JP2010232692A - Thin-film solar battery module and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thin film solar battery module capable of reducing the manufacturing cost. <P>SOLUTION: The thin-film solar battery module is provided with a plurality of sheets of thin film solar battery cell. a supporting plate G1 and a frame F1 consisting of a conductive material, while the thin film solar battery cell is constituted of a string, in which a plurality of thin film photoelectric conversion element consisting of a photoelectric conversion layer and a second electrode layer which are laminated sequentially are connected electrically in series mutually; while a string is formed at the inside of end surface neighbored to the frame F1 in an insulated substrate in the thin film solar battery cell, whereby the surface of the insulated substrate positioned in at least a predetermined insulating distance from the frame F1 is a nonconductive surface region 219a and the end part, positioned in a predetermined insulating distance in the outer peripheral end surface of one side opposed to the other thin-film solar battery cell is the nonconductive end face region 219b, in which there is no electric film. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a thin film solar cell module and a method for manufacturing the same, and more particularly to a thin film solar cell module including a plurality of thin film solar cells and a method for manufacturing the same.

  As shown in FIGS. 27 and 28, a conventional thin film solar cell module Pm includes a thin film photoelectric conversion element in which a first electrode layer, a photoelectric conversion layer (semiconductor layer), and a second electrode layer are sequentially stacked on an insulating substrate. Includes a thin film solar cell Ps having a string electrically connected in series with each other and a frame Pf attached to the outer peripheral edge of the two thin film solar cells Ps to connect and reinforce the cells. An aluminum frame Pf is widely used.

More specifically, in the thin-film solar battery Ps, the first electrode layer and the second electrode layer on both ends in the series connection direction of the strings are connected to the external terminals in the terminal box c via the bus bar a and the lead-out line b. In addition, the back surface side and the end surface side are sealed by the sealing member d. Then, by attaching the frame member Pf ₁ ~Pf ₅ between the two thin-film solar batteries Ps of the peripheral and cell and the thin film solar cell module Pm of one is produced (e.g., Non-Patent Document 1).

Kaneka product pamphlet "Kaneka Silicon PV" published on January 1, 2006

In such a conventional thin film solar cell module Pm, since the frame member Pf ₅ is used between the two thin film solar cells Ps, the frame member increases, the module weight increases, and the frame mounting work is complicated. There is a problem that the manufacturing cost of the thin-film solar cell module is increased due to the increase in complexity of wiring and wiring.
The present invention provides a thin-film solar cell module that can solve such problems and can reduce the manufacturing cost.

Thus, according to the present invention, a plurality of thin film solar cells, a support plate, and a frame made of a conductive material ,
The thin-film solar cell is electrically connected to a plurality of thin-film photoelectric conversion elements each having a first electrode layer, a photoelectric conversion layer, and a second electrode layer sequentially stacked on the surface of a planar insulating substrate having at least four sides. A string connected in series and a conductive film attached to the outer peripheral end surface of the insulating substrate ;
In a state where a plurality of thin film solar cells are arranged and fixed on the support plate, the frame is attached to the outer peripheral edge of the support plate ,
In the thin-film solar cell, the surface of the insulating substrate positioned at least within a predetermined insulating distance from the frame by forming the string inside the end surface of the insulating substrate close to the frame is a non-conductive surface region. And an end located within a predetermined insulating distance on the outer peripheral end surface facing one of the other adjacent thin-film solar cells is a non-conductive end surface region where the conductive film does not exist, and the non-conductive A predetermined withstand voltage is provided by the surface region and the non-conductive end surface region,
The insulating substrate has a shape lacking corners so that the end of the outer peripheral end surface of the one side is inclined in a direction away from the other adjacent thin-film solar cell as it goes from the inside to the outer peripheral side of the support plate. There is provided a thin film solar cell module in which the non-conductive end face region is formed in a shape portion lacking the corner portion .
According to another aspect of the present invention, a plurality of thin film photoelectric conversion elements in which a first electrode layer, a photoelectric conversion layer, and a second electrode layer are sequentially stacked on the surface of an insulating substrate are electrically connected in series with each other. A plurality of thin-film solar cells having a string formed and a conductive film attached to the outer peripheral end surface of the insulating substrate when the string is formed are placed on a support plate and sealed with an insulating sealing material and fixed. A sealing and fixing step, and a frame attaching step for attaching a frame made of a conductive material to the outer peripheral edge of the support plate that supports the plurality of thin film solar cells ,
Furthermore, before the sealing and fixing step, the cell preparation step of preparing the plurality of thin-film solar cells,
A string forming step of forming the string on at least a surface of a rectangular insulating substrate;
A film removing step of removing the film constituting the thin film photoelectric conversion element formed on the outer peripheral portion of the insulating substrate in the string forming step,
In the film removal step, a non-conductive surface region is formed by removing a film on the surface of the insulating substrate located within an insulating distance having a predetermined dielectric withstand voltage from the frame,
Furthermore, when a conductive film adheres to the outer peripheral end surface of the insulating substrate in the string forming step, it faces an adjacent thin film solar cell when a plurality of thin film solar cells are arranged in the subsequent sealing and fixing step. In order to remove the conductive film adhering to the end portion of the outer peripheral end surface of one side, the adjacent other ends as the end portion located within a predetermined insulation distance on the outer peripheral end surface of the one side moves from the inner side to the outer peripheral side of the support plate. The manufacturing method of the thin film solar cell module which removes a corner | angular part so that it may incline in the direction away from this thin film photovoltaic cell, and forms a nonelectroconductive end surface area | region is provided.

According to the present invention, a plurality of thin film solar cells are arranged and fixed on one support plate, and a frame is attached to the outer peripheral edge of the support plate, so that the frame between cells is omitted while maintaining strength. Since a battery module can be obtained, it is possible to reduce the number of frame members, reduce the weight of the module, reduce the number of man-hours for mounting the frame, simplify the wiring, and consequently reduce the manufacturing cost of the thin-film solar cell module Can do. Moreover, since there is no frame between cells, the advantage that the aesthetics of a thin film solar cell module improves is also acquired.
Moreover, even if a conductive film composed of the first electrode layer and the second electrode layer adheres to the outer peripheral end face of the insulating substrate, it is necessary as a thin film solar cell module by forming a non-conductive end face area together with the non-conductive surface area. In addition, it is possible to ensure a predetermined insulation withstand voltage and to form a film without covering the outer peripheral end face of the insulating substrate in the film forming apparatus. In addition, the insulating substrate is placed on a tray dedicated to the substrate, and the outer peripheral end surface of the insulating substrate is covered with the tray, so that the conductive film does not adhere to the outer peripheral end surface, but a large number of trays are required, and the insulating substrate is set on the tray The manufacturing cost increases due to an increase in the number of processes to be performed and the need for maintenance to remove the film attached to the tray surface. However, in the present invention, a film forming process without using a tray can be employed.
Furthermore, in this case, since the string is formed in the thin film solar cell up to the adjacent portion on the surface of two adjacent cells, the effective power generation area increases.
Here, in the present invention, the above-described non-conductive surface region and non-conductive end surface region do not require the first electrode layer, the photoelectric conversion layer, and the second electrode layer to be completely removed, but the conductive and insulating If the voltage resistance is not a problem, they may partially remain.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows Embodiment 1-1 of the thin film solar cell module of this invention, Comprising: Fig.1 (a) is a top view, FIG.1 (b) is a front view, FIG.1 (c) is a right view. It is a bottom view which shows the thin film solar cell module of Embodiment 1-1. It is a front sectional view showing the thin film solar cell module of Embodiment 1-1. It is an exploded view which shows the decomposition | disassembly state of the thin film solar cell module of Embodiment 1-1. 1 is a perspective view showing a thin film solar battery cell 10. 6A is a cross-sectional view taken along the line BB in FIG. 5, and FIG. 6B is a cross-sectional view taken along the line AA in FIG. It is sectional drawing which shows the state which has arrange | positioned the two thin film photovoltaic cell of Embodiment 1-1 adjacently. It is a perspective view which shows the state which has arrange | positioned two thin film photovoltaic cells of Embodiment 1-1 adjacently, and connected the wiring sheet. It is a block diagram of the wiring sheet in Embodiment 1-1. It is sectional drawing which shows the flame | frame attachment site | part of the thin film solar cell module of Embodiment 1-1, Comprising: Fig.10 (a) respond | corresponds to the cross section of Fig.6 (a), FIG.10 (b) is FIG.6 (b). Corresponds to the cross section. It is a perspective view which shows the state in which the string was formed in the cell preparation process in Embodiment 1-1. It is the sectional view on the AA line of FIG. It is a top view which shows the thin film solar cell module of Embodiment 1-2. It is a top view which shows the thin film solar cell module of Embodiment 1-3. It is a figure which shows the state which arrange | positions the thin film photovoltaic cell in Embodiment 1-3. It is a fragmentary sectional top view which shows the thin film solar cell module of Embodiment 2-1. It is a perspective view which shows the thin film photovoltaic cell in Embodiment 2-1. It is sectional drawing which arrange | positioned the thin film photovoltaic cell in Embodiment 2-1 side by side, Comprising: Fig.18 (a) shows a parallel connection state, FIG.18 (b) shows a serial connection state. It is a figure explaining the process of forming the nonelectroconductive end surface area | region of the thin film photovoltaic cell in Embodiment 2-1. It is a fragmentary sectional top view which shows the thin film solar cell module of Embodiment 2-2. It is a perspective view which shows the thin film photovoltaic cell in Embodiment 2-2. It is a figure explaining the process of forming the nonelectroconductive end surface area | region of the thin film photovoltaic cell in Embodiment 2-2. It is a fragmentary sectional top view which shows the thin film solar cell module of Embodiment 2-3. It is a top view which shows the thin film solar cell module M7 of Embodiment 2-4. It is a top view which shows the thin film solar cell module M8 of Embodiment 3. It is a perspective view which shows the thin film photovoltaic cell 410 in Embodiment 3. FIG. It is a top view which shows the conventional thin film solar cell module. It is a front sectional view showing a conventional thin film solar cell module.

