Manufacturing method of power generation module

Abstract

To provide a power generation module which can be adopted to a construction-material-integrated solar battery.SOLUTION: A manufacturing method of a power generation module, containing a first sub module and a second sub module, contains: a step of preparing a plurality of base sub modules forming a lamination film containing a solar battery film onto a main surface of a base substrate; a step of forming the first sub module by using a part which is not removed from the solar battery film by removing one part of the solar battery film from the main surface under a first processing condition as a solar battery layer of a power generation part, removing one part of the solar battery layer from the main surface under a second processing condition that is different from the first processing condition in one of the other base sub module, forming a second sub module by using a part which is not removed from the solar battery film as a solar battery layer of the power generation part, and making a removal area of the solar battery film to be different in the first and second sub module; and a step of arranging the first and second sub module so as to be adjacent each other.SELECTED DRAWING: Figure 9C

Description

[Technical field]

[0001] The present disclosure relates to photovoltaic modules, particularly photovoltaic modules that can be integrated into building materials. [Background technology]

[0002] Building-integrated photovoltaics (BIPV), which are integrated with building materials such as the roofs, exterior walls, and windows of buildings, are attracting attention. For example, Patent Document 1 proposes a building material with attached solar cells that can be used as a window. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-84640 A Summary of the Invention [Problem to be solved by the invention]

[0004] There are a wide variety of requirements for building-integrated solar cells. For example, power generation modules applied to building-integrated solar cells may be required to have design in addition to power generation performance. Also, they may be required to be compatible with a variety of building materials with different functions, shapes, sizes, etc. However, with the structure of Patent Document 1, it may be difficult to design to meet these requirements.

[0005] An object of the present disclosure is to solve the above-mentioned problems and to provide a power generating module that can be applied to a building material-integrated solar cell. [Means for solving the problem]

[0006] A method for manufacturing a power generation module according to the present disclosure is a method for manufacturing a power generation module including a first submodule and a second submodule, comprising the steps of: preparing a plurality of base submodules each having a laminated film including a solar cell film formed on a main surface of a base substrate; A process for processing the base sub-module, comprising the steps of: forming a first submodule by removing a portion of the solar cell film from the main surface of one of the base submodules under a first processing condition, the portion of the solar cell film that is not removed being a solar cell layer of a power generation section; forming a second submodule by removing a portion of the solar cell film from the main surface under second processing conditions different from the first processing conditions in another of the base submodules, and using the portion of the solar cell film that is not removed as the solar cell layer of the power generation unit; making the first submodule and the second submodule have different areas from each other in terms of the area of ​​the main surface from which the solar cell film is removed; and placing the first sub-module and the second sub-module adjacent to each other. Effect of the Invention

[0007] According to the present disclosure, it is possible to provide a power generating module that can be applied to a building material-integrated solar cell. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a schematic top view of the power generation module according to the first embodiment of the present disclosure. [Diagram 2] 2 is a schematic cross-sectional view taken along line II-II of the power generation module of FIG. 1. [Diagram 3] FIG. 2 is a schematic exploded perspective view of the power generation module of FIG. 1; [Figure 4] 2 is a schematic top view of one sub-module in the power generation module of FIG. 1. [Diagram 5] FIG. 5 is an enlarged top view of a portion of the submodule of FIG. 4. [Figure 6A] FIG. 6 is an enlarged cross-sectional view taken along the line VIA-VIA in FIG. 5. [Figure 6B] FIG. 6 is an enlarged cross-sectional view taken along the line VIB-VIB in FIG. 5. [Figure 7] 2 is an enlarged top view showing a part of the power generation module of FIG. 1. [Figure 8] FIG. 4 is a schematic top view showing another example of the power generation module according to the first embodiment. [Figure 9A] 11A to 11C are schematic perspective views showing a film forming step in the manufacturing method of the submodule. [Figure 9B] 11A to 11C are schematic perspective views showing a film forming step in the manufacturing method of the submodule. [Figure 9C] 11A to 11C are schematic perspective views showing a film processing step in the manufacturing method of the submodule. [Figure 9D] 5A to 5C are schematic cross-sectional views showing a film processing step in the manufacturing method of the submodule. [Figure 9E] 11A to 11C are schematic perspective views showing a film processing step in the manufacturing method of the submodule. [Figure 9F] 5A to 5C are schematic cross-sectional views showing a film processing step in the manufacturing method of the submodule. [Figure 10A] 5A to 5C are schematic cross-sectional views showing a film processing step in the manufacturing method of the submodule. [Figure 10B] 5A to 5C are schematic cross-sectional views showing a film processing step in the manufacturing method of the submodule. [Figure 10C] 5A to 5C are schematic cross-sectional views showing a film processing step in the manufacturing method of the submodule. [Figure 11] 11A to 11C are schematic top views showing a wiring formation step in the manufacturing method of the submodule. [Figure 12A] 2 is a schematic top view showing a submodule arrangement step in the manufacturing method of the power generation module of FIG. 1. [Figure 12B] 2 is a schematic top view showing a submodule arrangement step in the manufacturing method of the power generation module of FIG. 1. [Figure 13A] 2A to 2C are schematic cross-sectional views showing a sealing step in a method for manufacturing the power generation module of FIG. 1. [Figure 13B] 2A to 2C are schematic cross-sectional views showing a sealing step in a method for manufacturing the power generation module of FIG. 1. [Figure 13C] 2A to 2C are schematic cross-sectional views showing a sealing step in a method for manufacturing the power generation module of FIG. 1. [Figure 14] 1 is a schematic diagram illustrating the relationship between the solar cell film removal area ratio and the power generation section area ratio of a submodule and the light transmittance. FIG. [Figure 15] 11 is a flowchart illustrating a method for setting the light transmittance of a submodule. [Figure 16] FIG. 2 is a schematic enlarged top view showing an example of a string structure. [Figure 17] FIG. 13 is a schematic enlarged top view showing another example of a string structure. [Figure 18] FIG. 13 is a schematic enlarged top view showing yet another example of a string structure. [Figure 19A] FIG. 13 is an enlarged top view showing another example of the submodule. [Figure 19B] FIG. 13 is an enlarged top view showing another example of the submodule. [Figure 20] FIG. 11 is an enlarged top view showing one sub-module in the second embodiment of the present disclosure. [Figure 21] FIG. 2 is a schematic enlarged top view showing an example of a string structure. [Figure 22] FIG. 13 is a schematic enlarged top view showing another example of a string structure. [Figure 23] FIG. 13 is a schematic enlarged top view showing yet another example of a string structure. [Figure 24] FIG. 13 is an enlarged top view of one sub-module to illustrate a design example of varying string width and inter-string region width. [Diagram 25] FIG. 13 is a schematic top view showing an example of gradation of a module row. [Figure 26] FIG. 13 is a schematic top view showing another example of gradation of a module row. [Figure 27]10 is a schematic diagram for explaining the relationship between the distance in the Y direction from the upper end of a first submodule and the string area ratio and light transmittance in the power generation modules of the first and second embodiments. FIG. [Figure 28A] 1A to 1C are schematic cross-sectional views showing a film processing step in a manufacturing method for a submodule having gradation. [Figure 28B] 1A to 1C are schematic cross-sectional views showing a film processing step in a manufacturing method for a submodule having gradation. [Figure 28C] 1A to 1C are schematic cross-sectional views showing a film processing step in a manufacturing method for a submodule having gradation. [Figure 29A] 11A to 11C are schematic cross-sectional views showing other film processing steps in the method for manufacturing a submodule having gradation. [Figure 29B] 11A to 11C are schematic cross-sectional views showing another film formation process in the method for manufacturing a submodule having gradation. [Figure 29C] 11A to 11C are schematic cross-sectional views showing other film processing steps in the method for manufacturing a submodule having gradation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. Note that the present disclosure is not limited to this embodiment. In addition, substantially the same members in the drawings are given the same reference numerals. For the purpose of illustration, the dimensions of each element in the drawings may be exaggerated and are not necessarily drawn to scale. For reference, the drawings are shown with an X-axis, a Y-axis, and a Z-axis that are mutually orthogonal.

[0010] In the following, for the sake of convenience, terms indicating directions such as "upper", "lower", "right", "left", and "side" are used assuming a state during normal use, but are not intended to limit the state of use of the power generation module according to the present disclosure. Furthermore, in this specification, "orthogonal" means within a range of 90°±10°. "Parallel" means within a range of, for example, ±5°.

[0011] In the drawings described below, for reference, mutually orthogonal X-axis, Y-axis, and Z-axis are shown diagrammatically. In the following description, when the X-direction, Y-direction, or Z-direction is simply mentioned, it means the respective axial direction, and includes two opposite directions (e.g., -X-direction and +X-direction).

[0012] First Embodiment A basic configuration of a power generation module according to a first embodiment of the present disclosure will be described with reference to Fig. 1 to Fig. 3. Fig. 1 is a schematic top view of the power generation module according to the embodiment of the present disclosure. Fig. 2 is a schematic cross-sectional view taken along line II-II of the power generation module of Fig. 1. Fig. 3 is a schematic exploded perspective view of the power generation module of Fig. 1.

