Solar cell module and method for manufacturing the same

Abstract

To provide a solar cell module having high durability and a method of manufacturing the same.SOLUTION: The solar cell module 100 includes a conductive layer 2 disposed on a substrate 1, a perovskite solar cell element 3 disposed on the conductive layer 2, an electrode 4 disposed on the perovskite solar cell element 3, and a sealing material layer 5 that seals the perovskite solar cell element 3 and the electrode 4. The glass layer 53 includes a covering portion 531 that covers the base layer 51, an adhesive portion 532 that adheres to the conductive layer 2 at the outer edge of the base layer 51, and a sealing portion 533 that is formed between the conductive layer 2 and the base layer 51 and seals a space therebetween, and the covering portion 531, the adhesive portion 532, and the sealing portion 533 are continuously formed.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a solar cell module and a method for manufacturing the same. [Background technology]

[0002] Solar cell modules having perovskite solar cell elements that convert solar light energy into electrical energy have attracted attention because they have higher energy conversion efficiency than other solar cell modules, are lightweight, etc. However, perovskite solar cell elements have the problem of being easily deteriorated by oxygen, water, etc., and various technologies have been proposed to address this problem (see, for example, Patent Document 1).

[0003] Patent Document 1 describes a solar cell module including a perovskite solar cell element provided on a conductive layer, a base layer (called an adhesive layer in Patent Document 1) covering the perovskite solar cell element, and a sealant layer covering the base layer. The outer edge of the sealant layer is adhered to the conductive layer by a sealing portion, thereby sealing the perovskite solar cell element. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2023-38868 Summary of the Invention [Problem to be solved by the invention]

[0005] When sealing perovskite solar cell elements to protect them, it is necessary to strengthen the adhesion between the sealing material layer and the conductive layer. However, when the sealing material layer and the conductive layer are bonded by applying a sealing material to the outer edge and periphery of the sealing material layer, as in Patent Document 1, the sealing area becomes large, which poses a problem of reducing the power generation efficiency per unit area of ​​the solar cell module.

[0006] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a solar cell module that is highly durable while suppressing a decrease in power generation efficiency, and a method for manufacturing the same. [Means for solving the problem]

[0007] A solar cell module according to the present invention is characterized in that it comprises an electrically conductive layer disposed on a substrate, perovskite solar cell elements disposed on the conductive layer, electrodes disposed on the perovskite solar cell elements, and a sealant layer that seals the perovskite solar cell elements and the electrodes, wherein the sealant layer has a solvent-resistant base layer and a glass layer disposed on the base layer, and the glass layer has a covering portion that covers the base layer, an adhesive portion that adheres to the conductive layer at the outer edge of the base layer, and a sealing portion formed between the conductive layer and the base layer to seal the space between them, and the covering portion, adhesive portion, and sealing portion are formed continuously.

[0008] According to this configuration, the perovskite solar cell elements and electrodes are sealed by the sealing material layer having a glass layer, which isolates them from the atmosphere and improves the durability of the solar cell module. In particular, the glass layer has a covering portion that covers the base layer, an adhesive portion that adheres to the conductive layer at the outer edge of the base layer, and a sealing portion that seals between the conductive layer and the base layer, and these are formed continuously, so that the perovskite solar cell elements and electrodes are reliably covered by the glass layer and the intrusion of water and the like from the outside can be suppressed. Therefore, there is no need to seal the outer edge of the sealing material layer with a sealing material, resulting in a solar cell module that is highly durable while suppressing an increase in the sealing area.

[0009] A characteristic configuration of the manufacturing method of the solar cell module according to the present invention includes a first step of forming a solar cell by arranging an electrically conductive layer, a perovskite solar cell element, and an electrode on a substrate in this order; a second step of arranging an adhesive on the conductive layer at a position spaced from the perovskite solar cell element so as to surround the outer edges of the perovskite solar cell element; a third step of arranging a solvent-resistant base layer material on the adhesive so as to cover the perovskite solar cell element and the electrode, and pressing the base layer material and the adhesive together to form a base layer adhered to the conductive layer by the adhesive portion; and a fourth step of forming a glass layer on the base layer and the conductive layer, wherein the outer edge of the base layer after the third step is located outward from the outer edge of the adhesive portion, and in the fourth step, a part of the glass layer material that will become the glass layer penetrates between the base layer and the conductive layer by capillary action, forming a sealing portion that seals the space between them.