The thin film solar cell module of the present invention includes a plurality of thin film solar cells, a support plate, and a frame made of a conductive material , and the thin film solar cell has a first electrode layer on a surface of an insulating substrate, A plurality of thin film photoelectric conversion elements in which a photoelectric conversion layer and a second electrode layer are sequentially stacked have a string electrically connected in series with each other, and a plurality of thin film solar cells are arranged on the support plate. The frame is attached to the outer peripheral edge of the support plate in a fixed state.
Hereinafter, in the present specification, the “thin film photovoltaic cell” may be abbreviated as “cell”.

In the present invention, the support plate is not particularly limited as long as it has a strength capable of supporting a plurality of thin-film solar cells without being bent. For example, an insulating plate made of glass, plastic, ceramic, or the like. Alternatively, a conductive plate made of aluminum, stainless steel, or the like, or a composite plate in which a conductive plate is coated with a resin can be used.
When conductive plates and composite plates are used, depending on the material of the frame, which will be described later, if the frame is conductive, the frame and the support are provided so that the insulation withstand voltage required for the thin film solar cell module can be obtained. It is desirable to increase the insulation resistance between the plates, between the frame and the thin-film solar cells, and between the support plate and the thin-film solar cells.

Here, the dielectric withstand voltage means a characteristic that does not cause a discharge between the frame and the thin-film solar cell even when a predetermined high voltage is applied between the frame and the thin-film solar cell. It can be checked whether or not a predetermined withstand voltage is obtained by an insulation withstand voltage test defined in (IEC: 61646). In the case of a thin-film solar cell module whose system voltage is lower than 1000V, the international standard requires an insulation voltage resistance against a lightning surge withstand voltage of 6 KV.
Accordingly, the support plate is preferably an insulating plate that easily obtains high insulation voltage resistance, more preferably a support plate made of tempered glass or reinforced plastic, and particularly preferably tempered glass having excellent weather resistance. In addition, although the presence or absence of translucency of the support plate is not particularly limited, when the support plate side is a light-receiving surface of the thin-film solar battery cell, the support plate needs to be translucent, and also in terms of translucency Tempered glass is preferred over reinforced plastic.

In the present invention, the frame has a function of increasing the strength as a thin film solar cell module, and may further have a function as an attachment member and a support member when the thin film solar cell module is attached to an installation location. .
As the material of the frame, common aluminum, metals such as stainless steel and the like if example embodiment.

In the thin film solar cell module of the present invention, it is preferable that the plurality of thin film solar cells are waterproofed by sealing at least the entire string with a sealing member. As the sealing member, a sealing resin sheet (for example, ethylene-vinyl acetate copolymer (EVA), etc.) can be used. The sealing resin sheet is placed on the string and heated and pressurized under vacuum. Each thin film solar cell can be waterproofed by pressure bonding. Further, a protective sheet may be laminated on the sealing resin sheet.
Further, an insulating cushion material may be provided between the frame and the support plate and between the frame and the thin film solar cell. With this cushion material, it is possible to prevent the support plate from rattling with respect to the frame and to improve the above-mentioned insulation withstand voltage.

  Examples of the photoelectric conversion layer of the thin-film solar cell include a pn junction type, a pin junction type, a hetero junction type, and a tandem structure type in which a plurality of pn or pin junctions are stacked. In the present specification, the first conductivity type described later means p-type or n-type, and the second conductivity type means n-type or p-type which is the opposite conductivity type to the first conductivity type. .

  In this invention, the said insulated substrate of a thin film photovoltaic cell can function also as a mounting plate which attaches a thin film photovoltaic cell to a support plate other than the function as a board | substrate of a thin film photovoltaic cell. In this case, the insulating substrate can be mounted on the support plate and fixed by bonding or screwing, and bonding without using a metal member is preferable from the viewpoint of the above-mentioned insulation voltage resistance. The above-mentioned sealing resin sheet can be used for this adhesion.

Furthermore, the thin film solar cell module of the present invention is used for both a super straight type thin film solar cell using a translucent substrate as an insulating substrate and a substrate type thin film solar cell using a non-translucent substrate. Applicable.
In the case of the super straight type in which the insulating substrate is fixed on the support plate, the first electrode side is the light incident side, so that the support plate, the sealing resin sheet, and the insulating substrate are translucent. In the case of a substrate type in which an insulating substrate is fixed on a support plate, since the second electrode side is a light incident side, the presence or absence of translucency of the support plate, the sealing resin sheet, and the insulating substrate is not limited. However, the wiring work from the second electrode side is convenient, and in the substrate type, the wiring on the second electrode side prevents light reception. Therefore, the super straight type thin film solar cell having the first electrode side as the light incident side. Is preferred.

Moreover, the thin film solar cell module of this invention can also mount and fix the 2nd electrode side of a thin film photovoltaic cell on a support plate. In this case, the thin film solar cell is placed on the support plate by placing the thin film solar cell on the support plate with the second electrode side down through the sealing resin sheet, and heating and pressurizing in vacuum. Can be glued to. In this way, there is an advantage that the string can be sealed and fixed to the support plate at the same time.
Thus, in the case of the cell mounting structure in which the second electrode faces the support plate, when the thin film solar cell is a super straight type, the side opposite to the support plate is the light incident side, and the thin film solar cell is a substrate type. In some cases, the support plate side is the light incident side. However, in this case as well, the wiring work from the second electrode side is convenient, and in the substrate type, the wiring on the second electrode side prevents light reception. Therefore, the super straight type thin film having the first electrode side as the light receiving surface. Solar cells are preferred.

The thin film solar cell module of the present invention can be further configured as follows.
(1) In a plurality of thin film solar cells, two adjacent thin film solar cells are arranged apart from each other.
(2) The plurality of thin film solar cells further include a protective member that protects opposing edges of each thin film solar cell between two adjacent thin film solar cells.
The purpose of configuring the thin film solar cell module as described in the above (1) and (2) is that the opposing edges of the insulating substrates of two adjacent thin film solar cells are supported by the slight deflection of the support plate or This is to prevent the insulating substrate from cracking by causing the cells to accidentally collide with each other when the thin film solar cells are arranged on the plate.
In addition, when a thin film solar cell is less likely to cause substrate cracking, for example, when a resin substrate such as polyimide that is difficult to crack is used as an insulating substrate of the thin film solar cell, two adjacent thin film solar cells face each other. The edges may be arranged in contact with each other.

In the thin-film solar battery modules having the configurations (1) to (2) , adjacent two cells are arranged as follows and can be connected in series or in parallel.
( 3 ) In the thin-film solar battery, the second electrode at one end in the series connection direction of the strings is a lead electrode for the first electrode of the adjacent thin-film photoelectric conversion element, and the photoelectric conversion layer is on the first electrode side. Two adjacent thin-film solar cells that have a first-conductivity-type semiconductor layer and a second-conductivity-type semiconductor layer on the second electrode side and are aligned in the string serial connection direction are the second electrodes of one thin-film solar cell. The string of the two thin film solar cells is connected in series with each other by arranging the lead electrode of the other thin film solar cell in the direction close to each other and electrically connecting them.
( 4 ) In the thin-film solar battery, the second electrode at one end of the string in the serial connection direction is a lead electrode for the first electrode of the adjacent thin-film photoelectric conversion element, and the photoelectric conversion layer is on the first electrode side. In two adjacent thin-film solar cells having a first conductive-type semiconductor layer and a second conductive-type semiconductor layer on the second electrode side and arranged in the series connection direction of the strings, each thin-film solar cell has an extraction electrode Two thin-film solar cells are arranged in such a manner that the lead electrodes are arranged in directions away from each other or in the direction in which the lead electrodes are close to each other, and the second electrodes or lead-out electrodes that are adjacent to each other are electrically connected to each other. The strings of battery cells are connected in parallel to each other.
Hereinafter, embodiments of the thin-film solar cell module having the above-described various configurations and a manufacturing method thereof will be specifically described with reference to the drawings.

