TWI851990B - Solar cell module having groove structure and manufacturing method thereof - Google Patents

Abstract

The present invention discloses a solar cell module having groove structure and manufacturing method thereof. The groove structure of the solar cell module sinks into the substrate. The groove structure may be filled with the electrode which is regarded as the bottom wire embedded inside the substrate. Therefore, the solar cell layer and the top wire layer of the solar cell module having groove structure of the present invention may be directly manufactured on the entire surface of the transparent conductive layer, significantly increasing the energy conversion space and energy conversion efficiency.

Description

Trough-type solar cell module and preparation method thereof

The present invention discloses a trench-type solar cell module and a preparation method thereof, in particular, a trench-type solar cell module and a preparation method thereof in which a lower conductor is sunk into a substrate by means of laser or photo-etching trenching.

As green energy-related technologies are booming and gaining more and more attention, various green energy-related technologies are gradually becoming prominent in energy-related technologies. Among so many green energy technologies, solar energy is a very important branch. Specifically, most existing solar energy applications require the use of solar cells as components for converting light energy into electrical energy in the photoelectric effect.

In terms of the existing solar cell structure, they can be divided into many types according to the materials they are made of, such as silicon-based semiconductor cells, CdTe thin-film cells, CIGS thin-film cells, dye-sensitized thin-film cells, calcium-titanium batteries or organic material batteries, etc.

Silicon batteries are divided into single crystal silicon batteries, polycrystalline silicon batteries and amorphous silicon thin film batteries. For solar cells, the most important characteristic is its photoelectric conversion efficiency. Among current silicon-based solar cells, the efficiency of single crystal silicon batteries is about 25.0%; the efficiency of polycrystalline silicon batteries is about 20.4%.

Solid-state solar cells other than silicon cells all have an internal series electrode design when enlarged. These solid-state solar cells are composed of multiple solar cell units, multiple insulating components, and multiple connecting components connected in series.

However, the series-connected solar cell modules have many disadvantages, for example: the characteristics of the series-connected solar cell modules are high voltage and low current. However, the power requirements of small indoor IoT applications on the market are all in the low voltage and high current application range. Before the roof-type outdoor solar modules are combined into super-large modules, each solar cell unit component is also designed with low voltage and high current.

In addition, the effective power generation area of solid-state solar cells is limited by the width of the connecting components and the insulating components, and it is impossible to grow the photoelectric conversion layer in a large area, which in turn affects the photoelectric conversion efficiency of the solar module. Moreover, if the width of the connecting components and the insulating components is made thinner, the manufacturing cost will increase.

In order to solve the problems mentioned in the previous technology, the present invention provides a trough-type solar cell module and a preparation method thereof. The trough-type solar cell module is mainly composed of a substrate, a lower conductor, a transparent conductive layer, a light energy conversion structure layer and an upper conductive layer.

The substrate is provided with a plurality of wire grooves. The lower wire is correspondingly arranged in each of the wire grooves. Furthermore, the transparent conductive layer is arranged on the substrate and contacts the plurality of lower wires.

The light energy conversion structure layer is disposed on the transparent conductive layer, and the upper conductive layer is disposed on the light energy conversion structure layer. In the present invention, the plurality of wire grooves are separated by a gap between each other.

In order to obtain the trough solar cell module referred to in the present invention, the present invention further provides a method for preparing the trough solar cell module. The method for preparing the trough solar cell module comprises the following steps.

First, perform step (A), provide a substrate, and make a plurality of wire grooves on the substrate by a slotting method. Then perform step (B), use a slot filling method to set a lower wire in each of the wire grooves.

Then, step (C) is performed to form a transparent conductive layer on the substrate. Then, step (D) is performed to form a light energy conversion structure layer on the transparent conductive layer. After completion, step (E) is performed to form an upper conductive layer on the light energy conversion structure layer to obtain the above-mentioned trough solar cell module.

The above brief description of the present invention is intended to provide a basic explanation of several aspects and technical features of the present invention. The brief description of the invention is not a detailed description of the present invention, so its purpose is not to specifically list the key or important components of the present invention, nor is it used to define the scope of the present invention. It is only to present several concepts of the present invention in a concise way.

