JP2018082137A - Solar battery module, and method for manufacturing solar battery module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery module which has a structure enabling series wiring only on a film substrate, which enables the production of a solar battery module by a roll-to-roll method, and which eliminates the need for wiring when mounting the solar battery module, and enables the cost cutting.SOLUTION: A method for manufacturing a solar battery module comprises the steps of: performing an insulation process on a transparent conductive film 11A and a counter conductive film 12A in parallel with a longitudinal direction X1; providing a sealant 15 for arraying a plurality of cells C in a widthwise direction X2; disposing a conductive material 14 on the sealant 15 to electrically connect between a photoelectrode 11 and a counter electrode 12; providing an electrolyte solution 13 between a semiconductor layer 11B of the photoelectrode 11, and the counter electrode 12; bonding the photoelectrode 11 to the counter electrode 12; forming welding portions extending along in the widthwise direction X2 on the photoelectrode 11 and the counter electrode 12; disposing a wiring material along the longitudinal direction X1 at both ends in the widthwise direction X2; and cutting the photoelectrode 11 and the counter electrode 12 at an appropriate position of the welding portion.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a solar cell module and a method for manufacturing a solar cell module.

  Conventionally, a dye-sensitized solar cell is generally configured to include a photoelectrode, a counter electrode, and an electrolyte solution or an electrolyte solution layer. The photoelectrode includes at least a transparent conductive layer, a semiconductor layer, and a dye. It is known to have. In such a dye-sensitized solar cell, for example, when light is irradiated to the photoelectrode side, the dye adsorbed on the semiconductor layer absorbs light, and the electrons in the dye molecule are excited, and the electrons are converted into semiconductors. Passed to. Then, electrons generated on the photoelectrode side move to the counter electrode side through the external circuit, and the electrons return to the photoelectrode side through the electrolytic solution. By repeating such a process, electric energy is generated.

  As a method for manufacturing a solar cell module including such a dye-sensitized solar cell, for example, as shown in Patent Document 1, ultrasonic vibration is applied to a first electrode and a second electrode bonded together in a roll-to-roll method. A method of dividing into a plurality of cells by using and insulating and welding is known.

Japanese Patent No. 5702897

However, the conventional solar cell module composed of a dye-sensitized solar cell has the following problems.
That is, in the solar cell module disclosed in Patent Document 1, after cutting to separate the longitudinal direction of the electrodes continuously manufactured by a roll-to-roll method in order to connect the cells in series and parallel, Wiring work is performed for serial connection of the divided solar cell modules. For this reason, there is a problem in that an additional process associated with the wiring is required and the manufacturing cost increases. That is, when arranging a plurality of solar cell modules in, for example, a blind or the like, the plurality of solar cell modules are pasted on the blind substrate in a state of being spaced apart from each other, and then the respective solar cell modules are connected in series. This increases the labor and cost of wiring, and there is room for improvement in this respect.

  The present invention has been made in view of the above-described problems. By adopting a structure that allows serial wiring only on a film substrate, production by a roll-to-roll method is possible, and a solar cell is provided. It is an object of the present invention to provide a solar cell module and a method for manufacturing the solar cell module, in which wiring generated when the module is packaged becomes unnecessary and the cost can be reduced.

  In order to achieve the above object, a solar cell module according to the present invention has a transparent conductive film formed on the surface of a first substrate and extends in a first direction on the surface of the transparent conductive film of the first substrate. A first electrode in which a plurality of strip-shaped semiconductor layers adsorbing the existing dye are formed; a second electrode in which a counter conductive film is formed on the surface of a second base so as to face the first electrode; An electrolytic solution sealed between the semiconductor layer of the first electrode and the second electrode, and the electrolytic solution are sealed and divided in a second direction orthogonal to the first direction in plan view A sealing material for arranging the plurality of cells formed; a conductive material provided in a state of being covered with the sealing material; and electrically connecting the first electrode and the second electrode; and the first electrode And an insulation line extending along the second direction with respect to the second electrode, and arranged in the second direction. The plurality of cells electrically connected by serial wiring, the first insulating portion of the first base material disposed between cells adjacent in the second direction, and the second base material The conductive material is disposed between the second insulating portion, the adjacent cells are connected, and the adjacent submodules among the even number of submodules divided in the first direction by the insulating lines. One end portions in the second direction are electrically connected to each other by serial wiring by a wiring material, and the direction of the current flowing through the plurality of submodules is alternated for each of the submodules arranged in the first direction. It is characterized by having a circuit configuration that is replaced by.

In the present invention, a conductive material is disposed between the insulating portion of the first base material and the insulating portion of the second base material that are disposed between cells adjacent in the second direction of the first base material, Cells adjacent to each other in the two directions are electrically connected in series, and one end in the second direction of the submodule divided in the first direction by the insulating line is electrically connected by the serial wiring by the wiring material. Are connected in series. That is, in one submodule, electricity flows from the other end side in the second direction to one end side, and electricity on one end side flows to one end side of the other submodule via the wiring member, and in the other submodule. A circuit configuration in which electricity flows from one end side to the other end side in the second direction can be realized.
Thus, in the solar cell module according to the present invention, among the even number of submodules, the submodules on one end side in the second direction are electrically connected by the wiring material, and electricity can be taken out on the other end side. Become. That is, the entire structure has a structure in which the direction of electricity is alternately switched for each sub-module in plan view, or the entire structure has a structure in which electricity flows in a U-shape in plan view. Since it can arrange | position on the same side at an end side, a wiring structure can be simplified and wiring work can be performed easily.

  And in this invention, since it is a simple structure which provides a wiring material in the end of an adjacent submodule, and it also becomes possible to apply the simple manufacturing method which coats a wiring material, a roll-to-roll system Can easily adapt to. Since such a roll-to-roll method can be realized by a manufacturing process in which wiring members are continuously arranged in the first direction, it is not necessary to add a new work process.

  Further, in the solar cell module according to the present invention, in the first base material or the second base material, the conductive material is disposed at both end portions in the second direction, and terminals are taken out on the same base material surface. A portion may be provided.

  In the present invention, since the terminal extraction part of + terminal (positive electrode terminal) and − terminal (negative electrode terminal) can be provided on the same base material surface, the solar cell module is moved up and down when performing wiring work to the extraction electrode. This eliminates the need for the step of reversing, so that the labor of wiring work can be reduced.

  The method for manufacturing a solar cell module according to the present invention is a method for manufacturing a solar cell module for continuously manufacturing a solar cell module by a roll-to-roll method, and is transparent on the surface of the first substrate. A conductive film is formed, and a first electrode is formed in which a plurality of strip-shaped semiconductor layers are formed on the surface of the transparent conductive film of the first base material by adsorbing a dye extending in the longitudinal direction of the first base material A step of forming a second electrode in which a counter conductive film is formed on the surface of the second base so as to face the first electrode, and the transparent conductive film and the counter conductive film A step of performing an insulating process in parallel with the longitudinal direction, a step of providing a sealing material for arranging a plurality of cells in the width direction of the first base material and the second base material orthogonal to the longitudinal direction in plan view, A conductive material is disposed on the sealing material and the first electrode A step of electrically connecting the second electrode, a step of providing an electrolyte between the semiconductor layer of the first electrode and the second electrode, and bonding the first electrode and the second electrode. A step of forming an insulating line extending along the width direction with respect to the first electrode and the second electrode, and the longitudinal direction at both ends of the first substrate in the width direction. A step of disposing a wiring material along the line, and a step of cutting the first electrode and the second electrode at an arbitrary position of the insulating line.

