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CN1771608A - 受光或发光模块板及其制造方法 - Google Patents

受光或发光模块板及其制造方法 Download PDF

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Publication number
CN1771608A
CN1771608A CNA2003801102835A CN200380110283A CN1771608A CN 1771608 A CN1771608 A CN 1771608A CN A2003801102835 A CNA2003801102835 A CN A2003801102835A CN 200380110283 A CN200380110283 A CN 200380110283A CN 1771608 A CN1771608 A CN 1771608A
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CN
China
Prior art keywords
light
conductor wire
subjected
ball element
module plate
Prior art date
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Pending
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CNA2003801102835A
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English (en)
Inventor
中田仗祐
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Kyosemi Corp
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Kyosemi Corp
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Publication of CN1771608A publication Critical patent/CN1771608A/zh
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Abstract

本发明涉及具有呈矩阵状配置的多个的球状元件的受光或发光模块板。本发明的目的在于只用合格的球状元件构成受光或发光模块板，提高光电转换效率。受光模块板(1)具备呈矩阵状配置的多个的太阳能电池元件(2)、网状构件(3)、密封构件(4)。各太阳能电池元件(2)具备球面状的pn结(13)、连接pn结(13)的两极的、在隔着太阳能电池元件(2)的中心相对向的位置形成的正负电极(14、15)。网状构件(3)具有将各列的多个的太阳能电池元件(2)通电并联的平行配置的多条的导电线(20、21)和在太阳能电池元件(2)的行与行之间与导电线(20、21)垂直地配置、为了固定多条的导电线(20、21)而织成网状的绝缘性的张力线材(22)。

Description

受光或发光模块板及其制造方法
技术领域
本发明涉及受光或发光模块板及其制造方法，尤其涉及与球状元件电气连接的导电线和用于固定导电线的绝缘性张力线材网状交织的受光或发光模块板。
背景技术
目前，一般实际应用的太阳能电池中，通过在平面状的半导体晶片上扩散杂质等形成平面状的pn结。这样构成的太阳能电池在光垂直入射受光面的情况下输出功率最大，但输出功率随着光相对于受光面的入射角变小而下降。因此，这样的太阳能电池指向性强，无法持续、高效地利用光，而且为了将半导体结晶块切片制成晶片，边角料等加工损失大，导致制造成本的提高。
