TW202423263A - Long laminate, photovoltaic device, and method for producing photovoltaic device - Google Patents

Abstract

The present invention addresses the problem of providing: a long laminate which can be used in production of a high-quality photovoltaic device; a high-quality photovoltaic device; and a method for producing a photovoltaic device using said long laminate. The present invention pertains to a long laminate, and the like, the long laminate including a base material layer having a width direction and a longitudinal direction, and a laminate. The laminate includes: a first electrode formed on the base material layer; a photovoltaic layer at least partially formed on the first electrode; and a second electrode at least partially formed on the photovoltaic layer. The second electrode has a region 2-1 which is opposite to the first electrode, and a region 2-2 which is not opposite to the first electrode. The region 2-2 is present on one side in the width direction of the base material layer and is not present on the other side in the width direction of the base material layer. The long laminate is wound in a reel-shape.

Description

Long stacked layer, photovoltaic device, and method for manufacturing photovoltaic device

The present invention relates to a long stacked layer, a photovoltaic device, and a method for manufacturing the photovoltaic device.

In recent years, carbon dioxide emitted by the use of fossil fuels has become a cause of global warming. From the perspective of curbing global warming, research on solar cells that use sunlight as clean energy is gaining momentum. Solar cells are used not only outdoors but also indoors, and research on indoor solar cells for small IoT (Internet of Things) devices is also gaining momentum.

For example, regarding a solar cell used outdoors, Patent Document 1 discloses a solar cell that includes a laminate having a lower electrode, a power generation layer, and an upper electrode as a power generation portion, and an insulating portion exists at the boundary between a plurality of power generation portions. In this solar cell, a lower electrode, a power generation layer, and an upper electrode are sequentially laminated on a substrate, and these lower electrode, power generation layer, and upper electrode are patterned to form a predetermined concave-convex shape.

On the other hand, regarding solar cells used indoors, Patent Document 2 describes a solar cell module in which a solar cell cell has a lower electrode, a photoelectric conversion layer, and an upper electrode, and a current collector is provided on the upper electrode. Patent Document 2 also teaches that the solar cell module is manufactured in a roll-to-roll process. [Prior Technical Document] [Patent Document]

[Patent document 1] Japanese Patent Publication No. 6677087. [Patent document 2] International Publication No. 2013/137274 Brochure.

[The problem that the invention wants to solve]

However, in Patent Document 1, the existence ratio of the insulating portion in the boundary of the power generation portion is set to be 25% or more. Under this condition, since the ratio of the insulating portion increases and the power generation area decreases, the power generation area cannot be maximized relative to the total area of the laminated body with power generation function provided in the device, and the power generation efficiency is not sufficient. Furthermore, both Patent Document 1 and Patent Document 2 use an apparatus for preparing liquid, coating, film formation and other steps to manufacture the solar cell (hereinafter referred to as the laminated body with power generation function), and the solar cell has a certain shape and size. The voltage and current of the solar cell are also determined according to the size of the device. Therefore, after the solar cell is manufactured, it cannot match the shape and size of the device. Furthermore, in Patent Documents 1 and 2, it is considered to connect solar battery cells in series to reduce the wiring resistance to a certain extent, but it is desired to further reduce the wiring resistance.

On the other hand, as a means to solve the above-mentioned problem, it is considered to use a plurality of laminates including electrodes, power generation layers, etc. to produce a solar cell. However, for example, when a plurality of laminates (for example, a first laminate and a second laminate) are bonded to a device substrate, it is also hoped that even if a force is applied from the outside to the bonded first laminate and the second laminate to cause deformation, they can still stably perform their function as a photovoltaic device for a long period of time and have durability.

In view of the above, the subject of the present invention is to provide a long-layer body that can be used to manufacture high-quality photovoltaic devices, a high-quality photovoltaic device, and a method for manufacturing a photovoltaic device using the long-layer body. [Means for solving the subject]

That is, the present invention may include the following inventions. [1] A long stacked laminate comprising: a substrate layer having a width direction and a length direction; and a stacked laminate comprising a first electrode formed on the substrate layer, a photovoltaic layer at least partially formed on the first electrode, and a second electrode at least partially formed on the photovoltaic layer; the second electrode having a 2-1 region opposite to the first electrode and a 2-2 region not opposite to the first electrode; the 2-2 region exists on one side of the substrate layer in the width direction and does not exist on the other side of the substrate layer in the width direction; the long stacked laminate is wound into a reel shape. [2] The long stacked layer described in [1], wherein the first electrode has a 1-1 region opposite to the second electrode and a 1-2 region not opposite to the second electrode; the 1-2 region exists on the other side in the width direction and does not exist on the one side in the width direction. [3] The long stacked layer as described in [2], wherein the aforementioned 1-2 region has: a portion where no other layer is provided between the aforementioned 1-2 region and the height at which the aforementioned second electrode is provided on the aforementioned photovoltaic layer; The aforementioned 2-2 region has: a portion where no other layer is provided between a portion extending on the aforementioned substrate layer through the side surface of the aforementioned photovoltaic layer and the height at which the aforementioned second electrode is provided on the aforementioned photovoltaic layer; or the aforementioned photovoltaic layer has: a portion provided below the aforementioned 2-2 region and where no electrode is provided below. [4] A stacked structure comprising: a substrate layer; and the stacked structure comprises a first electrode on the substrate layer, a second electrode on the first electrode, and a photovoltaic layer between the first electrode and the second electrode; the first electrode has a portion which is not opposite to the second electrode and has no other layer between the first electrode and the height at which the second electrode is provided on the photovoltaic layer; The second electrode has a portion extending on the substrate layer through the side of the photovoltaic layer, and no other layer is provided between the extended portion and the height at which the second electrode is provided on the photovoltaic layer; or the photovoltaic layer has a portion provided below the second electrode, and no electrode exists below the second electrode. [5] A long stacked layer as described in any one of [1] to [4], wherein the stacked layer comprises a first electrode, a photovoltaic layer, and a second electrode, and a plurality of the stacked layers exist in the length direction of the substrate layer. [6] A long-layer structure as described in any one of [1] to [5], wherein a protective layer is further provided on the second electrode at least through a bonding layer; The first electrode is formed on the substrate layer at least through the bonding layer; The peeling force when the protective layer is peeled off from the second electrode is greater than the peeling force when the substrate layer is peeled off from the first electrode. [7] A long-layer structure as described in any one of [1] to [6], wherein the photovoltaic layer comprises an organic thin film. [8] A photovoltaic device comprising: a device substrate, a first laminate and a second laminate; The first laminate and the second laminate each include: a first electrode at least partially formed on the device substrate, a photovoltaic layer at least partially formed on the first electrode, and a second electrode at least partially formed on the photovoltaic layer; The first laminate and the second laminate are formed in parallel on the device substrate; In each of the first laminate and the second laminate, the second electrode has a 2-1 region opposite to the first electrode and a 2-2 region not opposite to the first electrode; In each of the aforementioned first laminate and the aforementioned second laminate, the aforementioned first electrode has a 1-1 region opposite to the aforementioned second electrode, and a 1-2 region not opposite to the aforementioned second electrode; In the aforementioned photovoltaic device, The aforementioned 1-2 region of the aforementioned first electrode of the aforementioned first laminate overlaps with the aforementioned 2-2 region of the aforementioned second electrode of the aforementioned second laminate and is electrically connected; or The photovoltaic layer of the first laminate has: a portion disposed below the 2-2 region of the second electrode of the first laminate and overlapping and electrically connected to the 1-2 region of the first electrode of the second laminate; and the 1-2 region of the first electrode of the second laminate has a portion where no other layers are disposed between the portion overlapping with the photovoltaic layer and the 1-1 region of the first electrode of the second laminate, from above the first electrode to the height where the second electrode is disposed on the photovoltaic layer of the second laminate. [9] A photovoltaic device as described in [8], wherein a first bonding layer is provided between the device substrate and the first electrode of one or both of the first laminate and the second laminate. [10] A photovoltaic device as described in [9], wherein a protective layer is provided on the second electrode of one or both of the first laminate and the second laminate via the second bonding layer, and in the photovoltaic device, a peeling force when peeling off the device substrate is greater than a peeling force when peeling off the protective layer. [11] A photovoltaic device as described in any one of [8] to [10], wherein a barrier layer is provided on the first layer and the second layer to cover the first layer and the second layer. [12] A photovoltaic device as described in any one of [8] to [11], wherein the photovoltaic layer comprises an organic thin film. [13] A photovoltaic device, wherein the stack of layers as described in any one of [1] to [7] is transferred onto a device substrate and electrically connected. [14] A method for manufacturing a photovoltaic device, which is a method for manufacturing a photovoltaic device using a long stacked layer as described in any one of [2], [3] and [5] to [7], comprising the following steps: peeling off the substrate layer from the long stacked layer; and transferring the long stacked layer to the device substrate in such a manner that the 1-2 region of the first electrode or the 2-2 region of the second electrode in the long stacked layer, or when the photovoltaic layer has a portion disposed below the 2-2 region, such portion overlaps and contacts the electrode disposed on the device substrate of the other stacked layer. [Invention effect]

According to the present invention, a long stacked layer that can be used to manufacture a high-quality photovoltaic device, a high-quality photovoltaic device, and a method for manufacturing a photovoltaic device using the long stacked layer can be provided.

