京セラの太陽電池研究開発と事業展開

京セラ株式会社白澤 勝彦

Solar

Solar

Eco-Building214kW

目次

京セラ太陽電池事業

研究開発

多結晶Si太陽電池

薄膜Si太陽電池

モジュール、システム

設置事例

ソーラービジョン

KYOCERA Solar HistoryKYOCERA Solar History

1975年京セラ太陽電池スタートし今日まで継続

90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12FY

京セラ太陽電池生産量

1000MW

800MW

600MW

KYOCERA SOLAR HISTORYKYOCERA SOLAR HISTORY

CASTING& CELL

KYOCERA PV OPERATION in JAPANKYOCERA PV OPERATION in JAPAN

Internal Processed Products

IngotIngot BlockBlock WaferWaferSiliconMaterial

SiliconMaterial

CellCell

ModuleModuleDesignDesignInstallationInstallationAfter ServiceAfter Service

MaintenanceMaintenance

INTEGRATED MANUFACTURING PROCESSINTEGRATED MANUFACTURING PROCESS

○ ○ ○ ○

Kyocera Quality & High Efficiency

Casting Cutting Wafer Slicing Solar cells Solarmodules

Silicon

Vertical integrationVertical integration ⇒⇒ Aims to maximize conversion efficiencies withAims to maximize conversion efficiencies withoptimization in all prooptimization in all production processesduction processes

Improvementof conversion

efficiencies

Improvement ofcrystallinequality

Impuritycontaminationmeasures

Optimization of slicing conditions

Thinner wafers

Improvement in quality of slicedmaterial

Passivation

Reactive IonEtching (RIE)technology

High sheetresistanceemitters

Improvementof contact metal

Optimization ofmaterial

Optimization ofFabricationprocess

KYOCERA PROCESS for HIGH EFFICIENCYKYOCERA PROCESS for HIGH EFFICIENCY

Japan

S-Korea

7 Production Sites 15 Sales Offices

China

Australia

India

Czech

Italy

Germany

France

USA

Brazil

ChinaCzech

Mexico

Japan （Cell x2 & Module)

Singapore

HongKong

Taipei

Spain

USA

KYOCERA PV Global Operation

NOElectricity

1.6 billion people

NOClean Water1 billion people

NOEducation

115 million children

NOSanitation

1.2 billion people

for The People

Solar

3 Benefits

Solar

3 Benefits

1 Environment

2 Energy

3 Human Contribution

BASIC HUMAN NEEDS

Source: JBIC

MISSION and RESPONSIBILITYMISSION and RESPONSIBILITY

VILLAGE ELECTRIFICATION TV, MONITOR

PUMP(AC) PUMP(DC) FOUNTAIN PV Diesel

Solar Home Systems

ICE MAKING

Sakura, JapanKYOCERA SOLAR CENTER

Supports Basic Human Needs

SOLAR TRAINING CENTERSOLAR TRAINING CENTER

26-YEAR-OLD MODULE TRACKING SYSTEM

DC LIGHT

MEDICAL Fridge

産業用

発電

プラント40%

14FY10 11 12 13

独立電源

住宅用

薄膜系結晶系

結晶系

結晶系

薄膜系結晶系

PV Market Size

6%

29%

25%

MARKET SEGMENTMARKET SEGMENT

多結晶

結晶系

シリコン系

微結晶

リボン結晶

アモルファス

太陽電池 化合物系

色素増感型

R & D Base

KYOCERA Solar Cells R&D

生産

薄膜系

単結晶

生産中止

生産中止

今回発表実用化を基軸にした研究開発

（コスト、品質、性能）

多結晶シリコン太陽電池

100mm□cell 150mm□cell

3BusBar3BusBar

Eff. (%)

RIE TextureRIE Texture

PECVD-SiNPassivation

PECVD-SiNPassivation

Multicrystalline Si Solar Cell

MWTMWT

156mm□cell

1980 20201985 1990 1990 1995 2000 2005 2010 201510

12

14

16

18

20

22

KYOCERA CELL EFFICIENCY TRENDKYOCERA CELL EFFICIENCY TREND

(D)EP少 (E)周辺部

(B)EP多目 (C)EP&亜粒界密集部

図1 (100)、(110)、(111)種子結晶を用いて成長した結晶の直胴上部の写真と分析位置の関係

図3 図1の結晶のμ-PCD法による少数ｷｬﾘｱﾗｲﾌﾀｲﾑ分布

図4 DLTS分析箇所の選択ｴｯﾁﾝｸﾞ後の光学顕微鏡写真

BC

D

E

BC

D

E

(223)