因此，在美国专利4581103号中揭示了，将高纯度金属硅熔化并滴下，制造粒状的p型结晶，向所述p型结晶扩散n型杂质，形成球面状的pn结的太阳能电池元件和通过铝箔连接所述太阳能电池元件的太阳能电池模块。所述太阳能电池模块不是在所述球状太阳能电池元件模块化之前就形成独立的电极，而是将太阳能电池元件机械地压入形成于一块铝箔的孔中，与n型表面电气连接，再将从孔下方突出的太阳能电池元件的n型层表面的一部分通过蚀刻等除去，使作为内芯的p型硅露出，让所述p型硅与另外的铝箔的表面接触，形成正电极。通过对多个具有pn结的太阳能电池元件进行所述连接，由2块铝箔使多个太阳能电池元件形成电极并在太阳能电池元件间形成并联，从而模块化。如果这样构成太阳能电池模块，则具有可以通过2块铝箔同时进行接合电极的形成和并联，但是由于连接n型层和铝箔后露出p型区域，难以判断每个太阳能电池元件的特性及其优劣。此外，如果这样构成，由于仅限于并联，为了提高输出电压，必须与其他的太阳能电池模块连接。如果缩小太阳能电池元件的直径，则2块铝箔之间的间距变短，变得难以使铝箔之间绝缘，制造工艺复杂化。不仅存在由于正负电极的位置在太阳能电池元件中心的下方，即两电极在不对称的位置上形成，通过正负两电极间的电流在电极距离短的地方发生偏置，无法充分提高光电转换效率等缺点，还存在由于光被铝箔遮挡，受光面只能是在铝箔的上方，无法接收到所有方向的光，无法提高输出功率的缺点。
在日本公报的特开平9-162434号公报中揭示了，由纵向延伸的线状的导体线材和横向延伸的玻璃纤维交织形成的玻璃纤维布承载多个球状太阳能电池元件的板状太阳能电池。在所述太阳能电池中，通过由导体线材承载太阳能电池元件，使导体线材间的绝缘变得简单。
但是，上述的日本专利特开平9-162434号公报所记载的太阳能电池所配置的太阳能电池元件中，在连接n型层和负极导体线材后，露出整个外围以n型层覆盖的p型区域，连接正极导体线材和p型区域。在连接导体线材和太阳能电池元件之前，由于只有n型层露出到外部，无法在连接前检查每个太阳能电池元件，产生与上述引用文献同样的问题。此外，由于连接p型区域的正极导体线材也和n型层连接，通过光照下进行电化学蚀刻分离pn结，使正极导体线材只连接p型区域，但由于各太阳能电池元件中蚀刻的进行速度不同，难以在所有太阳能电池元件内可靠地进行pn结的分离。
在所述公报的太阳能电池元件中，由于正极导体和负极导体在相对中心不对称的位置上连接，因此也产生与上述引用文献同样的问题。而且，所述问题在将太阳能电池元件换成球状的发光二极管时，造成以下的问题，即，由于只在导体线材间的狭小的区域发光，无法向所有方向发光，丧失球状的发光二极管的优点。
于是本申请的申请人提出了，如国际公开公报WO 98/15983号公报所示的，作为太阳能电池元件或发光器件的多个球状元件和连接所述球状元件的受光或发光模块板。所述球状元件具有：球状的p型(或n型)单晶半导体(硅等)、形成于所述单晶半导体的表面附近的n型(或p型)的扩散层、大致球面状的pn结、在隔着球状的单晶半导体的中心相对向的位置设置的一对正负电极。将这多个球状元件设置成多行多列的矩阵状，通过将它们串联或并联，构成受光或发光模块板。
这些球状元件中，由于电极在隔着其中心相对向的位置设置，通过将相邻的球状元件的正电极和负电极直接接触地排列，将多个球状元件串联是简单的，但将各球状元件并联并不简单。
为了改善这个问题，本申请的申请人在国际公开公报WO 03/017382号公报中，通过平行配置的2条导电线，隔着使电极方向一致配置的球状元件的正负电极，并联形成球状元件列，并通过连接相邻的球状元件列的导电线，串联球状元件列。
但是，在所述受光或发光模块板中，存在导电线的长轴方向的抗拉强度强，而其垂直方向非常弱的问题，因此需要使球状元件和导电线的连接变得简单，提高生产性。
本发明的目的在于，提供可以只用合格的球状元件构成的受光或发光模块板，提供抗拉强度强的受光或发光模块板，提供通过球状元件的光电转换或电光转换的效率高的受光或发光模块板，提供容易制造的受光或发光模块板。本发明的其他目的由本发明效果的记载和实施方式的记载可知。
发明的揭示
本发明所述的受光或发光模块板具有：多个的球状元件，所述球状元件具有受光或发光的功能，各自具有大致球面状的pn结和分别连接pn结的两极的位于球状元件两端的正负导电线连接部，而且极性一致，呈矩阵状排列；多条的导电线，所述导电线对于各列，通过各列的多个球状元件的正负导电线连接部，将各列的多个球状元件通电并联，且导电线平行配置；多条的绝缘性张力线材，所述线材在球状元件的行与行之间和多条的导电线垂直地配置，为了固定多条的导电线，与多条的导电线交织成网状。
为所述受光模块板时，与光的入射方向无关，当光入射受光模块板，该光照射极性一致且呈矩阵状配置的多个球状元件时，以形成于球状元件的大致球面状的pn结受光，通过球状元件的受光功能转换成电能。所述电能通过连接pn结的两极的位于球状元件的两端的正负导电线连接部向外部输出。为发光模块板时，从导电线通过导电线连接部向球状元件供给的电能通过球状元件的pn结转换成光能，将所述光向外部射出。