  In the present invention, a conductive material is disposed between the insulating part of the first base material and the insulating part of the second base material arranged between cells adjacent in the width direction of the first base material, and in the width direction. A solar cell module having a configuration in which adjacent cells are electrically connected in series, and cells of submodules divided in the longitudinal direction by an insulation line are electrically connected in series by a wiring material is rolled-to- It can be manufactured in a continuous state in the longitudinal direction by a roll method. That is, a module including an independent electric circuit can be produced by the roll-to-roll method by the solar cell module itself cut and divided at the position of the insulation line. In this way, the position and length of the conductive material, insulation line, and wiring material are set appropriately on the film substrate using the roll-to-roll method, and wiring is performed to achieve the set electrical characteristics (voltage, etc.). Therefore, it is possible to freely design series-parallel connection (circuit design) of cells.

  Further, in the present invention, when the manufactured solar cell module is packaged in a separate body (substrate), it is performed after attaching a plurality of solar cell modules to the substrate as in the prior art, and the solar cell modules are electrically connected to each other. Since the wiring work to connect becomes unnecessary, manufacturing efficiency can be improved. Thus, since it becomes possible to reduce an operation man-hour, reduction of manufacturing cost can be aimed at.

  In the method for manufacturing a solar cell module according to the present invention, in the step of performing the insulating process, the insulating pattern is formed at a position where the insulating position is shifted in the width direction at a constant period with respect to the longitudinal direction. This may be a feature.

  In this case, the insulating pattern is alternately formed in the width direction, so that the positions of the positive electrode and the negative electrode can be regularly switched for each submodule.

  Further, in the method for manufacturing a solar cell module according to the present invention, after the wiring material is arranged in a continuous state along the longitudinal direction and the insulating line is formed, a part of the wiring material in the longitudinal direction is formed. You may make it form a disconnection part by carrying out notch processing.

  In this case, by forming a disconnection portion at an appropriate location in the wiring material, it becomes possible to disconnect the cells of the submodules adjacent in the longitudinal direction across the insulating line. Therefore, a desired electric circuit can be designed according to the position of the disconnection portion.

  Moreover, the manufacturing method of the solar cell module according to the present invention may be characterized in that, in the step of arranging the wiring material, the wiring material in which a disconnection portion is formed in a part of the longitudinal direction is arranged.

  In this case, since the disconnection portion is formed simultaneously with the step of arranging the wiring material, the work of providing the disconnection portion after the arrangement of the wiring material becomes unnecessary, and the manufacturing efficiency can be improved.

  In the method for manufacturing a solar cell module according to the present invention, it is preferable that the insulating line is a fusion part that is fused along the width direction.

  In this case, the fusion part can be easily formed with respect to the first electrode and the second electrode that are moved by the roll-to-roll method by a manufacturing apparatus having appropriate fusion means extending along the width direction. Can be formed.

  Moreover, the manufacturing method of the solar cell module according to the present invention may be characterized in that the step of arranging the wiring material is performed simultaneously with the arrangement of the conductive material.

  In this case, since the arrangement pattern of the conductive material and the wiring material can be formed at the same time, the manufacturing efficiency can be improved.

  The method for manufacturing a solar cell module according to the present invention may be characterized in that the step of forming the insulating line is performed simultaneously with the insulating process.

  In this case, the production efficiency can be improved by simultaneously performing the insulation line and the insulation processing parallel to the longitudinal direction.

  In the method for manufacturing a solar cell module according to the present invention, a transparent conductive film is formed on the surface of the first substrate, and the longitudinal direction of the first substrate is formed on the surface of the transparent conductive film of the first substrate. A step of forming a first electrode in which a plurality of band-shaped semiconductor layers adsorbing a dye extending to the surface are formed, and a counter conductive film is formed on the surface of the second base so as to face the first electrode A step of forming a second electrode, a step of insulating the transparent conductive film and the counter conductive film in parallel to the longitudinal direction, the first base material orthogonal to the longitudinal direction in plan view, and the A step of providing a sealing material for arranging a plurality of cells in the width direction of the second base material; and a conductive material disposed on the sealing material to electrically connect the first electrode and the second electrode. Providing an electrolyte solution between the semiconductor layer of the first electrode and the second electrode; A step of bonding the first electrode and the second electrode, a step of arranging a wiring member along the longitudinal direction at both ends in the width direction of the first base, the first electrode and the second A first insulating line that extends along the width direction with respect to the electrode and does not partially insulate the wiring member on one end side in the width direction; a second insulating line that insulates the entire width direction; At a predetermined position in the longitudinal direction, and providing an odd number of the first insulating lines between the second insulating lines, and connecting the first electrode and the second electrode to the second insulating line. A solar cell module cut at the second insulation line, the width direction of the adjacent submodules among the even number of submodules divided by the first insulation line One end of the It is characterized by being electrically connected by series wiring by wood.

In the present invention, a conductive material is disposed between the insulating part of the first base material and the insulating part of the second base material arranged between cells adjacent in the width direction of the first base material, and in the width direction. Adjacent cells are electrically connected in series, and one end in the width direction of a pair of adjacent submodules divided in the longitudinal direction by the first insulating line is electrically connected by serial wiring by a wiring material. A solar cell module having a configuration connected in series can be manufactured. Therefore, the solar cell module itself cut and divided at the position of the second insulation line becomes an independent electric circuit, and such a solar cell module can be produced by a roll-to-roll method.
Further, in the present invention, when the manufactured solar cell module is packaged in a separate body (substrate), it is performed after attaching a plurality of solar cell modules to the substrate as in the prior art, and the solar cell modules are electrically connected to each other. Since the wiring work to connect becomes unnecessary, manufacturing efficiency can be improved. Thus, since it becomes possible to reduce an operation man-hour, reduction of manufacturing cost can be aimed at.

  In the method for manufacturing a solar cell module according to the present invention, it is preferable that the first insulating line and the second insulating line are a fusion part that is fused along the width direction.

  In this case, the first insulating line and the second electrode with respect to the first electrode and the second electrode moved by the roll-to-roll method by a manufacturing apparatus having an appropriate fusion means extending along the width direction. It is possible to easily form the fused portion forming the two insulating lines.

  Moreover, the manufacturing method of the solar cell module which concerns on this invention WHEREIN: The process of forming a said 1st insulation line and a said 2nd insulation line may be performed simultaneously when performing the said insulation process.

  In this case, manufacturing efficiency can be improved by performing simultaneously the insulation process parallel to a longitudinal direction with a 1st insulation line and a 2nd insulation line.

  According to the solar cell module of the present invention and the method for manufacturing a solar cell module, it is possible to produce by a roll-to-roll method by adopting a structure in which serial wiring can be performed only on the film substrate. Wiring generated when the solar cell module is packaged becomes unnecessary, and the cost can be reduced.

