WO2018174247A1 - Solar cell module and method for producing solar cell module - Google Patents

Abstract

The purpose of this invention is to provide a solar cell module and a method for producing solar cell, with which wiring can be performed efficiently by adopting a structure in which electrodes can be positioned leading out from the edge on the same side. This invention pertains to a solar cell module having a structure wherein a plurality of cells arranged in the width direction (X2) are electrically connected to one another by wires, a conductor (14) is positioned between a first insulating member of a first substrate (3A) and a second insulating part of a second substrate (3B) positioned between cells which adjoin one another in the width direction (X2), adjoining cells are connected to one another, and conductors (14) on one end (1a) side in the width direction (X2) in the pair of adjoining sub-modules (R, R) divided in the longitudinal direction (X1) by an insulating part (18) are electrically connected to one another, forming a circuit structure.

Description

Solar cell module and method for manufacturing solar cell module

The present invention relates to a solar cell module and a method for manufacturing a solar cell module.
This application claims priority based on Japanese Patent Application No. 2017-059239 filed in Japan on March 24, 2017 and Japanese Patent Application No. 2017-068340 filed in Japan on March 30, 2017, The contents are incorporated herein.

Conventionally, a solar cell module including a dye-sensitized solar cell is generally configured by including a photoelectrode, a counter electrode, and an electrolyte solution or an electrolyte solution layer. The photoelectrode includes at least a transparent conductive layer and a semiconductor layer. In addition, it is known to be configured with a pigment (see, for example, Patent Document 1). In such a solar cell module, for example, when light is irradiated to the photoelectrode side, the dye adsorbed on the semiconductor layer absorbs light, the electrons in the dye molecule are excited, and the electrons are passed to the semiconductor. It is. 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 solar cell module as described above, there is one in which two cells C and C are arranged in series in the width direction X2 as shown in FIGS. In this case, a transparent conductive film is formed on the surface of the first base material 3A, and a plurality of band-like semiconductor layers adsorbed with a dye extending in the longitudinal direction X1 are formed on the surface of the transparent conductive film of the first base material 3A. Between the photoelectrode 11, the counter electrode 12 having a counter conductive film formed on the surface of the second substrate 3B so as to oppose the photo electrode 11, and the semiconductor layer of the photo electrode 11 and the counter electrode 12. In a state where the stopped electrolyte solution 13, the electrolyte solution 13 are sealed, and the sealing material 15 that arranges the plurality of cells C divided in the width direction X <b> 2 in a plan view is covered with the sealing material 15. A conductive material 14 that electrically connects the photoelectrode 11 and the counter electrode 12, and an insulating line 18 that extends along the width direction X2 with respect to the photoelectrode 11 and the counter electrode 12, and has a width. There is a configuration in which a plurality of cells C arranged in the direction X2 are electrically connected by serial wiring. .
In this case, both end portions in the width direction X2 are extraction electrodes (+ electrode, −electrode).
When the battery is used, the + electrode and the − electrode are in positions opposite to each other, and are located away from each other, making it difficult to perform wiring work. Therefore, one end side of the submodules R and R partitioned by the insulating line 18 is electrically connected to each other by a wiring material such as copper tape, and electricity can be taken out at the other end side. There is a structure in which electricity flows in a letter shape.

Japanese Patent No. 5702897

However, in a conventional solar cell module in which electricity flows in a U shape in plan view, a method for providing electrical connection between submodules using a wiring material requires a separate process for providing the wiring material. Therefore, there is a need for a suitable method that enables efficient wiring, and there is room for improvement in that respect.

The present invention has been made in view of the above-described problems. By adopting a structure in which an extraction electrode can be arranged from the end on the same side, a solar cell module that can be efficiently wired, and a solar cell module An object is to provide a manufacturing method.

The present invention employs the following aspects in order to solve the above-described problems and achieve the object.
(1) A solar cell module according to an aspect of the present invention includes a first electrode, a second electrode, an electrolytic solution sealed between the first electrode and the second electrode, and the electrolytic solution. A laminated structure including a plurality of sealing materials to be sealed and a plurality of insulating lines, each of which is defined by the plurality of sealing materials and the plurality of insulating lines, each of which is composed of a plurality of cells. A solar cell module having a module, wherein the first electrode is formed on a surface of a first base material having a transparent conductive film formed on the surface, and on the surface of the transparent conductive film of the first base material, A plurality of semiconductor layers adsorbed with a dye extending in one direction, and the second electrode has a second substrate on which a counter conductive film is formed so as to face the first electrode. The electrolytic solution is sealed between the semiconductor layer of the first electrode and the second electrode. Each of the plurality of sealing materials extends between the first electrode and the second electrode along the first direction so as to seal the electrolyte solution, and The structure is divided into a plurality of cells, and the insulating line extends between the first electrode and the second electrode along a second direction orthogonal to the first direction in plan view. Thus, the stacked structure is divided into a plurality of submodules each composed of a plurality of cells, and for the cells adjacent in the second direction, the first electrode of one cell and the first of the other cell Two electrodes are electrically connected by a conductive material provided in a state covered with the sealing material, whereby the plurality of cells are connected, and in each cell, the first electrode and the second electrode In order to prevent short circuit with the first group Is provided with a first insulating portion extending in the first direction in the vicinity of a position adjacent to one conductive material, and in the second base material in the vicinity of a position adjacent to the other conductive material. A second insulating portion extending in the first direction is provided, and the conductive materials at the end on the same side in the second direction are electrically connected to each other in the adjacent submodule. It is a feature.

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 the conductive members on one end side in the second direction in the submodule divided in the first direction by the insulating lines are electrically connected in series. ing. Therefore, 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 the one end side of the other submodule via a conductive material, 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.
As described above, in the solar cell module according to the present invention, the sub-modules on one end side in the second direction are electrically connected to each other by the conductive material, and the whole has a structure in which electricity flows in a U shape in plan view. Therefore, it is possible to arrange the extraction electrode (positive electrode, negative electrode) on the same side only at the other end side in the second direction, the wiring structure can be simplified, and wiring work can be easily performed.

In this embodiment, a conductive material is provided on one end side of adjacent submodules, and a simple manufacturing method for applying a conductive material to a line can be applied. It can be easily adapted to a roll system (hereinafter referred to as RtoR system). Such a RtoR method can be realized by a manufacturing process in which a conductive material is continuously arranged in the first direction. Therefore, on one end side in the second direction, for example, a copper tape is attached or soldered so as to be along the first direction in the work after the battery is created as in the prior art, and a wiring material is not required. Therefore, the manufacturing process for providing the wiring material can be omitted, and the working efficiency for manufacturing can be improved with a simple configuration.

By disposing a conductive material on one end side in the second direction, electricity can flow through both the transparent conductive film on the first base material side and the opposing conductive film on the second base material side, so the path of electricity is The electric resistance is reduced by a factor of two, the value of current flowing through these conductive films can be reduced to ½ or less, and deterioration in power generation performance can be suppressed without deteriorating battery performance.

(2) In the solar cell module according to the above (1), from the portion where the conductive material on one end side in the second direction electrically connected in the adjacent submodule is disposed, the submodule The conductive substrate width to the one end may be 2 mm or more, and the width dimension of the conductive material on the one end side may be 0.5 mm or more.

In this case, the electric resistance flowing through both the transparent conductive film on the first base material side and the opposing conductive film on the second base material side can be reduced more reliably, and the current value flowing through these conductive films can be reduced. It can be reduced to ½ or less, and a decrease in power generation performance can be suppressed without deteriorating battery performance.

(3) In the solar cell module according to (1) or (2), for each of the adjacent submodules, the first insulating portion and the second insulating portion are alternately shifted in the second direction. The first insulating portion and the second insulating portion may be extended in the first direction so that at least a part of the first insulating portion and the second insulating portion are overlapped with the insulating line. .