球状元件具有连接pn结的两极的正负导电线连接部，所以可以在将球状元件装入受光或发光模块板之前检查球状元件，其结果，可以只将合格的球状元件装入受光或发光模块板，能够稳定地制造高品质的产品。此外，通过在安装前在球状元件形成正负导电线连接部，导电线连接部和导电线的连接变得简单，从而制造工艺变得简单。
由于沿列方向延伸的多条的导电线和沿行方向延伸的多条的绝缘性张力线材交织成网状，因此强度优异。球状元件的正负导电连接部连接大致球面状的pn结，且位于球状元件的两端，所以，可以有效地利用pn结的整个区域，提高电力或光发生的效率。
在这里，除了以上的结构，可以适当采用以下的结构。
(1)在所述各球状元件中，所述正负导电线连接部隔着球状元件的中心相对向地设置。
(2)设置将所述多个的球状元件与多条的导电线和多条的张力线材一起以包埋的状态收纳的透明合成树脂或透明玻璃制的密封构件。
(3)所述各球状元件为光电二极管或太阳能电池元件。
(4)所述各球状元件为发光二极管。
(5)所述导电线使用选自焊锡、导电性合成树脂、合金化金属的任一种，被连接于正负导电线连接部。
(6)所述受光或发光模块板被包埋于密封构件中，露出所述导电性线材的至少一部分。
(7)所述球状元件的列与列之间具有与导电线平行的与导电线交织的绝缘性的张力线材。
(8)所述密封构件使用透明合成树脂材料，构成柔性构件。
(9)在所述密封构件的与光的入射侧相反侧的一面构成反射从入射侧入射的光的反射膜。
(10)所述密封构件由以包埋状态收纳多个的球状元件的具有柔软性的透明的缓冲层和接合于所述缓冲层的两面上的透明的表面层构成。
(11)所述密封构件具有对球状元件无法吸收的热射线选择性地反射的高分子材料构成的热反射膜。
(12)具有将并联所述多个的球状元件的导电线多列串联的串联装置。
本发明所述的受光或发光模块板的制造方法，是具有呈矩阵状排列的具有受光或发光的功能的多个的球状元件、将各列的多个的球状元件通电并联的导电线、为了固定导电线而与导电线交织成网状的绝缘性的张力线材的受光或发光模块板的制造方法，所述方法具有：球状元件制造步骤，制造具有正负导电线连接部的球状元件；连接步骤，由通过导电线的电流产生的焦耳热熔化用于连接球状元件和导电线的接合构件，将球状元件和导电线通过接合构件连接。
采用所述的受光或发光模块板的制造方法，首先，在球状元件制造步骤中制造具有正负导电线连接部的多个球状元件，接着，在连接步骤中，通过由通过导电线的电流熔化的接合构件并联呈矩阵状排列的各列多个的球状元件和导电线。
因此，可以通过所述导电线连接部进行球状元件是否是合格品的检查，能够防止不合格的球状元件装入受光或发光模块板中。通过在安装前在球状元件形成正负导电线连接部，导电线连接部和导电线的连接变得可靠且简单，从而制造工艺变得简单。此外，由于通过导电线的电流熔化接合构件，连接导电线和球状元件，所以热效率高，可以容易地连接，节能化和制造工艺变得简单。
附图的简单说明
图1是本发明的实施方式所述的受光模块板的平面图，图2是受光模块板的局部放大平面图，图3是太阳能电池元件的放大截面图，图4是从图2的箭头IV方向的向视图，图5是从图2的箭头V方向的向视图，图6是图2的VI-VI线的截面图，图7是受光模块板所包含的太阳能电池模块的等效电路图，图8是制造太阳能电池元件的各步骤中太阳能电池元件的示意图，图9是将太阳能电池元件和导电线用定位工具电气连接的步骤的说明图，图10是变更方式所述的受光模块板的局部放大平面图，图11是变更方式所述的安装密封构件的受光模块板的主要部分的纵截面图，图12是变更方式所述的安装密封构件的受光模块板的主要部分的纵截面图，图13是变更方式所述的受光模块板的局部放大平面图。
实施发明的最佳方式
以下，对实施本发明的最佳方式进行说明。
所述实施方式是在以多行多列的矩阵状配置球状的太阳能电池元件的受光模块板(太阳能电池模块板)中使用本发明的一个例子。
如图1、图2所示，所述受光模块板1具有多个的太阳能电池元件2(相当于球状元件)、网状构件3(导电线混织玻璃布)、密封构件4等。
本申请人的申请相关的国际公开公报WO 98/15983和WO 03/036731等中揭示了与太阳能电池元件2大致相同结构的太阳能电池元件，所以在这里进行简单的说明。
如图1、图2所示，多个的太阳能电池元件2具有将光能转换成电能的受光功能，极性一致地呈矩阵状配置。例如，每1瓦发电输出功率使用约2000个的太阳能电池元件。
