JP2023147362A - Method for manufacturing solar cell module - Google Patents

Abstract

To provide a method for manufacturing a solar cell module, achieving high yield.SOLUTION: A method for manufacturing a solar cell module according to an aspect of the present invention includes the steps of: forming a first internal isolation groove that cuts a first electrode layer at the boundary of an area where a solar cell sub-cell is formed; forming a first external isolation groove that cuts the first electrode layer on the outer edge of an area where the solar cell module is formed; forming a second internal isolation groove that cuts a first charge transport layer, a photoelectric conversion layer, and a second charge transport layer at the boundary of an area where the solar cell sub-cell is formed; forming a third internal isolation groove that cuts at least a second electrode layer of the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the boundary of an area where the solar cell sub-cell is formed; and forming a second external isolation groove that cuts the first electrode layer, the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer, on the outer edge of an area where the solar cell module is formed.SELECTED DRAWING: Figure 1

Description

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

2. Description of the Related Art A solar cell module is known in which a plurality of solar cell subcells are electrically connected in series on a single base material. By modularizing the solar cell, the area between the subcells becomes an ineffective area, so the effective area decreases, but it is possible to reduce resistance loss, especially in the electrode on the light-receiving surface side. If solar cells are appropriately modularized, the reduction in resistance loss will outweigh the reduction in effective area and the improvement in photoelectric conversion efficiency.

The solar cell module includes a step of laminating a first electrode layer on a base material, a step of cutting the first electrode layer by first laser irradiation, and a step of laminating a first charge transport layer, a photoelectric conversion layer, and a second charge transport layer. step, a step of cutting the first charge transport layer, the photoelectric conversion layer, and the second charge conversion layer by second laser irradiation, a step of laminating the second electrode layer, and a step of cutting the first charge transport layer, the photoelectric conversion layer, and the second charge conversion layer. A step of cutting the charge transport layer and the second electrode layer by third laser irradiation is performed in this order, and the positions of the first laser irradiation, the second laser irradiation, and the third laser irradiation are sequentially shifted little by little. Accordingly, it can be manufactured by a method of forming a plurality of solar cell subcells electrically connected in series (see, for example, Patent Document 1).

Furthermore, in order to obtain a thin and flexible solar cell module, it is being considered to use a resin film as a base material. As a manufacturing method for solar cells using resin films as a base material, a polyimide film is formed by coating a varnish on a substrate that supports an intermediate product during manufacturing, and a first electrode and an electron transport layer are formed on this polyimide film. A method of obtaining a solar cell by forming a layer, a photoelectric conversion layer, a hole transport layer, and a second electrode and peeling a polyimide film from a substrate has been proposed (see, for example, Patent Document 2).

Japanese Patent Application Publication No. 2011-189408 International Publication No. 2020/026495

When forming a solar cell module on a resin film formed on a support substrate, the resin film may easily peel off from the support substrate at unexpected locations due to laser irradiation, which may reduce the yield of the solar cell module. be. Therefore, an object of the present invention is to provide a method for manufacturing a solar cell module with high yield.

A method for manufacturing a solar cell module according to one aspect of the present invention is a method for manufacturing a solar cell module having a plurality of solar cell subcells, and includes the steps of: laminating a resin base material layer on one main surface of a support substrate; a step of laminating a first electrode layer on a resin base material layer; a step of forming a first internal separation groove for cutting the first electrode layer at the boundary of the region where the solar cell subcell is to be formed by laser irradiation; and a step of laser irradiation. forming a first external separation groove for cutting the first electrode layer at the outer edge of the region where the solar cell module is to be formed; laminating a first charge transport layer on the first electrode layer; a step of laminating a photoelectric conversion layer on one charge transport layer; a step of laminating a second charge transport layer on the photoelectric conversion layer; , a step of forming a second internal separation groove for cutting the photoelectric conversion layer and the second charge transport layer; a step of laminating a second electrode layer on the second charge transport layer; forming a third internal separation groove that cuts at least the second electrode layer among the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the boundary of the region where the third electrode layer is formed; and cutting the first electrode layer, the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the outer edge of the region where the solar cell module is to be formed by laser irradiation. a step of forming a second external separation groove; and a step of peeling the resin base material layer inside the region where the solar cell module is formed from the support substrate; The intensity of the laser is higher than the intensity of the laser that forms the first internal separation groove, and the intensity of the laser that forms the second external separation groove is higher than the intensity of the laser that forms the third internal separation groove.

