TW201526255A - 太陽能電池的製造方法及製得的太陽能電池 - Google Patents
太陽能電池的製造方法及製得的太陽能電池 Download PDFInfo
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Abstract
本發明提供一種太陽能電池的製造方法,包括如下步驟:提供太陽能電池板,該太陽能電池板包括包括一受光表面,該受光表面為當太陽光垂直照射該太陽能電池板時最先與太陽光接觸的表面;配置光學塗覆液,該光學塗覆液包含相對折射率為1.05~2.5的雙折射性材料、膠粘劑及有機溶劑;於該太陽能電池板的受光表面塗覆該光學塗覆液,以於該受光表面形成一層光學塗覆液膜;固化該光學塗覆液膜,以於該受光表面形成一光學膜。本發明還提供一種由上述方法製得的太陽能電池。
Description
本發明是關於一種太陽能電池的製造方法及製得的太陽能電池。
太陽能電池板是可以將太陽能直接轉換成電能的裝置。然而,輻射到太陽能電池板上太陽能僅有15%左右被吸收轉換成電能,大部分的太陽能從電池板上反射出去。雖然藉由表面蝕刻技術可於太陽能電池板表面上製備出用於減反射的多個金字塔結構或多個逆金字塔結構,然只有在單晶矽太陽能電池上會有較良好完整的金字塔結構。另外,上述金字塔表面或逆金字塔表面只有在入射光為垂直入射時才有較好的降低反射率,但太陽光並非固定維持垂直入射不動,當改變入射光的角度時,反射率還是會因角度增大而遞增。
有鑒於此,有必要提供一種太陽能電池的製造方法,以提高太陽能電池在任何太陽光入射角度下平均吸收效率。
另外,還有必要提供一種由上述方法製得的太陽能電池。
一種太陽能電池的製造方法,包括如下步驟:提供太陽能電池板,該太陽能電池板包括包括一受光表面,該受光表面為當太陽光垂直照射該太陽能電池板時最先與太陽光接觸的表
面;配置光學塗覆液,該光學塗覆液包含相對折射率為1.05~2.5的雙折射性材料、膠粘劑及有機溶劑;於該太陽能電池板的受光表面塗覆該光學塗覆液,以於該受光表面形成一層光學塗覆液膜;固化該光學塗覆液膜,以於該受光表面形成一光學膜。
一種太陽能電池,包括太陽能電池板,該太陽能電池板包括包括一受光表面,該受光表面為當太陽光垂直照射該太陽能電池板時最先與太陽光接觸的表面,該太陽能電池還包括形成於該受光表面的光學膜,該光學膜包括相對折射率為1.05~2.5的雙折射性材料及膠粘劑。
上述太陽能電池的製造方法將含有高相對折射率的雙折射性材料的光學塗覆液塗覆於成品太陽能電池板的受光表面上,於該成品太陽能電池板的受光表面上形成該光學膜,利用該光學膜中的雙折射性材料(如排列整齊的液晶分子)的導光功能來改變出光方向,使非垂直入射的太陽光經過光學膜後變為垂直角度入射該受光表面,從而使更多的太陽光進入受光表面被受光表面吸收,減少太陽光的反射率,因此有效提升該太陽能電池在太陽光為非垂直角度下入射該受光表面情況下的光吸收率,從而提高太陽能電池的平均光吸收率。該方法工藝簡單。
100‧‧‧太陽能電池
10‧‧‧太陽能電池板
101‧‧‧受光表面
20‧‧‧光學膜
22‧‧‧雙折射性材料
圖1為本發明較佳實施例太陽能電池的示意圖。
圖2為本發明較佳實施例太陽能電池的光學膜的工作原理示意圖。
圖3至圖5為本發明較佳實施例太陽能電池與未形成有光學膜的太陽能電池在不同光入射角度下的光吸收率圖。
圖6為本發明較佳實施例太陽能電池相對於未形成有光學膜的太陽能電池在不同光入射角度下的光吸收率提升效率圖。
請參閱圖1,本發明較佳實施例的太陽能電池100的製造方法包括如下步驟:提供製作完成的太陽能電池板10(即成品太陽能電池板)。該太陽能電池板10可為現有的任意一種類型的太陽能電池板,如矽基半導體電池板、CdTe薄膜電池板、銅銦鎵硒(CIGS)薄膜電池板、III-V族化合物半導體電池板及有機材料電池板等,其中矽基半導體電池片又可為單晶電池、多晶電池及無定形矽薄膜電池等。該太陽能電池板10包括一受光表面101,該受光表面101為當太陽光垂直照射該太陽能電池板10時最先與太陽光接觸的表面。該受光表面101可為光滑的平面,也可為經蝕刻形成的粗糙面,還可以為具有週期性的三維結構的表面,如具有週期性的金字塔結構或者半圓球結構的表面。