(Embodiment 1-1 : Reference example )
FIG. 1 is a diagram showing Embodiment 1-1 of a thin film solar cell module of the present invention, in which FIG. 1 (a) is a plan view, FIG. 1 (b) is a front view, and FIG. 1 (c) is a right side view. It is. FIG. 2 is a bottom view showing the thin-film solar battery module according to Embodiment 1-1. FIG. 3 is a front sectional view showing the thin-film solar battery module according to Embodiment 1-1. FIG. 4 is an exploded view showing an exploded state of the thin film solar cell module of Embodiment 1-1.

<Description of the structure of the thin film solar cell module>
The thin-film solar battery module M1 according to Embodiment 1-1 includes a tempered glass G1 that is a support plate, two thin-film solar cells 10 that are spaced apart and fixed on the tempered glass G1, and two thin-films. The frame F1 attached to the outer periphery of the tempered glass G1 as a support plate which supported the photovoltaic cell 10 is provided.
The thin film solar cell module M1 further includes an adhesive layer 11 for bonding and fixing the two thin film solar cells 10 on the tempered glass G1, and the two thin film solar cells 10 fixed on the tempered glass G1. A covering layer 12 to be covered, a protective layer 13 covering the covering layer 12, and a wiring connection portion 14 for electrically connecting the two thin-film solar cells 10 are provided.
Hereinafter, a structure in which two thin-film solar cells 10 are fixed on the tempered glass G1 by the adhesive layer 11, covered by the covering layer 12 and the protective layer 13, and the wiring connection portion 14 is attached, This is referred to as a module body m1.

The tempered glass G1 is made of tempered glass having a thickness of about 2 to 4 mm, and is formed in a square plate shape.
The frame F1 includes four aluminum frame members f1 to f4 attached to the four sides of the rectangular module main body m1 and screw members (not shown) that connect adjacent frame members.

The frame member f1 includes a plate portion 1a having a length substantially the same as the length of one side of the module body m1, and three protruding piece portions that protrude perpendicularly from the inner surface of the plate portion 1a and extend over the entire length of the plate portion 1a. Consists of. The two protruding pieces of the frame member f1 are holding pieces 1b and 1c for inserting and holding one end edge of the module main body m1 between them, and the remaining protruding parts are attached for installation at the installation location. It is a piece 1d. Further, cylindrical screw mounting portions having screw holes are integrally provided at both ends of the inner surface of the plate portion 1a between the sandwiching pieces 1b and 1c. The frame member f3 disposed to face the frame member f1 has the same configuration as the frame member f1.
The frame member f2 has a plate portion and a pair of holding pieces similar to the frame member f1, but the length of the holding pieces is shorter than that of the plate portion, and an L-shape including the mounting piece in the frame member f1. The part is omitted. Furthermore, screw insertion holes are formed at both ends of the plate portion at positions corresponding to the screw mounting portions of the frame members f1 and f3. The frame member f4 disposed to face the frame member f2 has the same configuration as the frame member f2.

5 is a perspective view showing the thin-film solar battery cell 10, FIG. 6 (a) is a cross-sectional view taken along line BB in FIG. 5, and FIG. 6 (b) is a cross-sectional view taken along line AA in FIG. .
The thin-film solar battery 10 is a thin film in which a rectangular transparent insulating substrate 111 that is an insulating substrate, and a first electrode layer 112, a photoelectric conversion layer 113, and a second electrode layer 114 are sequentially stacked on the surface of the transparent insulating substrate 111. This is a super straight type thin film solar cell including a string S1 in which a plurality of photoelectric conversion elements 115 are electrically connected in series with each other.

As the transparent insulating substrate 111, a glass substrate having heat resistance and translucency in a subsequent film forming process, a resin substrate such as polyimide, and the like can be used. The first electrode layer 112 is made of a transparent conductive film, and is preferably made of a transparent conductive film made of a material containing ZnO or SnO ₂ . The material containing SnO ₂ may be SnO ₂ itself or a mixture of SnO ₂ and another oxide (for example, ITO which is a mixture of SnO ₂ and In ₂ O ₃ ).

The material of each semiconductor layer constituting the photoelectric conversion layer 113 is not particularly limited, and is made of, for example, a silicon-based semiconductor, a CIS (CuInSe ₂ ) compound semiconductor, a CIGS (Cu (In, Ga) Se ₂ ) compound semiconductor, or the like. Hereinafter, the description will be given by taking as an example the case where each semiconductor layer is made of a silicon-based semiconductor. “Silicon-based semiconductor” means amorphous or microcrystalline silicon, or a semiconductor in which carbon, germanium, or other impurities are added to amorphous or microcrystalline silicon (silicon carbide, silicon germanium, or the like). Further, “microcrystalline silicon” means silicon in a mixed phase state of crystalline silicon having a small crystal grain size (about several tens to thousands of thousands) and amorphous silicon. Microcrystalline silicon is formed, for example, when a crystalline silicon thin film is manufactured at a low temperature using a non-equilibrium process such as a plasma CVD method.
The photoelectric conversion layer 113 is formed by stacking a p-type semiconductor layer, an i-type semiconductor layer, and an n-type semiconductor layer in this order from the first electrode 112 side.
The p-type semiconductor layer is doped with p-type impurity atoms such as boron and aluminum, and the n-type semiconductor layer is doped with n-type impurity atoms such as phosphorus. The i-type semiconductor layer may be a completely non-doped semiconductor layer, or may be a weak p-type or weak n-type semiconductor layer that contains a small amount of impurities and has a sufficient photoelectric conversion function. Note that in this specification, “amorphous layer” and “microcrystalline layer” mean amorphous and microcrystalline semiconductor layers, respectively.

The configuration and material of the second electrode layer 114 are not particularly limited. In an example, the second electrode 114 has a stacked structure in which a transparent conductive film and a metal film are stacked on a photoelectric conversion layer. The transparent conductive film is made of SnO ₂ , ITO, ZnO or the like. The metal film is made of a metal such as silver or aluminum.
The transparent conductive film and the metal film can be formed by a method such as CVD, sputtering, or vapor deposition.

  The string S1 has a plurality of separation grooves 116 formed on the surface thereof. The plurality of separation grooves 116 are formed in a direction perpendicular to the serial connection direction (long side direction of the transparent insulating substrate 111) so as to electrically separate the second electrode 114 and the photoelectric conversion layer 113 of the two adjacent thin film photoelectric conversion elements 115. ). In addition, the stacked film 115a including the first electrode, the photoelectric conversion layer, and the second electrode at one end (the right end in FIG. 6B) of the string S1 in the series connection direction is formed to have a narrow width in the series connection direction. Therefore, the second electrode of the laminated film 115a is used as the extraction electrode 114a of the first electrode 112 of the adjacent thin film photoelectric conversion layer 115.

  Further, the string S1 of the cell 10 is formed on the inner side of the three end surfaces in the transparent insulating substrate 111 close to the frame F1 and the one end surface facing the other adjacent cells 10. That is, the outer peripheral region on the surface of the transparent insulating substrate 111 is a non-conductive surface region 119 having a certain width W to which the first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 are not attached. In this non-conductive surface region 119, a portion close to the frame F1 is a first non-conductive surface region 119a, and a portion close to another adjacent cell 10 is a second non-conductive surface region 119b. . The non-conductive surface region 119 will be described later in detail.

In the cell 10, the conductive film D composed of the first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 is attached to the entire outer peripheral end surface of the transparent insulating substrate 111. The conductive film D is attached to the outer peripheral end surface when the string S1 is formed on the surface of the transparent insulating substrate 111, and has a thickness of about 2 to 5 μm.

The two thin-film solar cells 10 configured in this way are arranged side by side as shown in FIG. 7 (a) or (b) so as to be separated from each other and adjacent to each other in the serial connection direction of the string S1. ing.
FIG. 7A shows a state in which two cells 10 are arranged so that the extraction electrode 114a of one cell 10 and the second electrode 115 of the other cell 10 are close to each other, and FIG. A state is shown in which two cells 10 are arranged so that the extraction electrode 114a of one cell 10 and the extraction electrode 114a of the other cell 10 are close to each other. Although not shown in FIG. 7, on the second electrode 114 and the extraction electrode 114a at both ends in the series connection direction in the string S1 of each cell 10, the bus bar 117 (see FIG. 8) along the longitudinal direction thereof. Are electrically connected by brazing material.

  These cells 10 are arranged so that the distance between the opposing end faces of the outer peripheral end faces of each insulating substrate 111 is about 0.1 to 5 mm, and the covering layer 12 enters between the opposing end faces. . Therefore, it is avoided that the insulating substrates 111 come into contact with each other to cause a substrate crack. In FIG. 7, the boundary line between the coating layer 12 around each cell 10 and the adhesive layer 11 on the tempered glass G1 is not shown. This is because the covering layer 12 and the adhesive layer 11 on the tempered glass G1 are both made of a resin sheet, and they are integrated by heat fusion, and will be described in detail later.