如图3所示，各太阳能电池元件2以电阻率0.3～1Ωm左右的p型硅单晶构成的直径约0.6～2.0mm的球状结晶10作为原材料形成。所述球状结晶10的一端形成平坦面11。除平坦面11外的球状结晶10的表面部分的大致全部区域形成磷(P)扩散的n+型扩散层12(厚约0.4～0.5μm)，在所述n+型扩散层12和p型区域的交界面形成大致球面状的pn结13。球状结晶10的直径约1.0mm的情况下，形成平坦面11的直径约0.5mm。但是，平坦面11的直径可以在约0.5mm以下。
在平坦面11上设置正电极14(相当于导电线连接部)，在隔着球状结晶10的中心与正电极14相对向的位置设置负电极15(相当于导电线连接部)。正电极14连接球状结晶10的p型区域，负电极15连接n+型扩散层12。正电极14烧结铝糊料形成，负电极15烧结银糊料形成。在除正电极14和负电极15的整个表面形成由SiO2(或者TiO2)的绝缘膜构成的防反射膜16(厚约0.6～0.7μm)。所述太阳能电池元件2具有受光功能，接收太阳光，在电极14、15之间产生0.5～0.6V的光电动势。
如图2、图4、图5所示，网状构件3具有正极用导电线20、负极用导电线21、玻璃纤维制的张力线材22。导电线20、21是由镍(42％)、铁(52％)和铬(6％)的合金构成的直径120μm的线材，其表面形成镀锡层(厚2～3μm)。
如图2所示，两导电线20、21都沿列方向平行延伸，相邻的太阳能电池元件2的各列的正极用导电线20和负极用导电线21的中心线的间隔为0.75mm，各列的太阳能电池元件2与相邻的列的太阳能电池元件2的中心的间隔为1.75mm。正极用导电线20通过钎焊膏23电气连接正电极14，负极用导电线21通过钎焊膏23电气连接负电极15。各列的多个的太阳能电池元件2通过两导电线20、21通电并联，同时将所有列的太阳能电池元件2通电串联。关于这些在之后叙述。
导电线并不局限于上述构成的线材，也可以由铁、铁(58％)·镍(42％)合金线、其他铁合金线、铜线、铍铜线、磷青铜线、其他铜合金线、银、银合金线、镍、镍合金线等构成，还可以将由这些材料制成的细线绞合以绞线形式构成，考虑电气、机械、化学性质等来加以应用。其中，特别是像铍铜线或磷青铜线这样的线材，具有弹力，所以可以可靠地保持和太阳能电池元件2的接触。
张力线材22在各行的太阳能电池元件2和与其相邻行的太阳能电池元件2之间，与导电线20、21垂直地沿行方向配置。各张力线材22由7条玻璃纤维(直径约9.0μm)绞合形成，以这样的3条张力线材22为1组，以间距约1.75mm的间隔配置在各行间。为了固定导电线20、21，各张力线材22在两导电线20、21间上下穿行地织入，多条的导电线20、21和多条的张力线材22交织呈网状，形状网状构件3。
如图6所示，为了保护多个的太阳能电池元件2和网状构件3，构成密封构件4，使其以包埋的状态收纳多个的太阳能电池元件2，导电线20、21和张力线材22。所述密封构件4使用绝缘性的透明的聚对二甲苯树脂，形成厚约100μm的板状。所述聚对二甲苯树脂具有以下的优点：可以少气孔、均一地涂布到精细的部分，气体和水蒸气的透过性小，对于放射线的稳定性高，折射率(约1.64)高，在太阳能电池元件2的表面的反射损失少等。因此，由于所述密封构件4可以形成薄薄地被覆太阳能电池元件2的表面的状态，具有以下优点：受光的方向性广，反射损失少，具柔软性，轻便，抗拉和抗弯强度大，采光率高等。
采用所述受光模块板1，与光的入射方向无关，光入射受光模块板1，该光照射极性一致且呈矩阵状配置的多个的太阳能电池元件2时，以形成于太阳能电池元件2的大致球面状的pn结13受光，通过太阳能电池元件2的受光功能转换成电能。所述电能通过连接pn结13的两极的隔着太阳能电池元件2的中心的相对向的正负电极14、15向外部输出。
接着，图7表示了受光模块板1所包含的太阳能电池模块的等效电路30。所述等价电路30，例如是将排列成多行多列的矩阵状的多个的太阳能电池元件2都换成发光二极管31的电路。如该等价电路30所示，各列的发光二极管31(太阳能电池元件2)通过正极用导电线20和负极用导电线21并联，而且，各列的正极用导电线20与相邻列的负极用导电线21通过串联用导电线34串联。假设1个太阳能电池元件2的输出电压为0.6V，行数为m，列数为n，则在正极端子32和负极端子33之间产生n×0.6V的光电动势。假设1个太阳能电池元件2产生的电流为I，则从正极端子32向外部负载输出m×I的电流。
通过这样将多个的太阳能电池元件2一一串联，即使是光无法入射到受光模块板1的一部分，一部分的太阳能电池元件2无法发电的状态，由于电流经其他的太阳能电池元件2通过，可以将输出减少的影响降到最小限度。
接着，对以上说明的受光模块板的制造方法进行说明。
先基于图8对太阳能电池元件2的这些方法进行说明，由于关于该制造方法，本申请人在国际公报WO 98/15983和WO 03/036731中进行了详细说明，在这里只简单地说明一下。