In the solar cell module manufacturing method described above, the resin of the resin base layer may be altered in quality by laser irradiation that forms the first external separation groove.

In the above solar cell module manufacturing method, the step of laminating the resin base layer may include the steps of applying a polyamic acid solution to the supporting substrate and heating the coating film of the polyamic acid solution. good.

The solar cell module according to the present invention has a high yield.

1 is a flowchart showing the steps of a solar cell module manufacturing method according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view showing a state in which a solar cell module is formed on a support substrate by the solar cell module manufacturing method of FIG. 1. FIG. FIG. 2 is a schematic plan view showing a laser irradiation position on a support substrate in the solar cell module manufacturing method of FIG. 1. FIG. FIG. 2 is a schematic cross-sectional view illustrating a first internal separation groove forming step and a first external separation groove forming step of the solar cell module manufacturing method of FIG. 1. FIG. FIG. 2 is a schematic cross-sectional view illustrating a first charge transport layer lamination step, a photoelectric conversion layer lamination step, and a second charge transport layer lamination step of the solar cell module manufacturing method of FIG. 1. FIG. FIG. 2 is a schematic cross-sectional view illustrating a second internal separation groove forming step of the solar cell module manufacturing method of FIG. 1. FIG. FIG. 2 is a schematic cross-sectional view illustrating a second electrode layer lamination step of the solar cell module manufacturing method of FIG. 1. FIG.

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a flowchart showing the steps of a solar cell module manufacturing method according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view showing the solar cell module 1 formed on the support substrate S by the solar cell module manufacturing method shown in FIG. In the figures, the dimensions of each component have been modified for clarity.

The solar cell module 1 manufactured by the solar cell module manufacturing method of FIG. A first charge transport layer 13 , a photoelectric conversion layer 14 laminated with the first charge transport layer 13 , a second charge transport layer 15 laminated with the photoelectric conversion layer 14 , and a photoelectric conversion layer 15 laminated with the second charge transport layer 15 a second electrode layer 16. As shown in FIG. 2, the solar cell module 1 has a resin base material layer 11 laminated on one main surface of a support substrate S, and an ineffective area E that is finally trimmed and not included in the solar cell module 1. It is formed surrounded by.

In addition, the solar cell module 1 has a plurality of first internal separation grooves 21 formed to cut the first electrode layer 12, and cuts the first charge transport layer 13, the photoelectric conversion layer 14, and the second charge transport layer 15. cutting at least the second electrode layer 16 of the plurality of second internal separation grooves 22 formed to and a plurality of third internal separation grooves 23 formed in this manner. The first internal separation groove 21, the second internal separation groove 22, and the third internal separation groove 23 are formed close to each other in this order, and define a plurality of solar cell subcells 2 that are electrically connected in series. The solar cell module 1 is provided at one end with a connection part 3 for electrically connecting to the first electrode layer 12 of the terminal solar cell subcell 2 via the second electrode layer 16, although it does not contribute to photoelectric conversion. It is being Although the solar cell module 1 according to this embodiment is intended to receive light from the resin base layer 11 side, it may be configured to receive light from the second electrode layer 16 side. Note that a larger solar cell module may be formed using a plurality of solar cell modules 1. That is, the solar cell module 1 may be used as a solar cell submodule.

On the support substrate S, a first external separation groove 31 formed to cut the first electrode layer 12, a first charge transport layer 13, and a photoelectric conversion layer are provided at the boundary between the solar cell module 1 and the ineffective region E. 14, a second external separation groove 32 is formed to cut through the second charge transport layer 15 and the second electrode layer 16. FIG. 3 shows the arrangement of the first internal separation groove 21, the second internal separation groove 22, and the third internal separation groove 23, and the first external separation groove 31 and the second external separation groove 32 on the support substrate S.