[0013] As shown in FIGS. 1 to 3, the power generating module 1 includes a first substrate 11, a second substrate 12, a plurality of sub-modules 100, a first filler material 31, and a second filler material 32. The first filler material 31 and the second filler material 32 are arranged in a rectangular shape.

[0014] In the following description, the power generation module 1 will be described as a power generation module that can be integrated with building materials such as a window of a building. The power generation module 1 can be used, for example, as a window that is arranged in a building so that external light enters from the second substrate 12 side.

[0015] The Z direction (also referred to as the "first direction") shown in Figs. 1 to 3 corresponds to the thickness direction of the power generation module 1. The thickness direction of the power generation module 1 is, for example, the stacking direction of the two substrates 11 and 12, or the stacking direction of the solar cell layer included in the power generation module 1. In addition, directions that intersect with each other (here, perpendicular) in a plane perpendicular to the Z direction are defined as the X direction and the Y direction. The Y direction may be, for example, the height direction of the window, and the X direction may be, for example, the width direction of the window.

[0016] The first substrate 11 and the second substrate 12 are translucent. "Translucent" means transparent to visible light. "Translucent" means, for example, that the transmittance of visible light is 50% or more, preferably 70% or more. The first substrate 11 and the second substrate 12 are, for example, rectangular glass substrates (strengthened glass substrates). As in FIG. 1, in a top view of the power generation module 1 or a part thereof, the second substrate 12 may be omitted for clarity.

[0017] 2, the first substrate 11 and the second substrate 12 are disposed so as to face each other in the Z direction. The second substrate 12, which is the light receiving side, may be thinner than the first substrate 11. The peripheral edge of the first substrate 11 and the peripheral edge of the second substrate 12 are sealed by a sealing member 50. In a plan view seen along the Z direction, the sealing member 50 is located outside the central region 13 of the first substrate 11 in which the submodule 100 is disposed. The sealing member 50 can be made of a thermoplastic elastomer such as butyl rubber.

[0018] Each of the multiple submodules 100 is a solar cell submodule having a solar cell (power generation section). The multiple submodules 100 are located between a first substrate 11 and a second substrate 12. Each submodule 100 has, for example, a rectangular planar shape. In the example shown in FIG. 1, the submodule 100 is disposed in a space surrounded by the first substrate 11, the second substrate 12, and a sealing member 50. The multiple submodules 100 are disposed in a central region 13 of the first substrate 11 so as not to overlap with each other in a plan view seen along the Z direction.

[0019] 2, the first filler 31 is located between the first substrate 11 and the lower surface of each submodule 100. The second filler 32 is located between the second substrate 12 and the upper surface of each submodule 100. As these fillers 31 and 32, for example, a filler such as polyolefin (PO) can be used.

[0020] The fillers 31 and 32 may fill the space surrounded by the first substrate 11, the second substrate 12, and the sealing member 50. This can suppress the effect of air on the solar cell layer in the submodule 100. An air layer may be partially formed in the space. In this example, the fillers 31 and 32 are arranged above and below the submodule 100, but they may be arranged only on one side.

[0021] In this embodiment, the submodules 100 are arranged in a matrix in two directions (here, the X direction and the Y direction) that intersect (here, perpendicular) with each other in a plan view along the Z direction. Columns Ra to Rd each consisting of a plurality of submodules arranged in the Y direction are referred to as "module columns." Rows R1 to R4 each consisting of a plurality of submodules arranged in the X direction are referred to as "module rows."

[0022] 1, 12 sub-modules 100 are arranged in 4 rows and 3 columns, constituting four module rows R1 to R4 and three module columns Ra to Rc. The multiple (four in this example) sub-modules constituting each of the module columns Ra to Rc are connected in parallel to each other. The three module columns Ra to Rc are connected in series in the X direction.

[0023] 1, the power generation module 1 further includes first wirings 41a-41c and second wirings 42a-42c extending in the Y direction between the first substrate 11 and the second substrate 12, and a plurality of third wirings 43 for connecting adjacent first wirings and second wirings. These wirings may be metal wirings. In this embodiment, these wirings are wires (tab wires) made of copper wires covered with solder.

[0024] The first wiring 41a and the second wiring 42a connect in parallel the multiple (four in this example) submodules 100 that make up the module row Ra. Similarly, the first wiring 41b, 41c and the second wiring 42b, 42c connect in parallel the multiple submodules 100 that make up the module rows Rb, Rc. In the example shown, the first wiring 41a-41c are provided at one end in the X direction of each of the module rows Ra-Rc. The second wiring (e.g., tab wires) 42a-42c are provided at the other end in the X direction of each of the module rows Ra-Rc.

[0025] The multiple third wirings 43 connect in series any two adjacent module columns among the three module columns Ra to Rc. The third wirings 43 are arranged to connect the first wiring of one of the two adjacent module columns to the second wiring of the other module column.

[0026] 1, the power generation module 1 further includes a pair of lead wires (positive / negative lead wires) 21, 22. The lead wires 21, 22 are, for example, metal wiring (for example, tab wires). The lead wires 21, 22 are electrically connected to the submodule 100 within a space surrounded by the first substrate 11, the second substrate 12, and the sealing member 50. The lead wires 21, 22 may be drawn out from within the space to the outside through the sealing member 50.

[0027] 1, the lead wire 21 is electrically connected to one end of the first wiring 41a of the leftmost module row Ra. The lead wire 22 is electrically connected to one end of the second wiring 42c of the rightmost module row Rc. The lead wire 21 may be an extended portion of the first wiring 41a, and the lead wire 22 may be an extended portion of the second wiring 42c.

[0028] (Structure of submodule 100) 4 to 6B, the structure of the submodule 100 in the power generation module 1 will be described. Here, one submodule in the module row Ra (FIG. 1) will be described as an example.

[0029] Fig. 4 is a schematic top view of one submodule in the power generation module. Fig. 5 is an enlarged top view of a portion of the submodule in Fig. 4. Fig. 5 shows an enlarged view of an area 100a shown in Fig. 4. Fig. 6A is an enlarged cross-sectional view taken along line VIA-VIA in Fig. 5. Fig. 6B is an enlarged cross-sectional view taken along line VIB-VIB in Fig. 5.

[0030] 4, each submodule 100 includes a light-transmitting base substrate 110, a power generation unit supported by the base substrate 110, and a pair of wirings 141, 142. In the example shown in Fig. 4, the power generation unit includes a plurality of linear strings 120.

[0031] The base substrate 110 is, for example, a rectangular glass substrate. The power generating section is located on a part of the main surface 110s of the base substrate 110.

[0032] The power generating section includes at least a solar cell layer. As described later, the power generating section has a laminated structure including at least a pair of transparent electrodes and a solar cell layer located between the pair of transparent electrodes. The laminated structure may be supported by the main surface 110s of the base substrate 110, but may not be in direct contact with the main surface 110s.

[0033] The wiring 141 is disposed on one end side of the base substrate 110. The wiring 142 is disposed on the other end side of the base substrate 110. In this example, the wirings 141 and 142 are disposed on both ends of the base substrate 110 in the X direction. The wirings 141 and 142 are electrically connected to the power generation unit. The wirings 141 and 142 are respectively connected to the wirings 141 and 142 of other submodules (not shown) adjacent in the Y direction to form the first wiring 41a and the second wiring 42a.

[0034] A plurality of strings 120, which are power generating units, are connected in parallel by wiring 141 and 142. Here, each string 120 extends in the X direction from one end side to the other end side of the base substrate 110. One end of each string 120 is connected to the wiring 141, and the other end is connected to the wiring 142.

[0035] The multiple strings 120 are arranged on the main surface 110s of the base substrate 110 at a distance from each other in the Y direction. In a plan view seen along the Z direction, the multiple strings 120 may extend, for example, parallel to each other. In a plan view seen along the Z direction, a region 130 of the main surface 110s of the base substrate 110 located between adjacent strings 120 is referred to as an "inter-string region."

[0036] As shown in FIGS. 5 and 6, each of the multiple strings 120 is a solar cell element string having multiple solar cell elements 150 connected in series.

[0037] As shown in FIG. 6A and FIG. 6B, each string 120 has a stacked structure L in which a plurality of layers including a lower transparent conductive layer LE, a solar cell layer PV, and an upper transparent conductive layer UE are stacked in the Z direction. These layers are supported on the main surface 110s. In the stacked structure L, the solar cell layer PV is located between the lower transparent conductive layer LE and the upper transparent conductive layer UE. The lower transparent conductive layer LE is located on the base substrate 110 side of the solar cell layer PV. The solar cell layer PV is, for example, a stacked film including an n-type semiconductor layer, an i-type semiconductor layer, and a p-type semiconductor layer from the base substrate 110 side. The solar cell layer PV may further include an electron transport layer and / or a hole transport layer as necessary.