[0010] According to this configuration, in the second step, the base layer material is pressed against the adhesive placed on the conductive layer so as to surround the outer edge of the perovskite solar cell element, thereby forming an adhesive portion that seals the conductive layer and the base layer. Furthermore, after the third step, the outer edge of the base layer is located outward from the outer edge of the adhesive portion, so the base layer and the conductive layer are not adhered to each other outside the adhesive portion. Therefore, when the glass layer material is applied to the base layer and the conductive layer in the fourth step, a portion of the glass layer material penetrates between the base layer and the conductive layer from the outer edge of the base layer by capillary action, forming a sealing portion that seals the base layer and the conductive layer. This double-seals the perovskite solar cell element and electrodes with the adhesive portion and the glass layer, thereby improving the durability of the solar cell module. Furthermore, since a sealing portion that is continuous with the covering portion and the adhesive portion can be formed without using a complicated method, a highly durable solar cell module can be manufactured using a simple method. [Brief explanation of the drawings]

[0011] [Figure 1]1 is a schematic diagram showing the configuration of a solar cell module according to a first embodiment. [Figure 2] FIG. 1 is a schematic plan view of a solar cell module according to a first embodiment. [Figure 3] FIG. 4 is a schematic diagram showing the configuration of a solar cell module according to a second embodiment. [Figure 4] 10A and 10B are views showing a second step of the method for manufacturing a solar cell module according to the second embodiment. [Figure 5] 10A and 10B are views showing a third step of the method for manufacturing a solar cell module according to the second embodiment. [Figure 6] 10A and 10B are views showing a third step of the method for manufacturing a solar cell module according to the second embodiment. [Figure 7] FIG. 10 is a view showing a fourth step of the method for manufacturing a solar cell module according to the second embodiment. [Figure 8] FIG. 10 is a schematic diagram showing the configuration of a solar cell module according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] First Embodiment An embodiment of a solar cell module 100 according to the present invention will be described below with reference to the drawings. However, the present invention is not limited to the following embodiment, and various modifications are possible without departing from the spirit of the present invention.

[0013] [Schematic configuration of solar cell module] 1, the solar cell module 100 includes a solar cell 10 and an encapsulant layer 5. The solar cell 10 is formed by laminating a substrate 1, a conductive layer 2, a perovskite solar cell element 3, and an electrode 4 in this order. The solar cell module 100 may include a plurality of solar cells 10.

[0014] 〔substrate〕 The substrate 1 functions as a support for the perovskite solar cell element 3 and the electrode 4. The substrate 1 is a transparent glass substrate, a semi-transparent glass substrate, a transparent resin substrate, or the like, and has insulating properties. As shown in Figure 2, the substrate 1 has a rectangular shape when viewed along the Z direction.

[0015] As shown in FIG. 1, an electrically conductive conductive layer 2 is laminated on a substrate 1. The orientation of the solar cell module 100 during use is not particularly limited, but it is preferable that the solar cell module 100 be used so that light is incident on the Z2 side of the substrate 1. Hereinafter, the direction from the substrate 1 to the electrically conductive layer 2 will be referred to as the "Z1 direction" (an example of a lamination direction), the opposite direction will be referred to as the "Z2 direction," and the Z1 direction and the Z2 direction will be collectively referred to as the "Z direction." Furthermore, one of the directions perpendicular to the Z direction will be referred to as the "X direction," and the direction perpendicular to the Z direction and the X direction will be referred to as the "Y direction" (see FIG. 2). Note that FIG. 2 is a view of the solar cell module 100 shown in FIG. 1 as viewed along the Z2 direction.

[0016] [Conductive Layer] The conductive layer 2 is formed on the Z1 side surface of the substrate 1 by CVD (chemical vapor deposition), sputtering, or the like. In this embodiment, the conductive layer 2 is formed on the entire Z1 side surface of the substrate 1. The conductive layer 2 contains, for example, fluorine-doped tin oxide (FTO), tin oxide (TO), or the like as a material. The perovskite solar cell element 3 is disposed (stacked) on the conductive layer 2 (on the Z1 side surface).