配置光學塗覆液。該光學塗覆液包含雙折射性材料22(參圖2)、膠粘劑及有機溶劑。該雙折射性材料22的相對折射率為1.05~2.5。所述雙折射性材料22可為但不限於液晶性分子、石英、方解石及紅寶石。該液晶性分子可為液晶聚合物。當雙折射性材料22為石英、方解石及紅寶石等材料時,所述石英、方解石及紅寶石具有類似液晶的形狀,即為橢圓形或者球狀;所述石英、方解石及紅寶石的粒徑小於1μm。所述雙折射性材料22於該光學塗覆液中的品質百分濃度根據不同的材料可於0.1%~33%範圍內選擇。當該雙折射性材料22為液晶性分子時,該液晶性分子於該光學塗覆液中的品質百分濃度為0.1%~5%。所述膠粘劑可為紫外光固化膠粘劑,也可為熱固化膠粘劑。該有機溶劑為透明,可為丙二醇甲醚醋酸酯
(propylene glycol monomethyl ether acetate,PGMEA)。
於該太陽能電池板10的受光表面101塗覆該光學塗覆液,以於該受光表面101形成一層光學塗覆液膜。將該光學塗覆液塗覆於該受光表面101的方法可為但不限於浸漬提拉法、旋塗法(spin coating)、瀉流塗覆法、噴塗法及層流塗覆法。該光學塗覆液膜的厚度可為5nm~800μm。對於同一種雙折射性材料,該光學塗覆液膜的厚度隨該雙折射性材料於該光學塗覆液中的品質百分濃度的增加而減小。
固化該光學塗覆液膜,以於該受光表面101形成一光學膜20。固化的方式可根據該光學塗覆液中的粘膠劑的類型來決定。比如,當該粘膠劑為紫外光固化粘膠劑時,可藉由紫外光照射的方式固化該光學塗覆液膜。較佳的,該固化過程是在氮氣保護下進行。該光學膜的厚度可為1nm~500μm。該光學膜20包括所述雙折射性材料22及所述透明的膠粘劑。在該光學膜20中,所述雙折射性材料較為整齊地排列。所述有機溶劑於固化過程中揮發去除。
可以理解的,該太陽能電池100的製造方法還可選擇性地包括於塗覆該光學塗覆液前對太陽能電池板10的受光表面101進行清潔。
該光學膜20由於含有高相對折射率(1.05~2.5)的雙折射性材料22,利用該排列整齊的雙折射性材料(如排列整齊的液晶分子)的導光功能來改變出光方向,使非垂直入射的太陽光經過光學膜20後變為垂直角度入射該受光表面101(參圖2),從而使更多的太陽光進入受光表面101且被太陽能電池板10吸收,減少太陽光的反射率,因此有效提升該太陽能電池在太陽光為非垂直角度下入射該受光表面101情況下的光吸收率,從而提高太陽能電池的平均光吸收率。
經實驗表明,當雙折射性材料22於光學塗覆液中的濃度過大
(大於33%)時,其固化後的光學膜20中因雙折射性材料過多,使得光學膜20的透光性較差,不利於提高太陽能電池的光吸收率;當雙折射性材料22於光學塗覆液中的濃度過小(大於0.1%)時,其固化後的光學膜20中因雙折射性材料含量過少,使得光學膜20的導光性太差,對降低反射作用不大。
請參閱圖1,本發明較佳實施例的太陽能電池包括該太陽能電池板10及塗覆於該太陽能電池板10的受光表面101的光學膜20。
實施例
提供製作完成的III-V族化合物太陽能電池板(成品電池板),並對該III-V族化合物太陽能電池板的受光表面進行清潔。
配置光學塗覆液。該光學塗覆液由液晶聚合物、紫外光固化粘粘劑及PGMEA組成。該液晶聚合物於該光學塗覆液中的品質百分濃度為1%。
藉由旋塗法於所述III-V族化合物太陽能電池板的受光表面塗覆該光學塗覆液,以於該受光表面形成一光學塗覆液膜。藉由旋塗法該塗覆該光學塗覆液膜分為兩個階段,第一階段為在500rpm轉速下旋轉III-V族化合物太陽能電池板10秒,以使光學塗覆液完全塗布該受光表面;第二階段在為3000rpm轉速下旋轉30秒,目的在於使光學塗覆液膜的厚度均勻。
固化該光學塗覆液膜。該固化步驟包括預烘烤及硬化兩個步驟。預烘烤為將塗覆有該光學塗覆液膜的III-V族化合物太陽能電池板於100℃下烘烤80秒,以將多餘的PGMEA揮發。該硬化步驟為將經預烘烤的III-V族化合物太陽能電池板於氮氣保護下用波段為365nm、功率為8W的紫外光照射3分鐘,使該光學塗覆液膜硬化為光學膜。
測試