[0038] The lower transparent conductive layer LE, the solar cell layer PV, and the upper transparent conductive layer UE are separated for each solar cell element 150. In this example, the solar cell layer PV and the upper transparent conductive layer UE are separated for each solar cell element 150 by a separation groove 160. The lower transparent conductive layer LE includes a lower transparent electrode 151 of each solar cell element 150. The upper transparent conductive layer UE includes an upper transparent electrode 155 of each solar cell element 150. The solar cell layer PV includes a semiconductor layer 153 of each solar cell element 150.

[0039] Each solar cell element 150 has a lower transparent electrode 151, an upper transparent electrode 155, and a semiconductor layer 153 located between the lower transparent electrode 151 and the upper transparent electrode 155. The lower transparent electrode 151 (or the upper transparent electrode 155) of the solar cell element 150 located at one end of each string 120 is electrically connected to the wiring 141. Similarly, the upper transparent electrode 155 (or the lower transparent electrode 151) of the solar cell element 150 located at the other end of each string 120 is electrically connected to the wiring 142.

[0040] The solar cell layer PV (i.e., the semiconductor layer 153) is a layer (photoelectric conversion layer) that converts absorbed light into electricity. The solar cell layer PV includes, for example, a perovskite compound (perovskite semiconductor) as a photoelectric conversion material. The perovskite compound is a perovskite crystal structure represented by the chemical formula ABX3 and a structure having a crystal similar thereto. A is a monovalent cation, B is a divalent cation, and X is a halogen anion. The lower transparent conductive layer LE and the upper transparent conductive layer UE are, for example, metal oxide layers having light transmission properties, such as indium tin oxide (ITO) or indium zinc oxide (IZO), or a fluorine-doped tin oxide (FTO) layer. Note that the materials of the layers constituting the solar cell element are not limited to those mentioned above, and known materials may be used.

[0041] (Power generation area ratio of 100 submodules) 4 and 5 are referred to again. In this specification, the ratio of the area of ​​the power generation section to the area of ​​the main surface 110s of the base substrate 110 in a plan view along the Z direction is referred to as the "power generation section area ratio." In the example shown in FIG. 4, the "area of ​​the power generation section" is the total area of ​​the multiple strings 120 in a plan view along the Z direction. The power generation section area ratio is, for example, approximately equal to the ratio of the area of ​​the portion where the solar cell layer PV (or solar cell film) exists to the area of ​​the main surface 110s in a plan view along the Z direction (hereinafter referred to as the "solar cell layer area ratio"). Therefore, the power generation section area ratio can also be said to be the solar cell layer area ratio.

[0042] In the submodule 100, the light transmittance of the power generating section for visible light incident in the Z direction is smaller than the light transmittance of the portion where the power generating section is not formed. This is because the power generating section includes a solar cell layer PV that has a lower visible light transmittance than, for example, a glass substrate. Therefore, by changing the power generating section area ratio, it is possible to adjust the light transmittance of the submodule 100 as a whole. In this specification, "light transmittance" refers to the transmittance (visible light transmittance) for visible light (wavelength 400 nm to 700 nm) incident on the power generating module 1 along the first direction (Z direction).

[0043] In the example shown in FIG. 5, the power generation section area ratio can be adjusted by the number of strings 120 arranged in the submodule 100, the width of each string 120 along the second direction (hereinafter, "string width") ws, the distance between two adjacent strings 120 along the second direction (Y direction) (hereinafter, "inter-string distance"), etc. The inter-string distance refers to the width of the inter-string region 130 along the second direction (hereinafter, "inter-string region width") wp. As an example, the power generation section area ratio of each submodule 100 can be appropriately selected within a range of, for example, 20 to 80%. As a result, the light transmittance of each submodule 100 can be adjusted to a desired value within a range of, for example, 20 to 80%.

[0044] (Arrangement of sub-modules in a power generation module) The power generating module 1 of this embodiment includes two submodules adjacent in the second direction in a plan view seen from the first direction (Z direction). The two adjacent submodules are configured to have different power generating section area ratios. In this specification, the one of the two adjacent submodules with the smaller power generating section area ratio may be referred to as the "first submodule," and the one with the larger power generating section area ratio may be referred to as the "second submodule." The first submodule may have a higher light transmittance than the second submodule.

[0045] Fig. 7 is an enlarged top view showing a part of the power generation module of Fig. 1. Fig. 7 shows an enlarged view of the submodule 100 in three rows and three columns located at the upper left among the submodules 100 shown in Fig. 1.

[0046] An example will be described using two submodules 101 and 102 in a module row Ra shown in Fig. 7. The submodules 101 and 102 are adjacent to each other in a second direction (Y direction here) in a plan view seen from a first direction (Z direction). In this example, the submodules 101 and 102 are connected in parallel to each other.

[0047] The power generation area ratio of the submodule 101 is smaller than the power generation area ratio of the submodule 102. That is, in this example, the submodule 101 corresponds to the "first submodule" and the submodule 102 corresponds to the "second submodule." This allows the light transmittance of the submodule 101 to be greater than the light transmittance of the submodule 102.

[0048] 7, the strings 120 are arranged at equal intervals in the Y direction in each of the submodules 101 and 102. The strings 120 are arranged more densely in the submodule 102 than in the submodule 101. Thus, the number of strings 120 in the submodule 102 is greater than the number of strings 120 in the submodule 101. The width of the strings 120 in the Y direction is, for example, all constant. In this way, the power generation section area ratio of the submodule 102 (here, the ratio of the total area of ​​the strings 120 to the main surface 110s) can be set to be greater than that of the submodule 101.

[0049] The power generating module 1 further includes a submodule 103 arranged on the opposite side of the submodule 102 to the submodule 101 in the second direction (here, the Y direction) in a plan view seen along the Z direction. The submodule 103 may be referred to as a "third submodule." The power generating section area ratio of the submodule 102 is smaller than the power generating section area ratio of the submodule 103. In this example, the strings 120 are arranged more densely in the submodule 103 than in the submodule 102.

[0050] 7, the sub-modules 100 constituting each of the module rows Ra to Rc may be configured so that the power generation area ratio decreases as the sub-module approaches one end of the module row (here, the upper (+Y side)). This makes it possible to change the light transmittance along the Y direction (for example, the height direction of the window).

[0051] The power generating module 1 further includes a submodule 104 arranged adjacent to the submodule 101 in a third direction (here, the X direction) intersecting the second direction in a plan view seen along the Z direction. The submodule 104 may be referred to as a "fourth submodule." The power generating section area ratio of the submodule 104 is equal to the power generating section area ratio of the submodule 101. In this example, the number of strings 120 of the submodule 104 is the same as that of the first submodule 101.

[0052] 7, the submodules 100 constituting each of the module rows R1 to R4 may all be configured to have the same power generation section area ratio, thereby making it possible to make the transmittance constant along the X direction (for example, the width direction of the window).

[0053] (Other examples of submodule arrangements) The power generation module of this embodiment may include at least two submodules adjacent to each other in the second direction and having different power generation area ratios. In FIG. 7, the first submodule is located above (+Y side) the second submodule, but it may be located below (-Y side). In FIG. 7, the second direction is described as the Y direction, but the second direction may be any direction (any direction in the XY plane) that intersects with the first direction, which is the thickness direction of the power generation module 1. The number and arrangement of the submodules are not limited to the example shown in FIG. 7. In FIG. 7, the submodules 100 are arranged in a matrix, but the submodules 100 may be arranged in only one direction.

[0054] FIG. 8 is a schematic top view showing another example of the power generation module according to the first embodiment.

[0055] The power generating module shown in FIG. 8 differs from the configuration shown in FIG. 2 in that it includes a single module row including a plurality of (three in this case) submodules 101-103.

[0056] The submodules 101-103 are configured to have a higher power generation area ratio as they are closer to one end of the module row Ra (here, the +Y side). Therefore, the light transmittance of the power generation module gradually increases in the +Y direction. As shown in the figure, the planar shape of each of the submodules 101-103 may be a rectangle that is long in the X direction, depending on, for example, the size of the window. With this configuration, it is possible to provide a power generation module that is simple and has a good appearance, without the need to arrange wiring between the submodules.

[0057] (Submodule manufacturing method) A method for manufacturing the submodule 100 will be described with reference to FIGS. 9A to 11.

[0058] The manufacturing method of the submodule 100 includes a film formation process of forming a laminated film including a solar cell film on the main surface of the base substrate, a film processing process of processing the laminated film to form a power generation section, and a wiring formation process of arranging wiring that electrically connects to the power generation section.

[0059] ·Film formation process 9A and 9B are schematic perspective views for explaining the film forming step.

[0060] 9A, a light-transmitting base substrate (for example, a glass substrate) 110 is prepared. Here, a glass substrate is prepared as the base substrate 110. Alternatively, a substrate whose surface is covered with a transparent conductive film, such as an FTO substrate, may be used.

