Photoelectric conversion device and method for manufacturing the same

Abstract

The present invention provides a photoelectric conversion device that is flexible and has excellent shock resistance, as well as a method for manufacturing the same. [Solution] According to the embodiment, a photoelectric conversion device 100 is provided, comprising a glass substrate 3, a photoelectric conversion element 8, and a silicone resin-containing layer 2. The glass substrate 3 has a thickness of 250 μm or less and has a first surface S1 and a second surface S2 located on the back side of the first surface S1. The photoelectric conversion element 8 is provided on the first surface S1 of the glass substrate 3. The silicone resin-containing layer 2 is provided on the second surface S2 of the glass substrate 3.

Description

Technical Field

[0001] Embodiments of the present invention relate to a photoelectric conversion device and a method for manufacturing the same.

Background Art

[0002] For photoelectric conversion devices such as perovskite solar cells, in order to prevent deterioration caused by water vapor and O2, it is necessary to take measures to prevent the permeation of water vapor and O2. A glass substrate is a material with high barrier properties against water vapor and the like. Therefore, a glass substrate enables a sealing structure with high barrier properties. On the other hand, a solar cell having a sealing structure using a glass substrate has a problem in impact resistance in outdoor use and the like. When the glass substrate is thickened to enhance the impact resistance, it becomes difficult to endow the solar cell with flexibility in terms of shape.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] Provided are a photoelectric conversion device having flexibility and excellent impact resistance, and a method for manufacturing the same.

Means for Solving the Problems

[0005] According to one embodiment, a photoelectric conversion device is provided comprising a glass substrate, a photoelectric conversion element, and a silicone resin-containing layer. The glass substrate has a thickness of 250 μm or less and has a first surface and a second surface located on the back side of the first surface. The photoelectric conversion element is provided on the first surface of the glass substrate. The silicone resin-containing layer is provided on the second surface of the glass substrate.

[0006] According to this embodiment, a photoelectric conversion element is formed on the first surface of the glass substrate. By chemically polishing the second surface located on the back side of the first surface of the glass substrate, the thickness of the glass substrate can be reduced to 250 μm or less. Forming a silicone resin-containing layer on the second surface of the glass substrate. A method for manufacturing a photoelectric conversion device is provided, which includes the following.

[0007] According to the embodiment, a laminate is obtained in which a first structural part including a first glass substrate having a first surface and a second surface and a first photoelectric conversion element provided on the first surface of the first glass substrate and a second structural part including a second glass substrate having a first surface and a second surface and a second photoelectric conversion element provided on the first surface of the second glass substrate are laminated, and the first photoelectric conversion element and the second photoelectric conversion element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the laminate, the thickness of the first and second glass substrates is reduced to 250 μm or less by chemically polishing the second surface of the first glass substrate and the second surface of the second glass substrate. To separate the first structural part and the second structural part from the laminate, A silicone resin-containing layer is formed on the second surface of the first glass substrate of the first structural part and on the second surface of the second glass substrate of the second structural part. A method for manufacturing a photoelectric conversion device is provided, which includes the following.

[0008] According to the embodiment, a first glass substrate having a first photoelectric conversion element on its first surface and a second glass substrate having a second photoelectric conversion element on its first surface are laminated in such a structure that the first photoelectric conversion element and the second photoelectric conversion element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. A silicone resin-containing layer is formed on the second surface of the first glass substrate and on the second surface of the second glass substrate. A method for manufacturing a photoelectric conversion device is provided, which includes the following.

[0009] According to the embodiment, a first glass substrate on which a first photoelectric conversion element is provided on a first surface and a second glass substrate having a first surface are laminated in such a structure that the first photoelectric conversion element is located between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. A silicone resin-containing layer is formed on the second surface of the first glass substrate and on the second surface of the second glass substrate. A method for manufacturing a photoelectric conversion device is provided, which includes the following. [Brief explanation of the drawing]