FIG. 8 shows a state in which an extraction line 1118 (for example, a copper wire) is electrically connected to each bus bar 117 of the two cells 10, and FIG. 9 is a configuration explanatory view of a wiring sheet 1119 having the extraction line 1118.
The wiring sheet 1119 includes four lead wires 1118 having a predetermined length, and a first insulating sheet 1120 and a second insulating sheet 1121 which are sandwiched between them in a state where they are spaced apart from each other and arranged substantially in parallel. It is installed on one cell 10 in the direction of series connection.
The first insulating sheet 1120 has a plurality of extraction holes 1120a for leading one end of each extraction line 1118 to the outside, and the second insulation sheet 1121 is formed in a shape that exposes only the other end of each extraction line 1118 to the outside. Has been. The first and second insulating sheets 1120 and 1121 are made of a resin sheet (for example, polyethylene, polypropylene, PET, etc.) and are heat-sealed with each other in a state where four lead wires 1118 are sandwiched side by side.

The plurality of extraction holes 1120a of the wiring sheet 1119 are arranged at positions close to each other, and one ends of the plurality of extraction lines 1118 are bent and led out from the extraction holes 1120a. The cover layer 12 and the protective layer 13 are also formed with a take-out hole for leading out one bent end of each take-out line 1118 to the outside.
In addition, the plurality of lead-out lines 1118 are set to lengths that are arranged at positions where the other ends thereof can come into contact with the bus bars 117 of the two cells 10 arranged side by side.
More specifically, in the embodiment 1-1, of the four lead-out lines 1118, the two adjacent lead-out lines 1118 are connected to the two bus bars 117 at the separated positions, and the other adjacent lead-out lines are connected. 1118 is connected to two bus bars 117 located at close positions.

The wiring connection portion 14 includes the wiring sheet 1119 and a terminal box 1123 having two output lines 1122 that are electrically connected to one end exposed to the outside of each extraction line 1118 of the wiring sheet 1119. Yes.
A lead-out terminal is provided at one end of the two output lines 1122, and two lead-out lines 1118 are electrically connected to each lead-out terminal, and a connector 1124 is connected to the other end of the two output lines 1122. Are provided.
The terminal box 1123 is fixed to the surface of the protective layer 13 with, for example, a silicone resin adhesive to prevent water from entering the inside.

The two thin film solar cells 10 are connected in series or in parallel to each other as will be described later.
When connected in series, two adjacent cells 10 aligned in the serial connection direction of the string S1 are arranged in a direction in which the second electrode 114 of one cell 10 and the extraction electrode 114a of the other cell 10 are close to each other. Thus, the strings S1 of the two cells 10 are connected in series with each other.
Specifically, as shown in FIG. 7A, when the two cells 10 are arranged and wired using the wiring sheet 1119, the adjacent extraction electrode 114a and the second electrode in the two cells 10 are adjacent to each other. 114 is connected to each other by connecting the two extraction lines 1118 to each other, and the second electrode 114 and the extraction electrode 114a that are separated from each other are connected to the two output lines 1122 via the other two extraction lines 1118. Thus, the two thin film solar cells 10 are connected in series.

In the case of parallel connection, in two adjacent cells 10 arranged in the serial connection direction of the strings S1, each cell 10 is arranged in a direction in which each extraction electrode 214a is separated from each other or in a direction in which each extraction electrode 214a is close to each other. In addition, the strings S1 of the two thin-film solar cells are connected in parallel to each other by electrically connecting the adjacent second electrodes 214 or the extraction electrodes 214a of the cells 10 to each other.
Specifically, as shown in FIG. 7B, when the two cells 10 are arranged and wired using the wiring sheet 1119, two adjacent extraction electrodes 114a in the two cells 10 are two. The second electrodes 114 that are connected to one output line 1122 through the lead-out line 1118 and are connected to the other output line 1122 through the other two lead-out lines 1118 are connected to each other. The thin film solar cells 10 are connected in parallel. In parallel connection, the cells 10 may be arranged in the opposite direction to the direction shown in FIG.

  In addition, by appropriately handling each lead-out line 1118 connected to each bus bar 117 of the two cells 10, the cells 10 are arranged side by side as shown in FIG. 7A or connected in parallel as shown in FIG. 7B. It is also possible to connect 10 in series.

10 is a cross-sectional view showing a frame mounting portion of the thin film solar cell module M1, FIG. 10 (a) corresponds to the cross section of FIG. 6 (a), and FIG. 10 (b) is a cross section of FIG. 6 (b). Correspond.
As shown in FIG. 10, in a state where the outer peripheral edge of the module main body m1 is pushed between the pair of sandwiching pieces 1b and 1c of the frame F1, the distance L from the plate portion 1a of the frame F1 to the string S1 of the cell 10 is The predetermined insulation distance described above. When the string S1 itself or at least one of the first electrode layer 112 and the second electrode layer 114 is formed on the surface of the transparent insulating substrate 111 within the predetermined insulating distance L, between the frame F1 and the string 2 A predetermined withstand voltage cannot be obtained. That is, when a high voltage of, for example, 6 KV is applied between the second electrode 114 or the extraction electrode 114a at the end in the serial connection direction of the frame F1 and the string 2, a discharge is generated between the frame F1 and the string.

In the present invention, the first electrode layer 112, the photoelectric conversion layer 113, and the first electrode layer 112 are formed on the surface of the transparent insulating substrate 111 within a predetermined insulating distance L in order to obtain a predetermined withstand voltage for preventing such discharge. The first non-conductive surface region 119a having a width W to which the two-electrode layer 114 is not attached is formed. For example, when the predetermined insulation distance L is 9 to 20 mm in order to obtain the insulation withstand voltage with respect to the lightning surge withstand voltage 6 KV of the international standard, the width W of the first non-conductive surface region 119a is 8.4 to 20 mm. Yes, 8.4 to 14 mm is preferable, and 8.4 to 11 mm is more preferable.
Further, the second non-conductive surface region 119b having the same width W is also formed on the surfaces of the adjacent cells 10 that are close to each other (see FIG. 1A). In this case, the adjacent surfaces of the adjacent cells 10 are separated from the plate portion 1a of the frame F1 by a distance greater than the predetermined insulating distance L, but the second non-conductive surface region 119b having a width W is required. . That is, the conductive film D composed of the first electrode layer 112 and the second electrode layer 114 is attached to the entire outer peripheral end face of the transparent insulating substrate 111, and the shortest distance from the attached film D to the frame F1 is greater than the predetermined insulating distance L. Nearby Therefore, it is because conduction or discharge occurs between the frame F1 and the string S1 and the second non-conductive surface region 119b is not via the conductive film D, the second non-consideration of this conductive film D A conductive surface region 119b is provided.

<Description of the structure of the thin film solar cell module>
The above-described thin film solar cell module M1 includes a cell manufacturing process for manufacturing the plurality of thin film solar cells, and a plurality of thin film solar cells arranged on a support plate are sealed with an insulating sealing material. The thin-film solar cell module can be manufactured by a sealing and fixing step of fixing and a frame attachment step of attaching a frame to the outer peripheral edge of the support plate that supports the plurality of thin-film solar cells.
Hereinafter, each process will be described in the order of processes.

[Cell manufacturing process]
In the cell manufacturing process, a string is formed by electrically connecting a plurality of thin film photoelectric conversion elements in which a first electrode layer, a photoelectric conversion layer, and a second electrode layer are sequentially stacked on at least a surface of an insulating substrate. A string forming step, and, when the frame is made of a conductive material, removing the first electrode layer, the photoelectric conversion layer, and the second electrode layer on the surface of the insulating substrate located within a predetermined insulating distance from the frame. And a film removing step for forming a first non-conductive surface region.
Furthermore, in the film removal step, when at least one of the first electrode layer and the second electrode layer adheres to the outer peripheral end surface of the insulating substrate in the string formation step, a plurality of the sealing and fixing steps in the subsequent step Removing the first electrode layer, the photoelectric conversion layer, and the second electrode layer on the adjacent surfaces of two adjacent thin film solar cells when the thin film solar cells are arranged, A second non-conductive surface region having the same width as the conductive surface region is formed.

In the string forming step, the string Sa shown in FIGS. 11 and 12 is manufactured as follows.
First, the first electrode layer 112 is laminated on the transparent insulating substrate 111 with a film thickness of about 500 to 1000 nm by a thermal CVD method, a sputtering method, or the like. The transparent insulating substrate 111 has a size of about 400 to 2000 mm × 400 to 2000 mm and a thickness of about 0.7 to 5.0 mm.
Next, a part of the first electrode layer 112 is removed at a predetermined interval (about 7 to 18 mm) by a laser scribing method to form a plurality of first separation grooves 112a.

Subsequently, the photoelectric conversion layer 113 is stacked with a film thickness of about 300 to 3000 nm so as to cover the first electrode layer 112 separated by the first separation groove 112a by a plasma CVD method or the like. Examples of the photoelectric conversion layer 113 include a silicon-based semiconductor thin film, and a p-type semiconductor layer, an i-type semiconductor layer, and an n-type semiconductor layer are sequentially stacked on the first electrode 112.
Thereafter, a part of the photoelectric conversion layer 113 is removed at a predetermined interval (about 7 to 18 mm) by a laser scribing method, thereby forming the plurality of contact lines 13a.