[0061] Next, as shown in FIG. 9B, a laminated film 170 including a lower transparent conductive film, a solar cell film, and an upper transparent conductive film in this order from the main surface 11010s side of the base substrate 110 is formed on the main surface 110s.

[0062] Each film in the laminated film 170 is formed by a known method and patterned as necessary. For example, the lower transparent conductive film may be patterned, and a contact portion that connects the upper transparent conductive film and the lower transparent conductive film may be formed as appropriate. When an FTO substrate is used, the transparent conductive film on the surface of the FTO substrate may be used as the lower transparent conductive film of the laminated film 170.

[0063] The solar cell film includes, for example, a perovskite compound. The solar cell film is applied on the lower transparent conductive film formed on the main surface 110s by a method such as spin coating or inkjet. The solar cell film is, for example, a laminated film including an n-type semiconductor film, an i-type semiconductor film (perovskite layer), and a p-type semiconductor film. First, the n-type semiconductor film is applied using an inkjet method and dried, and then the i-type semiconductor film that will be the upper layer is applied using an inkjet method and dried. Similarly, the p-type semiconductor film is applied using an inkjet method and dried to form a laminated film. The application and drying may be repeated in this manner to form a laminated film that will become the solar cell film.

[0064] ·Membrane processing process In the film processing step, first, as shown in Fig. 9C, a laser beam is scanned in the X direction to perform a first laser processing step (string forming step) on the laminated film 170 formed by the above method, and a part of the laminated film 170 is removed from the main surface 110s. Here, a scribing process such as laser scribing is performed. The part of the laminated film 170 that is not removed and remains on the main surface 110s becomes the power generating section (string 120).

[0065] Next, as shown in Fig. 9D, a second laser processing step (element separation step) is performed by scanning the laser light in the Y direction. As a result, a plurality of separation grooves (corresponding to the separation grooves 160 in Fig. 6A) extending in the Y direction are formed in each string 120, and the strings 120 are separated into a plurality of solar cell elements 150. In this manner, the stacked structure L illustrated in Fig. 6A is obtained.

[0066] The first laser processing step (FIG. 9C) will be described in more detail below with reference to FIGS. 10A to 10C. Here, an example will be described in which the lower transparent conductive film, the solar cell film, and the upper transparent conductive film constituting the laminated film 170 are all removed simultaneously by laser processing. It is sufficient that at least a part of the solar cell film is removed from the base substrate by laser processing. The other transparent conductive films may be processed by a method different from that of the solar cell film and may have a different pattern.

[0067] 10A to 10C are schematic cross-sectional views illustrating the film processing step.

[0068] As shown in FIG. 10A, the laser light LB is scanned in the X direction to irradiate the laminated film 170 with the laser light LB in a predetermined irradiation range (called the "irradiation width") wL. This removes the irradiated portion of the laminated film 170. The removed portion becomes a linear region (inter-string region) 130 extending in the X direction. When the irradiation width wL is wide, multiple scans may be performed to irradiate the predetermined range wL. In this example, the laminated film 170 is removed throughout the thickness direction to expose a part of the main surface 110s.

[0069] Next, as shown in FIG. 10B, the laser head is moved to shift the irradiation position of the laser light LB in the Y direction by a predetermined distance (called the "non-irradiation width") wT. In this state, the laser light LB is scanned in the X direction to perform laser irradiation on the laminated film 170 with an irradiation width wL, and a part of the laminated film 170 is removed. Between two removed parts adjacent in the Y direction, a line-shaped laminated structure having the same width as the non-irradiation width wT, that is, a string 120, is formed. As shown in FIG. 10C, the laminated film 170 is irradiated with laser while shifting the irradiation position in the Y direction. In this manner, a plurality of strings 120 arranged at equal intervals in the Y direction can be formed on the main surface 110s.

[0070] In this embodiment, a first submodule (e.g., submodule 101 in FIG. 7) and a second submodule (e.g., submodule 102 in FIG. 7) are fabricated by varying the processing conditions in the first laser processing step in the film processing step. This makes it possible to differentiate the removal area (total area) of the solar cell film, and therefore to fabricate two submodules with different light transmittances.

[0071] The irradiation width wL and the non-irradiation width wT of the laser beam LB can be appropriately set so as to obtain a desired light transmittance and power generation amount. For example, the irradiation width wL1 of the laser beam LB when manufacturing the first sub-module may be made larger than the irradiation width wL2 when manufacturing the second sub-module. Alternatively, the non-irradiation width wT1 when manufacturing the first sub-module may be made smaller than the non-irradiation width wT2 when manufacturing the second sub-module. An example of a method for separately manufacturing the sub-modules 101 and 102 will be described with reference to FIGS. 9A to 9F.

[0072] First, a plurality of base substrates 110 smaller in size than the first substrate 11 are prepared (FIG. 9A). On the main surface 110s of this substrate 110, a laminated film 170 is formed under the same lamination conditions, and a plurality of base sub-modules (hereinafter, "base sub-modules with a laminated film") are prepared (FIG. 9B).

[0073] Next, with respect to the base sub-module with a laminated film, as shown in FIG. 9C, a first laser processing step (string formation step) is performed under the first processing conditions (irradiation width wL1 and non-irradiation width wT1). Thereby, a plurality of strings 120 having a string width of wT1 and a string pitch of wL1 are formed on the base substrate 110. Next, as shown in FIG. 9D, a second laser processing step (element separation step) is performed to form a sub-module. This becomes the "first sub-module 101".

[0074] Similarly, with respect to the base sub-module with a laminated film (FIG. 9B), as shown in FIG. 9E, processing is performed under second processing conditions different from the first processing conditions (irradiation width wL2 (wL2 < wL1), non-irradiation width wT2 (wT2 = wT1)). Thereby, a plurality of strings 120 having a string width of wT2 (= wT1) and a string pitch of wL2 (< wL1) are formed on the base substrate 110. Next, as shown in FIG. 9F, a second laser processing step (element separation step) is performed to form a sub-module. This becomes the "second sub-module 102".

[0075] In this way, the second processing conditions for forming the second submodule are set to be equal in non-irradiation width compared to the first processing conditions, while only the irradiation width is set smaller, thereby forming the second submodule 102. The laser output for the laser processing is the same under both the first and second processing conditions.

[0076] The first and second submodules formed under these conditions have the relationship shown in Table 1 (see FIG. 16). These submodules have the same string width, but different inter-string region widths.

[0077] In this way, by forming the laminate film 170 on the base substrate 110 under common formation conditions in advance and producing multiple base submodules (base submodules with laminate film), the first submodule 101 and the second submodule 102 can be manufactured from the base submodule by changing the processing conditions of the first laser processing step.

[0078] ·Wiring formation process Fig. 11 is a schematic top view for explaining the wiring formation step. As shown in Fig. 11, wiring (e.g., tab wires) 141, 142 are formed on the base substrate 110 on which the strings 120 have been formed by the above-mentioned method. In this manner, the submodule 100 is manufactured.

[0079] The wirings 141 and 142 are disposed on one end side and the other end side of the substrate 110 in the X direction, respectively. In a plan view seen along the Z direction, the wirings 141 and 142 may be longer than the length of the substrate 110 in the Y direction, and the upper and lower ends of the wirings 141 and 142 may extend outside the substrate 110. The wiring 141 is connected to the upper transparent conductive layer or the lower transparent conductive layer at the left end of each string 120 at one end side of the base substrate 110. Similarly, the wiring 142 is connected to the upper transparent conductive layer or the lower transparent conductive layer at the right end of each string 120 at the other end side of the base substrate 110. Each of the wirings 141 and 142 may be connected to the upper end upper surface of the lower transparent conductive layer by, for example, soldering.

[0080] (Manufacturing method for power generation modules) Next, a method for manufacturing the power generating module 1 using the submodule 100 (FIG. 11) manufactured by the above method will be described with reference to FIGS. 12A to 13C.

[0081] A manufacturing method for a power generation module includes, for example, a submodule arrangement process in which multiple submodules are arranged on a first substrate and electrically connected to each other, and a sealing process in which the first substrate and a second substrate are bonded together with the multiple submodules sandwiched between them.

[0082] Sub-module placement process 12A and 12B are schematic top views for explaining the submodule arrangement process.

[0083] First, a first substrate (e.g., a glass substrate) is prepared, and a plurality of submodules 100 are arranged on a first surface 11s of the first substrate via a filler (filler 31 shown in FIG. 2, etc.). As the filler, for example, a filler sheet containing polyolefin is used. Here, twelve submodules 100 may be arranged in four rows and three columns.

[0084] In this embodiment, as shown in FIG. 12A, the wirings 141 and wirings 142 of two submodules 100 adjacent to each other in the Y direction (column direction) are connected to each other using, for example, solder. The wirings 141 of the submodules 100 in the same column are connected in the Y direction to form a first wiring 41a extending in the Y direction. Similarly, the wirings 142 of the submodules 100 in the same column are connected in the Y direction to form a second wiring 42a extending in the Y direction. This provides a module row Ra in which the submodules 100 in the same column are connected in parallel. Similarly, in the other module rows Rb and Rc, the first wirings 41b and 41c and the second wirings 42b and 42c that connect the four submodules 100 in parallel are formed.