10: Trough solar cell module

10’: Trough-type solar cell module

100: Substrate

101: Wire duct

200: Lower conductor

300: Transparent conductive layer

400: Light energy conversion structure layer

401: hole transport layer

402: Calcium-titanium absorbing layer

403:Electronic transmission layer

500: Upper conductive layer

501: Upper conductor layer

600:Packaging module

(A)~(E): Steps

Figure 1 is a schematic diagram of the structure of a trough-type solar cell module according to an embodiment of the present invention.

Figure 2 is a schematic diagram of the preparation process of the trough-type solar cell module of the embodiment of the present invention.

Figure 3 is a schematic diagram of another preparation process of the trough-type solar cell module according to an embodiment of the present invention.

Figure 4 is another structural schematic diagram of the trough-type solar cell module of the embodiment of the present invention.

Figure 5 is a flow chart of the method for preparing a trough-type solar cell module according to an embodiment of the present invention.

In order to understand the technical features and practical effects of the present invention and implement it according to the contents of the manual, the preferred embodiment shown in the figure is further described in detail as follows: First, please refer to Figure 1, which is a structural schematic diagram of the trough solar cell module of the embodiment of the present invention. As shown in Figure 1, the trough solar cell module 10 of the present embodiment is mainly composed of a substrate 100, a lower conductor 200, a transparent conductive layer 300, a light energy conversion structure layer 400 and an upper conductive layer 500. Furthermore, since the trough solar cell module 10 has a packaging requirement during use, the trough solar cell module 10 of the present embodiment is further provided with a packaging module 600.

Specifically, the packaging module 600 used in this embodiment can be selected from glass, polymer glue or metal oxide layer to achieve this, and the present invention is not limited to this.

In this embodiment, a plurality of wire grooves 101 are provided on the substrate 100. Specifically, the wire grooves 101 of this embodiment are separated by a gap. Moreover, the plurality of wire grooves 101 are made by means of laser grooving or photo-etching grooving. Therefore, the wire grooves 101 can be patterned into any shape required by the user, and the present invention is not limited thereto.

Furthermore, after the plurality of wire slots 101 are manufactured, the lower wire 200 is disposed in each wire slot 101. In this embodiment, the material of the lower wire 200 is metal, and the material of the metal is copper, silver, gold, platinum or a combination thereof. In this embodiment, the material of the lower wire 200 is preferably silver wire with the best conductivity.

In this embodiment, the method of filling the lower conductor 200 into a plurality of wire grooves 101 is not limited. In addition to the repeated steps of evaporation or etching in the general semiconductor process, it is also possible to use inkjet to accurately fill and then use precision laser (such as excimer laser) to remove the overflowed silver wire material. The present invention is not limited to this.

The transparent conductive layer 300 in this embodiment is disposed on the substrate 100 and is in contact with a plurality of lower conductive lines 200. Specifically, the material of the transparent conductive layer 300 in this embodiment is a transparent conductive oxide material (Transparent Conductive Oxide, TCO). More specifically, the transparent conductive oxide material (Transparent Conductive Oxide, TCO) can be selected from indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO).

As for the light energy conversion structure layer 400 of this embodiment, it is disposed on the transparent conductive layer 300. The light energy conversion structure layer 400 used in this embodiment is composed of a hole transport layer 401, a calcium titanium light absorption layer 402 and an electron transport layer 403.

The hole transport layer 401 is formed on the transparent conductive layer 300. The calcium-titanium light absorption layer 402 is formed on the hole transport layer 401. Finally, the electron transport layer 403 is formed on the calcium-titanium light absorption layer 402. The electron transport layer 403 is connected to the upper conductive layer 500.

In other possible embodiments of the present invention, the hole transport layer 401 and the electron transport layer 403 can also be formed in an inverted state. That is, the electron transport layer 403 is formed on the transparent conductive layer 300. The calcium titanate light absorption layer 402 is formed on the electron transport layer 403. Finally, the hole transport layer 401 is formed on the calcium titanate light absorption layer 402. And the hole transport layer 401 is connected to the upper conductive layer 500, which is not limited by the present invention.