[0017] [Perovskite solar cell element] The perovskite solar cell element 3 converts light energy into electrical energy. The perovskite solar cell element 3 has an electron transport layer 31, a photoelectric conversion layer 32, and a hole transport layer 33, which are arranged in this order along the Z1 direction. When viewed along the Z direction, the electron transport layer 31, the photoelectric conversion layer 32, and the hole transport layer 33 each have a rectangular shape, and in this embodiment, when viewed along the Z direction, the electron transport layer 31, the photoelectric conversion layer 32, and the hole transport layer 33 each have the same size (area).

[0018] The electron transport layer 31 is disposed on the Z1-side surface of the conductive layer 2. The electron transport layer 31 passes through (transports) electrons received from the photoelectric conversion layer 32 (described later). The electron transport layer 31 includes, as a material, a metal oxide such as titanium oxide, tin oxide, or zinc oxide. In this embodiment, the electron transport layer 31 includes an insulating layer 311 extending into the recess 21 formed by removing a portion of the conductive layer 2. The insulating layer 311 divides the conductive layer 2, which is in contact with the perovskite solar cell element 3, into two sections along the X direction. In the electron transport layer 31, electrons can move in the Z direction but have difficulty moving in directions perpendicular to the Z direction (the X and Y directions), restricting their movement between the two sections of the conductive layer 2 corresponding to each perovskite solar cell element 3. The electron transport layer 31 is sometimes referred to as a "blocking layer."

[0019] Since the substrate 1, the conductive layer 2, and the electron transport layer 31 are optically transparent, light such as sunlight and indoor light is guided to the photoelectric conversion layer 32 without being substantially absorbed (or without being absorbed) by the substrate 1, the conductive layer 2, and the electron transport layer 31.

[0020] The photoelectric conversion layer 32 absorbs light energy and converts it into electrical energy. Specifically, the photoelectric conversion layer 32 absorbs light and transfers excited electrons and holes to perform photoelectric conversion. The photoelectric conversion layer 32 includes a perovskite layer made of a perovskite compound. The photoelectric conversion layer 32 further includes a porous oxide semiconductor layer (for example, a porous titanium layer).

[0021] The hole transport layer 33 allows holes received from the photoelectric conversion layer 32 to pass through (transports holes). The hole transport layer 33 contains, for example, an organic compound such as chlorobenzene as a material. An electrode 4 is disposed on the hole transport layer 33 (on the Z1 side).

[0022] The electrode 4 is conductive and functions as a positive electrode. As shown in FIG. 1, the electrode 4 is disposed on (a part of) the Z1-side surface of the conductive layer 2, extending in the Z direction from the Z1-side surface of the hole transport layer 33, past each side surface of the perovskite solar cell element 3. The electrode 4 contains, for example, graphite, carbon black, carbon nanotubes, carbon nanofibers, carbon fibers, graphene, fullerene, or the like as a material. The electrode 4 may also be formed using a metal such as gold, platinum, silver, or copper, an alloy thereof, or an oxide conductor such as FTO or indium tin oxide (ITO).

[0023] A laminate formed by the perovskite solar cell element 3 and electrode 4 laminated on the conductive layer 2 of the substrate 1 in this manner is referred to as a solar cell 10. A solar cell module 100 may be formed by electrically connecting a plurality of solar cells 10.

[0024] Light, such as sunlight, enters the solar cell module 100 from the Z2 side of the substrate 1. When the light reaches the photoelectric conversion layer 32 via the substrate 1, the conductive layer 2, and the electron transport layer 31, it is absorbed in the photoelectric conversion layer 32, generating electrons and holes. The electrons generated in the photoelectric conversion layer 32 migrate to the conductive layer 2 (negative electrode) via the electron transport layer 31. At the same time, the holes generated in the photoelectric conversion layer 32 migrate to the electrode 4 (positive electrode) electrically connected to the hole transport layer 33. When a load (not shown) is connected between the conductive layer 2 and the electrode 4, the holes combine with the electrons that have traveled through the load. As a result, electricity is generated. Note that the electrons moving through the electron transport layer 31 move smoothly along the Z2 direction to reach the conductive layer 2, but as described above, the insulating layer 311 restricts their movement in a direction perpendicular to the Z direction. In other words, the solar cell module 100 is configured to prevent short circuits.

[0025] [Encapsulant layer] 1 and 2, the perovskite solar cell element 3 and the electrode 4 are sealed with a sealing material layer 5. This shields the perovskite solar cell element 3 and the electrode 4 from the atmosphere, improving the durability of the solar cell module 100.