Hereinafter, the present invention will be described in more detail according to the following embodiments. However, the present invention is not limited by the following embodiments. Of course, it can also be implemented by appropriately applying changes within the scope of the subject matter of the preceding and following texts, and they are all included in the technical scope of the present invention. In addition, in each figure, sometimes the hatching or component symbols are omitted for convenience. In this case, the manual or other figures should be referred to. Furthermore, since the dimensions of various components in the drawings are given priority in helping to understand the features of the present invention, they are sometimes different from the actual dimensions.

For ease of reference, an example is shown in the figure, and the description of up and down is used in this specification for explanation, but the present embodiment is not necessarily limited to this. For example, even if the change isotropic in up and down reversal, the objects and methods that can be realized by the ideas disclosed in this specification are also within the scope of disclosure of this embodiment. In this specification, regarding the relationship between two components A and B, it is sometimes recorded that component B is provided on component A, component B is provided on the upper surface of component A, etc. In addition to meaning the situation where component A and component B are in direct contact, such a description also allows other components to exist between component A and component B to the extent that the effect is not affected.

The present invention includes a long stacked layer, a photovoltaic device, and a method for manufacturing a photovoltaic device of the first aspect, and a long stacked layer, a photovoltaic device, and a method for manufacturing a photovoltaic device of the second aspect. In the following, unless the first aspect and the second aspect are specifically mentioned, both the first aspect and the second aspect may be considered to be mentioned. Furthermore, the symbols of the figures in the first aspect are represented by a combination of I and a number (I-1, etc.), and the symbols of the figures in the second aspect are represented by a combination of II and a number (II-1, etc.). The symbols of the figures of both the first aspect and the second aspect sometimes omit Roman numerals and are represented only by Arabic numerals.

1. Cone body The basic structure of the cone body is described with reference to FIGS. 1 to 3. FIG. 1 is a three-dimensional view of the cone body in an embodiment of the present invention, FIG. 2 is a cross-sectional view in a direction perpendicular to the length direction of the cone body in one embodiment (the first embodiment) of the present invention, and FIG. 3 is a cross-sectional view in a direction perpendicular to the length direction of the cone body in another embodiment (the second embodiment) of the present invention.

In the first and second aspects, the long stacked layer 1 (I-1, II-1) includes: a substrate layer 2 (I-2, II-2) having a width direction and a length direction, and a stacked layer 6 (I-6, II-6) formed on the substrate layer 2 (I-2, II-2). The stacked layer 6 (I-6, II-6) includes: a first electrode 3 (I-3, II-3) formed on the substrate layer 2 (I-2, II-2), a photovoltaic layer 4 (I-4, II-4) at least partially formed on the first electrode 3 (I-3, II-3), and a second electrode 5 (I-5, II-5) at least partially formed on the photovoltaic layer 4 (I-4, II-4), and has a power generation function. The second electrode 5 (I-5, II-5) has a 2-1 region (I-10, II-10) opposite to the first electrode 3 (I-3, II-3) and a 2-2 region not opposite to the first electrode 3 (I-3, II-3), and the 2-2 region exists on one side of the width direction of the substrate layer 2 (I-2, II-2) and does not exist on the other side of the width direction of the substrate layer 2 (I-2, II-2). The long-layer body 1 (I-1, II-1) is wound into a roll shape, for example. Furthermore, the long-layer body 1 (I-1, II-1) may also have a protective layer 7 (I-7, II-7) on the second electrode 5 (I-5, II-5). In the following, the width direction and length direction of a certain structure are mentioned for explanation. In this manual, the width direction of the structure is assumed to be substantially parallel to the width direction of the substrate layer, and the length direction of the structure is assumed to be substantially parallel to the length direction of the substrate layer. However, such explanation is only for convenience. For a certain structure, the lengths of these two directions can be appropriately changed within the range that does not affect the effect. Sometimes, the direction described as the length (long side) direction can be changed to the short side direction.

In the first embodiment of the long stacked layer I-1, the second electrode I-5 is preferably formed on the photovoltaic layer I-4, and is also formed on the side surface of the photovoltaic layer I-4 and the substrate layer I-2.

In the second state of the long stacked layer II-1, the second electrode II-5 is preferably formed only on the photovoltaic layer II-4, and preferably one side of the photovoltaic layer II-4 in the width direction is formed on the first electrode II-3, and the other side of the photovoltaic layer II-4 in the width direction is not formed on the first electrode II-3.

The long-walled laminate 1 has predetermined dimensions in the thickness direction, the width direction, and the length (long side) direction. The dimension in the length direction of the long-walled laminate 1 only needs to be longer than the dimension in the width direction, preferably 6 cm to 100 m, more preferably 10 cm to 80 m, and more preferably 15 cm to 50 m. The dimension in the width direction of the long-walled laminate 1 is preferably 1 cm to 100 cm, more preferably 2 cm to 80 cm, more preferably 5 cm to 60 cm, and more preferably 10 cm to 40 cm. The dimension of the thickness direction of the long stacked layer 1 is preferably 1 μm to 10000 μm, more preferably 2 μm to 8000 μm, further preferably 5 μm to 6000 μm, further preferably 10 μm to 4000 μm.

1. (1) Substrate layer The substrate layer 2 is not particularly limited as long as it has flexibility and heat resistance to form the first electrode 3, photovoltaic layer 4, and second electrode 5. Materials constituting the substrate layer 2 include organic materials, metal materials, cloth materials, paper materials, etc.

As organic materials, there can be mentioned polyester resin, methacrylic acid resin, methacrylic acid-maleic acid copolymer resin, polystyrene resin, fluorine resin, polyimide resin, fluorinated polyimide resin, polyamide resin, polyamide imide resin, polyether imide resin, cellulose resin, polyurethane resin, Polyetheretherketone resin, polycarbonate resin, alicyclic polyolefin resin, polyarylate resin, polyether sulphate resin, polysulphate resin, cycloolefin resin, polyethylene terephthalate resin, polyethylene naphthalate resin, polyethylene resin, polypropylene resin and other olefin resins; vinyl resins such as polyvinyl chloride resin and polyvinyl alcohol resin, etc. As metal materials, there are aluminum and copper that impart insulation. As fabric materials, there are non-woven fabrics, meshes, etc. As paper materials, there are paper or synthetic paper, etc.

The base material layer 2 may be any one of the above materials or a combination of the above materials. One or more organic materials, metal materials, cloth materials, and paper materials may be used.

Among them, from the viewpoint of flexibility and heat resistance, organic materials are preferred, and plastic films made of organic materials are more preferred. From the viewpoint of durability, plastic films preferably have a low water vapor permeability.

When an organic material is used as the base material layer 2, the organic material may have a predetermined glass transition temperature as an indicator of predetermined strength, and the glass transition temperature of the organic material is preferably 50° C. or higher, more preferably 60° C. or higher, and preferably 300° C. or lower, more preferably 280° C. or lower. The glass transition temperature can be calculated according to JIS K 7121, for example.

The shape of the substrate layer 2 may be any of a plate, a film, or a sheet. On the other hand, a curved surface structure may be formed on a part or all of the substrate layer 2. If a curved surface structure is formed, it can be applied to materials with streamlined shapes (for example, cars, airplanes, roof tiles, cups, bottles, etc.).