In the present invention, the end portions of the first insulating portion and the second insulating portion are arranged in a state where they are extended into the region of the ultrasonic fusion portion, and these end portions are arranged so as to overlap the ultrasonic fusion portion. Therefore, even if the position of the ultrasonic fusion part is formed at a position shifted in the first direction in the manufacturing process, it is possible to prevent separation between the insulating part and the ultrasonic fusion part. be able to. As a result, the cells adjacent in the second direction are reliably insulated from each other, so that leakage between these cells can be suppressed, and a decrease in power generation efficiency can be prevented, and the cells are electrically connected in series. Connected.
The first insulating portion and the second insulating portion that overlap the ultrasonic fusion portion are arranged in the first direction so as to overlap the region of the ultrasonic fusion portion as described above at a predetermined position of the transparent conductive film and the opposing conductive film. For example, it can be easily manufactured by performing a cutting process or a laser process.
Therefore, it can be easily adapted to a roll-to-roll system (hereinafter referred to as RtoR system).

(4) In the solar cell module according to (3) above, between the cells, between the adjacent submodules, the end portions of the insulating portion of one submodule and the insulating portion of the other submodule May overlap in the first direction.

In this case, since the end portions of the first insulating portion and the second insulating portion overlap each other in the first direction within the region of the ultrasonic fusion portion, the cells adjacent to each other in the second direction are surely connected. Can be insulated.

(5) The solar cell module according to (3), wherein the first insulating portion and the second insulating portion have an overlapping length with the insulating line of 0.1 mm or more and 5 mm or less. Also good.

(6) In the solar cell module according to (4), the first insulating part and the second insulating part have an overlap length with the insulating line of 0.1 mm or more and 5 mm or less. Also good.

In this case, by setting the range of the overlap length to 0.1 mm or more and 5 mm or less, a standard deviation amount in the first direction of the ultrasonic fusion part in the manufacturing method by the RtoR method (for example, 0. Even when 1 mm) occurs, the possibility that the first insulating portion and the second insulating portion are separated from the ultrasonic fusion portion is reduced, and leakage between cells adjacent in the second direction can be prevented.

(7) In the solar cell module according to the above (3), the length dimension K from the overlapping start position to the tip of the insulating line at each end of the first insulating portion and the second insulating portion K Is divided by the width L of the insulating line, and a range of 0 <K / L <1.5 may be set.

(8) In the solar cell module according to (4), the length dimension K from the overlap start position to the tip of the insulation line at each end of the first insulating portion and the second insulating portion is K. Is divided by the width L of the insulating line, and a range of 0 <K / L <1.5 may be set.

In this case, even if a standard deviation amount (for example, 0.1 mm) in the first direction of the ultrasonic fusion part occurs in the manufacturing method by the RtoR method, the first insulating part and the second insulating part are The possibility of separating from the ultrasonic fusion part is reduced, and leakage between cells adjacent in the second direction can be prevented. Since the value of K / L is smaller than 1.5, the length at which the tip of the insulating portion of one sub-module protrudes toward the other sub-module can be suppressed to a small value. This can be suppressed.
When the value of K / L exceeds 0.5, it is possible to more reliably cope with the ultrasonic wave deviation as described above, so that the ultrasonic part does not reach the first insulating part or the second insulating part. Even in the case of deviation, since the electric path flows so as to bypass the insulating portion, the resistance becomes high, and the deterioration of the battery performance can be reduced. Further, when the value exceeds 1.0, it is possible to obtain a more reliable improvement effect against the deviation of the ultrasonic fusion part as described above and the deviation not to be applied to the first insulating part or the second insulating part. The stability of performance can be increased.
The range of K / L is more preferably set in the range of 0.5 <K / L <1.5.
Further, the K / L range is more preferably set in the range of 1.0 <K / L <1.5.

(9) A method for manufacturing a solar cell module according to another aspect of 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. A transparent conductive film is formed on the surface of the material, and a plurality of semiconductor layers formed on the surface of the transparent conductive film of the first substrate and adsorbed with a dye extending in the first direction are formed. A step of forming one electrode, a step of 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, the transparent conductive film, and the counter conductive film A step of performing insulation processing in parallel to the first direction, and a plurality of cells extending in the first direction and extending in the second direction perpendicular to the first direction in plan view. A step of providing a sealing material to be arranged, and a conductive material in a state covered with the sealing material Arranging and electrically connecting the first electrode of one cell and the second electrode of the other cell with the conductive material for the cells adjacent to each other in the second direction; and the semiconductor of the first electrode A step of providing an electrolytic solution between the layer and the second electrode, a step of bonding the first electrode and the second electrode, and the second direction with respect to the first electrode and the second electrode. A first insulating line that extends along the first direction and does not partially provide the conductive material near one end in the second direction, and a second insulating line that insulates the entire second direction. Forming the first insulating line between the second insulating lines and cutting the first electrode and the second electrode at the position of the second insulating line. And a solar cell module cut by the second insulation line. For the sub-modules adjacent to each other among the sub-modules divided by the first insulation line, the ends on the same side in the second direction are electrically connected to each other by the series wiring by the conductive material. It is characterized by that.

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 configuration in which adjacent cells are electrically connected in series, and conductive materials on one end side in the width direction in a pair of adjacent submodules divided in the longitudinal direction by the first insulating line are electrically connected in series. The solar cell module can be manufactured in a continuous state in the longitudinal direction by a roll-to-roll method. Therefore, 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 second insulation line. In this way, the position and length of the conductive material, the first insulating line, and the second insulating line are appropriately set on the film substrate by the roll-to-roll method, and the wiring is set to have the set electrical characteristics (voltage, etc.) Therefore, series connection (circuit design) of cells can be freely designed.

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 past, and these solar cell modules are electrically connected to each other. Since wiring work 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.

(10) In the method for manufacturing a solar cell module according to (9), the first insulating line and the second insulating line are formed by a fusion part fused along the second direction. Alternatively, the insulating portion may be formed by closing an insulating portion insulated by the insulating processing means with a sealing material.

In this case, the first electrode and the second electrode moved in a roll-to-roll manner by a manufacturing apparatus having appropriate fusion means and insulation processing means extending along the width direction. It is possible to easily form a fusion portion that forms the insulation line and the second insulation line, or a portion where the insulation processing portion is blocked by the sealing material.

According to the solar cell module and the manufacturing method of the solar cell module of the present invention, efficient wiring can be achieved by adopting a structure in which the extraction electrode can be arranged from the end on the same side.