Subsequently, the second electrode layer 114 is formed by laminating a transparent conductive layer and a metal layer in this order so as to cover the photoelectric conversion layer 113 by sputtering, vapor deposition, or the like. As a result, the contact line 113a is filled with the second electrode layer 114. The transparent conductive layer has a thickness of about 300 to 2000 nm, and the metal layer has a thickness of about 100 to 10,000 nm.
Next, a part of the photoelectric conversion layer 113 and the second electrode layer 114 is removed at a predetermined interval (about 7 to 18 mm) by laser scribing to form a plurality of second separation grooves 116. .

The laser scribing method for forming the first separation groove 112a, the contact line 113a, and the second separation groove 116 uses a YAG laser or YVO4 adjusted to a wavelength that is absorbed by the layer to be removed when each groove is formed. A laser can be used.
For example, the first separation layer 112a is formed by patterning the first electrode layer 112 using the fundamental wave of YAG laser light (wavelength: 1064 nm) absorbed by the transparent conductive film or the fundamental wave of YVO ₄ laser light. Can do.
Further, for example, the contact line 113a can be formed by patterning the semiconductor layer 113 with an Nd: YAG laser second harmonic (wavelength 532 nm). At this time, since the second harmonic of the Nd: YAG laser is hardly absorbed by the first electrode layer 112 (transparent conductive film), the first electrode layer 112 is not removed.
In addition, the second isolation groove 116 can be formed by removing the semiconductor layer 113 and the second electrode layer 114 by the Nd: YAG laser second harmonic (wavelength 532 nm).

As a result, a string Sa in which a plurality of strip-shaped thin film photoelectric conversion elements 115 are connected in series to each other is formed on the entire surface of the transparent insulating substrate 111. In the string forming step, as shown in FIGS. 11 and 12, the conductive film D composed of the first electrode layer 112 and the second electrode layer 114 is attached to the outer peripheral end face of the transparent insulating substrate 111. This is because in the film forming apparatus, the film is formed without covering the outer peripheral end surface of the transparent insulating substrate 111. By installing the transparent insulating substrate 111 on a substrate-dedicated tray and covering the outer peripheral end surface of the transparent insulating substrate 111 with the tray, the conductive film D does not adhere to the outer peripheral end surface, but a large number of trays are required. Since the manufacturing cost increases due to an increase in the number of steps for setting 111 on the tray and the need for maintenance to remove the film attached to the tray surface, in Embodiment 1-1, the film forming step without using the tray is performed. Adopted.

[Membrane removal process]
In the film removal step, the first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 in the outer peripheral region on the surface of the transparent insulating substrate 111 are removed by a light beam, and a non-conductive material having a width W of 8.4 to 11 mm. The conductive surface region 119 is formed.
Thereby, the thin-film solar battery cell 10 having the non-conductive surface region 119 on the outer peripheral edge of the surface of the transparent insulating substrate 111 and having the above-described string S1 formed therein is formed. Although it is possible to remove the film by a mechanical method such as polishing or particle spraying, the method using a light beam is the most clean and practical method and is desirable.
Note that it is preferable to use a fundamental wave of YAG laser light (wavelength: 1064 nm) or a fundamental wave of YVO ₄ laser light as the light beam. Since the fundamental wave of the YAG laser beam and the fundamental wave of the YVO ₄ laser beam are transmitted through the SnO ₂ transparent insulating substrate 111 and absorbed by the transparent first electrode layer 112 such as SnO ₂ , the transparent insulating substrate By irradiating these light beams from the 111 side, the first electrode layer 112 can be selectively heated, and the first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 are evaporated by the heat. be able to.

Here, in the present invention, the YAG laser is an Nd: YAG laser, and the Nd: YAG laser is made of an yttrium aluminum garnet (Y ₃ Al ₅ O ₁₂ ) crystal containing neodymium ions (Nd ³⁺ ). From the YAG laser, the fundamental wave (wavelength: 1064 nm) of the YAG laser light oscillates.
The YVO ₄ laser is an Nd: YVO ₄ laser, and the Nd: YVO ₄ laser is composed of a YVO ₄ crystal containing neodymium ions (Nd ³⁺ ). YVO ₄ fundamental wave of YVO ₄ laser beam from a laser (wavelength: 1064 nm) is oscillated.

  After that, the bus bar 117 is electrically connected to the surfaces of the second electrode 114 and the extraction electrode 114a in the series connection direction of the string S1 through a brazing material (see FIG. 8).

[Sealing and fixing process]
In the sealing and fixing step, the adhesive layer EVA sheet 11a having the same size as the tempered glass G1 and a thickness of about 0.2 to 1.0 mm is placed on the tempered glass G1. The tempered glass G1 has a size of about 400 to 2000 mm × 400 to 2000 mm and a thickness of about 0.7 to 5.0 mm.
Then, the two thin-film solar cells 10 are disposed side by side on the EVA sheet 11a for the adhesive layer so as to be spaced apart from each other by about 0.1 to 3.0 mm, and then each lead-out line 1118 of the wiring sheet 1119 is connected to each bus bar 117. It is electrically connected with a brazing material (see FIGS. 4 and 8).

Subsequently, the coating layer EVA sheet 12 a is placed on the two cells 10, and the protective layer sheet 13 a made of a three-layer laminated film of PET / Al / PET is placed thereon. Note that the cover layer EVA sheet 12a and the protective layer sheet 13a are formed in advance with extraction holes through which end portions protruding outside the extraction lines 1118 of the wiring sheet 1119 pass.
Then, by thermocompression bonding these under vacuum, the two cells 10 are fixed on the tempered glass G 1 by the adhesive layer 11 and are resin-sealed by the covering layer 12 and the protective layer 13. Thereby, the coating layer 12 enters between the two cells 10, and the coating layer 12 and the adhesive layer 11 on the outer periphery of each cell 10 are heat-sealed.
Thereafter, each output line 1122 and each take-out line 1118 of the terminal box 1123 are connected, and the terminal box 1123 is bonded onto the surface of the protective layer 13, whereby the module body m1 is completed.

[Frame mounting process]
In the frame attaching process, the four frame members f1 to f4 are fitted into the outer peripheral edge of the module body m1, and the adjacent frame members are fixed with screws (see FIGS. 1 to 4).
Thereby, the thin film solar cell module M1 is completed.

According to the thin-film solar cell module M1 manufactured in this way, the frame between cells can be omitted while maintaining the strength, the frame members can be reduced, the weight of the module can be reduced, the number of steps for mounting the frame, the wiring can be reduced. Simplification and the like can be achieved, and as a result, manufacturing costs can be reduced.
Moreover, since there is no frame between cells, a thin film solar cell module with improved aesthetics can be obtained.
Also, using one type of cell 10, two cells 10 can be arranged adjacent to each other in either the state shown in FIG. 7A or the state shown in FIG. 7B.
Moreover, since the transparent insulating substrates 111 of the adjacent cells 10 do not contact each other, the transparent insulating substrates 111 are not accidentally collided with each other when the plurality of cells 10 are installed on the tempered glass G1, and the substrate is not cracked. Furthermore, when the transparent insulating substrates 111 are in contact with each other, when the module main body m1 is transported or when the frame F1 is attached to the module main body m1, the transparent insulating substrates 111 are pressured if the tempered glass G1 is bent even slightly. Although there exists a possibility of producing a substrate crack, such a thing does not occur in the thin film solar cell module M1 of this Embodiment 1-1.

(Modification of Embodiment 1-1 : Reference Example )
In the film removal process described with reference to FIGS. 5 and 6, the first non-conductive surface region 119 a in the vicinity of both ends in the longitudinal direction of the separation groove 116 is formed of the first electrode layer 112, the photoelectric conversion layer 113, and the second Instead of removing the electrode layer 114, it is desirable to remove the film stepwise as in the following process.

That is, first, the string S1 in the vicinity of both ends in the longitudinal direction of the separation groove 116 is irradiated with the second harmonic of the YAG laser light or the second harmonic of the YVO ₄ laser light from the transparent insulating substrate 111 side, and By scanning in a direction perpendicular to the longitudinal direction of the separation groove 116, the photoelectric conversion layer 113 and the second electrode layer 114 are evaporated to form a groove.
Thereafter, a fundamental wave of YAG laser light or a fundamental wave of YVO ₄ laser light having a wavelength different from that of the first laser light is irradiated from the transparent insulating substrate 111 side to a region further outside the groove, and the separation groove 116 is irradiated. The first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 located in a region further outside the groove are removed by scanning in a direction perpendicular to the longitudinal direction of the groove.
Thus, the first non-conductive surface region 119a in the vicinity of both ends in the longitudinal direction of the separation groove 116 can be formed by two-stage light beam irradiation. In this case, the first electrode layer 112 protrudes in the longitudinal direction of the separation groove 116 from the photoelectric conversion layer 113 and the second electrode layer 114. The protruding first electrode layer 112 corresponds to the bottom of the groove, and the groove disappears due to the formation of the non-conductive surface region 119a.