首先，使熔融状态的硅的液滴每次一定量地自由下落，在这期间通过过冷引起的迅速凝固形成直径约1.0mm的p型的球状单晶10，将该球状单晶10的一部分机械研磨从而形成平坦面11(参见图8(a))。
接着，将球状单晶10在含有约1000℃的水蒸气的氧气中加热约40分钟，形成厚约0.3μm的硅氧化膜35(参见图8(b))。接着，为了将硅氧化膜35作为只在需要的区域热扩散杂质(n型杂质)的掩模，在玻璃板上以均一的厚度熔融耐酸性的蜡，将平坦面11压放在所述蜡的表面，使蜡固化。接着，浸渍于缓冲蚀刻液(NH4HF2水溶液)中，只将从固化的蜡露出的硅氧化膜35蚀刻除去，然后，从玻璃板上将球状单晶10取下，除去蜡(参见图8(c))。
接着，将球状单晶10在从三氯氧磷(POCl3)液中发泡的氮气载气中于约960℃加热3分钟，在没有形成硅氧化膜35的球状单晶10的表面形成硅酸磷玻璃膜36，再将气氛气体换成干燥的氧气，于约980℃加热60秒，将n型杂质(磷)热扩散到球状单晶10的接近表面的内部。这样热扩散n型杂质，在除了用作为掩模的硅氧化膜35被覆的平坦面11及其周围之外的部分形成n+型扩散层12，同时在所述n+型扩散层12与球状单晶10的p型区域的交界面形成pn结13(参见图8(d))。
接着，将形成于平坦面11及其周围的硅氧化膜35用缓冲蚀刻液除去，再在干燥的氧气中于约800℃加热60秒，在球状单晶10的整个表面形成由硅氧化膜构成的同时也是钝化膜的防反射膜16(参见图8(e))。
接着，为了形成正电极14，在平坦面11点式印刷铝糊料37，为了形成负电极15，在隔着球状单晶10的中心与平坦面11相对向的位置的n+型扩散层12表面点式印刷银糊料38，将所述状态下的球状单晶10在氮气中于约800℃加热处理60分钟，铝糊料37和银糊料38贯穿防反射膜16，使铝糊料37和银糊料38分别与球状单晶10的p型区域和n+型扩散层12形成低电阻接触(欧姆接触)，从而完成太阳能电池元件2(参见图3)。
接着，测定完成了的太阳能电池元件2在日光模拟器光源的光照射下的电压-电流特性，判别太阳能电池元件2是合格品还是不合格品。
接着，如图9所示，为了将太阳能电池元件2定位，准备以指定间隔形成定位孔40的石英制的定位工具41。接着，将认定为合格品的太阳能电池元件2使电极14、15的方向(电极14、15的极性)一致地设置在定位工具41的定位孔40。由于在太阳能电池元件2上形成了平坦面11，可以容易地识别正负电极14、15，能够简单地电极14、15的方向一致地设置。
设置于定位工具41上的太阳能电池元件2的水平面上的赤道线与定位工具41的上表面大致同一高度。接着，为了防止太阳能电池元件2的移动和旋转，使定位孔40内减压，将太阳能电池元件2固定于定位孔40上。在定位工具41的上表面，为了使其不与钎焊膏23等接合材料接合，被覆碳或氮化硼膜。
接着，准备织入导电线20、21和张力线材22的网状构件3，在网状构件3的正极用导电线20与正电极14连接的部位和负极用导电线21与负电极15连接的部位通过点式印刷或滴涂器(dispenser)滴涂被覆钎焊膏23，将所述网状构件3从上方覆盖到固定于定位工具41的太阳能电池元件2上。接着，通过加压工具(图示略)使网状构件3和定位工具41的上表面贴紧，同时使被覆于导电线20、21的钎焊膏23与电极14、15贴紧。接着，在将多个的太阳能电池元件2和网状构件3承载于定位工具41上的状态下，向钎焊膏23照射红外线灯的集聚光束，熔化钎焊膏23，通过该钎焊膏23分别电气连接导电线20和电极14、导电线21和电极15。接着，将钎焊膏23所含的助溶剂洗净除去并干燥。
作为其他的连接方法，也可以在导电线20、21上通过电流，通过由该电流产生的焦耳热将钎焊膏23熔化，利用钎焊膏23的表面张力和流动性来连接。或者，还可以同时使用红外线灯和焦耳热熔化钎焊膏23来连接。采用该连接方法可以快速地连接。也可以用导电性环氧树脂代替钎焊膏23连接电极14、15和导电线20、21。在通过导电性环氧树脂连接的情况下，将网状构件3覆盖到太阳能电池元件2上后，将环氧树脂通过滴涂器滴涂到需要的地方，然后，用电炉等加热导电性环氧树脂使其固化即可。
接着，在太阳能电池元件2和网状构件3等遍及受光模块板1的整体的范围以约100μm的厚度形成作为密封构件4的聚对二甲苯树脂的被膜。所述密封构件4可以通过例如美国联合碳化物和塑料公司(米国ユニオンカ一バイド·アンド·プラステイツク社)开发的使用化学蒸镀(CVD)法的涂覆系统形成。密封构件4并不局限于聚对二甲苯树脂，还可以将硅酮树脂、聚氯乙烯、聚酯(PET)等透明的树脂以液体的状态通过喷涂或浸渍法成膜、固化从而形成。密封构件4通过这样的方法形成于受光模块板1上，从而完成受光模块板1。
