TW201830439A - Solar battery module and solar battery module manufacturing method - Google Patents

Abstract

The present invention has the steps of: insulating the transparent conductive film (11A) and the opposite conductive film (12A) in parallel with the longitudinal direction (X1); and arranging the plurality of cells (C) in the width direction (X2) a sealing material (15); a conductive material (14) disposed on the sealing material (15) to electrically connect the photoelectrode (11) and the counter electrode (12); and a semiconductor layer (11B) of the photoelectrode (11) An electrolyte (13) is disposed between the counter electrodes (12); the photoelectrode (11) is bonded to the counter electrode (12); and the photoelectrode (11) and the counter electrode (12) are formed along the width direction ( X2) the welded portion extending; the wiring material is disposed along the longitudinal direction (X1) at both end portions in the width direction (X2); and the photoelectrode (11) and the counter electrode (12) are cut at any of the welded portions. Broken.

Description

 Solar battery module and solar battery module manufacturing method  

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

The present application claims priority based on Japanese Patent Application No. 2016-217426, filed on Jan. 7, 2016, filed on Jan. herein.

Conventionally, a dye-sensitized solar cell is generally configured to include a photoelectrode, a counter electrode, and an electrolyte or electrolyte layer. The photoelectrode is known to have at least a transparent conductive layer, a semiconductor layer, and a dye. In such a dye-sensitized solar cell, for example, when light is applied to the photoelectrode, the dye adsorbed on the semiconductor layer absorbs light, and the electrons in the dye molecule are excited, and the electrons are transported to the semiconductor. Then, the electrons generated in the photoelectrode are moved to the opposite electrode through an external circuit, and the electrons are returned to the photoelectrode through the electrolyte. By repeating this process, it becomes a component of generating electrical energy.

As a method of manufacturing a solar cell module comprising such a dye-sensitized solar cell, for example, as disclosed in Patent Document 1, a roll-to-roll method is employed by using ultrasonic vibration. A method in which the bonded first electrode and the second electrode are insulated and welded to be divided into a plurality of cells.

[Patent Document 1] Japanese Patent No. 5702897

However, the solar cell module composed of the conventional dye-sensitized solar cell has the following problems.

In other words, in the solar battery module disclosed in Patent Document 1, in order to connect the units in series and parallel, the longitudinal direction of the electrode continuously manufactured by the roll-to-roll method is separated, and then the cutting is performed. The wiring operation is performed by connecting the divided solar battery modules to each other in series. Therefore, there is a problem that it is necessary to increase the manufacturing cost due to the additional steps of wiring. In other words, when a plurality of solar battery modules are disposed, for example, in a blind or the like, there is a case where a plurality of solar battery modules are attached to the substrate of the louver in a state of being spaced apart from each other. It is necessary to connect the respective solar cell modules to each other in series, thereby causing labor and time or cost of wiring.

The present invention has been made in view of the above problems, and an object thereof is to provide a solar battery module and a method for manufacturing a solar battery module, which are constructed by performing series wiring only on a film substrate. The production can be carried out by the roll-to-roll method, and the wiring generated when the solar cell module is externally mounted is not required, so that the cost can be reduced.

In order to achieve the above object in order to solve the above problems, the present invention adopts the following aspects.

(1) A solar cell module according to an aspect of the present invention includes a first electrode, a second electrode, an electrolyte sealed between the first electrode and the second electrode, and a plurality of seals sealing the electrolyte The material and the laminated structure of the plurality of insulated wires, wherein the plurality of secondary modules respectively defined by the plurality of cells defined by the plurality of sealing materials and the plurality of insulated wires are characterized in that: the first electrode a first substrate having a transparent conductive film formed on the surface thereof, and a plurality of strip-shaped semiconductor layers having a dye adsorbed in the first direction formed on the surface of the transparent conductive film of the first substrate, wherein The second electrode has a second substrate on the surface of which the opposite conductive film is formed to face the first electrode, and the electrolyte is sealed between the semiconductor layer of the first electrode and the second electrode. The plurality of sealing materials seal the electrolyte solution by extending between the first electrode and the second electrode along the first direction, and the laminated structure is The body is divided into a plurality of cells, and the plurality of insulated wires are extended between the first electrode and the second electrode in a second direction orthogonal to the first direction in a plan view, and the plurality of layers are stacked The structure is divided into a plurality of sub-modules each composed of a plurality of cells, and the first electrode of the one cell and the second electrode of the other cell are covered by the sealing material with respect to the cells adjacent in the second direction The conductive material disposed in the state is electrically connected, wherein the plurality of cells are connected in series, and in each of the cells, in order to prevent short circuit between the first electrode and the second electrode, the first substrate is adjacent to a conductive material. a first insulating portion extending along the first direction is disposed in the vicinity of the position, and a second insulating portion extending along the first direction is disposed in the second substrate adjacent to a position adjacent to the other conductive material The plurality of secondary modules are connected in such a manner that, with respect to the secondary modules adjacent in the first direction, the ends of the same side of the second direction are mutually connected by the wiring material Electrically connecting the wiring in series, and the currents flowing toward the plurality of secondary modules are alternately reversed in each of the above-described subassembly arranged in the direction of the above-described first.

In the present invention, a conductive material is disposed between the insulating portion of the first substrate disposed between the cells adjacent to each other in the second direction of the first substrate, and the insulating portion of the second substrate. The adjacent cells in the direction are electrically connected in series to each other, and the ends of the same side in the second direction of the secondary module divided by the insulated wires in the first direction are electrically connected in series by the wiring material in the form of series wiring. . That is, the following circuit configuration can be realized: in one sub-module, the electric current flows from the other end in the second direction to one end, and the electric power on one end side flows to one end side of the other sub-module via the wiring material, and then another time In the module, the electric current flows from one end of the second direction to the other end side.

As described above, in the solar battery module of the present invention, the secondary modules on the same side in the second direction of the plurality of secondary modules are electrically connected to each other by the wiring material, and can be electrically connected to the other end side. In other words, the structure in which the electrical orientation is alternately switched in each sub-module in a plan view or the structure in which the entire sub-module alternately flows in a U-shape in a plan view, and the extraction electrodes (positive electrode and negative electrode) can be disposed in the second direction. On the same side, the wiring structure can be simplified, and wiring work can be easily performed.

Moreover, since the present invention is a simple structure in which a wiring material is disposed on the same side of an adjacent sub-module, a simple manufacturing method of applying a wiring material to a wiring material can be applied, so that it can be simply adapted to a roll-to-roller. the way. Since it can be realized by the manufacturing step of continuously arranging the wiring material in the first direction by such a roll-to-roll method, it is not necessary to add a new work step.

(2) The solar cell module according to (1) above, wherein the conductive material disposed at both end portions of the second direction is on a surface of the substrate of the first substrate, or A terminal lead portion is provided on a surface of the base material of the second base material.

In this case, since the terminal lead portions of the + terminal (positive terminal) and the - terminal (negative terminal) can be provided on the same substrate surface, it is not necessary to reverse the solar cell module when wiring the extraction electrode. The steps can reduce the labor and time of wiring work.

(3) A method of manufacturing a solar cell module according to another aspect of the present invention is for continuously manufacturing a solar cell module by a roll-to-roll method, characterized in that the method has the following steps: forming a first electrode, The first electrode is formed with a transparent conductive film on the surface of the first substrate, and a plurality of semiconductor layers which are formed on the surface of the transparent conductive film of the first substrate and which are doped in the first direction and which are adsorbed with the dye are formed. Forming a second electrode, the second electrode is formed on the surface of the second substrate opposite to the first electrode to form a counter conductive film; the transparent conductive film and the opposite conductive film and the first Insulating processing in parallel; providing a sealing material extending along the first direction, arranging a plurality of cells in a second direction orthogonal to the first direction in a plan view; covering the sealing material a state-conducting conductive material, wherein, in the unit adjacent to the second direction, the first electrode of one unit is electrically connected to the second electrode of the other unit by the conductive material; An electrolyte is disposed between the semiconductor layer of the electrode and the second electrode; the first electrode is bonded to the second electrode; and the first electrode and the second electrode are formed with an insulated wire extending along the second direction And dividing into a plurality of sub-modules composed of a plurality of cells; and for the sub-modules adjacent in the first direction, the ends of the same side of the second direction are connected in series by wiring materials The form is electrically connected; and the first electrode and the second electrode are cut at positions of any of the insulated wires.