It is a top view which shows schematic structure of the dye-sensitized solar cell by the 1st Embodiment of this invention. It is the sectional view on the AA line shown in FIG. 1, Comprising: It is the fragmentary sectional view which looked at the dye-sensitized solar cell from the longitudinal direction. It is the BB sectional drawing shown in FIG. 1, Comprising: It is the fragmentary sectional view which looked at the dye-sensitized solar cell from the width direction. It is a perspective view which shows the whole structure of the manufacturing apparatus of a dye-sensitized solar cell. It is a perspective view which shows the state which has performed the insulation process with the cutting processing apparatus. It is a figure which shows the state which has performed the insulation process with the cutting device, Comprising: It is the front view which looked at the cutting device from the longitudinal direction. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which formed the photoelectrode in the 1st base material. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which performed the insulation process to the 2nd base material. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which performed the insulation process to the 1st base material. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which bonded together base materials. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which formed the melt | fusion part. It is a top view of the dye-sensitized solar cell of the manufacture process using a manufacturing apparatus, Comprising: It is a figure which shows the state which affixed the wiring material on the both ends of the width direction of a base material. It is CC sectional view taken on the line shown in FIG. It is the DD sectional view taken on the line shown in FIG. It is a perspective view which shows the structure of the dye-sensitized solar cell by 1st Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 2nd Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 2nd Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 2nd Embodiment. It is C'-C 'sectional view taken on the line shown in FIG. It is D'-D 'sectional view taken on the line shown in FIG. It is the EE sectional view taken on the line shown in FIG. It is the FF sectional view taken on the line shown in FIG. It is sectional drawing which shows the structure of another wiring material. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 3rd Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 3rd Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 4th Embodiment. It is a top view which shows the manufacturing process of the dye-sensitized solar cell by 4th Embodiment. (A), (b) is a figure which shows the state which is performing the insulation process with the laser irradiation apparatus which is an insulation process part by a modification, Comprising: It is the front view which looked at the laser irradiation apparatus from the longitudinal direction.

  Hereinafter, a solar cell module according to an embodiment of the present invention and a method for manufacturing the solar cell module will be described with reference to the drawings. The drawings used in the following description are schematic, and the length, width, thickness ratio, structure, and the like are not necessarily the same as the actual ones, and can be changed as appropriate.

(First embodiment)
As shown in FIG. 1, the solar cell module according to the present embodiment and the method for manufacturing the solar cell module are based on a roll-to-roll method (hereinafter referred to as RtoR method), which will be described later, as shown in FIG. It is manufactured by cutting a film type dye-sensitized solar cell 1 (solar cell module), which is produced by the manufacturing apparatus 4 (see FIG. 4) and extends long in one direction, to an appropriate length. In FIG. 1, arrows indicate the flow of electricity, and symbols + (plus) and-(minus) indicate a positive electrode and a negative electrode, respectively (the same applies to other drawings).
Here, in the dye-sensitized solar cell 1 shown in FIG. 1, FIG. 2, and FIG. 3, the length direction (long direction) is the longitudinal direction X1, and the direction orthogonal to the longitudinal direction X1 in plan view is the substrate ( The width direction X2 of the first base material 3A and the second base material 3B) to be described later is used in a unified manner.

  As shown in FIG. 2, the dye-sensitized solar cell 1 of the present embodiment includes a dye-sensitized solar cell (hereinafter referred to as “photosensitive electrode”) having a photoelectrode 11 and a counter electrode 12 provided to face the photoelectrode 11. Cell C) has a structure interposed between the pair of base materials 3A and 3B. In the dye-sensitized solar cell 1, conductive films 11A and 12A having conductive surfaces on the inner surfaces of the pair of base materials 3A and 3B are formed, and the photoelectrode 11 is formed on the conductive films 11A and 12A. The semiconductor layer 11 </ b> B and the catalyst layer 12 </ b> B of the counter electrode 12 are electrically connected to each other and are roughly configured.

  The dye-sensitized solar cell 1 according to the present embodiment is a solar cell module in which the photoelectrode 11 and the counter electrode 12 are opposed to each other via the conductive material 14 with a sealing function as described above, For various electric modules that require sealing of a plurality of cells C formed between one base material 3A and a second base material 3B and electrical series connection between the cells C, C,. Yes. Here, in the cell C of the submodule R to be described later, the direction connected in series is the width direction X2.

Specifically, the dye-sensitized solar cell 1 includes a first base material 3A, a second base material 3B, a photoelectrode 11 (first electrode), a counter electrode 12 (second electrode), an electrolytic solution 13, The conductive material 14, the sealing material 15, the first insulating part 16, the second insulating part 17, and the fusion part 18 (insulating line) are provided.
The photoelectrode 11 includes a transparent conductive film 11A laminated on the first base material 3A and a porous semiconductor layer 11B laminated on the transparent conductive film 11A.
The counter electrode 12 includes a counter conductive film 12A stacked on the second substrate 3B and a catalyst layer 12B stacked on the counter conductive film 12A.

The photoelectrode 11 is a band-shaped semiconductor layer in which a transparent conductive film 11A is formed on the surface of the first substrate 3A, and a dye extending in the longitudinal direction X1 is adsorbed on the surface of the transparent conductive film 11A of the first substrate 3A. A plurality of 11B are formed. A counter conductive film 12 </ b> A is formed on the counter electrode 12 so as to face the photoelectrode 11. The electrolytic solution 13 is sealed between the semiconductor layer 11 </ b> B of the photoelectrode 11 and the counter electrode 12. The sealing material 15 is configured to seal the electrolytic solution 13 and to arrange a plurality of cells C divided in the width direction X2.
The conductive material 14 is provided in a state of being covered with the sealing material 15, and is in direct contact with the transparent conductive film 11 </ b> A of the photoelectrode 11 and the counter conductive film 12 </ b> A of the counter electrode 12, and the photoelectrode 11 and the counter electrode 12. And electrically connect.

Sealing materials 15 and 15 are disposed on both sides of the conductive material 14 in the width direction X2. The conductive material 14 and the sealing material 15 bond between the photoelectrode 11 and the counter electrode 12. On the other hand, as shown in FIGS. 1 and 3, the dye-sensitized solar cell 1 is arranged with a certain interval in the longitudinal direction X <b> 1, and a fusion part 18 is formed over the entire width direction X <b> 2. Yes. The fused part 18 is formed by insulation and adhesion by means such as ultrasonic fusion (see the ultrasonic fused part 46 shown in FIG. 4).
In this manner, in the cells C each having the semiconductor layer 11B, the electrolytic solution 13 is liquid-tightly sealed in the gap in the thickness direction formed between the photoelectrode 11 and the counter electrode 12 by the conductive material 14. It is formed in the state.

A plurality of patterning portions (insulating portions 16,...) Insulated at predetermined positions of the transparent conductive film 11A and the counter conductive film 12A by a blade described later (a semicircular blade 52 of the cutting device 50 shown in FIGS. 5 and 6). 17) is provided. That is, as shown in FIG. 2, the transparent conductive film 11 </ b> A and the counter conductive film 12 </ b> A are formed with the first insulating portion 16 parallel to the longitudinal direction X <b> 1 by the insulating process by the cutting process at the position in contact with the sealing material 15. The transparent conductive film 11A between the adjacent first insulating portions 16, 16 formed on the first base 3A in one cell C of the cells C, C adjacent in the width direction X2, and the other cell A conductive material 14 is disposed between one cell C and the other cell C, with the opposing conductive film 12A between the adjacent second insulating portions 17 and 17 formed on the second base material 3B in C. It is connected to the.
Here, the first insulating portions 16 arranged in each of the adjacent submodules R and R among the submodules R (regions surrounded by a two-dot chain line in FIG. 1) defined by the fused portion 18 are , Patterning is performed at a position shifted in the width direction X2. The same applies to the second insulating portion 17.