接着，对以上说明的受光模块板1的作用、效果进行说明。
如果采用所述的受光模块板1，则由于太阳能电池元件2具有连接球状结晶10的平坦面11的正电极14和连接n+型扩散层12的负电极15，可以在装入受光模块板1之前对太阳能电池元件2通过日光模拟器进行检查。因此，在受光模块板1中可以只装入通过检查的合格的太阳能电池元件2，从而能够制造高品质的受光模块板1。此外，安装前，通过在太阳能电池元件2上形成正负电极14、15，能够既可靠又简单地连接电极14、15和导电线20、21，制造工艺变得简单。
由于网状构件3织入沿列方向延伸的导电线20、21和沿行方向延伸的张力线材22，可以实现柔性的受光模块板1，从而可以实现强度高的受光模块板1。尤其，通过以轻便的玻璃纤维构成张力线材22，能够既提高受光模块板1的强度，又实现轻型化。
太阳能电池元件2中，在隔着太阳能电池元件2的中心相对向的位置上设有各电极14、15，因此在太阳能电池元件2内产生的电流没有偏置，对称地通过，可以大幅减少电阻损耗，能够输出几乎所有在太阳能电池元件2的pn结产生的电力。而且，由于太阳能电池元件2形成球形，可以接收所有方向的入射光发电，能够输出所有其产生的电力，因此可以提高发电效率。受光模块板1被柔性的密封构件4保护，所以可以不损坏太阳能电池元件2和导电性20、21地进行变形。
太阳能电池元件2以在p型球状单晶10的表面部分形成n型扩散层的结构为主体构成，但也可以以在n型球状单晶的表面部分形成p型扩散层的结构为主体构成。此外，用于太阳能电池元件2的半导体并不局限于硅，也可以适用GaAs、GaAlAs、InP、InGaP、Ge、GaSb、InGaAs、InGaN等半导体。
下面对将前述实施方式进行部分变更的例子进行简单说明。
1)变更方式1(参见图10)
在变更方式中，通过将没有形成电极的状态的太阳能电池元件通过与导电线的合金化接合连接，制造受光模块板1A。以下，对其制造方法进行说明。
首先，制造图8(d)所示的太阳能电池元件，接着用缓冲蚀刻液将硅氧化膜35完全除去，制作太阳能电池元件2A。接着，准备织入了沿列方向延伸的正极用导电线20A和负极用导电线21A以及沿行方向延伸的张力线材22的网状构件3A。其中，两导电线20A、21A由能与硅发生共晶反应的含有1～2％硅的直径约120μm的铝线构成。张力线材22与上述实施方式中的张力线材22相同，因此略去说明。
接着，将多个的太阳能电池元件2A排列在与前述定位工具41相同的定位工具上，从其上方覆盖网状构件3A，使两导电线20A、21A与太阳能电池元件2A的平坦面11(相当于导电线连接部)和隔着太阳能电池元件2A的中心与平坦面11相对向的部位(相当于导电线连接部)接触。接着，在含有数个百分比氢气的氮气气氛中，在两导电线20A、21A通过数秒直流脉冲强电流，进行焦耳加热，使太阳能电池元件2A的平坦面11A与正极用导电线20A通过合金化接合而接合，同时使隔着太阳能电池元件2A的中心与平坦面11A相对向的部位的n+型扩散层12A与负极用导电线21A通过合金化接合而接合。通过所述合金化接合形成于导电线20A、21A和太阳能电池元件2A之间的合金化区域作为电极14A、15A发挥作用。所述合金化接合可以在约570℃～650℃的范围内进行。在所述合金化接合中，通过脉冲电流引起的急速加热和急速冷却，防止铝扩散，或合金化进行过度，可以实现良好的低电阻接触(欧姆接触)。接着，除去硅氧化膜36后，通过CVD法在太阳能电池元件2A上形成硅氧化膜或钛氧化膜等钝化膜，在受光模块板的整个面形成密封构件4，从而完成受光模块板1A。
导电线20A、21A可以使用镍(42％)、铁(52％)、铬(6％)的合金线(直径约120μm)代替铝线，在所述合金线和电极的接合处粘附铝或含1～2％硅的铝合金膜。在这样构成的情况下，也可以通过电流经过合金线产生的焦耳热熔化铝或铝合金膜，连接导电线20A、21A和太阳能电池元件2A。
所述合金线电导率、热传导率比铝线低，所以存在可以以较小的电流接合，同时提高抗拉强度的优点。另一方面，还可以使用铜线代替铝线用于导电线20A、21A，在所述铜线的接合处粘附金·硅合金、金·锗合金、金·锡合金等金合金膜，通过电流经过导电线20A、21A产生的焦耳热熔化金合金膜，连接导电线20A、21A和太阳能电池元件2A。金合金可以在比铝更低的温度下实现共晶反应引起的合金化接合。
