光用半導体モジュールの製造方法。
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- 2001-10-19 KR KR1020037005224A patent/KR100619614B1/ko not_active IP Right Cessation
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CN1479946A (zh) | 2004-03-03 |
CA2463981A1 (en) | 2003-05-01 |
US20050127379A1 (en) | 2005-06-16 |
US7602035B2 (en) | 2009-10-13 |
KR100619614B1 (ko) | 2006-09-01 |
EP1445804A4 (en) | 2008-03-05 |
CA2463981C (en) | 2011-11-29 |
KR20030081321A (ko) | 2003-10-17 |
AU2001295987B2 (en) | 2005-10-20 |
CN1220277C (zh) | 2005-09-21 |
WO2003036731A1 (en) | 2003-05-01 |
EP1445804A1 (en) | 2004-08-11 |
TW512542B (en) | 2002-12-01 |
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