  As shown in FIG. 2, the transparent conductive film 11A and the counter conductive film 12A of the cells C, C adjacent to each other in the width direction X2 are divided into a plurality by the patterning unit, and the plurality of transparent conductive films 11A and the counter conductive film 12A A pattern is formed. In the partitioned cell C, the opposite conductive film 12A of one cell C (for example, the first cell of C1) and the transparent conductivity of the other cell C (for example, the second cell of C2) adjacent to the first cell C1. The film 11A is electrically connected by the conductive material 14, and the first cell C1 and the second cell C2 are connected in series in the width direction X2. That is, when a plurality of cells C1, C2,... Are arranged in series in the gap between the first base material 3A and the second base material 3B, for example, (sealing material 15 / conducting material 14 / sealing) Stop material 15) / (first cell C1) / (sealing material 15 / conducting material 14 / sealing material 15) / (second cell C2) / (sealing material 15 / conducting material 14 / sealing material 15) / (Third cell)...

  The material of the first base material 3A and the second base material 3B is not particularly limited, and examples thereof include insulators such as a film-like resin, semiconductors, metals, and glass. Examples of the resin include poly (meth) acrylic acid ester, polycarbonate, polyester, polyimide, polystyrene, polyvinyl chloride, and polyamide. From the viewpoint of producing a thin and light flexible dye-sensitized solar cell 1, the substrate is preferably made of a transparent resin, more preferably a polyethylene terephthalate (PET) film or a polyethylene naphthalate (PEN) film. . The material of the first base material 3A and the material of the second base material 3B may be different.

  The types and materials of the transparent conductive film 11A and the counter conductive film 12A are not particularly limited, and a conductive film used for a known dye-sensitized solar cell can be applied. For example, a thin film made of a metal oxide is used. Can be mentioned. Examples of the metal oxide include tin-doped indium oxide (ITO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (ATO), indium oxide / zinc oxide (IZO), and gallium-doped zinc oxide (GZO). it can.

The semiconductor layer 11B is made of a material that can receive electrons from the adsorbed photosensitizing dye, and is usually preferably porous. The material which comprises the semiconductor layer 11B is not specifically limited, The material of the well-known semiconductor layer 11B is applicable, For example, metal oxide semiconductors, such as a titanium oxide, a zinc oxide, a tin oxide, are mentioned.
The photosensitizing dye supported on the semiconductor layer 11B is not particularly limited, and examples thereof include known dyes such as organic dyes and metal complex dyes. Examples of the organic dye include coumarin, polyene, cyanine, hemicyanine, and thiophene. As said metal complex pigment | dye, a ruthenium complex etc. are used suitably, for example.

  The material which comprises the catalyst layer 12B is not specifically limited, A well-known material is applicable, for example, carbons, such as platinum and a carbon nanotube, poly (3,4-ethylene dioxythiophene) -poly (styrene sulfone) Examples thereof include conductive polymers such as (acid) (PEDOT / PSS).

  The electrolytic solution 13 is not particularly limited, and an electrolytic solution used in a known dye-sensitized solar cell can be applied. Examples of the electrolytic solution 13 include an electrolytic solution in which iodine and sodium iodide are dissolved in an organic solvent.

  A known photosensitizing dye (not shown) is adsorbed on the surface including the porous interior in the semiconductor layer 11B with which the electrolytic solution 13 is in contact.

  The conductive material 14 is disposed between the plurality of semiconductor layers 11B extending in parallel and in one direction, in contact with the photoelectrode 11 on the first base 3A and the counter electrode 12 on the second base 3B, and It is provided between the photoelectrode 11 and the counter electrode 12. As the conductive material 14, for example, one or more selected from conductive wires, conductive tubes, conductive foils, conductive plates and conductive meshes, conductive pastes, and conductive particles are used. Here, the conductive paste is a conductive material having a relatively low rigidity and a soft form. For example, the conductive paste may have a form in which a solid conductive material is dispersed in a viscous dispersion medium such as an organic solvent or a binder resin. The conducting material 14 may have both functions of conduction and adhesion like a double-sided adhesive type copper tape.

  Examples of the conductive material used for the conductive material 14 include metals such as gold, silver, copper, chromium, titanium, platinum, nickel, tungsten, iron, and aluminum, or alloys of two or more of these metals. However, it is not particularly limited. Examples of the material also include resin compositions such as polyurethane and polytetrafluoroethylene (PTFE) in which conductive fine particles (for example, fine particles of the metal or alloy, fine particles of carbon black, etc.) are dispersed.

The sealing material 15 is a non-conductive member that can bond the opposing first substrate 3A and second substrate 3B and seal the cell C formed between the substrates 3A and 3B. If it is, it will not be restrict | limited in particular.
As a material of the sealing material 15, for example, a hot melt adhesive (thermoplastic resin), a thermosetting resin, an ultraviolet curable resin, and a resin including an ultraviolet curable resin and a thermosetting resin are temporarily used. And a resin material that has fluidity and is solidified by an appropriate treatment. Examples of the hot melt adhesive include polyolefin resin, polyester resin, polyamide resin, and the like. Examples of the thermosetting resin include an epoxy resin and a benzoxazone resin. Examples of the ultraviolet curable resin include those containing a photopolymerizable monomer such as acrylic acid ester and methacrylic acid ester.

Next, the RtoR method manufacturing apparatus 4 for manufacturing the dye-sensitized solar cell 1 having the above-described configuration will be specifically described with reference to the drawings.
As shown in FIG. 4, the manufacturing apparatus 4 includes a photoelectrode forming portion (not shown), a first insulating processing portion 41, a sealing material coating portion 42, a conductive material placement portion 43, an electrolyte coating portion 44, a base The material bonding portion 45 and the ultrasonic fusion portion 46 are arranged in this order from the upstream side to the downstream side in the first movement direction P1 of the first base material 3A.
Moreover, in the base material bonding part 45, the 1st base material 3A and the 2nd base material 3B are bonded together, and the 2nd moving direction P2 of the 2nd base material 3B moved separately from the 1st base material 3A. A counter electrode forming portion (not shown) and a second insulating processing portion 47 are arranged in this order. That is, the second base material 3 </ b> B that has passed through the second insulating processing portion 47 is bonded to the first base material 3 </ b> A at the base material bonding portion 45.

  The photoelectrode forming portion (not shown) is arranged at the most upstream portion in the first moving direction P1 in the manufacturing apparatus 4 and is configured to form the photoelectrode 11 in a predetermined region on the surface of the first base material 3A.

As shown in FIGS. 5 and 6, the first insulation processing portion 41 employs a cutting device 50 having a plurality of semicircular blades 52 in the present embodiment. The cutting device 50 includes a rotary shaft 51 that is rotatably provided around the axis O1, and a semicircular blade 52 that is disposed around the rotary shaft 51 at a predetermined interval in the direction of the axis O1. The axis O1 direction of the rotation shaft 51 is arranged in the width direction X2.
The semicircular blade 52 is provided continuously in a range of 180 ° along the circumferential direction of the outer peripheral surface of the rotary shaft 51, and is disposed in a region of a predetermined half-circular portion of the entire circumference as viewed from the axis O1 direction. The first semicircular blade 52A and the second semicircular blade 52B disposed in a region of another semicircular portion where the first semicircular blade 52A is not disposed. The plurality of first semicircular blades 52A simultaneously connect the plurality of insulating portions 16 of one adjacent submodule R among the submodules R of the first base material 3A defined in the longitudinal direction X1 by the fused portion 18. Form. Further, the plurality of second semicircular blades 52B simultaneously form the plurality of insulating portions 16 in the other region of the adjacent submodules R. The circumferential length (outer circumferential length) of the semicircular blade 52 is set so as to coincide with the length in the longitudinal direction X1 of the insulating portion 16 to be insulated in the submodule R.

