WO2019146684A1 - Electric module and method for manufacturing electric module - Google Patents

Electric module and method for manufacturing electric module Download PDF

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Publication number
WO2019146684A1
WO2019146684A1 PCT/JP2019/002236 JP2019002236W WO2019146684A1 WO 2019146684 A1 WO2019146684 A1 WO 2019146684A1 JP 2019002236 W JP2019002236 W JP 2019002236W WO 2019146684 A1 WO2019146684 A1 WO 2019146684A1
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WO
WIPO (PCT)
Prior art keywords
insulating portion
conductive film
electrode
sealing material
insulating
Prior art date
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PCT/JP2019/002236
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French (fr)
Japanese (ja)
Inventor
壮一郎 鈴木
博之 井川
Original Assignee
積水化学工業株式会社
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Application filed by 積水化学工業株式会社 filed Critical 積水化学工業株式会社
Priority to JP2019567140A priority Critical patent/JPWO2019146684A1/en
Publication of WO2019146684A1 publication Critical patent/WO2019146684A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
    • H01G9/20—Light-sensitive devices
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/542—Dye sensitized solar cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to an electrical module and a method of manufacturing the electrical module.
  • Priority is claimed on Japanese Patent Application No. 2018-009685, filed on Jan. 24, 2018, the content of which is incorporated herein by reference.
  • a dye-sensitized solar cell is generally known to be configured to include a photoelectrode, a counter electrode, and an electrolytic solution or an electrolytic solution layer.
  • the photoelectrode includes at least a transparent conductive layer, a semiconductor layer, and a dye.
  • the dye adsorbed to the semiconductor layer absorbs the light, the electrons in the dye molecule are excited, and the electrons are semiconductor Passed to Then, the electrons generated on the photo electrode side move to the counter electrode side through the external circuit, and the electrons return to the photo electrode side through the electrolytic solution. By repeating such a process, electric energy is generated.
  • first electrically conductive film and the second electrically conductive film are made to face each other by appropriately shifting the insulating portions, and the first base material and the second electrically conductive layer are sandwiched between the electrically conductive films.
  • the base material is pasted together (for example, refer to patent documents 1).
  • the series-structured dye-sensitized solar cell manufactured as described above is further subjected to insulation treatment at a desired position and cut out to a desired size according to the purpose of use of the dye-sensitized solar cell, etc. .
  • the above-mentioned insulation processing can be performed in a correct position by insulating by half cut processing, without cutting the 1st substrate and the 2nd substrate.
  • the present invention has been made in view of the above problems, and it is an object of the present invention to provide an electrical module and a method of manufacturing the electrical module which are subjected to a good insulation process and can prevent the occurrence of electrical leakage. Do.
  • the inventors of the present invention have conducted intensive studies to prevent the occurrence of electrical leakage particularly when the film-type electrical module is used by bending. As a result, it was found that by optimizing the width dimension of the insulating region formed by half-cut processing to a specific range, it is possible to prevent the processed ends from coming in contact even when the electric module is bent and used. . As a result, it has been found that regardless of the type of use of the electrical module, the occurrence of electrical leakage can be prevented, and excellent battery performance can be obtained, and the present invention has been completed.
  • the electric module according to the present invention comprises a first electrode, a first electrode having a first conductive film provided on the surface of the first substrate, a second substrate, and the second substrate.
  • a power generation unit including a semiconductor layer and a second electrode having a second conductive film provided on the surface of the first electrode, the second electrode being provided between the first electrode and the second electrode;
  • a plurality of power generation units provided spaced apart along the surface direction of the second electrode; and a sealing material provided on both sides of the power generation unit along the surface direction, the first conductive film and the above
  • the portion of the second conductive film opposed to the sealing material is formed so as to penetrate the first conductive film or the second conductive film in the thickness direction or to be open on the side of the sealing material.
  • a strip-shaped insulating portion formed in a plan view is provided, and the width dimension of the insulating portion in the surface direction is 0.1 mm. And characterized in that the upper 3mm or less.
  • the band-shaped insulating portions in plan view formed on the first conductive film of the first electrode and the second conductive film of the second electrode each have a width dimension of 0.
  • the insulation property is secured securely.
  • the wiring is provided between the sealing materials in the plane direction, the movement of the wiring is suppressed by the width dimension of each insulating portion being in the above range, and the power generation performance of the electric module is stable.
  • folding and using an electrical module means, for example, deforming the electrical module to such an extent that mechanical breakage does not occur according to the size and shape of the installation location of the electrical module.
  • the sealing material is provided to cover the entire opening on the sealing material side of the insulating portion.
  • the sealing material is provided so as to cover the entire opening of the insulating portion, thereby forming the first conductive film and the second conductive film when the electric module is in a bent state.
  • the end portions can be more reliably prevented from coming in contact with each other beyond the insulating portion.
  • the sealing material is provided such that at least a part of the sealing material enters the inside of the insulating portion.
  • the first conductive film and the second conductive film are provided in a state where the electric module is bent by providing at least a part of the sealing material into the inside of the insulating portion.
  • the formed ends can be further reliably prevented from coming in contact with each other beyond the insulating portion.
  • the width dimension in the surface direction of the insulating portion is more preferably 0.3 mm or more and 2 mm or less.
  • the electric module is bent The insulation in each of the insulating parts is more securely ensured.
  • a method of manufacturing an electric module according to the present invention manufactures an electric module having the above configuration, wherein the first electrode provided on the surface of the first base by cutting the first electrode.
  • the second conductive film provided on the surface of the second base material is penetrated in the thickness direction by cutting or formed into a concave shape so as to be open on the sealing material side
  • the first insulating portion and the second insulating portion formed in the first insulating step and the second insulating step are formed such that the width dimension in the surface direction is in the above range.
  • the power generation portion forming step forms the sealing material so as to cover the entire opening on the sealing material side of the first insulating portion. It is a process, It is preferable that the said bonding process is a process of bonding together the said 1st electrode and the said 2nd electrode so that the said sealing material may cover the whole opening of the said 2nd insulation part.
  • the end portions formed in the first conductive film and the second conductive film exceed the insulating portion. It is possible to manufacture an electrical module that can more reliably prevent contact.
  • the power generation portion forming step is a step of forming the sealing material so that at least a part thereof enters the inside of the first insulating portion.
  • the bonding step is more preferably a step of bonding the first electrode and the second electrode such that at least a part of the sealing material enters the inside of the second insulating portion.
  • the end portions formed in the first conductive film and the second conductive film exceed the insulating portion. It is possible to manufacture an electrical module that can further reliably prevent contact.
  • the first insulating step and the second insulating step may have the first insulating portion and the second insulating portion each having a width dimension in the surface direction It is more preferable to form so as to be 0.3 mm or more and 2 mm or less.
  • the insulation as described above is formed by forming the first insulating portion having the first electrode and the second insulating portion formed on the second electrode to have the above width dimensions. It is possible to manufacture an electrical module with a guaranteed quality.
  • the strip-shaped insulating portion formed in the first conductive film of the first electrode and the second conductive film of the second electrode has a width dimension in the planar direction of 0 .1 mm or more and 3 mm or less is adopted.
  • the first insulating portion and the second insulating portion formed in the first insulating step and the second insulating step each have a width dimension of 0.1 mm in the surface direction.
  • the method of forming so as to be 3 mm or less is employed.
  • FIG. 7 is a view schematically explaining another configuration of the electric module which is an embodiment to which the present invention is applied, and is a cross-sectional view taken along the line XX in FIG. 1; It is a top view which illustrates typically composition of an electric module which is other embodiments to which the present invention is applied.
  • FIG. 7 is a view schematically explaining another configuration of the electric module which is an embodiment to which the present invention is applied, and is a cross-sectional view taken along the line XX in FIG. 1; It is a top view which illustrates typically composition of an electric module which is other embodiments to which the present invention is applied.
  • FIG. 5 is a view schematically illustrating a configuration of an electric module according to another embodiment to which the present invention is applied, and is a cross-sectional view taken along line Y-Y shown in FIG. It is a top view which illustrates typically composition of an electric module which is other embodiments to which the present invention is applied. It is a top view which illustrates typically another composition of the electric module which is other embodiment to which the present invention is applied. It is a top view which illustrates typically another composition of the electric module which is other embodiment to which the present invention is applied. It is a figure which illustrates typically the manufacturing method of the electric module which is one Embodiment to which this invention is applied, and manufactured the 1st electrode and the 2nd electrode using the manufacturing apparatus to which a roll-to-roll system is applied.
  • FIGS. 12A and 12B See also the conventional figure).
  • FIGS. 12A and 12B See also the conventional figure.
  • the features that are the features may be shown enlarged for convenience, and the dimensional ratio of each component is different from the actual one.
  • the materials, dimensions, and the like exemplified in the following description are merely examples, and the present invention is not limited to them, and can be appropriately changed and implemented without changing the gist of the invention.
  • the film-type dye-sensitized solar cell manufactured using RtoR system is mentioned and demonstrated as an example of the electric module which concerns on this invention.
  • the electric module to which the present invention is applied is not limited to a dye-sensitized solar cell, and two electrodes subjected to insulation processing may be bonded together with a sealing material interposed therebetween, All electrical modules other than dye-sensitized solar cells are also included.
  • the electric module according to the present invention is not limited to one manufactured using the above RtoR method, that is, one continuously manufactured while conveying the base material in a predetermined direction, for example, in advance It also includes those in which a cell structure is formed for each of the cut substrates.
  • the dye-sensitized solar cell (electric module) 10 of this embodiment to which this invention is applied is 1st electrode 41, 2nd electrode 42, the electric power generation part 44, and sealing.
  • a material 46 and a wire 48 are provided.
  • the first electrode 41 has a first base 21 and a first conductive film 31 provided on the surface 21 a of the first base 21.
  • the first base material 21 is a member serving as a base of the first conductive film 31, a part of the power generation unit 44 (for example, the semiconductor layer 12 described later), the sealing material 46, and the wiring 48.
  • the material of the first base material 21 is not particularly limited as long as it is flexible enough to be applicable to continuous production of a solar cell using the RtoR method and can be formed into a large-area film.
  • Examples of the material of the first base 21 include transparent resin materials such as polyethylene terephthalate (PET), acrylic (PMMA), polycarbonate, polyethylene naphthalate (PEN), and polyimide.
  • the bending strength of the first base material 21 is not particularly limited, but when the dye-sensitized solar cell 10 is bent, a first insulating portion (insulating portion) 50A formed on the first conductive film 31 described later In the above, it is preferable to appropriately set while considering the material of the first base material 21 from the viewpoint of facilitating prevention of contact (shorting) between the processed end portions.
  • the bending strength of the first base material 21 is preferably 70 MPa or more, and more preferably 80 MPa or more.
  • the bending strength of the first base material 21 is preferably 150 MPa or less, and 140 MPa or less from the viewpoint of making it possible to bend the dye-sensitized solar cell 10 to such an extent that mechanical breakage does not occur. It is more preferable to do.
  • the first conductive film 31 is formed over the entire surface 21 a of the first base 21 (that is, the surface of the first base 21 on the second electrode 42 side) in the direction D1.
  • Examples of the material of the first conductive film 31 include tin oxide (ITO), zinc oxide, fluorine-doped tin oxide (FTO), and the like.
  • the second electrode 42 is provided on the second base 22 facing the first base 21 and on the surface 22 a of the second base 22 (the surface of the second base 22 on the side of the first electrode 41). And a conductive film 32.
  • the second base 22 is a member serving as a base of the second conductive film 32 and a part of the power generation unit 44 (for example, the catalyst layer 16 described later).
  • the material of the second base material 22 is, like the first base material 21, a material having flexibility to such an extent that it can be applied to the continuous production of a solar cell using the RtoR method and which can be formed into a large area film
  • it is not particularly limited.
  • the resin material similar to the 1st base material 21 is mentioned, for example.
  • the bending strength of the second base material 22 is not particularly limited, either, as in the case of the first base material 21, when the dye-sensitized solar cell 10 is bent, the second conductive film 32 described later is formed In the second insulating portion (insulation portion) 50B, the first base is preferred from the viewpoint of facilitating prevention of contact (shorting) of the processed ends with each other and bending of the end portions to such an extent that mechanical breakage does not occur.
  • the strength is preferably the same as that of the material 21.
  • the second conductive film 32 is formed over the entire surface 22 a of the second base 22 in the direction D1.
  • the compound similar to the 1st conductive film 31, etc. are mentioned, for example.
  • the power generation unit 44 is interposed between the first electrode 41 and the second electrode 42, and a plurality of the power generation units 44 are spaced along the surface direction of the first electrode 41 and the second electrode 42 (direction D1 shown in FIG. 2). It is provided.
  • the power generation unit 44 includes a semiconductor layer 12, an electrolytic solution (electrolyte) 14, and a catalyst layer 16.
  • the semiconductor layer 12 is formed in the power generation portion disposition region R44 of the surface 31a of the first conductive film 31 (that is, the surface of the first conductive film 31 on the second electrode 42 side).
  • a plurality of power generation unit disposition areas R44 are provided apart from one another in the direction D1 shown in FIG.
  • the semiconductor layer 12 is, for example, a porous layer dyed by supporting a sensitizing dye on a metal oxide or the like, and has a function of receiving and transporting an electron from the sensitizing dye.
  • metal oxides include titanium oxide (TiO 2 ), zinc oxide (ZnO), and tin oxide (SnO 2 ).
  • the aforementioned sensitizing dyes are composed of organic dyes or metal complex dyes.
  • the organic dye include various organic dyes such as coumarin dyes, polyene dyes, cyanine dyes, hemicyanine dyes, and thiophene dyes.
  • a metal complex dye a ruthenium complex etc. are mentioned, for example.
  • the electrolytic solution 14 is filled in the power generation unit disposition region R44 so as to be in contact with the semiconductor layer 12 and the catalyst layer 16 described below.
  • a solution in which a supporting electrolyte such as lithium iodide and iodine are mixed with a liquid component such as an ionic liquid such as acetonitrile, dimethylpropylimidazolium iodide or butylmethylimidazolium iodide as the electrolytic solution 14 (specific example In particular, non-aqueous solvents such as propionitrile etc. can be mentioned.
  • the catalyst layer 16 is formed in the power generation portion disposition region R44 of the surface 32a of the second conductive film 32 (that is, the surface of the second conductive film 32 on the first electrode 21 side), and a plurality of catalyst layers are provided separately from each other. There is.
  • the material of the catalyst layer 16 include PEDOT, platinum, ITO, polyaniline, carbon, and the like.
  • the sealing material 46 is for sealing the power generation portion 44 including the electrolytic solution 14 in the power generation portion disposition region R44 together with the seal portion 60 shown in FIG. 1.
  • the sealing material 46 is provided on both sides of the power generation unit 44 along the direction D1 shown in FIGS. 1 and 2.
  • the vicinity of each power generation portion 44 is enlarged Therefore, the sealing material 46 on only one side of the power generation unit 44 along the D1 direction is illustrated.
  • the sealing material 46 is provided in the sealing material disposition area R46 which is a region different from the power generation portion disposition area R44 so as to be adjacent to the power generation portion 44 in the D1 direction.
  • the sealing material 46 further includes a resin or the like for bonding the first electrode 41 and the second electrode 42 and bonding them to each other.
  • a resin material which contains at least 1 type in a thermoplastic resin, a thermosetting resin, or an ultraviolet curable resin is mentioned, for example.
  • thermoplastic resins include polyolefin resins, polyester resins, and polycarbonates.
  • thermosetting resin a phenol resin, an epoxy resin, a melanin resin, ethylene-vinyl acetate copolymer resin (EVA) etc. are mentioned, for example.
  • EVA ethylene-vinyl acetate copolymer resin
  • acrylic resin, an epoxy resin, etc. are mentioned, for example.
  • the viscosity of the resin material used for the sealing material 46 before curing is not particularly limited. However, as described in detail later, at the time of manufacturing the dye-sensitized solar cell 10, the resin material constituting the sealing material 46 is likely to enter the inside of the first insulating portion 50A or the second insulating portion 50B by curing. In order to do this, for example, it is preferable that the pressure be 300 Pa ⁇ s or less.
  • Wirings 48 are provided between the sealing materials 46 disposed in the sealing material disposition area R46 in the direction D1 shown in FIG.
  • the wiring 48 is a conductive structure for connecting the power generation units 44 including the semiconductor layer 12, the electrolytic solution 14, and the catalyst layer 16.
  • the material of the wiring 48 is not particularly limited as long as it is a conductive material, and examples thereof include known conductive materials, conductive pastes, or a mixture of conductive fine particles and an adhesive.
  • an adhesive 38 such as an epoxy resin or a phenol resin is used as the material of the wiring 48 from the viewpoint of easily cutting the wiring 48. It is preferable to employ a conductive paste in which conductive particles 36 of the above are mixed.
  • a binder made of the same material as the sealing material 46 may be used for the wiring 48.
  • the dye-sensitized solar cell 10 is a portion facing the sealing material 46 of the first conductive film 31 and the second conductive film 32 (ie, the sealing material In the arrangement region R46), the first insulating portion (insulating portion) 50A or the second insulating portion (insulating portion) 50B having a strip shape in plan view is provided. That is, the first conductive portion 31 of the first electrode 41 is provided with the first insulating portion 50A, and the second conductive portion 32 of the second electrode 42 is provided with the second insulating portion 50B. Further, in the example illustrated in FIG.
  • the first insulating portion 50A and the second insulating portion 50B are provided to penetrate the first conductive film 31 or the second conductive film 32 in the thickness direction.
  • the first insulating portion 50A is provided to divide the first conductive film 31
  • the second insulating portion 50B is provided to divide the second conductive film 32.
  • the entire opening on the sealing material 46 side in the first insulating portion 50A and the second insulating portion 50B is covered with the sealing material 46.
  • the first insulating portion 50A and the second insulating portion 50B have a width dimension in the plane direction, that is, a width dimension WL in the D1 direction shown in FIG. 2 is in the range of 0.1 mm to 3 mm. That is, in FIG. 1 and FIG. 2, the first conductive film 31 is divided by the width dimension WL of the above range by the first insulating portion 50A, and the second conductive film 32 is the width dimension of the above range by the second insulating portion 50B. By being divided by WL, insulation is secured at each position.
  • the dye-sensitized solar cell 10 of the present embodiment is provided with the first insulating portion 50A and the second insulating portion 50B, and the width dimension WL of these is 0.1 mm or more and 3 mm or less. Thereby, even when the dye-sensitized solar cell 10 is bent, it is possible to prevent the processed end portions formed in the first conductive film 31 and the second conductive film 32 from coming in contact with each other beyond the insulating portion, and the insulating property Secured. In addition, when the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above range, the dimensions and the area of the power generation portion 44 can be easily secured.
  • each insulating portion formed in each conductive film is less than 0.1 mm, as shown in FIGS. 12A and 12B, when an electric module (such as a dye-sensitized solar cell) is curved.
  • the processing end T may contact the processing end T adjacent to each other beyond the insulating region E to cause an electrical leak, which may cause a malfunction or a decrease in battery performance.
  • the width dimension WL of each insulating portion exceeds 3 mm, it may be difficult to sufficiently secure the dimensions and the area of the power generation portion 44.
  • the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is more preferably 0.3 mm or more and 2 mm or less in the D1 direction.
  • the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in this range, the insulating property in each insulating portion when the dye-sensitized solar cell 10 is bent as described above is It is possible to secure more securely, and to secure the dimensions and the area of the power generation unit 44 more sufficiently.
  • the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is more preferably 0.5 mm or more and 1 mm or less.
  • the width dimension of the sealing material 46 in the D1 direction is the entire opening of the first insulating portion 50A and the second insulating portion 50B. From the viewpoints of covering the coating material 46 and the adhesion strength between the sealing material 46 and the first conductive film 31 and between the sealing material 46 and the second conductive film 32, etc. It is preferable to make the width dimension larger than WL. Specifically, when the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is 0.1 mm, the width dimension of the sealing material 46 is preferably at least 1 mm or more. When the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is 3 mm, the width dimension of the sealing material 46 is preferably at least 5 mm or more.
  • the first insulating portion 50A and the second insulating portion 50B are substantially hollow while the entire opening is covered with the sealing material 46
  • the present embodiment is not limited to such a configuration.
  • at least a part of the sealing material 46 is inserted into the first insulating portion 50A and the second insulating portion 50B. It is preferable that it is formed from the viewpoint of reliably preventing the processed end portions from contacting (shorting) in the first insulating portion 50A and the second insulating portion 50B when the dye-sensitized solar cell is bent. .
  • an electrical leak is generated with a simple configuration regardless of the usage form of the dye-sensitized solar cell 10 by providing the above-described good insulating portion Can be prevented and excellent battery performance can be obtained. That is, regardless of the size and the shape of the installation space, the dye-sensitized solar cell 10 can be installed while flexibly changing the shape without reducing the battery performance.
  • the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above-described range so that the wire moves.
  • the dye-sensitized solar cell 10 according to the present invention is made of various resin materials as described above, it has a certain degree of flexibility (flexibility).
  • Flexibility As a bending form of the dye-sensitized solar cell (electric module) described in the present embodiment, as described above, for example, dye-sensitized solar to the extent that mechanical destruction does not occur according to the size and shape of the installation location There is a mode in which the battery is deformed.
  • the configuration is not limited to the configuration in which the second conductive film 32 penetrates (is divided) in the thickness direction.
  • the first conductive film 31 and the second conductive film 32 are not penetrated, and they are opened in the shape of a strip in plan view You may employ
  • the entire opening on the side of the sealing material 46 in the first insulating portion 51A and the second insulating portion 51B is configured to be covered by the sealing material 46.
  • a dye-sensitized solar cell Even when 10 is bent, the processed end portions formed in the first conductive film 31 and the second conductive film 32 can be prevented from contacting each other beyond the insulating portion, and the insulation property can be assuredly ensured.
  • the width dimension WL of the first insulating portion 51A and the second insulating portion 51B is in the above range, the dimension and the area of the power generation portion 44 can be easily secured.
  • the first insulating portion and the second insulating portion are formed in a concave shape so as not to penetrate the first conductive film 31 and the second conductive film 32, the first insulating portion and the second insulating portion are not It is preferable that the thickness of the bottom of the conductive film 31 and the second conductive film 32 be as thin as possible. More specifically, the depth dimension F of the first insulating portion 51A and the second insulating portion 51B in a cross section orthogonal to the D1 direction shown in FIG. 3 (that is, a cross section viewed in the D2 direction in FIG.
  • the ratio is approximately 6500 to 13000.
  • the first insulating portion 51A and the second insulating portion 51B exceeds the thickness dimension of the first conductive film 31 and the second conductive film 32.
  • the first insulating portion 51A and the second insulating portion 51B penetrate the first conductive film 31 and the second conductive film 32, and dig in the first base 21 and the second base 22 so as to form a concave insulation. A region will be formed. That is, in this case, similarly to the above, the first insulating portion 51A and the second insulating portion 51B are formed to penetrate the first conductive film 31 and the second conductive film 32, and in the following description, The same is true.
  • the depths of the first insulating portion 51A and the second insulating portion 51B may be uniform in the D2 direction shown in FIG. 3, that is, in the length direction, but within the above depth dimension F
  • the configuration may be uneven.
  • the width dimensions of the first insulating portion 51A and the second insulating portion 51B are adopted. It is preferable to make the relationship between WL and the width dimension in the D1 direction of the sealing material 46 the same as in the case of the first insulating portion 50A and the second insulating portion 50B described above.
  • the entire opening of the sealing material first insulating portion 51A and the second insulating portion 51B can be reliably covered with the sealing material 46, and between the sealing material 46 and the first conductive film 31, and The adhesive strength between the sealing material 46 and the second conductive film 32 can be enhanced.
  • the first insulating portion 51A and the second insulating portion 51B as illustrated in the example are not limited to the configuration in which the For example, as in the dye-sensitized solar cell 10D shown in FIG. 11, at least a part of the sealing material 46 is formed to enter the inside of the first insulating portion 51A and the second insulating portion 51B in a concave shape. Similar to the above, it is preferable from the viewpoint of facilitating prevention of contact (shorting) of the processed ends in the first insulating portion 51A and the second insulating portion 51B. Further, as in the example shown in FIG. 11, the inside of the first insulating portion 51A and the second insulating portion 51B is completely embedded with the sealing material 46, from the viewpoint of achieving the above-mentioned effects more remarkably. preferable.
  • a seal portion 60 in which the first electrode 41 and the second electrode 42 are bonded to each other is provided at a predetermined position in the D2 direction of the dye-sensitized solar cell 10 .
  • the seal portion 60 is formed by using, for example, a method such as ultrasonic welding from the outside in the thickness direction of the first electrode 41 and the second electrode 42 (that is, above and below the dye-sensitized solar cell 10).
  • the first base 21 and the second base 22 are pressure-bonded by applying or pressing a force to the first electrode 41 and the second electrode 42, thereby providing an electrically insulated part.
  • the first conductive film 31, the second conductive film 32, and the semiconductor layer 12 have a slight thickness between the pressure-bonded first base material 21 and the second base material 22.
  • the electrolytic solution 14 and the catalyst layer 16 may be interposed. However, since each of these layers is in a substantially divided state in the seal portion 60, the power generation portions 44 adjacent to the seal portion 60 are not electrically connected.
  • the first insulating portions 50A and 51A and the second insulating portions 50B and 51B are configured such that the entire opening is covered in the entire D2 direction (the length direction of each insulating portion).
  • the present invention is not limited to such a configuration.
  • a portion where the entire width direction (direction D1) of the openings of the first insulating portions 50A and 51A and the second insulating portions 50B and 51B is covered by the sealing material 46, and the opening Both exposed portions may be present.
  • the entire opening in the region in which the entire width direction of the opening of each insulating portion is covered is covered by about 80% or more of the entire length of each insulating portion in the D2 direction.
  • the above effect can be sufficiently obtained.
  • the first insulating portion 50A penetrating the respective conductive films in the thickness direction as described above is provided to the first insulating portion and the second insulating portion provided in the first conductive film 31 and the second conductive film 32.
  • the second insulating portion 50B or the first insulating portion 51A and the second insulating portion 51B formed in a concave shape are used.
  • the following configuration may be employed. That is, in the present invention, for example, as in the dye-sensitized solar cell 10B shown in FIGS.
  • the first insulating portion and the second insulating portion provided in the first conductive film 31 and the second conductive film 32 are You may comprise as the 1st insulation part 52A and the 2nd insulation part 52B of the structure by which the recessed part 52 opened to the sealing material 46 side was formed in multiple numbers along the surface direction.
  • the first insulating portion 52A and the second insulating portion 52B in the illustrated example have a configuration in which a plurality of concave portions 52 formed in a concave shape in the first conductive film 31 and the second conductive film 32 are arranged in a strip in a plan view There is.