[0010] [Figure 1] A schematic cross-sectional view showing a first example of a photoelectric conversion device according to an embodiment. [Figure 2] A schematic cross-sectional view showing an example of a photoelectric conversion element in the photoelectric conversion device shown in Figure 1. [Figure 3] A schematic cross-sectional view showing a second example of a photoelectric conversion device according to the embodiment. [Figure 4] A schematic cross-sectional view showing a third example of a photoelectric conversion device according to the embodiment. [Figure 5] A schematic cross-sectional view showing a fourth example of a photoelectric conversion device according to the embodiment. [Figure 6] A schematic cross-sectional view showing a fifth example of a photoelectric conversion device according to the embodiment. [Figure 7] A schematic cross-sectional view showing a sixth example of a photoelectric conversion device according to the embodiment. [Figure 8] Schematic cross-sectional view showing a step of Manufacturing Method I of the photoelectric conversion device of the first example. [Figure 9] Schematic cross-sectional view showing a step of Manufacturing Method I of the photoelectric conversion device of the first example. [Figure 10] Schematic cross-sectional view showing a step of Manufacturing Method I of the photoelectric conversion device of the first example. [Figure 11] Schematic cross-sectional view showing a step of Manufacturing Method I of the photoelectric conversion device of the first example. [Figure 12] Schematic cross-sectional view showing a step of Manufacturing Method II of the photoelectric conversion device of the first example. [Figure 13] Schematic cross-sectional view of the laminate shown in FIG. 12. [Figure 14] Schematic cross-sectional view showing a step of Manufacturing Method II of the photoelectric conversion device of the first example. [Figure 15] Schematic cross-sectional view showing a step of Manufacturing Method II of the photoelectric conversion device of the first example. [Figure 16] Schematic cross-sectional view showing a step of Manufacturing Method II of the photoelectric conversion device of the first example. [Figure 17] Schematic cross-sectional view showing a step of Manufacturing Method III of the photoelectric conversion device of the second example. [Figure 18] [[ID=3②]]Schematic cross-sectional view showing a step of Manufacturing Method V of the photoelectric conversion device of the fourth example. [Figure 19] Schematic cross-sectional view showing a step of Manufacturing Method V of the photoelectric conversion device of the fourth example. [Figure 20] Schematic cross-sectional view showing a step of Manufacturing Method V of the photoelectric conversion device of the fourth example. [Figure 21] Schematic cross-sectional view showing a step of Manufacturing Method VI of the photoelectric conversion device of the fifth example. [Figure 22] Schematic cross-sectional view showing a step of Manufacturing Method VI of the photoelectric conversion device of the fifth example. [Figure 23] Schematic cross-sectional view showing a step of Manufacturing Method VII of the photoelectric conversion device of the sixth example. [Figure 24] Schematic cross-sectional view showing the iron ball drop test in the example. [Modes for carrying out the invention]

[0011] (First Embodiment) According to the first embodiment, a photoelectric conversion device is provided. The photoelectric conversion device may be, for example, a solar cell or an organic electroluminescent (organic EL) device. An example of a solar cell is a perovskite solar cell.

[0012] An example of applying the photoelectric conversion device of the embodiment to a solar cell will be described with reference to Figures 1-7. In each figure, the stacking direction of the photoelectric conversion device and the thickness direction of the glass substrate are assumed to be parallel to the z-axis direction. The surface direction of the photoelectric conversion device is assumed to be parallel to the xy-plane. The x-axis, y-axis, and z-axis directions intersect approximately perpendicularly to each other. In addition, in each figure, components that are common to multiple drawings are denoted by the same reference numeral and their description is omitted.

[0013] <Example 1> Figure 1 shows a first example of a photoelectric conversion device according to the embodiment. The first example of a solar cell 100 comprises a layer 1 having ultraviolet shielding properties, a silicone resin-containing layer 2, a glass substrate 3, a transparent electrode 4, an element part 5, an adhesive layer 6, and a back sheet 7. Each component is stacked in the z-axis direction.

[0014] The glass substrate 3 has a thickness of 250 μm or less. Preferably, the lower limit of the thickness of the glass substrate 3 is 30 μm. The glass substrate 3 has a first surface S1 and a second surface S2 located on the back side of the first surface S1. The first surface S1 and the second surface S2 are both parallel to the xy plane. The glass substrate 3 may or may not be capable of shielding ultraviolet light. The shielding performance against ultraviolet light may be non-transmitting, absorbent, or scattering. Preferably, the glass substrate 3 is capable of shielding ultraviolet light with a wavelength of 350 nm or less.

[0015] A transparent electrode 4 is provided on the first surface S1 of the glass substrate 3. An element portion 5 is provided on the transparent electrode 4. The transparent electrode 4 and the element portion 5 constitute a solar cell element 8, which is a photoelectric conversion element. The solar cell element 8 will be described with reference to Figure 2. The solar cell element 8 comprises a transparent electrode 4 as the first electrode, a hole transport layer 9, a photoelectric conversion layer 10, an electron transport layer 11, and a cathode 12 as the second electrode. The transparent electrode 4, hole transport layer 9, photoelectric conversion layer 10, electron transport layer 11, and cathode 12 each have two surfaces that intersect with the thickness direction (z-axis direction) as their main surfaces. Each surface is parallel to the xy plane. One surface S3 of the transparent electrode 4 parallel to the xy plane is laminated on the first surface S1 of the glass substrate 3. On the other surface S4 of the transparent electrode 4 parallel to the xy plane, the hole transport layer 9, photoelectric conversion layer 10, electron transport layer 11, and cathode 12 are provided in this order. Light such as sunlight or artificial light is shone onto the transparent electrode 4 side through the glass substrate 3, for example, from the direction indicated by arrow L.

[0016] Examples of transparent electrodes 4 as the first electrode include films made of materials that have light transmittance and conductivity, such as indium tin oxide (ITO), zinc oxide (ZnO), tin dioxide (SnO2), and fluorine-doped tin oxide (FTO).

[0017] The hole transport layer 9 has functions such as blocking electrons generated in the photoelectric conversion layer 10 and selectively and efficiently transporting holes to the cathode 12.

[0018] An example of a photoelectric conversion layer 10 is a perovskite layer. An example of a perovskite-type compound is methylammonium lead iodide (CH3NH3PbI3).

[0019] The electron transport layer 11 has functions such as blocking holes generated in the photoelectric conversion layer 10 and selectively and efficiently transporting electrons to the transparent electrode 4.

[0020] The cathode 12, which serves as the second electrode, is made of a material that is conductive and, in some cases, light-transmitting. An example of the cathode 12 is a layer containing Ti and / or Al.