FIG. 1 is a perspective view showing the configuration of the solar cell module according to the first embodiment of the present invention. FIG. 2 is a plan view of the solar cell module shown in FIG. 3A is a cross-sectional view taken along line A1-A1 shown in FIG. 3B is a cross-sectional view taken along line B1-B1 shown in FIG. FIG. 4 is a perspective view showing the overall configuration of the solar cell module manufacturing apparatus. FIG. 5 is a plan view showing the manufacturing process of the solar cell module according to the present embodiment. FIG. 6 is a plan view showing a schematic configuration of the dye-sensitized solar cell according to the second embodiment of the present invention. FIG. 7 is a cross-sectional view taken along line A2-A2 shown in FIG. 1, and is a partial cross-sectional view of the dye-sensitized solar cell viewed from the longitudinal direction. FIG. 8 is a cross-sectional view taken along line B2-B2 shown in FIG. 1, and is a partial cross-sectional view of the dye-sensitized solar cell viewed from the width direction. FIG. 9 is a perspective view showing the overall configuration of the dye-sensitized solar cell manufacturing apparatus. FIG. 10 is a plan view of a dye-sensitized solar cell in the manufacturing process using the manufacturing apparatus, and shows a state in which the first base material is subjected to insulation processing. FIG. 11 is a plan view of a dye-sensitized solar cell in a manufacturing process using a manufacturing apparatus, and shows a state in which an insulating process is performed on a second base material. FIG. 12 is a plan view of a dye-sensitized solar cell in a manufacturing process using a manufacturing apparatus, and shows a state where base materials are bonded together. FIG. 13 is a plan view of a dye-sensitized solar cell in the manufacturing process using the manufacturing apparatus, and shows a state in which a fused portion is formed. FIG. 14A is a plan view showing the main parts of the insulating part and the ultrasonic fusion part. FIG. 14B is a view showing the main part of the insulating part and the ultrasonic fusion part, and is a cross-sectional view taken along line C1-C1 shown in FIG. 14A. FIG. 15 is a perspective view showing a state in which insulation processing is performed by a cutting apparatus. FIG. 16 is a view showing a state in which insulation processing is performed by the cutting apparatus, and is a front view of the cutting apparatus as viewed from the longitudinal direction. FIG. 17A is a plan view showing the main part in a state where the ultrasonic fusion part in FIG. 14A is displaced in the longitudinal direction. FIG. 17B is a view showing the main part in a state where the ultrasonic fusion part in FIG. 14B is displaced in the longitudinal direction, and is a cross-sectional view taken along line D1-D1 shown in FIG. 17A. FIG. 18A is a plan view showing the main part in a state where the ultrasonic fusion part in FIG. 14A is displaced in the longitudinal direction. FIG. 18B is a view showing a main part in a state where the ultrasonic fusion part in FIG. 14B is displaced in the longitudinal direction, and is a cross-sectional view taken along line E1-E1 shown in FIG. 18A. FIG. 19A is a plan view showing the main parts of the insulating part and the ultrasonic fusion part according to the first modification. FIG. 19B is a view showing the main parts of the insulating portion and the ultrasonic fusion portion according to the first modification, and is a cross-sectional view taken along line F1-F1 shown in FIG. 19A. FIG. 20 is a perspective view showing a schematic configuration of the dye-sensitized solar cell according to the second embodiment. FIG. 21A is a plan view showing the main parts of an insulating part and an ultrasonic fusion part according to a second modification. FIG. 21B is a view showing the main parts of the insulating portion and the ultrasonic fusion portion according to the second modification, and is a cross-sectional view taken along line G1-G1 shown in FIG. 21A. It is a top view which shows the structure of the conventional solar cell module. It is a figure which shows the structure of the conventional solar cell module, Comprising: It is the C2-C2 sectional view taken on the line shown in FIG.

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 length, width, thickness ratio, structure, and the like are not necessarily the same as actual ones, and can be changed as appropriate.

(First embodiment)
As shown in FIGS. 1 and 2, the solar cell module 1 according to the first embodiment has a first direction (hereinafter, referred to as an RtoR method) manufactured by a roll-to-roll method (to be described later) It is manufactured by cutting a film-type dye-sensitized solar cell extending in the longitudinal direction X1) into a predetermined length. The solar cell module 1 has two sections (sub-modules R and R) composed of a plurality of cells C arranged in the width direction X2 (second direction) orthogonal to the longitudinal direction X1 in a plan view. The adjacent submodules R and R are electrically connected to each other at the one end 1a side in the width direction X2.

1 and 2, the arrows indicate the flow of electricity, and the symbols + (plus) and-(minus) indicate the positive electrode and the negative electrode, respectively (the same applies to the other drawings).
Here, in the solar cell module 1, as described above, the longitudinal direction X1 is defined as the arrangement direction of the pair of submodules R and R, and the width direction X2 is defined as a direction orthogonal to the longitudinal direction X1 in plan view. Use.

As shown in FIG. 3A and FIG. 3B, the solar cell module 1 of the present embodiment includes a dye-sensitized solar cell (hereinafter referred to as a photosensitized solar cell) having a photoelectrode 11 and a counter electrode 12 provided to face the photoelectrode 11. , Simply referred to as cell C) has a structure inserted between the pair of base materials 3A and 3B. In the solar cell module 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 semiconductor of the photoelectrode 11 is formed on the conductive films 11A and 12A. The layer 11B and the catalyst layer 12B of the counter electrode 12 are electrically connected to each other and are roughly configured.

In the solar cell module 1, as described above, the photoelectrode 11 and the counter electrode 12 are disposed to face each other via the conductive material 14 having a sealing function, and are formed between the first base material 3A and the second base material 3B. A plurality (two in this case) of cells C and C are electrically connected in series along the width direction X2.

Specifically, the solar cell module 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, and a conductive material. 14, a sealing material 15, a first insulating portion 16, a second insulating portion 17, and a fused portion 18 (insulating line).
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 base material 3B, and a catalyst layer 12B stacked on the counter conductive film 12A.

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 manufacturing a thin and light flexible solar cell module 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 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 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 constituting the catalyst layer 12B is not particularly limited, and known materials can be applied. For example, carbons such as platinum and carbon nanotubes, poly (3,4-ethylenedioxythiophene) -poly (styrenesulfone) Examples thereof include conductive polymers such as (acid) (PEDOT / PSS).

The electrolytic solution 13 is sealed between the semiconductor layer 11 </ b> B of the photoelectrode 11 and the counter electrode 12.
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 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 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.

The conductive material 14 is provided in a state where both sides in the width direction X2 are 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. Are electrically connected to the counter electrode 12.

The conducting material 14 is arranged in parallel with each other between the photoelectrode 11 and the counter electrode 12, and is in contact with the photoelectrode 11 on the first base material 3A and the counter electrode 12 on the second base material 3B. As the conductive material 14, for example, at least one selected from a conductive wire, a conductive tube, a conductive foil, a conductive plate and a conductive mesh, and a conductive paste is 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.

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 include resin compositions such as polyurethane and polytetrafluoroethylene (PTFE) in which conductive fine particles (for example, fine particles of metal or alloy, fine particles of carbon black, etc.) are dispersed.

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. As shown in FIGS. 1 and 2, the solar cell module 1 has a fusion part 18 (insulation line) extending along the width direction X2 so as to define a pair of submodules R and R in the longitudinal direction X1. Is formed. 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).
Thus, in the cell C 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. Is formed.

A plurality of patterning portions (insulation treatment using a chemical insulation treatment using, for example, a cutting device provided with a blade, a laser irradiation device, an etching material, or the like) are provided at predetermined portions of the transparent conductive film 11A and the counter conductive film 12A. Insulating parts 16, 17) are provided. For example, as shown in FIGS. 3A and 3B, the first insulating portion 16 is formed to extend in the longitudinal direction X1 by the above-described insulating treatment at a position in contact with the predetermined sealing material 15 in the transparent conductive film 11A. Yes. The second insulating portion 17 is formed to extend in the longitudinal direction X1 by the above-described insulating treatment at a position in contact with the predetermined sealing material 15 in the counter conductive film 12A. And in this solar cell module 1, the transparent electroconductivity between adjacent 1st insulation parts 16 and 16 formed in the 1st base material 3A in one cell C among the cells C and C adjacent in the width direction X2 is demonstrated. The film 11A and the opposing conductive film 12A between the adjacent second insulating portions 17 and 17 formed on the second base material 3B in the other cell C are between one cell C and the other cell C. It is connected to the conductive material 14 disposed in the.

Among the submodules R and R, the first insulating portion 16 of one submodule R and the first insulating portion 16 of the other submodule R are patterned at positions shifted in the width direction X2. The same applies to the second insulating portion 17.

As shown in FIGS. 3A and 3B, the transparent conductive film 11A and the counter conductive film 12A are divided into a plurality of parts by the patterning portion. For example, as shown in FIG. 3A, in the partitioned cell C, the counter conductive film 12A of one cell C (for example, the first cell of reference C1) and the other cell C adjacent to the first cell C1 (for example, reference C2) The transparent conductive film 11A of the second cell) is electrically connected by the conductive material 14 (reference numeral 14B), and the first cell C1 and the second cell C2 are connected in series in the width direction X2. That is, in the gap between the first base material 3A and the second base material 3B, from the one end 1a to the other end side 1b in the width direction X2, (sealing material 15 / conductive material 14 (communication conductive material 14A). / Sealing material 15) / (first cell C1) / (sealing material 15 / conducting material 14 / sealing material 15) / (second cell C2) / (sealing material 15) in order. C1 and C2 are arranged in series.

