Solar cell module and method of producing the same

• US 20010023702A1
• Filed: 02/23/2001
• Published: 09/27/2001
• Est. Priority Date: 05/15/1998
• Status: Active Grant

• Current Assignee: Katsumi Nakagawa, Shoji Nishida, Yukiko Iwasaki
• Original Assignee: Katsumi Nakagawa, Shoji Nishida, Yukiko Iwasaki
• Inventors: Iwasaki, Yukiko, Nakagawa, Katsumi, Nishida, Shoji
• Granted Patent: US 6,384,313 B2
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: H01L 31/042 PV modules or arrays of single PV cells supporting structures for PV modules H02S20/00
• CPC Class Codes: H01L 31/0443 comprising bypass diodes integrated or directly associated with the devices, e.g. bypass diodes integrated or formed in or on the same substrate as the photovoltaic cells
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

The solar cell module of the present invention comprises a plurality of unit cells connected in series, each of the unit cells comprising in this order an electrode, a first semiconductor layer having a first conductivity type and a second semiconductor layer having a second conductivity type, wherein the electrode has a region not covered with the first semiconductor layer, wherein the second semiconductor layer has a main region and a subregion which are separated by a groove, wherein the main region of the second semiconductor layer in one unit cell of the unit cells is electrically connected to the region of the electrode not covered with the first semiconductor layer in another unit cell adjacent to the one unit cell, and wherein the region of the electrode not covered with the first semiconductor layer in the one unit cell is electrically connected to the subregion of the second semiconductor layer in the another unit cell, whereby it is possible to simplify a step of forming a bypass diode and the present invention therefore can provides a solar cell module with a high reliability at a low cost.

Claims

1. A solar cell module comprising a plurality of unit cells connected in series, each of the unit cells comprising in this order an electrode, a first semiconductor layer having a first conductivity type and a second semiconductor layer having a second conductivity type,

wherein the electrode has a region not covered with the first semiconductor layer,

wherein the second semiconductor layer has a main region and a subregion which are separated by a groove,

wherein the main region of the second semiconductor layer in one unit cell of the unit cells is electrically connected to the region of the electrode not covered with the first semiconductor layer in another unit cell adjacent to the one unit cell, and

wherein the region of the electrode not covered with the first semiconductor layer in the one unit cell is electrically connected to the subregion of the second semiconductor layer in the another unit cell.

2. A solar cell module according to

claim 1

, wherein the second semiconductor layer is a layer having a low resistance.

3. A solar cell module according to

claim 1

, wherein the second semiconductor layer is a doped layer having a high dopant density.

4. A solar cell module according to

claim 1

, wherein the first semiconductor layer is a p-type semiconductor layer and the second semiconductor layer is an n⁺-type semiconductor layer.

5. A solar cell module according to

claim 1

, wherein the first semiconductor layer is an n-type semiconductor layer and the second semiconductor layer is a p⁺-type semiconductor layer.

6. A solar cell module according to

claim 1

, wherein each of the unit cells has a rectangular shape, wherein a long side direction of the rectangular shape is arranged so as to be perpendicular to a generating line of a curved surface represented by a cylindrical surface or a conical surface, and wherein each of the unit cells is connected in series in a direction of the generating line.

7. A solar cell module according to

claim 1

, wherein at least one of the first semiconductor layer and the second semiconductor layer is a single-crystalline silicon layer.

8. A solar cell module according to

claim 1

, wherein at least one of the first semiconductor layer and the second semiconductor layer is a semiconductor sheet.

9. A solar cell module comprising a plurality of unit cells connected in series, each of the unit cells comprising in this order an electrode, a semiconductor layer and a transparent electrode layer,

wherein the electrode has a region not covered with the semiconductor layer,

wherein the transparent electrode layer has a main region and a subregion which are separated by a groove,

wherein the main region of the transparent electrode layer in one unit cell of the unit cells is electrically connected to the region of the electrode not covered with the semiconductor layer in another unit cell adjacent to the one unit cell, and

wherein the region of the electrode not covered with the semiconductor layer in the one unit cell is electrically connected to the subregion of the transparent electrode layer in the another unit cell.

10. A solar cell module according to

claim 9

, wherein each of the unit cells has a rectangular shape, wherein a long side direction of the rectangular shape is arranged so as to be perpendicular to a generating line of a curved surface represented by a cylindrical surface or a conical surface, and wherein each of the unit cells is connected in series in a direction of the generating line.

11. A solar cell module according to

claim 9

, wherein the semiconductor layer is a semiconductor sheet.