  • the first insulating portion 52A and the second insulating portion 52B shown in FIG. 5 are a plurality of recesses formed by applying some physical energy or chemical treatment to the first conductive film 31 or the second conductive film 32.
  • 52 is a region where the conductivity is significantly reduced compared to a region where no physical energy or chemical treatment or the like is given. That is, although the first insulating portion 52A and the second insulating portion 52B are not complete insulating portions, they are regions in which the conductivity is lowered as much as possible.
  • the recessed part 52 is shown intelligibly typically, the several recessed part 52 in this embodiment is individually or regularly independent in the predetermined condition like predetermined example like illustration.
  • the recesses formed continuously to roughen the surfaces 31 a and 32 a of the first conductive film 31 and the second conductive film 32 are also included.
  • the plurality of recesses 52 may be formed along the direction D1 shown in FIGS. 4 and 5, and the shape and arrangement of the plurality of recesses 52 can be appropriately adjusted in plan view (that is, the upper surface shown in FIG. 4) It can be done.
  • the plurality of recesses 52 may be formed spaced apart from each other by a predetermined distance in plan view, may be in contact with each other, or may partially overlap with each other. Further, for example, among the plurality of concave portions 52, some of the plurality of concave portions 52 may be formed to be separated from each other by a predetermined distance in plan view, and the remaining plurality of concave portions 52 may be in contact with each other. Alternatively, some of the plurality of recesses 52 may be formed spaced apart from each other by a predetermined distance in plan view, and the remaining plurality of recesses 52 may overlap with each other.
  • the plurality of recesses 52 may be formed in a dot shape in plan view.
  • the first electrode 41 side is shown in order to easily show the shape of the recess 52 in a plan view.
  • the first base 21 in FIGS. 6 to 7 may be replaced with the second base 22, and the first conductive film 31 in the figure may be replaced with the second conductive film 32.
  • the plurality of concave portions 52 arranged in a dot shape may be respectively formed in a circular shape in a plan view, and may be arranged in a so-called hexagonal close-packed shape.
  • the planar view shape of the recessed part 52 may be an ellipse, a triangle, a rectangle, five or more polygons other than circular shape, or another arbitrary shape.
  • the shortest distance w1 between the outer peripheral edges of the recessed portions 52a and the recessed portions 52b, 52c and 52d adjacent to the recessed portion 52a is the resistance value of the first insulating portion 52A and the second insulating portion 52B. It is preferable to appropriately set the internal series resistance value of the dye-sensitized solar cell 10 to be 5 times or more, preferably 10 times or more, more preferably 100 times or more.
  • the plurality of concave portions 52 arranged in a dot shape may be formed to be arranged along the D1 direction and the D2 direction in a plan view.
  • the recesses 52d and 52f of the row L3 adjacent to each other and along the D1 direction overlap in the D2 direction in plan view.
  • the shortest distance w2 of the outer peripheral edge of the concave portions 52 adjacent to each other along the D2 direction takes into consideration the shape, dimensions, etc. in plan view and cross-sectional view of the recess 52, and the resistance value of the first insulating portion 52A and the second insulating portion 52B is the inside of the dye-sensitized solar cell 10.
  • the shortest distance w2 is preferably 0% or more and 20% or less of the width dimension w52 of the recess 52 in the D2 direction, more preferably 0% or more and 10% or less of the width dimension w52, and the width dimension w52 More preferably, it is 0% or more and 1% or less.
  • the plurality of concave portions may be configured by concave streaks 56 formed in a net shape in plan view.
  • the grooves 56 extend along the D3 direction inclined at a predetermined angle with respect to the D2 direction, and the grooves 56A of the first conductive film 31.
  • a concave stripe 56B intersecting in the D3 direction and extending along the D4 direction by inclining at a predetermined angle in a direction opposite to the D3 direction with respect to the D2 direction.
  • the shortest distance w3 along the direction D1 of the convex portion 58 surrounded by the concave streaks 56A and 56B is the concave streaks 56A and 56B. It is necessary to set while taking into consideration the shape, size, and the like in plan view and cross-sectional view of the lens. Therefore, in the above-mentioned shortest distance w3, the resistance value of the first insulating portion 52A and the second insulating portion 52B is 5 times or more, preferably 10 times or more, more preferably the internal series resistance value of the dye-sensitized solar cell 10. It is preferable to set appropriately so as to be 100 times or more.
  • the depth of the groove 56 is preferably 90 to 13,000, where the thickness of the first conductive film 31 or the second conductive film 32 is 100.
  • the average depth of the recesses 52 is about 13 ⁇ m, and the first conductive film 31 or the second conductive film 32 The case where the ratio of about 6500 to 13000 is given when the thickness of the above is 100 is mentioned.
  • the depth of the recess 52 and the groove 56 when the thickness of the first conductive film 31 or the second conductive film 32 is 100 is a ratio of 95 or more and 12500 or less. More preferably, the ratio is 98 or more and 12000 or less.
  • the depths of the plurality of recesses 52 and the grooves 56 may be uniform or nonuniform.
  • the plurality of recesses 52 or the grooves 56 have a depth of less than 100, The recessed part 52 and the concave stripe 56 which are the ratio of the above may be mixed.
  • the current value flowing through the dye-sensitized solar cell 10 depends on the performance of the dye-sensitized solar cell 10 and the like. Even in the case of increase or decrease, the decrease in the conductivity of the first insulating portion 52A and the second insulating portion 52B is secured. When a relatively large current flows in the dye-sensitized cell 10, the first insulating portion 52A and the second insulating portion 52B can be obtained even if the decrease in conductivity in the first insulating portion 52A and the second insulating portion 52B is small. Can function as an insulating region.
  • the first insulating portion 52A and the second insulating portion 52B may function well as an isolation region. Therefore, the depth of the recess 52 should be appropriately adjusted by comprehensively taking into account the shape of the recess 52, the current value flowing to the dye-sensitized solar cell 10, and other parameters related to the dye-sensitized solar cell 10. Is preferred.
  • the recesses 52 and the grooves 56 are formed to have a density of 80% or more and 100% or less in plan view, in order to ensure insulation of the first insulating portion 52A and the second insulating portion 52B (and the recess 56). Is preferred.
  • the density of the recesses 52 in a plan view described in this specification is the percentage of the total area of the inner wall surfaces of the plurality of recesses 52 in a unit area (for example, 1 cm 2 ) in a plan view. It is a thing.
  • the density of the recessed portions 52 and the recessed streaks 56 in planar view is 80% or more and 100% or less It is preferably 90% or more and 100% or less.
  • the density centered on the place where the distance between the adjacent recessed portions 52 and the recessed streaks 56 is the smallest is It is preferably 80% or more and 100% or less, and more preferably 90% or more and 100% or less.
  • the distance between adjacent concave portions 52 when the concave portions 52 overlap with each other, this distance is set to 0 (zero). Furthermore, as shown in FIG. 6, the path through which the current I flows in the first insulating portion 52A and the second insulating portion 52B becomes longer (that is, the flow of the current I trying to advance along the D1 direction avoids the recess 52). As shown in FIG. 7, the density of the recess 52 in a plan view is 90% or more and 100% or less when the path through which the current I flows is short as shown in FIG. preferable.
  • the width dimension WL of the first insulating portion 52A and the second insulating portion 52B in the D1 direction be appropriately set in consideration of the material and conductivity of the first conductive film 31, etc.
  • 0.1 mm or more and 10 mm or less are preferable, 0.2 mm or more and 3 mm or less are more preferable, and 0.5 mm or more and 1 mm or less are more preferable.
  • the width dimension in the D1 direction of the first insulating portion 52A and the second insulating portion 52B is 10 mm or less, it becomes easy to secure the size and the area of the power generation portion 44.
  • the width dimension in the D1 direction of the first insulating portion 52A and the second insulating portion 52B is 0.1 mm or more, the decrease in conductivity in the first insulating portion 52A and the second insulating portion 52B is secured. Further, as shown in FIG. 8, even when the insulating portion is constituted by the concave streaks 56 formed in a net shape in plan view, it is preferable to set the region of the insulating portion to the same width as the above.
  • the difference in conductivity between the first insulating portion 52A and the second insulating portion 52B shown in FIGS. 4 and 5 and the region around the insulating portions 52A and 52B is the first insulating portion 52A and the second insulating portion to be formed. It can set suitably in consideration of the number of 52B, arrangement, etc., and is not limited in particular.
  • the electrical resistance of the electrical resistance of the first insulating portion 52A and the second insulating portion 52B is considered from the viewpoint of ensuring the insulation of the first insulating portion 52A and the second insulating portion 52B directly and reliably. There is a need.
  • the electric resistances of the first insulating portion 52A and the second insulating portion 52B are preferably five or more times the internal series resistance value of the dye-sensitized solar cell 10, and the inside of the dye-sensitized solar cell 10 It is more preferable that it is 10 times or more of series resistance value, and it is further more preferable that it is 100 times or more of internal series resistance value of the dye-sensitized solar cell 10. Further, as shown in FIG. 8, even when the insulating portion is constituted by the recessed streaks 56 formed in a net shape in a plan view, the electrical connection of the insulating portion can be performed by appropriately setting, for example, the arrangement pitch and interval of the stitches. It is preferable to set the resistance in the same range as described above.
  • the seal portion 60 in which the first electrode 41 and the second electrode 42 are bonded to each other at the predetermined position in the D2 direction of the dye-sensitized solar cell 10 in the D1 direction.
  • the seal portion 60 is a portion in which the first base 21 and the second base 22 are crimped from the outside in the thickness direction of the first electrode 41 and the second electrode 42 as described above, and are electrically insulated. .
  • the first insulating portion 52A and the second insulating portion 52B including a plurality of concave portions 52 as shown in FIGS. 4 to 7 or the concave streaks 56 formed in a net shape in a plan view as shown in FIG.
  • the entire opening of each insulating portion is the sealing material 46 (the same as in the case of the first insulating portion 50A and the second insulating portion 50B shown in FIGS. Preferably, it is covered by FIG.
  • the manufacturing method of the electric module concerning this invention is demonstrated.
  • the first electrode 41 continuously transported along the predetermined direction D41 and the continuous direction along the predetermined direction D42 using the manufacturing apparatus 70 illustrated in FIG. It is the method of manufacturing the dye-sensitized solar cell 10 as shown in FIG.1 and FIG.2 by bonding together the 2nd electrode 42 conveyed by this.
  • the start point side is the upstream side
  • the end point side is the downstream side.
  • the manufacturing method of the dye-sensitized solar cell 10 of the present embodiment is roughly configured including at least the following steps (1) to (4).
  • (1) By cutting the first electrode 41, the first conductive film 31 provided on the surface 21a of the first base material 21 is penetrated in the thickness direction, or it is in the form of a strip, which is concave.
  • First insulating step of forming the first insulating portion 50A (see FIGS. 1 to 3).
  • the second conductive film 32 provided on the surface 22a of the second base material 22 is penetrated in the thickness direction, or is concave, and it is strip-shaped in a plan view
  • a second insulating step of forming a second insulating portion (3) The second conductive film 32 when the first conductive film 31 and the second conductive film 32 are opposed to each other at the portion where the first insulating portion 50A is formed on the surface 31a of the first conductive film 31.
  • the sealing material 46 While forming the sealing material 46 in the position corresponding to the 2nd insulation part 50B formed in the surface 32a of the power generation, the electric power generation part 44 containing the semiconductor layer 12 is formed between the sealing materials 46 in a surface direction. Part formation process.
  • the manufacturing method of the dye-sensitized solar cell 10 of this embodiment is the 1st insulation part 50A and the 2nd insulation part in the 1st insulation process of said (1), and the 2nd insulation process of said (2) It is a method of forming 50B so that width dimension WL in a surface direction may be 0.1 mm or more and 3 mm or less, respectively.
  • the first base material 21 is continuously transported along a predetermined direction using a known sputtering method, a printing method, or the like while being continuously transported.
  • the first conductive film 31 is formed on the surface 21a, and the first conductive film 31 is wound in a roll shape with the first conductive film 31 directed outward.
  • the roll-shaped first base member 21 is placed in the manufacturing apparatus 70, and the first base member 21 is unwound in a predetermined direction, in the illustrated example, the D41 direction,
  • the first insulating portion 50A as shown in FIGS. 1 and 2 is formed in the insulating portion forming region R50 on the surface 31a of the first conductive film 31 using the above.
  • an insulation part formation apparatus 72 the laser processing apparatus, the metal mold
  • the method of forming the first insulating portion 50A and the insulating portion forming apparatus 72 are not particularly limited as long as they can form insulating portions in a penetrating manner or in a concave shape to ensure insulation. It is not a thing.
  • the insulating portion forming device 72 by using the insulating portion forming device 72, laser light is intermittently applied to a plurality of positions on the surface 31a of the first conductive film 31 to form the first insulating portion 50A while the first electrode is formed. 41 can be obtained.
  • the timing of emitting the laser beam, the irradiation power of the laser beam, and the like can be appropriately controlled by a program or the like incorporated in the insulating portion forming apparatus 72.
  • the first insulating portion 50A is formed such that the width dimension WL in the surface direction is 0.1 mm or more and 3 mm or less.
  • the width dimension WL can be adjusted by adjusting the thickness of each blade of the die cut roll, the size of the optical axis of the laser light, or the like.
  • the first insulation step it is more preferable to form the first insulating portion 50A so that the width dimension WL in the surface direction is 0.3 mm or more and 2 mm or less.
  • a porous layer made of a metal oxide such as titanium oxide is formed on the power generation portion arrangement region R44 of the surface 31a of the first conductive film 31 by a known aerosol deposition method (Aerosol Deposition method: AD method) or the like. Do. After that, the semiconductor layer 12 is formed by supporting the sensitizing dye on the porous layer. The semiconductor layer 12 may be formed in advance on the roll-shaped first substrate 21.
  • the sealing material is discharged at the same time, and the sealing material is disposed on the sealing material disposition region R46 of the first electrode 41, that is, the portion of the surface 31a of the first conductive film 31 where the first insulating portion 50A is formed.
  • the sealing material 46 is formed.
  • a resin material including at least one of the thermoplastic resin, the thermosetting resin, and the ultraviolet curable resin as described above is used.
  • the sealing material 46 is formed by applying the above-described sealing material to the sealing material arrangement region R46). That is, in the power generation portion forming step (a), when the first electrode 41 and the second electrode 42 are superimposed in the bonding step described later, that is, the first conductive film 31 and the second conductive film 32 are made to face each other. At this time, the sealing material 46 is formed on a portion of the surface 31 a of the first conductive film 31 corresponding to the second insulating portion 50 B formed on the second conductive film 32.
  • the sealing material 46 in the power generation portion formation step (a), as shown in FIG. 2, it is preferable to form the sealing material 46 so as to cover the entire opening of the first insulating portion 50A. Furthermore, in the power generation portion forming step (a), the sealing material 46 covers the entire opening of the second insulating portion 50B when the first electrode 41 and the second electrode 42 are bonded in the bonding step described later. It is more preferable to form in the position and the size which can be
  • the sealing material 46 in the power generation portion forming step (a), as in the example shown in FIG. 10, it is preferable to form the sealing material 46 so that at least a part thereof enters the inside of the first insulating portion 50A, It is more preferable to form so that the whole inside of the one insulation part 50A may be embedded.
  • a sealing material having a viscosity of 300 Pa ⁇ s or less in order to form the sealing material 46 so as to enter the inside of the first insulating portion 50A.
  • it is preferable to adjust the conveyance speed of the 1st electrode 41 in a electric power generation part formation process (a) suitably, and to set it relatively low.
  • the flow rate of the wiring material from the wiring material discharge port of the wiring forming device 78 is an appropriate flow rate taking into account the viscosity of the wiring material
  • the wiring material is discharged to form the wiring 48 in the wiring arrangement region R ⁇ b> 48 of the first electrode 41.
  • the electrolytic solution 14 is discharged from the application port of the electrolytic solution application device 74 at an appropriate flow rate taking into account the viscosity of the electrolytic solution 14, the transport speed of the first electrode 41, etc.
  • the electrolyte solution 14 is applied to R44.
  • the second base 22 is continuously transported in the predetermined direction while using the same method as the second base described above.
  • the second conductive film 32 is formed on the surface 22 a of the material 22, and is wound in a roll while the second conductive film 32 is directed outward.
  • the roll-shaped second base material 22 is installed in the manufacturing apparatus 70, and the second base material 22 is unwound in a predetermined direction, that is, D42 in the illustrated example.
  • the second insulating portion 50B as shown in FIGS. 1 and 2 is formed in the insulating portion forming region R50 on the surface 32a of the second conductive film 32 using the same insulating portion forming device 72 as described above. Thereby, the second electrode 42 is obtained.
  • the second insulating portion 50B is formed to have a width dimension WL in the plane direction of 0.1 mm or more and 3 mm or less by the same method as the first insulating step. Further, also in the second insulating step, as in the first insulating step, it is more preferable to form the second insulating portion 50B so that the width dimension WL in the surface direction is 0.3 mm or more and 2 mm or less.
  • ⁇ Generation part formation process (c)> Next, while the second electrode 42 is continuously transported along the direction D42, power generation of the surface 32a of the second conductive film 32 is performed using the catalyst layer forming apparatus 84 or the like by a known sputtering method, printing method or the like.
  • the catalyst layer 16 is formed in the part arrangement region R44.
  • the catalyst layer 16 may be formed in advance on the roll-shaped second base material 22.
  • the power generation unit 44 is formed by the above-described power generation unit formation process (a) to the power generation unit formation process (c).
  • the first electrode 41 is introduced between the first pressing roll 91 and the second pressing roll 92 disposed below the first pressing roll 91 along the substantially horizontal D41 direction, and from the obliquely upward D42 direction
  • the second electrode 42 is introduced, and the first electrode 41 and the second electrode 42 are superimposed via the power generation unit 44, the sealing material 46, and the wiring 48.
  • the overlapped first electrode 41 and second electrode 42 are passed between the first pressing roll 91 and the second pressing roll 92 to press the first electrode 41 and the second electrode 42 to each other.
  • the sealing material 46 is cured by irradiating the first electrode 41 and the second electrode 42 in a pressed state with ultraviolet light using a UV lamp (not shown) or the like, and the first electrode 41 is cured. And the sealing material 46, and the second electrode 42 and the sealing material 46 are bonded. At this time, it is preferable to bond the second electrode 42 and the sealing material 46 so that the entire opening of the second insulating portion 50B formed on the surface 32a of the second conductive film 32 is covered with the sealing material 46 .
  • the bonding step it is preferable to bond the first electrode 41 and the second electrode 42 so that at least a part of the sealing material 46 enters the inside of the second insulating portion 50B. Further, it is more preferable to bond the first electrode 41 and the second electrode 42 so that the entire inside of the second insulating portion 50B is embedded with the sealing material 46.
  • a method of employing a low viscosity sealing material as described above, or a curing process time by ultraviolet irradiation or the like is shortened.
  • a method of bonding the first electrode 41 and the second electrode 42 under the condition of sandwiching the sealing material 46 in a semi-cured state, or a method of strengthening the pressing force between the first electrode 41 and the second electrode 42, etc. Can be mentioned.
  • the power generation unit disposition region R44 is divided into a plurality of cells at a predetermined position (see FIG. 1), that is, along the direction D2.
  • a seal portion forming device 95 such as an ultrasonic wave application device to form the seal portion 60.
  • the dye-sensitized solar cell 10 which is an electric module as shown in FIG. 1 and FIG. 2 can be manufactured. After this, if necessary, the dye-sensitized solar cell may be cut out from the dye-sensitized solar cell 10 in a desired pattern and in the shape and size actually used.
  • each process of said manufacturing method is taking the case of manufacturing the dye-sensitized solar cell 10 shown to FIG.1 and FIG.2 as an example, the dye-sensitized solar cell 10A shown in FIG. 3, FIG. Also in the case of producing the dye-sensitized solar cell 10B shown in 4 and 5 and the dye-sensitized solar cell 10C shown in FIG. 10 or the dye-sensitized solar cell 10D shown in FIG. , Can be manufactured in a similar manner.
  • the plane formed on the first conductive film 31 in the first electrode 41 and the second conductive film 32 in the second electrode 42 Each of the first insulating portion 50A and the second insulating portion 50B in the shape of a visible band adopts a configuration in which the width dimension WL in the surface direction is 0.1 mm or more and 3 mm or less.
  • the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above range by being set to the above range. The movement is suppressed, and the power generation performance of the dye-sensitized solar cell 10 is stabilized.
  • the first insulating portion 50A and the second insulating portion 50B formed in the first insulating step and the second insulating step are respectively The method of forming so that width dimension WL in a surface direction may be 0.1 mm or more and 3 mm or less is adopted.
  • the respective end portions formed in the first conductive film 31 and the second conductive film 32 are the first insulating portion 50A and the second insulating portion 50A.
  • the dye-sensitized solar cell 10 can be manufactured which can be prevented from contacting beyond the two insulating portions 50B and the insulation property is reliably ensured. Therefore, regardless of the use form of the dye-sensitized solar cell 10, it is possible to prevent the occurrence of electrical leakage, and it is possible to obtain the dye-sensitized solar cell 10 having excellent cell performance.
  • dye-sensitized solar cell 10 was mentioned and explained as an example of an electric module, the electric module concerning the present invention will not be limited especially if it is an electric module which requires insulation processing.
  • Example 1 In Example 1, according to the procedure of the method of manufacturing an electric module according to the present invention shown in the above embodiment using materials as shown below, according to the present invention as shown in FIG. 1 and FIG.
  • the 1st electrode 41 used for the dye-sensitized solar cell (electric module) 10 was produced.
  • First base material 21 polyethylene terephthalate (PET)
  • First conductive film 31 ... indium tin oxide (ITO)
  • the processing conditions of the laser were adjusted so that the width dimension WL of the first insulating portion 50A was 3 mm.
  • the output intensity of the laser was adjusted so that the entire depth from the surface 31 a of the first conductive film 31 dug by laser processing penetrates at least the first conductive film 31. That is, in the present embodiment, the first electrode 41 is subjected to half-cut processing such that the first conductive film 31 is penetrated and the surface 21a of the first base material 21 is slightly dug.
  • One insulating portion 50A was formed.
  • the first electrode 41 obtained above After processing the first electrode 41 obtained above into a rectangular shape with a size of 200 mm, it was wound around a metal rod with a diameter of 5 mm, and both ends were grasped and bent at 360 degrees in a pseudo manner. At this time, the first electrode 41 was wound around the first insulating portion 50A formed by half-cut along the metal bar, and the presence or absence of current leakage in the first insulating portion 50A in this state was examined. .
  • the present embodiment it has been confirmed that current leakage does not occur in the first insulating portion 50A. That is, when the width dimension WL of the first insulating portion 50A is set to the above-mentioned dimension, the possibility that the processed end portions T contact with each other and electrical leak as shown in FIGS. 12A and 12B is extremely low. It has been confirmed that power generation is not affected even when the first electrode 41 described above is applied to a dye-sensitized solar cell and used by bending.
  • Example 2 In Example 2, the same conditions and procedures as in Example 1 were used except that laser processing was performed while adjusting the processing conditions of the laser such that the width dimension WL of the first insulating portion 50A was 0.1 mm.
  • the obtained first electrode 41 is processed into a rectangular shape with a size of 200 mm by a method similar to that of Example 1, and then wound around a metal rod with a diameter of 5 mm to be virtually bent at 360 degrees.
  • the current leak in the first insulating portion 50A did not occur. That is, even when the width dimension WL of the first insulating portion 50A is 0.1 mm, as in the case of the first embodiment, the possibility that the processed end portions come in contact with each other to cause an electrical leak is extremely low. It has been confirmed that power generation is not affected even when one electrode 41 is applied to a dye-sensitized solar cell and used by bending it.
  • the laser processing is performed while adjusting the processing conditions of the laser so that the first insulating portion does not penetrate the first conductive film 31 without changing the width dimension WL and becomes concave.
  • the first conductive film 31 has the first insulating portion 51A in the form of a strip and concave in plan view, provided in the dye-sensitized solar cell 10A shown in FIG.
  • the first electrode 41 was manufactured.
  • the output intensity of the laser is set so that the depth of the recessed first insulating portion 51A is such that at least a portion of the first conductive film 31 remains, ie, the depth not to penetrate the first conductive film 31. Adjusted.
  • the obtained first electrode 41 is processed into a rectangular shape with a size of 200 mm by a method similar to that of Example 1, and then wound around a metal rod with a diameter of 5 mm to be virtually bent at 360 degrees.
  • the current leak in the first insulating portion 50A did not occur. That is, even in the case where the first insulating portion 50A is formed in a band shape in a plan view and in a concave shape, the possibility that the processed end portions come in contact with each other and electrical leaks is extremely low as in the case of the first embodiment and the second embodiment. Even when the first electrode 41 described above is applied to a dye-sensitized solar cell and used by bending it, it has been confirmed that power generation is not affected.
  • Example 4 the first electrode 41 in which the first insulating portion 50A penetrating the first conductive film 31 is formed as shown in FIGS. 1 and 2 under the same conditions and procedure as the first embodiment.
  • the second conductive film 32 was laminated on the surface 22 a of the second base material 21 using a PET material as the second base material 22 and using an ITO material as the second conductive film 32.
  • the second insulating portion 50B penetrating (dividing) in a band shape in plan view is formed under the same conditions as the forming conditions of the first insulating portion 50A in the first embodiment.
  • a second electrode 42 as shown in FIGS. 1 and 2 was produced.
  • the processing conditions of the laser were adjusted so that the width dimension WL of the second insulating portion 50B was 3 mm, and the second insulating portion 50B was formed by laser processing.
  • an acrylic ultraviolet curable resin is applied as a sealing material to the surface 31 a of the first conductive film 31 in the first electrode 21 at a position corresponding to the first insulating portion 50A, as shown in FIGS. 1 and 2.
  • the sealing material 46 was formed so as to cover the entire opening of the first insulating portion 50A and to make the inside of the first insulating portion 50A substantially hollow.
  • the surface 32 a is formed on the second conductive film 32.
  • a sealing material 46 was formed by applying the same sealing material as described above to the portion corresponding to the second insulating portion 50B.
  • the wiring 48 was formed by flowing Micro Pearl (registered trademark: manufactured by Sekisui Chemical Co., Ltd.) as a wiring material into the wiring arrangement region R ⁇ b> 48 of the first electrode 41.
  • the electrolytic solution 14 was applied to the power generation unit disposition region R ⁇ b> 44 including the semiconductor layer 12 of the first electrode 41.
  • the catalyst layer 16 was formed in the power generation portion disposition region R44 of the surface 32a of the second conductive film 32 by a sputtering method using a commercially available sputtering apparatus. At this time, platinum was used as a catalyst layer material.