The interval between the first semicircular blades 52A adjacent in the axis O1 direction and the interval between the second semicircular blades 52B adjacent in the axis O1 direction are set to be equal. The first semicircular blade 52A and the second semicircular blade 52B are not arranged on the same circumference, but are provided at positions shifted in the direction of the axis O1.
Further, the semicircular blade 52 (52A, 52B) is applied only to the conductive films 11A, 12A when the semicircular blade 52 (52A, 52B) is rotated together with the rotary shaft 51 with respect to the surfaces of the base materials 3A, 3B on which the conductive films 11A, 12A are formed. Groove cuts are formed. That is, the conductive films 11A and 12A are set so that cuts are formed in the thickness direction, and even if a part of the base materials 3A and 3B is cut in the thickness direction, the whole is not cut.
In addition, the space | interval of the axis | shaft O1 direction of the semicircle blade 52, circumferential length, and the deviation | shift amount of the 1st semicircle blade 52A and the 2nd semicircle blade 52B in the axis | shaft O1 direction should be changed suitably according to the setting of the insulation part 16. Can do.

Next, as shown in FIG. 4, the sealing material application part 42 is arrange | positioned in the photoelectrode 11 arrange | positioned in the downstream of the 1st insulation process part 41, and formed in the predetermined area | region of the 1st base material 3A. The material 15 (see FIG. 2) is applied.
The conducting material arrangement part 43 is arranged on the downstream side of the sealing material application part 42 and is configured to arrange wiring (conducting material 14) between the sealing materials 15.
The electrolytic solution coating unit 44 is arranged on the downstream side of the conductive material arranging unit 43 and is configured to apply the electrolytic solution 13 to an uncoated region of the sealing material 15 in the first base material 3A.

The counter electrode forming part (not shown) is arranged at the most upstream part in the second moving direction P2 in the manufacturing apparatus 4, and is configured to form the counter electrode 12 in a predetermined region on the surface of the second base material 3B.
Since the second insulation processing portion 47 employs a cutting device 50 (see FIG. 5) similar to that provided in the first insulation processing portion 41 described above, detailed description thereof is omitted here.

  The base material bonding portion 45 is configured to bond the second base material 3B on which the counter electrode 12 is formed to the surface of the first base material 3A on which the photoelectrode 11 is formed. Specifically, the base material laminating part 45 is provided with a curing processing part (not shown) for curing the sealing material 15, and a pair of the first base material 3 </ b> A and the second base material 3 </ b> B are overlapped. By passing the laminating rollers 45A and 45B, the base materials 3A and 3B are bonded and bonded together.

  The ultrasonic fusion portion 46 forms the fusion portion 18 extending along the width direction X2 by fusing the first base material 3A and the second base material 3B by ultrasonic vibration with a certain interval in the longitudinal direction X1. However, it is configured to be divided into a plurality of submodules R.

  Next, a method of manufacturing the dye-sensitized solar cell 1 in which an electrical series circuit is configured using the RtoR manufacturing device 4 of the present embodiment described above will be specifically described with reference to the drawings.

  First, the manufacturing method of the dye-sensitized solar cell 1 produced using the manufacturing apparatus 4 shown in FIG. 4 is demonstrated. In the manufacturing apparatus 4, a film (1st base material 3A, 2nd base material 3B) is conveyed continuously, and the 2nd base material 3B is bonded together with respect to 1st base material 3A in which the photoelectrode 11 was formed. Thus, the dye-sensitized solar cell 1 is manufactured. And in the manufacturing apparatus 4 of this Embodiment, the film type dye increase which comprised the electrical series circuit on the film so that an electric current might flow alternately in the width direction X2 toward the advancing direction (longitudinal direction X1). A solar cell 1 is produced (see FIG. 1).

  In the production method for continuously producing the dye-sensitized solar cell 1 by the RtoR method, the transparent conductive film 11A is formed on the surface of the first substrate 3A, and the surface of the transparent conductive film 11A of the first substrate 3A. Forming a photoelectrode 11 in which a plurality of strip-like semiconductor layers 11B having adsorbed pigment extending in the longitudinal direction X1 are formed, and a counter conductive film so as to face the photoelectrode 11 on the surface of the second substrate 3B A step of forming the counter electrode 12 on which 12A is formed, a step of insulating the transparent conductive film 11A and the counter conductive film 12A in parallel to the longitudinal direction X1, and a width direction orthogonal to the longitudinal direction X1 in plan view A step of providing a sealing material 15 for arranging a plurality of cells C in X2, a step of arranging a conductive material 14 on the sealing material 15 to electrically connect the photoelectrode 11 and the counter electrode 12, and a light The semiconductor layer 11B of the electrode 11 and the counter electrode 12 The step of providing the electrolytic solution 13 on the substrate, the step of bonding the photoelectrode 11 and the counter electrode 12, and the step of forming the fused portion 18 extending along the width direction X2 with respect to the photoelectrode 11 and the counter electrode 12. And a step of disposing the wiring material 19 along the longitudinal direction X1 at both end portions in the width direction X2, and a step of cutting the photoelectrode 11 and the counter electrode 12 at the position of the arbitrary fused portion 18. ing.

Specifically, as shown in FIG. 7, the method for manufacturing the dye-sensitized solar cell 1 uses, for example, an aerosol deposition (AD) method in a semiconductor electrode forming portion (not shown) to form a transparent conductive film 11A. By laminating TiO2 on the first base material 3A on which is formed, the semiconductor layer 11B is formed at intervals in the width direction X2, and then the dye is adsorbed on the semiconductor layer 11B by a general method. Then, the photoelectrode 11 is formed. Here, FIG. 7 (the same applies to FIGS. 8 to 12 described later) shows a part of the dye-sensitized solar cell 1 continuously manufactured by the RtoR method.
Further, as shown in FIG. 8, in the counter electrode forming portion (not shown), platinum (Pt) is laminated on the second substrate 3B on which the counter conductive film 12A is formed by sputtering to form the catalyst layer 12B. Thus, the counter electrode 12 is formed.

In the first base material 3A that forms the photoelectrode 11 produced in the semiconductor electrode formation portion and moves in the first movement direction P1, in the cutting device 50 of the first insulation processing portion 41 shown in FIGS. Insulation processing is performed to form the first insulating portion 16 extending parallel to the longitudinal direction X1 by the rotation of the semicircular blade 52 (52A, 52B) at a position between the layer 11B and the semiconductor layer 11B.
At this time, as shown in FIG. 9, the first insulating portion 16 is regularly insulated at positions that are alternately shifted in the width direction X2 at regular intervals (the length in the longitudinal direction X1 of the submodule R). A pattern is formed. By alternately disposing the insulation processing patterns in this way, the positions of the positive electrode (positive electrode) and the negative electrode (negative electrode) can be regularly switched for each submodule R.

Next, as shown in FIG. 4, after processing the first insulating portion 16 of the photoelectrode 11, the sealing material is applied to the photoelectrode 11 formed in a predetermined region of the first base material 3 </ b> A by the sealing material coating portion 42. 15 is applied. At this time, the semiconductor layer 11B is applied so that the sealing material 15 is not covered.
And after arrange | positioning the conduction | electrical_connection material 14 between the sealing materials 15 in the conduction | electrical_connection material arrangement | positioning part 43, in the electrolyte solution application part 44, the electrolyte solution 13 in the uncoated area | region of the sealing material 15 in the 1st base material 3A. Apply.