The light energy conversion structure layer 400 of this embodiment can be manufactured by a wet process. However, other possible embodiments under the concept of the present invention can also be manufactured by a dry process such as a vacuum coating process or a solid-state reaction method, and the present invention is not limited thereto. Therefore, the upper conductive layer 500 of this embodiment is disposed on the light energy conversion structure layer 400.

In this embodiment, the material selection of the upper conductive layer 500 will affect the application possibility of the present invention. Specifically, when the material of the upper conductive layer 500 is selected as metal in the embodiment of FIG. 1, the material of the metal is copper, silver, gold, platinum or a combination thereof. In this embodiment, the material of the upper conductive layer 500 is preferably silver wire with the best conductivity. And the upper conductive layer 500 covering the light energy conversion structure layer 400 should be designed in a way to minimize the covering area.

In contrast, when other materials are selected for the upper conductive layer 500, reference may be made to FIG4 first. FIG4 is another structural schematic diagram of a trough-type solar cell module according to an embodiment of the present invention.

As shown in FIG. 4 , when the trough-type solar cell module 10 'as shown in FIG. 4 is implemented under the concept of the present invention, the material of the upper conductive layer 500 of the embodiment is selected from transparent conductive oxide materials (Transparent Conductive Oxide, TCO) such as indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO).

Due to the light-transmitting property of the transparent conductive oxide material (Transparent Conductive Oxide, TCO), the embodiment of FIG. 4 can further produce an upper conductive layer 501 on the upper conductive layer 500 in a patterned manner. Accordingly, the embodiment of the trough-type solar cell module 10' in FIG. 4 can have the function of receiving light and generating electricity on both sides through this structural characteristic.

Similarly, the material of the upper conductor layer 501 in the embodiment of FIG. 4 can be the same as the material of the lower conductor 200, and metal can be selected. In this embodiment, the metal material used to make the upper conductor layer 501 is copper, silver, gold, platinum or a combination thereof. In this embodiment, the material of the upper conductor layer 501 is also preferably silver wire with the best conductivity.

Please refer to Figure 5 in conjunction with Figures 2-4. Figure 2 is a schematic diagram of the preparation process of the trough solar battery module of the embodiment of the present invention; Figure 3 is another schematic diagram of the preparation process of the trough solar battery module of the embodiment of the present invention; and Figure 5 is a flow chart of the preparation method of the trough solar battery module of the embodiment of the present invention.

As shown in Figures 2 to 5, this embodiment first performs step (A), provides a substrate, and makes a plurality of wire grooves on the substrate by means of a slotting method.

In step (A), the substrate 100 of this embodiment is implemented by a transparent substrate. The transparent substrate can be quartz glass or sapphire glass, etc., and the present invention is not limited thereto. Specifically, the grooves 101 can be formed by laser or photochemical methods, and a predetermined pattern can be accurately etched through a mask.

Therefore, as shown in FIG. 2 , a plurality of precisely manufactured wire grooves 101 are distributed in an orderly manner on the substrate 100. Then, step (B) is performed to place a lower wire in each of the wire grooves using a slot filling method.

Step (B) corresponds to the schematic diagram in the middle of Figure 2. In step (B), in addition to the repeated steps of evaporation or etching in the general semiconductor process, the slot filling method can also use inkjet to accurately fill and then use precision laser (such as excimer laser) to remove the overflowed silver wire material. The present invention is not limited to this. Accordingly, the lower wire 200 can be made in a plurality of wire slots 101.

Then, step (C) is performed to form a transparent conductive layer on the substrate. Step (C) corresponds to the bottom schematic diagram in FIG. 2 . In the preparation of step (C), the material of the transparent conductive layer 300 is a transparent conductive oxide material (Transparent Conductive Oxide, TCO). More specifically, the transparent conductive oxide material (Transparent Conductive Oxide, TCO) can be selected from indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO).