[0021] The backsheet 7 is fixed to one side of the cathode 12 parallel to the xy plane by an adhesive layer 6. An example of the backsheet 7 is a sheet made of polyethylene terephthalate (PET) film coated with aluminum.

[0022] The thickness of the solar cell element 8 is set to a desired value depending on the type of solar cell and the element area. An example of a thickness is approximately 500 nm.

[0023] One side of the silicone resin-containing layer 2, parallel to the xy plane, is laminated on the second surface S2 of the glass substrate 3. A layer 1 having ultraviolet shielding properties (hereinafter referred to as the UV shielding layer) is laminated on the other side of the silicone resin-containing layer 2, parallel to the xy plane. The thickness of the silicone resin-containing layer 2 is preferably 300 μm or less. The silicone resin-containing layer 2 may or may not have ultraviolet shielding properties. If at least one of the silicone resin-containing layer 2 or the glass substrate 3 has ultraviolet shielding properties, the UV shielding layer 1 can be omitted. The silicone resin-containing layer 2 is preferably mainly composed of silicone resin. Here, the main component is the component that is present in the largest amount in the silicone resin-containing layer 2.

[0024] When one or more of the UV shielding layer 1, silicone resin-containing layer 2, and glass substrate 3 are capable of shielding ultraviolet light, it is desirable that the wavelength of the ultraviolet light be 350 nm or less. More desirable is that the material is capable of shielding ultraviolet light with a wavelength of 350 nm or less and transmitting light with a wavelength of 400 nm or more. Examples of materials that are capable of shielding ultraviolet light with a wavelength of 350 nm or less and transmitting light with a wavelength of 400 nm or more include TiO2 and WO3.

[0025] When light is shone onto the solar cell 100 with the above structure, for example, on the UV shielding layer 1 side, and the photoelectric conversion layer 10 absorbs the shone light, electrons and their corresponding holes are generated. Of the generated electrons and holes, for example, the electrons are collected at the cathode 12 via the electron transport layer 11. The holes are collected at the transparent electrode 4 via the hole transport layer 9. In this way, the photoelectric conversion reaction occurs.

[0026] By reducing the thickness of the glass substrate 3 to 250 μm or less, the weight of the solar cell 100 can be reduced. Furthermore, the shape of the solar cell 100 can be made flexible, making it easy to deform the solar cell 100 into desired shapes, such as by bending it. Silicone resin is highly elastic due to its weak intermolecular forces and easily absorbs impact. The silicone resin-containing layer 2 protects the glass substrate 3 from impact while ensuring the lightness and flexibility of the solar cell. Specifically, it can achieve impact resistance that can withstand hailstorm tests in accordance with JIS C 8917:2005 Environmental Test Methods and Durability Test Methods for Crystalline Solar Cell Modules. As a result, damage to the glass substrate 3 can be suppressed even when the solar cell 100 is used outdoors, thus maintaining the gas barrier properties of the glass substrate 3 against water vapor and O2 over a long period of time.

[0027] <Example 2> A second example of the solar cell of the embodiment will be described with reference to Figure 3. The solar cell 101 shown in Figure 3 has the same configuration as the solar cell 100, except that it includes a first sealing member 13. The first sealing member 13 covers the edges (four sides) of each of the components: the glass substrate 3, the transparent electrode 4, the element part 5, the adhesive layer 6, and the backsheet 7. The first sealing member 13 also covers the edges of the surface of the backsheet 7 parallel to the xy plane. The ends of the first sealing member 13 are fixed to the silicone resin-containing layer 2. For example, insulating tape can be used as the first sealing member 13. The first sealing member 13 can protect the glass substrate 3 from impact. Therefore, the impact resistance of the solar cell 101 can be further improved, and the reliability of the solar cell 101 can be further enhanced.

[0028] <Example 3> A third example of the solar cell according to the embodiment will be described with reference to Figure 4. The solar cell 102 shown in Figure 4 has the same configuration as the solar cell 100, except that it includes a second sealing member 14. The second sealing member 14 covers the edges (four sides) of each of the components: the UV shielding layer 1, the silicone resin-containing layer 2, the glass substrate 3, the transparent electrode 4, the element part 5, the adhesive layer 6, and the backsheet 7. The second sealing member 14 also covers the edges of the surface of the backsheet 7 parallel to the xy plane and the edges of the surface of the UV shielding layer 1 parallel to the xy plane. For example, insulating tape can be used as the second sealing member 14. The second sealing member 14 can protect the glass substrate 3 from impact. Therefore, the impact resistance of the solar cell 102 can be further improved, and the reliability of the solar cell 102 can be further enhanced.