  • the first electrode 41 is introduced along the substantially horizontal direction D41 between the first pressing roll 91 as shown in FIG. 9 and the second pressing roll 92 disposed therebelow, and also obliquely
  • the second electrode 42 was introduced from the upper direction D42, and the first electrode 41 and the second electrode 42 were superimposed via the power generation unit 44, the sealing material 46, and the wiring 48.
  • the overlapped first electrode 41 and second electrode 42 were passed between the first pressing roll 91 and the second pressing roll 92 to press the first electrode 41 and the second electrode 42 to each other.
  • the sealing material 46 is cured by irradiating the pressed first electrode 41 and the second electrode 42 with ultraviolet light using a UV lamp, and the first electrode 41 and the sealing material 46 are While bonding together, the 2nd electrode 42 and the sealing material 46 were bonded together. At this time, the second electrode 42 and the sealing material 46 were bonded so that the entire opening of the second insulating portion 50B formed on the surface 32a of the second conductive film 32 was covered with the sealing material 46.
  • the obtained dye-sensitized solar cell 10 is processed into a rectangular shape with a size of 200 mm by the same method as in Example 1, it is wound around a metal rod with a diameter of 5 mm and bent at 360 degrees in a pseudo manner The presence or absence of the current leak was confirmed, and no current leak occurred in the first insulating portion 50A and the second insulating portion 50B. That is, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is set to a size defined by the present invention, and the sealing material 46 is further provided to cover the entire opening of the first insulating portion 50A and the second insulating portion 50B. It has been confirmed that the possibility of electrical leakage due to the contact of the processing ends with each other is extremely low, and power generation is not affected even when the dye-sensitized solar cell 10 is used by bending.
  • Example 5 In the fifth embodiment, the procedure and conditions are the same as in the fourth embodiment except that the sealing material 46 is adjusted so that the sealing material 46 enters the insides of the first insulating portion 50A and the second insulating portion 50B. As shown in FIG. 10, a dye-sensitized solar cell 10C in which the insides of the first insulating portion 50A and the second insulating portion 50B were completely embedded with the sealing material 46 was manufactured.
  • an acrylic ultraviolet curable resin having a viscosity of 300 Pa ⁇ s is used as a sealing material so that the sealing material can easily enter the inside of the first insulating portion 50A and the second insulating portion 50B.
  • the work was left for approximately one minute.
  • lamination is performed as compared with Example 4 described above. The pressing force of the roll was raised. According to the above procedure, a dye-sensitized solar cell (electric module) according to the present invention as shown in FIG. 10 was produced.
  • the sealing material is formed such that the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is defined in the present invention, and the inside of the first insulating portion 50A and the second insulating portion 50B is completely embedded.
  • the obtained first electrode was processed into a rectangular shape with a size of 200 mm by the same method as in Examples 1 to 3 and then wound around a metal rod having a diameter of 5 mm to be virtually bent at 360 degrees When the presence or absence of the current leak at the time of was confirmed, it was confirmed that the leak has generate
  • the width dimension WL of the first insulating portion is equal to or less than a predetermined dimension, there is a high possibility that an electrical leak will occur due to the contact between the processing ends T, and such a first electrode is a dye-sensitized solar cell In the case of using it and bending it, it has become clear that there is a risk that the poor performance of the dye-sensitized solar cell may occur due to the insulation failure and the cell performance may deteriorate.
  • the present invention is applied, and the width dimension WL in the surface direction of each of the first conductive film in the first electrode and the second conductive film in the second electrode is 0.1 mm or more Even when the dye-sensitized solar cell (electric module) is bent by providing the first insulating portion and the second insulating portion in a planar view band of 3 mm or less, the electric due to the contact between the processing ends It is clear that it is possible to prevent the occurrence of a leak.
  • the electrical module of the present invention is excellent in cell characteristics because it can be well insulated, can prevent electrical leakage, and is particularly suitable in the field of electrical modules such as dye-sensitized solar cells. is there.
  • Dye-sensitized solar cell 12 semiconductor layer 21 first base material 21a surface 22 second base material 22a surface 31 first conductive film 31a surface 32 second conductive film 32a surface 41 first electrode 42 second electrode 44: Power generation unit 46: Sealing materials 50A, 51A, 52A: First insulating unit (insulating unit) 50B, 51B, 52B ... second insulating portion (insulating portion)

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Abstract

This electric module (10) is provided with: a first electrode (41) having a first substrate (21) and a first electroconductive film (31); a second electrode (42) having a second substrate (22) and a second electroconductive film (32); power generation units (44) that include a semiconductor layer (12) and are provided between the first electrode (41) and the second electrode (42), a plurality of the power generation units (44) being provided at a distance from each other along the planar direction of the first electrode (41) and the second electrode (42); and sealing materials (46) provided on both sides of the power generation units (44) along the planar direction. A first insulating part (50A) and a second insulating part (50B) having a strip shape in plan view are provided at portions of the first electroconductive film (31) and the second electroconductive film (32) facing a sealing material (46), each of the insulating parts being formed in a concave shape or formed so as to penetrate through the first electroconductive film (31) or the second electroconductive film (32) in the thickness direction. The planar-direction width dimension WL of the first insulating part (50A) and the second insulating part (50B) is 0.1-3 mm inclusive.

Description

電気モジュール及び電気モジュールの製造方法Electric module and method of manufacturing electric module
　本発明は、電気モジュール及び電気モジュールの製造方法に関する。
本出願は、２０１８年１月２４日に日本に出願された特願２０１８－００９６８５号に基づき優先権を主張し、その内容をここに援用する。 The present invention relates to an electrical module and a method of manufacturing the electrical module.
Priority is claimed on Japanese Patent Application No. 2018-009685, filed on Jan. 24, 2018, the content of which is incorporated herein by reference.
　近年、クリーンな発電源として、光エネルギーを直接かつ即時に電力に変換することができ、二酸化炭素等の汚染物質を排出しない電気モジュールである太陽電池が注目されている。その中でも、色素増感太陽電池は、高い変換効率を有し、比較的簡易な方法により製造され、かつ原材料の単価が安価であるため、次世代太陽電池として期待されている。 In recent years, as a clean power source, a solar cell that is an electric module that can convert light energy directly and immediately into electric power and does not discharge pollutants such as carbon dioxide attracts attention. Among them, dye-sensitized solar cells are expected as next-generation solar cells because they have high conversion efficiency, are manufactured by a relatively simple method, and are inexpensive in the cost of raw materials.
　従来、色素増感太陽電池は、一般に、光電極と、対向電極と、電解液又は電解液層とを備えて構成されることが知られている。また、光電極としては、少なくとも、透明導電層、半導体層、色素を有して構成されることが知られている。このような色素増感太陽電池においては、例えば、光電極側に光が照射されると、半導体層に吸着された色素が光を吸収し、色素分子内の電子が励起され、その電子が半導体へ渡される。そして、光電極側で発生した電子が外部回路を通じて対向電極側に移動し、この電子が電解液を通じて光電極側に戻る。このような過程が繰り返されることで、電気エネルギーが生じる構成とされている。 Conventionally, a dye-sensitized solar cell is generally known to be configured to include a photoelectrode, a counter electrode, and an electrolytic solution or an electrolytic solution layer. In addition, it is known that the photoelectrode includes at least a transparent conductive layer, a semiconductor layer, and a dye. In such a dye-sensitized solar cell, for example, when light is irradiated to the photoelectrode side, the dye adsorbed to the semiconductor layer absorbs the light, the electrons in the dye molecule are excited, and the electrons are semiconductor Passed to Then, the electrons generated on the photo electrode side move to the counter electrode side through the external circuit, and the electrons return to the photo electrode side through the electrolytic solution. By repeating such a process, electric energy is generated.
　直列構造の色素増感太陽電池の製造においては、先ず、表面に第一導電膜が設けられた第一基材及び表面に第二導電膜が設けられた第二基材に対して、それぞれの所望の位置で絶縁処理を行う。この際、必要に応じて触媒層等を設けた後、第一導電膜又は第二導電膜の絶縁処理を施した位置に合わせて封止材を設け、この封止材を介して、所定の領域に半導体層及び電解質（即ち、発電層）を設ける。その後、互いの絶縁箇所を適宜ずらして第一導電膜と第二導電膜とを対向させ、導電膜同士の間に封止材及び発電層等が挟まれた状態で第一基材と第二基材とを貼り合わせる（例えば、特許文献１を参照）。 In the production of a dye-sensitized solar cell having a series structure, first, the first base on which the first conductive film is provided and the second base on which the second conductive film is provided An insulation process is performed at a desired position. Under the present circumstances, after providing a catalyst layer etc. as needed, according to the position which performed the insulation process of the 1st conductive film or the 2nd conductive film, a sealing material is provided and predetermined | prescribed through this sealing material A semiconductor layer and an electrolyte (i.e., a power generation layer) are provided in the region. Thereafter, the first electrically conductive film and the second electrically conductive film are made to face each other by appropriately shifting the insulating portions, and the first base material and the second electrically conductive layer are sandwiched between the electrically conductive films. The base material is pasted together (for example, refer to patent documents 1).
　上記のようにして製造された直列構造の色素増感太陽電池は、色素増感太陽電池の使用目的等に合わせて、さらに、所望の位置で絶縁処理を施され、所望の大きさに切り出される。 The series-structured dye-sensitized solar cell manufactured as described above is further subjected to insulation treatment at a desired position and cut out to a desired size according to the purpose of use of the dye-sensitized solar cell, etc. .
特開２００７－２７３４２５号公報JP 2007-273425 A
　ところで、最近では、色素増感太陽電池の製造プロセスにおいて、特許文献１に記載のようなロール・ツー・ロール方式（以下、ＲｔｏＲ方式と称することがある）による連続生産方法が採用されるようになっている。ＲｔｏＲ方式を用いて色素増感太陽電池を製造する場合には、主として、ロールの周囲にカッターが設けられたダイカットロールと呼ばれる装置を用いる。そして、カッターの刃先で所望の位置の第一導電膜又は第二導電膜のみを切り込み加工する、所謂ハーフカット加工を行うことで、第一基材又は第二基材を切断することなく絶縁処理を行うことができる。 By the way, recently, in the manufacturing process of a dye-sensitized solar cell, a continuous production method by a roll-to-roll method (hereinafter sometimes referred to as RtoR method) as described in Patent Document 1 is adopted. It has become. In the case of producing a dye-sensitized solar cell using the RtoR method, an apparatus called a die-cut roll in which a cutter is provided around the roll is mainly used. And by performing so-called half cut processing in which only the first conductive film or the second conductive film at a desired position is cut by the blade edge of the cutter, insulation processing is performed without cutting the first base material or the second base material. It can be performed.
　一方、比較的小さい面積の色素増感太陽電池を製造する場合等には、例えば、レーザー加工装置等を用いて、所望の位置における第一導電膜及び第二導電膜のみを、厚み方向で全体又は一部を焼き切る。このように、第一基材及び第二基材を切断することなくハーフカット加工で絶縁させることで、上述の絶縁処理を正確な位置で行うことができる。 On the other hand, in the case of manufacturing a dye-sensitized solar cell having a relatively small area, for example, only the first conductive film and the second conductive film at the desired position in the thickness direction as a whole using a laser processing apparatus etc. Or burn out a part. Thus, the above-mentioned insulation processing can be performed in a correct position by insulating by half cut processing, without cutting the 1st substrate and the 2nd substrate.
　ここで、特にフィルム型の色素増感太陽電池の場合、この太陽電池を折り曲げた状態として使用することも想定される。しかしながら、上記のようなハーフカット加工で絶縁領域を形成した場合には、図１２Ａ及び図１２Ｂに示すように、太陽電池を湾曲させた際に、第一導電膜及び第二導電膜にそれぞれ形成された加工端部Ｔが、絶縁領域Ｅを超えて隣接する加工端部Ｔ同士で接触してしまい、電気的リークが発生するおそれがある。このような電気的リークが発生した場合には、色素増感太陽電池の動作不良が発生し、電池性能が低下するという問題があった。 Here, particularly in the case of a film type dye-sensitized solar cell, it is also conceivable to use this solar cell in a bent state. However, when the insulating region is formed by the above half-cut process, as shown in FIGS. 12A and 12B, when the solar cell is bent, it is formed on the first conductive film and the second conductive film, respectively. The processed end portion T contacts the adjacent processed end portions T beyond the insulating region E, which may cause an electrical leak. When such an electrical leak occurs, there is a problem that the malfunction of the dye-sensitized solar cell occurs and the cell performance is lowered.
　本発明は上記課題に鑑みてなされたものであり、良好な絶縁処理が施され、電気的リークが生じるのを防止することが可能な電気モジュール及び電気モジュールの製造方法を提供することを目的とする。 The present invention has been made in view of the above problems, and it is an object of the present invention to provide an electrical module and a method of manufacturing the electrical module which are subjected to a good insulation process and can prevent the occurrence of electrical leakage. Do.
　本発明者等は、特に、フィルム型の電気モジュールを折り曲げて使用した場合において電気的リークが発生するのを防止するため、鋭意検討を重ねた。この結果、ハーフカット加工によって形成される絶縁領域の幅寸法を特定の範囲に最適化することにより、電気モジュールを折り曲げて使用した場合でも、加工端部同士が接触するのを防止できることを知見した。これにより、電気モジュールの使用形態に関わらず、電気的リークが発生するのを防止でき、優れた電池性能が得られることを見出し、本発明を完成させた。 The inventors of the present invention have conducted intensive studies to prevent the occurrence of electrical leakage particularly when the film-type electrical module is used by bending. As a result, it was found that by optimizing the width dimension of the insulating region formed by half-cut processing to a specific range, it is possible to prevent the processed ends from coming in contact even when the electric module is bent and used. . As a result, it has been found that regardless of the type of use of the electrical module, the occurrence of electrical leakage can be prevented, and excellent battery performance can be obtained, and the present invention has been completed.
即ち、本発明に係る電気モジュールは、第一基材と、該第一基材の表面に設けられた第一導電膜とを有する第一電極と、第二基材と、該第二基材の表面に設けられた第二導電膜とを有する第二電極と、半導体層を含む発電部であって、前記第一電極と前記第二電極との間に設けられ、前記第一電極及び前記第二電極の面方向に沿って離間して複数設けられた発電部と、前記面方向に沿って前記発電部の両側に設けられた封止材と、を備え、前記第一導電膜及び前記第二導電膜の前記封止材と対向する部分に、それぞれ、前記第一導電膜又は前記第二導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状に形成された、平面視帯状の絶縁部が設けられており、且つ、該絶縁部の前記面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下であることを特徴とする。 That is, the electric module according to the present invention comprises a first electrode, a first electrode having a first conductive film provided on the surface of the first substrate, a second substrate, and the second substrate. A power generation unit including a semiconductor layer and a second electrode having a second conductive film provided on the surface of the first electrode, the second electrode being provided between the first electrode and the second electrode; A plurality of power generation units provided spaced apart along the surface direction of the second electrode; and a sealing material provided on both sides of the power generation unit along the surface direction, the first conductive film and the above The portion of the second conductive film opposed to the sealing material is formed so as to penetrate the first conductive film or the second conductive film in the thickness direction or to be open on the side of the sealing material. A strip-shaped insulating portion formed in a plan view is provided, and the width dimension of the insulating portion in the surface direction is 0.1 mm. And characterized in that the upper 3mm or less.
　本発明によれば、上記のように、第一電極における第一導電膜及び第二電極における第二導電膜に形成された平面視帯状の絶縁部が、それぞれ、面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下であることにより、電気モジュールを折り曲げた状態とした場合でも、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのを防止でき、絶縁性が確実に担保される。このような、良好な絶縁部が設けられることにより、電気モジュールの使用形態に関わらず、簡便な構成で電気的リークが発生するのを防止でき、優れた電池性能を得ることが可能になる。また、面方向において封止材同士の間に配線が設けられている場合には、各絶縁部の幅寸法が上述範囲とされることで配線の移動が抑えられ、電気モジュールの発電性能が安定する。 According to the present invention, as described above, the band-shaped insulating portions in plan view formed on the first conductive film of the first electrode and the second conductive film of the second electrode each have a width dimension of 0. By being 1 mm or more and 3 mm or less, even when the electric module is bent, it is possible to prevent the ends formed on the first conductive film and the second conductive film from coming in contact with each other beyond the insulating portion. The insulation property is secured securely. By providing such a good insulating portion, it is possible to prevent the occurrence of an electrical leak with a simple configuration regardless of the use form of the electric module, and it is possible to obtain excellent battery performance. Moreover, when the wiring is provided between the sealing materials in the plane direction, the movement of the wiring is suppressed by the width dimension of each insulating portion being in the above range, and the power generation performance of the electric module is stable. Do.
　なお、本明細書で説明する、「電気モジュールを折り曲げて使用する」とは、例えば、電気モジュールの設置場所のサイズや形状に合わせて、機械的破壊が生じない程度で電気モジュールを変形させることを意味する。 As used herein, “folding and using an electrical module” means, for example, deforming the electrical module to such an extent that mechanical breakage does not occur according to the size and shape of the installation location of the electrical module. Means
また、本発明に係る電気モジュールは、上記構成において、前記封止材が、前記絶縁部の前記封止材側における開口全体を覆うように設けられていることが好ましい。 Further, in the electric module according to the present invention, in the above-described configuration, preferably, the sealing material is provided to cover the entire opening on the sealing material side of the insulating portion.
本発明によれば、封止材が絶縁部の開口全体を覆うように設けられていることで、電気モジュールを折り曲げた状態とした場合に、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのをより確実に防止できる。 According to the present invention, the sealing material is provided so as to cover the entire opening of the insulating portion, thereby forming the first conductive film and the second conductive film when the electric module is in a bent state. The end portions can be more reliably prevented from coming in contact with each other beyond the insulating portion.
また、本発明に係る電気モジュールは、上記構成において、前記封止材が、少なくとも一部が前記絶縁部の内部に入り込むように設けられていることがより好ましい。 In the electric module according to the present invention, it is more preferable that the sealing material is provided such that at least a part of the sealing material enters the inside of the insulating portion.
本発明によれば、封止材の少なくとも一部が絶縁部の内部に入り込むように設けられていることで、電気モジュールを折り曲げた状態とした場合に、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのをさらに確実に防止できる。 According to the present invention, the first conductive film and the second conductive film are provided in a state where the electric module is bent by providing at least a part of the sealing material into the inside of the insulating portion. The formed ends can be further reliably prevented from coming in contact with each other beyond the insulating portion.
　また、本発明に係る電気モジュールは、上記構成において、前記絶縁部の前記面方向における幅寸法が０．３ｍｍ以上２ｍｍ以下であることがより好ましい。 Further, in the electric module according to the present invention, in the above-described configuration, the width dimension in the surface direction of the insulating portion is more preferably 0.3 mm or more and 2 mm or less.
　本発明によれば、第一電極に形成された第一絶縁部及び第二電極に形成された第二絶縁部が、それぞれ上記の幅寸法であることにより、電気モジュールを折り曲げた状態とした場合の各絶縁部における絶縁性がより確実に担保される。 According to the present invention, when the first insulating portion formed in the first electrode and the second insulating portion formed in the second electrode each have the above-described width dimensions, the electric module is bent The insulation in each of the insulating parts is more securely ensured.
また、本発明に係る電気モジュールの製造方法は、上記構成を備える電気モジュールを製造するであって、前記第一電極を切り込み加工することにより、前記第一基材の表面に設けられた前記第一導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状とされた、平面視帯状の第一絶縁部を形成する第一絶縁工程と、前記第二電極を切り込み加工することにより、前記第二基材の表面に設けられた前記第二導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状とされた、平面視帯状の第二絶縁部を形成する第二絶縁工程と、前記第一導電膜の表面において、前記第一絶縁部が形成された部分、及び、前記第一導電膜と前記第二導電膜とを対向させたときに、前記第二導電膜の表面に形成された前記第二絶縁部に対応する位置に、前記封止材を形成するとともに、前記面方向における前記封止材同士の間に、半導体層を含む発電部を形成する発電部形成工程と、前記第一導電膜と前記第二導電膜とを対向させ、前記第一電極と前記第二電極とを貼り合わせる貼合工程と、を有し、前記第一絶縁工程及び前記第二絶縁工程は、前記第一絶縁部及び前記第二絶縁部を、それぞれ、前記面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下となるように形成することを特徴とする。 A method of manufacturing an electric module according to the present invention manufactures an electric module having the above configuration, wherein the first electrode provided on the surface of the first base by cutting the first electrode. A first insulating step of forming a first insulating portion having a strip shape in plan view, which is formed so as to pass through a conductive film in the thickness direction or to be open toward the sealing material, and the second electrode When viewed from above, the second conductive film provided on the surface of the second base material is penetrated in the thickness direction by cutting or formed into a concave shape so as to be open on the sealing material side A second insulating step of forming a second insulating portion, and a portion of the surface of the first conductive film where the first insulating portion is formed, and the first conductive film and the second conductive film are opposed to each other Formed on the surface of the second conductive film when A power generation portion forming step of forming a power generation portion including a semiconductor layer between the sealing materials in the surface direction while forming the sealing material at a position corresponding to the second insulating portion; And bonding a first conductive film and the second conductive film opposite to each other and bonding the first electrode and the second electrode, wherein the first insulation process and the second insulation process The first insulating portion and the second insulating portion are each formed to have a width dimension in the surface direction of 0.1 mm or more and 3 mm or less.
本発明によれば、上記のように、第一絶縁工程及び第二絶縁工程において形成する第一絶縁部及び第二絶縁部を、それぞれ、前記面方向における幅寸法が上記範囲となるように形成することで、上述したような、電気モジュールを折り曲げた状態とした場合でも、第一導電膜及び第二導電膜に形成された端部同士が接触するのを防止でき、絶縁性が確実に担保された電気モジュールを製造できる。これにより、電気モジュールの使用形態に関わらず、電気的リークが発生するのを防止でき、優れた電池性能を有する電気モジュールを得ることが可能になる。 According to the present invention, as described above, the first insulating portion and the second insulating portion formed in the first insulating step and the second insulating step are formed such that the width dimension in the surface direction is in the above range. Thus, even when the electric module is bent as described above, the end portions formed on the first conductive film and the second conductive film can be prevented from coming in contact with each other, and the insulation can be reliably ensured. Can produce an electrical module. This makes it possible to prevent the occurrence of electrical leakage regardless of the type of use of the electrical module, and to obtain an electrical module having excellent battery performance.
また、本発明に係る電気モジュールの製造方法は、上記構成において、前記発電部形成工程が、前記封止材を、前記第一絶縁部の前記封止材側における開口全体を覆うように形成する工程であり、前記貼合工程が、前記封止材が前記第二絶縁部の開口全体を覆うように、前記第一電極と前記第二電極とを貼り合わせる工程であることが好ましい。 Further, in the method of manufacturing an electric module according to the present invention, in the above-described configuration, the power generation portion forming step forms the sealing material so as to cover the entire opening on the sealing material side of the first insulating portion. It is a process, It is preferable that the said bonding process is a process of bonding together the said 1st electrode and the said 2nd electrode so that the said sealing material may cover the whole opening of the said 2nd insulation part.
本発明によれば、上記のような方法を採用することで、電気モジュールを折り曲げた状態とした場合に、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのをより確実に防止できる電気モジュールを製造することが可能になる。 According to the present invention, when the electric module is bent by adopting the method as described above, the end portions formed in the first conductive film and the second conductive film exceed the insulating portion. It is possible to manufacture an electrical module that can more reliably prevent contact.
また、本発明に係る電気モジュールの製造方法は、上記構成において、前記発電部形成工程が、前記封止材を、少なくとも一部が前記第一絶縁部の内部に入り込むように形成する工程であり、前記貼合工程は、前記封止材の少なくとも一部が前記第二絶縁部の内部に入り込むように、前記第一電極と前記第二電極とを貼り合わせる工程であることがより好ましい。 Further, in the method of manufacturing an electric module according to the present invention, in the above-described configuration, the power generation portion forming step is a step of forming the sealing material so that at least a part thereof enters the inside of the first insulating portion. The bonding step is more preferably a step of bonding the first electrode and the second electrode such that at least a part of the sealing material enters the inside of the second insulating portion.
本発明によれば、上記のような方法を採用することで、電気モジュールを折り曲げた状態とした場合に、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのをさらに確実に防止できる電気モジュールを製造することが可能になる。 According to the present invention, when the electric module is bent by adopting the method as described above, the end portions formed in the first conductive film and the second conductive film exceed the insulating portion. It is possible to manufacture an electrical module that can further reliably prevent contact.
また、本発明に係る電気モジュールの製造方法は、上記構成において、前記第一絶縁工程及び前記第二絶縁工程が、前記第一絶縁部及び第二絶縁部を、それぞれ、前記面方向における幅寸法が０．３ｍｍ以上２ｍｍ以下となるように形成することがより好ましい。 Further, in the method of manufacturing an electric module according to the present invention, in the above-described configuration, the first insulating step and the second insulating step may have the first insulating portion and the second insulating portion each having a width dimension in the surface direction It is more preferable to form so as to be 0.3 mm or more and 2 mm or less.
本発明によれば、第一電極形成された第一絶縁部及び第二電極に形成された第二絶縁部を、それぞれ上記の幅寸法となるように形成することで、上記のような、絶縁性が確実に担保された電気モジュールを製造することが可能になる。 According to the present invention, the insulation as described above is formed by forming the first insulating portion having the first electrode and the second insulating portion formed on the second electrode to have the above width dimensions. It is possible to manufacture an electrical module with a guaranteed quality.
　本発明に係る電気モジュール及び電気モジュールの製造方法によれば、上記した構成により、以下の効果を奏する。
　すなわち、本発明に係る電気モジュールによれば、第一電極における第一導電膜及び第二電極における第二導電膜に形成された平面視帯状の絶縁部が、それぞれ、面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下である構成を採用している。これにより、電気モジュールを折り曲げた状態とした場合でも、第一導電膜及び第二導電膜に形成された端部同士が、絶縁部を超えて接触するのを防止でき、絶縁性が確実に担保される。このような、良好な絶縁部が設けられることにより、電気モジュールの使用形態に関わらず、簡便な構成で電気的リークが発生するのを防止でき、優れた電池性能を得ることが可能になる。 According to the electric module and the method for manufacturing the electric module according to the present invention, the following effects can be obtained by the above-described configuration.
That is, according to the electric module according to the present invention, the strip-shaped insulating portion formed in the first conductive film of the first electrode and the second conductive film of the second electrode has a width dimension in the planar direction of 0 .1 mm or more and 3 mm or less is adopted. Thereby, even when the electric module is in a bent state, it is possible to prevent the ends formed in the first conductive film and the second conductive film from coming in contact with each other beyond the insulating portion, and the insulation property is reliably ensured. Be done. By providing such a good insulating portion, it is possible to prevent the occurrence of an electrical leak with a simple configuration regardless of the use form of the electric module, and it is possible to obtain excellent battery performance.