The solar cell module manufacturing method according to the present embodiment for manufacturing such a solar cell module 1 includes a step of laminating a resin base material layer 11 on one main surface of the support substrate S (S01: resin base material layer lamination step). , a step of laminating the first electrode layer 12 on the resin base material layer 11 (S02: first electrode layer lamination step), and cutting the first electrode layer 12 at the boundary of the area where the solar cell subcell 2 is to be formed by laser irradiation. (S03: first internal separation groove forming step), and a first external separation step of cutting the first electrode layer 12 at the outer edge of the region where the solar cell module 1 is to be formed by laser irradiation. a step of forming the groove 31 (S04: first external isolation groove forming step); a step of laminating the first charge transport layer 13 on the first electrode layer 12 (S05: first charge transport layer laminating step); A step of laminating the photoelectric conversion layer 14 on the charge transport layer 13 (S6: photoelectric conversion layer lamination step) and a step of laminating the second charge transport layer 15 on the photoelectric conversion layer 14 (S7: second charge transport layer lamination step) and a step (S08: (second internal separation groove forming step), a step of laminating the second electrode layer 16 on the second charge transport layer 15 (S09: second electrode layer laminating step), and a step of forming a region where the solar cell subcell 2 is formed by laser irradiation. Step of forming a third internal separation groove 23 that cuts the first charge transport layer 13, photoelectric conversion layer 14, second charge transport layer 15, and second electrode layer 16 at the boundary (S10: third internal separation groove formation step) Then, at least the second electrode layer 16 of the first charge transport layer 13, photoelectric conversion layer 14, second charge transport layer 15, and second electrode layer 16 is cut at the boundary of the region where the solar cell subcell 2 is to be formed by laser irradiation. (S10: third internal isolation groove forming step), and the first charge transport layer 13, photoelectric conversion layer 14, A step of cutting the second charge transport layer 15 and the second electrode layer 16 (S11: second external separation groove forming step), and removing the resin base material layer 11 inside the region where the solar cell module 1 is to be formed from the support substrate S. A peeling process (S12: solar cell module peeling process) is provided.

In the resin base layer lamination step, a resin base layer 11 made of a resin such as polyimide, polyamide, polyethylene terephthalate, etc. is laminated on a support substrate S such as a glass plate. The resin base material layer 11 is a structural member that ensures the strength of the solar cell module 1. The resin base material layer 11 can be laminated by a method of forming polyimide on the support substrate S, including, for example, a step of applying a polyamic acid solution and a step of heating the coating film of the polyamic acid solution. preferable. Thereby, a thin and smooth resin base layer 11 can be formed. In particular, when forming the resin base material layer 11 made of polyimide on the support substrate S made of a glass plate, the formation of the first external separation groove 31 and the second external separation groove 32 separates the support substrate S and the resin base material layer 11. Adhesion can be appropriately controlled.

The lower limit of the thickness of the resin base layer 11 is preferably 3 μm, more preferably 10 μm. On the other hand, the upper limit of the thickness of the resin base layer 11 is preferably 50 μm, more preferably 30 μm. The strength of the solar cell module 1 can be ensured by setting the thickness of the resin base material layer 11 to be equal to or greater than the lower limit. Further, by setting the thickness of the resin base material layer 11 to be equal to or less than the above upper limit, flexibility can be imparted to the solar cell module 1, and the peeling prevention effect by the first external separation groove 31 becomes remarkable.

In the first electrode layer lamination step S02, the first electrode layer 12 is laminated on the entire one main surface of the resin base layer 11. The first electrode layer 12 may be laminated on the resin base layer 11 by, for example, a sputtering method, a vacuum evaporation method, or the like.

The first electrode layer 12 collects the first charge generated in the photoelectric conversion layer 14 through the first charge transport layer 13 and outputs it to the adjacent solar cell subcell 2 or to the outside. In this embodiment, the first electrode layer 12 is a positive electrode that collects holes. Furthermore, in the present embodiment, the first electrode layer 12 may be formed of a transparent conductive oxide (TCO) that has electrical conductivity and light transmittance. As the transparent conductive oxide forming the first electrode layer 12, for example, indium oxide, tin oxide, zinc oxide, titanium oxide, and composite oxides thereof can be used. Among these, indium-based composite oxides containing indium oxide as a main component are preferred. Indium oxide is particularly preferred from the viewpoint of high conductivity and transparency. Furthermore, it is preferred to add dopants to the indium oxide to ensure reliability or higher conductivity. Examples of the dopant include Sn, W, Zn, Ti, Ce, Zr, Mo, Al, Ga, Ge, As, Si, and S. As a particularly suitable example, ITO (Indium Tin Oxide), which is made by adding tin to indium oxide, is widely known.