In the present invention, the solar cell module configured to be disposed in a first direction in a roll-to-roll manner can be disposed between the cells adjacent to each other in the second direction of the first substrate. A conductive material is disposed between the insulating portion of the first substrate and the insulating portion of the second substrate, and the adjacent cells in the second direction are electrically connected in series to each other, and are divided by the insulated wire in the first direction. The units of the module are electrically connected in series to each other by a wiring material. That is, a module having a circuit in which the solar cell module itself separated by the position of the insulated wire is cut off can be produced by a roll-to-roll method. Since the position or length of the conductive material, the insulated wire, and the wiring material can be appropriately set on the film substrate by the roll-to-roll method, and the wiring can be manufactured by using the wiring having the set electrical characteristics (voltage, etc.), it is free. Ground-parallel connection of the ground setting unit (circuit design).

Further, in the present invention, when the solar cell module to be manufactured is externally mounted on an individual (substrate), it is not necessary to mount the plurality of solar cell modules on the substrate as in the prior art. Since the battery modules are electrically connected to each other, the manufacturing efficiency can be improved. In this way, the amount of work can be reduced, whereby the reduction in manufacturing cost can be achieved.

(4) The method for manufacturing a solar cell module according to (3) above, characterized in that in the step of performing the insulating process, an insulating process pattern is formed, wherein the insulating process pattern is changed in position relative to The first direction is a position shifted to the second direction by a fixed period.

In this case, by alternately forming the insulation processing pattern in the second direction, the positions of the positive electrode and the negative electrode can be regularly changed in each of the sub-modules.

(5) The method of manufacturing a solar cell module according to the above (3) or (4), wherein the wiring material is disposed in a state continuous along the first direction, and after the insulating wire is formed, One of the first directions of the wiring material is notched to form a broken portion.

In this case, by forming the disconnection portion at a suitable portion of the wiring material, the cells of the secondary module adjacent to each other in the first direction can be disconnected from each other.

Therefore, the required circuit can be designed according to the position of the broken portion.

(6) The method of manufacturing a solar cell module according to the above (3) or (4), wherein the step of disposing the wiring material is such that a disconnection portion is formed in one of the first directions. The above wiring material.

In this case, since the disconnection portion is also formed at the same time as the step of arranging the wiring material, it is not necessary to provide the disconnection portion after the arrangement of the wiring material, and the manufacturing efficiency can be improved.

(7) The method of manufacturing a solar cell module according to any one of the above (3), wherein the insulated wire is a welded portion that is welded along the second direction.

In this case, the first electrode and the second electrode which are moved by the roll-to-roll method can be easily formed into a welded portion by a manufacturing apparatus having a suitable welding means extending in the second direction.

(8) The method of manufacturing a solar cell module according to any one of the above (3) to (7), wherein the step of disposing the wiring material is performed simultaneously when the conductive material is disposed.

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

(9) The method of manufacturing a solar cell module according to any one of the above (3) to (7), wherein the step of forming the insulated wire is performed simultaneously with the insulating process.

In this case, manufacturing efficiency can be improved by simultaneously performing insulation processing parallel to the first direction.

(10) A method of manufacturing a solar cell module according to another aspect of the present invention is characterized by the steps of: forming a first electrode, the first electrode is formed on the surface of the first substrate with a transparent conductive film, and is formed a plurality of semiconductor layers having a pigment adsorbed in a first direction formed on a surface of the transparent conductive film of the first substrate; forming a second electrode, the second electrode being on a surface of the second substrate The first electrode is opposed to form a counter conductive film; the transparent conductive film and the opposite conductive film are insulated in parallel with the first direction; and a sealing material is provided, the sealing material is along the first a direction extending, wherein the plurality of cells are arranged in a second direction orthogonal to the first direction in a plan view; the conductive material is disposed in a state covered by the sealing material, and the cells adjacent to each other in the second direction are The conductive material electrically connects the first electrode of one unit to the second electrode of the other unit; and the electric current is disposed between the semiconductor layer of the first electrode and the second electrode Dissolving the first electrode and the second electrode; and arranging the wiring material along the first direction at both ends of the first substrate in the second direction; and the first electrode and the second electrode Forming a first insulated line and a second insulated line at a specific position in the first direction, and disposing the first insulated line between the second insulated lines, wherein the first insulated line is along the second direction Extending and partially insulating the wiring material at one end of the second direction, the second insulated wire is integrally insulated throughout the second direction; and the first electrode and the second electrode are on the second insulated wire In the solar cell module cut by the second insulated wire, the sub-module adjacent to the sub-module divided by the first insulated wire is provided by the wiring material The end portions on the same side in the second direction are electrically connected to each other in the form of a series wiring.

In the present invention, a solar cell module configured to insulate an insulating portion of a first substrate and a second substrate disposed between cells adjacent to each other in a second direction of the first substrate Conductive materials are disposed between the portions, the adjacent cells in the second direction are electrically connected in series, and the second one of the adjacent modules is divided by the first insulated wire in the first direction The ends on the same side of the direction are electrically connected to each other by wiring materials in the form of series wiring. Therefore, the solar cell module itself is divided into a circuit in which the position of the second insulated wire is cut and separated, and the solar cell module can be produced by a roll-to-roll method.

Further, in the present invention, when the solar cell module to be manufactured is externally mounted on an individual (substrate), it is not necessary to mount the plurality of solar cell modules on the substrate as in the prior art. Since the battery modules are electrically connected to each other, the manufacturing efficiency can be improved. In this way, the amount of work can be reduced, and thus the manufacturing cost can be reduced.

(11) The method of manufacturing a solar cell module according to the above (10), wherein the first insulated wire and the second insulated wire are welded portions that are welded along the second direction.

In this case, the first electrode and the second electrode that are moved by the roll-to-roll method can be easily formed into the first insulated wire and the first device by using a suitable welding device having a suitable welding means extending in the second direction. The welded portion of the two insulated wires.

(12) The method of manufacturing a solar cell module according to (10) or (11) above, wherein the step of forming the first insulated wire and the second insulated wire is performed while performing the insulating process get on.

In this case, the manufacturing efficiency can be improved by simultaneously performing the first insulating line and the second insulating line and insulating processing parallel to the first direction.

According to the solar cell module and the solar cell module manufacturing method of the aspects of the present invention, by fabricating a structure in which series wiring can be performed only on the film substrate, the roll-to-roll method can be used for production without further The wiring generated when the solar cell module is externally mounted can achieve a reduction in cost.