將未形成有所述光學膜的III-V族化合物太陽能電池板及經本實施例製得的具有所述光學膜的III-V族化合物太陽能電池板分別進行垂直入射角、15°及30°時光吸收率測試。所述垂直入射角是指與太陽能電池板的受光表面的法線平行的入射角,所述15°及30°是指太陽光入射方向與所述法線的夾角。由圖3至圖5可看出未做出抗反射層的III-V族太陽能電池無論在垂直入射光下,還是在15°或30°斜向光入射下,均有大幅提升,在垂直入射下效率由12.84%增加到13.71%,15°斜向照射下效率11.03%增加到10.26%,30°斜向照射下效率也從10.26%提升到11.98%。圖6為經本實施例製得的具有所述光學膜的太陽能電池相對於未形成有光學膜的太陽能電池在不同光入射角度下的光吸收率提升效率圖,提升效率=形成有光學膜後的效率-初始效率)/初始效率,所述初始速率即為未形成有光學膜的光吸收效率。可以看出,太陽能電池形成光學膜後在斜向角度的光吸收效率有明顯提升,在垂直入射角度提升6.78%,15°提升了17.41%,30°提升了16.76%。
上述太陽能電池100的製造方法將含有高相對折射率的雙折射性材料的光學塗覆液塗覆於成品太陽能電池板10的受光表面101上,於該成品太陽能電池板的受光表面上形成該光學膜20,利用該光學膜20中的雙折射性材料(如排列整齊的液晶分子)的導光功能來改變出光方向,使非垂直入射的太陽光經過光學膜20後變為垂直角度入射該受光表面101,從而使更多的太陽光進入受光表面101被受光表面101吸收,減少太陽光的反射率,因此有效提升該太陽能電池在太陽光為非垂直角度下入射該受光表面101情況下的光吸收率,從而提高太陽能電池的平均光吸收率。該方法工藝簡單。
100‧‧‧太陽能電池
10‧‧‧太陽能電池板
101‧‧‧受光表面
20‧‧‧光學膜
Claims (17)
- 一種太陽能電池的製造方法,包括如下步驟:提供太陽能電池板,該太陽能電池板包括一受光表面,該受光表面為當太陽光垂直照射該太陽能電池板時最先與太陽光接觸的表面;配置光學塗覆液,該光學塗覆液包含相對折射率為1.05~2.5的雙折射性材料、膠粘劑及有機溶劑;於該太陽能電池板的受光表面塗覆該光學塗覆液,以於該受光表面形成一層光學塗覆液膜;固化該光學塗覆液膜,以於該受光表面形成一光學膜。
- 如申請專利範圍第1項所述的太陽能電池的製造方法,其中所述太陽能電池板為矽基半導體電池板、CdTe薄膜電池板、銅銦鎵硒薄膜電池板、III-V族化合物半導體電池板及有機材料電池板中的一種。
- 如申請專利範圍第1項所述的太陽能電池的製造方法,其中所述雙折射性材料於該光學塗覆液中的品質百分濃度為0.1%~33%。
- 如申請專利範圍第3項所述的太陽能電池的製造方法,其中所述雙折射性材料為液晶性分子。
- 如申請專利範圍第4項所述的太陽能電池的製造方法,其中所述液晶性分子為液晶聚合物。
- 如申請專利範圍第4項所述的太陽能電池的製造方法,其中所述液晶性分子於該光學塗覆液中的品質百分濃度為0.1%~5%。
- 如申請專利範圍第3項所述的太陽能電池的製造方法,其中所述雙折射性材料為石英、方解石及紅寶石中的一種。
- 如申請專利範圍第3項所述的太陽能電池的製造方法,其中所述光學塗覆液膜的厚度為5nm~800μm。
- 一種太陽能電池,包括太陽能電池板,該太陽能電池板包括包括一受光表面,該受光表面為當太陽光垂直照射該太陽能電池板時最先與太陽光接觸的表面,其改良在於:該太陽能電池還包括形成於該受光表面的光學膜,該光學膜包括相對折射率為1.05~2.5的雙折射性材料及膠粘劑。
- 如申請專利範圍第9項所述的太陽能電池,其中所述太陽能電池板為矽基半導體電池板、CdTe薄膜電池板、銅銦鎵硒薄膜電池板、III-V族化合物半導體電池板及有機材料電池板中的一種。
- 如申請專利範圍第10項所述的太陽能電池,其中所述光表面為光滑的平面、經蝕刻的粗糙面及具有週期性的三維結構的表面中的一種。
- 如申請專利範圍第9項所述的太陽能電池,其中所述雙折射性材料於該光學塗覆液中的品質百分濃度為0.1%~33%。
- 如申請專利範圍第12項所述的太陽能電池,其中所述雙折射性材料為液晶性分子。
- 如申請專利範圍第13項所述的太陽能電池,其中所述液晶性分子為液晶聚合物。
- 如申請專利範圍第13項所述的太陽能電池,其中所述液晶性分子於該光學塗覆液中的品質百分濃度為0.1%~5%。
- 如申請專利範圍第12項所述的太陽能電池,其中所述雙折射性材料為石英、方解石及紅寶石中的一種。
- 如申請專利範圍第12項所述的太陽能電池,其中所述光學膜的厚度為5nm~800μm。
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