The lower limit of the thickness of the first electrode layer 12 is preferably 5 nm, more preferably 10 nm. On the other hand, the upper limit of the thickness of the first electrode layer 12 is preferably 200 nm, more preferably 150 nm. By setting the thickness of the first electrode layer 12 to be equal to or greater than the lower limit, the photoelectric conversion efficiency can be improved by reducing the electrical resistance. Further, by setting the thickness of the first electrode layer 12 to be equal to or less than the upper limit, the amount of light incident on the photoelectric conversion layer 14 can be increased, thereby improving photoelectric conversion efficiency. The first electrode layer 12 may have a multilayer structure, such as a stacked structure of a polycrystalline ITO layer and an amorphous ITO layer, for example.

In the first internal isolation groove forming step S03, the first internal isolation groove 21 is formed by removing the first electrode layer 12 in a plurality of parallel lines in plan view using laser ablation. As the laser for irradiation, for example, a THG (third harmonic) laser or the like can be used. The intensity of the laser beam used to form the first internal separation grooves 21 is set so that the first electrode layer 12 can be reliably insulated between the solar cell subcells 2 and damage to the resin base layer 11 can be minimized. In order to reduce damage, it is preferable to make the laser incident from the film surface side.

Considering that it is formed by laser ablation, the width of the first internal separation groove 21 is preferably 10 μm or more and 200 μm or less, and more preferably 20 μm or more and 100 μm or less. This makes it possible to ensure reliable separation between the solar cell subcells 2 and to ensure the effective area of the solar cell subcells 2.

In the first external separation groove forming step of S04, the first electrode layer 12 is linearly removed by laser ablation so as to define the outer edge of the region where the solar cell module 1 is to be formed, as shown in FIG. A first external separation groove 31 is formed. The intensity of the laser that forms the first external separation groove 31 is set higher than the intensity of the laser that forms the first internal separation groove 21, and the intensity of the laser that forms the first external separation groove 31 is set higher than that of the laser that forms the first internal separation groove 21. The adhesion of the resin base material layer 11 to the support substrate S is improved by changing the properties with heat. It is preferable to use IR rather than THG to apply more heat. Further, in order to apply more heat, it is preferable to apply a laser from the substrate side. This can prevent the resin base material layer 11 from peeling off from the support substrate S during subsequent steps and handling between steps. In order to improve adhesion, it is preferable to form a plurality of lines rather than one line.

Some of the first external separation grooves 31 may be formed in place of the first internal separation grooves 21 at the outer edge of the solar cell module 1 .

The order of the first internal isolation groove forming process and the first external isolation groove forming process may be reversed or may be performed in parallel. For example, by setting the movement path of the laser head without distinguishing between the first internal separation groove 21 and the first external separation groove 31, and sequentially adjusting the laser output, the first internal separation groove 21 and the first external separation groove 31 can be An external separation groove 31 may also be formed.

In the first charge transport layer lamination step of S05, the first charge transport layer 13 is laminated on the first electrode layer 12. It is preferable that the first charge transport layer 13 fills the inner surfaces of the first inner isolation groove 21 and the first outer isolation groove 31 . The first charge transport layer 13 is a layer that allows first polarity charges (photocarriers) generated in the photoelectric conversion layer 14 to pass, and in this embodiment, hole transport that transfers holes to the first electrode layer 12. layer (HTL). The first charge transport layer 13 may be formed by, for example, a sputtering method, a vacuum evaporation method, or the like. In addition, when the first charge transport layer 13 contains an organic substance, the first charge transport layer 13 can be formed by, for example, applying a solution of the organic substance and drying it.