[0029] <Example 4> A fourth example of the solar cell according to the embodiment will be described with reference to Figure 5. The solar cell 103 shown in Figure 5 comprises first and second solar cell elements 8A and 8B, and first and second glass substrates 3A and 3B. The element portion 5A of the first solar cell element 8A and the element portion 5B of the second solar cell element 8B are bonded together with an adhesive layer 6 interposed between them. The first transparent electrode 4A of the first solar cell element 8A has the first glass substrate 3A, the first silicone resin-containing layer 2A, and the first UV shielding layer 1A laminated in this order. The second transparent electrode 4B of the second solar cell element 8B has the second glass substrate 3B, the second silicone resin-containing layer 2B, and the second UV shielding layer 1B laminated in this order. The third sealing member 15 covers the ends (four sides) of the first and second solar cell elements 8A and 8B bonded together by the adhesive layer 6. The third sealing member 15 can protect the solar cell elements 8. The third sealing member 15 is formed from an insulating resin, such as epoxy resin. According to the solar cell 103 described above, light can be captured from both outermost layers of the laminate to generate electricity. Therefore, the power generation efficiency of the solar cell per unit volume can be increased. Note that Figure 5 shows the case where there is one adhesive layer 6, but the adhesive layer 6 is not limited to this and may be two or more layers, for example.

[0030] <Example 5> A fifth example of the solar cell according to the embodiment will be described with reference to Figure 6. The solar cell 104 shown in Figure 6 comprises a solar cell element 8 and first and second glass substrates 3A and 3B. The first glass substrate 3A, the first silicone resin-containing layer 2A, and the first UV shielding layer 1A are laminated in this order on the transparent electrode 4 of the solar cell element 8. The second glass substrate 3B is fixed to the element portion 5 of the solar cell element 8 by an adhesive layer 6. The second silicone resin-containing layer 2B is laminated on the second glass substrate 3B. The second glass substrate 3B does not have a solar cell element. Therefore, it is not necessary to provide a UV shielding layer on the second silicone resin-containing layer 2B, but it may have one.

[0031] The third sealing member 15 covers the ends (four sides) of the solar cell element 8 and the adhesive layer 6. Furthermore, both ends of the third sealing member 15 in the z-axis direction are fixed to the first and second glass substrates 3A and 3B. The third sealing member 15 can protect the solar cell element 8. The third sealing member 15 is formed from an insulating resin, such as epoxy resin. According to the solar cell 104 described above, since the solar cell element 8 is located between the first glass substrate 3A and the second glass substrate 3B, it has excellent barrier function against gases such as water vapor and oxygen. Therefore, degradation of the solar cell element 8 due to water vapor and oxygen can be suppressed.

[0032] <Example 6> A sixth example of the embodiment of the solar cell will be described with reference to Figure 7. The solar cell 105 shown in Figure 7 has a similar structure to the solar cell 104 of the fifth example, except that it does not use the third sealing member 15. With the solar cell 105, since the solar cell element 8 is located between the first glass substrate 3A and the second glass substrate 3B, it has excellent barrier function against gases such as water vapor and oxygen. Therefore, it is possible to suppress the degradation of the solar cell element 8 by water vapor and oxygen.

[0033] The solar cells of the embodiments illustrated in Examples 1 to 6 comprise a glass substrate with a thickness of 250 μm or less, a photoelectric conversion element provided on the first surface of the glass substrate, and a silicone resin-containing layer provided on the second surface of the glass substrate. The solar cells of the embodiments achieve excellent impact resistance while improving lightness and flexibility. Furthermore, the solar cells of the embodiments also ensure a barrier function against gases such as water vapor and oxygen. Moreover, as shown in the examples, the solar cells of the embodiments can withstand impact resistance that conforms to the hailstorm test in accordance with JIS C 8917:2005 Environmental test methods and durability test methods for crystalline solar cell modules. As a result, damage to the glass substrate can be suppressed even when the solar cell is used outdoors, and the gas barrier properties of the glass substrate against water vapor and oxygen can be maintained over a long period of time.

[0034] In the example above, the first electrode (transparent electrode 4) was designated as the anode and the second electrode as the cathode 12, but the arrangement of these electrodes may be reversed. That is, the first electrode (transparent electrode 4) may be the cathode and the second electrode may be the anode. In this case, the arrangement of the hole transport layer 9 and the electron transport layer 11 will also be reversed.

[0035] (Second Embodiment) According to the second embodiment, a method for manufacturing a photoelectric conversion device according to the first embodiment is provided. An example of applying the method of the second embodiment to a method for manufacturing a solar cell will be described with reference to Figures 8 to 24. In each figure, it is assumed that the stacking direction of the photoelectric conversion device and the thickness direction of the glass substrate are parallel to the z-axis direction. It is assumed that the surface direction of the photoelectric conversion device is parallel to the xy-plane. The x-axis, y-axis, and z-axis directions intersect approximately perpendicularly to each other. In addition, in each figure, components that are common to multiple drawings are denoted by the same reference numeral and their description is omitted.

[0036] <Manufacturing method for the first example of solar cell 100> The first example solar cell 100 is manufactured, for example, by manufacturing method I and manufacturing method II.

[0037] Manufacturing method I will be explained with reference to Figure 8-11.

[0038] Manufacturing method I comprises forming a solar cell element as a photoelectric conversion element on the first surface of a glass substrate, reducing the thickness of the glass substrate to 250 μm or less by chemical polishing the second surface located on the back side of the first surface of the glass substrate, and forming a silicone resin-containing layer on the second surface of the glass substrate.