In the first-stage light beam irradiation described above, the photoelectric conversion layer 113 and the first layer are removed without removing the first electrode layer 112 in the irradiation region of the second harmonic of the YAG laser light or the second harmonic of the YVO ₄ laser light. Only the two-electrode layer 114 can be removed. Thereby, the longitudinal sections of the photoelectric conversion layer 113 and the second electrode layer 114 are exposed in the groove.
In the second-stage light beam irradiation, at least a groove (irradiation of the first-stage light beam) is present between the exposed longitudinal sections of the photoelectric conversion layer 113 and the second electrode layer 114 and the first electrode layer 112 to be evaporated. There is a distance of the width of the area. Therefore, in the second-stage light beam irradiation, the first electrode layer 112, the photoelectric conversion layer 113, and the second electrode layer 114 at the peripheral portion are evaporated at a time corresponding to the width of the groove. Since the first electrode layer 112 is less likely to be reattached to the vertical cross section of the photoelectric conversion layer 113, leakage current between the first electrode layer 112 and the second electrode layer 114 can be reduced.

(Embodiment 1-2 : Reference example )
FIG. 13 is a plan view showing the thin-film solar battery module according to Embodiment 1-2.
The thin film solar cell module M2 of the embodiment 1-2 has a module body in which three cells 10 of the embodiment 1-1 are arranged side by side (in the serial connection direction of the thin film photoelectric conversion elements) on the rectangular tempered glass G2. m2 is substantially the same as the thin-film solar cell module M1 of Embodiment 1-1 described above except that the frame F2 corresponding to the length of each side of the outer peripheral edge of the module body m2 is attached to the module body m2. It is the composition. In FIG. 13, the same reference numerals are given to the same configurations as those in Embodiment 1-1.

In the case of the thin-film solar battery module M2 of Embodiment 1-2, the size of the tempered glass G2, the frame F2, the EVA sheet, and the like to be used is increased, but can be manufactured according to the manufacturing method of Embodiment 1-1.
Also in the case of Embodiment 1-2, the cells 10 are arranged apart from each other, and can be connected in series or in parallel using a wiring sheet (see FIG. 8) having six lead-out lines. At this time, even if all three cells 10 are arranged in the same direction (see FIG. 7A) or one cell 10 of the three cells is arranged in a different direction, the lead lines connected to each bus bar Appropriate handling can handle both series and parallel connections.

(Embodiment 1-3 : Reference example )
FIG. 14 is a plan view showing the thin-film solar battery module according to Embodiment 1-3.
In the thin-film solar battery module M3 of Embodiment 1-3, a module main body m3 is manufactured by arranging four cells 10 side by side on a rectangular tempered glass G3, and the outer periphery of the module main body m3. Except that the frame F3 corresponding to the length of each side is attached to the module main body m3, the configuration is substantially the same as that of the thin-film solar cell module M1 of Embodiment 1-1 described above. In FIG. 14, the same components as those in Embodiment 1-1 are denoted by the same reference numerals.

In the case of the thin film solar cell module M3 of Embodiment 1-3, the size of the tempered glass G3, the frame F3, the EVA sheet, and the like to be used is increased, but can be manufactured according to the manufacturing method of Embodiment 1-1. Also in this case, the cells 10 are arranged apart from each other.
In this case, the two cells 10 in each side-by-side row can be connected in series or in parallel by the same method as in Embodiment 1-1. Alternatively, the four cells can be connected in series or in parallel by appropriate handling of the eight lead wires connected to each bus bar of the four cells 10.

(Embodiment 1-4 : Reference example )
FIG. 15 is a process diagram illustrating a part of the manufacturing process of the thin-film solar cell module according to Embodiment 1-4.
In Embodiment 1-1 to Embodiment 1-3, in the sealing and fixing step, a plurality of cells are installed on the EVA sheet for adhesion on the tempered glass G so as to be spaced apart from each other, and then the entire plurality of cells are assembled. By thermocompression bonding with the coating EVA sheet, the coating layer enters between the cells and the cell edge is protected. In Embodiment 1-4, the cell edge between cells is protected by a method different from such a method.

  In the case where two cells 10 are used, as shown in FIG. 15A, in the sealing and fixing step, after the EVA sheet 11a for adhesion is placed on the tempered glass G1, a predetermined intermediate position of the EVA sheet 11a is obtained. A bar-shaped protective member 11b is installed at the position. Then, the two cells 10 are placed on the EVA sheet 11a so that the end surfaces thereof abut against the protective member 11b. FIG. 15B shows a state in which two cells 10 are placed on the EVA sheet 11a. Subsequent steps are the same as those in Embodiment 1-1. In FIG. 15, the same reference numerals are given to the same elements as those in the embodiment 1-1.

The protective member 11b may be made of an insulating material that is softer than the insulating substrate of the cell 10, but is preferably a resin material that is thermally fused to the adhesive layer and the covering layer, and is the same material as the adhesive layer and the covering layer. EVA which is is more preferable. The length of the protective member 11b is suitably the same as the length of the end face of the cell 10 that comes into contact, but it may be shorter. Further, a plurality of short protection members 11b may be arranged at a predetermined interval. Moreover, what is necessary is just to set the thickness of the protection member 11b to the separation dimension (for example, about 0.1-5.0 mm) of the cell 10 which adjoins.
In this way, the plurality of cells 10 can be quickly installed at the position where the EVA sheet 11a is to be installed, and the substrate can be prevented from cracking due to the cells contacting each other.

(Embodiment 2-1)
FIG. 16 is a partial cross-sectional plan view showing the thin-film solar battery module M4 according to Embodiment 2-1, FIG. 17 is a perspective view showing the thin-film solar battery 210 according to Embodiment 2-1, and FIG. FIG. 18A shows a parallel connection state, and FIG. 18B shows a series connection state. In FIGS. 16 to 18, the same reference numerals are given to the same elements as those in Embodiment 1-1.

  In the thin-film solar battery module M4 of Embodiment 2-1, the thin-film solar battery 210 has an effective power generation area that contributes to power generation increased from that of the thin-film solar battery 10 of Embodiment 1-1 (see FIG. 5). It is. The thin-film solar battery module M4 of Embodiment 2-1 has substantially the same configuration as that of Embodiment 1-1 except that this cell 210 is different.

The thin-film solar battery 210 of Embodiment 2-1 includes a plurality of thin-film photoelectric conversion elements 215 in which the first electrode layer 212, the photoelectric conversion layer 213, and the second electrode layer 214 are sequentially stacked on the surface of the transparent insulating substrate 211. The strings S2 are electrically connected in series to each other, and the strings S2 are formed on the inner side of the three end faces of the transparent insulating substrate 211 adjacent to the frame F1. That is, the surface of the transparent insulating substrate 211 positioned at least within a predetermined insulating distance from the frame F1 is a non-conductive surface region 219a to which the first electrode layer 212, the photoelectric conversion layer 213, and the second electrode layer 214 are not attached. ing.
Further, in the plurality of thin film solar cells, the portions located at least within the predetermined insulation distance from the frame F1 on the opposing end surfaces of the two adjacent thin film solar cells 210 are the first electrode layer 212 and the second electrode layer. A non-conductive end face region 219b to which 214 is not attached is formed. In addition, the 2nd electrode layer of the one end side of the string S2 in the serial connection direction is made into the extraction electrode 214a of the 1st electrode 212 of the adjacent thin film photoelectric element 215 similarly to Embodiment 1-1.

That is, in the thin-film solar battery 10 of Embodiment 1-1 (see FIG. 5), the adjacent portion on the surface of the two adjacent cells 210 is the second non-conductive surface region 119b. The thin-film solar cell 210 of 2-1 has an effective power generation area increased because the string S2 is formed up to the adjacent portion on the surface of the two adjacent cells 210.
In this case, since the conductive film D similar to that of Embodiment 1-1 is attached to the outer peripheral end face of the transparent insulating substrate 211 of the cell 210, it is attached to the opposing end faces of the two adjacent thin-film solar cells 210. The conductive film D is in contact with the string S2 on the end face side. When the conductive film D on the end face is within the predetermined insulation distance L (see FIG. 10) from the frame F, between the frame F1 and the string S2 to which a high voltage as high as 6 KV is applied to test the predetermined dielectric strength. As a result, discharge occurs through the conductive film D.

Therefore, in order for the cell 210 to have a predetermined withstand voltage, each of the adjacent end surfaces of the two thin-film solar cells 210 adjacent to each other has an end located at least within the predetermined insulation distance L from the frame F1. The nonconductive end face region 219b is formed by cutting off the corner of the transparent insulating substrate 211 of the cell 210.
As a method for cutting off the corners of the transparent insulating substrate 211 of the cell 210, for example, as shown in FIG. 19A, a surface (non-conductive) near the corners of the transparent insulating substrate 211 using a commercially available glass cutter C is used. A non-conductive end face region 219b having the same width as the width W of the non-conductive surface region 219a is formed by attaching a groove-like flaw 220 to the conductive surface region 219a) and bending the corners starting from the flaw 220. Can do.

In the manufacturing process of the thin-film solar battery module M4 of Embodiment 2-1, the non-conductive end face region 219b is formed by cutting off the corners of the transparent insulating substrate 211 at the end of the film removing process in the cell manufacturing process. And it is the same as that of the manufacturing process of Embodiment 1-1 except the connection method mentioned later differing a little.
Also in the case of the embodiment 2-1, as shown in FIG. 18, the two adjacent cells 210 are arranged on the tempered glass G <b> 1 via the adhesive layer 11 in a state of being separated from each other. Then, the cells 210 can be connected in parallel as shown in FIG. 18 (a), or the cells 210 can be connected in series as shown in FIG. 18 (b).