1, 1A‧‧‧Dye-sensitized solar cells (solar battery modules)

1a‧‧‧One end

1b‧‧‧The other end

4‧‧‧ Manufacturing equipment

11‧‧‧Photoelectrode (first electrode)

11A‧‧‧Transparent conductive film

11B‧‧‧Semiconductor layer

12‧‧‧ opposite electrode (second electrode)

12A‧‧‧ opposite conductive film

12B‧‧‧ catalyst layer

3A‧‧‧First substrate

3B‧‧‧Second substrate

13‧‧‧ electrolyte

14‧‧‧Conducting materials

15‧‧‧ Sealing material

16‧‧‧First insulation

17‧‧‧Second insulation

17A‧‧‧3rd insulation

17B‧‧‧ Non-insulated parts

18‧‧‧welding joint (insulated wire)

18A‧‧‧Non-welding

181‧‧‧First welded joint (first insulated wire)

19, 19A, 19B, 19C‧‧‧ wiring materials

19a‧‧‧Disconnection Department

41‧‧‧First Insulation Processing Department

42‧‧‧Sealing material coating department

43‧‧‧Conducting Material Configuration Department

44‧‧‧Electrolyte Coating Department

45‧‧‧Substrate bonding department

46‧‧‧Supersonic welding

47‧‧‧Second Insulation Processing Department

50‧‧‧Incision processing device

51‧‧‧Rotary axis

52, 52A, 52B‧‧‧ semicircular knife

53‧‧‧Laser illumination device

C‧‧‧ unit

P1‧‧‧First moving direction

P2‧‧‧ second moving direction

R‧‧‧ modules

X1‧‧‧long direction (first direction)

X2‧‧‧ width direction (second direction, width direction of the first substrate and the second substrate)

Fig. 1 is a plan view showing a schematic configuration of a dye-sensitized solar cell according to a first embodiment of the present invention.

Fig. 2 is a cross-sectional view taken along line A-A of Fig. 1, and is a partial cross-sectional view of the dye-sensitized solar cell viewed from the longitudinal direction.

3 is a cross-sectional view taken along line B-B of FIG. 1, and is a partial cross-sectional view of the dye-sensitized solar cell viewed from the width direction.

Fig. 4 is a perspective view showing the overall configuration of a manufacturing apparatus of a dye-sensitized solar cell.

Fig. 5 is a perspective view showing a state in which insulation processing is performed by a slit processing device.

Fig. 6 is a view showing a state in which the insulation processing is performed by the slit processing device, and is a front view of the slit processing device as viewed from the longitudinal direction.

Fig. 7 is a plan view of a dye-sensitized solar cell using a manufacturing process of a manufacturing apparatus, and is a view showing a state in which a photoelectrode is formed on a first substrate.

Fig. 8 is a plan view showing a dye-sensitized solar cell using a manufacturing process of the manufacturing apparatus, and showing a state in which the second substrate is subjected to insulation processing.

Fig. 9 is a plan view showing a dye-sensitized solar cell using a manufacturing process of the manufacturing apparatus, and showing a state in which the first substrate is subjected to insulation processing.

Fig. 10 is a plan view showing a dye-sensitized solar cell using a manufacturing process of the manufacturing apparatus, and showing a state in which the substrates are bonded to each other.

Fig. 11 is a plan view showing a dye-sensitized solar cell using a manufacturing process of the manufacturing apparatus, and showing a state in which a welded portion is formed.

FIG. 12 is a plan view of a dye-sensitized solar cell in a manufacturing process using a manufacturing apparatus, and is a view showing a state in which wiring materials are attached to both end portions in the width direction of the substrate.

Figure 13 is a cross-sectional view taken along line C-C shown in Figure 12.

Figure 14 is a cross-sectional view taken along line D-D of Figure 12.

Fig. 15 is a perspective view showing the configuration of a dye-sensitized solar cell according to the first embodiment.

Fig. 16 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the second embodiment.

Fig. 17 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the second embodiment.

Fig. 18 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the second embodiment.

Figure 19 is a cross-sectional view taken along line C'-C' shown in Figure 18.

Figure 20 is a cross-sectional view taken along line D'-D' of Figure 18.

Figure 21 is a cross-sectional view taken along line E-E shown in Figure 18.

Figure 22 is a cross-sectional view taken along line F-F shown in Figure 18.

Fig. 23 is a cross-sectional view showing the configuration of another wiring material.

Fig. 24 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the third embodiment.

Fig. 25 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the third embodiment.

Fig. 26 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the fourth embodiment.

Fig. 27 is a plan view showing a manufacturing process of the dye-sensitized solar cell of the fourth embodiment.

FIG. 28A is a view showing a state in which insulation processing is performed by a laser irradiation device as an insulating portion of a modification, and is a front view of the laser irradiation device viewed from the longitudinal direction.

FIG. 28B is a view showing a state in which the insulation processing is performed by the laser irradiation device as the insulating portion of the modification, and is a front view of the laser irradiation device viewed from the longitudinal direction.

Hereinafter, a solar cell module and a method of manufacturing a solar cell module according to an embodiment of the present invention will be described based on the drawings. In addition, the drawings used in the following description are schematic, and the ratios, structures, and the like of the length, the width, and the thickness are not limited to the same as the actual object, and can be appropriately changed.

 (First embodiment)  

As shown in Fig. 1, the solar cell module and the solar cell module manufacturing method of the present embodiment are based on the following roll-to-roll method (hereinafter referred to as R to R method) as shown in Fig. 1 . The film-type dye-sensitized solar cell 1 (solar cell module) which is formed in the manufacturing apparatus 4 (see FIG. 4) and which is elongated in a long direction is cut to an appropriate length and manufactured. In addition, in FIG. 1, the arrow shows the electrical flow direction, and the component symbol + (positive) and - (negative) respectively represent a positive electrode and a negative electrode (the other figures are the same).

Here, in the dye-sensitized solar cell 1 shown in FIG. 1, FIG. 2, and FIG. 3, the longitudinal direction (long direction) is set to the longitudinal direction X1 (first direction), and is viewed in plan view. The direction orthogonal to the longitudinal direction X1 is defined as the width direction X2 (second direction) of the base material (the first base material 3A and the second base material 3B described below), and is used hereinafter.

As shown in Fig. 2, the dye-sensitized solar cell 1 of the present embodiment has a structure in which a dye-sensitized solar cell (hereinafter simply referred to as cell C) is interposed between a pair of substrates 3A and 3B, and the dye-sensitized sun The battery unit has a photoelectrode 11 and a counter electrode 12 disposed opposite the photoelectrode 11. Further, the dye-sensitized solar cell 1 is configured such that conductive films 11A and 12A are formed on the inner surfaces of the pair of base materials 3A and 3B, and the photoelectrodes 11 are electrically connected to the conductive films 11A and 12A. The semiconductor layer 11B and the catalyst layer 12B of the counter electrode 12.

In the dye-sensitized solar cell 1 of the present embodiment, as described above, the solar cell module in which the photoelectrode 11 and the counter electrode 12 are opposed to each other via the conductive material 14 having a sealing function is formed in the first place. A plurality of cells C between the substrate 3A and the second substrate 3B are sealed, and various electrical modules in which the cells C, C, ..., and C are electrically connected in series are targeted. Here, in the unit C of the following sub-module R, the direction of the series connection is the width direction X2.

Specifically, the dye-sensitized solar cell 1 includes a first base material 3A, a second base material 3B, a photoelectrode 11 (first electrode), a counter electrode 12 (second electrode), an electrolytic solution 13, and a conductive material 14, The sealing material 15, the first insulating portion 16, the second insulating portion 17, and the welded portion 18 (insulated wire).

The photoelectrode 11 includes a transparent conductive film 11A laminated on the first base member 3A and a porous semiconductor layer 11B laminated on the transparent conductive film 11A.

Further, the counter electrode 12 includes the counter conductive film 12A laminated on the second base material 3B and the catalyst layer 12B laminated on the counter conductive film 12A.

The photoelectrode 11 is formed with a transparent conductive film 11A on the surface of the first substrate 3A, and a plurality of adsorbed pigments extending in the longitudinal direction X1 are formed on the surface of the transparent conductive film 11A of the first substrate 3A. The strip-shaped semiconductor layer 11B. The counter electrode 12 is formed with a counter conductive film 12A so as to face the photoelectrode 11 . The electrolytic solution 13 is sealed between the semiconductor layer 11B of the photoelectrode 11 and the counter electrode 12. The sealing material 15 is configured to seal the electrolytic solution 13 and arrange a plurality of cells C that are divided in the width direction X2.