The dimension of the substrate layer 2 in the thickness direction is, for example, 0.5 μm to 50 μm, preferably 1 μm to 20 μm, more preferably 2 μm to 10 μm, and further preferably 3 μm to 8 μm. The dimensions of the substrate layer 2 in the width direction and the length direction may also be the same as those of the stacked layer 1 in the width direction and the length direction.

The base layer 2 is preferably wound into a roll shape. As described above, when a plurality of laminated bodies 6 are present along the longitudinal direction of the base layer 2, the base layer 2 is preferably wound into a roll shape along the longitudinal direction. By winding the substrate layer 2 into a roll shape, when there are substrate layer 2 (I-2, II-2), laminate 6 (I-6, II-6) (including first electrode 3 (I-3, II-3), photovoltaic layer 4 (I-4, II-4), second electrode 5 (I-5, II-5)) on substrate layer 2 (I-2, II-2), and protective layer 7 (I-7, II-7), the protective layer 7 (I-7, II-7) can also be wound into a roll shape. In this way, the long laminate 1 (I-1, II-1) wound into a roll shape is preferably formed into a film roll. When forming a film roll, for example, when the long-layered structure 1 includes a plurality of long-layered structures 6, the handling of the long-layered structure 1 can be facilitated. In this specification, when the long-layered structure 1 (I-1, II-1) is described as being rolled into a roll, it means that the long-layered structure 1 (I-1, II-1) is rolled into a roll as a whole and the long-layered structure 1 (I-1, II-1) is partially rolled into a roll.

The substrate layer 2 is preferably in contact with the first electrode 3 via the bonding layer, and the substrate layer 2 is preferably peelable in a manner that enables the laminate 6 including the first electrode 3, the photovoltaic layer 4, and the second electrode 5 to be attached to a desired object. In the case where the substrate layer 2 is in contact with the first electrode 3 via the bonding layer, if the substrate layer 2 is peeled off, for example, the bonding layer remains on the side of the first electrode 3, and the first electrode 3 can be attached to a desired object by the bonding force of the bonding layer. It is preferred that a bonding layer is partially provided in the portion used for electrical connection described later, such as the first electrode 3, or no bonding layer is provided. The same is true for other bonding layers described later.

As described above, the bonding layer itself can be a layer that can be peeled off, but a peeling layer different from the bonding layer can also be provided. When the peeling layer and the bonding layer are provided in sequence between the substrate layer 2 and the first electrode 3, if the substrate layer 2 is peeled off, for example, the bonding layer remains on the first electrode 3 side, and the first electrode 3 can be attached to a desired object by the bonding force of the bonding layer. By providing the peeling layer, the substrate layer 2 can be easily peeled off. As materials for the peeling layer, silicone-based materials and non-silicone-based materials (such as acrylic materials and urethane materials) can be listed.

1. (2) Laminated body The laminated body 6 (I-6, II-6) includes a first electrode 3 (I-3, II-3), a photovoltaic layer 4 (I-4, II-4) and a second electrode 5 (I-5, II-5). In the laminated body 6 (I-6, II-6), at least a portion of the photovoltaic layer 4 (I-4, II-4) is formed on the first electrode 3 (I-3, II-3), and at least a portion of the second electrode 5 (I-5, II-5) is formed on the photovoltaic layer 4 (I-4, II-4). The first electrode 3 (I-3, II-3), the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5) can be stacked in sequence, and other layers can also be formed between the first electrode 3 (I-3, II-3) and the photovoltaic layer 4 (I-4, II-4), and between the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5). Other layers are preferably hole extraction layers, electron extraction layers, and bonding layers composed of conductive paste, etc., as described later.

The laminate 6 (I-6, II-6) including the first electrode 3 (I-3, II-3), the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5) may exist in one in the length direction of the substrate layer 2 (I-2, II-2), or may exist in a plurality along the length direction of the substrate layer 2 (I-2, II-2), preferably in a plurality along the length direction of the substrate layer 2 (I-2, II-2). When there are a plurality of laminates 6, it is preferred that there is a region where no laminate is formed between one laminate 6 and other laminates 6. Each laminate constitutes each element unit by means of this region. The plurality of laminates 6 are preferably laminates having the same structure.

When there are a plurality of laminates 6 in the length direction of the substrate layer 2, the number of laminates 6 is preferably 2 to 1000, more preferably 3 to 700, further preferably 5 to 400, further preferably 10 to 100.

The laminate 6 including the first electrode 3, the photovoltaic layer 4, and the second electrode 5 may be present in one or more layers in the width direction of the base layer 2.

The dimension of the laminate 6 in the width direction is, for example, 1 cm to 100 cm, preferably 2 cm to 80 cm, more preferably 5 cm to 60 cm, and more preferably 10 cm to 40 cm. The dimension of the laminate 6 in the length direction is, for example, 5 cm to 200 cm, preferably 10 cm to 150 cm, more preferably 15 cm to 100 cm, and more preferably 20 cm to 80 cm. The dimension of the laminate 6 in the thickness direction is, for example, 30 nm to 3000 nm, preferably 60 nm to 2400 nm, more preferably 90 nm to 1800 nm, and more preferably 150 nm to 1200 nm.

1.(3) First electrode The first electrode 3 (I-3, II-3) formed on the substrate layer 2 preferably has a 1-1 region (I-8, II-8) opposite to the second electrode 5 (I-5, II-5), and a 1-2 region (I-9, II-9) not opposite to the second electrode 5 (I-5, II-5). By having the first electrode 3 with this structure, in the first embodiment, the overlapping portion of the second electrode I-5 with other laminates can be arranged to connect multiple laminates in series and electrically connect them, and in the second embodiment, the overlapping portion of the photovoltaic layer II-4 with other laminates can be arranged to connect multiple laminates in series and electrically connect them. As a result, even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Furthermore, in the first embodiment, since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. The 1-2 region (I-9, II-9) of the first electrode can be a region where the second electrode 5 (I-5, II-5) is not formed, and can also be a region where both the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5) are not formed.

The 1-2 region (I-9, II-9) of the 1st electrode is preferably present on the other side of the width direction of the substrate layer 2 (I-2, II-2), and is also present on one side of the width direction of the substrate layer 2 (I-2, II-2). That is, the 1-2 region (I-9, II-9) of the 1st electrode is preferably not present on both sides of the 1-1 region (I-8, II-8) (2-1 region (I-10, II-10)) opposite to the 1st electrode 3 (I-3, II-3) and the 2nd electrode 5 (I-5, II-5), but is present on one side of the 1-1 region (I-8, II-8) (2-1 region (I-10, II-10)).

In the examples of Figs. 2 and 3, the first electrode 3 (I-3, II-3) more specifically has a portion where no other layers are provided between the height of the first electrode 3 (I-3, II-3) (which may be renamed as the 1-2 region (I-9, II-9)) and the second electrode 5 (I-5, II-5) provided on the photovoltaic layer 4 (I-4, II-4). In the examples of Figs. 2 and 3, the portion is provided at the end of the first electrode 3 (I-3, II-3). When manufacturing the photovoltaic device described later, by overlapping and contacting the electrodes of other laminates with the portion, a plurality of laminates connected in series can be formed.

When the first electrode 3 has a 1-1 region and a 1-2 region, the 1-1 region is preferably larger than the 1-2 region. That is, when the total length of the 1-1 region and the 1-2 region of the first electrode 3 (taking the length in the width direction as a reference) is set to 100%, the length ratio of the 1-1 region is preferably more than 50% and less than 90%, more preferably more than 60% and less than 85%, and further preferably more than 65% and less than 80%. If it is this length ratio, the electrons can flow in and out of the electrode smoothly.

On the other hand, when the total length of the 1-1 region and the 1-2 region of the first electrode 3 (the length in the width direction is set as a reference) is set to 100%, the length ratio of the 1-2 region is preferably 10% or more and less than 50%, more preferably 15% or more and less than 40%, and further preferably 20% or more and less than 35%. When the 1-2 region of the first electrode 3 satisfies the length ratio in the above range, as described later, if it is bonded to other laminates, a portion (overlapping portion) electrically connected to the second electrode or photovoltaic layer of the other laminates is formed, thereby connecting a plurality of laminates in series. As a result, even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Furthermore, in the first embodiment, since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. Furthermore, even if it is deformed by external force, it can stably perform its function for a long time, thereby improving the durability of the photovoltaic device.