The fused portion 18 extends from the other end 1b toward the one end 1a side in the width direction X2 of each of the submodules R and R with the communication conducting material 14A on the one end 1a side remaining. Thereby, each photoelectrode 11 and the counter electrode 12 in the submodules R and R constitute an electric circuit electrically connected by the communication conductor 14A.
Here, of the adjacent submodules R and R, the one that takes the other end 1b of the photoelectrode 11 as an extraction electrode (positive electrode) is called a first submodule R1 (FIG. 3A), and the other end 1b of the counter electrode 12 is called the other end 1b. What is taken as an extraction electrode (negative electrode) is referred to as a second submodule R2 (FIG. 3B).

The photoelectrode 11 in the second submodule R2 is cut out at the other end 1b in the width direction X2 of the first base material 3A. That is, the first base material 3A in the first submodule R1 projects outward from the sealing material 15 on the other end 1b side in the width direction X2, and this projecting portion becomes the extraction electrode (positive electrode 31). And as shown to FIG. 3A, 3 A of 1st base materials in 2nd submodule R2 are cut | disconnected in the position of the sealing material 15 by the side of the other end 1b.

As shown in FIGS. 3A and 3B, in the first submodule R1 and the second submodule R2, the position overlapping the predetermined sealing material 15 in the transparent conductive film 11A of the photoelectrode 11 is along the longitudinal direction X1. The first insulating portion 16 that extends and divides the transparent conductive film 11A in the width direction X2 is formed. In the first submodule R1, the first insulating portion 16 is formed on the transparent conductive film 11A that overlaps the sealing material 15 that is close to the other end 1b side of the conductive material 14. In the second submodule R2, the first insulating portion 16 is formed on the transparent conductive film 11A that overlaps the sealing material 15 that is close to the other end 1b side of the electrolytic solution 13.

The counter electrode 12 in the first submodule R1 is cut out at the other end 1b in the width direction X2 of the second base material 3B. That is, the second base material 3B in the second submodule R2 projects outward from the sealing material 15 on the other end 1b side in the width direction X2, and this projecting portion becomes the extraction electrode (negative electrode 32). Then, as shown in FIG. 3B, the second base material 3A in the first submodule R1 is cut at the position of the sealing material 15 on the other end 1b side.

As shown in FIGS. 3A and 3B, in the first submodule R and the second submodule R, the position overlapping the predetermined sealing material 15 in the counter conductive film 12A of the counter electrode 12 is along the longitudinal direction X1. A second insulating portion 17 that extends and divides the opposing conductive film 12A in the width direction X2 is formed. In the first submodule R, the second insulating portion 17 is formed on the opposing conductive film 12A that overlaps the sealing material 15 that is close to the other end 1b side of the electrolytic solution 13. In the second submodule R, the second insulating portion 17 is formed on the opposing conductive film 12A that overlaps the sealing material 15 that is close to the other end 1b side of the conductive material 14.

The solar cell module 1 according to the present embodiment configured as described above has the first insulating portion of the first base material 3A disposed between the cells C adjacent to each other in the width direction X2 of the first base material 3A. 16 and the second insulating part 17 of the second base material 3B, the conductive material 14 is disposed, and the cells C and C adjacent in the width direction X2 are electrically connected in series, and the first insulating line 18A The communication members 14A on the one end 1a side in the width direction X2 between the submodules R1 and R2 divided in the longitudinal direction X1 are electrically connected in series. Then, the electricity E flows from the other end 1b side in the width direction X2 of the first submodule R1 to the one end 1a side, and the electricity E on the one end 1a side places the conductive material 14 on the one end 1a side of the other second submodule R2. In addition, the circuit configuration has a series structure in which electricity E flows from the one end 1a side to the other end 1b side in the width direction X2 of the first submodule R1.
As shown in FIG. 1, in the first sub-module R1 and the second sub-module R2, the directions of the electricity E flowing in the first direction are opposite to each other in the width direction X2, and both of the electricity extraction electrodes (positive electrode 31 and negative electrode 32) are wide. It arrange | positions at the one end 1a side of the direction X2.

In the solar cell module 1 according to the present embodiment, as shown in FIGS. 1 to 3, the communication member 14A on the one end 1a side in the width direction X2 of the first base material 3A and the second base material 3B is disposed. The conductive substrate width D1 from the portion to the one end 1a is set to 2 mm or more, and the width dimension D2 of the communication conductive material 14A on the one end 1a side is set to 0.5 mm or more.

Next, a method for manufacturing the solar cell module 1 of the present embodiment and a method for manufacturing using the RtoR manufacturing apparatus 4 will be specifically described with reference to the drawings.
As shown in FIG. 4, in the method for manufacturing the solar cell module 1, a transparent conductive film 11A is formed on the surface of the first base 3A, and a dye extending in the longitudinal direction X1 is formed on the surface of the transparent conductive film 11A. A step of forming a photoelectrode 11 in which a plurality of adsorbed strip-shaped semiconductor layers 11B are formed, and a counter electrode 12 in which a counter conductive film 12A is formed on the surface of the second substrate 3B so as to face the photoelectrode 11 A forming step, an insulating process for forming the first insulating portion 16 and the second insulating portion 17 extending parallel to the longitudinal direction X1 with respect to the transparent conductive film 11A and the counter conductive film 12A, and a width direction in a 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 A step of providing an electrolyte 13, a step of bonding the photoelectrode 11 and the counter electrode 12, a done.

Specifically, in the semiconductor electrode forming portion (not shown), for example, by using an aerosol deposition (AD) method, TiO 2 is laminated on the first base material 3A on which the transparent conductive film 11A is formed. After the semiconductor layer 11B is formed at an interval in the width direction X2, the photoelectrode 11 is formed by adsorbing a dye on the semiconductor layer 11B by a general method. In the counter electrode forming section (not shown), the counter electrode 12 is formed by stacking platinum (Pt) on the second substrate 3B on which the counter conductive film 12A is formed by sputtering to form the catalyst layer 12B. To do.

In the first base material 3A that forms the photoelectrode 11 manufactured in the semiconductor electrode formation portion and moves in the first movement direction P1, the semi-circle is formed at the position between the semiconductor layer 11B and the semiconductor layer 11B in the cutting device 41. Insulation processing is performed to form the first insulating portion 16 extending parallel to the longitudinal direction X1 by the rotation of the blade 52. At this time, the first insulating portion 16 is formed with a regular insulating pattern that is alternately displaced in the width direction X2 at regular intervals (the length in the longitudinal direction X1 of the submodule R). By alternately arranging 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, after processing the first insulating portion 16 of the photoelectrode 11, the sealing material 15 is applied to the photoelectrode 11 formed in a predetermined region of the first base 3 </ b> A by the sealing material coating portion 42. 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, in the cutting device 47, the position between the catalyst layer 12B and the catalyst layer 12B Thus, an insulation 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. At this time, a regular insulating pattern is formed in the second insulating portion 17 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). 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 unit 45, the sealing material 15 is cured by a curing processing unit (not shown), and the first base material 3A and the second base material 3B that have been subjected to insulation processing are overlapped. By passing the pair of laminating rollers 45A and 45B, both base materials 3A and 3B are bonded and bonded. At this time, as shown in FIGS. 3A and 3B, 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 displaced in the width direction X <b> 2 in the bonded state. As a result, a plurality of cells C 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. 4, 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. A fused portion 18 (18A, 18B) 18A extending along the width direction X2 is formed and divided into a plurality of submodules R, R,.

At this time, in the portion excluding the positive electrode 31 and the negative electrode 32 of the photoelectrode 11 and the counter electrode 12, the first fused portion 18A (first insulation) that does not partially insulate the conductive material 14 on the one end 1a side in the width direction X2. Line) and second fused portions 18B (second insulation lines) that are insulated over the entire width direction X2 are alternately formed in the longitudinal direction X1. Thereafter, the photoelectrode 11 and the counter electrode 12 are cut at the position of the second fused portion 18B. A two-dot chain line denoted by reference numeral 18L in FIG. 5 indicates a cutting line in the second fused portion 18B.
And the solar cell module cut | disconnected by the 2nd melt | fusion part 18B is the conduction | electrical_connection materials 14 by the side of the one end 1a of the width direction X2 of a pair of adjacent submodules R1 and R2 divided | segmented by the 1st melt | fusion part 18A. Are manufactured in an electrically connected state.