The conductive material 14 is provided in a state of being covered by the sealing material 15, and is in direct contact with the transparent conductive film 11A of the photoelectrode 11 and the opposite conductive film 12A of the counter electrode 12, and electrically connects the photoelectrode 11 and the counter electrode 12.

Sealing materials 15 and 15 are disposed on both sides of the conductive material 14 in the width direction X2. The photoelectrode 11 and the counter electrode 12 are followed by the conduction of the material 14 and the sealing material 15. On the other hand, in the dye-sensitized solar cell 1, as shown in FIGS. 1 and 3, the welded portion 18 is formed at a fixed interval in the longitudinal direction X1 and integrally formed across the width direction X2. The welded portion 18 is formed by means of ultrasonic welding or the like (see the ultrasonic welding portion 46 shown in Fig. 4) for insulation and subsequent formation.

In this manner, the cells C each having the semiconductor layer 11B are formed by liquid-tightly sealing the electrolytic solution 13 by the conductive material 14 in a state of being formed in the gap between the photoelectrode 11 and the counter electrode 12 in the thickness direction. .

A plurality of patterning portions insulated by a cutter (a semicircular knife 52 of the slit processing device 50 as shown in FIGS. 5 and 6) are provided at specific portions of the transparent conductive film 11A and the opposite conductive film 12A. (insulation portions 16, 17). That is, as shown in FIG. 2, the transparent conductive film 11A and the opposite conductive film 12A are in contact with the sealing material 15, and the first insulating portion 16 parallel to the longitudinal direction X1 is formed by the insulating treatment by the slit processing. The transparent conductive film 11A formed between the adjacent first insulating portions 16, 16 of the first substrate 3A and the other unit in one of the cells C, C adjacent in the width direction X2 The opposite conductive film 12A formed between the adjacent second insulating portions 17, 17 of the second substrate 3B in C is connected to the conductive material 14 disposed between one unit C and the other unit C.

The first insulating portions 16 of each of the adjacent sub-modules R, R arranged in the sub-module R (the region surrounded by the two-dot chain line in FIG. 1) formed by the welded portion 18 are in width The position shifted in the direction X2 is patterned. This case is also the same in the second insulating portion 17.

As shown in FIG. 2, the transparent conductive film 11A and the opposite conductive film 12A adjacent to each other in the width direction X2 are divided into a plurality of patterned portions to form a plurality of transparent conductive films 11A and opposite sides. A pattern of the conductive film 12A. In the divided cell C, the opposite conductive film 12A of one cell C (for example, the first cell of the component symbol C1) and the other cell C adjacent to the first cell C1 (for example, the second cell of the component symbol C2) The transparent conductive film 11A is electrically connected by the conductive material 14 and is in a state in which the first unit C1 and the second unit C2 are connected in series in the width direction X2. In other words, when a plurality of cells C1, C2, ... are arranged in series in a gap between the first substrate 3A and the second substrate 3B, for example, the sealing material 15 / the conductive material 14 can be used. /sealing material 15) / (first unit C1) / (sealing material 15 / conductive material 14 / sealing material 15) / (second unit C2) / (sealing material 15 / conductive material 14 / sealing material 15) / (the first The order of 3 units)... is configured.

The material of the first base material 3A and the second base material 3B is not particularly limited, and examples thereof include an insulator such as a film-form resin, a semiconductor, a metal, and glass. Examples of the resin include poly(meth)acrylate, polycarbonate, polyester, polyimine, polystyrene, polyvinyl chloride, and polyamine. From the viewpoint of producing a thinner and lighter soft dye-sensitized solar cell 1, the substrate is preferably made of a transparent resin, more preferably a polyethylene terephthalate (PET) film or a polyethylene naphthalate. Ester (PEN) film. Further, the material of the first base material 3A and the material of the second base material 3B may be different.

The type and material of the transparent conductive film 11A and the counter conductive film 12A are not particularly limited, and a conductive film for a known dye-sensitized solar cell can be applied, and examples thereof include a film made of a metal oxide. Examples of the metal oxide include tin-doped indium oxide (ITO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (ATO), indium oxide/zinc oxide (IZO), and gallium-doped zinc oxide (GZO).

The semiconductor layer 11B is made of a material capable of receiving electrons from the adsorbed light sensitizing dye, and is generally preferably porous. The material constituting the semiconductor layer 11B is not particularly limited, and a material of the known semiconductor layer 11B can be applied, and examples thereof include metal oxide semiconductors such as titanium oxide, zinc oxide, and tin oxide.

The photosensitizing dye to be carried on the semiconductor layer 11B is not particularly limited, and examples thereof include known pigments such as organic dyes and metal complex dyes. Examples of the organic dye include a coumarin system, a polyene system, a cyanine system, a hemicyamine system, and a thiophene system. As the metal complex dye, for example, a ruthenium complex or the like can be preferably used.

The material constituting the catalyst layer 12B is not particularly limited, and a known material can be applied, and examples thereof include carbons such as platinum and carbon nanotubes, and poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonic acid). Conductive polymer such as PEDOT/PSS).

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

In the semiconductor layer 11B which is in contact with the electrolytic solution 13, a known photo-sensitizing dye (not shown) is adsorbed on the surface including the inside of the porous material.

The conductive material 14 is disposed between the plurality of semiconductor layers 11B extending parallel to each other and extending in one direction, and is in contact with the photoelectrode 11 on the first substrate 3A and the counter electrode 12 on the second substrate 3B, and is disposed on Between the photoelectrode 11 and the counter electrode 12. As the conductive material 14, for example, one or more selected from the group consisting of a wire, a conductive tube, a conductive foil, a conductive plate, a conductive mesh, a conductive paste, and conductive particles can be used. Here, the conductive paste refers to a conductive material having a relatively low rigidity and a soft shape. For example, the conductive material may have a solid conductive material dispersed in a viscous dispersion medium such as an organic solvent or a binder resin. The conductive material 14 can also have both conduction and subsequent functions as a double-sided type of copper strip.

Examples of the conductive material for the conductive material 14 include metals such as gold, silver, copper, chromium, titanium, platinum, nickel, tungsten, iron, and aluminum, or alloys of two or more of these metals, but no particular one. limited. Further, as the material, a resin composition such as a polyurethane or a polytetrafluoroethylene (PTFE) in which conductive fine particles (for example, fine particles of the metal or alloy or fine particles of carbon black) are dispersed may be used.

The sealing material 15 is not particularly limited as long as it is a non-conductive member capable of sealing the opposing first base material 3A and the second base material 3B and sealing the unit C formed between the base materials 3A and 3B.

Examples of the material of the sealing material 15 include a hot melt adhesive (thermoplastic resin), a thermosetting resin, an ultraviolet curable resin, and a resin containing an ultraviolet curable resin and a thermosetting resin, which are temporarily fluid and can be handled by appropriate treatment. Cured resin material, etc. Examples of the hot-melt adhesive include a polyolefin resin, a polyester resin, and a polyamide resin. Examples of the above thermosetting resin include an epoxy resin and a benzoic acid. Ketone (benzoxazone) resin and the like. Examples of the ultraviolet curable resin include those containing a photopolymerizable monomer such as acrylate or methacrylate.

Next, a manufacturing apparatus 4 of the R to R method for producing the dye-sensitized solar cell 1 having the above configuration will be specifically described using a drawing.

As shown in FIG. 4, in the manufacturing apparatus 4, a photoelectrode forming part (not shown), a first insulating processed part 41, a sealing material application part 42, a conductive material arrangement part 43, an electrolyte solution application part 44, and a base material. The bonding portion 45 and the ultrasonic welding portion 46 are disposed downstream from the upstream of the first moving direction P1 of the first base member 3A.