[0039] As shown in Figure 8, a solar cell element 8 is formed on the first surface S1 of the glass substrate 16. Each layer constituting the solar cell element 8 is formed by appropriately selecting a method from, for example, sputtering, coating, or vapor deposition, depending on the type of layer. The glass substrate 16 is a glass substrate before polishing. The thickness of the glass substrate 16 is greater than 250 μm. The thickness of the glass substrate 16 can be, for example, in the range of 500 μm to 700 μm. Next, the backsheet 7 is fixed to the element portion 5 of the solar cell element 8 by an adhesive layer 6. In this way, a laminate 200 is obtained.

[0040] Next, as shown in Figure 9, the surface of the backsheet 7 of the laminate 200 parallel to the xy plane, and the edges (four sides) of the backsheet 7, adhesive layer 6, element part 5, transparent electrode 4, and glass substrate 16 are covered with a protective sheet 17. The protective sheet 17 is to prevent the chemical polishing solution from coming into contact with areas other than the surface to be processed S2. Chemical polishing is performed by bringing the second surface S2 of the glass substrate 16 into contact with the processing solution. The processing solution is, for example, a mixed aqueous solution of hydrogen fluoride (HF) and nitric acid (HNO3). This reduces the thickness of the glass substrate 16 to 250 μm or less. As a result, as shown in Figure 10, a laminate with a glass substrate 3 having a thickness of 250 μm or less is obtained. By thinning the glass substrate through chemical polishing, damage to the glass substrate during handling during manufacturing can be reduced.

[0041] Next, as shown in Figure 11, the protective sheet 17 is removed from the laminate. Then, by providing the silicone resin-containing layer 2 and the UV shielding layer 1 on the glass substrate 3, the solar cell 100 shown in Figure 1 is obtained. The silicone resin-containing layer 2 is formed by, for example, coating or sheet bonding. The UV shielding layer 1 is formed by, for example, sputtering, coating or sheet bonding.

[0042] Manufacturing method II will be explained with reference to Figure 12-16.

[0043] Manufacturing method II involves laminating a first structural part including a first glass substrate having a first surface and a second surface and a first photoelectric conversion element provided on the first surface of the first glass substrate, and a second structural part including a second glass substrate having a first surface and a second surface and a second photoelectric conversion element provided on the first surface of the second glass substrate, thereby obtaining a laminate with a structure in which the first photoelectric conversion element and the second photoelectric conversion element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the laminate, the thickness of the first and second glass substrates is reduced to 250 μm or less by chemically polishing the second surface of the first glass substrate and the second surface of the second glass substrate. The laminate is separated into a first structural part and a second structural part. This includes forming a silicone resin-containing layer on the second surface of the first glass substrate of the first structural part and on the second surface of the second glass substrate of the second structural part.

[0044] As shown in Figure 12, the second structural part 200B is laminated onto the first structural part 200A. The first structural part 200A is a laminate in which the transparent electrode 4A of the first solar cell element 8A, the element part 5A of the first solar cell element 8A, the adhesive layer 6A, and the backsheet 7A are laminated in this order on the first surface S5 of the first glass substrate 16A. On the other hand, the second structural part 200B is a laminate in which the transparent electrode 4B of the second solar cell element 8B, the element part 5B of the second solar cell element 8B, the adhesive layer 6B, and the backsheet 7B are laminated in this order on the first surface S6 of the second glass substrate 16B. The first and second structural parts 200A and 200B are manufactured, for example, by the same method as the laminate 200 of Method I.

[0045] The backsheet 7A of the first structural part 200A and the backsheet 7B of the second structural part 200B are superimposed. Adhesive 18 is applied to the edges (four sides) of each of the resulting laminate, including the first solar cell element 8A, adhesive layer 6A, backsheet 7A, backsheet 7B, adhesive layer 6B, and second solar cell element 8B, to integrate these layers. An example of adhesive 18 is epoxy resin. In this way, a laminate 201 is obtained in which the first solar cell element 8A and the second solar cell element 8B are positioned between the first surface S5 of the first glass substrate 16A and the first surface S6 of the second glass substrate 16B. A plan view of the laminate as seen from the first glass substrate 16A side is shown in Figure 13.

[0046] Next, the second surface S7 of the first glass substrate 16A located in one of the outermost layers of the laminate 201 and the second surface S8 of the second glass substrate 16B located in the other outermost layer are chemically polished to reduce the thickness of the first glass substrate 16A and the second glass substrate 16B to 250 μm or less. Chemical polishing can be performed in the same manner as described in Method I. The laminate 202 after chemical polishing is shown in Figure 14. In Figure 14, the first glass substrate 16A and the second glass substrate 16B after chemical polishing are shown as the first glass substrate 3A and the second glass substrate 3B, respectively.

[0047] Next, as shown in Figure 15, in order to remove the adhesive 18 adhering to the four sides of the first solar cell element 8A, adhesive layer 6A, backsheet 7A, backsheet 7B, adhesive layer 6B, and second solar cell element 8B of the laminate 201, the adhesive 18 is removed by cutting along the thickness direction (z-axis direction) at positions 19 corresponding to the gap between the side and the adhesive 18. The gap between the side and the adhesive 18 may or may not exist. As illustrated in Figure 15, the presence of a gap between the side and the adhesive 18 is preferable because it facilitates separation from the adhesive 18.