It is also possible to improve manufacturing efficiency by simultaneously performing the insulation processing of the first fused portion 18A and the second insulating portion 18B.
The insulating process of the fused portion 18 in which the photoelectrode 11 and the counter electrode 12 are fused along the width direction X2 is performed by the first insulating portion 16 of the first base material 3A and the second insulating portion 17 of the second base material 3B. It may be performed at the same time, thereby improving the production efficiency.

Next, the effect | action of the solar cell module 1 mentioned above and the manufacturing method of the solar cell module 1 solar cell module 1 is demonstrated in detail using drawing.
In the solar cell module 1 according to the present embodiment, as shown in FIGS. 1 and 2, the electricity E created for each cell C flows from the other end 1b of the first submodule R toward the one end 1a, The second submodule R flows from one end 1a to the other end 1b. Further, since the one end 1a of the first submodule R and the one end 1a of the second submodule R are connected by the communication conducting material 14A, the electricity E of the one end 1a of the first submodule R is connected to the communication conducting material 14A. Flows toward the second submodule R. As described above, the solar cell module 1 has a configuration in which the sub-modules R and R are electrically connected to each other at the one end 1a side and the electricity E can be taken out from the other end 1b side. That is, the entire structure is such that electricity E flows in a U shape in plan view, and the extraction electrodes (positive electrode 31 and negative electrode 32) can be on the same side (the other end 1b) in the width direction X2, thus simplifying the wiring structure. And wiring work can be easily performed.

The present embodiment has a simple structure in which the conductive material 14 is provided on the one end 1a side of the adjacent second submodules R and R and the communication conductive material 14A is provided. For this reason, since the conductive material 14 is simply applied by line coating, it can be easily applied to the RtoR method.
In this case, since it can be realized by a manufacturing process in which the communication conducting material 14A is continuously arranged in the longitudinal direction X1 by the RtoR method, it is not necessary to add a new work process. Therefore, on one end 1a side in the width direction X2, for example, a copper tape is attached or soldered so as to follow the longitudinal direction X1 in the work after creating the battery as in the above-described embodiment. It becomes unnecessary. Therefore, the manufacturing process for providing the wiring material can be omitted, and the working efficiency for manufacturing can be improved with a simple configuration.

By disposing the conductive material 14 (communication conductive material 14A) in the second region M2 described above, electricity is supplied to both the transparent conductive film 11A on the first base material 3A side and the opposing conductive film 12A on the second base material 3B side. Since the flow of electricity E is doubled, the electric resistance is reduced, the current value flowing through these conductive films 11A and 12A can be reduced to ½ or less, and the battery performance is not deteriorated. , It is possible to suppress a decrease in power generation performance.
In order to make such a current value ½ or less, the conductive base material width D1 from the portion where the communication conductive material 14A is disposed to the one end 1a as in the present embodiment is 2 mm or more, and the one on the one end 1a side. It is preferable that the width D2 of the communication conductive material 14A is 0.5 mm or more.

Thus, in the solar cell module 1 of this Embodiment, the extraction electrode of the positive electrode 31 and the negative electrode 32 can be arrange | positioned at the other end 1b side of the width direction X2, and the electrodes 31 and 32 are arrange | positioned at a short distance. As a result, the wiring structure is simple, and the wiring work can be easily performed. Therefore, as in the case where the extraction electrodes are provided on both the left and right sides in the width direction X2, it is possible to eliminate the problem that the electrodes are separated from each other and difficult to wire.

Next, another embodiment of the solar cell module of the present invention will be described with reference to the accompanying drawings. The same reference numerals are used for the same or similar members and parts as those of the first embodiment described above. A description is omitted, and a configuration different from the first embodiment will be described.

(Second Embodiment)
As shown in FIG. 6, the dye-sensitized solar cell 101 (solar cell module) of the second embodiment is manufactured by a roll-to-roll method (hereinafter referred to as an RtoR method) described later. It is manufactured by cutting a film-type dye-sensitized solar cell that extends long in one direction (longitudinal direction X1) into a predetermined length.

In FIG. 6, arrows indicate the flow of electricity (same as in FIG. 7), and symbols + (plus) and − (minus) indicate a positive electrode and a negative electrode, respectively (the same applies to other figures).
Here, in the dye-sensitized solar cell 101, as described above, the longitudinal direction X1 is defined as the arrangement direction of the submodules R, and the width direction X2 is defined as a direction orthogonal to the longitudinal direction X1 in plan view.

As shown in FIG. 7, the dye-sensitized solar cell 101 according to the second embodiment is a dye-sensitized solar cell having a photoelectrode 111 and a counter electrode 112 provided to face the photoelectrode 111 ( Hereinafter, cell C) has a structure inserted between a pair of base materials 103A and 103B. In the dye-sensitized solar cell 101, conductive films 111A and 112A having inner surfaces of the pair of base materials 103A and 103B are formed, and the photoelectrode 111 is formed on the conductive films 111A and 112A. The semiconductor layer 111 </ b> B and the catalyst layer 112 </ b> B of the counter electrode 112 are electrically connected to each other and are schematically configured.

In the dye-sensitized solar cell 101, as described above, the photoelectrode 111 and the counter electrode 112 are arranged to face each other via the conductive material 114 having a sealing function, and between the first base material 103A and the second base material 103B. A plurality of formed cells C, C,... Are electrically connected in series along the width direction X2.

Specifically, the dye-sensitized solar cell 101 includes a first base material 103A, a second base material 103B, a photoelectrode 111 (first electrode), a counter electrode 112 (second electrode), an electrolytic solution 113, A conductive material 114, a sealing material 115, a first insulating part 116, a second insulating part 117, and an ultrasonic fusion part 118 are provided.
The photoelectrode 111 includes a transparent conductive film 111A stacked on the first base material 103A and a porous semiconductor layer 111B stacked on the transparent conductive film 111A. The counter electrode 112 includes a counter conductive film 112A stacked on the second base material 103B, and a catalyst layer 112B stacked on the counter conductive film 112A.

Since the materials of the first base material 103A and the second base material 103B are the same as those in the first embodiment, detailed description thereof is omitted here.

The photoelectrode 111 is a band-shaped semiconductor layer in which a transparent conductive film 111A is formed on the surface of the first base material 103A, and a dye extending in the longitudinal direction X1 is adsorbed on the surface of the transparent conductive film 111A of the first base material 103A. A plurality of 111B are formed. A counter conductive film 112 </ b> A is formed on the counter electrode 112 so as to face the photoelectrode 111.

Since the types and materials of the transparent conductive film 111A and the counter conductive film 112A are the same as those in the first embodiment, detailed description thereof is omitted here.

The electrolytic solution 113 is sealed between the semiconductor layer 111 </ b> B of the photoelectrode 111 and the counter electrode 112.
Since the electrolytic solution 113 is the same as that of the first embodiment, detailed description thereof is omitted here.

The sealing material 115 is configured to seal the electrolytic solution 113 and to arrange a plurality of cells C divided in the width direction X2. The sealing material 115 is a non-conductive member that can bond the opposing first base material 103A and second base material 103B and seal the cell C formed between the base materials 103A and 103B. If it is, it will not be restrict | limited in particular.

Since the material of the sealing material 115 is the same as that of the first embodiment, detailed description thereof is omitted here.

The conductive material 114 is provided in a state where both sides in the width direction X2 are covered with the sealing material 115, and is in direct contact with the transparent conductive film 111A of the photoelectrode 111 and the counter conductive film 112A of the counter electrode 112. And the counter electrode 112 are electrically connected.