[0085] 12B, the second wiring 42a of the module row Ra and the first wiring 41b of the module row Rb are electrically connected by a third wiring 43. The third wiring (e.g., a tab wire) 43 may be connected to the second wiring 42a and the first wiring 41b by, for example, soldering. Similarly, the second wiring 42b of the module row Rb and the first wiring 41c of the module row Rc are connected by the third wiring 43. This connects the module rows Ra to Rc in series.

[0086] Next, the lead wire 21 is connected to the first wiring 41a of the leftmost module row Ra, and the lead wire 22 is connected to the second wiring 42c of the rightmost module row Rc. In this manner, a first substrate with submodules is formed.

[0087] In this example, at least one third wiring 43 is arranged between two submodules 100 adjacent in the X direction, but the number, arrangement (position in the Y direction) and so on of the third wiring 43 are not limited to the example shown in the figure.

[0088] ·Sealing process 13A to 13C are schematic cross-sectional views for explaining the sealing process, Fig. 13A shows a state in which submodules 100 are arranged on the first surface 11s of the first substrate 11 via the filler 31 by the method described above.

[0089] As shown in Fig. 13B, the second substrate 12 is disposed above the submodule 100 shown in Fig. 13A via a filler 32. For example, a filler sheet containing polyolefin is used as the filler 32. The fillers 31 and 32 may have a size larger than the central region 13 in which the submodule 100 is disposed in a plan view from the Z direction. In a plan view seen along the Z direction, the periphery of the filler sheet may be located between the outer edge of the central region 13 and the periphery of the first substrate 11 and the second substrate 12.

[0090] After this, lamination is performed. In lamination, as shown in FIG. 13C, the fillers 31 and 32 melt under reduced pressure and wrap around to cover the side surfaces of the submodule 100 (the side surfaces close to the edges of the first substrate 11), and the first substrate 11 and the second substrate 12 are bonded together. This makes it difficult for an air layer to remain near the side surfaces of the submodule 100, thereby suppressing the influence of air on the solar cell layer. As shown in the figure, the entire side surfaces of the submodule 100 may be covered with the fillers 31 and 32. Next, a sealing member (e.g., butyl rubber) 50 is disposed between the first substrate 11 and the second substrate 12 outside the central region 13, thereby sealing the space between the first substrate 11 and the second substrate 12. The sealing member 50 is disposed, for example, so as to surround the central region 13. The sealing member 50 may be disposed outside the fillers 31 and 32. In this manner, the power generation module 1 is manufactured.

[0091] In the above, sealing member 50 is disposed and sealed after lamination, but lamination may be performed after sealing member 50 is disposed and sealed.

[0092] (Submodule light transmittance setting) As described above, in this embodiment, the light transmittance of the submodules can be adjusted by the total area of ​​the solar cell film removed when manufacturing each submodule.

[0093] FIG. 14 is a schematic diagram showing the relationship between the solar cell membrane removed area ratio and power generation section area ratio of the submodule and the light transmittance in the thickness direction (Z direction) of the submodule.

[0094] The "light transmittance" on the vertical axis of the graph shown in FIG. 14 is the light transmittance excluding the wiring (tab wires) formed on both ends of the submodule. The "solar cell film removal area rate" is the ratio of the area of ​​the solar cell film removed by laser processing or the like to the main surface of the base substrate. A solar cell film removal area rate of 0% refers to a state in which the solar cell film is formed on the entire main surface of the base substrate. The power generation area rate at this time is, for example, 100%. A solar cell film removal area rate of 100% refers to a state in which the solar cell film has been removed from the entire main surface of the base substrate and no solar cell film remains, and the power generation area rate is 0%.

[0095] As can be seen from FIG. 14, the light transmittance increases as the area of ​​the solar cell film removed increases. In other words, the light transmittance increases as the power generation section area ratio decreases. The light transmittance of the submodule when all of the solar cell film is removed is approximately 100%, not taking into account the light transmittance of the first and second substrates. The relationship between the light transmittance and the solar cell film removal area ratio shown in FIG. 14 is one example, and may vary depending on the material, thickness, and formation method of the solar cell film, the structure of the power generation section, etc.

[0096] By utilizing the relationship shown in FIG. 14, it is possible to set the light transmittance for each submodule.

[0097] 15 is a flowchart showing an example of a method for setting the light transmittance of a submodule. Here, an example will be described in which a submodule is designed with the width of each string being constant.

[0098] First, the light transmittance (target value) of the submodule is set according to requirements such as the use, design, and power generation capacity (power generation efficiency per unit area) of the power generation module (STEP 1).

[0099] Next, the total removal area of ​​the solar cell film is set based on the target value of the light transmittance (STEP 2). For a solar cell film made of the same material as the solar cell film used in the submodule, the relationship between the solar cell film removal area rate and the light transmittance as shown in FIG. 14 may be obtained in advance. The removal area can be set based on that relationship.

[0100] Next, the number of strings is set based on the area to be removed (STEP 3). Furthermore, the area of ​​the solar cell film to be removed by one laser irradiation (i.e. the area of ​​the region between the strings) is set (STEP 4). Based on this setting, data for the laser processing machine (laser irradiation position, irradiation width, etc.) is set (STEP 5).

[0101] In the above method, the string width is designed to be constant, but the width of the inter-string region may be designed to be constant. Alternatively, the arrangement pitch of the strings may be designed to be constant. The string width is determined based on the non-irradiated width wT shown in Figures 10A to 10C, for example. The inter-string region width is determined based on the irradiated width wL shown in Figures 10A to 10C.

[0102] (Example of string structure for the first and second sub-modules) An example of a string structure will be described with reference to Figures 16 to 18. Figures 16 to 18 are schematic enlarged top views of two adjacent submodules 101 and 102. In these figures, wiring is omitted from the illustration.

[0103] The string structures shown in Figs. 16 to 18 are referred to as the first string structure to the third string structure, respectively. An overview of each structure is shown in Table 1. Table 1 shows the relationship between the string width ws1, the width of the inter-string region (inter-string region width) wp1, the number of strings (total number) N1, and the arrangement pitch pt1 of the first submodule 101, and the string width ws2, the width of the inter-string region wp2, the number of strings N2, and the arrangement pitch pt2 of the second submodule 102 in each structure. The "arrangement pitch" here is the distance between the upper ends of two strings 120 adjacent in the Y direction, and is a distance equivalent to the sum of the string width and the inter-string region width.

[0104] [Table 1]

[0105] According to the first string structure, by making the string widths ws1 and ws2 of the submodules 101 and 102 the same, it is possible to make the power generation output of each string 120 in the submodules 101 and 102 the same.

[0106] The second string structure has the advantage that by making the inter-string region widths wp1, wp2 of the submodules 101, 102 the same, the two submodules 101, 102 can be manufactured under the same processing conditions (laser irradiation width) in the process of processing the solar cell film.

[0107] In the third string structure, the arrangement pitch pt of the strings 120 is constant in the two submodules 101 and 102, but the string width and the width of the inter-string region are different from each other. This makes it easier to design each submodule.

[0108] In the first to third string structures, the string area ratio is constant for each pitch in each of the submodules 101, 102. As illustrated in Fig. 16, the "string area ratio" refers to the ratio of the area S2 of a string 120 to the total area S1 of the string 120 and the inter-string region 130 adjacent to the string 120 in the second direction (e.g., the -Y direction). For this reason, when the arrangement pitches pt1, pt2 are sufficiently small with respect to the length of the main surface in the Y direction, the light transmittance in each of the submodules 101, 102 is approximately uniform.

[0109] The first string structure to the third string structure can be applied to a module row Ra (FIG. 7) including three or more submodules 101-103 arranged in the Y direction. This makes it possible to change the light transmittance in the Y direction in the module row Ra, as shown by line 90 in FIG. 27. That is, in this embodiment, a gradation is formed not in each submodule but in the entire module row Ra.

[0110] The configuration of the power generation module in this embodiment is not limited to the illustrated example. For example, in the top view shown in FIG. 2, the Y direction may be the width direction of the window, and the X direction may be the height direction of the window. The power generation section of the power generation module 1 may have at least one solar cell element, and may not have a solar cell element string structure. Each submodule 100 may be electrically connected to at least one other submodule, and the wiring structure may be appropriately selected. In the illustrated example, the thickness, shape (size), and material of the multiple submodules 100 constituting the power generation module 1 are all the same, but may be different. Furthermore, the sealing structure between the submodule 100 and the first substrate 11 and the second substrate 12, the structure of the filler, and the like may be appropriately changed.