The manufacturing method of the transparent conductive layer 300 in step (C) can also be realized by using semiconductor process methods such as evaporation or sputtering, and the present invention is not limited thereto. Next, please refer to FIG. 3 and FIG. 5 at the same time. Step (D) corresponds to the top schematic diagram in FIG. 3 .

Step (D) is to form a light energy conversion structure layer on the transparent conductive layer. In this embodiment, the light energy conversion structure layer 400 is a solid structure made of three layers. Further, step (D) is to form a calcium titanite light absorption layer 402 on the hole transport layer 401 after forming a hole transport layer 401 on the transparent conductive layer 300. Next, a hole transport layer 403 is formed on the calcium titanite light absorption layer 402 to complete the manufacture of the light energy conversion structure layer 400 of this embodiment.

Similarly, each layer structure in the light energy conversion structure layer 400 of this embodiment can be manufactured by a wet process. However, other possible embodiments under the concept of the present invention can also be manufactured by a dry process such as a vacuum coating process or a solid-state reaction method, and the present invention is not limited thereto.

Next, as shown in the two lower schematic diagrams in FIG. 3 , step (E) is to form an upper conductive layer on the light energy conversion structure layer to obtain the trough solar cell module as described above. Specifically, the trough solar cell module 10 obtained by this embodiment has an extremely high photoelectric conversion area.

Similarly, if the material used to make the upper conductive layer 500 in step (E) is metal, the material of the metal is copper, silver, gold, platinum or a combination thereof. In this embodiment, the material of the upper conductive layer 500 is preferably silver wire with the best conductivity. And the upper conductive layer 500 covering the light energy conversion structure layer 400 should be designed in a way to minimize the covering area.

In contrast, when other materials are selected as the material of the upper conductive layer 500 in step (E), the material of the upper conductive layer 500 can be implemented as in the embodiment of FIG. 4 using transparent conductive oxide materials (Transparent Conductive Oxide, TCO) such as Indium Tin Oxide (ITO), Indium-doped Zinc Oxide (IZO), Al-doped Zinc Oxide (AZO) or F-doped Tin Oxide (FTO).

Due to the light-transmitting property of the transparent conductive oxide material (Transparent Conductive Oxide, TCO), after the upper conductive layer 500 is completed in step (E), an upper conductive layer 501 as shown in FIG. 4 can be further manufactured on the upper conductive layer 500 in a patterned manner. Accordingly, the trough solar cell module 10' in FIG. 4 can be made to have the function of receiving light and generating electricity on both sides through this structural property.

In the embodiment of the preparation method, as shown in FIG. 4, when there is a need to make the upper conductor layer 501, the material used for the upper conductor layer 501 can be the same as that used for making the lower conductor 200, that is, metal. In this embodiment, the metal material used to make the upper conductor layer 501 is copper, silver, gold, platinum gold or a combination thereof. Specifically, the material of the upper conductor layer 501 is also preferably silver wire with the best conductivity.

The embodiments of the present invention can be manufactured under more flattened conditions. The flattening process helps with quality management during large-area manufacturing and can effectively reduce corner defects in solar cell modules. In addition, the structure of the trough solar cell module 10 or trough solar cell module 10' can maximize the effective area and process quality of the module power generation, thereby improving the overall photoelectric conversion efficiency.

However, the above is only a preferred embodiment of the present invention, and it cannot be used to limit the scope of implementation of the present invention. That is, simple changes and modifications made according to the scope of the patent application and the description of the present invention are still within the scope of the present invention.