[0048] Next, the laminate 202 is divided into two parts along the boundary between backsheet 7A and backsheet 7B, separating the first structural part 200A and the second structural part 200B. The first structural part 200A after separation is shown in Figure 16. By providing a silicone resin-containing layer and a UV shielding layer on the first glass substrate 3A of the first structural part 200A and the second glass substrate 3B of the second structural part 200B, a solar cell 100 with the structure shown in Figure 1 is obtained. The silicone resin-containing layer is formed by, for example, coating or sheet bonding. The UV shielding layer is formed by, for example, sputtering, coating or sheet bonding.

[0049] <Manufacturing method for solar cell 101, example 2> The second example solar cell 101 is manufactured, for example, by manufacturing method III.

[0050] Manufacturing method III will be explained with reference to Figure 17.

[0051] Manufacturing method III comprises forming a solar cell element as a photoelectric conversion element on the first surface of a glass substrate, chemically polishing the second surface located on the back side of the first surface of the glass substrate to reduce the thickness of the glass substrate to 250 μm or less, covering the edges of the solar cell element and the glass substrate with a sealing member, and forming a silicone resin-containing layer on the second surface of the glass substrate.

[0052] First, the laminate 200 is fabricated, the protective sheet 17 is formed, and the glass substrate 16 is chemically polished using the same method as described in manufacturing method I, to obtain a laminate as shown in Figure 17, in which the glass substrate 3, transparent electrode 4, element part 5, adhesive layer 6, and back sheet 7 are laminated in the z-axis direction.

[0053] Next, the glass substrate 3, transparent electrode 4, element part 5, adhesive layer 6, and the edges (four sides) of the back sheet 7 are covered with the first sealing member 13. The edges of the surface of the back sheet 7 parallel to the xy plane are also covered with the first sealing member 13.

[0054] Next, a silicone resin-containing layer 2 and a UV shielding layer 1 are provided on the glass substrate 3 to obtain the solar cell 101 shown in Figure 3. The silicone resin-containing layer 2 is formed by, for example, coating or sheet bonding. The UV shielding layer 1 is formed by, for example, sputtering, coating or sheet bonding.

[0055] <Manufacturing method for solar cell 102, example 3> The third example solar cell 102 is manufactured, for example, by manufacturing method IV. Manufacturing method IV includes manufacturing the first example solar cell 100 by manufacturing method I or manufacturing method II, and covering the edges (four sides) of each component, the UV shielding layer 1, the silicone resin-containing layer 2, the glass substrate 3, the transparent electrode 4, the element part 5, the adhesive layer 6, and the backsheet 7, with the second sealing member 14. The edge of at least one surface (xy plane) of the UV shielding layer 1 or the backsheet 7 may also be covered with the second sealing member 14.

[0056] <Manufacturing method for solar cell 103, example 4> The fourth example of solar cell 103 is manufactured, for example, by manufacturing method V. Manufacturing method V involves stacking a first glass substrate on which a first solar cell element is provided as a first photoelectric conversion element on its first surface, and a second glass substrate on which a second solar cell element is provided as a second photoelectric conversion element on its first surface, in a structure in which the first solar cell element and the second solar cell element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. This includes forming a silicone resin-containing layer on the second surface of the first glass substrate and on the second surface of the second glass substrate.

[0057] Manufacturing method V will be explained with reference to Figures 18-20.

[0058] First and second assemblies 203A and 203B are prepared. The first assembly 203A is shown in Figure 18. The first assembly 203A has a structure in which a first transparent electrode 4A, a first element part 5A, and a first adhesive layer 6A are stacked in this order in the z-axis direction on an unpolished first glass substrate 16A. The second assembly 203B has a structure in which a second transparent electrode 4B, a second element part 5B, and a second adhesive layer 6B are stacked in this order in the z-axis direction on an unpolished second glass substrate 16B. The stacking of each component is carried out by appropriately selecting from methods such as sputtering, coating, and vapor deposition, depending on the type of component.

[0059] Next, as shown in Figure 19, the second assembly 203B is laminated onto the first assembly 203A. Lamination is performed by overlapping the first adhesive layer 6A of the first assembly 203A with the second adhesive layer 6B of the second assembly 203B. In the resulting laminate 204, the first solar cell element 8A and the second solar cell element 8B are positioned between the first surface S5 of the first glass substrate 16A and the first surface S6 of the second glass substrate 16B. Subsequently, the ends (four sides) of the first and second solar cell elements 8A and 8B, which are bonded together by the first adhesive layer 6A and the second adhesive layer 6B, are covered with the third sealing member 15.

[0060] Next, as shown in Figure 20, the second surface S7 of the first glass substrate 16A and the second surface S8 of the second glass substrate 16B of the laminate 204 are chemically polished to reduce the thickness of the first and second glass substrates 16A and 16B to 250 μm or less. In this way, a laminate 204 is obtained having the first and second glass substrates 3A and 3B with a thickness of 250 μm or less. Note that in Figures 19 and 20, a boundary is shown between the first adhesive layer 6A of the first assembly 203A and the second adhesive layer 6B of the second assembly 203B to clarify the distinction between them, but the boundary does not always exist.

[0061] Next, a first silicone resin-containing layer 2A and a first UV shielding layer 1A are provided on the first glass substrate 3A of the laminate 204. A second silicone resin-containing layer 2B and a second UV shielding layer 1B are provided on the second glass substrate 3B. The silicone resin-containing layer is formed, for example, by coating or sheet bonding. The UV shielding layer is formed, for example, by sputtering, coating or sheet bonding. In this way, a solar cell 103 with a structure similar to that of Figure 5 is obtained, except that the adhesive layer 6 consists of a first adhesive layer 6A and a second adhesive layer 6B.