[0026] The encapsulant layer 5 has a base layer 51 disposed on the Z1-side surface of the electrode 4, and a glass layer 53 disposed on the Z1-side surface of the base layer 51. As shown in FIG. 2 , when viewed along the Z direction, the base layer 51 and the glass layer 53 are each rectangular. Furthermore, the area of ​​the encapsulant layer 5 in a plan view (when viewed in the Z direction) is larger than the areas of the perovskite solar cell element 3 and the electrode 4, and the area of ​​the glass layer 53 in the encapsulant layer 5 is larger than the area of ​​the base layer 51. The perovskite solar cell element 3 and the electrode 4 are entirely covered by the base layer 51, and the base layer 51 is entirely covered by the glass layer 53.

[0027] The base layer 51 may be a transparent resin or the like that is solvent-resistant and heat-resistant, and for example, polyethylene terephthalate (PET) or the like can be used. When forming the glass layer 53, a solution in which a glass component is dissolved in a solvent such as ether is coated toward the Z1 side of the solar cell 10, and since the base layer 51 has solvent resistance, it can protect the perovskite solar cell element 3 and the electrode 4 from the solvent. Furthermore, since it has heat resistance, it can maintain durability even when the solar cell module 100 is subjected to a thermal cycle.

[0028] The glass layer 53 has a covering portion 531 that covers the base layer 51, an adhesive portion 532 that adheres to the conductive layer 2 at the outer edge of the base layer 51, and a sealing portion 533 that is formed between the conductive layer 2 and the base layer 51. Here, the outer edge of the base layer 51 refers to the region near the outer edge of the base layer 51. The adhesive portion 532 adheres to the conductive layer 2, and the sealing portion 533 seals the conductive layer 2 and the base layer 51, thereby preventing water and oxygen from penetrating into the sealant layer 5. Furthermore, because the covering portion 531, adhesive portion 532, and sealing portion 533 are formed continuously, the perovskite solar cell element 3 and the electrode 4 are reliably sealed by the glass layer 53.

[0029] The glass layer 53 may be made of polysilazane or the like. If the glass layer 53 is formed on the Z1-side surface of the base layer 51, the glass layer 53 can be formed with a uniform thickness regardless of the shape of the electrode 4, thereby preventing cracks in the glass layer 53 due to variations in thickness. The thicknesses (dimensions in the Z direction) of the covering portion 531 and the adhesive portion 532 in the glass layer 53 may be any value, but the thickness of the sealing portion 533 should be smaller than the thicknesses of the covering portion 531 and the adhesive portion 532. The thicknesses of the adhesive portion 532 and the sealing portion 533 should be 1 μm or less. If the thickness of the glass layer 53 is 1 μm or less, cracks in the glass layer 53 can be prevented. The sealing portion 533 should not be in contact with the perovskite solar cell element 3.

[0030] In this way, the perovskite solar cell elements 3 and the electrodes 4 are sealed by the glass layer 53, eliminating the need for adhesives or the like to seal the edges of the sealing material layer 5, making it possible to reduce the manufacturing cost and improve manufacturing efficiency of the solar cell module 100. Furthermore, the sealing material layer 5 in this embodiment does not contain a conductive material such as metal foil, and therefore short circuits between the sealing material layer 5 and the solar cell 10 can be prevented.

[0031] [Method for manufacturing solar cell module] Next, a description will be given of a method for manufacturing the solar cell module 100. The method for manufacturing the solar cell module 100 in this embodiment includes a first step of forming the solar cell 10, a third step of forming the base layer 51 on the solar cell 10, and a fourth step of forming the glass layer 53 on the base layer 51 and the conductive layer 2.

[0032] First, a first step is carried out to form a solar cell 10. In the first step, a conductive layer 2 is formed on the Z1 side surface of the substrate 1. The conductive layer 2 may be formed by, for example, CVD (chemical vapor deposition) or sputtering. Next, laser scribing is carried out to partially remove the conductive layer 2, forming recesses 21. Thereafter, a perovskite solar cell element 3 and an electrode 4 are formed on the Z1 side surface of the conductive layer 2 by a known method, thereby obtaining the solar cell 10.