10: Trough solar cell module

100: Substrate

101: Wire duct

200: Lower conductor

300: Transparent conductive layer

400: Light energy conversion structure layer

401: hole transport layer

402: Calcium-titanium absorbing layer

403:Electronic transmission layer

500: Upper conductive layer

600:Packaging module

Claims (16)

A slot-type solar cell module comprises: a substrate, on which a plurality of wire slots are arranged; a lower wire, which is arranged in each of the wire slots by a slot filling method; a transparent conductive layer, which is arranged on the substrate and in contact with the plurality of lower wires; a light energy conversion structure layer, which is arranged on the transparent conductive layer; an upper conductive layer, which is arranged on the light energy conversion structure layer; and an upper wire layer, which is arranged on the upper conductive layer; wherein the plurality of wire slots are separated by a space between each other; wherein the slot filling method is a metal material that is precisely filled by an inkjet and then removed by a laser. A trough-type solar cell module as described in claim 1, wherein a packaging module is further provided outside the solar cell module. As described in claim 1, the trough solar cell module, wherein the material of the transparent conductive layer is a transparent conductive oxide material (Transparent Conductive Oxide, TCO). A trough solar cell module as described in claim 3, wherein the transparent conductive oxide material (Transparent Conductive Oxide, TCO) is indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO). A trough-type solar cell module as described in claim 1, wherein the material of the lower conductor and the upper conductive layer is metal. A trough solar cell module as described in claim 5, wherein the metal is made of copper, silver, gold, platinum or a combination thereof. The trough solar cell module as described in claim 1, wherein the material of the upper conductive layer is a transparent conductive oxide material (Transparent Conductive Oxide, TCO). A trough solar cell module as described in claim 7, wherein the transparent conductive oxide material (Transparent Conductive Oxide, TCO) is indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO). A trough solar cell module as described in claim 1, wherein the light energy conversion structure layer is a calcium-titanium solar cell structure, comprising: a hole transport layer formed on the transparent conductive layer; a calcium-titanium light absorption layer formed on the hole transport layer; and an electron transport layer formed on the calcium-titanium light absorption layer, the electron transport layer being connected to the upper conductive layer. A trough solar cell module as described in claim 1, wherein the light energy conversion structure layer is a calcium-titanium solar cell structure, comprising: an electron transport layer formed on the transparent conductive layer; a calcium-titanium light absorption layer formed on the electron transport layer; and a hole transport layer formed on the calcium-titanium light absorption layer, the hole transport layer being connected to the upper conductive layer. A method for preparing a trench solar cell module comprises: (A) providing a substrate and forming a plurality of line grooves on the substrate by a slotting method; (B) using a slot filling method to set a lower wire in each of the line grooves, the slot filling method is a metal material that is precisely filled by an inkjet and then removed by a laser; (C) forming a transparent conductive layer on the substrate; (D) forming a light energy conversion structure layer on the transparent conductive layer; (E) forming an upper conductive layer on the light energy conversion structure layer; (F) forming an upper wire layer on the upper conductive layer, so as to obtain the trench solar cell module as described in claim 1. A method for preparing a trench solar cell module as described in claim 11, wherein the trenching method is laser trenching or photo-etching trenching. The method for preparing a trough solar cell module as described in claim 11, wherein the light energy conversion structure layer is a calcium-titanium solar cell structure, comprising: a hole transport layer formed on the transparent conductive layer; a calcium-titanium light absorption layer formed on the hole transport layer; and an electron transport layer formed on the calcium-titanium light absorption layer, the electron transport layer being connected to the upper conductive layer. The method for preparing a trough solar cell module as described in claim 11, wherein the light energy conversion structure layer is a calcium-titanium solar cell structure, comprising: an electron transport layer formed on the transparent conductive layer; a calcium-titanium light absorption layer formed on the electron transport layer; and a hole transport layer formed on the calcium-titanium light absorption layer, the hole transport layer being connected to the upper conductive layer. The method for preparing a trough solar cell module as described in claim 11, wherein the material of the upper conductive layer is a transparent conductive oxide material (Transparent Conductive Oxide, TCO). A method for preparing a trough solar cell module as described in claim 15, wherein the transparent conductive oxide material (Transparent Conductive Oxide, TCO) is indium tin oxide (Indium Tin Oxide, ITO), indium-doped zinc oxide (Indium-doped Zinc Oxide, IZO), aluminum-doped zinc oxide (Al-doped Zinc Oxide, AZO) or fluorine-doped tin oxide (F-doped Tin Oxide, FTO).

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