　また、本発明に係る電気モジュールの製造方法によれば、第一絶縁工程及び第二絶縁工程において形成する第一絶縁部及び第二絶縁部を、それぞれ、前記面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下となるように形成する方法を採用している。これにより、上記のように、電気モジュールを折り曲げた状態とした場合でも、第一導電膜及び第二導電膜に形成された端部同士が接触するのを防止でき、絶縁性が確実に担保された電気モジュールを製造できる。従って、電気モジュールの使用形態に関わらず、電気的リークが発生するのを防止でき、優れた電池性能を有する電気モジュールを得ることが可能になる。 Further, according to the method of manufacturing an electric module according to the present invention, the first insulating portion and the second insulating portion formed in the first insulating step and the second insulating step each have a width dimension of 0.1 mm in the surface direction. The method of forming so as to be 3 mm or less is employed. Thereby, as described above, even when the electric module is bent, it is possible to prevent the end portions formed in the first conductive film and the second conductive film from being in contact with each other, and the insulation property is reliably ensured. Can produce electrical modules. Therefore, regardless of the type of use of the electrical module, it is possible to prevent the occurrence of electrical leakage and to obtain an electrical module having excellent battery performance.
本発明を適用した一実施形態である電気モジュールの構成を模式的に説明する平面図である。It is a top view which illustrates typically composition of an electric module which is one embodiment to which the present invention is applied. 本発明を適用した一実施形態である電気モジュールの構成を模式的に説明する図であり、図１中に示すＸ－Ｘ断面図である。It is a figure which illustrates typically the structure of the electric module which is one Embodiment to which this invention is applied, and is XX sectional drawing shown in FIG. 本発明を適用した一実施形態である電気モジュールの別の構成を模式的に説明する図であり、図１中に示すＸ－Ｘ断面図である。FIG. 7 is a view schematically explaining another configuration of the electric module which is an embodiment to which the present invention is applied, and is a cross-sectional view taken along the line XX in FIG. 1; 本発明を適用した他の実施形態である電気モジュールの構成を模式的に説明する平面図である。It is a top view which illustrates typically composition of an electric module which is other embodiments to which the present invention is applied. 本発明を適用した他の実施形態である電気モジュールの構成を模式的に説明する図であり、図４中に示すＹ－Ｙ断面図である。FIG. 5 is a view schematically illustrating a configuration of an electric module according to another embodiment to which the present invention is applied, and is a cross-sectional view taken along line Y-Y shown in FIG. 本発明を適用した他の実施形態である電気モジュールの構成を模式的に説明する平面図である。It is a top view which illustrates typically composition of an electric module which is other embodiments to which the present invention is applied. 本発明を適用した他の実施形態である電気モジュールの別の構成を模式的に説明する平面図である。It is a top view which illustrates typically another composition of the electric module which is other embodiment to which the present invention is applied. 本発明を適用した他の実施形態である電気モジュールの、さらに別の構成を模式的に説明する平面図である。It is a top view which illustrates typically another composition of the electric module which is other embodiment to which the present invention is applied. 本発明を適用した一実施形態である電気モジュールの製造方法について模式的に説明する図であり、ロール・ツー・ロール方式を適用した製造装置を用いて、第一電極及び第二電極を製造した後、これらを貼り合わせて電気モジュールを製造する手順を示す概略図である。It is a figure which illustrates typically the manufacturing method of the electric module which is one Embodiment to which this invention is applied, and manufactured the 1st electrode and the 2nd electrode using the manufacturing apparatus to which a roll-to-roll system is applied. It is the schematic which shows the procedure which bonds these together and manufactures an electric module. 本発明を適用した他の実施形態である電気モジュールの構成を模式的に説明する断面図である。It is sectional drawing which demonstrates typically the structure of the electric module which is other embodiment to which this invention is applied. 本発明を適用した他の実施形態である電気モジュールの構成を模式的に説明する断面図である。It is sectional drawing which demonstrates typically the structure of the electric module which is other embodiment to which this invention is applied. 従来の電気モジュールの構成の一部を示す模式図である。It is a schematic diagram which shows a part of structure of the conventional electric module. 従来の電気モジュールの構成の一部を示す模式図である。It is a schematic diagram which shows a part of structure of the conventional electric module.
　以下、図面を参照して本発明に係る電気モジュール及び電気モジュールの製造方法の実施の形態について、図１～図１１を適宜参照しながら、その構成を詳細に説明する（図１２Ａ及び図１２Ｂの従来図も適宜参照）。なお、以下の説明で用いる図面は、その特徴をわかりやすくするために、便宜上、特徴となる部分を拡大して示している場合があり、各構成要素の寸法比率等は、実際とは異なる場合がある。また、以下の説明において例示される材料、寸法等は一例であって、本発明はそれらに限定されるものではなく、その要旨を変更しない範囲で適宜変更して実施することが可能である。 Hereinafter, the configuration of the electric module and the method of manufacturing the electric module according to the present invention will be described in detail with reference to the drawings with reference to FIGS. 1 to 11 as appropriate (FIGS. 12A and 12B). See also the conventional figure). In the drawings used in the following description, in order to make the features easy to understand, the features that are the features may be shown enlarged for convenience, and the dimensional ratio of each component is different from the actual one. There is. In addition, the materials, dimensions, and the like exemplified in the following description are merely examples, and the present invention is not limited to them, and can be appropriately changed and implemented without changing the gist of the invention.
　なお、以下の説明においては、本発明に係る電気モジュールの一例として、ＲｔｏＲ方式を用いて製造されるフィルム型の色素増感太陽電池を挙げて説明する。ここで、本発明を適用した電気モジュールは、色素増感太陽電池に限定されず、絶縁処理が施された二枚の電極同士を、封止材を介在させて貼り合わせたものであれば、色素増感太陽電池以外の電気モジュールも全て含むものである。また、本発明に係る電気モジュールは、上記のＲｔｏＲ方式を用いて製造されるもの、即ち、基材を所定の方向に搬送しつつ連続的に製造されるものには限定されず、例えば、予め切り分けられた基材毎にセル構造が形成されているものも含むものである。 In addition, in the following description, the film-type dye-sensitized solar cell manufactured using RtoR system is mentioned and demonstrated as an example of the electric module which concerns on this invention. Here, the electric module to which the present invention is applied is not limited to a dye-sensitized solar cell, and two electrodes subjected to insulation processing may be bonded together with a sealing material interposed therebetween, All electrical modules other than dye-sensitized solar cells are also included. Further, the electric module according to the present invention is not limited to one manufactured using the above RtoR method, that is, one continuously manufactured while conveying the base material in a predetermined direction, for example, in advance It also includes those in which a cell structure is formed for each of the cut substrates.
［電気モジュール（色素増感太陽電池）の構成］
　図１及び図２に示すように、本発明を適用した本実施形態の色素増感太陽電池（電気モジュール）１０は、第一電極４１と、第二電極４２と、発電部４４と、封止材４６と、配線４８と、備えている。 [Configuration of electric module (dye-sensitized solar cell)]
As shown in FIG.1 and FIG.2, the dye-sensitized solar cell (electric module) 10 of this embodiment to which this invention is applied is 1st electrode 41, 2nd electrode 42, the electric power generation part 44, and sealing. A material 46 and a wire 48 are provided.
　第一電極４１は、第一基材２１と、この第一基材２１の表面２１ａに設けられた第一導電膜３１とを有する。 The first electrode 41 has a first base 21 and a first conductive film 31 provided on the surface 21 a of the first base 21.
　第一基材２１は、第一導電膜３１、発電部４４の一部（例えば、後述の半導体層１２）や封止材４６、及び配線４８の基台となる部材である。第一基材２１の材質は、ＲｔｏＲ方式を用いた太陽電池の連続生産に適用できる程度に柔軟性を有し、大面積フィルム状に形成可能な材質であれば、特に限定されない。このような第一基材２１の材質としては、例えば、ポリエチレンテレフタレート（ＰＥＴ）、アクリル（ＰＭＭＡ）、ポリカーボネート、ポリエチレンナフタレート（ＰＥＮ）、又はポリイミド等の透明の樹脂材料が挙げられる。 The first base material 21 is a member serving as a base of the first conductive film 31, a part of the power generation unit 44 (for example, the semiconductor layer 12 described later), the sealing material 46, and the wiring 48. The material of the first base material 21 is not particularly limited as long as it is flexible enough to be applicable to continuous production of a solar cell using the RtoR method and can be formed into a large-area film. Examples of the material of the first base 21 include transparent resin materials such as polyethylene terephthalate (PET), acrylic (PMMA), polycarbonate, polyethylene naphthalate (PEN), and polyimide.
なお、第一基材２１の曲げ強度としては、特に限定されないが、色素増感太陽電池１０を折り曲げた際に、後述の第一導電膜３１に形成される第一絶縁部（絶縁部）５０Ａにおいて、加工端部同士が接触（短絡）するのを防止し易くなる観点から、第一基材２１の材料を勘案しながら適宜設定することが好ましい。具体的には、第一基材２１の曲げ強度は、７０ＭＰａ以上とすることが好ましく、８０ＭＰａ以上とすることがより好ましい。一方、色素増感太陽電池１０を、機械的破壊が生じない程度で折り曲げることが可能に構成する観点からは、第一基材２１の曲げ強度は、１５０ＭＰａ以下とすることが好ましく、１４０ＭＰａ以下とすることがより好ましい。 The bending strength of the first base material 21 is not particularly limited, but when the dye-sensitized solar cell 10 is bent, a first insulating portion (insulating portion) 50A formed on the first conductive film 31 described later In the above, it is preferable to appropriately set while considering the material of the first base material 21 from the viewpoint of facilitating prevention of contact (shorting) between the processed end portions. Specifically, the bending strength of the first base material 21 is preferably 70 MPa or more, and more preferably 80 MPa or more. On the other hand, the bending strength of the first base material 21 is preferably 150 MPa or less, and 140 MPa or less from the viewpoint of making it possible to bend the dye-sensitized solar cell 10 to such an extent that mechanical breakage does not occur. It is more preferable to do.
　第一導電膜３１は、第一基材２１の表面２１ａ（即ち、第一基材２１における第二電極４２側の面）のＤ１方向全体にわたって成膜されている。第一導電膜３１の材質としては、例えば、酸化スズ（ＩＴＯ）、酸化亜鉛、フッ素ドープ酸化スズ（ＦＴＯ）等が挙げられる。 The first conductive film 31 is formed over the entire surface 21 a of the first base 21 (that is, the surface of the first base 21 on the second electrode 42 side) in the direction D1. Examples of the material of the first conductive film 31 include tin oxide (ITO), zinc oxide, fluorine-doped tin oxide (FTO), and the like.
　第二電極４２は、第一基材２１に対向する第二基材２２と、第二基材２２の表面２２ａ（第二基材２２における第一電極４１側の面）に設けられた第二導電膜３２とを有する。 The second electrode 42 is provided on the second base 22 facing the first base 21 and on the surface 22 a of the second base 22 (the surface of the second base 22 on the side of the first electrode 41). And a conductive film 32.
第二基材２２は、第二導電膜３２、及び発電部４４の一部（例えば、後述の触媒層１６）の基台となる部材である。第二基材２２の材質は、第一基材２１と同様に、ＲｔｏＲ方式を用いた太陽電池の連続生産に適用できる程度に柔軟性を有し、大面積フィルム状に形成可能な材質であれば、特に限定されない。第二基材２２の材質としては、例えば、第一基材２１と同様の樹脂材料が挙げられる。 The second base 22 is a member serving as a base of the second conductive film 32 and a part of the power generation unit 44 (for example, the catalyst layer 16 described later). The material of the second base material 22 is, like the first base material 21, a material having flexibility to such an extent that it can be applied to the continuous production of a solar cell using the RtoR method and which can be formed into a large area film For example, it is not particularly limited. As a material of the 2nd base material 22, the resin material similar to the 1st base material 21 is mentioned, for example.
第二基材２２の曲げ強度としても、特に限定されず、第一基材２１の場合と同様、色素増感太陽電池１０を折り曲げた際に、後述の第二導電膜３２に形成される第二絶縁部（絶縁部）５０Ｂにおいて、加工端部同士が接触（短絡）するのを防止し易くなること、並びに、機械的破壊が生じない程度で折り曲げることを可能にする観点から、第一基材２１と同様の強度であることが好ましい。 The bending strength of the second base material 22 is not particularly limited, either, as in the case of the first base material 21, when the dye-sensitized solar cell 10 is bent, the second conductive film 32 described later is formed In the second insulating portion (insulation portion) 50B, the first base is preferred from the viewpoint of facilitating prevention of contact (shorting) of the processed ends with each other and bending of the end portions to such an extent that mechanical breakage does not occur. The strength is preferably the same as that of the material 21.
第二導電膜３２は、第二基材２２の表面２２ａのＤ１方向全体にわたって成膜されている。第二導電膜３２の材質としては、例えば、第一導電膜３１と同様の化合物等が挙げられる。 The second conductive film 32 is formed over the entire surface 22 a of the second base 22 in the direction D1. As a material of the 2nd conductive film 32, the compound similar to the 1st conductive film 31, etc. are mentioned, for example.
　発電部４４は、第一電極４１と第二電極４２との間に挟まれ、第一電極４１及び第二電極４２の面方向（図２中に示すＤ１方向）に沿って間隔をおいて複数設けられている。発電部４４は、半導体層１２と、電解液（電解質）１４と、触媒層１６と、を含む。 The power generation unit 44 is interposed between the first electrode 41 and the second electrode 42, and a plurality of the power generation units 44 are spaced along the surface direction of the first electrode 41 and the second electrode 42 (direction D1 shown in FIG. 2). It is provided. The power generation unit 44 includes a semiconductor layer 12, an electrolytic solution (electrolyte) 14, and a catalyst layer 16.
　半導体層１２は、第一導電膜３１の表面３１ａ（即ち、第一導電膜３１における第二電極４２側の面）の発電部配置領域Ｒ４４に形成されている。発電部配置領域Ｒ４４は、図２中に示すＤ１方向において、互いに離間して複数設けられている。 The semiconductor layer 12 is formed in the power generation portion disposition region R44 of the surface 31a of the first conductive film 31 (that is, the surface of the first conductive film 31 on the second electrode 42 side). A plurality of power generation unit disposition areas R44 are provided apart from one another in the direction D1 shown in FIG.
　半導体層１２は、例えば、金属酸化物等に増感色素が担持されることによって染色された多孔質層であり、増感色素から電子を受け取って輸送する機能を有する。このような金属酸化物としては、例えば、酸化チタン（ＴｉＯ２）、酸化亜鉛（ＺｎＯ）、又は酸化スズ（ＳｎＯ２）等が挙げられる。 The semiconductor layer 12 is, for example, a porous layer dyed by supporting a sensitizing dye on a metal oxide or the like, and has a function of receiving and transporting an electron from the sensitizing dye. Examples of such metal oxides include titanium oxide (TiO 2 ), zinc oxide (ZnO), and tin oxide (SnO 2 ).
　上述の増感色素は、有機色素又は金属錯体色素から構成される。有機色素としては、例えば、クマリン系、ポリエン系、シアニン系、ヘミシアニン系、又はチオフェン系等の各種有機色素等が挙げられる。金属錯体色素としては、例えば、ルテニウム錯体等が挙げられる。 The aforementioned sensitizing dyes are composed of organic dyes or metal complex dyes. Examples of the organic dye include various organic dyes such as coumarin dyes, polyene dyes, cyanine dyes, hemicyanine dyes, and thiophene dyes. As a metal complex dye, a ruthenium complex etc. are mentioned, for example.
　電解液１４は、半導体層１２、及び、以下に説明する触媒層１６に接触するように、発電部配置領域Ｒ４４に充填されている。電解液１４としては、例えば、アセトニトリル、ヨウ化ジメチルプロピルイミダゾリウム又はヨウ化ブチルメチルイミダゾリウム等のイオン液体等の液体成分に、ヨウ化リチウム等の支持電解質とヨウ素とが混合された溶液（具体的には、プロピオニトリル等の非水系溶剤）等が挙げられる。 The electrolytic solution 14 is filled in the power generation unit disposition region R44 so as to be in contact with the semiconductor layer 12 and the catalyst layer 16 described below. A solution in which a supporting electrolyte such as lithium iodide and iodine are mixed with a liquid component such as an ionic liquid such as acetonitrile, dimethylpropylimidazolium iodide or butylmethylimidazolium iodide as the electrolytic solution 14 (specific example In particular, non-aqueous solvents such as propionitrile etc. can be mentioned.
　触媒層１６は、第二導電膜３２の表面３２ａ（即ち、第二導電膜３２における第一電極２１側の面）の発電部配置領域Ｒ４４に形成されており、互いに離間して複数設けられている。触媒層１６の材質としては、例えば、ＰＥＤＯＴ、プラチナ、ＩＴＯ、ポリアニリン、又はカーボン等が挙げられる。 The catalyst layer 16 is formed in the power generation portion disposition region R44 of the surface 32a of the second conductive film 32 (that is, the surface of the second conductive film 32 on the first electrode 21 side), and a plurality of catalyst layers are provided separately from each other. There is. Examples of the material of the catalyst layer 16 include PEDOT, platinum, ITO, polyaniline, carbon, and the like.
　封止材４６は、図１中に示すシール部６０とともに、電解液１４を含む発電部４４を発電部配置領域Ｒ４４に封止するためのものである。封止材４６は、図１及び図２中に示すＤ１方向に沿って発電部４４の両側に設けられている。但し、図１及び図２中においては、後述する絶縁部形成領域Ｒ５０（第一絶縁部５０Ａ及び第二絶縁部５０Ｂ）の構造を分かりやすく説明するために、それぞれの発電部４４の近傍を拡大して示していることから、Ｄ１方向に沿った発電部４４の一方の側のみの封止材４６を図示している。具体的には、封止材４６は、Ｄ１方向において発電部４４と隣接するように、発電部配置領域Ｒ４４とは異なる領域である封止材配置領域Ｒ４６に設けられている。 The sealing material 46 is for sealing the power generation portion 44 including the electrolytic solution 14 in the power generation portion disposition region R44 together with the seal portion 60 shown in FIG. 1. The sealing material 46 is provided on both sides of the power generation unit 44 along the direction D1 shown in FIGS. 1 and 2. However, in FIG. 1 and FIG. 2, in order to explain the structure of the insulating portion forming region R50 (the first insulating portion 50A and the second insulating portion 50B) described later in an easy-to-understand manner, the vicinity of each power generation portion 44 is enlarged Therefore, the sealing material 46 on only one side of the power generation unit 44 along the D1 direction is illustrated. Specifically, the sealing material 46 is provided in the sealing material disposition area R46 which is a region different from the power generation portion disposition area R44 so as to be adjacent to the power generation portion 44 in the D1 direction.
　封止材４６は、さらに、第一電極４１と第二電極４２とを貼り合わせて互いを接着するための樹脂等を含む。このような封止材４６の材質としては、例えば、熱可塑性樹脂、熱硬化性樹脂、又は紫外線硬化性樹脂のうち少なくとも一種を含む樹脂材料が挙げられる。
上記のような熱可塑性樹脂としては、例えば、ポリオレフィン系樹脂、ポリエステル系樹脂、ポリカーボネート等が挙げられる。
また、熱硬化性樹脂としては、例えば、フェノール樹脂、エポキシ樹脂、メラニン樹脂、エチレン・酢酸ビニル共重合樹脂（ＥＶＡ）等が挙げられる。
また、紫外線硬化性樹脂としては、例えば、アクリル系樹脂、エポキシ樹脂等が挙げられる。 The sealing material 46 further includes a resin or the like for bonding the first electrode 41 and the second electrode 42 and bonding them to each other. As a material of such a sealing material 46, the resin material which contains at least 1 type in a thermoplastic resin, a thermosetting resin, or an ultraviolet curable resin is mentioned, for example.
Examples of such thermoplastic resins include polyolefin resins, polyester resins, and polycarbonates.
Moreover, as a thermosetting resin, a phenol resin, an epoxy resin, a melanin resin, ethylene-vinyl acetate copolymer resin (EVA) etc. are mentioned, for example.
Moreover, as an ultraviolet curable resin, acrylic resin, an epoxy resin, etc. are mentioned, for example.
封止材４６に用いられる樹脂材料の硬化前の粘度としては、特に限定されない。しかしながら、詳細を後述するように、色素増感太陽電池１０の製造時、硬化することで封止材４６を構成する樹脂材料が、第一絶縁部５０Ａ又は第二絶縁部５０Ｂの内部に入り込みやすくするためには、例えば、３００Ｐａ・ｓ以下であることが好ましい。 The viscosity of the resin material used for the sealing material 46 before curing is not particularly limited. However, as described in detail later, at the time of manufacturing the dye-sensitized solar cell 10, the resin material constituting the sealing material 46 is likely to enter the inside of the first insulating portion 50A or the second insulating portion 50B by curing. In order to do this, for example, it is preferable that the pressure be 300 Pa · s or less.
図２中に示すＤ１方向において、封止材配置領域Ｒ４６に配置された封止材４６同士の間には、配線４８が設けられている。配線４８は、半導体層１２、電解液１４、及び触媒層１６を含む発電部４４同士を接続するための導電構造である。配線４８の材質としては、導通可能な素材であれば特に限定されず、例えば、公知の導電材、導電ペースト、又は導電性微粒子と接着剤の混合物等が挙げられる。なお、色素増感太陽電池１０を所望のパターンで切り出す際に、配線４８を容易に切断可能とする観点からは、配線４８の材質として、例えば、エポキシ樹脂やフェノール樹脂等の接着剤３８に適量の導電粒子３６を混合した導通ペーストを採用することが好ましい。また、配線４８には、封止材４６と同様の材料からなるバインダーを用いてもよい。 Wirings 48 are provided between the sealing materials 46 disposed in the sealing material disposition area R46 in the direction D1 shown in FIG. The wiring 48 is a conductive structure for connecting the power generation units 44 including the semiconductor layer 12, the electrolytic solution 14, and the catalyst layer 16. The material of the wiring 48 is not particularly limited as long as it is a conductive material, and examples thereof include known conductive materials, conductive pastes, or a mixture of conductive fine particles and an adhesive. When the dye-sensitized solar cell 10 is cut out in a desired pattern, an appropriate amount of an adhesive 38 such as an epoxy resin or a phenol resin is used as the material of the wiring 48 from the viewpoint of easily cutting the wiring 48. It is preferable to employ a conductive paste in which conductive particles 36 of the above are mixed. Further, for the wiring 48, a binder made of the same material as the sealing material 46 may be used.
　そして、色素増感太陽電池１０は、図２中に示したＤ１方向に直交する断面において、第一導電膜３１及び第二導電膜３２の封止材４６と対向する部分（即ち、封止材配置領域Ｒ４６）に、平面視において帯状の第一絶縁部（絶縁部）５０Ａ又は第二絶縁部（絶縁部）５０Ｂが設けられている。即ち、第一電極４１の第一導電膜３１には第一絶縁部５０Ａが設けられており、第二電極４２の第二導電膜３２には第二絶縁部５０Ｂが設けられている。また、図２に示す例においては、第一絶縁部５０Ａ及び第二絶縁部５０Ｂは、第一導電膜３１又は第二導電膜３２を厚み方向で貫通するように設けられている。換言すると、第一絶縁部５０Ａは、第一導電膜３１を分断するように設けられており、第二絶縁部５０Ｂは、第二導電膜３２を分断するように設けられている。また、図２に示す例では、第一絶縁部５０Ａ及び第二絶縁部５０Ｂにおける封止材４６側の開口全体が、封止材４６によって覆われている。 Then, in the cross section orthogonal to the D1 direction shown in FIG. 2, the dye-sensitized solar cell 10 is a portion facing the sealing material 46 of the first conductive film 31 and the second conductive film 32 (ie, the sealing material In the arrangement region R46), the first insulating portion (insulating portion) 50A or the second insulating portion (insulating portion) 50B having a strip shape in plan view is provided. That is, the first conductive portion 31 of the first electrode 41 is provided with the first insulating portion 50A, and the second conductive portion 32 of the second electrode 42 is provided with the second insulating portion 50B. Further, in the example illustrated in FIG. 2, the first insulating portion 50A and the second insulating portion 50B are provided to penetrate the first conductive film 31 or the second conductive film 32 in the thickness direction. In other words, the first insulating portion 50A is provided to divide the first conductive film 31, and the second insulating portion 50B is provided to divide the second conductive film 32. Further, in the example illustrated in FIG. 2, the entire opening on the sealing material 46 side in the first insulating portion 50A and the second insulating portion 50B is covered with the sealing material 46.
　そして、第一絶縁部５０Ａ及び第二絶縁部５０Ｂは、面方向における幅寸法、即ち、図２中に示すＤ１方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下の範囲とされている。即ち、図１及び図２において、第一導電膜３１は、第一絶縁部５０Ａによって上記範囲の幅寸法ＷＬで分断され、第二導電膜３２は、第二絶縁部５０Ｂによって上記範囲の幅寸法ＷＬで分断されることで、それぞれの位置において絶縁性が担保されている。 The first insulating portion 50A and the second insulating portion 50B have a width dimension in the plane direction, that is, a width dimension WL in the D1 direction shown in FIG. 2 is in the range of 0.1 mm to 3 mm. That is, in FIG. 1 and FIG. 2, the first conductive film 31 is divided by the width dimension WL of the above range by the first insulating portion 50A, and the second conductive film 32 is the width dimension of the above range by the second insulating portion 50B. By being divided by WL, insulation is secured at each position.
　本実施形態の色素増感太陽電池１０は、第一絶縁部５０Ａ及び第二絶縁部５０Ｂが設けられ、且つ、これらの幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下である。これにより、色素増感太陽電池１０を折り曲げた場合でも、第一導電膜３１及び第二導電膜３２に形成された加工端部同士が絶縁部を超えて接触するのを防止でき、絶縁性が確実に担保される。また、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬが上記範囲であることで、発電部４４の寸法や面積を確保し易くなる。 The dye-sensitized solar cell 10 of the present embodiment is provided with the first insulating portion 50A and the second insulating portion 50B, and the width dimension WL of these is 0.1 mm or more and 3 mm or less. Thereby, even when the dye-sensitized solar cell 10 is bent, it is possible to prevent the processed end portions formed in the first conductive film 31 and the second conductive film 32 from coming in contact with each other beyond the insulating portion, and the insulating property Secured. In addition, when the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above range, the dimensions and the area of the power generation portion 44 can be easily secured.