[0033] Next, a third step is performed in which a base layer material 510 for forming the base layer 51 is disposed on the solar cell 10 (see FIG. 5). The base layer 51 is preferably disposed on the conductive layer 2 so as to entirely cover the perovskite solar cell element 3 and the electrode 4.

[0034] Subsequently, a fourth step is performed to form a glass layer 53 on the Z1 side surface of the base layer 51. The glass layer 53 is obtained by applying a glass layer material onto the base layer 51 and the conductive layer 2 and then curing the applied material. As the glass layer material, a solution of polysilazane dissolved in ether or the like can be used.

[0035] Covering portion 531 and adhesive portion 532 can be formed by applying a glass layer material to base layer 51 and conductive layer 2 on the outer edge of base layer 51. At this time, conductive layer 2 and base layer 51 are not bonded to each other, so a gap is formed between them. Therefore, a portion of the glass layer material penetrates into the gap from the outer edge of base layer 51 by capillary action, forming sealing portion 533. Therefore, according to this method, sealing portion 533 can be formed simultaneously with the formation of adhesive portion 532, so that covering portion 531, adhesive portion 532, and sealing portion 533 can be formed continuously, and a highly durable solar cell module 100 can be obtained without using a special manufacturing method.

[0036] Second Embodiment Next, a solar cell module 100 according to a second embodiment will be described with reference to Fig. 3. As shown in Fig. 3, the solar cell module 100 according to the second embodiment includes an adhesive portion 6 that bonds the conductive layer 2 and the sealing material layer 5 on the perovskite solar cell element 3 side of the sealing portion 533.

[0037] The adhesive portion 6 is disposed at a position spaced apart from the perovskite solar cell element 3 and the electrode 4 so as to surround the outer edges thereof (see FIG. 6). As shown in FIG. 3, a sealing portion 533 and an adhesive portion 532 are formed on the outer edge of the adhesive portion 6, and the contact interface between the adhesive portion 6 and the sealing portion 533 overlaps with the base layer 51 when viewed in the Z direction (plan view). That is, the outer edge of the base layer 51 is adhered to the conductive layer 2 by the glass layer 53 and the adhesive portion 6. In this way, in the solar cell module 100 of this embodiment, the perovskite solar cell element 3 and the electrode 4 are doubly sealed by the glass layer 53 and the adhesive portion 6, and therefore the intrusion of atmospheric gases, water, and the like can be more reliably prevented.

[0038] The dimensions of the adhesive portion 6 in the X and Y directions are preferably 5 mm or less, and more preferably 2 mm or less. Even if the contact area between the adhesive portion 6 and the base layer 51 and the conductive layer 2 is small, the solar cell 10 is doubly sealed by the glass layer 53, so durability is not compromised. Furthermore, by reducing the contact area between the adhesive portion 6 and the conductive layer 2, the sealing area can be reduced, which prevents a decrease in the power generation efficiency of the solar cell module 100.

[0039] The adhesive portion 6 is preferably made of a material having insulating and gas barrier properties, such as epoxy resin.

[0040] Next, a manufacturing method for the solar cell module 100 according to the second embodiment will be described with reference to Figures 4 to 7. The manufacturing method according to this embodiment includes a first step of forming the solar cell 10, a second step of arranging an adhesive 60 that forms the adhesive portion 6 on the conductive layer 2, a third step of forming a base layer 51 on the solar cell 10, and a fourth step of forming a glass layer 53 on the base layer 51 and the conductive layer 2.

[0041] The first step can be performed in the same manner as in the first embodiment. In the second step, as shown in FIG. 4 , an adhesive 60 is placed on the conductive layer 2 at a position spaced apart from the perovskite solar cell element 3 and the electrode 4, so as to surround the outer edges of these elements. The adhesive 60 will stretch when pressed in the subsequent third step, so it is advisable to place it taking into consideration this stretching allowance. In this embodiment, the adhesives 60 are placed at positions spaced a fixed distance apart from each other along each side of the perovskite solar cell element 3, but the method of placing the adhesives 60 is not limited to this. The placement method may be changed depending on the type of adhesive 60 and the strength of the compression bonding of the base layer material 510.