1. (4) Second electrode At least a portion of the second electrode 5 (I-5, II-5) is formed on the photovoltaic layer 4 (I-4, II-4). In the first embodiment, the second electrode I-5 is not formed only on the photovoltaic layer I-4, but is preferably also formed on the side surface of the photovoltaic layer I-4 and the substrate layer I-2. In the example of FIG. 2, the second electrode I-5 has a portion extending on the substrate layer I-2 via the side surface of the photovoltaic layer I-4 (the 2-2z region described later). In the second embodiment, the second electrode II-5 is preferably formed only on the photovoltaic layer II-4.

The following describes the 2-1 region and the 2-2 region of the second electrode 5. The 2-1 region of the second electrode 5 is similar to the 1-1 region of the first electrode 3, and corresponds to the region where the first electrode 3 and the second electrode 5 face each other.

The 2-2 region 11 (I-11, II-11) of the second electrode 5 (I-5, II-5) is not opposite to the first electrode 3 (I-3, II-3), but exists on one side of the width direction of the substrate layer 2 (I-2, II-2), and does not exist in the region on the other side of the width direction of the substrate layer 2 (I-2, II-2). It is preferably formed only in the region on one side of the width direction of the substrate layer 2 (I-2, II-2).

In the first embodiment, the 2-2 region I-11 may also include a 2-2x region disposed on the photovoltaic layer I-4 (in FIG. 2, a region surrounded by symbols I-11xI and I-11yh), a 2-2y region disposed on the side of the photovoltaic layer I-4 (in FIG. 2, a region surrounded by symbols I-11yI and I-11yh), and a 2-2z region disposed on the substrate layer I-2 (in FIG. 2, a region surrounded by symbols I-11zI and I-11zh). The 2-2y region is preferably in contact with the side of the photovoltaic layer I-4, and the 2-2x region is preferably connected to the 2-2z region.

In the example of FIG. 2 of the first aspect, the 2-2z region of the second electrode 5 (I-5) is more specifically the 2-2z region of the 2-2 region I-11 of the second electrode 5 (I-5), as described above, which is a portion extending on the substrate layer I-2 via the side of the photovoltaic layer I-4, and no other layer is provided between the portion and the height at which the second electrode 5 (I-5) is provided on the photovoltaic layer I-4. In the example of FIG. 2, the portion is provided at the end of the second electrode 5 (I-5). By configuring the 2-2z region in this way, when manufacturing the photovoltaic device described later, by overlapping and contacting the 2-2z region with the electrodes of other laminates, a plurality of laminates connected in series can be formed.

In the first embodiment, the side of the photovoltaic layer I-4 is based on the lower surface of the photovoltaic layer I-4 and may have an inclination (e.g., more than 0 degrees to less than 90 degrees). When the inclination is 90 degrees, it may be vertical relative to the upper and lower surfaces of the photovoltaic layer I-4. The 2-2y region provided on the side of the photovoltaic layer I-4 may form a rectangle, parallelogram, etc. The upper and lower surfaces of the second electrode I-5 constituting the 2-2y region may also have an inclination starting point and an inclination ending point, and may also form an inclined surface (the inclination is based on the upper surface of the substrate layer I-2, e.g., more than 0 degrees to less than 90 degrees). The tilt starting point may be a point close to the substrate layer I-2, and the tilt ending point may be a point far from the substrate layer I-2.

In the first embodiment, the symbol I-11xI may be, for example, the length of the line segment connecting the contact between the lower surface of the second electrode I-5 and the upper surface of the photovoltaic layer I-4 corresponding to the contact between the 2-1 region I-10 and the 2-2 region I-11 of the second electrode I-5, and the contact between the upper surface of the photovoltaic layer I-4 and the side surface of the photovoltaic layer I-4. The symbol I-11yI may be, for example, the length of the line segment connecting the contact between the upper surface of the photovoltaic layer I-4 and the side surface of the photovoltaic layer I-4 and the contact between the surface parallel to the upper surface of the photovoltaic layer I-4 and the inclined surface originating from the upper surface of the second electrode I-5 (or the length corresponding to the dimension in the thickness direction of the second electrode I-5). Furthermore, the symbol I-11yI may be, for example, the length of the line segment connecting the two points formed by projecting the inclination starting point and the inclination ending point of the upper surface of the second electrode I-5 onto the upper surface of the substrate layer I-2. The symbol I-11zI may be, for example, the length of the line segment connecting the end point of the upper surface of the second electrode I-5 corresponding to the end point of the 2-2 region I-11 and the inclination starting point of the upper surface of the second electrode I-5. The symbol I-11xh may be, for example, the height corresponding to the dimension in the thickness direction of the second electrode I-5. The symbol I-11yh may be, for example, the height corresponding to the dimension in the thickness direction of the laminate I-6 composed of the first electrode I-3, the photovoltaic layer I-4, and the second electrode I-5. The symbol I-11zh may be, for example, the height corresponding to the dimension in the thickness direction of the first electrode I-3 and/or the second electrode I-5.

In the first embodiment, the lengths of the 2-2x region, the 2-2y region, and the 2-2z region (taking the length in the width direction as a reference) preferably have the relationship: the length of the 2-2x region (symbol I-11xI in FIG. 2 ) < the length of the 2-2y region (symbol I-11yI in FIG. 2 ) < the length of the 2-2z region (symbol I-11zI in FIG. 2 ). The thicknesses of the 2-1 region I-10 and the 2-2 region I-11 preferably have the following relationship: the thickness of the 2-1 region I-10 < the thickness of the 2-2 region I-11. The thicknesses of the 2-2x region, the 2-2y region, and the 2-2z region preferably have the following relationship: the thickness of the 2-2z region (symbol I-11zh in FIG2 ) ≦ the thickness of the 2-2x region (symbol I-11xh in FIG2 ) ＜ the thickness of the 2-2y region (symbol I-11yh in FIG2 ).

The 2-2 region (I-11, II-11) of the second electrode 5 (I-5, II-5) is preferably not present on both sides of the 2-1 region (I-10, II-10) (1-1 region 8 (I-8, II-8)) that the first electrode 3 (I-3, II-3) and the second electrode 5 (I-5, II-5) are opposite, but is present on one side of the 2-1 region (I-10, II-10) (1-1 region (I-8, II-8)). By having the second electrode 5 with this structure, an overlapping portion with other laminates can be provided, thereby connecting a plurality of laminates in series and electrically connecting them. As a result, even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Furthermore, in the first aspect, since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced.

When the total length of the 2-1 region and the 2-2 region of the second electrode 5 (taking the length in the width direction as a reference) is assumed to be 100%, the length ratio of each of the 2-1 region and the 2-2 region is as follows.

In the first embodiment, from the viewpoint of the inflow or outflow of electrons between the 2-1 region I-10 of the second electrode I-5 and the photovoltaic layer, it is preferred to have a longer length of the 2-1 region I-10 and the 2-2 region I-11. When the total length of the 2-1 region I-10 and the 2-2 region I-11 of the second electrode I-5 (taking the length in the width direction as a reference) is set to 100%, the length ratio of the 2-1 region I-10 of the second electrode I-5 is preferably 45% to 80%, more preferably 50% to 75%, and further preferably 55% to 70%. If the length ratio is 45% or more, electrons can flow in or out smoothly between the photovoltaic layer. On the other hand, if the length ratio is 80% or less, the length equivalent to the 2-2 region can be ensured.

In the first embodiment, from the perspective of ensuring the bonding portion formed in the width direction of the substrate layer with other laminates, the 2-2 region I-11 of the second electrode I-5 may have a length shorter than the length of the 2-1 region I-10. When the total length of the 2-1 region I-10 and the 2-2 region I-11 of the second electrode I-5 (taking the length in the width direction as a reference) is set to 100%, the length ratio of the 2-2 region I-11 of the second electrode I-5 is preferably 20% to 55%, more preferably 25% to 50%, and further preferably 30% to 45%. If the length ratio is 20% or more, it is easy to ensure the bonding portion with other laminates. On the other hand, if the length ratio is less than 55%, electrons can flow in or out smoothly between the photovoltaic layer and the photovoltaic layer.

That is, when the 2-2 region I-11 of the second electrode I-5 satisfies the length ratio within the above range, if it is bonded to other laminates, a portion (overlapping portion) electrically connected to the first electrode or photovoltaic layer 4 of other laminates is formed, thereby forming a plurality of laminates with power generation functions connected in series. As a result, even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Furthermore, in the first embodiment, since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. Furthermore, even if it is deformed by external force, it can still function stably for a long time, thereby improving the durability of the photovoltaic device.