　ここで、各導電膜に形成される各絶縁部の幅寸法ＷＬが０．１ｍｍ未満だと、図１２Ａ及び図１２Ｂに示すように、電気モジュール（色素増感太陽電池等）を湾曲させた際に、加工端部Ｔが、絶縁領域Ｅを超えて隣接する加工端部Ｔ同士で接触して電気的リークが発生し、動作不良や電池性能が低下を招く場合がある。
一方、各絶縁部の幅寸法ＷＬが３ｍｍを超えると、発電部４４の寸法や面積を十分に確保するのが難しくなる場合がある。 Here, when the width dimension WL of each insulating portion formed in each conductive film is less than 0.1 mm, as shown in FIGS. 12A and 12B, when an electric module (such as a dye-sensitized solar cell) is curved. In addition, the processing end T may contact the processing end T adjacent to each other beyond the insulating region E to cause an electrical leak, which may cause a malfunction or a decrease in battery performance.
On the other hand, if the width dimension WL of each insulating portion exceeds 3 mm, it may be difficult to sufficiently secure the dimensions and the area of the power generation portion 44.
　上記の観点からは、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬは、Ｄ１方向における幅寸法ＷＬが０．３ｍｍ以上２ｍｍ以下であることがより好ましい。第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬをこの範囲とした場合には、上述したような、色素増感太陽電池１０を折り曲げた状態とした場合の各絶縁部における絶縁性がより確実に担保され、且つ、発電部４４の寸法や面積をより十分に確保することが可能になる。
また、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬは、さらに好ましくは０．５ｍｍ以上１ｍｍ以下である。 From the above viewpoint, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is more preferably 0.3 mm or more and 2 mm or less in the D1 direction. When the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in this range, the insulating property in each insulating portion when the dye-sensitized solar cell 10 is bent as described above is It is possible to secure more securely, and to secure the dimensions and the area of the power generation unit 44 more sufficiently.
Further, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is more preferably 0.5 mm or more and 1 mm or less.
また、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬを上記範囲とした場合、封止材４６のＤ１方向における幅寸法は、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの開口全体を覆うこと、並びに、封止材４６と第一導電膜３１との間、及び、封止材４６と第二導電膜３２との間の接着強度を高めること等の観点から、上記の幅寸法ＷＬよりも大きな幅寸法とすることが好ましい。具体的には、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬが０．１ｍｍである場合には、封止材４６の幅寸法は、少なくとも１ｍｍ以上であることが好ましい。また、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬが３ｍｍである場合には、封止材４６の幅寸法は、少なくとも５ｍｍ以上であることが好ましい。 When the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above range, the width dimension of the sealing material 46 in the D1 direction is the entire opening of the first insulating portion 50A and the second insulating portion 50B. From the viewpoints of covering the coating material 46 and the adhesion strength between the sealing material 46 and the first conductive film 31 and between the sealing material 46 and the second conductive film 32, etc. It is preferable to make the width dimension larger than WL. Specifically, when the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is 0.1 mm, the width dimension of the sealing material 46 is preferably at least 1 mm or more. When the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is 3 mm, the width dimension of the sealing material 46 is preferably at least 5 mm or more.
ここで、図２に示す例の色素増感太陽電池１０においては、第一絶縁部５０Ａ及び第二絶縁部５０Ｂが、開口全体が封止材４６によって覆われながら略空洞とされているが、本実施形態では、このような構成には限定されない。本実施形態においては、例えば、図１０中に示す色素増感太陽電池１０Ｃのように、封止材４６の少なくとも一部が、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部に入り込むように形成されていることが、色素増感太陽電池を折り曲げた際に、第一絶縁部５０Ａ及び第二絶縁部５０Ｂにおいて、加工端部同士が接触（短絡）するのを確実に防止できる観点から好ましい。また、図示例のように、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部が封止材４６で完全に埋め込まれていることが、上記効果がより顕著に得られる観点からさらに好ましい。 Here, in the dye-sensitized solar cell 10 of the example shown in FIG. 2, the first insulating portion 50A and the second insulating portion 50B are substantially hollow while the entire opening is covered with the sealing material 46, The present embodiment is not limited to such a configuration. In the present embodiment, for example, as in the dye-sensitized solar cell 10C shown in FIG. 10, at least a part of the sealing material 46 is inserted into the first insulating portion 50A and the second insulating portion 50B. It is preferable that it is formed from the viewpoint of reliably preventing the processed end portions from contacting (shorting) in the first insulating portion 50A and the second insulating portion 50B when the dye-sensitized solar cell is bent. . Further, as in the illustrated example, it is more preferable that the insides of the first insulating portion 50A and the second insulating portion 50B be completely embedded with the sealing material 46 from the viewpoint of achieving the above-mentioned effects more remarkably.
本実施形態の色素増感太陽電池１０は、上記のような、良好な絶縁部が設けられることにより、色素増感太陽電池１０の使用形態に関わらず、簡便な構成で電気的リークが発生するのを防止でき、優れた電池性能を得ることが可能になる。即ち、設置スペースのサイズや形状に関わらず、電池性能を低下させることなく、形状をフレキシブルに可変させながら色素増感太陽電池１０を設置できる。また、面方向において封止材４６同士の間に配線が設けられている場合には、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬが上述範囲とされることで配線の移動が抑えられ、色素増感太陽電池１０の発電性能が安定する効果が得られる。 In the dye-sensitized solar cell 10 of the present embodiment, an electrical leak is generated with a simple configuration regardless of the usage form of the dye-sensitized solar cell 10 by providing the above-described good insulating portion Can be prevented and excellent battery performance can be obtained. That is, regardless of the size and the shape of the installation space, the dye-sensitized solar cell 10 can be installed while flexibly changing the shape without reducing the battery performance. In addition, in the case where a wire is provided between the sealing materials 46 in the plane direction, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above-described range so that the wire moves. Thus, the effect of stabilizing the power generation performance of the dye-sensitized solar cell 10 can be obtained.
　なお、本発明に係る色素増感太陽電池１０は、上記のような各種の樹脂材料等で構成されることから、一定の柔軟性（屈曲性）を有して構成される。本実施形態で説明する色素増感太陽電池（電気モジュール）の折り曲げ形態としては、上述したように、例えば、設置場所のサイズや形状に合わせて、機械的破壊が生じない程度で色素増感太陽電池を変形させる形態が挙げられる。 Since the dye-sensitized solar cell 10 according to the present invention is made of various resin materials as described above, it has a certain degree of flexibility (flexibility). As a bending form of the dye-sensitized solar cell (electric module) described in the present embodiment, as described above, for example, dye-sensitized solar to the extent that mechanical destruction does not occur according to the size and shape of the installation location There is a mode in which the battery is deformed.
　さらに、本発明に係る電気モジュールに備えられる第一絶縁部及び第二絶縁部としては、図２中に例示した第一絶縁部５０Ａ及び第二絶縁部５０Ｂのような、第一導電膜３１及び第二導電膜３２を厚み方向で貫通（分断）した構成のものには限定されない。本発明においては、例えば、図３に示す色素増感太陽電池１０Ａのように、第一導電膜３１及び第二導電膜３２を貫通せず、平面視帯状で封止材４６側に開口して凹状に形成され、且つ、幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下の範囲である第一絶縁部５１Ａ及び第二絶縁部５１Ｂを有した構成を採用してもよい。図３に示す例でも、第一絶縁部５１Ａ及び第二絶縁部５１Ｂにおける封止材４６側の開口全体が、封止材４６によって覆われるように構成されている。このような、凹状の第一絶縁部５１Ａ及び第二絶縁部５１Ｂを有する構成を採用した場合においても、上記の第一絶縁部５０Ａ及び第二絶縁部５０Ｂの場合と同様、色素増感太陽電池１０を折り曲げても、第一導電膜３１及び第二導電膜３２に形成された加工端部同士が絶縁部を超えて接触するのを防止でき、絶縁性が確実に担保される。また、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの幅寸法ＷＬが上記範囲であることで、発電部４４の寸法や面積を確保し易くなる。 Furthermore, as the first insulating portion and the second insulating portion provided in the electric module according to the present invention, the first conductive film 31 and the first insulating portion 50A and the second insulating portion 50B illustrated in FIG. The configuration is not limited to the configuration in which the second conductive film 32 penetrates (is divided) in the thickness direction. In the present invention, for example, as in the dye-sensitized solar cell 10A shown in FIG. 3, the first conductive film 31 and the second conductive film 32 are not penetrated, and they are opened in the shape of a strip in plan view You may employ | adopt the structure formed in concave shape and having the 1st insulation part 51A and the 2nd insulation part 51B which are the ranges of 0.1 mm-3 mm in width dimension WL. Also in the example shown in FIG. 3, the entire opening on the side of the sealing material 46 in the first insulating portion 51A and the second insulating portion 51B is configured to be covered by the sealing material 46. Even in the case of adopting such a configuration having the concave first insulating portion 51A and the second insulating portion 51B, as in the case of the first insulating portion 50A and the second insulating portion 50B, a dye-sensitized solar cell Even when 10 is bent, the processed end portions formed in the first conductive film 31 and the second conductive film 32 can be prevented from contacting each other beyond the insulating portion, and the insulation property can be assuredly ensured. In addition, when the width dimension WL of the first insulating portion 51A and the second insulating portion 51B is in the above range, the dimension and the area of the power generation portion 44 can be easily secured.
ここで、第一絶縁部及び第二絶縁部を、第一導電膜３１及び第二導電膜３２を貫通しない凹状に構成した場合には、その絶縁性を確実に担保する観点からは、第一導電膜３１及び第二導電膜３２における底部の厚みをできるだけ薄く構成することが好ましい。より具体的には、図３中に示すＤ１方向に直交する断面（即ち、図３中においてＤ２方向で見た断面）における第一絶縁部５１Ａ及び第二絶縁部５１Ｂの深さ寸法Ｆは、例えば、第一導電膜３１及び第二導電膜３２の厚みを１００としたときに、この厚みに対して９０以上１３０００以下の割合とすることが好ましい。一例としては、第一導電膜３１及び第二導電膜３２の厚みが１００～２００ｎｍである場合には、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの深さ寸法Ｆが１３μｍ程度であり、第一導電膜３１又は第二導電膜３２の深さを１００としたときに６５００～１３０００程度の割合であることが好ましい。 Here, in the case where the first insulating portion and the second insulating portion are formed in a concave shape so as not to penetrate the first conductive film 31 and the second conductive film 32, the first insulating portion and the second insulating portion are not It is preferable that the thickness of the bottom of the conductive film 31 and the second conductive film 32 be as thin as possible. More specifically, the depth dimension F of the first insulating portion 51A and the second insulating portion 51B in a cross section orthogonal to the D1 direction shown in FIG. 3 (that is, a cross section viewed in the D2 direction in FIG. 3) is For example, when the thickness of the first conductive film 31 and the second conductive film 32 is 100, it is preferable to set the ratio to 90 or more and 13000 or less with respect to the thickness. As an example, when the thickness of the first conductive film 31 and the second conductive film 32 is 100 to 200 nm, the depth dimension F of the first insulating portion 51A and the second insulating portion 51B is about 13 μm, and When the depth of the one conductive film 31 or the second conductive film 32 is 100, it is preferable that the ratio is approximately 6500 to 13000.
なお、上記において、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの深さ寸法Ｆが、第一導電膜３１及び第二導電膜３２の厚み寸法を超える割合となるケースが発生する。しかしながら、これは、第一絶縁部５１Ａ及び第二絶縁部５１Ｂが第一導電膜３１及び第二導電膜３２を貫通し、第一基材２１及び第二基材２２を掘り込むようにして凹状の絶縁領域が形成される場合となる。即ち、この場合には、上記同様、第一絶縁部５１Ａ及び第二絶縁部５１Ｂが、第一導電膜３１及び第二導電膜３２を貫通するように形成されるものであり、以下の説明においても同様である。 In the above, a case occurs in which the depth dimension F of the first insulating portion 51A and the second insulating portion 51B exceeds the thickness dimension of the first conductive film 31 and the second conductive film 32. However, in this case, the first insulating portion 51A and the second insulating portion 51B penetrate the first conductive film 31 and the second conductive film 32, and dig in the first base 21 and the second base 22 so as to form a concave insulation. A region will be formed. That is, in this case, similarly to the above, the first insulating portion 51A and the second insulating portion 51B are formed to penetrate the first conductive film 31 and the second conductive film 32, and in the following description, The same is true.
また、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの深さは、図３中に示すＤ２方向、即ち、長さ方向において均一であってもよいが、上記の深さ寸法Ｆの範囲内で不均一な構成とされていてもよい。 Further, the depths of the first insulating portion 51A and the second insulating portion 51B may be uniform in the D2 direction shown in FIG. 3, that is, in the length direction, but within the above depth dimension F The configuration may be uneven.
本実施形態では、図３中に示すような、凹状の第一絶縁部５１Ａ及び第二絶縁部５１Ｂを備える構成を採用した場合においても、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの幅寸法ＷＬと封止材４６のＤ１方向における幅寸法との関係を、上述した第一絶縁部５０Ａ及び第二絶縁部５０Ｂの場合と同様の関係とすることが好ましい。これにより、封止材第一絶縁部５１Ａ及び第二絶縁部５１Ｂの開口全体を、封止材４６で確実に覆うことができるとともに、封止材４６と第一導電膜３１との間、及び、封止材４６と第二導電膜３２との間の接着強度を高めることが可能になる。 In the present embodiment, even when the configuration including the concave first insulating portion 51A and the second insulating portion 51B as shown in FIG. 3 is adopted, the width dimensions of the first insulating portion 51A and the second insulating portion 51B. It is preferable to make the relationship between WL and the width dimension in the D1 direction of the sealing material 46 the same as in the case of the first insulating portion 50A and the second insulating portion 50B described above. Thus, the entire opening of the sealing material first insulating portion 51A and the second insulating portion 51B can be reliably covered with the sealing material 46, and between the sealing material 46 and the first conductive film 31, and The adhesive strength between the sealing material 46 and the second conductive film 32 can be enhanced.
また、図３中に例示したような、凹状の第一絶縁部５１Ａ及び第二絶縁部５１Ｂを備える構成を採用した場合でも、図示例のような、第一絶縁部５１Ａ及び第二絶縁部５１Ｂが略空洞状態とされた構成には限定されない。例えば、図１１中に示す色素増感太陽電池１０Ｄのように、封止材４６の少なくとも一部が、凹状とされた第一絶縁部５１Ａ及び第二絶縁部５１Ｂの内部に入り込むように形成されていることが、上記同様、第一絶縁部５１Ａ及び第二絶縁部５１Ｂにおいて加工端部同士が接触（短絡）するのをより防止し易くなる観点から好ましい。また、図１１に示す例のように、第一絶縁部５１Ａ及び第二絶縁部５１Ｂの内部が封止材４６で完全に埋め込まれていることが、上記効果がより顕著に得られる観点からさらに好ましい。 In addition, even in the case where the configuration including the concave first insulating portion 51A and the second insulating portion 51B as illustrated in FIG. 3 is adopted, the first insulating portion 51A and the second insulating portion 51B as illustrated in the example. The configuration is not limited to the configuration in which the For example, as in the dye-sensitized solar cell 10D shown in FIG. 11, at least a part of the sealing material 46 is formed to enter the inside of the first insulating portion 51A and the second insulating portion 51B in a concave shape. Similar to the above, it is preferable from the viewpoint of facilitating prevention of contact (shorting) of the processed ends in the first insulating portion 51A and the second insulating portion 51B. Further, as in the example shown in FIG. 11, the inside of the first insulating portion 51A and the second insulating portion 51B is completely embedded with the sealing material 46, from the viewpoint of achieving the above-mentioned effects more remarkably. preferable.
また、図１に示すように、色素増感太陽電池１０のＤ２方向における所定の位置には、Ｄ１方向にわたって第一電極４１と第二電極４２とが貼り合わされたシール部６０が設けられている。このシール部６０は、第一電極４１及び第二電極４２の厚み方向の外方（即ち、色素増感太陽電池１０の上方及び下方）から、例えば、超音波融着等の方法を用いて第一電極４１及び第二電極４２に力を加えるか、又は押圧することによって、第一基材２１と第二基材２２とが圧着されることで、電気的に絶縁された部分である。また、図示を省略しているが、圧着された第一基材２１と第二基材２２との間には、僅かな厚みで、第一導電膜３１、第二導電膜３２、半導体層１２、電解液１４及び触媒層１６が介在している場合がある。しかしながら、これの各層は、シール部６０においてほぼ分断された状態なので、シール部６０に隣接する発電部４４同士を電気的に接続するものではない。 In addition, as shown in FIG. 1, a seal portion 60 in which the first electrode 41 and the second electrode 42 are bonded to each other is provided at a predetermined position in the D2 direction of the dye-sensitized solar cell 10 . The seal portion 60 is formed by using, for example, a method such as ultrasonic welding from the outside in the thickness direction of the first electrode 41 and the second electrode 42 (that is, above and below the dye-sensitized solar cell 10). The first base 21 and the second base 22 are pressure-bonded by applying or pressing a force to the first electrode 41 and the second electrode 42, thereby providing an electrically insulated part. Although not shown, the first conductive film 31, the second conductive film 32, and the semiconductor layer 12 have a slight thickness between the pressure-bonded first base material 21 and the second base material 22. The electrolytic solution 14 and the catalyst layer 16 may be interposed. However, since each of these layers is in a substantially divided state in the seal portion 60, the power generation portions 44 adjacent to the seal portion 60 are not electrically connected.
ここで、本実施形態においては、第一絶縁部５０Ａ，５１Ａ及び第二絶縁部５０Ｂ，５１Ｂが、それぞれＤ２方向（各絶縁部の長さ方向）の全体において、開口全体が覆われている構成を説明しているが、このような構成には限定されない。例えば、各絶縁部のＤ２方向において、第一絶縁部５０Ａ，５１Ａ及び第二絶縁部５０Ｂ，５１Ｂの開口の幅方向（Ｄ１方向）全体が封止材４６によって覆われている箇所と、開口が露出している箇所の両方が存在していてもよい。このような場合、例えば、各絶縁部の開口の幅方向全体が覆われている領域が、Ｄ２方向における各絶縁部の全長に対して、概ね８０％以上の領域で開口全体が覆われていれば、上記効果が十分に得られる。 Here, in the present embodiment, the first insulating portions 50A and 51A and the second insulating portions 50B and 51B are configured such that the entire opening is covered in the entire D2 direction (the length direction of each insulating portion). However, the present invention is not limited to such a configuration. For example, in the direction D2 of each insulating portion, a portion where the entire width direction (direction D1) of the openings of the first insulating portions 50A and 51A and the second insulating portions 50B and 51B is covered by the sealing material 46, and the opening Both exposed portions may be present. In such a case, for example, the entire opening in the region in which the entire width direction of the opening of each insulating portion is covered is covered by about 80% or more of the entire length of each insulating portion in the D2 direction. For example, the above effect can be sufficiently obtained.
［電気モジュールの他の例］
上記実施形態においては、第一導電膜３１及び第二導電膜３２に設けられる第一絶縁部及び第二絶縁部を、上記のような、各導電膜を厚み方向で貫通する第一絶縁部５０Ａ及び第二絶縁部５０Ｂ、あるいは、凹状に形成された第一絶縁部５１Ａ及び第二絶縁部５１Ｂとしたが、例えば、以下のような構成を採用することもできる。
　即ち、本発明においては、例えば、図４，５に示す色素増感太陽電池１０Ｂのように、第一導電膜３１及び第二導電膜３２に設けられる第一絶縁部及び第二絶縁部を、封止材４６側に開口する凹部５２が面方向に沿って複数形成された構成の第一絶縁部５２Ａ及び第二絶縁部５２Ｂとして構成してもよい。図示例の第一絶縁部５２Ａ及び第二絶縁部５２Ｂは、第一導電膜３１及び第二導電膜３２に凹状に形成された複数の凹部５２が、平面視帯状に配列された構成とされている。 [Another example of electrical module]
In the above embodiment, the first insulating portion 50A penetrating the respective conductive films in the thickness direction as described above is provided to the first insulating portion and the second insulating portion provided in the first conductive film 31 and the second conductive film 32. The second insulating portion 50B or the first insulating portion 51A and the second insulating portion 51B formed in a concave shape are used. However, for example, the following configuration may be employed.
That is, in the present invention, for example, as in the dye-sensitized solar cell 10B shown in FIGS. 4 and 5, the first insulating portion and the second insulating portion provided in the first conductive film 31 and the second conductive film 32 are You may comprise as the 1st insulation part 52A and the 2nd insulation part 52B of the structure by which the recessed part 52 opened to the sealing material 46 side was formed in multiple numbers along the surface direction. The first insulating portion 52A and the second insulating portion 52B in the illustrated example have a configuration in which a plurality of concave portions 52 formed in a concave shape in the first conductive film 31 and the second conductive film 32 are arranged in a strip in a plan view There is.
　図５中に示す第一絶縁部５２Ａ及び第二絶縁部５２Ｂは、第一導電膜３１や第二導電膜３２に何らかの物理的エネルギーや化学的処理等が加えられることによって形成された複数の凹部５２により、物理的エネルギー又は化学的処理等が与えられていない領域に比べて導電性が著しく低下している領域である。即ち、第一絶縁部５２Ａ及び第二絶縁部５２Ｂは、完全な絶縁部では無いものの、導電性を可能な限り低下させた領域である。 The first insulating portion 52A and the second insulating portion 52B shown in FIG. 5 are a plurality of recesses formed by applying some physical energy or chemical treatment to the first conductive film 31 or the second conductive film 32. 52 is a region where the conductivity is significantly reduced compared to a region where no physical energy or chemical treatment or the like is given. That is, although the first insulating portion 52A and the second insulating portion 52B are not complete insulating portions, they are regions in which the conductivity is lowered as much as possible.
また、図５においては、凹部５２を分かりやすく模式的に示しているが、本実施形態における複数の凹部５２は、図示例のような、所定の条件で規則的に又は不規則的に個々独立して形成された凹部の他、例えば、第一導電膜３１や第二導電膜３２の表面３１ａ，３２ａを荒らすように連続的に形成された凹部も含むものである。 Moreover, in FIG. 5, although the recessed part 52 is shown intelligibly typically, the several recessed part 52 in this embodiment is individually or regularly independent in the predetermined condition like predetermined example like illustration. In addition to the recesses formed as described above, for example, the recesses formed continuously to roughen the surfaces 31 a and 32 a of the first conductive film 31 and the second conductive film 32 are also included.
複数の凹部５２は、図４，５中に示すＤ１方向に沿って形成されていればよく、平面視（即ち、図４に示す上面側）における複数の凹部５２の形状や配置は適宜調整可能とすることができる。複数の凹部５２は、平面視で互いに所定の間隔で離間して形成されていてもよく、それぞれ接していてもよく、あるいは、部分的に重なり合っていてもよい。また、例えば、複数の凹部５２のうち、一部の複数の凹部５２は平面視で互いに所定の間隔で離間して形成され、残りの複数の凹部５２同士は接している構成としてもよい。あるいは、一部の複数の凹部５２は平面視で互いに所定の間隔で離間して形成され、残りの複数の凹部５２同士が重なり合っている構成としてもよい。 The plurality of recesses 52 may be formed along the direction D1 shown in FIGS. 4 and 5, and the shape and arrangement of the plurality of recesses 52 can be appropriately adjusted in plan view (that is, the upper surface shown in FIG. 4) It can be done. The plurality of recesses 52 may be formed spaced apart from each other by a predetermined distance in plan view, may be in contact with each other, or may partially overlap with each other. Further, for example, among the plurality of concave portions 52, some of the plurality of concave portions 52 may be formed to be separated from each other by a predetermined distance in plan view, and the remaining plurality of concave portions 52 may be in contact with each other. Alternatively, some of the plurality of recesses 52 may be formed spaced apart from each other by a predetermined distance in plan view, and the remaining plurality of recesses 52 may overlap with each other.
　複数の凹部５２は、例えば、図６～７に示すように、平面視でドット状に形成されていてもよい。なお、図６～７に示す例においては、凹部５２の平面視での形状を分かりやすく示すために、第一電極４１側のみを図示している。第二電極４２については、図６～７における第一基材２１を第二基材２２に置き換え、同図における第一導電膜３１を第二導電膜３２に置き換えればよい。 For example, as shown in FIGS. 6 to 7, the plurality of recesses 52 may be formed in a dot shape in plan view. In the examples shown in FIGS. 6 to 7, only the first electrode 41 side is shown in order to easily show the shape of the recess 52 in a plan view. For the second electrode 42, the first base 21 in FIGS. 6 to 7 may be replaced with the second base 22, and the first conductive film 31 in the figure may be replaced with the second conductive film 32.
図６に示すように、ドット状に配置された複数の凹部５２は、平面視でそれぞれ円形に形成され、所謂六方最密状に配置されていてもよい。また、凹部５２の平面視形状は、円形の他、楕円形、三角形や矩形、五以上の多角形、あるいは、その他の任意の形状であってもよい。具体的には、第一導電膜３１の表面３１ａの面内の、Ｄ１方向に直交するＤ２方向に沿って見たとき、Ｄ１方向に沿う列Ｌ１上で隣り合う凹部５２ａ，５２ｂの中間に、列Ｌ１の前後方向に隣り合い、且つＤ１方向に沿う列Ｌ２上の凹部５２ｃと、列Ｌ３上の凹部５２ｄが位置している。また、第一導電膜３１の表面３１ａにおいて、凹部５２ａと隣り合う凹部５２ｂ，５２ｃ，５２ｄとの外周縁同士の最短距離ｗ１は、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの抵抗値が、色素増感太陽電池１０の内部直列抵抗値の５倍以上、好ましくは１０倍以上、より好ましくは１００倍以上になるように適宜設定されることが好ましい。 As shown in FIG. 6, the plurality of concave portions 52 arranged in a dot shape may be respectively formed in a circular shape in a plan view, and may be arranged in a so-called hexagonal close-packed shape. Moreover, the planar view shape of the recessed part 52 may be an ellipse, a triangle, a rectangle, five or more polygons other than circular shape, or another arbitrary shape. Specifically, when viewed along the D2 direction orthogonal to the D1 direction, in the plane of the surface 31a of the first conductive film 31, in the middle of the concave portions 52a and 52b adjacent on the row L1 along the D1 direction, The recess 52c on the row L2 adjacent to the row L1 in the front-rear direction and along the D1 direction and the recess 52d on the row L3 are located. Further, on the surface 31a of the first conductive film 31, the shortest distance w1 between the outer peripheral edges of the recessed portions 52a and the recessed portions 52b, 52c and 52d adjacent to the recessed portion 52a is the resistance value of the first insulating portion 52A and the second insulating portion 52B. It is preferable to appropriately set the internal series resistance value of the dye-sensitized solar cell 10 to be 5 times or more, preferably 10 times or more, more preferably 100 times or more.