[0042] Next, a third step is performed to form the base layer 51. In the third step, as shown in FIG. 5 , a base layer material 510 that forms the base layer 51 is placed on the adhesive 60, the perovskite solar cell element 3, and the electrode 4 so as to entirely cover them. The area of ​​the base layer material 510 in a plan view is larger than the area surrounded by the outer edge of the adhesive portion 6 that is formed by pressing the adhesive 60. Furthermore, the base layer material 510 is placed so that the outer edge of the base layer 51 after pressure-bonding is positioned outward from the outer edge of the adhesive portion 6. Note that the base layer material 510 should be placed taking into consideration the extension allowance of the adhesive 60.

[0043] When the adhesive 60 and the base layer material 510 are bonded together by heat and pressure bonding or the like, a base layer 51 and an adhesive portion 6 are formed, as shown in FIG. 6 . In this embodiment, the adhesive 60 arranged along each side of the perovskite solar cell element 3 is stretched and integrated to form an adhesive portion 6 surrounding the outer edge of the perovskite solar cell element 3. The base layer 51 is fixed to the conductive layer 2 by the adhesive portion 6. Furthermore, the base layer material 510 is arranged so that the outer edge of the base layer 51 is located outward from the outer edge of the adhesive portion 6, and therefore the outer peripheral edge of the base layer 51 located outward from the adhesive portion 6 is not adhered to the conductive layer 2 by the adhesive portion 6. Therefore, a small gap is formed between the base layer 51 and the conductive layer 2 at the outer peripheral edge of the base layer 51.

[0044] Finally, a fourth step is performed to form a glass layer 53 on the base layer 51 and the conductive layer 2. In the fourth step, a glass layer material is applied to the base layer 51 and the conductive layer 2 and cured to obtain the glass layer 53. As in the first embodiment, the glass layer material is applied to the base layer 51 and the conductive layer 2 at the outer edge of the base layer 51, thereby forming a covering portion 531 and an adhesive portion 532, as shown in FIG. 7 . At this time, a portion of the glass layer material penetrates by capillary action into the portion of the outer edge of the base layer 51 that is not adhered to the conductive layer 2. This forms a sealing portion 533 between the outer edge of the base layer 51 and the conductive layer 2. The glass layer material penetrates into the inside of the base layer 51 until it contacts the adhesive portion 6, so the sealing portion 533 is formed to adhere to the adhesive portion 6. At this time, the adhesive portion 6 stops the glass layer material from penetrating inside the base layer 51, thereby preventing contact between the glass layer material and the perovskite solar cell element 3 and suppressing damage to the perovskite solar cell element 3 caused by the glass layer material.

[0045] According to this manufacturing method, it is possible to obtain a highly durable solar cell module 100 without using a special manufacturing method.

[0046] Other Embodiments Next, other embodiments of the solar cell module 100 will be described.

[0047] (a) As shown in Fig. 8, the sealing material layer 5 may have a peelable intermediate layer 52. The intermediate layer 52 is preferably disposed at least between the base layer 51 and the glass layer 53. In the example shown in Fig. 8, the intermediate layer 52 is disposed on the Z2-side surface and the Z1-side surface of the base layer 51.

[0048] The intermediate layer 52 may be hydrophilic and peelable. If the intermediate layer 52 is hydrophilic, it is possible to eliminate the need for a hydrophilic treatment of the base layer 51 when forming the glass layer 53 on the base layer 51. Furthermore, if the intermediate layer 52 is peelable, it is possible to prevent adhesion between the base layer 51 and the glass layer 53.

[0049] Because the base layer 51 and intermediate layer 52 have different linear expansion coefficients from the glass layer 53, if the base layer 51 and the glass layer 53 are bonded together, the glass layer 53 may not be able to keep up with the expansion and contraction of the base layer 51 due to thermal cycles, which may result in cracking of the glass layer 53. In this embodiment, the peelable intermediate layer 52 prevents the intermediate layer 52 and the glass layer 53 from bonding together, so that stresses caused by the expansion and contraction of the base layer 51 and the intermediate layer 52 do not act on the glass layer 53, preventing cracking of the glass layer 53. In other words, the intermediate layer 52 acts as a stress relief layer, thereby improving the durability of the glass layer 53.

[0050] For example, a silicone-based resin or a non-silicone-based resin can be used for the intermediate layer 52. For example, a cross-linked alkyl compound can be used as the non-silicone-based resin. If the intermediate layer 52 does not contain Si, there is no risk of Si diffusing into the base layer 51 and the glass layer 53, and therefore there is no risk of their composition or function being impaired. The intermediate layer 52 may be obtained by coating the surface of the base layer 51 with a non-silicone-based resin.