The main material of the first charge transport layer 13, which is a hole transport layer, is, for example, a metal oxide such as nickel oxide (NiO) or copper oxide (Cu ₂ O), for example, PTAA (Poly(bis(4-phenyl)). Examples include organic substances such as 2,4,6-trimethylphenyl)amine) and Spiro-MeOTAD. Further, the first charge transport layer 13 is made of, for example, 2PACz ([2-(9H-Carbazol-9-yl)ethyl]phosphonic acid), MeO-2PACz ([2-(3,6-Dimethoxy-9H-carbazol-9 Self-assembled monolayer (SAM: Self-Assembled Monolayers). When the first charge transport layer 13 is formed of a self-assembled monolayer, the solvent penetrates between the support substrate S and the resin base layer 11 during coating of the material solution, preventing the resin base layer 11 from peeling off. Therefore, the effect of preventing peeling of the resin base layer 11 due to the formation of the first external separation groove 31 becomes particularly remarkable. Note that the first charge transport layer 13 may have a multilayer structure.

The thickness of the first charge transport layer 13 can vary greatly depending on its material, the structure of adjacent layers, etc., but can be, for example, 0.5 nm or more and 200 nm or less, especially when it is a self-assembled monolayer. It can be the thickness of material molecules.

In the photoelectric conversion layer lamination step of S06, the photoelectric conversion layer 14 is laminated on the first charge transport layer 13. The photoelectric conversion layer 14 absorbs incident light and generates photocarriers (electrons and holes). The photoelectric conversion layer 14 may contain a perovskite compound.

When the perovskite compound is methylammonium lead halide (MAPbX ₃ (CH ₃ NH ₃ PbX ₃ )), the photoelectric conversion layer 14 includes a lead halide (PbX ₂ ) material and halogen. It can be formed by sequentially depositing methylammonium chloride (MAX) materials and reacting thin films of these materials at reaction temperatures. For example, when the perovskite compound is methylammonium lead iodide (MAPbI _y X _(3-y) (CH _{3 NH 3} PbI _y ) material and methylammonium iodide (MAI) material in order, and the thin films of these materials are reacted at a reaction temperature. The photoelectric conversion layer 14 can also be formed, for example, by a sol-gel method in which a perovskite compound is synthesized within a liquid-phase coating film, a coating method in which a solution containing a pre-synthesized perovskite compound is applied, or the like.

The perovskite compound contained in the photoelectric conversion layer 14 includes an organic atom A containing at least one of monovalent organic ammonium ions and amidinium ions, a metal atom B generating divalent metal ions, and iodide ions. A compound represented by ABX ₃ containing a halogen atom X containing at least one of I, bromide ion Br, chloride ion Cl, and fluoride ion F can be used. Among these, when the photoelectric conversion layer 14 is formed by a vapor deposition method (dry process), methylammonium MA (CH ₃ NH ₃ ) and formamidinium FA (CH(NH ₂ ) ₂ ) are preferable as the organic atoms A; B is preferably lead Pb, and the halogen atom X is preferably at least one of iodide I, bromide ion Br, and chloride ion Cl.

Specifically, preferred perovskite compounds include methylammonium lead halide MAPbX ₃ (CH ₃ NH ₃ PbX ₃ ), MAPbI ₃ , MAPbBr ₃ , MAPbCl ₃ and the like, or formamidinium lead halide FAPbX 3 (CH (NH ₂ ) _{2PbX 3} ), FAPbI ₃ , FAPbBr ₃ , FAPbCl ₃ , and the like. Note that the halogen atom X may include a plurality of types. Examples of perovskite compounds containing iodide I and other halogen atoms X include methylammonium lead iodide MAPbI _y X _(3-y) (CH ₃ NH ₃ PbI _y X _(3-y) ), MAPbI _y Br _{( 3-y)} , etc. (y is any positive integer). Furthermore, methylammonium lead halide and formamidinium lead halide may be mixed, such as (FAPbI ₃ )z(MAPbBr3)100-z (z is any positive integer).

The thickness of the photoelectric conversion layer 14 depends on the forming material, etc., but is preferably 100 nm or more and 1000 nm or less in order to increase the light absorption rate and reduce the migration distance of the generated charges.

In the second charge transport layer lamination step of S07, the second charge transport layer 15 is laminated on the photoelectric conversion layer 14. As a result, a laminate as shown in FIG. 5 is obtained. The second charge transport layer 15 is a layer that allows charges of the second polarity generated in the photoelectric conversion layer 14 to pass through. In this embodiment, it is an electron transport layer (ETL) that transfers electrons to the second electrode layer 16. The second charge transport layer 15 may be formed, for example, by a sol-gel method, a coating method, or the like.