采用所述制造方法，不需要预先形成正负的正电极，可以简单地进行太阳能电池元件2A和导电线20A、21A的连接，因此能够提高生产性，降低制造成本。
2)变更方式2(参见图11、图12)
以下，对改变密封构件的变更方式进行说明。
可以如图11所示，构成受光模块板1B。在该受光模块板1B中，密封构件4B具备以包埋状态收纳太阳能电池元件2和网状构件3的具有柔软性的缓冲层46和接合在缓冲层46上下两面的透明的表面层45。表面层45由厚约2mm的透明的白板强化玻璃板构成。
在制作所述受光模块板1B时，以表面层45、EVA(乙烯乙酸乙烯酯)板、接合太阳能电池元件2的网状构件3、EVA板、表面层45的顺序重叠，通过将其在层压装置内抽真空的同时加热，熔化EVA板，将该EVA熔液填充于上下的表面层45之间作为缓冲层46，将太阳能电池元件2和网状构件3通过缓冲层46固定。
通过以由聚碳酸酯或聚丙烯等树脂构成的透明的板材构成表面层45，可以实现受光模块板1B的低成本化和轻型化。此外，缓冲层46也可以以PBV(聚乙烯醇缩丁醛)、聚丙烯、硅酮树脂等透明树脂构成。
通过这样以2个表面层45隔着太阳能电池元件2和网状构件3地构成，可以提高对抗机械冲击的强度，能够制成透视式的受光模块板用作窗玻璃。
另一方面，可以如图12所示构成受光模块板1C的密封构件4C。所述受光模块板1C的密封构件4C从下层开始由柔性PE(聚酯)类树脂薄膜50、铝蒸镀膜51、由PE类树脂构成的多层膜的反射膜52、由EVA树脂构成的埋设太阳能电池元件2和网状构件3的与前述缓冲层同样的填充材料53、PE类树脂层54、热射线反射膜55、PE类树脂层56构成。
反射膜52形成于与光的入射侧相反侧的面，将从入射侧入射并穿过太阳能电池元件2之间的光反射和散射，照射太阳能电池元件2，从而提高光的利用效率和发电效率。热射线反射膜55由折射率不同的高分子材料多层化构成。热射线反射膜55通过多层化产生的干涉作用，将无法通过太阳能电池元件2吸收的热射线(波长1350nm以上)选择性地反射，从而减少太阳能电池元件2的升温，提高光电转换效率。因此，从受光模块板1C的受光面(上表面)入射的光，首先通过热射线反射膜55反射一部分不需要的热射线，剩余的光的一部分被太阳能电池元件2吸收，一部分穿过太阳能电池元件2之间，这些穿过太阳能电池元件2之间光经反射膜52反射被太阳能电池元件2吸收。
也可以用聚碳酸酯、聚萘二甲酸乙二醇酯、含氟树脂等柔性合成树脂构成。填充材料53可以使用硅酮树脂和聚乙烯醇缩丁醛树脂等代替EVA树脂。反射膜52或热射线反射膜55可以适当省却，其他各层也可以根据需要的功能适当改变。
3)变更方式3
在受光模块板的制造方法中可以使用卷到卷法(ロ一ルツ一ロ一ル法)。通过卷到卷法制造时，可以形成如下的结构，将网状构件的宽度方向的两端用聚酰亚胺薄膜等耐热性树脂膜固定，在该耐热性树脂膜上设置链轮孔，在所述链轮孔中嵌合上链轮，传送网状构件，并进行卷取。
4)变更方式4
在上述的实施方式中，对球状元件是太阳能电池元件的受光模块板进行了说明，但球状元件并不局限于太阳能电池元件，还可以适用球状的光电二极管和发光二极管。关于这些球状的光电二极管和发光二极管，与上述太阳能电池元件2大致同样的结构，其具体构成本申请人在WO 98/15983号公报中已提出，所以略去说明。具有发光二极管的发光模块板中，如果发光二极管中通过正向的电流，则通过pn结电能转换成光能，从pn结旁产生对应于结晶和扩散层的材料的波长的光，射向外部。这样由球状的发光二极管构成的发光模块板中，可以全方位地发光，此外，通过在一部分设置反射板，可以只向需要的方向发光。而且，通过将RGB3色的发光二极管矩阵状地排列，通过控制装置可控地构成这些发光二极管，可以将发光模块板作为彩色显示器。也可以由一种颜色的发光二极管构成单色的显示器。在由光电二极管构成的受光模块板中，可以将所有方向的光转换成电信号。
5)变更方式5
在上述的实施方式中，对将所有列的太阳能电池元件串联的例子进行了说明，但还可以如下构成，设置可改变串联列数的多个的开关，根据光的强度和所需的电量通过控制装置切换多个的开关。
6)变更方式6
在上述的实施方式中，具有密封构件，但密封构件并不是通常必需的结构，可以适当省却。
本发明并不局限于以上说明的实施方式，只要是从业者在不超出本发明的思路的范围内，可以对前述的实施方式附加各种变更后进行实施，本发明也包括这些变更方式。
7)变更方式7
张力构件的条数可以适当改变。在上述实施方式中以3条张力线材22为一组配置在太阳能电池元件2的行与行之间，但张力线材的条数不局限于3条，根据需要的结构，可以以1条或多条为一组进行配置。