The first base material 3A and the second base material 3B are bonded to each other in the base material bonding portion 45, and are arranged in the second moving direction P2 of the second base material 3B moving separately from the first base material 3A. An electrode forming portion (not shown) and a second insulating processed portion 47. The second base material 3B of the second insulating processed portion 47 is bonded to the first base material 3A at the base material bonding portion 45.

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

As shown in Figs. 5 and 6, the first insulating processed portion 41 employs a slit processing device 50 having a plurality of semicircular blades 52 in this embodiment. The slit machining device 50 includes a rotary shaft 51 that is rotatably provided around the axis O1, and a semicircular cutter 52 that is disposed at a predetermined interval around the rotary shaft 51 at a predetermined interval in the direction of the axis O1, and the axis O1 of the rotary shaft 51 is oriented. It is arranged toward the width direction X2.

The semicircular blade 52 is continuously provided in the range of 180° along the circumferential direction of the outer circumferential surface of the rotating shaft 51, and is disposed by the first semicircular blade 52A disposed in a region of a specific half of the whole circumference as viewed from the direction of the axis O1. And a second semicircular blade 52B disposed in a region where the other half of the first semicircular blade 52A is not disposed. The plurality of first semicircular blades 52A simultaneously form a plurality of insulating portions 16 adjacent to the secondary module R adjacent to the secondary module R of the first substrate 3A formed by the welded portion 18 in the longitudinal direction X1. The plurality of second semicircular knives 52B simultaneously form a plurality of insulating portions 16 of the other of the adjacent sub-modules R. The circumference (outer circumference) of the semicircular blade 52 is set to match the length of the longitudinal direction X1 of the insulating portion 16 that is insulated in the secondary module R.

The first semicircular blades 52A adjacent in the direction of the axis O1 are spaced apart from each other, and the second semicircular blades 52B adjacent to each other in the direction of the axis O1 are equidistant from each other. The first semicircular knife 52A and the second semicircular cutter 52B are not disposed on the same circumference, but are disposed at positions shifted in the direction of the axis O1.

When the semicircular blades 52 (52A, 52B) rotate together with the rotating shaft 51 with respect to the surfaces of the base materials 3A and 3B on which the conductive films 11A and 12A are formed, only the slits in the groove shape are formed in the conductive films 11A and 12A. In other words, the conductive films 11A and 12A are set to have slits in the thickness direction, and one of the thickness directions of the base materials 3A and 3B is not completely cut by the slit.

The interval between the axis O1 direction of the semicircular blade 52, the circumferential length, and the amount of displacement of the first semicircular blade 52A and the second semicircular blade 52B in the direction of the axis O1 can be appropriately changed according to the setting of the insulating portion 16.

As shown in FIG. 4, the sealing material application portion 42 is disposed downstream of the first insulating processed portion 41, and applies a sealing material 15 to the photoelectrode 11 formed in a specific region of the first base member 3A (see FIG. 2). The composition.

The conductive material placement portion 43 is disposed downstream of the sealing material application portion 42 and has a configuration in which wiring (conductive material 14) is disposed between the sealing materials 15 .

The electrolyte application portion 44 is disposed downstream of the conductive material placement portion 43 and is configured to apply the electrolytic solution 13 to the region of the first base material 3A where the seal material 15 is not applied.

The counter electrode forming portion (not shown) is disposed in the most upstream portion of the second moving direction P2 in the manufacturing apparatus 4, and forms the counter electrode 12 in a specific region on the surface of the second base member 3B.

The second insulating processed portion 47 is the same as the slit processing device 50 (see FIG. 5) provided in the slit processing device provided in the first insulating processed portion 41, and thus detailed description thereof will be omitted.

The base material bonding portion 45 has a configuration in which the second base material 3B on which the counter electrode 12 is formed is bonded to the surface of the first base material 3A on which the photoelectrode 11 is formed. Specifically, the base material bonding portion 45 is provided with a curing treatment portion (not shown) for curing the sealing material 15 , and the first base material 3A and the second base material 3B are overlapped with each other. The pair of bonding rolls 45A and 45B pass, and the two base materials 3A and 3B are bonded together.

The ultrasonic welding portion 46 is configured such that the first base material 3A and the second base material 3B are welded at a fixed interval in the longitudinal direction X1 by ultrasonic vibration, thereby forming the welded portion 18 extending in the width direction X2. Divided into a plurality of sub-modules R.

Next, a method of manufacturing the dye-sensitized solar cell 1 having the electric series circuit using the above-described R to R type manufacturing apparatus 4 of the present embodiment will be specifically described with reference to the drawings.

First, a method of manufacturing the dye-sensitized solar cell 1 produced by using the manufacturing apparatus 4 shown in Fig. 4 will be described. In the manufacturing apparatus 4, the film is continuously conveyed (the first base material 3A and the second base material 3B), and the second base material 3B is bonded to the first base material 3A on which the photoelectrode 11 is formed to produce a dye sensitization. Solar battery 1. Further, in the manufacturing apparatus 4 of the present embodiment, a film type dye-sensitized solar cell in which an electric series circuit is formed on the film so as to alternately flow a current in the width direction X2 toward the traveling direction (longitudinal direction X1) is prepared. 1 (refer to Figure 1).

The manufacturing method for continuously producing the dye-sensitized solar cell 1 by the R to R method has the steps of forming a photoelectrode 11 formed on the surface of the first substrate 3A with a transparent conductive film 11A. And a plurality of strip-shaped semiconductor layers 11B on which the dye is extended in the longitudinal direction X1 are formed on the surface of the transparent conductive film 11A of the first substrate 3A; and the counter electrode 12 is formed, and the counter electrode 12 is formed The opposite conductive film 12A is formed on the surface of the second substrate 3B so as to face the photoelectrode 11; the transparent conductive film 11A and the opposite conductive film 12A are insulated in parallel with the longitudinal direction X1; The sealing material 15 is such that a plurality of cells C are arranged in the width direction X2 orthogonal to the longitudinal direction X1 in plan view; the conductive material 14 is disposed on the sealing material 15 to connect the photoelectrode 11 and the counter electrode 12 Electrically connected; an electrolyte 13 is disposed between the semiconductor layer 11B of the photoelectrode 11 and the counter electrode 12; the photoelectrode 11 and the counter electrode 12 are bonded; and the photoelectrode 11 and the counter electrode 12 are formed along the width direction X2. Extended welded portion 18; both ends in the width direction X2 Arranged with the longitudinal direction X1 wiring material 19; and the photoelectrode 11 and the counter electrode 12 is cut off at any position of the welded portion 18.

Specifically, as shown in FIG. 7 , the method of manufacturing the dye-sensitized solar cell 1 is a semiconductor electrode forming portion (not shown), and a transparent conductive film is formed by using, for example, an aerosol deposition (AD) method. The TiO ₂ is deposited on the first base material 3A of 11A, whereby the semiconductor layer 11B is formed at intervals in the width direction X2, and then the dye is adsorbed on the semiconductor layer 11B by a usual method, thereby forming the photoelectrode 11 . Fig. 7 (the same applies to Figs. 8 to 12 below) shows a part of the dye-sensitized solar cell 1 which is continuously manufactured by the R to R method.

As shown in FIG. 8, in the counter electrode forming portion (not shown), platinum (Pt) is deposited on the second substrate 3B of the counter conductive film 12A by sputtering to form the catalyst layer 12B. Thereby, the counter electrode 12 is formed.

