JP-7855384-B2 - Solar cell module manufacturing method

JP7855384B2JP 7855384 B2JP7855384 B2JP 7855384B2JP-7855384-B2

Inventors

三島良太

Assignees

株式会社カネカ

Dates

Publication Date: 20260508
Application Date: 20220330

Claims (3)

A method for manufacturing a solar cell module having multiple solar cell subcells, A process of laminating a resin substrate layer onto one main surface of the support substrate, The process of laminating a first electrode layer onto the resin substrate layer, A step of forming a first internal separation groove that cuts the first electrode layer at the boundary of the region where the solar cell subcell is formed by laser irradiation, A step of forming a first external separation groove that cuts the first electrode layer at the outer edge of the region where the solar cell module is formed by laser irradiation, The process involves laminating a first charge transport layer onto the first electrode layer, The process of laminating a photoelectric conversion layer onto the first charge transport layer, The process involves laminating a second charge transport layer onto the aforementioned photoelectric conversion layer, A step of forming a second internal separation groove that cuts through the first charge transport layer, the photoelectric conversion layer, and the second charge transport layer at the boundary of the region where the solar cell subcell is formed by laser irradiation, The process involves laminating a second electrode layer onto the second charge transport layer, A step of forming a third internal separation groove at the boundary of the region where the solar cell subcell is formed by laser irradiation, which cuts at least the second electrode layer among the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer, A step of forming a second external separation groove that cuts through the first electrode layer, the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer at the outer edge of the region where the solar cell module is formed by laser irradiation, A step of peeling the resin substrate layer inside the region where the solar cell module is formed from the support substrate, Equipped with, The steps of forming the first internal separation groove and forming the first external separation groove are performed before the step of laminating the first charge transport layer. The intensity of the laser forming the first external separation groove is higher than the intensity of the laser forming the first internal separation groove so as to alter the material of the resin substrate layer at the back of the first external separation groove, and the intensity of the laser forming the second external separation groove is higher than the intensity of the laser forming the third internal separation groove. Method for manufacturing solar cell modules.
The solar cell module manufacturing method according to claim 1, wherein the resin of the resin substrate layer is altered by laser irradiation to form the first external separation groove.
The module manufacturing method according to claim 1 or 2, wherein the step of laminating the resin substrate layer includes the steps of coating the support substrate with a polyamic acid solution and heating the coating film of the polyamic acid solution.

Description

This invention relates to a method for manufacturing solar cell modules. A solar cell module is known in which multiple solar cell subcells are electrically connected in series on a single substrate. While modularizing solar cells reduces the effective area due to the inactive regions between subcells, it significantly reduces resistive losses, particularly at the electrodes on the light-receiving side. If solar cells are properly modularized, the improvement in photoelectric conversion efficiency due to reduced resistive losses outweighs the reduction in effective area. A solar cell module can be manufactured by sequentially performing the following steps: laminating a first electrode layer onto a substrate; cutting the first electrode layer with a first laser irradiation; laminating a first charge transport layer, a photoelectric conversion layer, and a second charge transport layer; cutting the first charge transport layer, the photoelectric conversion layer, and the second charge conversion layer with a second laser irradiation; laminating a second electrode layer; and cutting the first charge transport layer, the photoelectric conversion layer, the second charge transport layer, and the second electrode layer with a third laser irradiation; thereby forming multiple solar cell subcells electrically connected in series by sequentially shifting the positions of the first, second, and third laser irradiations (see, for example, Patent Document 1). Furthermore, to obtain flexible, thin solar cell modules, the use of a resin film as a substrate is being considered. A proposed method for manufacturing solar cells using a resin film as a substrate involves forming a polyimide film by coating a substrate that supports an intermediate product during manufacturing. This involves forming a first electrode, an electron transport layer, a photoelectric conversion layer, a hole transport layer, and a second electrode on this polyimide film, and then peeling the polyimide film from the substrate to obtain a solar cell (see, for example, Patent Document 2). Japanese Patent Publication No. 2011-189408International Publication No. 2020/026495 This flowchart shows the procedure for a solar cell module manufacturing method according to one embodiment of the present invention.Figure 1 is a schematic cross-sectional view showing a solar cell module formed on a support substrate using the solar cell module manufacturing method.Figure 1 is a schematic plan view showing the laser irradiation position on the support substrate in the solar cell module manufacturing method.Figure 1 is a schematic cross-sectional view illustrating the first internal separation groove formation step and the first external separation groove formation step of the solar cell module manufacturing method.Figure 1 is a schematic cross-sectional view illustrating the first charge transport layer stacking process, the photoelectric conversion layer stacking process, and the second charge transport layer stacking process of the solar cell module manufacturing method.Figure 1 is a schematic cross-sectional view illustrating the second internal separation groove formation step in the solar cell module manufacturing method.Figure 1 is a schematic cross-sectional view illustrating the second electrode layer stacking process in the solar cell module manufacturing method. The embodiments of the present invention will be described below with reference to the drawings. Figure 1 is a flowchart showing the procedure for a solar cell module manufacturing method according to one embodiment of the present invention. Figure 2 is a schematic cross-sectional view showing a solar cell module 1 formed on a support substrate S by the solar cell module manufacturing method of Figure 1. Note that the dimensions of each component in the figures have been modified for clarity. The solar cell module 1 manufactured by the solar cell module manufacturing method shown in Figure 1 comprises a resin substrate layer 11, a first electrode layer 12 laminated on the resin substrate layer 11, a first charge transport layer 13 laminated on the first electrode layer 12, a photoelectric conversion layer 14 laminated on the first charge transport layer 13, a second charge transport layer 15 laminated on the photoelectric conversion layer 14, and a second electrode layer 16 laminated on the second charge transport layer 15. As shown in Figure 2, the solar cell module 1 is formed with the resin substrate layer 11 laminated on one main surface of the support substrate S, and is ultimately trimmed and surrounded by an inactive region E that is not included in the solar cell module 1. Furthermore, the solar cell module 1 includes a plurality of first internal isolation grooves 21 formed to cut through the first electrode layer 12, a plurality of second internal isolation grooves 22 formed to cut through the first charge transport layer 13, the photoelectric conversion layer 14, and the second charge