[0062] <Manufacturing method for solar cell 104, example 5> The fifth example of solar cell 104 is manufactured, for example, by manufacturing method VI. Manufacturing method VI involves stacking a first glass substrate on which a solar cell element is provided as a photoelectric conversion element on its first surface, and a second glass substrate having a first surface, in a structure in which the solar cell element is positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. This includes forming a silicone resin-containing layer on the second surface of the first glass substrate and on the second surface of the second glass substrate.

[0063] Manufacturing method VI will be explained with reference to Figures 21 and 22.

[0064] As shown in Figure 21, a laminate 205 is fabricated in which a transparent electrode 4, an element portion 5, and an adhesive layer 6 are positioned from the first surface S5 side between the first surface S5 of an unpolished first glass substrate 16A and the first surface S6 of an unpolished second glass substrate 16B. The lamination of each component is carried out by appropriately selecting from methods such as sputtering, coating, and vapor deposition, depending on the type of component. After that, an adhesive 15 is applied to the edges (four sides) of the transparent electrode 4, the element portion 5, and the adhesive layer 6 to integrate these layers. An example of the adhesive 15 is epoxy resin. The adhesive 15 can function as a third sealing member 15.

[0065] Next, as shown in Figure 22, the second surface S7 of the first glass substrate 16A and the second surface S8 of the second glass substrate 16B of the laminate 205 are chemically polished to reduce the thickness of the first and second glass substrates 16A and 16B to 250 μm or less. In this way, a laminate 205 is obtained having the first and second glass substrates 3A and 3B with a thickness of 250 μm or less.

[0066] Next, a first silicone resin-containing layer 2A and a first UV shielding layer 1A are provided on the first glass substrate 3A of the laminate 205. A second silicone resin-containing layer 2B is provided on the second glass substrate 3B. The silicone resin-containing layer is formed, for example, by coating or sheet bonding. The UV shielding layer is formed, for example, by sputtering, coating or sheet bonding. This process yields a solar cell 104 with the structure shown in Figure 6.

[0067] <Manufacturing method for solar cell 105, example 6> The sixth example solar cell 105 is manufactured, for example, by manufacturing method VII. In manufacturing method VII, a laminate 205 is prepared according to manufacturing method VI and then chemically polished. After that, a step is performed to remove the adhesive 15 from the laminate 205. After the removal of the adhesive 15, a silicone resin-containing layer is formed according to manufacturing method VI.

[0068] The process of removing the adhesive will be explained with reference to Figure 23.

[0069] In the laminate 205 after chemical polishing, in order to remove the adhesive 15 adhering to the edges (four sides) of the transparent electrode 4, element portion 5, and adhesive layer 6, the laminate is cut in the thickness direction (z-axis direction) along the vicinity 20 of the boundary between the side and the adhesive 15, and the adhesive 15 is removed. Here, a gap may or may not exist between the side and the adhesive 15. A gap between the side and the adhesive 15 is preferable because it facilitates separation from the adhesive 15.

[0070] Next, a first silicone resin-containing layer 2A and a first UV shielding layer 1A are provided on the first glass substrate 3A of the laminate 205. A second silicone resin-containing layer 2B is provided on the second glass substrate 3B. The silicone resin-containing layer is formed, for example, by coating or sheet bonding. The UV shielding layer is formed, for example, by sputtering, coating or sheet bonding. This results in a solar cell 105 with the structure shown in Figure 7.

[0071] According to the second embodiment described above, the solar cell of the first embodiment can be manufactured efficiently. In the second embodiment, the glass substrate was thinned by polishing, but instead of polishing, a glass substrate with a thickness of 250 μm or less may be used from the beginning of the manufacturing process. [Examples]

[0072] The following describes an example of a solar cell. The impact resistance of the solar cell in the embodiment was confirmed by a hailstorm test in accordance with JIS C 8917:2005 Environmental Test Methods and Durability Test Methods for Crystalline Solar Cell Modules.

[0073] For the test, we used a solar cell 100 from the first example that did not have the UV shielding layer 1. As shown in Figure 24, the solar cell 100 from the first example was placed on a test stand (not shown) with the silicone resin-containing layer 2 facing upwards. Based on the iron ball drop test specified in JIS R 3212, which simulates a hailstorm test, an iron ball 30 with a diameter of 38.1 mm and a weight of 225 g was dropped from a height of 1 m along direction 31, and the iron ball 31 struck the surface of the silicone resin-containing layer 2 of the solar cell 100. No damage such as cracks occurred in the glass substrate 3. The same iron ball drop test was also performed on solar cells 103, 104, and 105 from the fourth to sixth examples, which use the first and second glass substrates 3A and 3B, respectively. No damage such as cracks occurred in either the first or second glass substrates 3A or 3B. From the above tests, it was confirmed that a solar cell with flexibility and excellent impact resistance can be realized by this embodiment.