On the other hand, in the 2nd base material 3B which forms the counter electrode 12 produced in the counter electrode formation part, and moves to the 2nd moving direction P2, the cutting apparatus 50 of the 2nd insulation process part 47 shown in FIG.5 and FIG.6. In FIG. 5, the insulating process is performed to form the second insulating portion 17 extending parallel to the longitudinal direction X1 by the rotation of the semicircular blade 52 (52A, 52B) at a position between the catalyst layer 12B and the catalyst layer 12B.
At this time, as shown in FIG. 8, the second insulating portion 17 is regularly insulated at positions that are alternately displaced in the width direction X2 at regular intervals (the length in the longitudinal direction X1 of the submodule R). Pattern is formed. By alternately arranging in this way, the positions of the + and − poles can be regularly switched for each submodule R.

  Next, in the base material laminating portion 45 shown in FIG. 4, the sealing material 15 is cured by a curing processing unit (not shown), and the first base material 3 </ b> A and the second base material 3 </ b> B that are insulated are overlapped. By passing a pair of laminating rollers 45A and 45B in the combined state, both base materials 3A and 3B are bonded and bonded. At this time, as shown in FIG. 10, the first insulating portion 16 of the first base material 3 </ b> A and the second insulating portion 17 of the second base material 3 </ b> B are shifted in the width direction X <b> 2 in the bonded state, As a result, a plurality of cells C that are divided and arranged in the width direction X2 through the conductive material 14 (see FIG. 2) are electrically connected in series.

Next, after bonding, in the ultrasonic fusion part 46, as shown in FIG. 11, the first base material 3A and the second base material 3B are melted by ultrasonic vibration at a constant interval in the longitudinal direction X1. The fused portion 18 is formed to extend along the width direction X2 and is divided into a plurality of submodules R.
Further, as shown in FIG. 12, the wiring material 19 is pasted to the both ends 3a and 3b in the width direction X2 of both the base materials 3A and 3B which are pasted, along the longitudinal direction X1, for example, by copper tape or soldering. . At this time, the wiring members 19 are arranged in a state in which the ends of the fused portions 18 arranged in the longitudinal direction X1 are alternately covered in the width direction X2. Thereby, the dye-sensitized solar cell 1 in which the cells C of the submodules R connected in series are connected in series can be manufactured, and electricity is alternately generated in the width direction X2 for each submodule R (arrow E in FIG. 12). Direction). The dye-sensitized solar cell 1 can be cut along the fused portion 18, and cut at a desired length position (two-dot chain line indicated by T in FIG. 12). The dye-sensitized solar cell 1 can be produced. For example, as the dye-sensitized solar cell 1 after cutting, one having three submodules R, one having two submodules R, or one having four or more submodules R continuous as shown in FIG. Can be manufactured.

Here, the structure of the wiring member 19 will be described more specifically.
FIG. 13 shows a wiring material 19A for the extraction electrode in the positive electrode. FIG. 14 shows a wiring material 19B for the extraction electrode in the negative electrode. Thus, by arrange | positioning the conduction | electrical_connection material 14 in the both ends of the width direction X2 (2nd direction) of a film, it is + on the same base material surface (here on the base material surface of 2nd base material 3B). A terminal (positive terminal) and a negative terminal (negative terminal) extraction electrode (terminal extraction portion) can be provided. Therefore, when performing the wiring work to the extraction electrode, the step of inverting the dye-sensitized solar cell 1 up and down becomes unnecessary, and the labor of the wiring work can be reduced. Here, in FIG. 13, electricity also flows from the counter electrode 12 to the photoelectrode 11 also to the conductive material 14 near the wiring material 19 </ b> A, but electricity does not flow first from the photoelectrode 11 side, so the flow of electricity is omitted. (The same applies to FIG. 19 described later).
The longitudinal direction X1 is an arrangement direction of the submodules R and corresponds to the “first direction” of the present invention, and the width direction X2 is a direction orthogonal to the longitudinal direction X1 in a plan view. Corresponds to "direction".

FIG. 15 shows a dye-sensitized solar cell 1 </ b> A (solar cell module) manufactured by cutting at the fusion portion 18 so as to have two submodules R and R in the first embodiment.
The dye-sensitized solar cell 1A shown in FIG. 15 has a battery structure in which two sections (submodules R and R) each composed of a plurality of cells C arranged in the width direction X2 are adjacent to each other in the longitudinal direction X1. One end 1a (one end portion) in the width direction X2 in the adjacent submodules R and R is electrically connected by a wiring member 19 through a series wiring. In the dye-sensitized solar cell 1A, the first fusion part 181 extending from the other end 1b toward the one end 1a side with the wiring member 19 on the one end 1a side left in the width direction X2 in each sub-module R ( A first insulating line) is formed. That is, the photoelectrodes 11 and the counter electrodes 12 in the submodules R and R constitute an electric circuit electrically connected by the wiring material 19. In FIG. 15, the symbol E indicates the direction of current.

And when constructing the dye-sensitized solar cell 1A described above, the first substrate 3A and the counter electrode on which the photoelectrode 11 is formed in the step of bonding the first substrate 3A and the second substrate 3B together. The second base material 3B on which 12 is formed is bonded in a state shifted in the width direction X2. Then, the wiring material 19 is arrange | positioned along the longitudinal direction X1 at the both ends 1a and 1b of the width direction X2 of 3 A of 1st base materials. Next, a first insulating line 181 that extends along the width direction X2 with respect to the first base material 3A and the second base material 3B and does not partially insulate the wiring material 19 on the one end 1a side in the width direction X2, Second insulating lines (not shown) for insulating over the entire width direction X2 are alternately formed in the longitudinal direction X1. Then, it manufactures by cut | disconnecting 1st base material 3A and 2nd base material 3B in the position of a 2nd insulation line. In the present embodiment, a cut portion 1c is formed between the sub modules R and R from the other end 1b side toward the one end 1a. The cut portion 1c is set to a length that does not cut the cell C closest to the other end 1b.
The dye-sensitized solar cell 1 </ b> A manufactured in this way is formed by the wiring material 19 on the second base 3 </ b> B at one end 1 a in the width direction X <b> 2 in the pair of adjacent submodules R and R divided by the first insulating line 181. It is electrically connected, and the other electrode 1b can be provided with the same base material (here, the second base material 3B) and an extraction electrode.

Next, the effect | action of the manufacturing method of the dye-sensitized solar cell 1 and 1A mentioned above is demonstrated in detail using drawing.
In the present embodiment, as shown in FIG. 2, the first insulating portion 16 of the first base material 3A and the second base material 3B arranged between the cells C, C adjacent to each other in the width direction X2. A sub-module R in which the conductive material 14 is disposed between the insulating portion 17 and the cells C and C adjacent to each other in the width direction X2 are electrically connected in series and divided in the longitudinal direction X1 by the fusion portion 18. The dye-sensitized solar cell 1 having a configuration in which the cells C and C are electrically connected in series by the wiring material 19 can be manufactured in a state of being continuous in the longitudinal direction X1 by the RtoR method. That is, a module having an independent electric circuit can be produced by the RtoR method by the dye-sensitized solar cell 1 itself cut and divided at the position of the fusion part 18. In this manner, the position and length of the conductive material 14, the fused portion 18, and the wiring material 19 are appropriately set on the film substrate by the RtoR method, and the wiring is performed so that the set electrical characteristics (voltage, etc.) are obtained. Therefore, it is possible to freely design the series-parallel connection (circuit design) of the cells C.