In the example of FIG. 3 of the second aspect, the photovoltaic layer II-4 has a portion provided below the second electrode II-5 (more specifically, provided below the 2-2 region II-11) where no electrode exists. In the example of FIG. 3, the portion is provided at the end of the photovoltaic layer II-4. Thus, when manufacturing the photovoltaic device described later, by overlapping and contacting the electrodes of other laminates, a plurality of laminates connected in series can be formed.

In the second embodiment, from the viewpoint of ensuring the bonding portion with other laminates, the 2-2 region II-11 of the second electrode II-5 may also have a length longer than the length of the 2-1 region II-10. In the second embodiment, when the total length of the 2-1 region II-10 and the 2-2 region II-11 of the second electrode II-5 (taking the length in the width direction as a reference) is set to 100%, the length ratio of the 2-2 region II-11 of the second electrode II-5 is preferably 45% to 80%, more preferably 50% to 75%, and further preferably 55% to 70%.

In the second embodiment, when the total length of the 2-1 region II-10 and the 2-2 region II-11 of the second electrode II-5 (the length in the width direction is taken as a reference) is set to 100%, the length ratio of the 2-1 region II-10 of the second electrode II-5 is preferably 20% to 55%, more preferably 25% to 50%, and further preferably 30% to 45%. If the length ratio is 20% or more, the strength of the laminate can be easily ensured. On the other hand, if the length ratio is 55% or less, the bonding portion with other laminates can be easily ensured.

The 2-2 region (I-11, II-11) of the second electrode 5 (I-5, II-5) and the 1-2 region (I-9, II-9) of the first electrode 3 (I-3, II-3) are preferably present on one side and the other side of the width direction of the substrate layer 2 (I-2, II-2), respectively. The 2-2 region 11 of the second electrode 5 and the 1-2 region of the first electrode 3 may have the same length or different lengths.

It is preferred that one of the first electrode 3 and the second electrode 5 is a negative electrode (anode) and the other is a positive electrode (cathode). Furthermore, it is preferred that at least the second electrode 5 is light-transmissive, and it is more preferred that both the second electrode 5 and the first electrode 3 are light-transmissive. The first electrode 3 and the second electrode 5 are made of conductive materials respectively, and may be a single layer or a multilayer structure of two or more layers.

The negative electrode is made of a conductive material with a high work function, and the electrons flow out to the electrode of the external circuit. As materials constituting the negative electrode, there can be listed: metal oxides such as nickel oxide, tin oxide, indium oxide, indium tin oxide (ITO), indium-zirconium oxide (IZO), titanium oxide, indium oxide or zinc oxide; metals such as gold, platinum, silver, chromium, cobalt, and their alloys. Furthermore, as materials constituting the negative electrode, PEDOT:PSS formed by doping polythiophene derivatives with polystyrene sulfonic acid, and conductive polymer materials formed by doping polypyrrole or polyaniline with iodine can be used. When the negative electrode is a transparent electrode, it is preferred to use a light-transmitting metal oxide such as ITO, zinc oxide or tin oxide, and it is more preferred to use ITO.

The dimension of the electrode that serves as the negative electrode in the first electrode or the second electrode in the thickness direction is, for example, 10 nm to 1000 nm, preferably 20 nm to 800 nm, more preferably 30 nm to 600 nm, and further preferably 50 nm to 400 nm. If the dimension of the electrode that serves as the negative electrode in the thickness direction is within such a range, light can be efficiently converted into electricity without reducing the transmittance.

The dimension in the width direction of the electrode serving as the negative electrode in the first electrode or the second electrode may be the same as or different from the dimension in the width direction of the laminate body 6.

The electrode that becomes the negative electrode among the first electrode or the second electrode may also have a predetermined sheet resistance, and the value of the sheet resistance is, for example, 1Ω/□ to 1000Ω/□, preferably 2Ω/□ to 500Ω/□, and more preferably 5Ω/□ to 100Ω/□.

The electrode that becomes the negative electrode in the first electrode or the second electrode can be formed by using a vacuum film-forming method such as evaporation or sputtering; a wet coating method that forms a film by applying ink containing nanoparticles, etc., or can be formed into a predetermined shape by etching, etc. as needed.

The positive electrode is an electrode made of a conductive material with a low work function and into which electrons flow. As materials constituting the positive electrode, there are: metals such as platinum, gold, silver, copper, iron, tin, zinc, aluminum, indium, chromium, lithium, sodium, potassium, cesium, calcium, magnesium and their alloys; inorganic salts such as lithium fluoride and cesium fluoride; metal oxides such as nickel oxide, aluminum oxide, lithium oxide, and cesium oxide. Preferred materials constituting the positive electrode are metals such as platinum, gold, silver, copper, iron, tin, aluminum, calcium, indium and alloys made of indium oxide tin and the above metals.

The dimension of the electrode that serves as the positive electrode in the first electrode or the second electrode in the thickness direction is, for example, 10 nm to 1000 nm, preferably 20 nm to 800 nm, more preferably 30 nm to 600 nm, and further preferably 50 nm to 400 nm. If the dimension of the electrode that serves as the positive electrode in the thickness direction is within such a range, light can be efficiently converted into electricity without reducing the transmittance.

The dimension in the width direction of the electrode serving as the positive electrode in the first electrode or the second electrode may be the same as or different from the dimension in the width direction of the laminate body 6.

The electrode serving as the positive electrode among the first electrode or the second electrode may also have a predetermined sheet resistance, and the sheet resistance value is, for example, 1Ω/□ to 1000Ω/□, preferably 2Ω/□ to 500Ω/□, and more preferably 5Ω/□ to 100Ω/□.

The electrode serving as the positive electrode of the first electrode or the second electrode can be formed by vacuum film forming methods such as evaporation and sputtering; wet coating methods such as coating ink containing nanoparticles to form a film, etc., and can also be formed into a predetermined shape by etching, etc. as needed.

The negative electrode and the positive electrode may use one or more materials in each layer, or may have a layered structure of more than two layers, or may form other layers on the negative electrode and the positive electrode. The materials used in the other layers are poly(ethylenedioxythiophene): poly(styrenesulfonic acid) (PEDOT:PSS), molybdenum oxide, lithium fluoride, 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline, etc.

From the viewpoint that at least one of the first and second electrodes absorbs sunlight, it is preferred that the first and second electrodes have light transmittance, and it is more preferred that the first and second electrodes have a light transmittance of preferably 40% or more, more preferably 55% or more, further preferably 85% or more, further preferably 90% or more in the wavelength range of 360nm to 830nm. When the first and second electrodes are light transmittance electrodes, it is sufficient that the electrodes are formed using the above-mentioned metal oxides or their alloys.

1. (5) Photovoltaic layer At least a portion of the photovoltaic layer 4 (I-4, II-4) is formed on the first electrode 3 (I-3, II-3). In the first embodiment, the photovoltaic layer I-4 is formed not only on the first electrode I-3 but also on the substrate layer I-2.

As materials constituting the photovoltaic layer 4, organic compound materials (e.g., organic pigment materials, organic semiconductor materials) and the like can be cited. Among them, among the materials constituting the photovoltaic layer 4, organic semiconductor materials are preferred from the viewpoints of lightness, flexibility, etc., and the photovoltaic layer 4 preferably includes an organic thin film. When an organic pigment material is used as a material constituting the photovoltaic layer 4, as the organic pigment material, coumarin derivatives and mercurochrome pigments that can sensitize the pigment can be cited.

Organic semiconductor materials can be roughly divided into p-type and n-type. However, because the holes and electrons that contribute to conduction change depending on the electronic state, doping state, and trapping state of the material, it is sometimes impossible to clearly classify them into p-type and n-type. Even the same material may exhibit both p-type and n-type properties.

P-type semiconductors can be made of polymer organic semiconductor compounds, low molecular organic semiconductor compounds, etc. Examples of polymer organic semiconductor compounds include: copolymeric polymer semiconductor compounds such as polythiophene, polyfluorene, polyphenylene vinylene, polythienylene vinylene, polyacetylene, polyaniline, etc.; polymer semiconductor compounds such as substituted oligothiophene; semiconductor compounds obtained by copolymerizing two or more monomers, etc. The polymer organic semiconductor compound may be one compound or a mixture of a plurality of compounds.