(212)

(111)(304)

BC

DE

信州大学・干川研との共同研究

種子結晶

■Multi Seed法による大粒径CZ多結晶育成による解析ｷｬｽﾃｨﾝｸﾞｳｴﾊのﾗｲﾌﾀｲﾑ分布

図2 図1の結晶中の4点のDLTS分析の結果

-7 .E+12

-5 .E+12

-3 .E+12

-1 .E+12

1 .E+12

3 .E+12

5 .E+12

0 50 10 0 15 0 20 0 2 5 0 30 0

Tempera ture [K]

サンプルB

サンプルC

サンプルD

サンプルE

DLTS

Signal[c

m-3]

Fe-B(53K）Fei(240-250K）

CRYSTAL GROWTH TECHNOLOGYCRYSTAL GROWTH TECHNOLOGY

Ingot Producing Process Improvement of Crystalline QualityTime

Simulation Quality Control&

Heat ControlHeat Control

IngotIngotSiliconMaterial

SiliconMaterial

To Make High Quality Crystal

BlockBlock WaferWafer CellCell ModuleModule

CRYSTAL QUALITY CONTROLCRYSTAL QUALITY CONTROL

PECVD SiN ProcessAnti-Reflection＋Bulk Passivation

B. Sopori, 24th IEEE PVSC, 1619,1994

スキャナー取り込み

1st PVSEC, Kobe, p37, 1984

SEM EBIC

250℃

400℃

SiN Process 1984年

Reactive Ion Etching ( RIE )1996年

RIEEtching

Chemical

400 500 600 700 800 900 1000 1100

Wavelength [nm]

25

20

15

10

5

0

Su

rfa

ce

Re

fle

cta

nce

[%]

Chemical Etching

RIE Etching

Etching

9st PVSEC, Miyazaki, p109, 1996

RIE TEXTURE, 1996RIE TEXTURE, 1996

Three Bus Bar ( 3.B.B. )

→ Bus Bar Finer

Expand light-receiving area

Decrease Resistance

Help the Capture of ElectricityGenerated any Area

High EfficiencyHigh Reliability

High Reliability

High Efficiency

Decrease of Output Loss by Cell Crack

3.B.B., 20043.B.B., 2004

17.7Effi. [%]

0.770FF

0.620Voc [V]

8.596Isc [A]Cell Area （232.5cm2）

Key Technologies

● Crystal Quality

● Texture Structure by RIE Method

● SiN Passivation

● ３BB Electrodes

p-type mc-Si wafer

FingerBusbar

Textured surface

ARC

Emitter(90 ohm/sq)90

Back contact

p layer+

CELL EFFICIENCY 17.7%, 2004CELL EFFICIENCY 17.7%, 2004

MWT BC as Ideal Structure for Multicrystalline-Si Cell

η=18.3% （ 37.3mA/cm2 、 0.626V、 78.5%）

High EfficiencyGood Appearance

for less shadowing area

Low BreakageEasy Module Assembling

for one-side connecting

Metal Wrap Through Back Contact

n-finger

throughhole p-electrodeBSF

emitter

n-bus bar

No Bus bar on front sideNo Bus bar on front side

AIST : National Institute of Advanced Industrial Science and Technology

Cell Area （233.3 cm2）

CELL EFFICIENCY 18.3%, 2007CELL EFFICIENCY 18.3%, 2007

15.0

15.5

16.0

16.5

17.0

17.5

18.0

100 120 140 160 180

Cell Thickness [µm]

Eff

icie

ncy

[%]

0

2

4

6

8

10

0 100 200

セル厚 [µm]

そり

[mm

]Cell Thickness : 100µm

n contact Through hole

ARC

<p> mc-Si

p+ BSFPassivation

p contact

n+ diffusion

texture

n grid

基板プロセス● 少数キャリア寿命向上

結晶化技術：不純物（Fe、 O、 C、···）析出物、転位、粒径、亜粒界

セルプロセス● ゲッタリング● 選択エミッタ● 裏面パッシベーション● 低抵抗細線電極構造● 光閉じ込め構造

Multicrystalline Si 薄型

化、高効率化

Approach Toward High Effi. and Low Cost）

薄膜シリコン太陽電池開発

Si Thin Film Solar Cells

“Cat-PECVD method” features ;

– H2 and SiH4 are introducedseparately.