また、図７に示すように、ドット状に配置された複数の凹部５２は、平面視においてＤ１方向及びＤ２方向に沿って配列するように形成されていてもよい。具体的には、Ｄ１方向に沿う列Ｌ１上で隣り合う凹部５２ａ，５２ｂと、列Ｌ１の前後方向に隣り合い、且つＤ１方向に沿う列Ｌ２の凹部５２ｃ，５２ｅ、及び列Ｌ１の前後方向に隣り合い、且つＤ１方向に沿う列Ｌ３の凹部５２ｄ，５２ｆとは、平面視においてＤ２方向で重なっている。図７に例示した複数の凹部５２の配置形態のように、Ｄ２方向においてＤ１方向に直交する断面（図５に示す断面）に凹部５２が現れない位置ＰＸが存在する配置では、第一絶縁部５２Ａ及び第二絶縁部５２Ｂとしての低導電性を実現する観点から、Ｄ２方向に沿って隣り合う凹部５２，５２同士の外周縁の最短距離ｗ２を設定する必要がある。このため、上記の最短距離ｗ２は、凹部５２の平面視及び断面視における形状や寸法等を勘案し、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの抵抗値が色素増感太陽電池１０の内部直列抵抗値の５倍以上、好ましくは１０倍以上、より好ましくは１００倍以上になるように適宜設定されることが好ましい。例えば、最短距離ｗ２は、凹部５２のＤ２方向の幅寸法ｗ５２の０％以上２０％以下であることが好ましく、幅寸法ｗ５２の０％以上１０％以下であることがより好ましく、幅寸法ｗ５２の０％以上１％以下であることがより好ましい。 Further, as shown in FIG. 7, the plurality of concave portions 52 arranged in a dot shape may be formed to be arranged along the D1 direction and the D2 direction in a plan view. Specifically, the concave portions 52a and 52b adjacent on the row L1 along the D1 direction, the concave portions 52c and 52e of the row L2 adjacent to the longitudinal direction of the row L1 and along the D1 direction, and the longitudinal direction of the row L1 The recesses 52d and 52f of the row L3 adjacent to each other and along the D1 direction overlap in the D2 direction in plan view. As in the arrangement form of the plurality of recesses 52 illustrated in FIG. 7, in the arrangement in which the position PX where the recesses 52 do not appear in the cross section orthogonal to the D1 direction in the D2 direction (the cross section shown in FIG. From the viewpoint of realizing low conductivity as the 52A and the second insulating portion 52B, it is necessary to set the shortest distance w2 of the outer peripheral edge of the concave portions 52 adjacent to each other along the D2 direction. For this reason, the shortest distance w2 described above takes into consideration the shape, dimensions, etc. in plan view and cross-sectional view of the recess 52, and the resistance value of the first insulating portion 52A and the second insulating portion 52B is the inside of the dye-sensitized solar cell 10. It is preferable to set appropriately so as to be 5 times or more, preferably 10 times or more, more preferably 100 times or more of the series resistance value. For example, the shortest distance w2 is preferably 0% or more and 20% or less of the width dimension w52 of the recess 52 in the D2 direction, more preferably 0% or more and 10% or less of the width dimension w52, and the width dimension w52 More preferably, it is 0% or more and 1% or less.
また、図８に示すように、複数の凹部は、平面視で網状に形成された凹条５６によって構成されていてもよい。具体的には、凹条５６は、第一導電膜３１の表面３１ａにおいて、Ｄ２方向に対して所定の角度で傾斜するＤ３方向に沿って延在する凹条５６Ａと、第一導電膜３１の表面３１ａにおいて、Ｄ２方向に対してＤ３方向とは逆の方向に所定の角度で傾斜することによってＤ３方向に交差し、且つ、Ｄ４方向に沿って延在する凹条５６Ｂと、を有している。第一絶縁部５２Ａ及び第二絶縁部５２Ｂとしての低導電性を実現する観点から、凹条５６Ａ，５６Ｂに囲まれた凸部５８のＤ１方向に沿った最短距離ｗ３は、凹条５６Ａ，５６Ｂの平面視及び断面視における形状や寸法等を勘案しながら設定する必要がある。このため、上記の最短距離ｗ３は、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの抵抗値が色素増感太陽電池１０の内部直列抵抗値の５倍以上、好ましくは１０倍以上、より好ましくは１００倍以上になるように適宜設定されることが好ましい。 Further, as shown in FIG. 8, the plurality of concave portions may be configured by concave streaks 56 formed in a net shape in plan view. Specifically, in the surface 31 a of the first conductive film 31, the grooves 56 extend along the D3 direction inclined at a predetermined angle with respect to the D2 direction, and the grooves 56A of the first conductive film 31. And in the surface 31a, a concave stripe 56B intersecting in the D3 direction and extending along the D4 direction by inclining at a predetermined angle in a direction opposite to the D3 direction with respect to the D2 direction. There is. From the viewpoint of realizing low conductivity as the first insulating portion 52A and the second insulating portion 52B, the shortest distance w3 along the direction D1 of the convex portion 58 surrounded by the concave streaks 56A and 56B is the concave streaks 56A and 56B. It is necessary to set while taking into consideration the shape, size, and the like in plan view and cross-sectional view of the lens. Therefore, in the above-mentioned shortest distance w3, the resistance value of the first insulating portion 52A and the second insulating portion 52B is 5 times or more, preferably 10 times or more, more preferably the internal series resistance value of the dye-sensitized solar cell 10. It is preferable to set appropriately so as to be 100 times or more.
　第一絶縁部及び第二絶縁部としての低導電性を実現する観点から、上述した図６～８に示す配置、及び、これらの図面に示す配置以外において、Ｄ１方向に直交する断面における凹部５２や凹条５６の深さは、第一導電膜３１又は第二導電膜３２の厚みを１００としたときの９０以上１３０００以下の割合であることが好ましい。一例としては、第一導電膜３１及び第二導電膜３２の深さが１００～２００ｎｍである場合に、凹部５２の平均深さが１３μｍ程度であり、第一導電膜３１又は第二導電膜３２の厚みを１００としたときに６５００～１３０００程度の割合である場合が挙げられる。また、上述のように、第一導電膜３１又は第二導電膜３２の厚みを１００としたときの凹部５２や凹条５６の深さは、９５以上１２５００以下の割合であることがより好ましく、９８以上１２０００以下の割合であることがさらに好ましい。 From the viewpoint of realizing low conductivity as the first insulating portion and the second insulating portion, the recesses 52 in the cross section orthogonal to the D1 direction other than the arrangements shown in FIGS. 6 to 8 described above and the arrangements shown in these drawings The depth of the groove 56 is preferably 90 to 13,000, where the thickness of the first conductive film 31 or the second conductive film 32 is 100. As an example, when the depths of the first conductive film 31 and the second conductive film 32 are 100 to 200 nm, the average depth of the recesses 52 is about 13 μm, and the first conductive film 31 or the second conductive film 32 The case where the ratio of about 6500 to 13000 is given when the thickness of the above is 100 is mentioned. Further, as described above, it is more preferable that the depth of the recess 52 and the groove 56 when the thickness of the first conductive film 31 or the second conductive film 32 is 100 is a ratio of 95 or more and 12500 or less. More preferably, the ratio is 98 or more and 12000 or less.
　また、複数の凹部５２や凹条５６の深さは、互いに均一であってもよく、不均一であってもよい。例えば、複数の凹部５２や凹条５６には、第一導電膜３１又は第二導電膜３２の厚みを１００としたときの深さが１００未満の割合である凹部５２や凹条５６と、１００以上の割合である凹部５２や凹条５６とが混在していてもよい。 In addition, the depths of the plurality of recesses 52 and the grooves 56 may be uniform or nonuniform. For example, when the thickness of the first conductive film 31 or the second conductive film 32 is 100, the plurality of recesses 52 or the grooves 56 have a depth of less than 100, The recessed part 52 and the concave stripe 56 which are the ratio of the above may be mixed.
Ｄ１方向に直交する断面における凹部５２や凹条５６の深さが上記範囲内に設定されていることで、色素増感太陽電池１０の性能等によって当該色素増感太陽電池１０に流れる電流値が増減した場合であっても、第一絶縁部５２Ａ及び第二絶縁部５２Ｂにおける導電性の低下が担保される。なお、色素増感電池１０に比較的大きい電流が流れる場合は、第一絶縁部５２Ａ及び第二絶縁部５２Ｂにおける導電性の低下率が小さくても、第一絶縁部５２Ａ及び第二絶縁部５２Ｂが絶縁領域として機能し得る。一方、色素増感電池１０に比較的小さい電流が流れる場合は、第一絶縁部５２Ａ及び第二絶縁部５２Ｂにおける導電性の低下率がより大きい方が、第一絶縁部５２Ａ及び第二絶縁部５２Ｂは絶縁領域として十分に機能し得る。従って、凹部５２の深さは、凹部５２の形状や色素増感太陽電池１０に流れる電流値、及び、その他の色素増感太陽電池１０に関するパラメータ等を総合的に勘案して適切に調整することが好ましい。 By setting the depths of the concave portions 52 and the concave streaks 56 in the cross section orthogonal to the D1 direction within the above range, the current value flowing through the dye-sensitized solar cell 10 depends on the performance of the dye-sensitized solar cell 10 and the like. Even in the case of increase or decrease, the decrease in the conductivity of the first insulating portion 52A and the second insulating portion 52B is secured. When a relatively large current flows in the dye-sensitized cell 10, the first insulating portion 52A and the second insulating portion 52B can be obtained even if the decrease in conductivity in the first insulating portion 52A and the second insulating portion 52B is small. Can function as an insulating region. On the other hand, in the case where a relatively small current flows in the dye-sensitized cell 10, the larger the decrease in conductivity in the first insulating portion 52A and the second insulating portion 52B is, the first insulating portion 52A and the second insulating portion 52B may function well as an isolation region. Therefore, the depth of the recess 52 should be appropriately adjusted by comprehensively taking into account the shape of the recess 52, the current value flowing to the dye-sensitized solar cell 10, and other parameters related to the dye-sensitized solar cell 10. Is preferred.
第一絶縁部５２Ａ及び第二絶縁部５２Ｂ（並びに凹部５６）の絶縁性が確実に担保される点から、凹部５２や凹条５６は、平面視での密度が８０％以上１００％以下で形成されていることが好ましい。本明細書において説明する、凹部５２の平面視での密度とは、平面視での単位面積（例えば、１ｃｍ２）において、複数の凹部５２の内壁面の合計面積が占める割合を百分率で表したものである。具体的には、複数の凹部５２や凹条５６が平面視で均一（規則的）に形成されている場合では、凹部５２や凹条５６の平面視での密度は８０％以上１００％以下であることが好ましく、９０％以上１００％以下であることがより好ましい。一方、複数の凹部５２や凹条５６が平面視で不均一（不規則的）に形成されている場合では、隣り合う凹部５２や凹条５６同士の距離が最も小さい箇所を中心とする密度が８０％以上１００％以下であることが好ましく、９０％以上１００％以下であることがより好ましい。ここで、上記の「隣り合う凹部５２同士の距離」としては、凹部５２同士が重なり合っている場合には、この距離を０（ゼロ）とする。
さらに、図６に示すように、第一絶縁部５２Ａ及び第二絶縁部５２Ｂにおいて電流Ｉが流れる経路が長くなる（即ち、Ｄ１方向に沿って進もうとする電流Ｉの流れが凹部５２を避けるようにＤ２方向に迂回する）場合に比べて、図７に示すように、電流Ｉが流れる経路が短い場合には、凹部５２の平面視での密度は９０％以上１００％以下であることが好ましい。 The recesses 52 and the grooves 56 are formed to have a density of 80% or more and 100% or less in plan view, in order to ensure insulation of the first insulating portion 52A and the second insulating portion 52B (and the recess 56). Is preferred. The density of the recesses 52 in a plan view described in this specification is the percentage of the total area of the inner wall surfaces of the plurality of recesses 52 in a unit area (for example, 1 cm 2 ) in a plan view. It is a thing. Specifically, in the case where the plurality of recessed portions 52 and the recessed streaks 56 are formed uniformly (regularly) in plan view, the density of the recessed portions 52 and the recessed streaks 56 in planar view is 80% or more and 100% or less It is preferably 90% or more and 100% or less. On the other hand, in the case where the plurality of recessed portions 52 and the recessed streaks 56 are formed unevenly (irregularly) in plan view, the density centered on the place where the distance between the adjacent recessed portions 52 and the recessed streaks 56 is the smallest is It is preferably 80% or more and 100% or less, and more preferably 90% or more and 100% or less. Here, as the above-mentioned “distance between adjacent concave portions 52”, when the concave portions 52 overlap with each other, this distance is set to 0 (zero).
Furthermore, as shown in FIG. 6, the path through which the current I flows in the first insulating portion 52A and the second insulating portion 52B becomes longer (that is, the flow of the current I trying to advance along the D1 direction avoids the recess 52). As shown in FIG. 7, the density of the recess 52 in a plan view is 90% or more and 100% or less when the path through which the current I flows is short as shown in FIG. preferable.
また、同様の観点から、Ｄ１方向における第一絶縁部５２Ａ及び第二絶縁部５２Ｂの幅寸法ＷＬは、第一導電膜３１の材質や導電性等を勘案して適切に設定することが望ましく、例えば、０．１ｍｍ以上１０ｍｍ以下であることが好ましく、０．２ｍｍ以上３ｍｍ以下であることがより好ましく、０．５ｍｍ以上１ｍｍ以下であることがさらに好ましい。第一絶縁部５２Ａ及び第二絶縁部５２ＢのＤ１方向における幅寸法が１０ｍｍ以内であることにより、発電部４４の寸法や面積を確保し易くなる。また、第一絶縁部５２Ａ及び第二絶縁部５２ＢのＤ１方向における幅寸法が０．１ｍｍ以上であることにより、第一絶縁部５２Ａ及び第二絶縁部５２Ｂにおける導電性の低下が担保される。
また、図８に示すように、平面視で網状に形成された凹条５６によって絶縁部を構成した場合においても、絶縁部の領域を上記同様の幅寸法とすることが好ましい。　　　 From the same point of view, it is desirable that the width dimension WL of the first insulating portion 52A and the second insulating portion 52B in the D1 direction be appropriately set in consideration of the material and conductivity of the first conductive film 31, etc. For example, 0.1 mm or more and 10 mm or less are preferable, 0.2 mm or more and 3 mm or less are more preferable, and 0.5 mm or more and 1 mm or less are more preferable. When the width dimension in the D1 direction of the first insulating portion 52A and the second insulating portion 52B is 10 mm or less, it becomes easy to secure the size and the area of the power generation portion 44. In addition, when the width dimension in the D1 direction of the first insulating portion 52A and the second insulating portion 52B is 0.1 mm or more, the decrease in conductivity in the first insulating portion 52A and the second insulating portion 52B is secured.
Further, as shown in FIG. 8, even when the insulating portion is constituted by the concave streaks 56 formed in a net shape in plan view, it is preferable to set the region of the insulating portion to the same width as the above.
図４，５等に示す第一絶縁部５２Ａ及び第二絶縁部５２Ｂと、当該絶縁部５２Ａ，５２Ｂの周囲の領域との導電性の差は、形成する第一絶縁部５２Ａ及び第二絶縁部５２Ｂの数や配置等を勘案して適宜設定することができ、特に限定されない。本実施形態においては、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの絶縁性が確実且つ直接担保される観点から、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの電気抵抗の電気抵抗を考慮する必要がある。上記の観点から、第一絶縁部５２Ａ及び第二絶縁部５２Ｂの電気抵抗は、色素増感太陽電池１０の内部直列抵抗値の５倍以上であることが好ましく、色素増感太陽電池１０の内部直列抵抗値の１０倍以上であることがより好ましく、色素増感太陽電池１０の内部直列抵抗値の１００倍以上であることがさらに好ましい。
また、図８に示すように、平面視で網状に形成された凹条５６によって絶縁部を構成した場合においても、例えば、編み目の配列ピッチや間隔等を適宜設定することで、絶縁部の電気抵抗を上記同様の範囲に設定することが好ましい。 The difference in conductivity between the first insulating portion 52A and the second insulating portion 52B shown in FIGS. 4 and 5 and the region around the insulating portions 52A and 52B is the first insulating portion 52A and the second insulating portion to be formed. It can set suitably in consideration of the number of 52B, arrangement, etc., and is not limited in particular. In the present embodiment, the electrical resistance of the electrical resistance of the first insulating portion 52A and the second insulating portion 52B is considered from the viewpoint of ensuring the insulation of the first insulating portion 52A and the second insulating portion 52B directly and reliably. There is a need. From the above viewpoint, the electric resistances of the first insulating portion 52A and the second insulating portion 52B are preferably five or more times the internal series resistance value of the dye-sensitized solar cell 10, and the inside of the dye-sensitized solar cell 10 It is more preferable that it is 10 times or more of series resistance value, and it is further more preferable that it is 100 times or more of internal series resistance value of the dye-sensitized solar cell 10.
Further, as shown in FIG. 8, even when the insulating portion is constituted by the recessed streaks 56 formed in a net shape in a plan view, the electrical connection of the insulating portion can be performed by appropriately setting, for example, the arrangement pitch and interval of the stitches. It is preferable to set the resistance in the same range as described above.
また、本例においても、図４に示すように、色素増感太陽電池１０のＤ２方向における所定の位置には、Ｄ１方向にわたって第一電極４１と第二電極４２とが貼り合わされたシール部６０が設けられている。このシール部６０は、上記同様、第一電極４１及び第二電極４２の厚み方向の外方から、第一基材２１及び第二基材２２が圧着され、電気的に絶縁された部分である。 Also in this example, as shown in FIG. 4, the seal portion 60 in which the first electrode 41 and the second electrode 42 are bonded to each other at the predetermined position in the D2 direction of the dye-sensitized solar cell 10 in the D1 direction. Is provided. The seal portion 60 is a portion in which the first base 21 and the second base 22 are crimped from the outside in the thickness direction of the first electrode 41 and the second electrode 42 as described above, and are electrically insulated. .
なお、図４～図７に示すような複数の凹部５２からなる第一絶縁部５２Ａ及び第二絶縁部５２Ｂ、又は、図８に示すような平面視で網状に形成された凹条５６からなる絶縁部の、何れの構成を採用した場合においても、図１，２中に示した第一絶縁部５０Ａ及び第二絶縁部５０Ｂの場合と同様、各絶縁部の開口全体が封止材４６（図５を参照）によって覆われていることが好ましい。 The first insulating portion 52A and the second insulating portion 52B including a plurality of concave portions 52 as shown in FIGS. 4 to 7 or the concave streaks 56 formed in a net shape in a plan view as shown in FIG. In any of the configurations of the insulating portions, the entire opening of each insulating portion is the sealing material 46 (the same as in the case of the first insulating portion 50A and the second insulating portion 50B shown in FIGS. Preferably, it is covered by FIG.
また、図４～図７に示す第一絶縁部５２Ａ及び第二絶縁部５２Ｂ、又は、図８に示す凹条５６からなる絶縁部の、何れの構成を採用した場合においても、図１０中に示した第一絶縁部５０Ａ及び第二絶縁部５０Ｂ等の場合と同様、封止材４６の少なくとも一部が各絶縁部の内部に入り込むように形成されていることが好ましい。また、図示例のように、各絶縁部の内部が封止材４６で完全に埋め込まれていることがより好ましい。 Furthermore, in any of the configurations of the first insulating portion 52A and the second insulating portion 52B shown in FIG. 4 to FIG. 7 or the insulating portion consisting of the concave streaks 56 shown in FIG. As in the case of the first insulating portion 50A and the second insulating portion 50B shown, it is preferable that at least a part of the sealing material 46 be formed so as to enter the inside of each insulating portion. Further, as shown in the illustrated example, it is more preferable that the inside of each insulating portion be completely filled with the sealing material 46.
［電気モジュールの製造方法］
　次いで、本発明に係る電気モジュールの製造方法について説明する。
　本実施形態の電気モジュールの製造方法は、図９に例示する製造装置７０を用いて、所定の方向Ｄ４１に沿って連続的に搬送される第一電極４１と、所定の方向Ｄ４２に沿って連続的に搬送される第二電極４２とを貼り合わせることによって、図１及び図２に示すような色素増感太陽電池１０を製造する方法である。
なお、以下の説明では、図９中に示す搬送方向Ｄ４１，Ｄ４２において、始点側を上流側とし、終点側を下流側として説明する。 [Method of manufacturing electric module]
Then, the manufacturing method of the electric module concerning this invention is demonstrated.
In the method of manufacturing the electric module according to the present embodiment, the first electrode 41 continuously transported along the predetermined direction D41 and the continuous direction along the predetermined direction D42 using the manufacturing apparatus 70 illustrated in FIG. It is the method of manufacturing the dye-sensitized solar cell 10 as shown in FIG.1 and FIG.2 by bonding together the 2nd electrode 42 conveyed by this.
In the following description, in the transport directions D41 and D42 shown in FIG. 9, the start point side is the upstream side, and the end point side is the downstream side.
　本実施形態の色素増感太陽電池１０の製造方法は、少なくとも、以下の（１）～（４）の各工程を備えて概略構成される。
（１）第一電極４１を切り込み加工することにより、第一基材２１の表面２１ａに設けられた第一導電膜３１を厚み方向で貫通するか、あるいは、凹状とされた、平面視帯状の第一絶縁部５０Ａを形成する第一絶縁工程（図１～図３を参照）。
（２）第二電極４２を切り込み加工することにより、第二基材２２の表面２２ａに設けられた第二導電膜３２を厚み方向で貫通するか、あるいは、凹状とされた、平面視帯状の第二絶縁部を形成する第二絶縁工程。
　（３）第一導電膜３１の表面３１ａにおいて、第一絶縁部５０Ａが形成された部分、及び、第一導電膜３１と第二導電膜３２とを対向させたときに、第二導電膜３２の表面３２ａに形成された第二絶縁部５０Ｂに対応する位置に封止材４６を形成するとともに、面方向における封止材４６同士の間に、半導体層１２を含む発電部４４を形成する発電部形成工程。
（４）第一導電膜３１と第二導電膜３２とを対向させ、第一電極４１と第二電極４２とを貼り合わせる貼合工程。 The manufacturing method of the dye-sensitized solar cell 10 of the present embodiment is roughly configured including at least the following steps (1) to (4).
(1) By cutting the first electrode 41, the first conductive film 31 provided on the surface 21a of the first base material 21 is penetrated in the thickness direction, or it is in the form of a strip, which is concave. First insulating step of forming the first insulating portion 50A (see FIGS. 1 to 3).
(2) By cutting the second electrode 42, the second conductive film 32 provided on the surface 22a of the second base material 22 is penetrated in the thickness direction, or is concave, and it is strip-shaped in a plan view A second insulating step of forming a second insulating portion;
(3) The second conductive film 32 when the first conductive film 31 and the second conductive film 32 are opposed to each other at the portion where the first insulating portion 50A is formed on the surface 31a of the first conductive film 31. While forming the sealing material 46 in the position corresponding to the 2nd insulation part 50B formed in the surface 32a of the power generation, the electric power generation part 44 containing the semiconductor layer 12 is formed between the sealing materials 46 in a surface direction. Part formation process.
(4) A bonding step of causing the first conductive film 31 and the second conductive film 32 to face each other and bonding the first electrode 41 and the second electrode 42.
そして、本実施形態の色素増感太陽電池１０の製造方法は、上記（１）の第一絶縁工程、及び、上記（２）の第二絶縁工程において、第一絶縁部５０Ａ及び第二絶縁部５０Ｂを、それぞれ、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下となるように形成する方法である。 And the manufacturing method of the dye-sensitized solar cell 10 of this embodiment is the 1st insulation part 50A and the 2nd insulation part in the 1st insulation process of said (1), and the 2nd insulation process of said (2) It is a method of forming 50B so that width dimension WL in a surface direction may be 0.1 mm or more and 3 mm or less, respectively.
＜第一絶縁工程＞
　まず、図示略のＲｔｏＲ方式を採用した装置を用いて、第一基材２１を所定の方向に沿って連続的に搬送しながら、公知のスパッタリング法や印刷法等により、第一基材２１の表面２１ａに第一導電膜３１を形成し、第一導電膜３１を外側に向けた状態でロール状に巻き取る。なお、予め、表面２１ａに第一導電膜３１が形成されている第一基材２１を用いても構わない。 <First insulation process>
First, using a device that adopts the RtoR method (not shown), the first base material 21 is continuously transported along a predetermined direction using a known sputtering method, a printing method, or the like while being continuously transported. The first conductive film 31 is formed on the surface 21a, and the first conductive film 31 is wound in a roll shape with the first conductive film 31 directed outward. In addition, you may use the 1st base material 21 by which the 1st conductive film 31 is previously formed in the surface 21a.
　次いで、図９に示すように、製造装置７０にロール状の第一基材２１を設置し、第一基材２１を所定の方向、図示例ではＤ４１方向に巻き出し、絶縁部形成装置７２を用いて、第一導電膜３１の表面３１ａにおける絶縁部形成領域Ｒ５０に、図１及び図２に示すような第一絶縁部５０Ａを形成する。このような絶縁部形成装置７２としては、例えば、ダイカットロールを備えた加工装置の他、レーザー加工装置、押圧用の金型、エッチング液の塗布装置等が挙げられる。即ち、第一絶縁部５０Ａの形成方法及び絶縁部形成装置７２は、各絶縁部を貫通、又は、凹状に形成し、絶縁性を担保することができる方法又は装置であれば、特に限定されるものではない。また、例えば、絶縁部形成装置７２を用いて、第一導電膜３１の表面３１ａの複数の位置に、断続的にレーザー光を照射することによって、第一絶縁部５０Ａを形成しながら第一電極４１を得ることができる。この場合、レーザー光を出射するタイミングやレーザー光の照射パワー等は、絶縁部形成装置７２に内蔵されたプログラム等によって適宜制御することができる。 Next, as shown in FIG. 9, the roll-shaped first base member 21 is placed in the manufacturing apparatus 70, and the first base member 21 is unwound in a predetermined direction, in the illustrated example, the D41 direction, The first insulating portion 50A as shown in FIGS. 1 and 2 is formed in the insulating portion forming region R50 on the surface 31a of the first conductive film 31 using the above. As such an insulation part formation apparatus 72, the laser processing apparatus, the metal mold | die for pressing, the coating apparatus of an etching liquid, etc. are mentioned other than the processing apparatus provided with the die-cut roll, for example. That is, the method of forming the first insulating portion 50A and the insulating portion forming apparatus 72 are not particularly limited as long as they can form insulating portions in a penetrating manner or in a concave shape to ensure insulation. It is not a thing. In addition, for example, by using the insulating portion forming device 72, laser light is intermittently applied to a plurality of positions on the surface 31a of the first conductive film 31 to form the first insulating portion 50A while the first electrode is formed. 41 can be obtained. In this case, the timing of emitting the laser beam, the irradiation power of the laser beam, and the like can be appropriately controlled by a program or the like incorporated in the insulating portion forming apparatus 72.