As low molecular organic semiconductor compounds, there can be listed: condensed aromatic hydrocarbons such as naphthacene, pentacene, and pyrene; oligothiophenes containing 4 or more thiophene rings; containing one or more selected from thiophene ring, benzene ring, fluorene ring, naphthalene ring, anthracene ring, thiazole ring, thiadiazole ring, and benzothiazole ring, and a total of 4 or more connected; phthalocyanine compounds and their metal complexes, porphyrin compounds such as tetraphenylporphyrin and their metal complexes, and other large cyclic compounds. The molecular weight of the low molecular organic semiconductor compound is, for example, 100 or more and 5000 or less, preferably 200 or more and 2000 or less.

In the above, as the material constituting the photovoltaic layer 4, the case of using organic semiconductor materials used in organic thin film solar cells is mainly described. However, the photovoltaic layer 4 of the present embodiment is not limited to this. As the material constituting the photovoltaic layer 4, for example, silicon-based solar cells such as crystalline silicon solar cells and amorphous silicon solar cells; compound-based solar cells such as CIS (copper indium selenide) solar cells, CIGS (copper indium gallium selenide) solar cells, and CdTe (cadmium telluride) solar cells; organic-inorganic hybrid solar cells (also called perovskites solar cells), and dye-sensitized solar cells and other solar cells can be used. More specifically, as the material constituting the photovoltaic layer 4, for example, silicon materials, inorganic compound materials other than silicon materials, calcium-titanium materials, and quantum dot materials can be used. As silicon materials, single crystal silicon, polycrystalline silicon, microcrystalline silicon, amorphous silicon, etc. can be listed. As inorganic compound materials, InGaAs, GaAs, CIS, CIGS, CZTS, CdTe/Cds, InP, SiGe, Ge, ZnO/CuAlO ₂ , etc. can be listed. When such materials can be used, a thin film layer can be formed, which is advantageous in terms of easy handling when winding into a roll shape and transferring described later.

As the n-type semiconductor, for example, fullerene compounds, quinolinol derivative metal complexes such as 8-hydroxyquinoline aluminum, condensed cyclic tetracarboxylic acid diimides such as naphthalenetetracarboxylic acid diimide or perylenetetracarboxylic acid diimide, perylene diimide derivatives, terpyridine metal complexes, tropolone metal complexes, flavonol metal complexes, perynone derivatives, benzimidazole derivatives, benzoxazole derivatives, thiazole derivatives, benzothiazole derivatives, benzothiadiazole derivatives, oxadiazole derivatives, thiadiazole derivatives, triazole derivatives, pyrazine derivatives, phenanthroline derivatives, quinoxaline derivatives, benzoquinoline derivatives, borane derivatives, anthracene, pyrene, condensed tetraphenylene, condensed pentaphenylene, etc., fluorides of polycyclic aromatic aromatic hydrocarbons, etc., single-layer carbon nanotubes, etc.

The photovoltaic layer 4 only needs to contain at least a p-type semiconductor and an n-type semiconductor. The photovoltaic layer 4 may be a single layer or may be composed of a laminated structure of two or more layers. The photovoltaic layer 4 may contain an n-type semiconductor and a p-type semiconductor in different layers, or may contain an n-type semiconductor and a p-type semiconductor in the same layer. Furthermore, the n-type semiconductor and the p-type semiconductor used in the photovoltaic layer 4 may be one or more types.

Examples of the structure of the photovoltaic layer 4 include: a bulk heterojunction type having a layer (i layer) in which a p-type semiconductor and an n-type semiconductor are separated within the layer; a stacked type (heterogeneous pn junction type) having an interface between a layer containing a p-type semiconductor (p layer) and a layer containing an n-type semiconductor (n layer); a Schottky type; and combinations thereof.

The dimension of the photovoltaic layer 4 in the thickness direction is, for example, greater than 10 nm and less than 1000 nm, preferably greater than 20 nm and less than 500 nm, and more preferably greater than 50 nm and less than 300 nm. The dimension of the photovoltaic layer 4 in the width direction is, for example, smaller than the dimension of the laminate 6 in the width direction.

The photovoltaic layer 4 is preferably formed by a coating method, and more preferably by a wet coating method. As coating methods, there can be listed: rotary coating method, reverse roll coating method, gravure coating method, kiss coating method, spray coating method, air knife coating method, impregnation coating method, curtain coating method, etc.

1. (6) Electron transport layer An electron transport layer (in the example of FIG. 3 , electron transport layer II-12) may also be provided between the photovoltaic layer 4 and the electrode. The electron transport layer extracts the electrons generated in the photovoltaic layer 4 and acts as an energy barrier to the holes. The material constituting the electron transport layer may be any material through which electrons can easily move, and examples thereof include organic materials such as polyphenylene vinylene containing cyano groups, oxadiazole compounds, benzimidazole compounds, naphthalene tetracarboxylic acid compounds, perylene derivatives, phthalocyanine containing fluorine groups, and inorganic materials such as phosphine oxides, phosphine sulfides, titanium oxide, zinc oxide, indium oxide, tin oxide, gallium oxide, tin sulfide, indium sulfide, and zinc sulfide.

The dimension of the electron transport layer in the thickness direction is, for example, not less than 1 nm and not more than 300 nm, preferably not less than 2 nm and not more than 200 nm, and more preferably not less than 5 nm and not more than 100 nm.

The second embodiment of the long-layered laminate II-1 preferably has an electron transport layer II-12 between the first electrode II-3 and the photovoltaic layer II-4, and/or between the second electrode II-5 and the photovoltaic layer II-4. In the example of FIG. 3 , the long-layered laminate II-1 has an electron transport layer II-12 between the 1-1 region II-8 of the first electrode II-3 and the photovoltaic layer II-4, and another electron transport layer II-12 between the 2-2 region II-11 of the second electrode II-5 and the photovoltaic layer II-4. This embodiment is not limited to this. For example, the long stacked layer II-1 may have an electron transport layer II-12 between the 2-1 region II-10 of the second electrode II-5 and the photovoltaic layer II-4, and may also have another electron transport layer II-12 located below the 2-2 region II-11 of the second electrode II-5 and in contact with the lower surface of the photovoltaic layer II-4.

1.7 (Protective layer) The long-layer body 1 (I-1, II-1) preferably has a protective layer 7 (I-7, II-7) on the second electrode 5 (I-5, II-5). The protective layer 7 is preferably a layer that prevents the degradation of the layer body 6 due to erosion caused by temperature, humidity, natural light, wind and rain, etc.

Examples of materials for the protective layer 7 include polyester resins such as polyethylene resin, polypropylene resin, cycloolefin resin, acrylonitrile-styrene resin, acrylonitrile-butadiene-styrene resin, polyvinyl chloride resin, fluorine resin, polyethylene terephthalate resin, polyethylene naphthalate resin, phenol resin, polyacrylic resin, polyamide resin, polyimide resin, polyurethane resin, polysilicone resin, and the like.

When the protective layer 7 has weather resistance, the protective layer 7 is preferably a fluororesin. Examples of the fluororesin include polytetrafluoroethylene, 4-fluoroethylene-perchloroalkoxy copolymer, 4-fluoroethylene-6-fluoropropylene copolymer, 2-ethylene-4-fluoroethylene copolymer, polyvinylidene fluoride, polyvinyl fluoride, and the like.

The protective layer 7 may be composed of one material or two or more materials. The protective layer 7 may be one layer or two or more layers.

The dimension of the protective layer 7 in the thickness direction is, for example, 0.5 μm to 100 μm, preferably 1 μm to 50 μm, and more preferably 2 μm to 30 μm. If the dimension of the protective layer in the thickness direction is reduced, the flexibility is increased. The dimensions of the protective layer 7 in the width direction and the length direction may also be the same as those of the long-walled laminate 1 in the width direction and the length direction.

The protective layer 7 preferably allows visible light to pass through. The light transmittance of the protective layer 7 in the visible light range of wavelength 360nm to 830nm is preferably 80% or more, more preferably 90% or more, and further preferably 95% or more.