  Further, in the present embodiment, when the produced dye-sensitized solar cell 1 is packaged in a separate body (substrate), it is performed after attaching a plurality of dye-sensitized solar cells to the substrate as in the past, Since the wiring work for electrically connecting the sensitized solar cells is not necessary, the production efficiency can be improved. Thus, since it becomes possible to reduce an operation man-hour, reduction of manufacturing cost can be aimed at.

Further, in the dye-sensitized solar cell 1A having the pair of submodules R and R as shown in FIG. 15 described above, the submodules R and R on the one end 1a side in the width direction X2 are electrically connected to each other by the wiring material 19. It becomes a structure which can take out electricity by the end 1b side. That is, the whole structure is such that electricity flows in a U shape in plan view, and the lead-out electrode (positive electrode, negative electrode) can be arranged on the same side on the other end 1b side in the width direction X2, thereby simplifying the wiring structure. Wiring work can be performed easily.
In this embodiment, the wiring member 19 is provided at one end 1a of the adjacent submodules R and R, and a simple manufacturing method for applying the wiring member 19 to a line can be applied. Therefore, it can be easily adapted to the RtoR method. Since it can be realized by a manufacturing process in which the wiring member 19 is continuously arranged in the longitudinal direction X1 by such an RtoR method, it is not necessary to add a new work process.

  Next, other embodiments according to the solar cell module and the solar cell module manufacturing method of the present invention will be described with reference to the accompanying drawings, but the same or similar members and parts as those in the first embodiment described above. The same reference numerals are used to omit the description, and a configuration different from that of the first embodiment will be described.

(Second Embodiment)
As shown in FIG. 16, the second embodiment is a manufacturing method for continuously manufacturing the dye-sensitized solar cell 1 by the RtoR method, and is wired along the longitudinal direction X1 at both ends in the width direction X2. This is a method in which the step of arranging the material 19 is performed in the previous step of the step of bonding the photoelectrode 11 and the counter electrode 12 together. In other words, after the sealing material 15 is provided, the wiring material 19 is disposed on the first base material 3A simultaneously with the conductive material 14. In the second embodiment, the wiring member 19 is arranged continuously in the longitudinal direction X1, and after the fusion part 18 is provided, as shown in FIG. The disconnection part 19a by which the part was notched is formed.

As the wiring material 19 at this time, a double-sided adhesive type copper tape or a material to which a curable silver paste is applied can be employed. It is also possible to combine the photoelectrode 11 side with a copper tape and the counter electrode 12 side with a curable silver paste. Further, the copper tape may be taken out and used for electrodes, and the curable silver paste may be used for series connection with cells adjacent in the longitudinal direction X1.
In the second embodiment, it is possible to cut the connection between the cells C and C of the submodule R adjacent to each other in the longitudinal direction X1 by forming the disconnection portions 19a at appropriate positions in the wiring material 19. . Therefore, a desired electric circuit can be designed according to the position of the disconnection part 19a. In the second embodiment, since the arrangement pattern of the conductive material 14 and the wiring material 19 can be formed simultaneously, the manufacturing efficiency can be improved.

Here, the structure of the wiring member 19 will be described more specifically. FIG. 18 shows the dye-sensitized solar cell 1 after bonding the first base material 3A and the second base material 3B and before providing the fused portion 18.
FIG. 19 shows a wiring material 19A for the extraction electrode in the positive electrode. FIG. 20 shows a wiring material 19B for the extraction electrode in the negative electrode. 21 and 22 show a wiring material 19C for connection that connects cells adjacent in the longitudinal direction X1. In this way, by arranging the conductive material 14 at both ends in the width direction X2 of the film, the + terminal (positive terminal) on the same base material surface (here, the base material surface of the second base material 3B) and -An extraction electrode (terminal extraction portion) for a terminal (negative electrode terminal) can be provided. Therefore, when performing the wiring work to the extraction electrode, the step of inverting the dye-sensitized solar cell 1 up and down becomes unnecessary, and the labor of the wiring work can be reduced.

  Further, as shown in FIG. 23, the connecting wiring member 19C may be configured such that the bridging electrode is adjusted at a level that cannot be cut by ultrasonic vibration.

  In the second embodiment as well, as in the first embodiment described above, dye sensitization produced by cutting at the fused portion 18 so as to have two submodules R and R. It can be set as a solar cell (solar cell module) (refer FIG. 15).

(Third embodiment)
Next, in the third embodiment shown in FIG. 24, in the step of arranging the wiring material 19, the wiring material 19 is applied so as to be staggered along the longitudinal direction X <b> 1 on the photoelectrode 11 side and the counter electrode 12 side. Manufacturing method. That is, the cells C and C on both sides sandwiching the disconnection portion 19a where the wiring material 19 is not arranged in the longitudinal direction X1 are not connected when the wiring material 19 is arranged. Therefore, as compared with the case where the wiring material 19 is continuously arranged at the time of arranging the wiring material 19 as in the second embodiment, there is an advantage that the step of providing the disconnection portion 19a in the wiring material 19 is not necessary. .

Further, in the third embodiment, as shown in FIG. 25, after the photoelectrode 11 and the counter electrode 12 are bonded together, the photoelectrode 11 and the counter electrode 12 are fused along the width direction X2. In the process of forming the fused portion 18, the non-fused portion 18 </ b> A (the portion surrounded by the two-dot dotted line in FIG. 25) is secured. Here, the reason for forming the non-fused portion 18A in which the fused portion 18 is not provided is that the non-fused portion 18A is on the side where the wiring material 19 is applied, and the coated wiring material 19 is thereby disconnected. Can be avoided. Thereby, the insulation of the wiring material 19 by fusion | fusion can be prevented.
The non-fused portion 18A is a position facing the disconnection portion 19a of the wiring member 19 in the width direction X2. That is, the non-fused portion 18A is a portion where the ultrasonic fusion machine is not applied in the ultrasonic fusion portion 46 shown in FIG.

(Fourth embodiment)
Next, the fourth embodiment shown in FIG. 26 is an insulating process for forming a third insulating portion 17A corresponding to the fused portion 18 in which the photoelectrode 11 and the counter electrode 12 are fused along the width direction X2. Is a manufacturing method that is performed simultaneously with the insulating processing of the photoelectrode 11 and the counter electrode 12 (only the second insulating portion 17 is shown in FIG. 26). In this case, in order to make the fusion | bond part 18 electrically connect with the cells C and C which adjoin the longitudinal direction X1 in the both ends of the width direction X2, between the both ends of the width direction X2, a clearance gap ( Insulation is performed with the non-insulating portion 17B and the portion surrounded by the dotted line in FIG.
As shown in FIG. 27, only the portion T to be cut is sealed by ultrasonic fusion.
In the fourth embodiment, the manufacturing efficiency can be improved by simultaneously performing the third insulating portion 17A and the insulating process parallel to the longitudinal direction X1.

  As mentioned above, although the solar cell module by this invention and embodiment of the manufacturing method of a solar cell module were described, this invention is not limited to said embodiment, In the range which does not deviate from the meaning, it changes suitably. Is possible.