The first base material 3A that forms the photoelectrode 11 formed by the semiconductor electrode forming portion and moves in the first moving direction P1 is in the slit processing device 50 of the first insulating processed portion 41 shown in FIGS. 5 and 6. The insulating process of the first insulating portion 16 extending in parallel with the longitudinal direction X1 is formed by the rotation of the semicircular blade 52 (52A, 52B) at a position between the semiconductor layer 11B and the semiconductor layer 11B.

At this time, as shown in FIG. 9, the first insulating portion 16 is formed with a regular insulating pattern which is alternately shifted in the width direction X2 every fixed interval (the length of the longitudinal direction X1 of the secondary module R). By alternately arranging the insulation processing patterns in this manner, the positions of the + pole (positive electrode) and the - pole (negative electrode) can be regularly changed in each of the sub-modules R.

Next, as shown in FIG. 4, after the processing of the first insulating portion 16 of the photoelectrode 11, the sealing material 15 is applied to the photoelectrode 11 formed in a specific region of the first substrate 3A by the sealing material applying portion 42. . At this time, the sealing material 15 is applied so as not to be coated on the semiconductor layer 11B.

Then, after the conductive material 14 is disposed between the sealing materials 15 in the conductive material disposing portion 43, the electrolytic solution is applied to the region of the first base material 3A where the sealing material 15 is not applied. Liquid 13.

A second substrate 3B for forming the counter electrode 12 formed by the counter electrode forming portion and moving in the second moving direction P2, and a slit processing device for the second insulating processed portion 47 shown in FIGS. 5 and 6 In the case of 50, the insulating process of the second insulating portion 17 extending in parallel with the longitudinal direction X1 is formed by the rotation of the semicircular blade 52 (52A, 52B) at a position between the catalyst layer 12B and the catalyst layer 12B.

At this time, as shown in FIG. 8, the second insulating portion 17 is formed into a pattern of insulation processing which is a regular position at which the fixed interval (the length of the longitudinal direction X1 of the secondary module R) is alternately shifted in the width direction X2. By thus alternately arranging, the position of the + pole and the - pole can be regularly changed in each of the submodules R.

Then, in the substrate bonding portion 45 shown in FIG. 4, the sealing material 15 is cured by a curing treatment portion (not shown), and the first substrate 3A and the second substrate which are subjected to insulation processing are used. When the pair of bonding rollers 45A and 45B are passed in a state in which 3B is overlapped, the two base materials 3A and 3B are bonded to each other. At this time, in the state of being bonded, as shown in FIG. 10, the first insulating portion 16 of the first base member 3A and the second insulating portion 17 of the second base member 3B are shifted in the width direction X2. Thereby, a plurality of cells C which are divided and arranged in the width direction X2 via the conductive material 14 (see FIG. 2) are electrically connected in series.

Next, after the bonding, in the ultrasonic welding portion 46, as shown in FIG. 11, the first base material 3A and the second base material 3B are welded at a fixed interval in the longitudinal direction X1 by ultrasonic vibration. On the other hand, the welded portion 18 extending in the width direction X2 is formed to be divided into a plurality of sub-modules R.

Further, as shown in FIG. 12, the both end portions 3a and 3b in the width direction X2 of the bonded two base materials 3A and 3B are attached to the wiring by, for example, a copper tape or soldering along the longitudinal direction X1. Material 19. At this time, the wiring member 19 is disposed in a state in which the end portions of the welded portions 18 arranged in the longitudinal direction X1 are alternately covered in the width direction X2. Thereby, the dye-sensitized solar cell 1 in which the cells C of the sub-modules R connected in series are connected in series can be manufactured, and electrically alternates in the width direction X2 of each sub-module R (the direction of the arrow E in FIG. 12). ) The ground flows. The dye-sensitized solar cell 1 can be cut along the welded portion 18, and can be cut at a position of any desired length (in FIG. 12, the two-point chain of the component symbol T) to produce a desired length of pigmentation. Sense solar battery 1. For example, as the dye-sensitized solar cell 1 after the cutting, it is possible to manufacture three sub-modules R, two sub-modules R, or four or more sub-modules R as shown in FIG. Founder.

Here, the structure of the wiring member 19 will be specifically described.

Fig. 13 shows a wiring material 19A for the extraction electrode in the positive electrode. Fig. 14 shows a wiring material 19B for the extraction electrode in the negative electrode. By arranging the conductive material 14 at both end portions in the width direction X2 (second direction) of the film, a + terminal can be provided on the same substrate surface (here, the substrate surface of the second substrate 3B). The lead terminal of the positive terminal) and the - terminal (negative terminal) (terminal lead-out portion). Therefore, it is not necessary to reverse the step of inverting the dye-sensitized solar cell 1 when wiring the lead electrode, and the labor and time of the wiring work can be reduced. Here, in FIG. 13, the conductive material 14 of the wiring material 19A also electrically flows from the counter electrode 12 to the photoelectrode 11, but the electric current does not flow out from the photoelectrode 11 first, so the electrical flow is omitted (the following diagram) 19 is the same).

Further, the direction in which the longitudinal direction X1 is the sub-module R is equivalent to the "first direction" of the present invention, and the width direction X2 is the direction orthogonal to the longitudinal direction X1 in plan view, which corresponds to the present invention. The second direction."

Fig. 15 shows a dye-sensitized solar cell 1A (solar cell module) manufactured by cutting the fusion-bonding portion 18 so as to have two secondary modules R and R in the first embodiment.

The dye-sensitized solar cell 1A shown in Fig. 15 is formed by arranging two sub-units C arranged in the width direction X2 (secondary modules R and R) adjacent to each other in the longitudinal direction X1. The battery structure is such that one end (one end) of the width direction X2 of the adjacent sub-modules R and R is electrically connected to each other by the wiring material 19 in the form of series wiring. Further, in the dye-sensitized solar cell 1A, the first fusion bonding extending from the other end 1b toward the one end 1a side is formed in the width direction X2 of each of the sub-modules R in the state in which the wiring material 19 on the one end 1a side is retained. Part 181 (first insulated wire). That is, each of the photoelectrodes 11 and the counter electrode 12 of the sub-modules R and R constitutes a circuit electrically connected by the wiring material 19. Further, in Fig. 15, the symbol E indicates the orientation of the current.

Further, in the case of performing the dye-sensitized solar cell 1A, in the step of bonding the first substrate 3A and the second substrate 3B, the first substrate 3A and the counter electrode provided by the photoelectrode 11 are provided. The second base material 3B formed in 12 is bonded in a state of being shifted in the width direction X2. Thereafter, the wiring member 19 is disposed along the longitudinal direction X1 at both ends 1a and 1b of the width direction X2 of the first base material 3A. Then, the first insulating line 181 and the second insulating line (not shown) are alternately formed in the longitudinal direction X1 of the first base material 3A and the second base material 3B, and the first insulated wire 181 is along the width direction. X2 extends and partially isolates the wiring material 19 on the one end 1a side in the width direction X2, and the second insulated wire is integrally insulated throughout the width direction X2. Thereafter, it is produced by cutting the first base material 3A and the second base material 3B at the position of the second insulated wire. Further, in the present embodiment, the notch portion 1c is formed between the sub-modules R and R from the other end 1b toward the one end 1a. The notch portion 1c is a length that does not cut the unit C closest to the other end 1b.

The dye-sensitized solar cell 1A manufactured in this manner is configured such that the second substrate 3B which can be one end 1a in the width direction X2 of the adjacent one of the adjacent sub-modules R and R divided by the first insulating line 181 is made of the wiring material 19 Electrically connected, at the other end 1b, an extraction electrode is provided on the same substrate (here, the second substrate 3B).

Next, the action of the above-described method of producing the dye-sensitized solar cells 1, 1A will be described in detail using a pattern.