The protective layer 7 can be formed on the second electrode 5 through the bonding layer, similarly to the base layer 2. The protective layer 7 can be peeled off similarly to the base layer 2. When the protective layer 7 is formed on the second electrode 5 through the bonding layer, if the protective layer 7 is peeled off, for example, the bonding layer remains on the second electrode 5, and the desired object (barrier layer, etc.) can be attached to the second electrode 5 by the bonding force of the bonding layer. When the protective layer 7 is provided on the base layer 2 with a plurality of laminates having the same structure as the laminate 6, it can be provided on each laminate, or one protective layer 7 can be provided on a plurality of laminates. The bonding layer provided on the protective layer 7 may be a peelable layer, or a peelable layer different from the bonding layer may be provided. That is, when the peelable layer and the bonding layer are provided in sequence between the protective layer 7 and the second electrode 5, if the protective layer 7 is peeled off, for example, the bonding layer remains on the second electrode 5 side, and the bonding force of the bonding layer makes it possible to attach a desired object (barrier layer, etc.) to the second electrode 5, etc. By providing the peelable layer, the protective layer 7 can be easily peeled off. It is preferred that the peeling force when peeling the substrate layer 2 from the first electrode 3 is different from the peeling force when peeling the protective layer 7 from the second electrode 5. Such peeling force is derived from the bonding layer and/or the peeling layer described above. From the perspective of easy attachment to an attachment object (preferably a device substrate), the peeling force when peeling the protective layer 7 from the second electrode 5 is preferably greater than the peeling force when peeling the substrate layer 2 from the first electrode 3. Thereby, the base material layer 2 becomes easier to be peeled off before the protective layer 7, and the first electrode 3 and the like can be attached to the object without the protective layer 7 being peeled off. In this specification, the case where the base material layer 2 is peeled off when attached to the attachment object is mainly described, but when attached to the attachment object, the protective layer 7 can also be peeled off without peeling the base material layer 2. In such a case, it is preferred that the peeling force when peeling the base material layer 2 from the first electrode 3 is greater than the peeling force when peeling the protective layer 7 from the second electrode 5. Thereby, the protective layer 7 becomes easier to be peeled off before the base material layer 2. Among the first electrode 3 and the second electrode 5, the electrode that exists on the outside after being attached to the attachment object is preferably a transparent electrode.

The protective layer 7 and the base layer 2 may have predetermined rigidity (e.g., bending rigidity), and preferably, the protective layer 7 and the base layer 2 have different rigidities. More preferably, the rigidity of the protective layer 7 is greater than that of the base layer 2. Thereby, the long-walled laminate 1 can be easily rolled into a roll shape.

The stacked layer 1 includes: a stacked body 6 including a first electrode 3, a photovoltaic layer 4 and a second electrode 5, and preferably further includes a region where the stacked body 6 is not formed. The region where the stacked body 6 is not formed includes: a region where the first electrode 3, the photovoltaic layer 4 and the second electrode 5 are not formed on the substrate layer 2; a region where the photovoltaic layer 4 and the second electrode 5 are not formed on the first electrode 3; a region where the second electrode 5 is not formed on the photovoltaic layer 4; and a gap region formed between the second electrode 5 and the protective layer 7. This region is located when a plurality of stacked layers 1 partially overlap each other and are attached to a device substrate, and can be used to form a photovoltaic device described later.

In other words, in the cross section perpendicular to the length direction of the stacked layer 1 (I-1, II-1), the first electrode 3 (I-3, II-3), the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5) are 1/2 the width direction of the stacked layer 6 (I-6, II-6) (the first electrode 3 (I-3, I-4) is 1/2 the width direction of the stacked layer 6 (I-6, II-6) (the first electrode 3 (I-3, I-4) is 1/2 the width direction of the stacked layer 6 (I-6, II-6) The area ratio of the area obtained by multiplying the width direction dimension of the photovoltaic layer 4 (I-3), the photovoltaic layer 4 (I-4, II-4) and the second electrode 5 (I-5, II-5) when projected onto the substrate layer 2) and the thickness direction dimension is preferably 60% to 95%, more preferably 65% to 90%, and further preferably 70% to 85%. If the ratio of this area is 60% or more, it is easy to ensure the strength of the photovoltaic device itself. If the ratio of this area is 95% or less, it is easy to ensure the area for connecting the laminates in series and arranging them in parallel.

In the long-walled laminate 1, from the viewpoint of increasing the power generation area relative to the total area of the laminate having power generation function provided in the device, it is ideal to reduce the area of the insulating layer irradiated with light relative to the light-receiving surface of the device. With respect to 100% of the area of the long-walled laminate, the area of the insulating layer is preferably 10% by area or less, more preferably 5% by area or less, further preferably 1% by area or less, further preferably 0% by area. That is, it is preferred that the long-walled laminate does not contain an insulating layer. In addition, when an insulating layer is used, the insulating layer can be set at any location as long as it is not set between the laminates arranged in series, for example, as long as it can ensure the insulation between the first electrode and the second electrode of each laminate.

2. Photovoltaic device Next, the basic structure of the photovoltaic device is described with reference to FIGS. 4 to 9. FIG. 4 is a diagram showing a method of manufacturing a photovoltaic device by sequentially attaching a plurality of laminates 6 of a long laminate 1 provided in an embodiment of the present invention to a device substrate. FIG. 5 is a plan view showing a photovoltaic device obtained by sequentially attaching a plurality of laminates 6 (preferably laminates 6 formed by peeling off a substrate layer 2) provided in a long laminate 1 to a device substrate. FIG. 6 shows an example of a cross-sectional view of a photovoltaic device according to an embodiment (the first embodiment) of the present invention, and FIGS. 7 and 8 show another example of a cross-sectional view of a photovoltaic device according to an embodiment (the first embodiment) of the present invention. FIG. 9 shows an example of a cross-sectional view of a photovoltaic device according to another embodiment (the second embodiment) of the present invention.

Referring to FIG. 4 , a method for manufacturing a photovoltaic device is described. A long laminate 1 is formed by arranging a plurality of laminates 6 having the same structure (comprising a first electrode 3, a photovoltaic layer 4, and a second electrode 5 in sequence) along the length direction. First, the substrate layer 2 is peeled off from the long laminate 1 in such a manner that at least the first electrode 3 of the first laminate among the plurality of laminates 6 is exposed, and the exposed surface of the first electrode 3 is attached to the device substrate 2a, thereby forming the first laminate on the device substrate 2a. Next, the substrate layer 2 is peeled off from the long laminate 1 in such a manner that at least the first electrode 3 of the second laminate, for example, arranged at the next wall of the first laminate, is exposed. In the case where the first electrodes 3 of the first laminate and the second laminate are exposed by the first peeling of the substrate layer 2, the second peeling is not necessary. The surface of the first electrode 3 of the exposed second laminate is attached to the device substrate 2a in such a manner that the surface is parallel to the long side of the first laminate and overlaps with a part of the first laminate to form an overlapping portion 30. Thus, the second laminate is formed on the device substrate 2a. For example, by repeating this step, a photovoltaic device 40 in which a desired number of laminates 6 are connected in series can be manufactured. This specification mainly describes the case where a photovoltaic device 40 is manufactured as described above from a plurality of laminates 6 arranged on the same long laminate 1. For example, a photovoltaic device 40 with the same structure as above can be manufactured by attaching laminates 6 arranged on different long laminates 1 to the same device substrate 2a.

The photovoltaic device 40 is described with reference to FIG5. As described above, the photovoltaic device 40 uses a plurality of laminates 6 (preferably laminates 6 from which the substrate layer 2 is peeled off) disposed on a long laminate 1, and the first laminate, the second laminate, the third laminate, and the fourth laminate (in FIG5, the laminates are assigned symbols 1a, 1b, 1c, and 1d in order of appearance) of the plurality of laminates 6 are attached to the device substrate 2a in a manner that adjacent laminates partially overlap each other. The overlapping portion 30 of the laminate 1a, laminate 1b, laminate 1c, and laminate 1d is where the first electrode I-3 of a certain laminate overlaps with the second electrode I-5 of another laminate to achieve electrical connection in the first embodiment, and where the first electrode II-3 of a certain laminate overlaps with the photovoltaic layer II-4 of another laminate to achieve electrical connection in the second embodiment. That is, in the photovoltaic device 40, a plurality of laminates 6 arranged on the long laminate 1 are transferred to the device substrate 2a and electrically connected.