– Catalyzer is located only onthe way of H2 gas line.

– Catalyzer is Ta or W wire. It isThe tenperature is around1800 ºC.

– H2 gas is heated by thecatalyzer and some amountsof atomic hydrogen areproduced.

Microcrystalline Silicon Thin Film by Cat-PECVD methodHigh rate deposition with high film quality by gas heating

SILICON THIN FILM SOLAR CELLS

Sputtering

With Cat

Without Cat

Thermal CVD

Cross sectional TEM image of our tandem cell

Glass substrate

SnO2

A-Si:Htop cell

μc-Si:Hbottom cell

Ag

ITO

nip

n

i

p

Sputtering

With Cat

Without Cat

Thermal CVD

Cross sectional TEM image of our tandem cell

Glass substrate

SnO2

A-Si:Htop cell

μc-Si:Hbottom cell

Ag

ITO

nip

n

i

p

High rate deposit ion by Cat-Plasma-CVD

0

5

10

15

20

0.0 0.5 1.0 1.5 2.0 2.5

Deposition rate [nm/s]

Tan

dem

cellinitialefficiency

[％]

■◆ With Cat□◇ Without Cat

13.8％＠1.6nm/s

a-Si/μc-Si ｔandem cell V-I characteristics

0

5

10

15

0 0.5 1 1.5

Voltage [V]

Jp[m

A/cm

2]

Ini.Effi.＝ 13.8％

＠1.6nm/s

S=1cm2

2-Tandem Solar Cell with/without Cat

SILICON THIN FILM SOLAR CELLS

MODULE＆SYSTEM

Annual average temperature map

High Effi. MoHigh Reliability

Large Size MoInstallation Method

積雪

高温

Focus on Quality

日本から海外へ

TEMP. Analysis

STRUCTURE Analysis

KYOCERA QUALITY MANAGEMENTKYOCERA QUALITY MANAGEMENT

Structure Analysis

Snow LoadIssues : Strength of Frame

Durability of Module

Test example

Wrap of frameWrap of frameby slippedby slippedsnowsnow

BlPV ModulesIssues : Higher Temperature

TEMP. Analysis

Issues : Reliability Metal Fittings

Frameless ModulesFall away

Direction ofshort frameDirection ofshort frame

Pass the test

Direction oflong frameDirection oflong frame

Without ALframe

KYOCERA QUALITY MANAGEMENTKYOCERA QUALITY MANAGEMENT

Long-Term Sequential Testby TUV Rheinland Japan

Damp Heat

Thermal Cycling

Humidity Freeze

Bypass Diode

Need to Pass with Same Module

KYOCERA Passed

Plan to Complete by December 2010

KYOCERA FIRST IN THE WORLD

PASSED MAJOR TESTING

Long-TermReliability

KYOCERA QUALITY MANAGEMENTKYOCERA QUALITY MANAGEMENT

Test Condition is Harsher than Standard IEC

25205 10 15

1984 2009

▲10%

▲20%

▲30%

【Year】

25YEARS

Proven Performance

25

▲9.6%Ave.

【Year】

23

Ave. ▲8.6%

Sakura Solar CenterEstablished ： 1984

【System】【Ave. Temperature】 14.2 deg c

Long Term Reliability

43kW Grid-tie ※25年の実証データをベースに、更に出力特性の測定精度・ばらつき等、外的要因も考慮した数値

REAL DATA BY FIELD TEST

KYOCERA QUALITY MANAGEMENTKYOCERA QUALITY MANAGEMENT

太陽電池設置工事実習 施工士認定試験 電気工事実習

京セラソーラー施工士：住宅用ソーラー発電システムに関連する技術・性能及び知識を有し、

導入の背景：

施工品質京セラソーラー施工士認定制度

かつ社会人としてのモラルを有していると京セラソーラーコーポレーションが認定した方

良質な

設計

良質な施工

安全作業

施工品質・信頼性向上

お客様の満足度向上

施工の不具合等は、お客様や社会の信頼を裏切り、企業の存続さえも左右しかねません。「品質」最重要視の経営をしていくために導入。

KYOCERA QUALITY MANAGEMENTKYOCERA QUALITY MANAGEMENT

17.3% Module Aperture Area Efficiency achieved (Jan. 2010)