In the present embodiment, the dye-sensitized solar cell 1 having the following configuration can be manufactured in a state of being continuous in the longitudinal direction X1 by the R to R method: as shown in FIG. 2, it is disposed in the width direction X2. A conductive material 14 is disposed between the first insulating portion 16 of the first substrate 3A and the second insulating portion 17 of the second substrate 3B between the adjacent cells C and C, and adjacent cells in the width direction X2 C and C are electrically connected in series, and the cells C and C of the secondary module R which are divided by the welded portion 18 in the longitudinal direction X1 are electrically connected in series to each other by the wiring member 19. In other words, a module having a circuit independent of the dye-sensitized solar cell 1 that is cut and divided at the position of the welded portion 18 can be produced by the R to R method. The position or length of the conductive material 14, the welded portion 18, and the wiring member 19 can be appropriately set on the film substrate by the R to R method, and the wiring can be manufactured by using the wiring having the set electrical characteristics (voltage, etc.). Therefore, the series-parallel connection (circuit design) of the unit C can be freely designed.

Further, in the present embodiment, when the dye-sensitized solar cell 1 produced is externally attached to an individual (substrate), it is not necessary to mount a plurality of dye-sensitized solar cells on the substrate as in the prior art. Since the dye-sensitized solar cells are electrically connected to each other, the manufacturing efficiency can be improved. In this way, the amount of work can be reduced, whereby the reduction in manufacturing cost can be achieved.

Further, the dye-sensitized solar cell 1A having the pair of sub-modules R and R as shown in FIG. 15 described above is configured such that the sub-modules R and R of the one end 1a side in the width direction X2 are electrically connected to each other by the wiring material 19. It is possible to draw electricity at the other end 1b. In other words, the entire structure is electrically U-shaped in a plan view, and since the extraction electrodes (positive electrode and negative electrode) can be disposed on the same side of the other end 1b in the width direction X2, the wiring structure can be simplified, and the wiring structure can be easily simplified. Perform wiring work.

Further, in the present embodiment, a simple structure in which the wiring material 19 is provided at one end 1a of the adjacent sub-modules R and R is used, and a simple manufacturing method of applying the wiring material 19 by wire can be applied, and thus it is also possible to simply Adapt to the R to R mode. Since it can be realized by the manufacturing step of continuously arranging the wiring material 19 in the longitudinal direction X1 by such a R to R method, it is not necessary to add a new work step.

Next, other embodiments obtained by the solar cell module and the solar cell module manufacturing method of the present invention will be described with reference to the accompanying drawings, but the same or similar components and partial components as those of the above-described first embodiment are used. The same reference numerals are given to omit the description, and the configuration different from the first embodiment will be described.

 (Second embodiment)  

As shown in FIG. 16, the second embodiment is a method of manufacturing the dye-sensitized solar cell 1 by the R to R method, and is a step before the step of bonding the photoelectrode 11 and the counter electrode 12. A method of arranging the wiring material 19 along the longitudinal direction X1 at both end portions in the width direction X2. In other words, the wiring material 19 is placed on the first base material 3A simultaneously with the conductive material 14 after the sealing material 15 is provided. In the second embodiment, the wiring member 19 is continuously disposed in the longitudinal direction X1. After the welded portion 18 is provided, as shown in FIG. 17, a portion of the longitudinal direction X1 of the wiring member 19 is notched. The disconnection portion 19a.

As the wiring material 19 at this time, a double-sided adhesive type copper tape or a hardened silver paste may be used. Further, the photoelectrode 11 may be a copper strip, and the counter electrode 12 may be a combination of curable silver paste. Further, the copper strip may be used as a lead-out electrode, and the curable silver paste may be connected in series to a unit adjacent in the longitudinal direction X1.

In the second embodiment, the disconnecting portions 19a are formed in appropriate portions of the wiring member 19, and the cells C and C of the secondary module R adjacent in the longitudinal direction X1 can be connected to each other. Therefore, the required circuit can be designed according to the position of the disconnecting portion 19a. Further, in the second embodiment, since the arrangement pattern of the conductive material 14 and the wiring member 19 can be simultaneously formed, the manufacturing efficiency can be improved.

The structure of the wiring member 19 will be specifically described. FIG. 18 shows the dye-sensitized solar cell 1 after the first base material 3A and the second base material 3B are bonded together and before the welded portion 18 is provided.

FIG. 19 shows the lead electrode wiring material 19A in the positive electrode. FIG. 20 shows the lead electrode wiring material 19B in the negative electrode. Fig. 21 and Fig. 22 show a wiring material 19C for connection in which cells adjacent in the longitudinal direction X1 are connected to each other. By arranging the conductive material 14 at both end portions in the width direction X2 of the film, the + terminal (positive terminal) and the - terminal can be provided on the same substrate surface (here, the substrate surface of the second substrate 3B). The extraction electrode (terminal lead-out portion) of the (negative electrode terminal). Therefore, it is not necessary to reverse the step of inverting the dye-sensitized solar cell 1 when wiring the lead electrode, thereby reducing the labor and time of the wiring work.

Moreover, as shown in FIG. 23, the connection wiring material 19C may be configured such that the level of the bridge electrode cannot be adjusted by ultrasonic vibration.

In the case of the second embodiment, a dye-sensitized solar cell manufactured by cutting the fusion portion 18 so as to have two secondary modules R and R can be produced in the same manner as in the first embodiment. (Solar battery module) (Refer to Figure 15).

 (Third embodiment)  

Next, the third embodiment shown in FIG. 24 is a method of manufacturing the wiring member 19 in such a manner that the wiring member 19 is applied so that the photoelectrode 11 and the counter electrode 12 are staggered in the longitudinal direction X1. . In other words, the cells C and C which are disposed on both sides of the disconnecting portion 19a in which the wiring member 19 is not disposed in the longitudinal direction X1 are not connected to each other at the time of arranging the wiring member 19.

Therefore, compared with the case where the wiring material 19 is continuously arranged at the time of arranging the wiring material 19 as in the second embodiment, there is an advantage that the step of providing the disconnecting portion 19a in the wiring member 19 is provided.

As shown in FIG. 25, in the third embodiment, in the step of forming the welded portion 18, the non-welded non-welded portion 18A (the portion surrounded by the dotted line in FIG. 25) is secured, and the welded portion 18 is formed. After the photoelectrode 11 and the counter electrode 12 are bonded together, the photoelectrode 11 and the counter electrode 12 are welded in the width direction X2. The reason why the non-welding portion 18A in which the welded portion 18 is not provided is formed is that the non-welded portion 18A is coated with the side of the wiring member 19, whereby the disconnected wiring material 19 can be prevented from being broken. Thereby, insulation of the wiring material 19 due to welding can be prevented.

The non-welding portion 18A is located at a position facing the disconnection portion 19a of the wiring member 19 in the width direction X2. That is, the non-welding portion 18A is a portion of the ultrasonic welding portion 46 shown in FIG. 4 that does not touch the ultrasonic fusion splicer.

 (Fourth embodiment)  

Next, in the fourth embodiment shown in FIG. 26, the insulating process for forming the third insulating portion 17A and the insulating process of the photoelectrode 11 and the counter electrode 12 (only the second insulating portion 17 is described in FIG. 26) are simultaneously performed. In the manufacturing method, the third insulating portion 17A corresponds to the welded portion 18 that welds the photoelectrode 11 and the counter electrode 12 in the width direction X2. In this case, the welded portion 18 is in a state in which both ends in the width direction X2 are electrically connected to the cells C and C adjacent in the longitudinal direction X1, so that a gap is formed between the both ends in the width direction X2. The state of the portion (the portion surrounded by the non-insulating portion 17B and the broken line in Fig. 26) is insulated.

Further, as shown in Fig. 27, only the portion T to be cut is sealed by ultrasonic welding.