When the fabricated cell 210 is one in which the second electrode layer 214 is disposed on the end face sides of the two adjacent cells 210 facing each other, as shown in FIG. The second electrode layers 214 can be connected in parallel by electrically connecting the second electrode layers 214 with the interconnector 221 via a brazing material.
Further, the bus bar 217 is electrically connected to the lead electrodes 214a spaced from each cell 210 via a brazing material, and the three extraction lines (see FIGS. 8 and 9) of the wiring sheet are connected to the interconnector 221 and each bus bar. 2 connected in parallel by electrically connecting to 217, connecting one output line on the interconnector side to one output line, and connecting two output lines on the bus bar side to the other output line. The current generated in one cell 210 can be taken out.

Note that, in the cell 210, as in the right cell 210a of FIG. 18B, the extraction electrode 214a may be arranged on the end surface sides of two adjacent cells facing each other. May be connected by an interconnector to connect cells 210 in parallel.
In this way, when connecting in parallel, one type of cell 210 may be manufactured.

In the case of series connection shown in FIG. 18B, in two adjacent cells 210, one cell 210 has a second electrode layer 214 disposed on the opposite end face side, and the other cell 210a has an extraction electrode 214a on the opposite end face side. The second electrode layer 214 and the extraction electrode 214a are connected by the interconnector 221, and the bus bar 217 is connected to the surfaces of the extraction electrode 214a and the second electrode 214 that are separated from each other. In this case, two types of cells 210 and 210a are required.
In the case of series connection, each cell 210 is electrically connected to the bus bar 217 of each cell 210 with two lead wires (see FIG. 8 and FIG. 9), and each lead wire is connected to each output line. The current generated at 210 can be taken out.

(Embodiment 2-2)
FIG. 20 is a partial sectional plan view showing the thin-film solar battery module M5 of Embodiment 2-2, and FIG. 21 is a perspective view showing the thin-film solar battery 310 in Embodiment 2-2. 20 and 21, the same reference numerals are given to the same elements as those in Embodiment 1-1.
In the cell 210 (see FIG. 17) of the embodiment 2-1 described above, the non-conductive end face region 219b is formed by cutting off a corner of the transparent insulating substrate 211. The cell 310 is different from the embodiment 2-1 in that the non-conductive end face region 319b is formed without cutting off the corners of the transparent insulating substrate 311. Other configurations in the embodiment 2-2 are the same as those in the embodiment 2-1.

  In the cell 310 of the embodiment 2-2, the end surface of the end located at least within the predetermined insulation distance L (see FIG. 10) from the frame F1 is polished or polished on the opposing end surfaces of the two adjacent thin film solar cells 310. By performing the etching process, a nonconductive end face region 319b having the same width as the width W of the nonconductive surface region 319a is formed. In FIG. 21, reference numeral 311 denotes an insulating substrate, S3 denotes a string, and 315 denotes a thin film photoelectric conversion element.

When the non-conductive end face region 319b is formed by polishing, for example, as shown in FIG. 22, after the string S3 is formed, the polished end face portion where the non-conductive end face region of the cell 310 is to be formed is exposed and set the cover member K for covering the peripheral portion to the cell 310, and polished by hand-held polisher P while applying water to the conductive film D of the polished end face portion, a conductive film D until the transparent insulated substrate 311 is exposed Remove.
At this time, if water and polishing debris scatter and adhere to the surface of the cell 310, it is necessary to clean the cell surface, so that the collar provided on the cover member K prevents water and polishing debris from scattering to the cell surface. It is preferable to do. Furthermore, it is preferable to perform polishing while sucking water and polishing waste.
In the case of forming the nonconductive end face region 319b by the etching process, the conductive film D in the end face portion where the nonconductive end face region of the cell 310 is to be formed is removed using an etching solution.
The manufacturing process of the thin-film solar cell module M5 of Embodiment 2-2 is the same as the manufacturing process of Embodiment 2-1, except that the nonconductive end face region 219b is formed by such polishing or etching treatment.

(Embodiment 2-3)
FIG. 23 is a partial cross-sectional plan view showing the thin-film solar battery module according to Embodiment 2-3.
The thin film solar cell module M6 of the embodiment 2-3 has a module main body m6 mounted on a rectangular tempered glass G2 by placing two cells 210 of the embodiment 2-1 and three cells 210a described later side by side. A frame F2 corresponding to the length of each side of the outer peripheral edge of the module main body m6 is attached to the module main body m6. In FIG. 23, elements similar to those in Embodiment 1-1 are denoted by the same reference numerals.

  In this case, the cell 210a arranged in the center has one end face in the string series connection direction formed in the same structure as the right end face of the left cell 210 shown in FIG. 18B, and the other end face is It is formed in the same structure as the left end face of the right cell 210 shown in FIG. That is, in the cell 210a, a string is formed up to an end face close to the adjacent cells 210 on both sides. In other words, the cell 210a is formed by separating two non-conductive surface regions 219a on the surface along the side close to the frame F6.

In Embodiment 2-3, the two cells 210 on the both sides and the central cell 210a are arranged on the tempered glass G6 via an adhesive layer in a state of being separated from each other. At this time, it is preferable from the viewpoint of simplifying the wiring structure that the three cells 210 and 210a are arranged in a direction in which they are connected in series by an interconnector as shown in FIG.
In addition, Embodiment 2-3 is the same as Embodiment 2-1 except the above-mentioned structure, and can be manufactured according to the manufacturing process of Embodiment 1-1.

(Embodiment 2-4)
FIG. 24 is a plan view showing the thin-film solar battery module M7 according to Embodiment 2-4.
In the thin-film solar battery module M7 of Embodiment 2-4, four cells 210 are arranged horizontally and vertically on a rectangular tempered glass G3 to produce a module body m7. Except that the frame F3 corresponding to the length of each side is attached to the module main body m7, the configuration is substantially the same as the thin-film solar cell module M4 of Embodiment 2-1. In FIG. 24, the same reference numerals are given to the same elements as those in the embodiment 1-1.

In the case of the thin film solar cell module M7 of the embodiment 2-4, the size of the tempered glass G3, the frame F3, the EVA sheet, and the like to be used is increased, but can be manufactured according to the manufacturing method of the embodiment 2-1. . However, the following points are changed.
In the case of the embodiment 2-4, the conductive film D (see FIG. 17) is attached to the outer peripheral end face of each cell 210B, and one long side and one short side of each cell 210B are close to each other along the frame F3. In addition, the remaining long side and short side extend in a direction away from the frame F3.
Therefore, first, in each cell 210B, the non-conductive surface region 219a is formed in the outer surface region along the long side and the short side close to the frame F3. Second, in each cell 210B, the corners adjacent to the long side and short side frame F3 extending in the direction away from the frame F3 are cut away to form the non-conductive end face region 219b. If it does in this way, the insulation withstand voltage property required as thin film solar cell module M7 can be obtained.

Third, on the surface of the cell 210B, an electrically insulating separation groove Q is formed along a short side adjacent to the adjacent cell 210B in the longitudinal direction of the separation groove. This electrical insulation separation groove Q prevents the string from being short-circuited by the conductive film attached to the outer peripheral end face of the cell 210B.
The method for forming the electrical insulation separation groove Q is the same as the method described in the modification of the embodiment 1-1 described above. First, the photoelectric conversion layer and the second electrode layer are removed by the first-stage light beam irradiation. Forming the first groove, and then removing the first step pole layer, the photoelectric conversion layer, and the second electrode layer outside the first groove by light beam irradiation in the second step, An electrically insulating separation groove Q including the first groove is formed.
In the case of the embodiment 2-4, the cells 210B are arranged apart from each other. In this case, the two cells 210B in each side-by-side row can be connected in series or in parallel by the same method as in Embodiment 2-1.

Embodiment 2-5
Instead of the thin-film solar battery 210 used in Embodiment 2-3 (FIG. 23), the thin-film solar battery 310 described in Embodiment 2-2 (FIG. 21) may be used. In addition, when arranging three cells, the cell arrange | positioned in the center can form a string to the full end part of a serial connection direction similarly to Embodiment 2-3.
In addition, the thin-film solar battery 210B used in the embodiment 2-4 (FIG. 24) does not form the non-conductive end face region 219b by cutting off the corners, but the embodiment 2-2 (FIG. 21 and FIG. As described in 22), the nonconductive end face region may be formed by polishing or etching.

(Embodiment 3 : Reference example )
FIG. 25 is a plan view showing the thin-film solar battery module M8 according to the third embodiment, and FIG. 26 is a perspective view showing the thin-film solar battery 410 according to the third embodiment. In FIG. 25 and FIG. 26, the same reference numerals are given to the same elements as those in the embodiment 1-1. In FIG. 26, reference numeral 411 denotes an insulating substrate, 415 denotes a thin film photoelectric conversion element, S4 denotes a string, 419a denotes a nonconductive surface region, 419b denotes a nonconductive end surface region, and m8 denotes a module body.