12. A method of producing a solar cell module, which comprises the steps of:

providing a plurality of unit cells, each of the unit cells being produced by forming a second semiconductor layer having a second conductivity type on one surface of a first semiconductor layer having a first conductivity type, forming a groove in the second semiconductor layer to separate the second semiconductor layer into a main region and a subregion, and forming an electrode having a region not covered with the first semiconductor layer on other surface of the first semiconductor layer;

adjacently arranging the plurality of unit cells;

electrically connecting the main region of the second semiconductor layer in one unit cell of the unit cells to the region of the electrode not covered with the first semiconductor layer in another unit cell adjacent to the one unit cell;

electrically connecting the region of the electrode not covered with the first semiconductor layer in the one unit cell to the subregion of the second semiconductor layer in the another unit cell.

13. A method of producing a solar cell module according to

claim 12

, wherein the formation of the groove is conducted by laser scribing.

14. A method of producing a solar cell module, which comprises the steps of:

providing a plurality of unit cells, each of the unit cells being produced by forming a transparent electrode layer on one surface of a semiconductor layer, forming a groove in the transparent electrode layer to separate the transparent electrode layer into a main region and a subregion, and forming an electrode having a region not covered with the semiconductor layer on other surface of the semiconductor layer;

adjacently arranging the plurality of unit cells;

electrically connecting the main region of the transparent electrode layer in one unit cell of the unit cells to the region of the electrode not covered with the semiconductor layer in another unit cell adjacent to the one unit cell;

electrically connecting the region of the electrode not covered with the semiconductor layer in the one unit cell to the subregion of the transparent electrode layer in the another unit cell.

15. A method of producing a solar cell module according to

claim 14

, wherein the formation of the groove is conducted by laser scribing.

16. A method of producing a solar cell module, which comprises the steps of:

providing a plurality of unit cells, each of the unit cells being produced by forming a dopant supplying layer on one surface of a first semiconductor layer having a first conductivity type, forming a groove in the dopant supplying layer to separate the dopant supplying layer into a main region and a subregion, forming a second semiconductor layer having a second conductivity type in the one surface of the first semiconductor layer by diffusing a dopant from the dopant supplying layer, and forming an electrode having a region not covered with the first semiconductor layer on other surface of the first semiconductor layer;

adjacently arranging the plurality of unit cells;

electrically connecting the main region of the second semiconductor layer in one unit cell of the unit cells to the region of the electrode not covered with the first semiconductor layer in another unit cell adjacent to the one unit cell;

electrically connecting the region of the electrode not covered with the first semiconductor layer in the one unit cell to the subregion of the second semiconductor layer in the another unit cell.

17. A method of producing a solar cell module according to

claim 16

, wherein the formation of the groove is conducted by laser scribing.

18. A method of producing a solar cell module, which comprises the steps of:

providing a plurality of unit cells, each of the unit cells being produced by forming a first semiconductor layer having a first conductivity type on an electrode, forming a second semiconductor layer having a second conductivity type on the first semiconductor layer, and forming a groove in the second semiconductor layer to separate the second semiconductor layer into a main region and a subregion, a portion of a surface of the electrode being exposed;

adjacently arranging the plurality of unit cells;

electrically connecting the main region of the second semiconductor layer in one unit cell of the unit cells to the region of the electrode not covered with the first semiconductor layer in another unit cell adjacent to the one unit cell;

electrically connecting the region of the electrode not covered with the first semiconductor layer in the one unit cell to the subregion of the second semiconductor layer in the another unit cell.

19. A method of producing a solar cell module according to

claim 18

, wherein the first semiconductor layer is formed so that the portion of the surface of the electrode is exposed.

20. A method of producing a solar cell module according to

claim 18

, wherein after the first semiconductor layer is formed, the portion of the surface of the electrode is exposed.

21. A method of producing a solar cell module according to

claim 18

, wherein the formation of the groove is conducted by laser scribing.

22. A method of producing a solar cell module, which comprises the steps of:

providing a plurality of unit cells, each of the unit cells being produced by forming a semiconductor layer on an electrode, forming a transparent electrode layer on the semiconductor layer, and forming a groove in the transparent electrode layer to separate the transparent electrode layer into a main region and a subregion, a portion of a surface of the electrode being exposed;

adjacently arranging the plurality of unit cells;

electrically connecting the main region of the transparent electrode layer in one unit cell of the unit cells to the region of the electrode not covered with the semiconductor layer in another unit cell adjacent to the one unit cell;

electrically connecting the region of the electrode not covered with the semiconductor layer in the one unit cell to the subregion of the transparent electrode layer in the another unit cell.

23. A method of producing a solar cell module according to

claim 22

, wherein the first semiconductor layer is formed so that the portion of the surface of the electrode is exposed.

24. A method of producing a solar cell module according to

claim 22

, wherein after the first semiconductor layer is formed, the portion of the surface of the electrode is exposed.

25. A method of producing a solar cell module according to

claim 22

, wherein the formation of the groove is conducted by laser scribing.