The conducting material 114 is disposed in parallel between the photoelectrode 11 and the counter electrode 112, and is in contact with the photoelectrode 111 on the first base material 103A and the counter electrode 112 on the second base material 103B. Since the conductive material 114 is the same as that of the first embodiment, a detailed description thereof is omitted here.

Since the conductive material used for the conductive material 114 is the same as that of the first embodiment, detailed description thereof is omitted here.

Sealing materials 115 and 115 are disposed on both sides of the conducting material 114 in the width direction X <b> 2, and the photoelectrode 111 and the counter electrode 112 are bonded by the conducting material 114 and the sealing material 115. As shown in FIGS. 6 and 8, the dye-sensitized solar cell 101 has ultrasonic fusion extending along the width direction X2 so as to define a plurality of submodules R, R,... In the longitudinal direction X1. A portion 118 (insulation line) is formed. The ultrasonic fusion part 118 is formed by insulation and adhesion by means such as ultrasonic fusion (see ultrasonic fusion means 146 shown in FIG. 9).
In this way, in the cells C each having the semiconductor layer 111B, the electrolytic solution 113 is liquid-tightly sealed in the gap in the thickness direction formed between the photoelectrode 111 and the counter electrode 112 by the conductive material 114. It is formed in the state.

A plurality of patterning portions (first insulating portion 116, second insulating portion) that are insulated by using, for example, a cutting device equipped with a cutting tool, a laser irradiation device, or the like are provided at predetermined positions of the transparent conductive film 111A and the counter conductive film 112A. Part 117). For example, as shown in FIG. 7, the first insulating portion 116 is formed to extend in the longitudinal direction X1 by the above-described insulation treatment at a position in contact with the predetermined sealing material 115 in the transparent conductive film 111A (FIG. 7). 10). The second insulating portion 117 is formed to extend in the longitudinal direction X1 by the above-described insulating treatment at a position in contact with the predetermined sealing material 115 in the counter conductive film 112A (see FIG. 11). And in this dye-sensitized solar cell 101, the adjacent 1st insulation part 116 formed in the 1st base material 103A in one cell C (C1 of FIG. 7) among the cells C and C adjacent in the width direction X2. , 116 between the transparent conductive film 111A and the opposing conductive film 112A between the adjacent second insulating parts 117 and 117 formed on the second base material 103B in the other cell C (C2 in FIG. 7). Is connected to a conductive material 114 disposed between one cell C1 and the other cell C2.

As shown in FIG. 10, the first insulating portion 116 of one submodule R of the submodules R and R and the first insulating portion 116 of the other submodule R are patterned at positions shifted in the width direction X2. Has been. The same applies to the second insulating portion 117 shown in FIG.

As shown in FIGS. 12 and 13, the first insulating portion 116 and the second insulating portion 117 are insulated by the ultrasonic fusion portion 118 between the cells C and C arranged in the width direction X1. Each module R is disposed at a position that is alternately shifted across the conductive material 114 in the width direction X2. And as shown to FIG. 14A and FIG. 14B, between the cells C and C, the edge part 116a of the 1st insulation part 116 and the 2nd insulation part 117 which are formed in each of the adjacent submodules R and R between. The end portion 117 a is arranged so as to extend into the region of the ultrasonic fusion portion 118 in the longitudinal direction X 1 so as to overlap the ultrasonic fusion portion 118. Further, between the cells C and C, the end portions 116a and 117a of the adjacent submodules R and R adjacent to each other between the one insulating portion 116 and 117 and the other insulating portion 116 and 117 are in the longitudinal direction. It overlaps with X1.
The first insulating portion 116 and the second insulating portion 117 have an overlapping length K (FIG. 14A) with the ultrasonic fusion portion set to be 0.1 mm or more and 5 mm or less.

Next, a manufacturing method using the RtoR method in the dye-sensitized solar cell 101 according to the second embodiment will be specifically described with reference to the drawings.
As shown in FIG. 9, in the method of manufacturing the dye-sensitized solar cell 101, first, a transparent conductive film 111A is formed by using, for example, an aerosol deposition (AD) method in a semiconductor electrode forming portion (not shown). After laminating TiO2 on the first base material 103A formed to form the semiconductor layer 111B at an interval in the width direction X2, a dye is adsorbed on the semiconductor layer 111B by a general method, thereby producing a photoelectrode 111 is formed. In the counter electrode forming portion (not shown), platinum (Pt) is stacked on the second substrate 103B on which the counter conductive film 112A is formed by a sputtering method to form the catalyst layer 112B, thereby forming the counter electrode 112. To do.

In the first base material 103A that forms the photoelectrode 111 produced in the semiconductor electrode formation portion and moves in the first movement direction P1, the semi-circle is formed at a position between the semiconductor layer 111B and the semiconductor layer 111B in the cutting apparatus 150. Insulation processing is performed to form the first insulating portion 116 extending parallel to the longitudinal direction X1 by the rotation of the blade 152. At this time, as shown in FIG. 10, 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 arranging 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.

Here, as shown in FIG.15 and FIG.16, the 1st insulation process part 141 employ | adopts the incision processing apparatus 150 provided with the several semicircle blade 152 in this Embodiment. The cutting device 150 includes a rotary shaft 151 provided so as to be rotatable about an axis O1, and a semicircular blade 152 arranged around the rotary shaft 151 at a predetermined interval in the direction of the axis O1. The axis O1 direction of the rotating shaft 151 is arranged in the width direction X2.
The semicircular blade 152 is continuously provided in a range of 180 ° along the circumferential direction of the outer peripheral surface of the rotating shaft 151, and is disposed in a predetermined half-circumferential region of the entire circumference as viewed from the axis O1 direction. The first semicircular blade 152A and the second semicircular blade 152B disposed in a region of another semicircular portion where the first semicircular blade 152A is not disposed. The plurality of first semicircular blades 152A includes a plurality of insulating portions 116 of one adjacent submodule R among the submodules R of the first base material 103A defined in the longitudinal direction X1 by the ultrasonic fusion portion 118. Are formed at the same time. The plurality of second semicircular blades 152B simultaneously form a plurality of insulating portions 116 in the other region of the adjacent submodules R. The circumferential length (outer circumferential length) of the semicircular blade 152 is set so as to coincide with the length in the longitudinal direction X1 of the insulating portion 116 to be insulated in the submodule R.

The interval between the first semicircular blades 152A adjacent in the axis O1 direction and the interval between the second semicircular blades 152B adjacent in the axis O1 direction are set to be equal. The first semicircular blade 152A and the second semicircular blade 152B are not arranged on the same circumference, but are provided at positions shifted in the direction of the axis O1.
The semicircular blades 152 (152A, 152B) are grooved only in the conductive films 111A, 112A when rotated together with the rotating shaft 151 with respect to the surfaces of the base materials 103A, 103B on which the conductive films 111A, 112A are formed. Form a notch. For example, the conductive films 111A and 112A are set so that cuts are formed in the thickness direction, and even if a part of the base materials 103A and 103B is cut in the thickness direction, the whole is not cut.
The interval in the axis O1 direction of the semicircular blade 152, the circumferential length, and the shift amount in the axis O1 direction of the first semicircular blade 152A and the second semicircular blade 152B can be changed as appropriate according to the setting of the insulating portion 116. .

Next, after processing the first insulating portion 116 of the photoelectrode 111, the sealing material 115 is applied to the photoelectrode 111 formed in a predetermined region of the first base material 103 </ b> A by the sealing material application portion 142. At this time, the semiconductor layer 111B is applied so that the sealing material 115 is not covered.
And after arrange | positioning the electrically conductive material 114 between the sealing materials 115 in the electrically conductive material arrangement | positioning part 143, in the electrolyte solution application part 144, the electrolyte solution 113 in the uncoated area | region of the sealing material 115 in the 1st base material 103A. Apply.