[0051] (b) The solar cell module 100 may be protected by a protective layer (not shown). The protective layer may be provided so as to cover the encapsulant layer 5, and may include a primary encapsulating layer that encapsulates the perovskite solar cell element 3 and prevents moisture from entering from the outside, and a durable secondary encapsulating layer that is disposed on top of the primary encapsulating layer.

[0052] In the above-described embodiment, the following configurations are envisioned. (1) A solar cell module 100 comprising an electrically conductive layer 2 arranged on a substrate 1, a perovskite solar cell element 3 arranged on the conductive layer 2, an electrode 4 arranged on the perovskite solar cell element 3, and a sealing material layer 5 that seals the perovskite solar cell element 3 and the electrode 4, wherein the sealing material layer 5 has a solvent-resistant base layer 51 and a glass layer 53 arranged on the base layer 51, and the glass layer 53 has a covering portion 531 that covers the base layer 51, an adhesive portion 532 that adheres to the conductive layer 2 at the outer edge of the base layer 51, and a sealing portion 533 formed between the conductive layer 2 and the base layer 51 to seal the space between them, and wherein the covering portion 531, adhesive portion 532 and sealing portion 533 are continuously formed.

[0053] According to this configuration, the perovskite solar cell elements 3 and electrodes 4 are sealed by the sealing material layer 5 having the glass layer 53, which isolates them from the atmosphere and improves the durability of the solar cell module 100. In particular, the glass layer 53 has a covering portion 531 that covers the base layer 51, an adhesive portion 532 that adheres to the conductive layer 2 at the outer edge of the base layer 51, and a sealing portion 533 that seals between the conductive layer 2 and the base layer 51, and because these are formed continuously, the perovskite solar cell elements 3 and electrodes 4 are reliably covered by the glass layer 53, making it possible to prevent the intrusion of water and the like from the outside. This eliminates the need to seal the outer edge of the sealing material layer 5 with a sealing material, resulting in a solar cell module 100 that is highly durable while preventing an increase in the sealing area.

[0054] (2) In the solar cell module 100 of (1), an adhesive portion 6 that bonds the conductive layer 2 and the sealing material layer 5 is provided on the side of the sealing portion 533 of the sealing material layer 5 closer to the perovskite solar cell element 3, and it is preferable that the contact interface between the adhesive portion 6 and the sealing portion 533 overlaps with the base layer 51 in a planar view.

[0055] According to this configuration, the perovskite solar cell element 3 and the electrode 4 are sealed not only by the sealing portion 533 but also by the adhesive portion 6, which more reliably prevents intrusion of water and the like into the solar cell module 100 and improves the durability of the solar cell module 100. Furthermore, if the contact interface between the adhesive portion 6 and the sealing portion 533 overlaps with the base layer 51 in a plan view, the arrangement area of ​​the adhesive portion 6 and the glass layer 53 does not increase, so it is possible to improve durability without affecting the power generation efficiency of the solar cell module 100. Furthermore, the adhesive portion 6 can prevent contact between the sealing portion 533 and the perovskite solar cell element 3.

[0056] (3) In the solar cell module 100 of (1) or (2), the encapsulant layer 5 further includes a peelable intermediate layer 52, and the intermediate layer 52 is preferably disposed at least between the base layer 51 and the glass layer 53.

[0057] According to this configuration, peelable intermediate layer 52 is disposed between base layer 51 and glass layer 53, preventing adhesion between glass layer 53 and intermediate layer 52. Therefore, even if solar cell module 100 is subjected to a thermal cycle, base layer 51 and intermediate layer 52 can deform independently of glass layer 53, and stresses associated with deformation of base layer 51 and intermediate layer 52 do not act on glass layer 53, thereby preventing cracking of glass layer 53. In other words, intermediate layer 52 acts as a stress relaxation layer, resulting in solar cell module 100 with highly durable glass layer 53.