Examples of the main material of the second charge transport layer 15, which is an electron transport layer, include fullerene, PCBM, and the like. Examples of fullerenes include C60, C70, their hydrides, oxides, metal complexes, derivatives with added alkyl groups, etc., such as PCBM ([6,6]-Phenyl-C61-Butyric Acid Methyl Ester). It will be done. In particular, by forming the second charge transport layer 15 from a material containing fullerene containing lithium Li, electron transport efficiency can be improved. Further, the second charge transport layer 15 may have a multilayer structure.

The thickness of the second charge transport layer 15 may vary greatly depending on its material, the structure of adjacent layers, etc., but may be, for example, 3 nm or more and 50 nm or less.

In the second internal separation groove forming step of S08, the first charge transport layer 13, the photoelectric conversion layer 14, and the second charge transport layer 15 are removed in a plurality of parallel lines by laser ablation, thereby forming the structure shown in FIG. Thus, a plurality of second internal isolation grooves 22 are formed. The width of the second internal isolation groove 22 may be similar to the width of the first internal isolation groove 21, but in order to ensure the connection of the second electrode layer 16 to the first electrode layer 12, The width may be larger than 21.

In the second electrode layer lamination step of S09, the second electrode layer 16 is laminated on the second charge transport layer 15, as shown in FIG. The second electrode layer 16 is an electrode that makes a pair with the first electrode layer 12, and is a negative electrode in this embodiment. The second electrode layer 16 is laminated so as to be in contact with the first electrode layer 12 at the deep part of the second internal separation groove 22 in order to electrically connect the adjacent solar cell subcells 2 in series. The second electrode layer 16 may include a metal layer made of copper or the like, for example, in order to reduce electrical resistance. Further, the second electrode layer 16 may have a multilayer structure including a transparent conductive oxide layer or the like to improve adhesion to the second charge transport layer 15. The second electrode layer 16 may be laminated by a method such as a sputtering method, a vacuum evaporation method, or a plating method.

The lower limit of the thickness of the second electrode layer 16 is preferably 10 nm, more preferably 20 nm. On the other hand, the upper limit of the thickness of the second electrode layer 16 is preferably 200 nm, more preferably 100 nm. By setting the thickness of the second electrode layer 16 to be equal to or greater than the lower limit, current collection resistance can be made sufficiently small. Further, by setting the thickness of the second electrode layer 16 to be less than or equal to the above upper limit, it becomes easy to form the third internal separation groove 23.

In the third internal separation groove forming step S10, the first charge transport layer 13, photoelectric conversion layer 14, second charge transport layer 15, and second electrode layer 16 are removed in a plurality of parallel lines by laser ablation. Thus, a plurality of third internal isolation grooves 23 are formed. Thereby, as shown in FIG. 2, the solar cell module 1 surrounded by the ineffective area E is formed on the support substrate S. The width of the third internal separation groove 23 is the same as the width of the first internal separation groove 21 and the first external separation groove 31.

In the second external separation groove forming step of S11, at least the surface layer of the resin base layer 11, the first electrode layer 12, and the first charge transport layer are removed by laser ablation so as to define the outer edge of the region where the solar cell module 1 is to be formed. The second external separation groove 32 is formed by linearly removing the layer 13, the photoelectric conversion layer 14, the second charge transport layer 15, and the second electrode layer 16. The intensity of the laser that forms the second external separation groove 32 is set higher than the intensity of the laser that forms the third internal separation groove 23, and the intensity of the laser that forms the second external separation groove 32 is set higher than the intensity of the laser that forms the third internal separation groove 23. Preferably, it is formed so that it is reduced in size and can be easily broken. Therefore, the intensity of the laser in the second external separation groove forming process is set so that the heat input to the resin base layer 11 is greater than the heat input to the resin base layer 11 in the first external separation groove forming process. It is preferable that On the other hand, if the heat input is too high, separation becomes difficult due to alteration, so it is desirable to use THG.
In other words, the second external separation groove 32 separates the laminate of the resin base layer 11 , the first charge transport layer 13 , the photoelectric conversion layer 14 , the second charge transport layer 15 and the second electrode layer 16 from the solar cell module 1 . It is divided into an invalid area E.