　そして、第一絶縁工程においては、第一絶縁部５０Ａを、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下となるように形成する。この際、例えば、ダイカットロールの各刃の厚みや、レーザー光の光軸のサイズ等を調整することにより、幅寸法ＷＬを調整することが可能である。 Then, in the first insulating step, the first insulating portion 50A is formed such that the width dimension WL in the surface direction is 0.1 mm or more and 3 mm or less. At this time, for example, the width dimension WL can be adjusted by adjusting the thickness of each blade of the die cut roll, the size of the optical axis of the laser light, or the like.
　なお、第一絶縁工程においては、第一絶縁部５０Ａを、面方向における幅寸法ＷＬが０．３ｍｍ以上２ｍｍ以下となるように形成することがより好ましい。 In the first insulation step, it is more preferable to form the first insulating portion 50A so that the width dimension WL in the surface direction is 0.3 mm or more and 2 mm or less.
＜発電部形成工程（ａ）＞
次に、公知のエアロゾルデポジション法（Ａｅｒｏｓｏｌ　Ｄｅｐｏｓｉｔｉｏｎ　ｍｅｔｈｏｄ：ＡＤ法）等により、第一導電膜３１の表面３１ａの発電部配置領域Ｒ４４に、酸化チタン等の金属酸化物からなる多孔質層を形成する。その後、多孔質層に増感色素を担持させることで、半導体層１２を形成する。なお、半導体層１２は、ロール状の第一基材２１に予め形成されていてもよい。 <Generation part formation process (a)>
Next, a porous layer made of a metal oxide such as titanium oxide is formed on the power generation portion arrangement region R44 of the surface 31a of the first conductive film 31 by a known aerosol deposition method (Aerosol Deposition method: AD method) or the like. Do. After that, the semiconductor layer 12 is formed by supporting the sensitizing dye on the porous layer. The semiconductor layer 12 may be formed in advance on the roll-shaped first substrate 21.
　次に、Ｄ４１方向に沿って搬送される第一電極４１に対して、封止材塗布装置７６の塗布口から、封止材料の粘性や第一電極４１の搬送速度等を勘案した適切な流量で封止材料を排出させ、第一電極４１の封止材配置領域Ｒ４６、即ち、第一導電膜３１の表面３１ａにおける第一絶縁部５０Ａが形成された部分に封止材料を塗布することで封止材４６を形成する。この際、封止材４６の材料として、上述したような、熱可塑性樹脂、熱硬化性樹脂、又は紫外線硬化性樹脂のうち少なくとも一種を含む樹脂材料を用いる。 Next, for the first electrode 41 conveyed along the D41 direction, an appropriate flow rate taking into consideration the viscosity of the sealing material, the conveyance speed of the first electrode 41, and the like from the application port of the sealing material application device 76 The sealing material is discharged at the same time, and the sealing material is disposed on the sealing material disposition region R46 of the first electrode 41, that is, the portion of the surface 31a of the first conductive film 31 where the first insulating portion 50A is formed. The sealing material 46 is formed. At this time, as the material of the sealing material 46, a resin material including at least one of the thermoplastic resin, the thermosetting resin, and the ultraviolet curable resin as described above is used.
さらに、発電部形成工程（ａ）では、第一導電膜３１の表面３１ａにおける、後述の第二絶縁工程で第二導電膜３２の表面３２ａに形成される第二絶縁部５０Ｂに対応した部分（封止材配置領域Ｒ４６）に、上記の封止材料を塗布することで封止材４６を形成する。つまり、発電部形成工程（ａ）では、後述の貼合工程において第一電極４１と第二電極４２とを重ね合わせたとき、即ち、第一導電膜３１と第二導電膜３２とを対向させたときに、第一導電膜３１の表面３１ａにおける、第二導電膜３２に形成された第二絶縁部５０Ｂに対応した部分に封止材４６を形成する。 Furthermore, in the power generation portion forming step (a), a portion corresponding to the second insulating portion 50B formed on the surface 32a of the second conductive film 32 in the second insulating step described later on the surface 31a of the first conductive film 31 The sealing material 46 is formed by applying the above-described sealing material to the sealing material arrangement region R46). That is, in the power generation portion forming step (a), when the first electrode 41 and the second electrode 42 are superimposed in the bonding step described later, that is, the first conductive film 31 and the second conductive film 32 are made to face each other. At this time, the sealing material 46 is formed on a portion of the surface 31 a of the first conductive film 31 corresponding to the second insulating portion 50 B formed on the second conductive film 32.
発電部形成工程（ａ）においては、図２中に示すように、封止材４６を、第一絶縁部５０Ａの開口全体を覆うように形成することが好ましい。さらに、発電部形成工程（ａ）では、後述の貼合工程において第一電極４１と第二電極４２とを貼り合わせたときに、封止材４６が第二絶縁部５０Ｂの開口全体を覆うことができる位置及び大きさで形成することがより好ましい。 In the power generation portion formation step (a), as shown in FIG. 2, it is preferable to form the sealing material 46 so as to cover the entire opening of the first insulating portion 50A. Furthermore, in the power generation portion forming step (a), the sealing material 46 covers the entire opening of the second insulating portion 50B when the first electrode 41 and the second electrode 42 are bonded in the bonding step described later. It is more preferable to form in the position and the size which can be
さらに、発電部形成工程（ａ）においては、図１０中に示す例のように、封止材４６を、少なくとも一部が第一絶縁部５０Ａの内部に入り込むように形成することが好ましく、第一絶縁部５０Ａの内部全体を埋め込むように形成することがより好ましい。このように、封止材４６を、第一絶縁部５０Ａの内部に入り込むように形成するためには、封止材料として、粘度が３００Ｐａ・ｓ以下のものを用いることが好ましい。また、発電部形成工程（ａ）における第一電極４１の搬送速度を適宜調整し、低めに設定することが好ましい。また、封止材料を第一絶縁部５０Ａ上に塗布した後、１分以上の時間で放置することも効果的である。また、封止材４６を、第一絶縁部５０Ａの内部に入り込むように形成するためには、第一電極４１と第二電極４２とを貼り合わせる際に、互いに押圧することがより好ましい。 Furthermore, in the power generation portion forming step (a), as in the example shown in FIG. 10, it is preferable to form the sealing material 46 so that at least a part thereof enters the inside of the first insulating portion 50A, It is more preferable to form so that the whole inside of the one insulation part 50A may be embedded. As described above, in order to form the sealing material 46 so as to enter the inside of the first insulating portion 50A, it is preferable to use a sealing material having a viscosity of 300 Pa · s or less. Moreover, it is preferable to adjust the conveyance speed of the 1st electrode 41 in a electric power generation part formation process (a) suitably, and to set it relatively low. It is also effective to leave it for 1 minute or more after applying the sealing material on the first insulating portion 50A. Moreover, in order to form the sealing material 46 so as to enter the inside of the first insulating portion 50A, it is more preferable to press the first electrode 41 and the second electrode 42 when they are pasted together.
＜配線形成工程＞
　次に、Ｄ４１方向に沿って搬送される第一電極４１に対して、配線形成装置７８の配線材料排出口から、配線材料の粘性や第一電極４１の搬送速度等を勘案した適切な流量で配線材料を排出させ、第一電極４１の配線配置領域Ｒ４８に配線４８を形成する。 <Wire formation process>
Next, with respect to the first electrode 41 conveyed along the D41 direction, the flow rate of the wiring material from the wiring material discharge port of the wiring forming device 78 is an appropriate flow rate taking into account the viscosity of the wiring material The wiring material is discharged to form the wiring 48 in the wiring arrangement region R <b> 48 of the first electrode 41.
＜発電部形成工程（ｂ）＞
　次に、電解液塗布装置７４の塗布口から、電解液１４の粘性や第一電極４１の搬送速度等を勘案した適切な流量で電解液１４を排出させ、半導体層１２を含む発電部配置領域Ｒ４４に電解液１４を塗布する。 <Generation part formation process (b)>
Next, the electrolytic solution 14 is discharged from the application port of the electrolytic solution application device 74 at an appropriate flow rate taking into account the viscosity of the electrolytic solution 14, the transport speed of the first electrode 41, etc. The electrolyte solution 14 is applied to R44.
＜第二絶縁工程＞
　次に、第一絶縁工程と同様に図示略のＲｔｏＲ方式を採用した装置を用いて、第二基材２２を所定の方向に沿って連続的に搬送しながら、上記同様の方法によって第二基材２２の表面２２ａに第二導電膜３２を形成し、第二導電膜３２を外側に向けた状態でロール状に巻き取る。また、上記同様、予め、表面２２ａに第二導電膜３２が形成されている第二基材２２を用いても構わない。 <Second insulation process>
Next, using the apparatus adopting the RtoR method (not shown) in the same manner as in the first insulation step, the second base 22 is continuously transported in the predetermined direction while using the same method as the second base described above. The second conductive film 32 is formed on the surface 22 a of the material 22, and is wound in a roll while the second conductive film 32 is directed outward. Moreover, you may use the 2nd base material 22 by which the 2nd conductive film 32 is previously formed in surface 22a similarly to the above.
　次いで、第一絶縁工程と同様、図９に示すように、製造装置７０にロール状の第二基材２２を設置し、第二基材２２を所定の方向、図示例ではＤ４２方向に巻き出し、上記同様の絶縁部形成装置７２を用いて、第二導電膜３２の表面３２ａにおける絶縁部形成領域Ｒ５０に、図１及び図２に示すような第二絶縁部５０Ｂを形成する。これにより、第二電極４２が得られる。 Next, as in the first insulation step, as shown in FIG. 9, the roll-shaped second base material 22 is installed in the manufacturing apparatus 70, and the second base material 22 is unwound in a predetermined direction, that is, D42 in the illustrated example. The second insulating portion 50B as shown in FIGS. 1 and 2 is formed in the insulating portion forming region R50 on the surface 32a of the second conductive film 32 using the same insulating portion forming device 72 as described above. Thereby, the second electrode 42 is obtained.
なお、第二絶縁工程においても、第一絶縁工程と同様の方法により、第二絶縁部５０Ｂを、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下となるように形成する。
また、第二絶縁工程においても、第一絶縁工程と同様、第二絶縁部５０Ｂを、面方向における幅寸法ＷＬが０．３ｍｍ以上２ｍｍ以下となるように形成することがより好ましい。 Also in the second insulating step, the second insulating portion 50B is formed to have a width dimension WL in the plane direction of 0.1 mm or more and 3 mm or less by the same method as the first insulating step.
Further, also in the second insulating step, as in the first insulating step, it is more preferable to form the second insulating portion 50B so that the width dimension WL in the surface direction is 0.3 mm or more and 2 mm or less.
＜発電部形成工程（ｃ）＞
　次に、第二電極４２をＤ４２方向に沿って連続的に搬送しながら、公知のスパッタリング法や印刷法等により、触媒層形成装置８４等を用いて、第二導電膜３２の表面３２ａの発電部配置領域Ｒ４４に触媒層１６を形成する。なお、触媒層１６は、ロール状の第二基材２２上に予め形成されていても構わない。
　上述した発電部形成工程（ａ）～発電部形成工程（ｃ）により、発電部４４が形成される。 <Generation part formation process (c)>
Next, while the second electrode 42 is continuously transported along the direction D42, power generation of the surface 32a of the second conductive film 32 is performed using the catalyst layer forming apparatus 84 or the like by a known sputtering method, printing method or the like. The catalyst layer 16 is formed in the part arrangement region R44. The catalyst layer 16 may be formed in advance on the roll-shaped second base material 22.
The power generation unit 44 is formed by the above-described power generation unit formation process (a) to the power generation unit formation process (c).
＜貼合工程＞
　次に、第一押圧ロール９１と、その下方に配置された第二押圧ロール９２との間に、略水平なＤ４１方向に沿って第一電極４１を導入するとともに、斜め上方のＤ４２方向から第二電極４２を導入し、発電部４４、封止材４６及び配線４８を介して第一電極４１と第二電極４２とを重ね合わせる。
次いで、重ね合わせた第一電極４１と第二電極４２とを、第一押圧ロール９１と第二押圧ロール９２との間を通過させ、第一電極４１及び第二電極４２を互いに押圧する。 <Pasting process>
Next, the first electrode 41 is introduced between the first pressing roll 91 and the second pressing roll 92 disposed below the first pressing roll 91 along the substantially horizontal D41 direction, and from the obliquely upward D42 direction The second electrode 42 is introduced, and the first electrode 41 and the second electrode 42 are superimposed via the power generation unit 44, the sealing material 46, and the wiring 48.
Next, the overlapped first electrode 41 and second electrode 42 are passed between the first pressing roll 91 and the second pressing roll 92 to press the first electrode 41 and the second electrode 42 to each other.
　次いで、押圧された状態の第一電極４１及び第二電極４２に対して、図示略のＵＶランプ等を用いて紫外線を照射する等の方法により、封止材４６を硬化させ、第一電極４１と封止材４６とを貼り合わせるとともに、第二電極４２と封止材４６とを貼り合わせる。このとき、第二導電膜３２の表面３２ａに形成された第二絶縁部５０Ｂの開口全体が封止材４６で覆われるように、第二電極４２と封止材４６とを貼り合わせることが好ましい。 Next, the sealing material 46 is cured by irradiating the first electrode 41 and the second electrode 42 in a pressed state with ultraviolet light using a UV lamp (not shown) or the like, and the first electrode 41 is cured. And the sealing material 46, and the second electrode 42 and the sealing material 46 are bonded. At this time, it is preferable to bond the second electrode 42 and the sealing material 46 so that the entire opening of the second insulating portion 50B formed on the surface 32a of the second conductive film 32 is covered with the sealing material 46 .
さらに、貼合工程においては、封止材４６の少なくとも一部が第二絶縁部５０Ｂの内部に入り込むように、第一電極４１と第二電極４２とを貼り合わせることが好ましい。また、第二絶縁部５０Ｂの内部全体を封止材４６で埋め込むように、第一電極４１と第二電極４２とを貼り合わせることがより好ましい。このように、封止材４６を第二絶縁部５０Ｂの内部に入り込ませるためには、上述したような低粘度の封止材料を採用する方法や、紫外線照射等による硬化処理時間を短縮し、半硬化の状態で封止材４６を挟み込む条件で、第一電極４１と第二電極４２とを貼り合わせる方法、あるいは、第一電極４１と第二電極４２との間の押圧力を強める方法等が挙げられる。 Furthermore, in the bonding step, it is preferable to bond the first electrode 41 and the second electrode 42 so that at least a part of the sealing material 46 enters the inside of the second insulating portion 50B. Further, it is more preferable to bond the first electrode 41 and the second electrode 42 so that the entire inside of the second insulating portion 50B is embedded with the sealing material 46. As described above, in order to allow the sealing material 46 to enter the inside of the second insulating portion 50B, a method of employing a low viscosity sealing material as described above, or a curing process time by ultraviolet irradiation or the like is shortened. A method of bonding the first electrode 41 and the second electrode 42 under the condition of sandwiching the sealing material 46 in a semi-cured state, or a method of strengthening the pressing force between the first electrode 41 and the second electrode 42, etc. Can be mentioned.
　第一電極４１及び第二電極４２と封止材４６とを貼り合わせた後に、所定の位置において（図１参照）、即ち、発電部配置領域Ｒ４４をＤ２方向に沿って複数のセルに区画する境界において、超音波付与装置等のシール部形成装置９５を用いて、第一電極４１と第二電極４２に超音波振動を付与し、シール部６０を形成する。 After bonding the first electrode 41 and the second electrode 42 and the sealing material 46, the power generation unit disposition region R44 is divided into a plurality of cells at a predetermined position (see FIG. 1), that is, along the direction D2. At the boundary, ultrasonic vibration is applied to the first electrode 41 and the second electrode 42 using a seal portion forming device 95 such as an ultrasonic wave application device to form the seal portion 60.
　以上の工程により、図１及び図２に示すような電気モジュールである色素増感太陽電池１０を製造することができる。この後、必要に応じて、色素増感太陽電池１０から所望のパターンで、実際に使用される形状及びサイズで色素増感太陽電池を切り出してもよい。 According to the above steps, the dye-sensitized solar cell 10 which is an electric module as shown in FIG. 1 and FIG. 2 can be manufactured. After this, if necessary, the dye-sensitized solar cell may be cut out from the dye-sensitized solar cell 10 in a desired pattern and in the shape and size actually used.
　なお、上記の製造方法の各工程の説明は、図１及び図２に示す色素増感太陽電池１０を製造する場合を例に挙げているが、図３に示す色素増感太陽電池１０Ａ、図４，５に示す色素増感太陽電池１０Ｂ、図１０に示す色素増感太陽電池１０Ｃ、又は、図１１に示す色素増感太陽電池１０Ｄを製造する場合においても、各製造条件を適宜変更しながら、同様の方法で製造することができる。 In addition, although description of each process of said manufacturing method is taking the case of manufacturing the dye-sensitized solar cell 10 shown to FIG.1 and FIG.2 as an example, the dye-sensitized solar cell 10A shown in FIG. 3, FIG. Also in the case of producing the dye-sensitized solar cell 10B shown in 4 and 5 and the dye-sensitized solar cell 10C shown in FIG. 10 or the dye-sensitized solar cell 10D shown in FIG. , Can be manufactured in a similar manner.
［作用効果］
　以上説明したように、本実施形態の電気モジュールである色素増感太陽電池１０によれば、第一電極４１における第一導電膜３１及び第二電極４２における第二導電膜３２に形成された平面視帯状の第一絶縁部５０Ａ及び第二絶縁部５０Ｂが、それぞれ、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下である構成を採用している。これにより、色素増感太陽電池１０を折り曲げた状態とした場合でも、第一導電膜３１及び第二導電膜３２に形成された各端部同士が、第一絶縁部５０Ａ又は第二絶縁部５０Ｂを超えて接触するのを防止でき、絶縁性が確実に担保される。このような、良好な第一絶縁部５０Ａ又は第二絶縁部５０Ｂが設けられることにより、色素増感太陽電池１０の使用形態に関わらず、簡便な構成で電気的リークが発生するのを防止でき、優れた電池性能を得ることが可能になる。また、面方向において封止材４６同士の間に配線４８が設けられている場合には、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬが上述範囲とされることで配線４８の移動が抑えられ、色素増感太陽電池１０の発電性能が安定する。 [Function effect]
As explained above, according to the dye-sensitized solar cell 10 which is the electric module of the present embodiment, the plane formed on the first conductive film 31 in the first electrode 41 and the second conductive film 32 in the second electrode 42 Each of the first insulating portion 50A and the second insulating portion 50B in the shape of a visible band adopts a configuration in which the width dimension WL in the surface direction is 0.1 mm or more and 3 mm or less. Thereby, even when the dye-sensitized solar cell 10 is in a bent state, the respective end portions formed in the first conductive film 31 and the second conductive film 32 are the first insulating portion 50A or the second insulating portion 50B. Contact can be prevented, and the insulation is assuredly ensured. By providing such a favorable first insulating portion 50A or second insulating portion 50B, it is possible to prevent the occurrence of electrical leakage with a simple configuration regardless of the use form of the dye-sensitized solar cell 10 It becomes possible to obtain excellent battery performance. Further, in the case where the wiring 48 is provided between the sealing materials 46 in the surface direction, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is in the above range by being set to the above range. The movement is suppressed, and the power generation performance of the dye-sensitized solar cell 10 is stabilized.
　また、本実施形態の電気モジュールである色素増感太陽電池１０の製造方法によれば、第一絶縁工程及び第二絶縁工程において形成する第一絶縁部５０Ａ及び第二絶縁部５０Ｂを、それぞれ、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下となるように形成する方法を採用している。これにより、上記のように、色素増感太陽電池１０を折り曲げた状態とした場合でも、第一導電膜３１及び第二導電膜３２に形成された各端部同士が第一絶縁部５０Ａ及び第二絶縁部５０Ｂを超えて接触するのを防止でき、絶縁性が確実に担保された色素増感太陽電池１０を製造できる。従って、色素増感太陽電池１０の使用形態に関わらず、電気的リークが発生するのを防止でき、優れた電池性能を有する色素増感太陽電池１０を得ることが可能になる。 Further, according to the method of manufacturing the dye-sensitized solar cell 10 which is the electric module of the present embodiment, the first insulating portion 50A and the second insulating portion 50B formed in the first insulating step and the second insulating step are respectively The method of forming so that width dimension WL in a surface direction may be 0.1 mm or more and 3 mm or less is adopted. Thus, as described above, even when the dye-sensitized solar cell 10 is in a bent state, the respective end portions formed in the first conductive film 31 and the second conductive film 32 are the first insulating portion 50A and the second insulating portion 50A. The dye-sensitized solar cell 10 can be manufactured which can be prevented from contacting beyond the two insulating portions 50B and the insulation property is reliably ensured. Therefore, regardless of the use form of the dye-sensitized solar cell 10, it is possible to prevent the occurrence of electrical leakage, and it is possible to obtain the dye-sensitized solar cell 10 having excellent cell performance.
［その他の形態］
　以上、本発明の好ましい実施形態について詳述したが、本発明は上記の実施形態に限定されるものではなく、特許請求の範囲内に記載された本発明の要旨の範囲内において、種々の変形・変更が可能である。 [Other forms]
Although the preferred embodiments of the present invention have been described above in detail, the present invention is not limited to the above embodiments, and various modifications may be made within the scope of the subject matter of the present invention described in the claims.・ Change is possible.
　例えば、上述の実施形態では、電気モジュールの一例として色素増感太陽電池１０を挙げて説明したが、本発明に係る電気モジュールは絶縁処理を要する電気モジュールであれば特に限定されない。 For example, in the above-mentioned embodiment, although dye-sensitized solar cell 10 was mentioned and explained as an example of an electric module, the electric module concerning the present invention will not be limited especially if it is an electric module which requires insulation processing.
　以下、実施例および比較例により本発明をさらに具体的に説明するが、本発明は以下の実施例に限定されるものではない。 Hereinafter, the present invention will be more specifically described by way of Examples and Comparative Examples, but the present invention is not limited to the following Examples.
［実施例１］
　実施例１においては、まず、以下に示すような材料を用いて、上記実施形態に示した本発明に係る電気モジュールの製造方法の手順で、図１及び図２に示すような本発明に係る色素増感太陽電池（電気モジュール）１０に用いられる第一電極４１を作製した。
（１）第一基材２１…ポリエチレンテレフタレート（ＰＥＴ）
（２）第一導電膜３１…酸化インジウムスズ（ＩＴＯ） Example 1
In Example 1, according to the procedure of the method of manufacturing an electric module according to the present invention shown in the above embodiment using materials as shown below, according to the present invention as shown in FIG. 1 and FIG. The 1st electrode 41 used for the dye-sensitized solar cell (electric module) 10 was produced.
(1) First base material 21: polyethylene terephthalate (PET)
(2) First conductive film 31 ... indium tin oxide (ITO)
　また、第一導電膜３１の絶縁部形成領域Ｒ５０に、市販のレーザー加工機（アスク工業株式会社製、型番；ＶＳＬ２．３０）を用いて、平面視帯状で貫通（分断）した第一絶縁部５０Ａを形成した。この際、第一絶縁部５０Ａの幅寸法ＷＬが３ｍｍとなるようにレーザーの加工条件を調整した。また、レーザー加工によって掘り込まれる、第一導電膜３１の表面３１ａからの全体深さが、少なくとも第一導電膜３１を貫通するようにレーザーの出力強度を調整した。即ち、本実施例においては、第一電極４１に対して、第一導電膜３１を貫通するとともに、第一基材２１の表面２１ａが若干掘り込まれるようなハーフカット加工を施すことにより、第一絶縁部５０Ａを形成した。 In addition, a first insulating portion formed in a band shape in a plan view in a band shape in the insulating portion forming region R50 of the first conductive film 31 using a commercially available laser processing machine (manufactured by ASK Industrial Co., Ltd., model number: VSL 2.30) Formed 50A. At this time, the processing conditions of the laser were adjusted so that the width dimension WL of the first insulating portion 50A was 3 mm. Further, the output intensity of the laser was adjusted so that the entire depth from the surface 31 a of the first conductive film 31 dug by laser processing penetrates at least the first conductive film 31. That is, in the present embodiment, the first electrode 41 is subjected to half-cut processing such that the first conductive film 31 is penetrated and the surface 21a of the first base material 21 is slightly dug. One insulating portion 50A was formed.
　そして、上記で得られた第一電極４１を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけ、両端をつかんで擬似的に３６０度で折り曲げた。この際、ハーフカット加工で形成した第一絶縁部５０Ａが金属棒に沿うように、第１電極４１を巻きかけた状態とし、この状態での第一絶縁部５０Ａにおける電流リークの有無を調べた。 Then, after processing the first electrode 41 obtained above into a rectangular shape with a size of 200 mm, it was wound around a metal rod with a diameter of 5 mm, and both ends were grasped and bent at 360 degrees in a pseudo manner. At this time, the first electrode 41 was wound around the first insulating portion 50A formed by half-cut along the metal bar, and the presence or absence of current leakage in the first insulating portion 50A in this state was examined. .
この結果、本実施例では、第一絶縁部５０Ａにおいて電流リークが生じていないことが確認できた。即ち、第一絶縁部５０Ａの幅寸法ＷＬを上記寸法とした場合には、図１２Ａ及び図１２Ｂに示したような、加工端部Ｔ同士が接触して電気的リークが生じる可能性は極めて低く、上記の第一電極４１を色素増感太陽電池に適用して、折り曲げて使用した場合でも、発電には影響がないことが確認できた。 As a result, in the present embodiment, it has been confirmed that current leakage does not occur in the first insulating portion 50A. That is, when the width dimension WL of the first insulating portion 50A is set to the above-mentioned dimension, the possibility that the processed end portions T contact with each other and electrical leak as shown in FIGS. 12A and 12B is extremely low. It has been confirmed that power generation is not affected even when the first electrode 41 described above is applied to a dye-sensitized solar cell and used by bending.