The thin film solar cell 410 in the thin film solar cell module M8 is similar to the cell 310 of the embodiment 2-2 (FIG. 21), but the conductive film is not attached to the outer peripheral end surface of the transparent insulating substrate 411. Is different.
In the cell 410 of Embodiment 3, the first electrode layer, the photoelectric conversion layer, and the second electrode layer are formed only on the surface region of the transparent insulating substrate 411 in the string formation step.
At this time, although not shown in the figure, the transparent insulating substrate 411 is set on the tray for exclusive use of the substrate, and the width W adjacent to the frame F of the transparent insulating substrate 411 by the peripheral wall of the tray and the flange portion bent inward from the peripheral wall. By forming the string S4 so as to cover the outer peripheral region and the entire outer peripheral end surface, the non-conductive surface region 219a having a width W remains on the surface of the transparent insulating substrate 411, and the non-conductive end surface region is formed on the entire outer peripheral end surface. 419b remains.
According to this method, the step of removing the first electrode layer, the photoelectric conversion layer, and the second electrode layer by the light beam performed in Embodiment 2-2 to form a non-conductive surface region and the polishing or etching process are performed. The step of forming the nonconductive end face region can be omitted.

(Other embodiments)
1. You may make it protect the board | substrate end surface by arrange | positioning the protection member demonstrated in Embodiment 1-4 between the adjacent cells in Embodiment 2-1 to Embodiment 3. FIG.
2. In the cell 410 according to the third embodiment, the string S4 is formed only on the surface of the transparent insulating substrate 411 so that no conductive film is formed on the outer peripheral end face, and the string S4 is formed up to the boundary with the end face facing the adjacent cell. However, a non-conductive surface region narrower than the width W may be formed on the surface of the insulating substrate near the boundary. The reason for this is that when setting the transparent insulating substrate 411 on the substrate-dedicated tray, if there is any gap between the end surface of the transparent insulating substrate 411 and the peripheral wall of the tray, the entire length of the end surface is This is because a conductive film adheres to the vicinity of the boundary, and a predetermined dielectric withstand voltage cannot be ensured. Such a problem becomes more conspicuous when the end surface of the transparent insulating substrate 411 is processed into a round shape. Therefore, if a string is formed on the surface of the transparent insulating substrate 411 using a tray in which a flange is formed along the entire circumference of the peripheral wall, it is possible to reliably prevent the conductive film from adhering to the end face. A predetermined insulation voltage resistance can be ensured.
3. Embodiments 1-1 to 3 described above exemplify the case where adjacent cells are arranged apart from each other. For example, if a polyimide substrate that is difficult to break the substrate is used, the cell configuration remains as it is, and the adjacent cells They can be placed in contact with each other.
4). In Embodiment 1-1 to Embodiment 3 described above, the case where the frame is a metal frame is illustrated, but an insulating frame may be used. In this case, the film removal process in the cell manufacturing process is omitted. Furthermore, since a commercially available product can be used as the thin film solar cell produced in the cell production process in which the film removal process is omitted, in this case, the entire cell production process can be omitted.

10, 210, 210a, 310, 410 Thin film solar cell 11b Protective member 111, 211, 311, 411 Transparent insulating substrate (insulating substrate)
112, 212 First electrode layer 113, 213 Photoelectric conversion layer 114, 214 Second electrode layer 114a, 214a Lead electrode 115, 215 Thin film photoelectric conversion element 119a, 119b, 219a, 319a, 419a Non-conductive surface region 219b, 319b, 419b Non-conductive end face region
D conductive film F1, F2, F3 Frame G1, G2, G3 Tempered glass (support plate)
L Predetermined insulation distance S1, S2, S3, S4 String

Claims (10)

A plurality of thin film solar cells, a support plate, and a frame made of a conductive material ,
The thin-film solar cell is electrically connected to a plurality of thin-film photoelectric conversion elements each having a first electrode layer, a photoelectric conversion layer, and a second electrode layer sequentially stacked on the surface of a planar insulating substrate having at least four sides. A string connected in series and a conductive film attached to the outer peripheral end surface of the insulating substrate ;
In a state where a plurality of thin film solar cells are arranged and fixed on the support plate, the frame is attached to the outer peripheral edge of the support plate ,
In the thin-film solar cell, the surface of the insulating substrate positioned at least within a predetermined insulating distance from the frame by forming the string inside the end surface of the insulating substrate close to the frame is a non-conductive surface region. And an end located within a predetermined insulating distance on the outer peripheral end surface facing one of the other adjacent thin-film solar cells is a non-conductive end surface region where the conductive film does not exist, and the non-conductive A predetermined withstand voltage is provided by the surface region and the non-conductive end surface region,
The insulating substrate has a shape lacking corners so that the end of the outer peripheral end surface of the one side is inclined in a direction away from the other adjacent thin-film solar cell as it goes from the inside to the outer peripheral side of the support plate. The thin-film solar cell module is characterized in that the non-conductive end face region is formed in a shape portion lacking the corner portion . The thin film solar cell module according to claim 1, wherein the support plate is tempered glass. The thin film solar cell module according to claim 1 or 2 , wherein two adjacent thin film solar cells are arranged apart from each other in the plurality of thin film solar cells. The thin film solar cell module according to claim 3 , further comprising a protective member that protects opposing edges of each thin film solar cell between two adjacent thin film solar cells in the plurality of thin film solar cells. . In the thin film solar cell, the second electrode at one end of the strings in the serial connection direction is a lead electrode for the first electrode of the adjacent thin film photoelectric conversion element, and the photoelectric conversion layer is on the first electrode side. A first conductive type semiconductor layer and a second conductive type semiconductor layer on the second electrode side,
Two adjacent thin-film solar cells arranged in the series connection direction of the strings are arranged in a direction in which the second electrode of one thin-film solar cell and the extraction electrode of the other thin-film solar cell are close to each other. The thin film solar cell module according to any one of claims 1 to 4 , wherein the strings of the two thin film solar cells are connected in series with each other by being electrically connected to each other. In the thin film solar cell, the second electrode at one end of the strings in the serial connection direction is a lead electrode for the first electrode of the adjacent thin film photoelectric conversion element, and the photoelectric conversion layer is on the first electrode side. A first conductive type semiconductor layer and a second conductive type semiconductor layer on the second electrode side,
In two adjacent thin-film solar cells arranged in the series connection direction of the strings, each thin-film solar cell is arranged in a direction in which each extraction electrode is separated from each other or in a direction in which each extraction electrode is close to each other, and by the second electrode or between extraction electrodes between adjacent thin-film solar batteries are electrically connected, the two thin-film solar cell strings in any one of claims 1 to 4 connected in parallel to each other The thin film solar cell module described. A string in which a plurality of thin film photoelectric conversion elements each having a first electrode layer, a photoelectric conversion layer, and a second electrode layer sequentially stacked on the surface of an insulating substrate are electrically connected in series with each other, and the insulation is performed when the string is formed. A plurality of thin film solar cells each having a conductive film attached to an outer peripheral end surface of a substrate, placed on a support plate, sealed with an insulating sealing material, and fixed; and the plurality of thin films A frame attachment step of attaching a frame made of a conductive material to the outer peripheral edge of the support plate supporting the solar battery cell ;
Furthermore, before the sealing and fixing step, the cell preparation step of preparing the plurality of thin-film solar cells,
A string forming step of forming the string on at least a surface of a rectangular insulating substrate;
A film removing step of removing the film constituting the thin film photoelectric conversion element formed on the outer peripheral portion of the insulating substrate in the string forming step,
In the film removal step, a non-conductive surface region is formed by removing a film on the surface of the insulating substrate located within an insulating distance having a predetermined dielectric withstand voltage from the frame,
Furthermore, when a conductive film adheres to the outer peripheral end surface of the insulating substrate in the string forming step, it faces an adjacent thin film solar cell when a plurality of thin film solar cells are arranged in the subsequent sealing and fixing step. In order to remove the conductive film adhering to the end portion of the outer peripheral end surface of one side, the adjacent other ends as the end portion located within a predetermined insulation distance on the outer peripheral end surface of the one side moves from the inner side to the outer peripheral side of the support plate. A method for producing a thin-film solar battery module, comprising forming a non-conductive end face region by removing a corner so as to incline in a direction away from the thin-film solar battery cell . The manufacturing method of the thin film photovoltaic module of Claim 7 which arranges a plurality of thin film photovoltaic cells so that two adjacent thin film photovoltaic cells may be spaced apart and arrange | positioned in the said sealing fixation process. The thin film solar cell module according to claim 8, further comprising a step of placing a protective member on the support plate and arranging two thin film solar cells on the support plate so as to sandwich the protective member in the sealing and fixing step. Manufacturing method. In the film removing step, the first electrode layer of the outer peripheral region in the surface of the insulating substrate, and a photoelectric conversion layer and the second electrode layer is removed by the light beam to form a non-conductive surface region of claim 7-9 The manufacturing method of the thin film solar cell module as described in any one.

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