  For example, in the above-described embodiment, the incision processing device 50 is employed as means for performing insulation processing by the insulation processing portions 41 and 47, but is not limited thereto. For example, as shown in FIGS. 28A and 28B, a plurality of laser irradiation devices 53, 53,... Are arranged at predetermined intervals in the width direction X2, and the fused portion 18 (see FIG. 1). A laser irradiation device 53 for irradiating the laser L corresponding to each defined submodule R is set, and the laser is alternately switched for each submodule R as shown in FIG. 28 (a) and FIG. 28 (b). By processing, the first insulating portion 16 is formed on the transparent conductive film 11A of the first base material 3A and the opposing conductive film of the second base material 3B, similarly to the incision processing device 50 of the above-described embodiment. The second insulating portion 17 can be formed for 12A.

  Moreover, in one dye-sensitized solar cell (solar cell module), the number of submodules R is not limited to this embodiment, and can be arbitrarily set as long as it is an even number.

  In addition, it is possible to appropriately replace the components in the above-described embodiments with known components without departing from the spirit of the present invention.

1, 1A Dye-sensitized solar cell (solar cell module)
1a one end 1b other end 4 manufacturing apparatus 11 photoelectrode (first electrode)
11A Transparent conductive film 11B Semiconductor layer 12 Counter electrode (second electrode)
12A Opposing conductive film 12B Catalyst layer 3A First base material 3B Second base material 13 Electrolyte solution 14 Conductive material 15 Sealing material 16 First insulating portion 17 Second insulating portion 17A Third insulating portion 17B Non-insulating portion 18 Fusion portion (Insulation line)
18A Non-fused part 181 First fused part (first insulation line)
19, 19A, 19B, 19C Wiring material 19a Disconnected portion 41 First insulation processing portion 42 Sealing material coating portion 43 Conducting material placement portion 44 Electrolyte coating portion 45 Base material bonding portion 46 Ultrasonic fusion portion 47 No. Two insulation processing parts 50 Cutting processing device 51 Rotating shaft 52, 52A, 52B Semicircular blade 53 Laser irradiation device C Cell P1 First moving direction P2 Second moving direction R Submodule X1 Longitudinal direction (first direction)
X2 width direction (second direction, width direction of first substrate and second substrate)

Claims (12)

A transparent conductive film is formed on the surface of the first base material, and a plurality of strip-like semiconductor layers are formed on the surface of the transparent conductive film of the first base material to which a dye extending in the first direction is adsorbed. One electrode,
A second electrode having a counter conductive film formed on the surface of the second base so as to face the first electrode;
An electrolyte solution sealed between the semiconductor layer of the first electrode and the second electrode;
Sealing the electrolytic solution, and a sealing material for arranging a plurality of cells divided in a second direction orthogonal to the first direction in plan view;
A conductive material provided in a state of being covered with the sealing material, and electrically connecting the first electrode and the second electrode;
An insulation line extending along the second direction with respect to the first electrode and the second electrode;
With
The plurality of cells arranged in the second direction are electrically connected by serial wiring,
The conductive material is disposed between the first insulating part of the first base material disposed between cells adjacent in the second direction and the second insulating part of the second base material, Adjacent cells are connected,
One end of the second direction in adjacent submodules among the even number of submodules divided in the first direction by the insulating line are electrically connected by a series wiring by a wiring material,
The solar cell module according to claim 1, wherein a direction of a current flowing through the plurality of submodules is configured to be alternately switched for each of the submodules arranged in the first direction.   In the first base material or the second base material, the conducting material is disposed at both end portions in the second direction, and a terminal lead-out portion is provided on the same base material surface. The solar cell module according to claim 1. A solar cell module manufacturing method for continuously manufacturing solar cell modules by a roll-to-roll method,
A transparent conductive film is formed on the surface of the first substrate, and a plurality of strip-shaped semiconductor layers in which a dye extending in the longitudinal direction of the first substrate is adsorbed on the surface of the transparent conductive film of the first substrate Forming the formed first electrode;
Forming a second electrode in which a counter conductive film is formed on the surface of the second substrate so as to face the first electrode;
Performing an insulating process in parallel with the longitudinal direction on the transparent conductive film and the counter conductive film;
Providing a sealing material for arranging a plurality of cells in the width direction of the first base material and the second base material orthogonal to the longitudinal direction in plan view;
Disposing a conductive material on the sealing material to electrically connect the first electrode and the second electrode;
Providing an electrolyte solution between the semiconductor layer of the first electrode and the second electrode;
Bonding the first electrode and the second electrode;
Forming an insulation line extending along the width direction with respect to the first electrode and the second electrode;
Arranging the wiring material along the longitudinal direction at both ends of the first base in the width direction;
Cutting the first electrode and the second electrode at an arbitrary position of the insulation line;
The manufacturing method of the solar cell module characterized by having. In the step of performing the insulating process,
The method for manufacturing a solar cell module according to claim 3, wherein an insulation processing pattern is formed in which the insulation processing position changes to a position shifted in the width direction at a constant period with respect to the longitudinal direction. The wiring material is arranged in a continuous state along the longitudinal direction,
5. The method for manufacturing a solar cell module according to claim 3, wherein, after the insulation line is formed, a disconnection portion is formed by cutting out a part of the wiring material in the longitudinal direction. 6. .   5. The method for manufacturing a solar cell module according to claim 3, wherein in the step of arranging the wiring material, the wiring material in which a disconnection portion is formed in a part of the longitudinal direction is arranged.   The method for manufacturing a solar cell module according to claim 3, wherein the insulating line is a fused portion fused along the width direction.   The method of manufacturing a solar cell module according to any one of claims 3 to 7, wherein the step of arranging the wiring material is performed simultaneously with the arrangement of the conductive material.   The method of manufacturing a solar cell module according to any one of claims 3 to 7, wherein the step of forming the insulating line is performed at the same time when the insulating process is performed. A transparent conductive film is formed on the surface of the first substrate, and a plurality of strip-shaped semiconductor layers in which a dye extending in the longitudinal direction of the first substrate is adsorbed on the surface of the transparent conductive film of the first substrate Forming the formed first electrode;
Forming a second electrode in which a counter conductive film is formed on the surface of the second substrate so as to face the first electrode;
Performing an insulating process in parallel with the longitudinal direction on the transparent conductive film and the counter conductive film;
Providing a sealing material for arranging a plurality of cells in the width direction of the first base material and the second base material orthogonal to the longitudinal direction in plan view;
Disposing a conductive material on the sealing material to electrically connect the first electrode and the second electrode;
Providing an electrolyte solution between the semiconductor layer of the first electrode and the second electrode;
Bonding the first electrode and the second electrode;
A step of arranging a wiring material along the longitudinal direction at both ends in the width direction of the first substrate;
A first insulating line that extends along the width direction with respect to the first electrode and the second electrode and that does not partially insulate the wiring member on one end side in the width direction, and over the entire width direction. Forming a second insulating line to be insulated at a predetermined position in the longitudinal direction, and providing an odd number of the first insulating lines between the second insulating lines;
Cutting the first electrode and the second electrode at a position of the second insulating line;
Have
In the solar cell module cut by the second insulation line, one end in the width direction of the adjacent submodules among the even number of submodules divided by the first insulation line is formed by the wiring material. A method for manufacturing a solar cell module, wherein the solar cell module is electrically connected by serial wiring.   The method for manufacturing a solar cell module according to claim 10, wherein the first insulating line and the second insulating line are fusion parts fused along the width direction.   The method for manufacturing a solar cell module according to claim 10 or 11, wherein the step of forming the first insulating line and the second insulating line is performed simultaneously with the insulating process.

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