On the other hand, in the 2nd base material 103B which forms the counter electrode 112 produced in the counter electrode formation part and moves to the 2nd moving direction P2, in the cutting device 150, the position between the catalyst layer 112B and the catalyst layer 112B Thus, an insulating process for forming the second insulating portion 117 extending in parallel with the longitudinal direction X1 is performed by the rotation of the semicircular blade 152 (see FIGS. 15 and 16). At this time, as shown in FIG. 11, the second insulating portion 117 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 145, the sealing material 115 is cured by a curing processing portion (not shown), and the first base material 103 </ b> A and the second base material 103 </ b> B that have been subjected to insulation processing are overlapped. By passing the pair of laminating rollers 145A and 145B, both base materials 13A and 13B are bonded and bonded together. At this time, as shown in FIG. 12, the first insulating portion 116 of the first base material 103 </ b> A and the second insulating portion 117 of the second base material 103 </ b> B are shifted in the width direction X <b> 2 in the bonded state, As a result, the plurality of cells C divided and arranged in the width direction X2 through the conductive material 114 (see FIG. 7) are electrically connected in series.

Next, as shown in FIGS. 9 and 13, after bonding, the ultrasonic fusion means 146 ultrasonicates the first base material 103 </ b> A and the second base material 103 </ b> B with a certain interval in the longitudinal direction X <b> 1. An ultrasonic fusion bonding portion 118 that is fused by vibration and extends along the width direction X2 is formed and divided into a plurality of submodules R, R,.

Further, as shown in FIG. 6, the wiring material 119 is attached to both ends of the bonded base materials 103A and 103B in the width direction X2 along the longitudinal direction X1 by, for example, copper tape or soldering. At this time, the wiring member 119 is disposed in a state where the ends of the ultrasonic fusion portions 118 arranged in the longitudinal direction X1 are alternately covered in the width direction X2. This makes it possible to manufacture the dye-sensitized solar cell 101 in which the cells C of the submodules R connected in series are connected in series, and electricity is alternated in the width direction X2 for each submodule R (arrow E in FIG. 6). Direction). The dye-sensitized solar cell 101 can be cut along the ultrasonic fusion part 118, and is cut at a position of any desired length to produce the dye-sensitized solar cell 101 having a desired length. be able to.

Next, the effect | action of the dye-sensitized solar cell 101 mentioned above is demonstrated in detail using drawing.
In the dye-sensitized solar cell 101 according to the present embodiment, as shown in FIGS. 14A and 14B, the end portions 116 a and 117 a of the first insulating portion 116 and the second insulating portion 117 are within the region of the ultrasonic fusion portion 118. 17A and 17B, the end portions 116a and 117a are disposed so as to overlap the ultrasonic fusion portion 118, and therefore the position of the ultrasonic fusion portion 118 in the manufacturing process is shown in FIGS. 17A and 17B. As shown in FIGS. 18A and 18B, even when formed at a position shifted in the longitudinal direction X1, it is possible to prevent the insulation portions 116 and 117 and the ultrasonic fusion portion 118 from being separated. Can do.

FIG. 17A and FIG. 17B show a case where, in the manufacturing process, the ultrasonic weld 118 is insulated at a position shifted to the left side of the paper with respect to the normal center axis O. FIG. 18A and FIG. 18B show a case where, in the manufacturing process, the ultrasonic fusion part 118 is insulated at a position shifted to the right side of the paper with respect to the normal center axis O. As described above, in the present embodiment, even when the ultrasonic fusion part 118 is displaced due to a construction error, the end parts 116 a and 117 a of the first insulation part 116 and the second insulation part 117 overlap with the ultrasonic fusion part 118. Can be maintained.

Therefore, since the cells C and C adjacent in the width direction X2 are reliably insulated from each other, it is possible to suppress the occurrence of leakage between the cells C and C and to prevent a decrease in power generation efficiency. C and C are electrically connected in series.
In the present embodiment, the end portions 1116a and 117a of the first insulating portion 116 and the second insulating portion 117 overlap with each other in the longitudinal direction X1 within the region of the ultrasonic fusion portion 118, so that they are adjacent to the width direction X2. The matching cells C and C can be reliably insulated from each other.

As described above, in the present embodiment, adjacent submodules R and R are electrically connected in series via the wiring member 119 (see FIG. 6) on one end side in the width direction X2. In one submodule R, electricity flows from the other end side in the width direction X2 to one end side, and electricity on one end side flows to one end side of the other submodule R via the wiring member 119, and the other submodule R The circuit configuration in which electricity flows from one end side to the other end side in the width direction X2 can be realized.

As described above, the first insulating portion 116 and the second insulating portion 117 that overlap the ultrasonic fusion portion 118 overlap the region of the ultrasonic fusion portion 118 at a predetermined position of the transparent conductive film 111A and the opposing conductive film 112A. It can be easily manufactured by performing, for example, cutting or laser processing along the longitudinal direction X1. Therefore, it can be easily adapted to the RtoR method.

In the present embodiment, as shown in FIG. 14A, the range of the overlapping length K between the insulating portions 116 and 117 and the ultrasonic fusion portion 118 may be set to 0.1 mm or more and 5 mm or less. By setting the numerical value in such a range, even when a standard deviation amount (for example, 0.1 mm) in the longitudinal direction X1 of the ultrasonic fused portion 118 occurs in the manufacturing method by the RtoR method, the first insulating portion 116 is used. In addition, the second insulating portion 117 is not separated from the ultrasonic fused portion 118, and leakage between the cells C and C adjacent in the width direction X2 can be prevented.

Furthermore, as shown in FIGS. 19A and 19B, the length dimension K from the overlapping start positions 116b and 117b to the tips 116c and 117c at the respective ends of the insulating portions 116 and 117 with the ultrasonic fusion portion is set. The value divided by the width dimension L of the ultrasonic fused portion 118 may be set to be in the range of 0 <K / L <1.5. The range of K / L is preferably set in the range of 0.5 <K / L <1.5, and more preferably in the range of 1.0 <K / L <1.5. More preferred.
In this case, even if a standard deviation amount (for example, 0.1 mm) in the longitudinal direction X1 of the ultrasonic fused portion 118 occurs in the manufacturing method by the RtoR method, the first insulating portion 116 and the second insulating portion. The possibility that the 117 is separated from the ultrasonic fusion part 118 is reduced, and leakage between the cells C and C adjacent to each other in the width direction X2 can be prevented. Since the value of K / L is smaller than 1.5, the length at which the tips 116c and 117c of the insulating portions 116 and 117 of one submodule R protrude to the other submodule R side on the opposite side can be kept small. Therefore, it can suppress becoming an electrical resistance in the other submodule R. When the value of K / L exceeds 0.5, it is possible to more reliably cope with the ultrasonic wave deviation as described above, and the ultrasonic wave part becomes the first insulating part 116 or the second insulating part 117. Even in a case where the deviation is not so great, the electric path flows so as to bypass the insulating portions 116 and 117, so that the resistance becomes high and the deterioration of the battery performance can be reduced.

K / L may be in a range smaller than 2.0, but if this value is 1.5 or more and less than 2.0, the protruding length toward the opposite sub-module R side as described above becomes large. As a result, the electrical resistance increases and the performance decreases.
And in the 1st modification shown in Drawing 19A and Drawing 19B, since K / L exceeds 1.0, the shift of ultrasonic fusion part 118 as mentioned above, the 1st insulation part 116, or the 2nd insulation A more reliable improvement effect can be expected even with respect to a deviation that does not affect the portion 117, and the stability of the manufactured battery performance can be enhanced.

In the present embodiment, as shown in FIG. 14A, the overlap (overlap length l) in the longitudinal direction X1 of the first insulating portion 116 of one submodule R and the second insulating portion 117 of the other submodule is measured by ultrasonic waves. The value divided by the width dimension L of the fused part 118 may be set to be in the range of 0 <K / L <1.5.