[0074] According to at least one embodiment or example of the photoelectric conversion device, it comprises a glass substrate with a thickness of 250 μm or less, a photoelectric conversion element provided on the first surface of the glass substrate, and a silicone resin-containing layer provided on the second surface of the glass substrate. According to such a photoelectric conversion device, excellent impact resistance can be achieved while reducing weight and improving flexibility. Therefore, damage to the glass substrate can be suppressed even when the photoelectric conversion device is used outdoors, and the gas barrier properties of the glass substrate, such as water vapor and oxygen, can be maintained for a long period of time.

[0075] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. [Explanation of Symbols]

[0076] 1...UV shielding layer, 1A...First UV shielding layer, 1B...Second UV shielding layer, 2...Silicone resin-containing layer, 2A...First silicone resin-containing layer, 2B...Second silicone resin-containing layer, 3...Glass substrate, 3A...First glass substrate, 3B...Second glass substrate, 4...Transparent electrode, 4A...First transparent electrode, 4B...Second transparent electrode, 5...Element part, 5A...First element part, 5B...Second element part, 6...Adhesive layer, 6A...First adhesive layer, 6B...Second adhesive layer, 7...Backsheet, 7A...First backsheet, 7B...Second backsheet, 8...Solar cell element, 8A...First solar cell element, 8B...Second solar cell 10...Potential element, 9...Hole transport layer, 10...Photoelectric conversion layer, 11...Electron transport layer, 12...Cathode, 13...First sealing member, 14...Second sealing member, 15...Third sealing member, 15...Adhesive, 16...Glass substrate, 16A...First glass substrate, 16B...Second glass substrate, 17...Protective sheet, 18...Adhesive, 19...Cutting position, 20...Near the boundary, 100~105...Solar cell, 200...Laminate, 200A...First structural part, 200B...Second structural part, 201...Laminate, 202...Laminate, 203A...First assembly, 203B...Second assembly, 204...Laminate, 205...Laminate.

Claims

1. A glass substrate having a thickness of 250 μm or less, and having a first surface and a second surface located on the back side of the first surface, A photoelectric conversion element provided on the first surface of the glass substrate, A silicone resin-containing layer provided on the second surface of the glass substrate and A photoelectric conversion device equipped with the following features.

2. The photoelectric conversion device according to claim 1, wherein at least one of the glass substrate or the silicone resin-containing layer is capable of shielding from ultraviolet light.

3. The photoelectric conversion device according to claim 1, further comprising a layer provided in the silicone resin-containing layer and capable of shielding against ultraviolet light.

4. The glass substrate is designated as the first glass substrate. A second glass substrate having a thickness of 250 μm or less and having a first surface and a second surface located on the back side of the first surface, A second silicone resin-containing layer provided on the second surface of the second glass substrate and Furthermore, The photoelectric conversion device according to claim 1, wherein the first surface of the second glass substrate is spaced apart from the first surface of the first glass substrate, and the photoelectric conversion element is located between the first surface of the second glass substrate and the first surface of the first glass substrate.

5. The photoelectric conversion device according to claim 4, further comprising a second photoelectric conversion element provided on the first surface of the second glass substrate.

6. The photoelectric conversion device described in claim 1 is a perovskite solar cell.

7. To form a photoelectric conversion element on the first surface of a glass substrate, By chemically polishing the second surface located on the back side of the first surface of the glass substrate, the thickness of the glass substrate is reduced to 250 μm or less. A silicone resin-containing layer is formed on the second surface of the glass substrate. A method for manufacturing a photoelectric conversion device, comprising the above.

8. To obtain a laminate having a structure in which the first photoelectric conversion element and the second photoelectric conversion element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate, by laminating a first structural part including a first structural part including a first structural part including a first structural part including a first structural part including a first structural part including a first structural part including a first structural part and the second structural part including a second structural part including a second structural part including a first structural part including a first structural part and the first surface of the second glass substrate, and the first photoelectric conversion element and the second photoelectric conversion element. In the laminate, the thickness of the first glass substrate and the second glass substrate is reduced to 250 μm or less by chemically polishing the second surface of the first glass substrate and the second surface of the second glass substrate. To separate the first structural part and the second structural part from the laminate, A silicone resin-containing layer is formed on the second surface of the first glass substrate of the first structural part and on the second surface of the second glass substrate of the second structural part. A method for manufacturing a photoelectric conversion device, comprising the above.

9. A first glass substrate having a first photoelectric conversion element on its first surface and a second glass substrate having a second photoelectric conversion element on its first surface are stacked in such a structure that the first photoelectric conversion element and the second photoelectric conversion element are positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. A silicone resin-containing layer is formed on the second surface of the first glass substrate and on the second surface of the second glass substrate. A method for manufacturing a photoelectric conversion device, comprising the above.

10. A first glass substrate having a first photoelectric conversion element on its first surface and a second glass substrate having a first surface are stacked in such a structure that the first photoelectric conversion element is positioned between the first surface of the first glass substrate and the first surface of the second glass substrate. In the resulting laminate, the second surface located on the back side of the first surface of the first glass substrate and the second surface located on the back side of the first surface of the second glass substrate are chemically polished to reduce the thickness of the first and second glass substrates to 250 μm or less. A silicone resin-containing layer is formed on the second surface of the first glass substrate and on the second surface of the second glass substrate. A method for manufacturing a photoelectric conversion device, comprising the above.

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