In the fourth embodiment, the third insulating portion 17A and the insulating process parallel to the longitudinal direction X1 are simultaneously performed, whereby the manufacturing efficiency can be improved.

In the above, the embodiment of the method for manufacturing the solar cell module and the solar cell module of the present invention has been described. However, the present invention is not limited to the above embodiment, and can be appropriately modified without departing from the scope of the invention.

For example, in the above embodiment, the slit processing device 50 is used as the means for performing the insulation processing by the insulating processed portions 41, 47, but the invention is not limited thereto. For example, as shown in FIGS. 28(a) and (b), a plurality of the laser irradiation devices 53, 53, ... are arranged at a predetermined interval in the width direction X2, and each of the welded portions 18 is set in advance. The laser irradiation device 53 that irradiates the laser beam L with reference to the sub-module R formed in FIG. 1 is alternately arranged as shown in FIGS. 28(a) and 28(b) for each sub-module R. In the same manner as the slit processing apparatus 50 of the above-described embodiment, the first insulating portion 16 is formed on the transparent conductive film 11A of the first base material 3A, and the opposing conductive film 12A is formed on the second base material 3B. Two insulating portions 17.

Further, in one dye-sensitized solar cell (solar battery module), the number of the sub-modules R is not limited to this embodiment, and may be arbitrarily set as long as it is an even number.

Further, the constituent elements in the above-described embodiments may be appropriately replaced with well-known constituent elements within the scope of the gist of the invention.

 [Industrial availability]  

According to the solar cell module and the solar cell module manufacturing method of the present invention, by fabricating a structure in which wiring can be performed only on the film substrate, the roll-to-roll method can be used, and the outer sun is not required. The wiring generated during the battery module can achieve a reduction in cost.

Claims (12)

 A solar cell module comprising a first electrode, a second electrode, an electrolyte sealed between the first electrode and the second electrode, a plurality of sealing materials sealing the electrolyte, and a plurality of insulated wires The multilayer structure has a plurality of sub-modules each consisting of a plurality of cells defined by the plurality of sealing materials and the plurality of insulated wires, wherein the first electrode has a transparent conductive film formed on the surface a first substrate of the film, and a plurality of strip-shaped semiconductor layers of the surface of the transparent conductive film formed on the first substrate and having a dye extending in a first direction, the second electrode having a surface The first electrode is formed in a manner opposite to the second substrate of the opposite conductive film, and the electrolyte is sealed between the semiconductor layer of the first electrode and the second electrode, and the plurality of sealing materials are Separating the electrolyte from the first electrode and the second electrode along the first direction, and dividing the laminated structure into a plurality of cells, the plurality of insulated wires are respectively separated by In the first The electrode and the second electrode extend along a second direction orthogonal to the first direction in plan view, and the laminated structure is divided into a plurality of sub-modules each composed of a plurality of cells. The unit adjacent to the second direction, the first electrode of one unit and the second electrode of the other unit are electrically connected by a conductive material disposed in a state covered by the sealing material, whereby the plurality of units are connected in series In each unit, in order to prevent a short circuit between the first electrode and the second electrode, a first insulating portion extending in the first direction is disposed in the first substrate adjacent to a position adjacent to the conductive material. Providing, in the second substrate, a second insulating portion extending in the first direction adjacent to a position adjacent to the other conductive material, the plurality of sub-modules being connected in the following manner: about the first side The adjacent modules of the second direction, the ends of the same side of the second direction are electrically connected to each other by the wiring material in the form of series wiring, and the currents flowing through the plurality of submodules are arranged in the first One The subassembly of up alternately reversed.    The solar cell module of claim 1, wherein the conductive material disposed at both end portions of the second direction is on a substrate surface of the first substrate or the second substrate A terminal lead portion is provided on the surface of the substrate.    A solar cell module manufacturing method for continuously manufacturing a solar cell module by a roll-to-roll method, characterized in that the method has the following steps: forming a first electrode, the first The electrode is formed on the surface of the first substrate with a transparent conductive film, and a plurality of semiconductor layers having a pigment adsorbed in the first direction and formed on the surface of the transparent conductive film of the first substrate are formed; a second electrode, the second electrode is formed on the surface of the second substrate opposite to the first electrode to form a counter conductive film; the transparent conductive film and the opposite conductive film are parallel to the first direction Performing insulation processing; providing a sealing material extending along the first direction, arranging a plurality of cells in a second direction orthogonal to the first direction in a plan view; and arranging the state covered by the sealing material And a conductive material, wherein the first electrode of one unit is electrically connected to the second electrode of the other unit by the conductive material; and the semiconductor layer of the first electrode Second electric An electrolyte is disposed between the first electrode and the second electrode; the first electrode and the second electrode are formed with an insulated wire extending along the second direction, and are divided into a plurality of cells. a plurality of secondary modules; wherein, in the secondary module adjacent to the first direction, the ends of the same side of the second direction are electrically connected to each other by a wiring material; and the first An electrode and the second electrode are cut at a position of any of the insulated wires.    The method of manufacturing a solar cell module according to claim 3, wherein in the step of performing the insulating process, an insulating processing pattern is formed, wherein the insulating processing pattern is changed in position to be fixed relative to the first direction The position at which the period is offset from the second direction.    The method of manufacturing a solar cell module according to claim 3, wherein the wiring material is disposed in a continuous state along the first direction, and after the insulating wire is formed, by the wiring material One of the first directions is subjected to slit processing to form a broken portion.    The method of manufacturing a solar cell module according to claim 3, wherein in the step of disposing the wiring material, the wiring material in which the disconnecting portion is formed in one of the first directions is disposed.    The method of manufacturing a solar cell module according to any one of claims 3 to 6, wherein the insulated wire is a welded portion that is welded along the second direction.    The method of manufacturing a solar cell module according to any one of claims 3 to 7, wherein the step of disposing the wiring material is performed simultaneously when the conductive material is disposed.    The method of manufacturing a solar cell module according to any one of claims 3 to 7, wherein the step of forming the insulated wire is performed simultaneously while performing the insulating process.    A method for manufacturing a solar cell module, comprising the steps of: forming a first electrode, the first electrode forming a transparent conductive film on a surface of the first substrate, and forming the transparent conductive formed on the first substrate a plurality of semiconductor layers on the surface of the film extending in the first direction and adsorbing the dye; forming a second electrode, the second electrode being formed on the surface of the second substrate in such a manner as to face the first electrode a conductive film; the transparent conductive film and the opposite conductive film are insulated from the first direction; a sealing material is disposed, the sealing material extends along the first direction, and the plurality of cells are viewed in a plan view Aligning the first direction orthogonal to the second direction; arranging the conductive material in a state covered by the sealing material, and the first electrode of one unit and the other by the conductive material with respect to the unit adjacent in the second direction a second electrode of a unit is electrically connected; an electrolyte is disposed between the semiconductor layer and the second electrode of the first electrode; the first electrode is bonded to the second electrode; and the first substrate is The A wiring material is disposed along the first direction at both ends of the second direction; and the first insulating line and the second insulating line are formed at the specific position of the first direction and the second electrode, and The first insulated wire is disposed between the two insulated wires, wherein the first insulated wire extends along the second direction and the portion of the wiring material in the second direction is partially uninsulated, the second insulated wire is throughout The second direction is integrally insulated; and the first electrode and the second electrode are cut at a position of the second insulated wire; and in the solar cell module cut by the second insulated wire, The adjacent modules in the sub-module divided by the first insulated wire are electrically connected to each other at the same side of the second direction by the wiring material in the form of series wiring.    The method of manufacturing a solar cell module according to claim 10, wherein the first insulated wire and the second insulated wire are welded portions that are welded along the second direction.    The method of manufacturing a solar cell module according to claim 10, wherein the step of forming the first insulated wire and the second insulated wire is performed simultaneously while performing the insulating process.