[0111] The shape and material of each component of the power generation module are not particularly limited. For example, the first substrate 11, the second substrate 12, or the base substrate 110 of the submodule 100 is not limited to a glass substrate, and may be a transparent resin substrate such as an acrylic substrate. In the above embodiment, the solar cell layer PV containing a perovskite compound is used, but the solar cell layer PV may be a layer containing other known photoelectric conversion materials, such as a thin-film silicon-based semiconductor layer of amorphous silicon or microcrystalline silicon, a compound semiconductor layer of CIS or CIGS, or an organic semiconductor layer.

[0112] The configuration of the submodule 100 is not limited to the illustrated example. The multiple strings 120 may extend from one end side to the other end side of the base substrate, and may not necessarily extend along the X direction. For example, as illustrated in FIG. 19A, some or all of the strings 120 may extend obliquely with respect to the Y direction. Alternatively, as illustrated in FIG. 19B, some or all of the strings 120 may extend in a curved shape.

[0113] (effect) Thus, the power generating module 1 includes a plurality of submodules 100. The plurality of submodules 100 include a first submodule 101 and a second submodule 102 arranged adjacent to each other in a plan view seen along the first direction. Each of the plurality of submodules 100 includes a light-transmitting base substrate 110 and a power generating unit located on a part of a main surface 110s of the base substrate 110. The power generating unit includes at least a solar cell layer PV supported by the main surface 110s. In a plan view, the area ratio of the power generating unit to the main surface 110s in the first submodule 101 (power generating unit area ratio) is smaller than the area ratio of the power generating unit to the main surface 110s in the second submodule 102.

[0114] Since the power generating module 1 includes two sub-modules 101 and 102 with different power generating area ratios, the function, design, etc. can be changed depending on the position, thereby increasing the degree of freedom in design. More specifically, as the power generation area ratio of each submodule 100 increases, the power generation efficiency per unit area increases, but the light transmittance may decrease. For this reason, by making the power generation area ratios of the two submodules 101 and 102 different, not only the power generation efficiency per unit area but also the light transmittance can be made different from each other. This makes it possible to design the power generation module 1 according to its intended use (such as the building material used and the environment in which it is used). Furthermore, the difference in light transmittance can be utilized to enhance the design.

[0115] Generally, a solar cell array is formed by arranging solar cells with the same structure (same power generation performance). In contrast, in this embodiment, a power generation module is formed by combining multiple sub-modules with different power generation section structures (power generation performance), thereby adding, for example, design.

[0116] In this embodiment, the power generating unit itself having a solar cell function is used to achieve the desired design or light transmittance, and there is no need to add a separate member. Therefore, it is possible to provide a power generating module with a high design quality while suppressing an increase in the manufacturing process and number of parts.

[0117] The power generation module 1 further includes a first substrate 11 having translucency and a second substrate 12 having translucency. The second substrate 12 is disposed so as to face the first substrate 11 in a first direction (Z direction). The multiple submodules 100 are located between the first substrate 11 and the second substrate 12. A main surface 110s of a base substrate 110 of the submodule 100 is disposed so as to face the second substrate 12, for example.

[0118] According to the above configuration, the power generation module 1 has a configuration in which the multiple sub-modules 100 are smaller than the first substrate 11 and the second substrate 12 and are arranged between the first substrate 11 and the second substrate 12, so that the power generation module 1 can accommodate building materials of various sizes by changing the number and arrangement of the sub-modules 100.

[0119] Furthermore, in the power generation module 1, the first substrate 11, the second substrate 12, and the base substrate 110 are translucent and can transmit light in a first direction of the power generation module 1. Therefore, the power generation module 1 can be suitably applied to applications requiring high visible light transmittance, such as building material-integrated solar cells for building windows.

[0120] In each of the first submodule 101 and the second submodule 102, the power generating section may include a plurality of strings 120 supported on the main surface 110s of the base substrate 110. Each of the plurality of strings 120 is a solar cell element string 120 having a structure in which a plurality of solar cell elements 150 are connected in series. In a plan view seen along the first direction, each of the plurality of strings 120 extends from one end side to the other end side of the base substrate 110. With the above configuration, in each of the submodules 101, 102, it is possible to design the transmittance and realize a desired design by changing the number, arrangement, etc. of the strings 120.

[0121] The first submodule and the second submodule are adjacent to each other in a second direction in a plan view, and each of the first submodule 101 and the second submodule 102 may further include a first wiring 141 arranged on one end side of the base substrate 110 and a second wiring 142 arranged on the other end side of the base substrate 110. In each of the first submodule 101 and the second submodule 102, the multiple strings 120 may be arranged at a distance from each other in the second direction. Each of the multiple strings 120 may extend from the first wiring 141 to the second wiring 142 in a third direction (X direction) intersecting the second direction.

[0122] According to the above configuration, the multiple strings 120 in each of the submodules 101 and 102 are connected in parallel. This makes it possible to reduce the effect of differences in power generation performance due to differences in string width on the power generation performance of the submodules, even when strings 120 with different widths are formed (see the embodiment described later).

[0123] In at least one of the first submodule 101 and the second submodule 102, the multiple strings 120 may be arranged at equal intervals in the second direction in a plan view along the first direction. With the above configuration, in the processing step of the solar cell film when manufacturing the submodule, laser processing for forming the multiple strings 120 can be performed with the processing conditions (irradiation width wL of the laser light LB) set to a constant value.

[0124] The multiple submodules 100 may further include a third submodule 103 located on the opposite side of the second submodule 102 to the first submodule 101 in the second direction. In a plan view seen along the first direction, the area ratio of the power generation section to the main surface 110s in the second submodule 102 may be smaller than the area ratio of the power generation section to the main surface 110s in the third submodule 103. With the above configuration, it becomes possible to change the light transmittance in the second direction in a module row including the submodules 101 to 103 (see line 90 in FIG. 27).

[0125] The multiple submodules 100 may further include a fourth submodule 104. In a plan view seen along the first direction, the fourth submodule 104 is disposed adjacent to the first submodule 101 in a third direction intersecting the second direction. In a plan view seen along the first direction, an area ratio of the power generating section to the main surface 110s in the fourth submodule 104 may be equal to an area ratio of the power generating section to the main surface 110s in the first submodule 101.

[0126] The fourth submodule 104 does not need to be designed exclusively for it, and may be the same as the first submodule 101. In that case, there is no need to design an area ratio for the fourth submodule, and it is sufficient to arrange the same one as the first submodule 101. In addition, the strings 120 of the first submodule 101 and the fourth submodule 104 are arranged on the first substrate 11 so as to be substantially in a straight line in the X direction. This makes it possible to make the transmittance constant in the X direction. Furthermore, a sense of unity in the design can be achieved as a power generation module.

[0127] The above configuration makes it possible to make the light transmittance of the power generation module 1 constant in the third direction (X direction). This makes it possible to realize a unified design, particularly when the power generation module 1 is applied to a building material with a large area. In addition, it is possible to make the current capacity of the first submodule 101 and the fourth submodule 104 the same, which is particularly advantageous when these submodules are connected in series.

[0128] The first submodule 101 and the second submodule 102 may be connected in parallel. This can increase the output current. Also, compared to the case where these submodules 101 and 102 are connected in series, the effect on the power generation performance of the power generation module 1 caused by the difference in the power generation performance area ratio between the submodules 101 and 102 can be reduced.

[0129] The multiple submodules 100 may form a solar cell array. For example, the power generation module 1 includes multiple module rows Ra to Rc. Each module row includes at least a first submodule 101 and a second submodule 102, and extends in a second direction in a plan view along the first direction. The multiple module rows Ra to Rc are arranged in a third direction (X direction) intersecting the second direction, and are connected in series. With the above configuration, the maximum current and maximum voltage of the power generation module 1 can be set within a desired range by combining series connection and parallel connection.

[0130] The solar cell layer PV may contain, for example, a perovskite compound. A solar cell film (perovskite film) containing a perovskite compound can be easily formed by a coating technique such as an inkjet method or a spin coating method. In addition, the perovskite film applied on the substrate can be easily processed into a fine shape by, for example, laser processing, and the like, and the design can be further improved. As a result, a precise gradation is easily formed by the multiple strings 120. In this way, by using a layer containing a perovskite compound as the solar cell layer PV, the degree of freedom in design can be further increased. Therefore, it can be more suitably applied to a building material-integrated solar cell.

[0131] According to this embodiment, the process of forming the submodule 100 includes a film forming process of forming a laminated film 170 including a solar cell film on the main surface 110s of the light-transmitting base substrate 110, and a film processing process of processing the laminated film 170 to form a power generating section (e.g., a plurality of strings 120) including a solar cell layer PV on a part of the main surface 110s. The film processing process includes a laser processing process of removing a part of the solar cell film from the main surface 110s by laser processing, whereby the part of the solar cell film that has not been removed becomes the solar cell layer PV of the power generating section. In the laser processing process, the removed area of ​​the solar cell film relative to the area of ​​the main surface 110s is made different between the first submodule 101 and the second submodule 102.