［実施例２］
　実施例２においては、第一絶縁部５０Ａの幅寸法ＷＬが０．１ｍｍとなるようにレーザーの加工条件を調整してレーザー加工を行った点を除き、実施例１と同様の条件及び手順で、第一導電膜３１を貫通する第一絶縁部５０Ａが形成された第一電極４１を作製した。 Example 2
In Example 2, the same conditions and procedures as in Example 1 were used except that laser processing was performed while adjusting the processing conditions of the laser such that the width dimension WL of the first insulating portion 50A was 0.1 mm. The 1st electrode 41 in which the 1st insulating part 50A which penetrated the 1st conductive film 31 was formed was produced.
　そして、実施例１と同様の方法により、得られた第一電極４１を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけて擬似的に３６０度で折り曲げた際の電流リークの有無を確認したところ、第一絶縁部５０Ａにおける電流リークは生じていなかった。即ち、第一絶縁部５０Ａの幅寸法ＷＬを０．１ｍｍとした場合でも、実施例１の場合と同様、加工端部同士が接触して電気的リークが生じる可能性は極めて低く、上記の第一電極４１を色素増感太陽電池に適用し、それを折り曲げて使用した場合であっても、発電には影響がないことが確認できた。 Then, the obtained first electrode 41 is processed into a rectangular shape with a size of 200 mm by a method similar to that of Example 1, and then wound around a metal rod with a diameter of 5 mm to be virtually bent at 360 degrees. When the presence or absence of the leak was confirmed, the current leak in the first insulating portion 50A did not occur. That is, even when the width dimension WL of the first insulating portion 50A is 0.1 mm, as in the case of the first embodiment, the possibility that the processed end portions come in contact with each other to cause an electrical leak is extremely low. It has been confirmed that power generation is not affected even when one electrode 41 is applied to a dye-sensitized solar cell and used by bending it.
［実施例３］
　実施例３においては、第一絶縁部を、幅寸法ＷＬはそのままで、第一導電膜３１を貫通せず、凹状となるようにレーザーの加工条件を調整してレーザー加工を行った点を除き、実施例１と同様の条件及び手順で、図３に示した色素増感太陽電池１０Ａに備えられるような、第一導電膜３１に平面視帯状で凹状とされた第一絶縁部５１Ａが形成された第一電極４１を作製した。この際、凹状とされた第一絶縁部５１Ａの深さが、少なくとも第一導電膜３１の一部が残る程度、即ち、第一導電膜３１を貫通しない程度となるように、レーザーの出力強度を調整した。 [Example 3]
In the third embodiment, the laser processing is performed while adjusting the processing conditions of the laser so that the first insulating portion does not penetrate the first conductive film 31 without changing the width dimension WL and becomes concave. Under the same conditions and procedures as in Example 1, the first conductive film 31 has the first insulating portion 51A in the form of a strip and concave in plan view, provided in the dye-sensitized solar cell 10A shown in FIG. The first electrode 41 was manufactured. At this time, the output intensity of the laser is set so that the depth of the recessed first insulating portion 51A is such that at least a portion of the first conductive film 31 remains, ie, the depth not to penetrate the first conductive film 31. Adjusted.
　そして、実施例１と同様の方法により、得られた第一電極４１を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけて擬似的に３６０度で折り曲げた際の電流リークの有無を確認したところ、第一絶縁部５０Ａにおける電流リークは生じていなかった。即ち、第一絶縁部５０Ａを平面視帯状で凹状に形成した場合においても、実施例１及び実施例２の場合と同様、加工端部同士が接触して電気的リークが生じる可能性は極めて低く、上記の第一電極４１を色素増感太陽電池に適用し、それを折り曲げて使用した場合であっても、発電には影響がないことが確認できた。 Then, the obtained first electrode 41 is processed into a rectangular shape with a size of 200 mm by a method similar to that of Example 1, and then wound around a metal rod with a diameter of 5 mm to be virtually bent at 360 degrees. When the presence or absence of the leak was confirmed, the current leak in the first insulating portion 50A did not occur. That is, even in the case where the first insulating portion 50A is formed in a band shape in a plan view and in a concave shape, the possibility that the processed end portions come in contact with each other and electrical leaks is extremely low as in the case of the first embodiment and the second embodiment. Even when the first electrode 41 described above is applied to a dye-sensitized solar cell and used by bending it, it has been confirmed that power generation is not affected.
［実施例４］
実施例４においては、実施例１と同様の条件及び手順で、図１及び図２中に示すような、第一導電膜３１を貫通する第一絶縁部５０Ａが形成された第一電極４１を作製した。
また、実施例４では、第二基材２２としてＰＥＴ材料を用いるとともに、第二導電膜３２としてＩＴＯ材料を用いて、第二基材２１の表面２２ａに第二導電膜３２を積層した。さらに、第二導電膜３２の絶縁部形成領域Ｒ５０に、実施例１における第一絶縁部５０Ａの形成条件と同様の条件で、平面視帯状で貫通（分断）した第二絶縁部５０Ｂを形成することにより、図１及び図２中に示すような第二電極４２を作製した。この際、第二絶縁部５０Ｂの幅寸法ＷＬが３ｍｍとなるようにレーザーの加工条件を調整し、レーザー加工によって第二絶縁部５０Ｂを形成した。 Example 4
In the fourth embodiment, the first electrode 41 in which the first insulating portion 50A penetrating the first conductive film 31 is formed as shown in FIGS. 1 and 2 under the same conditions and procedure as the first embodiment. Made.
In Example 4, the second conductive film 32 was laminated on the surface 22 a of the second base material 21 using a PET material as the second base material 22 and using an ITO material as the second conductive film 32. Furthermore, in the insulating portion forming region R50 of the second conductive film 32, the second insulating portion 50B penetrating (dividing) in a band shape in plan view is formed under the same conditions as the forming conditions of the first insulating portion 50A in the first embodiment. Thus, a second electrode 42 as shown in FIGS. 1 and 2 was produced. At this time, the processing conditions of the laser were adjusted so that the width dimension WL of the second insulating portion 50B was 3 mm, and the second insulating portion 50B was formed by laser processing.
次いで、第一電極２１における第一導電膜３１の表面３１ａに、第一絶縁部５０Ａに対応する位置で、封止材料としてアクリル系紫外線硬化樹脂を塗布することで、図１及び図２中に示すように、第一絶縁部５０Ａの開口全体を覆うとともに、第一絶縁部５０Ａの内部が略空洞状態になるように封止材４６を形成した。これとともに、第一導電膜３１の表面３１ａにおいて、後工程となる後述の貼合工程で第一電極２１と第二電極２２とを重ね合わせたときに、第二導電膜３２の表面３２ａに形成された第二絶縁部５０Ｂに対応する部分に、上記同様の封止材料を塗布することで、封止材４６を形成した。 Next, an acrylic ultraviolet curable resin is applied as a sealing material to the surface 31 a of the first conductive film 31 in the first electrode 21 at a position corresponding to the first insulating portion 50A, as shown in FIGS. 1 and 2. As shown, the sealing material 46 was formed so as to cover the entire opening of the first insulating portion 50A and to make the inside of the first insulating portion 50A substantially hollow. At the same time, on the surface 31 a of the first conductive film 31, when the first electrode 21 and the second electrode 22 are superimposed in the later-described bonding step, which will be a post process, the surface 32 a is formed on the second conductive film 32. A sealing material 46 was formed by applying the same sealing material as described above to the portion corresponding to the second insulating portion 50B.
次いで、第一電極４１の配線配置領域Ｒ４８に、配線材料としてミクロパール（登録商標：積水化学工業株式会社製）を流入させることで、配線４８を形成した。
次いで、第一電極４１の半導体層１２を含む発電部配置領域Ｒ４４に電解液１４を塗布した。
次いで、市販のスパッタ装置を用いたスパッタリング法により、第二導電膜３２の表面３２ａの発電部配置領域Ｒ４４に触媒層１６を形成した。この際、触媒層材料として白金を用いた。 Then, the wiring 48 was formed by flowing Micro Pearl (registered trademark: manufactured by Sekisui Chemical Co., Ltd.) as a wiring material into the wiring arrangement region R <b> 48 of the first electrode 41.
Subsequently, the electrolytic solution 14 was applied to the power generation unit disposition region R <b> 44 including the semiconductor layer 12 of the first electrode 41.
Next, the catalyst layer 16 was formed in the power generation portion disposition region R44 of the surface 32a of the second conductive film 32 by a sputtering method using a commercially available sputtering apparatus. At this time, platinum was used as a catalyst layer material.
次いで、図９中に示すような第一押圧ロール９１と、その下方に配置された第二押圧ロール９２との間に、略水平なＤ４１方向に沿って第一電極４１を導入するとともに、斜め上方のＤ４２方向から第二電極４２を導入し、発電部４４、封止材４６及び配線４８を介して第一電極４１と第二電極４２とを重ね合わせた。
次いで、重ね合わせた第一電極４１と第二電極４２とを、第一押圧ロール９１と第二押圧ロール９２との間を通過させ、第一電極４１及び第二電極４２を互いに押圧した。 Next, the first electrode 41 is introduced along the substantially horizontal direction D41 between the first pressing roll 91 as shown in FIG. 9 and the second pressing roll 92 disposed therebelow, and also obliquely The second electrode 42 was introduced from the upper direction D42, and the first electrode 41 and the second electrode 42 were superimposed via the power generation unit 44, the sealing material 46, and the wiring 48.
Next, the overlapped first electrode 41 and second electrode 42 were passed between the first pressing roll 91 and the second pressing roll 92 to press the first electrode 41 and the second electrode 42 to each other.
次いで、押圧された状態の第一電極４１及び第二電極４２に対し、ＵＶランプを用いて紫外線を照射することにより、封止材４６を硬化させ、第一電極４１と封止材４６とを貼り合わせるとともに、第二電極４２と封止材４６とを貼り合わせた。このとき、第二導電膜３２の表面３２ａに形成された第二絶縁部５０Ｂの開口全体が封止材４６で覆われるように、第二電極４２と封止材４６とを貼り合わせた。 Next, the sealing material 46 is cured by irradiating the pressed first electrode 41 and the second electrode 42 with ultraviolet light using a UV lamp, and the first electrode 41 and the sealing material 46 are While bonding together, the 2nd electrode 42 and the sealing material 46 were bonded together. At this time, the second electrode 42 and the sealing material 46 were bonded so that the entire opening of the second insulating portion 50B formed on the surface 32a of the second conductive film 32 was covered with the sealing material 46.
次いで、貼り合わせられた第一電極４１及び第二電極４２に対し、図１中に示すような、発電部配置領域Ｒ４４をＤ２方向に沿って複数のセルに区画する境界において、超音波付与装置を用いて超音波振動を付与し、シール部６０を形成した。
以上の手順により、図１及び図２に示すような本発明に係る色素増感太陽電池（電気モジュール）１０を作製した。 Next, with respect to the bonded first electrode 41 and second electrode 42, as shown in FIG. 1, an ultrasonic wave application device at the boundary that divides the power generation unit disposition region R44 into a plurality of cells along the D2 direction. Ultrasonic vibration was applied to form a seal portion 60.
According to the above procedure, a dye-sensitized solar cell (electric module) 10 according to the present invention as shown in FIGS. 1 and 2 was produced.
そして、実施例１と同様の方法により、得られた色素増感太陽電池１０を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけて擬似的に３６０度で折り曲げた際の電流リークの有無を確認したところ、第一絶縁部５０Ａ及び第二絶縁部５０Ｂにおける電流リークは生じていなかった。即ち、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬを本発明で規定する寸法とし、さらに、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの開口全体を覆うように封止材４６を設けることにより、加工端部同士が接触して電気的リークが生じる可能性は極めて低く、色素増感太陽電池１０を折り曲げて使用した場合でも、発電には影響がないことが確認できた。 Then, after the obtained dye-sensitized solar cell 10 is processed into a rectangular shape with a size of 200 mm by the same method as in Example 1, it is wound around a metal rod with a diameter of 5 mm and bent at 360 degrees in a pseudo manner The presence or absence of the current leak was confirmed, and no current leak occurred in the first insulating portion 50A and the second insulating portion 50B. That is, the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is set to a size defined by the present invention, and the sealing material 46 is further provided to cover the entire opening of the first insulating portion 50A and the second insulating portion 50B. It has been confirmed that the possibility of electrical leakage due to the contact of the processing ends with each other is extremely low, and power generation is not affected even when the dye-sensitized solar cell 10 is used by bending.
［実施例５］ 
実施例５においては、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部に封止材４６が入り込むように、各条件を調整した点を除き、実施例４と同様の条件の及び手順により、図１０中に示すような、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部が封止材４６で完全に埋め込まれた色素増感太陽電池１０Ｃを作製した。 [Example 5]
In the fifth embodiment, the procedure and conditions are the same as in the fourth embodiment except that the sealing material 46 is adjusted so that the sealing material 46 enters the insides of the first insulating portion 50A and the second insulating portion 50B. As shown in FIG. 10, a dye-sensitized solar cell 10C in which the insides of the first insulating portion 50A and the second insulating portion 50B were completely embedded with the sealing material 46 was manufactured.
実施例５においては、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部に封止材料が入り込みやすくなるように、封止材料として、粘度が３００Ｐａ・ｓのアクリル系紫外線硬化樹脂を用いるとともに、封止材料を塗布する工程の後、概ね１分程度でワークを放置した。さらに、実施例５では、第二絶縁部５０Ｂの内部に封止材料が入り込みやすくなるように、第一電極４１と第二電極４２とを貼合する際、上記の実施例４に比べてラミネートロールの押圧力を上昇させた。
以上の手順により、図１０に示すような本発明に係る色素増感太陽電池（電気モジュール）を作製した。 In the fifth embodiment, an acrylic ultraviolet curable resin having a viscosity of 300 Pa · s is used as a sealing material so that the sealing material can easily enter the inside of the first insulating portion 50A and the second insulating portion 50B. After the step of applying the sealing material, the work was left for approximately one minute. Furthermore, in Example 5, when bonding the first electrode 41 and the second electrode 42 so that the sealing material can easily enter the inside of the second insulating portion 50B, lamination is performed as compared with Example 4 described above. The pressing force of the roll was raised.
According to the above procedure, a dye-sensitized solar cell (electric module) according to the present invention as shown in FIG. 10 was produced.
そして、実施例４等と同様の方法により、得られた色素増感太陽電池を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけて擬似的に３６０度で折り曲げた際の電流リークの有無を確認したところ、第一絶縁部５０Ａ及び第二絶縁部５０Ｂにおける電流リークは生じていなかった。即ち、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの幅寸法ＷＬを本発明で規定する寸法とし、さらに、第一絶縁部５０Ａ及び第二絶縁部５０Ｂの内部を完全に埋め込むように封止材４６を設けることにより、加工端部同士が接触して電気的リークが生じる可能性は極めて低く、色素増感太陽電池１０を折り曲げて使用した場合でも、発電には影響がないことが確認できた。 And, after processing the obtained dye-sensitized solar cell into a rectangular shape with a size of 200 mm by the same method as Example 4 etc., winding it around a metal rod with a diameter of 5 mm and bending it at 360 degrees in a pseudo manner The presence or absence of the current leak was confirmed, and no current leak occurred in the first insulating portion 50A and the second insulating portion 50B. That is, the sealing material is formed such that the width dimension WL of the first insulating portion 50A and the second insulating portion 50B is defined in the present invention, and the inside of the first insulating portion 50A and the second insulating portion 50B is completely embedded. By providing the 46, the possibility of electrical leakage due to contact between the processed ends is extremely low, and it has been confirmed that power generation is not affected even when the dye-sensitized solar cell 10 is used by bending. .
［比較例］
　比較例においては、第一絶縁部の幅寸法ＷＬが０．０５ｍｍとなるようにレーザーの出力強度を調整してレーザー加工を行った点を除き、実施例１と同様の条件及び手順で、第一導電膜を貫通する第一絶縁部が形成された第一電極を作製した。 [Comparative example]
In the comparative example, under the same conditions and procedures as in Example 1, except that the laser processing was performed by adjusting the output intensity of the laser so that the width dimension WL of the first insulating portion was 0.05 mm, The 1st electrode in which the 1st insulation part which penetrated one electric conduction film was formed was produced.
　そして、実施例１～実施例３と同様の方法により、得られた第一電極を２００ｍｍのサイズで矩形状に加工した後、直径５ｍｍの金属棒に巻きかけて擬似的に３６０度で折り曲げた際の電流リークの有無を確認したところ、第一絶縁部おいてリークが発生していることが確認された。即ち、第一絶縁部の幅寸法ＷＬが所定寸法以下である場合には、加工端部Ｔ間の接触による電気的リークが生じる可能性が高く、このような第一電極を色素増感太陽電池に適用し、それを折り曲げて使用した場合には、絶縁不良によって色素増感太陽電池の動作不良が発生し、電池性能が低下するおそれがあることが明らかとなった。 Then, the obtained first electrode was processed into a rectangular shape with a size of 200 mm by the same method as in Examples 1 to 3 and then wound around a metal rod having a diameter of 5 mm to be virtually bent at 360 degrees When the presence or absence of the current leak at the time of was confirmed, it was confirmed that the leak has generate | occur | produced in the 1st insulation part. That is, when the width dimension WL of the first insulating portion is equal to or less than a predetermined dimension, there is a high possibility that an electrical leak will occur due to the contact between the processing ends T, and such a first electrode is a dye-sensitized solar cell In the case of using it and bending it, it has become clear that there is a risk that the poor performance of the dye-sensitized solar cell may occur due to the insulation failure and the cell performance may deteriorate.
　上記の各実施例及び比較例の結果より、本発明が適用され、第一電極における第一導電膜及び第二電極における第二導電膜に、それぞれ、面方向における幅寸法ＷＬが０．１ｍｍ以上３ｍｍ以下である平面視帯状の第一絶縁部及び第二絶縁部が設けられることで、色素増感太陽電池（電気モジュール）を湾曲させた場合であっても、加工端部間の接触による電気的リークが生じるのを防止できることが明らかである。 From the results of the above-described Examples and Comparative Examples, the present invention is applied, and the width dimension WL in the surface direction of each of the first conductive film in the first electrode and the second conductive film in the second electrode is 0.1 mm or more Even when the dye-sensitized solar cell (electric module) is bent by providing the first insulating portion and the second insulating portion in a planar view band of 3 mm or less, the electric due to the contact between the processing ends It is clear that it is possible to prevent the occurrence of a leak.
　本発明の電気モジュールは、良好な絶縁処理が施され、電気的リークが生じるのを防止でき、電池特性に優れたものなので、特に、色素増感型太陽電池等の電気モジュールの分野において好適である。 The electrical module of the present invention is excellent in cell characteristics because it can be well insulated, can prevent electrical leakage, and is particularly suitable in the field of electrical modules such as dye-sensitized solar cells. is there.
１０，１０Ａ，１０Ｂ，１０Ｃ，１０Ｄ…色素増感太陽電池（電気モジュール）
１２…半導体層
２１…第一基材
　２１ａ…表面
２２…第二基材
　２２ａ…表面
３１…第一導電膜
　３１ａ…表面
３２…第二導電膜
　３２ａ…表面
４１…第一電極
４２…第二電極
４４…発電部
４６…封止材
５０Ａ，５１Ａ，５２Ａ…第一絶縁部（絶縁部）
５０Ｂ，５１Ｂ，５２Ｂ…第二絶縁部（絶縁部）
  10, 10A, 10B, 10C, 10D ... Dye-sensitized solar cell (electric module)
12 semiconductor layer 21 first base material 21a surface 22 second base material 22a surface 31 first conductive film 31a surface 32 second conductive film 32a surface 41 first electrode 42 second electrode 44: Power generation unit 46: Sealing materials 50A, 51A, 52A: First insulating unit (insulating unit)
50B, 51B, 52B ... second insulating portion (insulating portion)

Claims (8)

  1. 第一基材と、該第一基材の表面に設けられた第一導電膜とを有する第一電極と、
    　第二基材と、該第二基材の表面に設けられた第二導電膜とを有する第二電極と、
    半導体層を含む発電部であって、前記第一電極と前記第二電極との間に設けられ、前記第一電極及び前記第二電極の面方向に沿って離間して複数設けられた発電部と、
    前記面方向に沿って前記発電部の両側に設けられた封止材と、を備え、
    前記第一導電膜及び前記第二導電膜の前記封止材と対向する部分に、それぞれ、前記第一導電膜又は前記第二導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状に形成された、平面視帯状の絶縁部が設けられており、且つ、該絶縁部の前記面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下であることを特徴とする電気モジュール。     A first electrode having a first substrate and a first conductive film provided on the surface of the first substrate;
    A second electrode having a second base and a second conductive film provided on the surface of the second base;
    A power generation unit including a semiconductor layer, the power generation unit being provided between the first electrode and the second electrode, and provided in a plurality along the surface direction of the first electrode and the second electrode. When,
    A sealing material provided on both sides of the power generation unit along the surface direction;
    Either the first conductive film or the second conductive film is penetrated in a thickness direction in a portion facing the sealing material of the first conductive film and the second conductive film, or the sealing material side And an insulating portion formed in a concave shape so as to open in a plan view and having a width in the plane direction of the insulating portion of 0.1 mm or more and 3 mm or less. module.
  2. 前記封止材は、前記絶縁部の前記封止材側における開口全体を覆うように設けられていることを特徴とする請求項１に記載の電気モジュール。 The said sealing material is provided so that the whole opening in the said sealing material side of the said insulation part may be covered, The electric module of Claim 1 characterized by the above-mentioned.
  3. 前記封止材は、少なくとも一部が前記絶縁部の内部に入り込むように設けられていることを特徴とする請求項１又は請求項２に記載の電気モジュール。 The electric module according to claim 1, wherein the sealing material is provided so that at least a part of the sealing material enters the inside of the insulating portion.
  4. 前記絶縁部の前記面方向における幅寸法が０．３ｍｍ以上２ｍｍ以下であることを特徴とする請求項１～請求項３の何れか一項に記載の電気モジュール。 The electric module according to any one of claims 1 to 3, wherein a width dimension in the surface direction of the insulating portion is 0.3 mm or more and 2 mm or less.
  5. 　請求項１～請求項４の何れか一項に記載の電気モジュールを製造する、電気モジュールの製造方法であって、
    　前記第一電極を切り込み加工することにより、前記第一基材の表面に設けられた前記第一導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状とされた、平面視帯状の第一絶縁部を形成する第一絶縁工程と、
    　前記第二電極を切り込み加工することにより、前記第二基材の表面に設けられた前記第二導電膜を厚み方向で貫通するか、あるいは、前記封止材側に開口するように凹状とされた、平面視帯状の第二絶縁部を形成する第二絶縁工程と、
    前記第一導電膜の表面において、前記第一絶縁部が形成された部分、及び、前記第一導電膜と前記第二導電膜とを対向させたときに、前記第二導電膜の表面に形成された前記第二絶縁部に対応する位置に、前記封止材を形成するとともに、前記面方向における前記封止材同士の間に、半導体層を含む発電部を形成する発電部形成工程と、
    前記第一導電膜と前記第二導電膜とを対向させ、前記第一電極と前記第二電極とを貼り合わせる貼合工程と、を有し、
    前記第一絶縁工程及び前記第二絶縁工程は、前記第一絶縁部及び前記第二絶縁部を、それぞれ、前記面方向における幅寸法が０．１ｍｍ以上３ｍｍ以下となるように形成することを特徴とする電気モジュールの製造方法。     A method of manufacturing an electrical module, comprising: manufacturing the electrical module according to any one of claims 1 to 4;
    By cutting the first electrode, the first conductive film provided on the surface of the first base material is penetrated in the thickness direction, or concaved so as to open on the sealing material side. A first insulating step of forming a first insulating portion having a strip shape in plan view;
    By cutting the second electrode, the second conductive film provided on the surface of the second base material is penetrated in the thickness direction, or concaved so as to open on the sealing material side. A second insulating step of forming a second insulating portion having a strip shape in plan view;
    The surface of the first conductive film is formed on the surface of the second conductive film when the portion where the first insulating portion is formed and the first conductive film and the second conductive film are opposed to each other. A power generation portion forming step of forming the sealing material at a position corresponding to the second insulating portion and forming a power generation portion including a semiconductor layer between the sealing materials in the surface direction;
    And bonding the first conductive film and the second conductive film to face each other and bonding the first electrode and the second electrode.
    The first insulating step and the second insulating step are characterized in that the first insulating portion and the second insulating portion are formed such that the width dimension in the surface direction is 0.1 mm or more and 3 mm or less. Method of manufacturing an electrical module.
  6. 前記発電部形成工程は、前記封止材を、前記第一絶縁部の前記封止材側における開口全体を覆うように形成し、
    前記貼合工程は、前記封止材が前記第二絶縁部の開口全体を覆うように、前記第一電極と前記第二電極とを貼り合わせることを特徴とする請求項５に記載の電気モジュールの製造方法。     In the power generation portion forming step, the sealing material is formed to cover the entire opening on the sealing material side of the first insulating portion.
    The electric module according to claim 5, wherein the bonding step bonds the first electrode and the second electrode such that the sealing material covers the entire opening of the second insulating portion. Manufacturing method.
  7. 前記発電部形成工程は、前記封止材を、少なくとも一部が前記第一絶縁部の内部に入り込むように形成し、
    前記貼合工程は、前記封止材の少なくとも一部が前記第二絶縁部の内部に入り込むように、前記第一電極と前記第二電極とを貼り合わせることを特徴とする請求項５又は請求項６に記載の電気モジュールの製造方法。     In the power generation unit forming step, the sealing material is formed such that at least a part thereof enters the inside of the first insulating unit.
    The said bonding process bonds the said 1st electrode and the said 2nd electrode together, so that at least one part of the said sealing material entraps into the inside of the said 2nd insulation part. The manufacturing method of the electric module of claim 6.
  8. 前記第一絶縁工程及び前記第二絶縁工程は、前記第一絶縁部及び第二絶縁部を、それぞれ、前記面方向における幅寸法が０．３ｍｍ以上２ｍｍ以下となるように形成することを特徴とする請求項５～請求項７の何れか一項に記載の電気モジュールの製造方法。 The first insulating step and the second insulating step are characterized in that the first insulating portion and the second insulating portion are each formed so that the width dimension in the surface direction is 0.3 mm or more and 2 mm or less. A method of manufacturing an electric module according to any one of claims 5 to 7.
PCT/JP2019/002236 2018-01-24 2019-01-24 Electric module and method for manufacturing electric module WO2019146684A1 (en)

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JP2017059832A (en) * 2015-09-18 2017-03-23 積水化学工業株式会社 Solar cell

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JP2009193911A (en) * 2008-02-18 2009-08-27 Sony Corp Dye-sensitized photoelectric conversion element and its manufacturing method, dye-sensitized photoelectric conversion element module and its manufacturing method, electronic device, and method for manufacturing porous silica film
JP2011129383A (en) * 2009-12-18 2011-06-30 Aisin Seiki Co Ltd Dye-sensitized solar cell
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