(Third embodiment)
In the dye-sensitized solar cell 101A according to the second embodiment shown in FIG. 20, 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. The battery structure is such that adjacent submodules R and R are electrically connected to each other on the one end 101a side in the width direction X2.
The ultrasonic fusion part 118 extends from the other end 1b toward the one end 101a in the width direction X2 in each of the submodules R and R with the wiring member 119 on the one end 101a side left. Thereby, each photoelectrode 111 and the counter electrode 112 in the submodules R and R constitute an electric circuit electrically connected by the wiring member 119.

In the third embodiment, the submodules R and R on the one end 1a side in the longitudinal direction X1 are electrically connected to each other by the wiring member 119, and the ultrasonic fusion portion 118 that divides the pair of submodules R and R is used. The end portions 116a and 117a of the insulating portions 116 and 117 of each submodule R are overlapped with the region. Therefore, in each submodule R, the cells C and C adjacent to each other in the width direction X2 can be reliably insulated, and a structure in which electricity E flows in a U shape as a whole can be realized. Therefore, in this embodiment, it is possible to arrange the extraction electrodes (positive electrode 131, negative electrode 132) on the same side only on the other end 101b side in the width direction X2, simplify the wiring structure, and facilitate the wiring work. It can be carried out.

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 first embodiment described above, the number of cells provided in each of the submodules R1 and R2 is two. However, the number of cells is not limited to this and can be set to an appropriate number. .
In the first embodiment, the conductive base material width D1 from the portion where the communication conductive material 14A is arranged to the one end 1a is 2 mm or more, and the width dimension D2 of the communication conductive material 14A on the one end 1a side is 0.5 mm or more. Although it is set, it is not limited to such dimensions.

In the second embodiment described above, between the cells C and C, of the adjacent submodules R and R, one insulating portion 116 and 117 and the other insulating portion 116 and 117 on the side close to each other. Although the parts 116a and 117a are configured to overlap with each other in the longitudinal direction X1, it is not limited to such a structure. For example, as in the second modification shown in FIGS. 21A and 21B, the end portions 116a and 117a may be separated from each other in the longitudinal direction X1 and do not overlap.
The point is that the end portions 116a and 117a of the first insulating portion 116 and the second insulating portion 117 are extended to the ultrasonic fusion portion 118 in the longitudinal direction X1 so as to overlap the ultrasonic fusion portion 118. It is only necessary to be arranged in. Then, the length dimension in the region (the overlapping length K between the insulating portions 116 and 117 and the ultrasonic fusion portion 118) is also set to the setting range (0.1 mm or more and 5 mm or less) of the above-described embodiment. There is no limitation.

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

DESCRIPTION OF SYMBOLS 1 Solar cell module 1a, 101a One end 1b, 101b The other end 4, 104 Manufacturing apparatus 11, 111 Photoelectrode (1st electrode)
11A, 111A Transparent conductive film 11B, 111B Semiconductor layer 12, 112 Counter electrode (second electrode)
12A, 112A Opposing conductive film 12B, 112B Catalyst layer 3A, 103A First base material 3B, 103B Second base material 13, 113 Electrolytic solution 14, 114 Conductive material 15, 115 Sealing material 16, 116 First insulating portion 17, 117 Second insulating portion 117A Third insulating portion 117B Non-insulating portion 18 Fused portion (insulating line)
18A First fusion part (first insulation line)
18B Second fusion part (second insulation line)
118 Ultrasonic weld (insulation line)
101, 101A Dye-sensitized solar cell (solar cell module)
C cell K overlapping portion R between insulating parts R sub-module X1 longitudinal direction (first direction)
X2 width direction (second direction, width direction of first substrate and second substrate)

Claims (10)

1. A first electrode, a second electrode, an electrolyte solution sealed between the first electrode and the second electrode, a plurality of sealing materials for sealing the electrolyte solution, and a plurality of insulating lines; A solar cell module having submodules each composed of a plurality of cells, defined by the plurality of sealing materials and the plurality of insulation lines,
   The first electrode adsorbs a first base material having a transparent conductive film formed on the surface thereof, and a dye extending in the first direction formed on the surface of the transparent conductive film of the first base material. A plurality of semiconductor layers,
   The second electrode has a second substrate on which a counter conductive film is formed so as to face the first electrode,
   The electrolytic solution is sealed between the semiconductor layer of the first electrode and the second electrode,
   The plurality of encapsulants seal the electrolyte solution by extending along the first direction between the first electrode and the second electrode, respectively, and the laminated structure Into multiple cells,
   The insulating line extends between the first electrode and the second electrode along a second direction perpendicular to the first direction in a plan view, thereby each of the stacked structures, Divided into multiple sub-modules consisting of multiple cells,
   For cells adjacent in the second direction, the first electrode of one cell and the second electrode of the other cell are electrically connected by a conductive material provided in a state covered with the sealing material. Thereby connecting the plurality of cells;
   In each cell, the first base material extends in the first direction in the vicinity of a position adjacent to one conductive material so that a short circuit between the first electrode and the second electrode is prevented. One insulating portion is provided, and the second base material is provided with a second insulating portion extending in the first direction in the vicinity of the position adjacent to the other conductive material,
   About the said adjacent submodule, the said electrically conductive materials of the edge part of the same side of said 2nd direction are electrically connected, The solar cell module characterized by the above-mentioned.
2. The conductive substrate width from the portion where the conductive material on one end side in the second direction to be electrically connected in the adjacent submodule to the one end of the submodule is 2 mm or more, on the one end side The solar cell module according to claim 1, wherein a width of the conductive material is 0.5 mm or more.
3. For each of the adjacent submodules, the first insulating portion and the second insulating portion are arranged at positions shifted alternately in the second direction,
   The at least one part of the edge part side of said 1st insulation part and said 2nd insulation part is extended in said 1st direction so that it may overlap with said insulation line, The Claim 1 or 2 characterized by the above-mentioned. The solar cell module described.
4. Between the cells, the end portions of the insulating portion of one submodule and the insulating portion of the other submodule of the adjacent submodules overlap with each other in the first direction, The solar cell module according to claim 3.
5. 4. The solar cell module according to claim 3, wherein the first insulating part and the second insulating part have an overlapping length with the insulating line of 0.1 mm or more and 5 mm or less.
6. 5. The solar cell module according to claim 4, wherein the first insulating part and the second insulating part have an overlapping length with the insulating line of 0.1 mm or more and 5 mm or less.
7. The range of the value obtained by dividing the length dimension K from the overlap start position of the first insulating part and the second insulating part to the front end with the insulating line by the width dimension L of the insulating line is The solar cell module according to claim 3, wherein 0 <K / L <1.5 is set.
8. The range of the value obtained by dividing the length dimension K from the overlap start position to the tip of the insulation line at each end of the first insulation part and the second insulation part by the width dimension L of the insulation line is: The solar cell module according to claim 4, wherein the solar cell module is set in a range of 0 <K / L <1.5.
9. 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 semiconductor layers formed on the surface of the transparent conductive film of the first substrate are adsorbed with a dye extending in the first direction. Forming a 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 first direction on the transparent conductive film and the counter conductive film;
   Providing a sealing material that extends along the first direction and arranges a plurality of cells in a second direction orthogonal to the first direction in plan view;
   A conductive material is disposed in a state of being covered with the sealing material, and the first electrode of one cell and the second electrode of the other cell are electrically connected to each other in the second direction by the conductive material. Connecting to
   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 first insulating line that extends along the second direction with respect to the first electrode and the second electrode, and does not partially provide the conductive material near one end in the second direction; Forming a second insulating line that insulates the whole in two directions at a predetermined position in the first direction, and providing the first insulating line between the second insulating lines;
   Cutting the first electrode and the second electrode at a position of the second insulating line;
   Have
   The solar cell module cut by the second insulation line is connected to the same end in the second direction with respect to the adjacent submodules among the submodules divided by the first insulation line. A method of manufacturing a solar cell module, wherein the solar cell module is electrically connected by serial wiring with a material.
10. The first insulating line and the second insulating line are formed by a fusion part fused along the second direction, or the insulation processing part insulated by the insulation processing means is closed with a sealing material. The method of manufacturing a solar cell module according to claim 9, wherein

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