IP Library Granted Patent US 9,755,088
Granted Patent B2
US 9,755,088 · App. 14/623,854 · Granted Sep 5, 2017

Solar cell manufacturing method

Inventors: Satoshi Tohoda (Osaka, JP); Kenta Ishimura (Osaka, JP); Yayoi Nakatsuka (Osaka, JP)
Assignee: SANYO ELECTRIC CO., LTD.
H01L31/022425H01B1/22H01L31/0747H01L31/18Y02E10/50
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Quick Facts
Patent No.
US 9,755,088
App. No.
14/623,854
Granted
Sep 5, 2017
Kind
B2
Abstract

In a method for manufacturing a solar cell, a first electrode is formed on one surface of a photoelectric conversion section by means of screen printing using a conductive paste, and a second electrode having an area larger than that of the first electrode is formed on the other surface of the photoelectric conversion section by means of screen printing using a conductive paste having viscosity lower than that of the conductive paste.

Claims (34)

1. A method of manufacturing a solar cell, comprising:

forming a first electrode over one surface of a photoelectric conversion unit by screen printing of a first conductive paste; and

forming a second electrode having a larger area than that of the first electrode over the other surface of the photoelectric conversion unit by screen printing of a second conductive paste having a lower viscosity than that of the first conductive paste,

wherein each of the first conductive paste and the second conductive paste contains a conductive filler, a binder resin, and an solvent,

at least one of a type and a content for at least one of the binder resin and the solvent differs between the first conductive paste and the second conductive paste,

the first electrode comprises a plurality of first finger sections arranged in parallel to each other and the second electrode comprises a plurality of second finger sections arranged in parallel to each other, more of the second finger sections being provided than the first finger sections,

the first conductive paste and the second conductive paste are cured by heating to form the first electrode and the second electrode such that the conductive filler is dispersed in the binder resin,

the first conductive paste includes the binder resin which is not yet cured in the form of a solid which can dissolve in the solvent or in the form of liquid or paste at room temperature, and

the second conductive paste includes the binder resin which is not yet cured in the form of a solid which can dissolve in the solvent or in the form of liquid or paste at room temperature;

the conductive filler of the first conductive paste and the conductive filler of the second conductive paste are a same type of conductive filler.

2. The method of manufacturing the solar cell according to claim 1 , wherein

a content of the solvent of the second conductive paste is larger than a content of the solvent of the first conductive paste.

3. The method of manufacturing the solar cell according to claim 1 , wherein

the solvent of the first conductive paste is a first solvent, and

the solvent of the second conductive paste is a second solvent of a different type than the first solvent.

4. The method of manufacturing the solar cell according to claim 1 , wherein

the first conductive paste contains a first binder resin as the binder resin, and

the second conductive paste contains, as the binder resin, a second binder resin of a different type to the first binder resin.

5. The method of manufacturing the solar cell according to claim 1 , wherein

the viscosity of the second conductive paste is set lower as an area of the second electrode becomes larger.

6. The method of manufacturing the solar cell according to claim 1 , wherein

a photoelectric conversion unit is formed by forming an amorphous semiconductor layer on each of one surface and the other surface of a crystalline semiconductor substrate before forming the first electrode and the second electrode.

7. The method of manufacturing the solar cell according to claim 1 , wherein

the forming of the first electrode and the second electrode comprises curing the first electrode and the second electrode by heating at 200° C. or lower.

8. The method of manufacturing the solar cell according to claim 1 , wherein

the number of the finger sections of the second electrode is set to 2 times to 6 times the number of the finger sections of the first electrode.

9. The method of manufacturing the solar cell according to claim 1 , wherein

the thickness of the second electrode is thinner than that of the first electrode.

10. The method of manufacturing the solar cell according to claim 9 , wherein

the thickness of the second electrode is 5 μm to 60 μm.

11. The method of manufacturing the solar cell according to claim 1 , further comprising forming the photoelectric conversion unit before forming the first electrode and the second electrode,

wherein the forming of the photoelectric conversion unit comprises forming a first transparent conductive layer on a light receiving surface, and forming a second transparent conductive layer on a back surface,

wherein in the forming of the first electrode, the first electrode is formed on the first transparent conductive layer, and

wherein in the forming of the second electrode, the second electrode is formed on the second transparent conductive layer.

Assignments (3)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 29, 2015
From: TOHODA, SATOSHI; ISHIMURA, KENTA; NAKATSUKA, YAYOI
To: SANYO ELECTRIC CO., LTD.
Reel/Frame 035281/0018 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 27, 2015
From: SANYO ELECTRIC CO., LTD.
To: PANASONIC CORPORATION
Reel/Frame 035269/0821 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 27, 2015
From: PANASONIC CORPORATION
To: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.
Reel/Frame 035269/0827 →
Continuity (2)
Continuation PCTJP2012072147 · Aug 31, 2012
Related Publication 20160043243A1 · Feb 11, 2016