In the illustrated example, the second external separation groove 32 is formed inside the first external separation groove 31, but it may be formed outside the first external separation groove 31, and the second external separation groove 32 may be formed outside the first external separation groove 31. The first external separation groove 31 may be formed at the same position to overlap with the first external separation groove 31 . Further, the second external separation groove 32 may be formed in place of the third internal separation groove 23 at the outer edge of the solar cell module 1. Thereby, the area ratio of the solar cell subcells 2 in the solar cell module 1 can be improved. Note that when the second external separation grooves 32 on both sides of the solar cell subcell 2 in the connection direction are replaced with the third internal separation grooves 23, the connection part 3 cannot be formed, but the end face of the solar cell module 1 or the resin base material layer Electrical connection can be made at the first electrode layer 12 exposed in the region where part of the electrode layer 11 is removed.

The order of the third internal isolation groove forming process and the second external isolation groove forming process may be reversed or may be performed in parallel.

In the solar cell module peeling step of S12, the resin base material layer 11 inside the second external separation groove 32 is peeled from the support substrate S, thereby separating the solar cell module 1. By applying relatively large heat to the resin base material layer 11 to form the second external separation groove 32, the resin base material layer 11 can be relatively easily removed from the support substrate S starting from the second external separation groove 32. It can be peeled off.

In the solar cell module manufacturing method according to the present embodiment including the above steps, since the first external separation groove 31 is formed, it is possible to prevent the resin base material layer 11 from peeling off from the support substrate S during the manufacturing process. The yield of battery module 1 can be improved. Moreover, in the solar cell module manufacturing method according to the present embodiment, since the second external separation groove 32 is formed, the solar cell module 1 can be selectively peeled off from the support substrate S with relative ease. Thereby, it is also possible to prevent damage to the solar cell module 1 due to application of excessive stress during peeling from the support substrate S.

Although the embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and various changes and modifications are possible. By way of example, the method for manufacturing a solar cell module according to the invention may include the step of laminating further layers such as anti-reflection coatings, protective coatings, etc.

1 Solar cell module 2 Solar cell subcell 3 Connection portion 11 Resin base material layer 12 First electrode layer 13 First charge transport layer 14 Photoelectric conversion layer 15 Second charge transport layer 16 Second electrode layer 21 First internal separation groove 22 2 Internal separation groove 23 3rd internal separation groove 31 1st external separation groove 32 2nd external separation groove E Invalid area S Support substrate

Claims (3)

A method for manufacturing a solar cell module having a plurality of solar cell subcells, the method comprising:
a step of laminating a resin base material layer on one main surface of the support substrate;
Laminating a first electrode layer on the resin base layer;
forming a first internal separation groove for cutting the first electrode layer at the boundary of the region where the solar cell subcell is to be formed by laser irradiation;
forming a first external separation groove for cutting the first electrode layer at the outer edge of the region where the solar cell module is to be formed by laser irradiation;
laminating a first charge transport layer on the first electrode layer;
Laminating a photoelectric conversion layer on the first charge transport layer;
Laminating a second charge transport layer on the photoelectric conversion layer;
forming a second internal separation groove that cuts the first charge transport layer, the photoelectric conversion layer, and the second charge transport layer at the boundary of the region where the solar cell subcell is formed by laser irradiation;
laminating a second electrode layer on the second charge transport layer;
cutting at least the second electrode layer among the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the boundary of the region where the solar cell subcell is formed by laser irradiation; 3 forming an internal separation groove;
a second external cutting of the first electrode layer, the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the outer edge of the region where the solar cell module is to be formed by laser irradiation; forming a separation groove;
Peeling the resin base material layer inside the region where the solar cell module is to be formed from the support substrate;
Equipped with
The intensity of the laser that forms the first external separation groove is higher than the intensity of the laser that forms the first internal separation groove, and the intensity of the laser that forms the second external separation groove is higher than the intensity of the laser that forms the third internal separation groove. higher than the intensity of the laser that forms the
Solar cell module manufacturing method. The solar cell module manufacturing method according to claim 1, wherein the resin of the resin base layer is altered by laser irradiation to form the first external separation groove. The module according to claim 1 or 2, wherein the step of laminating the resin base layer includes the steps of applying a polyamic acid solution to the supporting substrate and heating the coating film of the polyamic acid solution. Production method.

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