还可以将张力线材用绝缘性的芳族聚酰胺纤维等高强度的合成树脂或塑料构成。通过这样的构成，可以进一步提高受光或发光模块板的柔软性和抗拉强度，同时能够降低材料成本。
如图13所示的受光模块板1D所示，不光将绝缘性的张力线材22以与导体线垂直的方向配置，还可以将张力线材22a配置于各太阳能电池元件列之间，以与导体线平行的方向织入。通过这样的构成，可以提高导体线延伸方向的抗拉强度。图13中，在与实施方式同样的结构标记了同样的符号，所以略去说明。
8)变更方式8
在上述的实施方式中，在各列分别设置正负导电线，但也可以采取以一条导电线兼作相邻的正极用导电线和负极用导电线的结构。通过这样的结构，省去了串联用导电线，可以使结构简化，列间的间隔减小，使受光或发光模块板小型化。
9)变更方式9
在上述的实施方式中，在球状太阳能电池元件2上形成平坦面11，但也可以适用不形成所述平坦面11的太阳能电池元件。这样构成时，较好是改变正负电极的形状，使正负电极可以容易地识别地构成。

Claims (14)

1.受光或发光模块板，其特征在于，具备：
多个的球状元件，所述球状元件具有受光或发光的功能，各自具有大致球面状的pn结和分别连接pn结的两极的位于球状元件两端的正负导电线连接部，而且极性一致，呈矩阵状排列；
多条的导电线，所述导电线对于各列，通过各列的多个球状元件的正负导电线连接部，将各列的多个球状元件通电并联，且导电线平行配置；
多条的绝缘性张力线材，所述线材在球状元件的行与行之间和多条的导电线垂直地配置，为了固定多条的导电线，与多条的导电线交织成网状。
2.如权利要求1所述的受光或发光模块板，其特征还在于，在所述的各球状元件件中，所述正负导电线连接部隔着球状元件的中心相对向地设置。
3.如权利要求2所述的受光或发光模块板，其特征还在于，设置密封构件，所述密封构件将所述多个的球状元件与多条的导电线和多条的张力线材一起以包埋的状态收纳，由透明合成树脂或透明玻璃制成。
4.如权利要求2所述的受光或发光模块板，其特征还在于，所述各球状元件为光电二极管或太阳能电池元件。
5.如权利要求2所述的受光或发光模块板，其特征还在于，所述各球状元件为发光二极管。
6.如权利要求2所述的受光或发光模块板，其特征还在于，所述导电线使用选自焊锡、导电性合成树脂、合金化金属的任一种，被连接于正负导电线连接部。
7.如权利要求6所述的受光或发光模块板，其特征还在于，所述受光或发光模块板被包埋于密封构件中，露出所述导电性线材的至少一部分。
8.如权利要求2所述的受光或发光模块板，其特征还在于，所述球状元件的列与列之间具有与导电线平行的与导电线交织的绝缘性的张力线材。
9.如权利要求3所述的受光或发光模块板，其特征还在于，所述密封构件使用透明合成树脂材料，构成柔性构件。
10.如权利要求3所述的受光或发光模块板，其特征还在于，在所述密封构件的与光的入射侧相反侧的一面构成反射从入射侧入射的光的反射膜。
11.如权利要求3所述的受光或发光模块板，其特征还在于，所述密封构件由以包埋状态收纳多个的球状元件的具有柔软性的透明的缓冲层和接合于所述缓冲层的两面上的透明度表面层构成。
12.如权利要求3所述的受光或发光模块板，其特征还在于，所述密封构件具有对球状元件无法吸收的热射线选择性地反射的高分子材料构成的热反射膜。
13.如权利要求2所述的受光或发光模块板，其特征还在于，具有将并联所述多个的球状元件的导电线多列串联的串联装置。
14.受光或发光模块板的制造方法，所述方法是具有呈矩阵状排列的具有受光或发光的功能的多个的球状元件、将各列的多个的球状元件通电并联的导电线、为了固定导电线而与导电线交织成网状的绝缘性的张力线材的受光或发光模块板的制造方法，其特征在于，所述方法具有：
球状元件制造步骤，制造具有正负导电线连接部的球状元件；
连接步骤，由通过导电线的电流产生的焦耳热熔化用于连接球状元件和导电线的接合构件，将球状元件和导电线通过接合构件连接。
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JP3899111B2 (ja) 2007-03-28
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US7214557B2 (en) 2007-05-08
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US20060169992A1 (en) 2006-08-03

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