[0132] According to the above method, it is possible to manufacture a power generation module 1 including two submodules 101 and 102 having different removal area ratios of the solar cell film, i.e., different area ratios of the solar cell layer PV constituting the power generation section. The light transmittance of the submodules 101 and 102 can vary depending on the removal area ratios of the solar cell film. Therefore, according to the above method, two submodules having different light transmittances can be easily manufactured by only changing the laser processing conditions (e.g., the irradiation width wL and non-irradiation width wT of the laser light LB). Furthermore, various designs can be realized by changing the combination and arrangement of submodules having different light transmittances. For example, it is also possible to manufacture a power generation module by selecting and combining submodules according to customer requests. Therefore, it is possible to manufacture a power generation module with excellent design while suppressing the increase in the number of manufacturing steps and manufacturing costs.

[0133] Second Embodiment A power generation module according to a second embodiment of the present disclosure will be described below. The power generation module of this embodiment differs from the first embodiment in that, in at least one submodule, multiple strings are arranged to form a gradation. Below, differences from the first embodiment will be mainly described, and overlapping descriptions will be omitted as appropriate.

[0134] FIG. 20 is an enlarged top view showing one sub-module in the second embodiment of the present disclosure.

[0135] 20, in the submodule 100, the multiple strings 120 are arranged to form a gradation in which the inter-string region width wp gradually changes along the Y direction. The widths (string widths) of the strings 120 may be the same or different. The gradation can also be formed by gradually changing the string width, string area ratio, etc. within one submodule, as described later.

[0136] According to this embodiment, by forming a gradation in the strings 120, the power generation area ratio of the submodule, and therefore the light transmittance, can be set.

[0137] (Example of string structure for the first and second sub-modules) A gradation may be formed across two adjacent sub-modules. Design examples of the string structure will be described with reference to Figs.

[0138] 21 to 23 are schematic enlarged top views of two adjacent submodules 101 and 102. In these figures, wiring is omitted.

[0139] 21 to 23, the power generation area ratio of the submodule 101 is smaller than the power generation area ratio of the submodule 102. Also, along the direction from the submodule 101 to the submodule 102 (-Y direction), a gradation is formed in which the string area ratio (S2 / S1 shown in FIG. 21) gradually increases.

[0140] The string structures shown in Figures 21 to 23 are referred to as the fourth string structure to the sixth string structure, respectively. An overview of each structure is shown in Table 2. "Gradually decreasing (or increasing)" in Table 2 means gradually decreasing (or increasing) in the -Y direction.

[0141] [Table 2]

[0142] In the fourth string structure, the inter-string region width wp is set to gradually decrease along the second direction (here, the -Y direction) from the submodule 101 to the submodule 102. Since the string width (width of the power generating section) ws is constant, it is possible to make the power generation output of the multiple strings 120 the same.

[0143] In the fifth string structure, the string width ws is set to gradually increase along the second direction (here, the -Y direction) from the submodule 101 to the submodule 102. Since the inter-string region width wp is constant, it is advantageous in that it is not necessary to change the processing conditions (laser irradiation width) for each string when processing the solar cell film. Also, each of the submodules 101 and 102 has a structure in which multiple strings 120 with different string widths (solar cell element widths) ws are connected in parallel. In this way, by intentionally combining multiple strings (multiple solar cell elements) with different power generation section structures (power generation performance) to form a submodule, design is added to the submodule.

[0144] In the sixth string structure, the string arrangement pitch pt is constant from the submodule 101 to the submodule 102. By changing both the string width ws and the inter-string region width wp, the string area ratio is set to gradually increase along the second direction.

[0145] According to the fourth to sixth string structures, the strings 120 of the submodule 101 are arranged so that the string area ratio increases toward the submodule 102. On the other hand, the strings 120 of the submodule 102 are arranged so that the string area ratio increases toward the submodule 101. The minimum string area ratio of the submodule 102 is greater than the maximum string area ratio of the submodule 101. This makes it possible to form a gradation across the submodules 101 and 102.

[0146] (How to set the light transmittance of the sub-module) In this embodiment, the light transmittance of each submodule can be set in a manner similar to that described with reference to Figures 14 and 15. However, in order to form a gradation, the string width ws and / or the inter-string region width wp are set according to the position on the main surface of the base substrate (the position in the second direction).

[0147] In the examples shown in Figures 21 to 23, the string width, etc. are changed for each string, but the main surface 110s of the base substrate 110 may be divided into multiple regions in the second direction, and the string width, inter-string region width, etc. may be made different for each region.

[0148] Table 3 shows a design example of the sixth string structure. In this example, as shown in Fig. 24, the main surface 110s of the base substrate 110 is divided into a plurality of regions r1 to r5 in the second direction, and the string width ws and the inter-string region width wp of each region are set. In Table 3, the widths ws and wp are shown as a ratio to the arrangement pitch pt.

[0149] [Table 3]

[0150] (Module column gradient) When the fourth to sixth string structures (FIGS. 21 to 23) are applied to a module row having, for example, three or more submodules, a gradation can be formed in which the string area ratio changes in one direction in the module row (including not only within each submodule but also between the submodules). Therefore, each submodule has a gradation, and multiple (e.g., three) submodules as a whole can have a gradation that incorporates the individual gradations.

[0151] 25 and 26 are schematic top views illustrating an example of a module row gradation. These figures illustrate a module row Ra including submodules 101 to 103. In the module row Ra, a gradation is formed from the upper end of submodule 101 to the lower end of submodule 103.

[0152] In the example shown in FIG. 25, the arrangement pitches pt1, pt2, and pt3 and the numbers of strings N1, N2, and N3 in the submodules 101 to 103 satisfy the following relationships. pt1=pt2=pt3 N1=N2=N3 (here, 15) In the module row Ra, the string width ws increases gradually (here, in 45 steps) along the second direction (here, the -Y direction). The inter-string region width wp decreases gradually along the second direction. This forms a gradation in which the string area ratio gradually increases along the second direction.

[0153] In the example shown in FIG. 25, the string area ratio changes regularly (or quasi-regularly) in the second direction across the module row Ra. Therefore, as shown in FIG. 27 by a line 91, the light transmittance can be smoothly increased across the submodules 101 to 103 in the module row Ra. For example, the change in the string area ratio in a portion spanning two adjacent submodules is approximately the same as the change in the string area ratio in each submodule. The string area may change regularly in the portion spanning two submodules as well. Note that in FIG. 27, the change in the string area ratio that changes stepwise for each pitch is shown by a pseudo straight line, assuming that the string width and interval are sufficiently small compared to the size of the base substrate.

[0154] In the module row Ra shown in FIG. 26, the arrangement pitches pt1 to pt3 and the numbers of strings N1 to N3 in the submodules 101 to 103 satisfy the following relationship. pt1>pt2>pt3 N1 <N2<N3 In each of the submodules 101 to 103, the strings 120 are arranged at equal pitches. The string width ws gradually increases along the second direction (here, the -Y direction), and the inter-string region width wp gradually decreases along the second direction. This module row Ra can be said to be, for example, a configuration in which the string width is changed is applied to the submodules 101 to 103 shown in FIG. 7.

[0155] In the example shown in Fig. 26, each of the submodules 101 to 103 has a gradation, and the string area ratio changes rapidly between adjacent submodules. For example, the change in the string area ratio in the portion straddling two adjacent submodules is larger than the change in the string area ratio within each submodule. Therefore, as shown in Fig. 27 by a line 92, the change in the light transmittance in the module row is larger between two adjacent submodules than within these two submodules.

[0156] Although only three submodules 101-103 are shown in Figs. 25 and 26, a module row having a gradation may be formed by four or more submodules. Furthermore, a plurality of module rows having the same gradation structure may be arranged in the X direction. Furthermore, the gradation of this embodiment may be formed in one region spanning a plurality of submodules. For example, the gradation may be formed only in the lower portion of the first submodule and the upper portion of the second submodule in a plan view.

[0157] (Submodule manufacturing method) The submodule having the gradation can be manufactured by the same method as the above-mentioned embodiment, except for the film processing step of processing the solar cell film. Hereinafter, the film processing step in this embodiment will be described with reference to Figures 10A to 10C, focusing on the differences from the above-mentioned steps, and the same description will be omitted as appropriate.

[0158] 28A to 28C are schematic cross-sectional views illustrating steps in a method for processing a laminated film including a solar cell film.

[0159] 28A to 28C are applied to a configuration in which the inter-string region width is gradually changed (see FIG. 21). This method differs from the method shown in FIGS. 10A to 10C in that the irradiation width (irradiation range) is set so that the width of the laminated film to be removed gradually increases (or decreases).