33

25th EUPVSEC/WCPEC, Valencia, 2010

I-V measurement done by the Research Center of Photovoltaics, Characterization , Testing and System Team, AIST

Back ContactModule

HIGH EFFICIENCY MODULEHIGH EFFICIENCY MODULE

Stylish & PowerfulStep StyleMulti LayoutHarmonize

JAPANESE PRODUCTS LINEUPJAPANESE PRODUCTS LINEUP

Stylish & PowerfulStep StyleMulti LayoutHarmonizeBIPV

Basic Style

For Flat-Roof

For Gable Roof

防汚タイプモジュールAntifouling Frame Module

No Dust

埃なし

Dust

埃あり

モジュール出力モジュール出力 従来比約従来比約１．２％１．２％UPUP

防汚タイプモジュール

標準モジュール

排水部拡大

SAMURAIⓇ

ECONOROOTSⓇ

HEYBANⓇ

SeamJointedFoldedPlate

SpecificSheetMetal

Bolt JointedFolded Plate

WaterproofAnchor

WaterproofingWork &

Maintenance

NoWaterproofing

Work

Suitable Installation on Any Condition

Commerciaｌ

Residential

Ground Mounting For Okinawa Slate Tile Japanese Flat PlateHorizontalSheet Metal BIPV

Slope Roof

Ground Roof

Light Through

Facade

Sheet Metal Roof

低コスト材料自動化架台標準化

高発電量高透過性放熱特性高効率低照度特性温度係数

デザイン大型化BIPV

高信頼性 周辺機器多機能コントローラ制御技術パワコン蓄電

環境配慮リサイクルリユース軽量化

BEMSBuilding Energy Management

System蓄電装置Battery 受電盤／連系制御盤

Gridcontroll er

システム制御装置

System controll er

センサー，通信端末

Sensor

既設電力系統

Grid太陽電池アレイPV

Community micro grid

i i

Charging plug

Inf ormationB oard

PCS

i

Battery

i i

Phot ovol taic array

Large scale SEMS

PV Power Plant

BIPV

Approach 開発課題（モジュール、シ

ステム）

HEMSHome Energy Management

System

設置事例

Salamanca - Spain

13.8MW

Bern Football Stadium 1.35MWBern Football Stadium 1.35MW

2008 Stadium2008 StadiumEuropean WORLD CUPEuropean WORLD CUP

Station 11.6kWSwitzerland

sol-E Suisse AG/BKW FMB Energie AG

Alaska Pipeline - USA

New JerseyCommercial 1MWAlaska Pipeline - USA

Colorado - USA48kW

Parking 201kW

Alvarado WaterTreatment Facility

1.2MW

Univ. of S. Carolina Parking

16kW

系統連系：浄水場用システム

東京・朝霞浄水場

– 1.2MW

JAPANJAPAN

【AEON mall, Hanyu: 100kW】

Spread of storeinstallations by AEON

【AEON Kagoshima:140kW Total】

Roofs of parking lots57.5kW

Roof of bus stops 25.5kW

【Asahi Shokuhin (Kochi): 500kW】

外務省50ｋｗ

内閣府40ｋｗ

財務省40ｋｗ

国土交通省46ｋｗ経済産業省40ｋｗ

導入事例 霞ヶ関中央省庁No.24

PV System: 10.7kWPV System: 10.7kW

系統連系：ソーラー防災システム

災害時対応

– 照明

– 充電（携帯電話）

– 給油ポンプ

– 冷蔵庫

– 他

KYOCERA Solar Quality: Validation & Proof

クリーンなｴﾈﾙｷﾞｰ太陽電池を。

エベレスト

BangladeshBangladesh IndonesiaIndonesia

South AfricaSouth Africa

Solar Home SystemsSolar Home Systems

LifeLife Is CarriedIs CarriedThe VitalThe Vital

Solar RefrigeratorMoving Hospital

Solar RefrigeratorMoving Hospital

Tunisia

BASIC HUMAN NEEDSBASIC HUMAN NEEDS

.美しい地球を次世代に

What a Wonderful Job!

太陽の恵みに感謝して愛と誠と調和をベースに生きる

to be thankful

Living a sincere, harmonious life with lovein appreciation of the bounty of the sun