[0058] (4) A first step of forming a solar cell 10 by arranging an electrically conductive layer 2, a perovskite solar cell element 3, and an electrode 4 on a substrate 1 in this order; a second step of arranging an adhesive 60 on the electrically conductive layer 2 at a position spaced apart from the perovskite solar cell element 3 so as to surround the outer edge of the perovskite solar cell element 3; and a second step of arranging a solvent-resistant base layer material 510 on the adhesive 60 so as to cover the perovskite solar cell element 3 and the electrode 4, thereby forming a solar cell 10 by adhering the base layer material 510 and the adhesive 60. and a fourth step of forming a glass layer 53 on the base layer 51 and the conductive layer 2, wherein the outer edge of the base layer 51 after the third step is located outward from the outer edge of the adhesive portion 6, and in the fourth step, a part of the glass layer material that will become the glass layer 53 penetrates between the base layer 51 and the conductive layer 2 by capillary action, thereby forming a sealing portion 533 that seals the space between them.

[0059] According to this configuration, in the second step, the base layer material 510 arranged on the conductive layer 2 so as to surround the outer edge of the perovskite solar cell element 3 is pressed against the adhesive 60 arranged on the conductive layer 2 so as to surround the outer edge of the perovskite solar cell element 3, thereby forming an adhesive portion 6 that seals the conductive layer 2 and the base layer 51. Furthermore, after the third step, the outer edge of the base layer 51 is located outward from the outer edge of the adhesive portion 6, so the base layer 51 and the conductive layer 2 are not adhered to each other outside the adhesive portion 6. Therefore, when the glass layer material is applied to the base layer 51 and the conductive layer 2 in the fourth step, a portion of the glass layer material penetrates between the base layer 51 and the conductive layer 2 from the outer edge of the base layer 51 due to capillary action, forming a sealing portion 533 that seals the base layer 51 and the conductive layer 2. As a result, the perovskite solar cell element 3 and the electrode 4 are doubly sealed by the adhesive portion 6 and the glass layer 53, thereby improving the durability of the solar cell module 100. Furthermore, since the sealing portion 533 that is continuous with the covering portion 531 and the adhesive portion 532 can be formed without using a complicated method, it is possible to manufacture the highly durable solar cell module 100 using a simple method. [Industrial Applicability]

[0060] The present invention can be used for a solar cell module having a perovskite solar cell element and a method for manufacturing the solar cell module. [Explanation of symbols]

[0061] 1: substrate, 2: conductive layer, 3: perovskite solar cell element, 4: electrode, 5: sealing material layer, 6: adhesive portion, 10: solar cell, 51: base layer, 52: intermediate layer, 53: glass layer, 60: adhesive, 100: solar cell module, 510: base layer material, 531: covering portion, 532: adhesive portion, 533: sealing portion

Claims

1. a conductive layer disposed on the substrate; a perovskite solar cell element disposed on the conductive layer; and an electrode disposed on the perovskite solar cell element; a sealing material layer that seals the perovskite solar cell element and the electrodes, the encapsulant layer includes a solvent-resistant base layer and a glass layer disposed on the base layer; the glass layer has a covering portion that covers the base layer, an adhesive portion that adheres to the conductive layer at an outer edge of the base layer, and a sealing portion that is formed between the conductive layer and the base layer and seals the conductive layer and the base layer, The covering portion, the adhesive portion, and the sealing portion are continuously formed in the solar cell module.

2. an adhesive portion for adhering the conductive layer and the sealing material layer, the adhesive portion being located on the perovskite solar cell element side of the sealing portion of the sealing material layer; The solar cell module according to claim 1 , wherein a contact interface between the adhesive portion and the sealing portion overlaps with the base layer in a plan view.

3. The sealant layer further includes an intermediate layer having peelability, The solar cell module according to claim 1 , wherein the intermediate layer is disposed at least between the base layer and the glass layer.

4. a first step of forming a solar cell by arranging an electrically conductive layer, a perovskite solar cell element, and an electrode on a substrate in this order; a second step of placing an adhesive on the conductive layer at a position spaced from the perovskite solar cell element so as to surround the outer edge of the perovskite solar cell element; a third step of placing a solvent-resistant base layer material on the adhesive so as to cover the perovskite solar cell element and the electrode, and pressing the base layer material and the adhesive together to form a base layer adhered to the conductive layer by an adhesive portion; a fourth step of forming a glass layer on the base layer and the conductive layer; an outer edge of the base layer after the third step is located outward from an outer edge of the adhesive portion; In the fourth step, a portion of the glass layer material that will become the glass layer penetrates between the base layer and the conductive layer by capillary action, forming a sealing portion that seals the space between the two.

Images