[0160] As shown in FIG. 28A, the laser light LB is scanned in the X direction to irradiate the laminated film 170 with the laser light LB at an irradiation width wL1. This removes the irradiated portion of the laminated film 170. Next, as shown in FIG. 28B, the irradiation position of the laser light LB is shifted in the Y direction by a predetermined distance (non-irradiation width) wT, and the laminated film 170 is irradiated with the laser light LB at an irradiation width wL2 (wL2>wL1) larger than the irradiation width wL1. As shown in FIG. 28C, the laminated film 170 is processed while shifting the irradiation position at equal intervals in the Y direction and changing the irradiation width. In this way, a gradation is formed on the main surface 110s in which the intervals between the strings 120 gradually change in the Y direction.

[0161] 29A to 29C are schematic cross-sectional views illustrating steps in another method for processing a laminated film including a solar cell film.

[0162] 29A to 29C is applied to a configuration in which the string width is gradually changed (see FIG. 22). This method differs from the method shown in FIGS. 10A to 10C in that the laminated film is processed while changing the moving distance (non-irradiation width) of the laser head.

[0163] Specifically, as shown in Fig. 29A, first, the laser light LB is scanned in the X direction to irradiate the laminated film 170 with the laser light LB at an irradiation width wL, and the irradiated portion of the laminated film 170 is removed. Next, as shown in Fig. 29B, the irradiation position of the laser light LB is shifted in the Y direction by a predetermined distance (non-irradiation width) wT1, and the laminated film 170 is irradiated with the laser. Next, as shown in Fig. 29C, the irradiation position of the laser light LB is shifted in the Y direction by a non-irradiation width wT2 larger than the non-irradiation width wT1, and laser irradiation is performed. This forms a gradation in which the width of the string 120 gradually changes.

[0164] <Effects, etc.> In this embodiment, in each of the multiple submodules 100, the main surface 110s of the base substrate 110 includes multiple inter-string regions 130 located between two adjacent strings 120. At least the string 120 of the first submodule 101 may be configured, for example, as follows. The multiple strings 120 are arranged at a distance from each other in the second direction such that at least one of the string width ws, the inter-string region width wp, and the string area ratio S2 / S1 form a gradation that gradually changes along the second direction. In a plan view seen along the first direction, the string width ws is the width of each string 120 along the second direction. The inter-string region width wp is the width of each inter-string region 130 along the second direction. The string area ratio S2 / S1 is the ratio of the area S2 of each string 120 to the total area S1 of each string 120 and the inter-string regions 130 adjacent to that string 120 in the second direction in a plan view seen along the first direction.

[0165] According to the above configuration, the first submodule 101 has a gradation along the second direction (Y direction), so that the design of the power generation module 1 can be further improved.

[0166] The multiple submodules 100 may further include a third submodule 103 located on the opposite side of the second submodule 102 from the first submodule 101 in the second direction (Y direction). A string 120 of these submodules 101 to 103 may be configured, for example, as follows. In each of the submodules 101 to 103, the multiple strings 120 are arranged such that at least one of the string width ws, the inter-string region width wp, and the string area ratio S2 / S1 gradually increases along the second direction. A gradation is formed from the submodule 101 across the submodule 102 to the submodule 103 in which at least one of the string width ws and the inter-string region width wp gradually increases along the second direction.

[0167] According to the above configuration, a gradation is formed in each of the submodules 101 to 103, and a gradation is also formed across the submodules 101 to 103. This allows the design of the power generation module 1 to be further improved.

[0168] The multiple submodules 100 may further include a fourth submodule 104. The fourth submodule 104 is arranged adjacent to the first submodule 101 in a third direction (X direction) intersecting the second direction (Y direction) in a plan view seen from the first direction (Z direction). The multiple strings 120 of the fourth submodule 104 may be arranged to form a gradation similar to that of the first submodule 101. With the above configuration, a gradation with a sense of unity can be formed over a wider range.

[0169] Furthermore, in this embodiment, the gradation is formed by laser processing the solar cell film. Therefore, by changing the laser processing conditions (irradiation width, non-irradiation width), it is possible to manufacture sub-modules with various gradations.

[0170] Overview of the embodiment <1> The method for producing a power generation module according to the present disclosure includes: A method for manufacturing a power generation module including a first submodule and a second submodule, comprising: preparing a plurality of base submodules each having a laminated film including a solar cell film formed on a main surface of a base substrate; A process for processing the base sub-module, comprising the steps of: forming a first submodule by removing a portion of the solar cell film from the main surface of one of the base submodules under a first processing condition, the portion of the solar cell film that is not removed being a solar cell layer of a power generation section; forming a second submodule by removing a portion of the solar cell film from the main surface under second processing conditions different from the first processing conditions in another of the base submodules, and using the portion of the solar cell film that is not removed as the solar cell layer of the power generation unit; making the first submodule and the second submodule have different areas from each other in terms of the area of ​​the main surface from which the solar cell film is removed; and placing the first sub-module and the second sub-module adjacent to each other. <2> <1> In the method for producing the power generation module according to the present invention, and bonding a first substrate and a second substrate together with the first sub-module and the second module sandwiched therebetween. <3> <1> or <2> In the method for producing the power generation module according to the present invention, In a plan view, the first submodule, the second submodule, and the third submodule are aligned in the second direction. <4> <1> from <3> 2. The method for producing a power generation module according to claim 1, A fourth submodule, having the same power generation area ratio as the first submodule, is disposed relative to the first submodule in a direction (third direction) perpendicular to the second module. <5> <1> from <4> 2. The method for producing a power generation module according to claim 1, The strings of adjacent submodules in the third direction (X direction) are aligned. For example, the strings of the first submodule and the strings of the fourth submodule are aligned (almost in a straight line) in the horizontal direction (X direction). <6> <1> from <5> 2. The method for producing a power generation module according to claim 1, The strings of the first and second submodules are parallel to the third direction (X direction) and extend in a line from one end to the other of the base substrate. <7> <1> from <6> 2. The method for producing a power generation module according to claim 1, Within the submodule, one end of the strings and the other end of the strings (the right ends (- / +) of the strings and the left ends (+ / -) of the strings) are connected by wiring. <8> <1> from <7> 2. The method for producing a power generation module according to claim 1, The wiring adjacent to each other in the third direction (X direction) is connected to each other. One end of the submodule is electrically connected to the other end of another submodule adjacent to the submodule in the third direction. The above wirings are connected to each other by wiring 43. <9> <1> from <8> 2. The method for producing a power generation module according to claim 1, The sub-modules are connected to each other by wiring (also in the second direction (Y direction)). The sub-modules are connected to each other by wiring 41. <10> <1> from <9> 2. The method for producing a power generation module according to claim 1, The solar cell film comprises a perovskite compound, The perovskite in the laminated film is formed by coating, and in the film processing process, strings are formed by laser processing. <11> <1> from <10> In the method for manufacturing a power generation module described in any one of the above, a lead wire 21 on one end side of a submodule extends outward from the first substrate, and a lead wire 22 on the other end side of the same or a different submodule also extends outward from the first substrate. The pair of lead wires 21, 22 form +side / -side lead wires. [Industrial Applicability]

[0171] INDUSTRIAL APPLICABILITY The power generating module according to the present disclosure is useful as a power generating module that can be applied to building material-integrated solar cells, for example, windows of buildings, such as power generating glass. [Explanation of symbols]

[0172] 1 Power generation module 11 First board 11s 1st page 12 Second board 13 Central area 21, 22 Lead wire 31 First filler 32 Second filler 41, 41a to 41c First wiring 42, 42a~42c Second wiring 43 3rd wiring 50 Sealing member 100 Submodules 101 First Submodule 102 Second submodule 103 Third Submodule 104 4th Submodule 110 Base board 110s Base substrate main surface 120 String 130 Interstring area 141, 142 Wiring 150 Solar cell element 151 Lower transparent electrode 153 Semiconductor Layer 155 Upper transparent electrode 160 Separation groove 170 Laminated Film LB laser light LE Lower transparent conductive layer PV solar cell layer UE upper transparent conductive layer pt, pt1~pt3 Array pitch R1~R3 ​​module row Ra~Rd module row ws String width wp Interstring area width wL, wL1, wL2 irradiation width wT, wT1, wT2 Non-illuminated width

Claims

1. A method for manufacturing a power generation module including a first sub-module and a second sub-module, comprising the steps of: preparing a plurality of base submodules each having a laminated film including a solar cell film formed on a main surface of a base substrate; A process for processing the base sub-module, comprising the steps of: forming a first submodule by removing a portion of the solar cell film from the main surface of one of the base submodules under a first processing condition, the portion of the solar cell film that is not removed being a solar cell layer of a power generation unit; forming a second submodule by removing a portion of the solar cell film from the main surface under second processing conditions different from the first processing conditions in another of the base submodules, and using the portion of the solar cell film that is not removed as the solar cell layer of the power generation unit; making the first submodule and the second submodule have different areas from each other in terms of the area of ​​the main surface from which the solar cell film is removed; and disposing the first sub-module and the second sub-module adjacent to each other.

2. The method for manufacturing a power generating module according to claim 1 , further comprising the step of bonding a first substrate and a second substrate together with the first sub-module and the second module sandwiched therebetween.

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