Referring to FIG6 , the photovoltaic device 1-40 of the first embodiment is described. The photovoltaic device 1-40 includes: a device substrate 1-2a, a first laminate 1-6a, and a second laminate 1-6b. The first laminate 1-6a includes: a first electrode 1-3a at least partially formed on the device substrate 1-2a, a photovoltaic layer 1-4a at least partially formed on the first electrode 1-3a, and a second electrode 1-5a at least partially formed on the photovoltaic layer 1-4a. The second laminate I-6b includes: a first electrode I-3b at least partially formed on the device substrate I-2a, a photovoltaic layer I-4b at least partially formed on the first electrode I-3b, and a second electrode I-5b at least partially formed on the photovoltaic layer I-4b.

Furthermore, in the photovoltaic device 1-40, the first layer 1-6a and the second layer 1-6b are formed in parallel on the device substrate 1-2a. In the cross section of the first layer 1-6a and the second layer 1-6b in the parallel direction, the area occupied by the first electrode 1-3a and the first electrode 1-3b, the photovoltaic layer 1-4a and the photovoltaic layer 1-4b, and the second electrode 1-5a and the second electrode 1-5b is equal to the width direction size of the first layer 1-6a and the second layer 1-6b (dividing the first electrode 1-3a, the photovoltaic layer 1-4b, and the second electrode 1-5a and the second electrode 1-5b). The ratio of the area obtained by multiplying the width direction dimension of I-4a and the second electrode I-5a when projected onto the device substrate I-2a and the width direction dimension of the first electrode I-3b, the photovoltaic layer I-4b, and the second electrode I-5b when projected onto the device substrate I-2a) with the thickness direction dimension of the first laminate I-6a or the second laminate I-6b is, for example, greater than 60% and less than 95%.

The configuration of the photovoltaic device 1-40 is described in detail with reference to FIG. 7. The second electrode 1-5a of the first laminate 1-6a has a 2-1 region 1-10a opposite to the first electrode 1-3a of the first laminate 1-6a, and a 2-2 region 1-11a not opposite to the first electrode 1-3a of the first laminate 1-6a. The second electrode 1-5b of the second laminate 1-6b has a 2-1 region 1-10b opposite to the first electrode 1-3b of the second laminate 1-6b, and a 2-2 region 1-11b not opposite to the first electrode 1-3b of the second laminate 1-6b. The first electrode I-3a of the first laminate I-6a has a 1-1 region I-8a opposite to the second electrode I-5a of the first laminate I-6a, and a 1-2 region I-9a not opposite to the second electrode I-5a. The first electrode I-3b of the second laminate I-6b has a 1-1 region I-8b opposite to the second electrode I-5b of the first laminate I-6b, and a 1-2 region I-9b not opposite to the second electrode I-5b. The 1-2 region I-9a of the 1st electrode I-3a of the 1st laminate I-6a overlaps and is electrically connected to the 2-2 region I-11b of the 2nd electrode I-5b of the 2nd laminate I-6b (in FIG. 6 , the 1st laminate I-6a is equivalent to laminate A, and the 2nd laminate I-6b is equivalent to laminate B). Thus, even after the laminate with power generation function is manufactured, the shape and size of the device can be adapted, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Furthermore, since the 1st electrode and the 2nd electrode can be connected in a planar manner, the wiring resistance can be reduced. The above description made with reference to FIGS. 5 to 7 also holds true in the example of FIG. 8, and the same symbols as those in FIG. 7 are given in FIG. 7 and FIG. 8. In the examples of FIG. 7 and FIG. 8, the 1st-2nd region I-9a of the 1st electrode I-3a of the 1st laminate body I-6a is overlapped on the 2nd-2nd region I-11b of the 2nd electrode I-5b of the 2nd laminate body I-6b and electrically connected, but the present embodiment is not limited thereto, and the 2nd-2nd region I-11b of the 2nd electrode I-5b of the 2nd laminate body I-6b may also be overlapped on the 1st-2nd region I-9a of the 1st electrode I-3a of the 1st laminate body I-6a and electrically connected.

In the example of Figures 7 and 8 of the first state, the above-mentioned overlapping portion in the 1-2 region I-9a of the first electrode I-3a of the first laminate I-6a and the 2-2 region I-11b of the second electrode I-5b of the second laminate I-6b has: there is no portion in which other layers are arranged between the overlapping portion and the height at which the second electrodes I-5a and I-5b are arranged on the photovoltaic layer I-4a and the photovoltaic layer I-4b. Furthermore, in the examples of FIG. 7 and FIG. 8, regarding the first laminate body I-6a, the second electrode I-5a has a portion extending on the base material layer I-2a via the side surface of the photovoltaic layer I-4a, and a portion where no other layer is provided between the extended portion and the height at which the second electrode I-5a is provided on the photovoltaic layer I-4a. The extended portion is equivalent to the above-mentioned 2-2z region of the 2-2 region I-11a of the second electrode I-5a. By configuring in this way, the electrodes of other laminate bodies overlap and contact the extended portion, thereby forming a further series connection.

Next, referring to FIG9 , the second embodiment of the photovoltaic device II-40 is described. The photovoltaic device II-40 includes: a device substrate II-2a, a first laminate II-6a, and a second laminate II-6b. The first laminate II-6a includes: a first electrode II-3a at least partially formed on the device substrate II-2a, a photovoltaic layer II-4a at least partially formed on the first electrode II-3a, and a second electrode II-5a at least partially formed on the photovoltaic layer II-4a. The second laminate II-6b includes: a first electrode II-3b at least partially formed on the device substrate II-2a, a photovoltaic layer II-4b at least partially formed on the first electrode II-3b, and a second electrode II-5b at least partially formed on the photovoltaic layer II-4b.

Furthermore, in the photovoltaic device II-40, the first layer II-6a and the second layer II-6b are formed in parallel on the device substrate II-2a, and in the cross section in the parallel direction of the first layer II-6a and the second layer II-6b, the area occupied by the first electrode II-3a and the first electrode II-3b, the photovoltaic layer II-4a and the photovoltaic layer II-4b, and the second electrode II-5a and the second electrode II-5b is relatively large relative to the first layer II-6a and the second layer II-6b. The ratio of the area obtained by multiplying the widthwise dimension of II-6b (the widthwise dimension when the first electrode II-3a, photovoltaic layer II-4a, and second electrode II-5a are projected onto the device substrate II-2a, and the widthwise dimension when the first electrode II-3b, photovoltaic layer II-4b, and second electrode II-5b are projected onto the device substrate II-2a) by the thicknesswise dimension of the first laminate II-6a or the second laminate II-6b is, for example, greater than 60% and less than 95%. The second electrode II-5a of the first laminate II-6a has a 2-1 region II-10a opposite to the first electrode II-3a of the first laminate II-6a, and a 2-2 region II-11a not opposite to the first electrode II-3a of the first laminate II-6a. The second electrode II-5b of the second laminate II-6b has a 2-1 region II-10b opposite to the first electrode II-3b of the second laminate II-6b, and a 2-2 region II-11b not opposite to the first electrode II-3b of the second laminate II-6b. The first electrode II-3a of the first laminate II-6a has a 1-1 region II-8a opposite to the second electrode II-5a of the first laminate II-6a, and a 1-2 region II-9a not opposite to the second electrode II-5a. The first electrode II-3b of the second laminate II-6b has a 1-1 region II-8b opposite to the second electrode II-5b of the first laminate II-6b, and a 1-2 region II-9b not opposite to the second electrode II-5b. The photovoltaic layer II-4a of the first laminate II-6a is overlapped on the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b and is electrically connected (in FIG. 9 , the first laminate II-6a is equivalent to laminate A, and the second laminate II-6b is equivalent to laminate B).

In the example of Figure 9 of the second state, the photovoltaic layer II-4a of the first laminate II-6a has: a portion disposed below the 2-2 region II-11a of the second electrode II-5a of the first laminate II-6a and overlapping and electrically connected to the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b. Furthermore, the 1-2 region II-9b of the 1st electrode II-3b of the 2nd laminate II-6b has a portion without other layers between the portion overlapping the photovoltaic layer II-4a and the 1-1 region II-8b of the 1st electrode II-3b of the 2nd laminate II-6b, from above the 1st electrode II-3b to the height where the 2nd electrode II-5b is provided on the photovoltaic layer II-4b of the 2nd laminate II-6b. Furthermore, in the example of FIG. 9 , regarding the first laminate II-6a, more specifically the first electrode II-3a, the first-2 region II-9a of the first electrode II-3a has: a portion where no other layer is provided between the first electrode II-3a (which may be renamed the first-2 region II-9a) and the height where the second electrode II-5a is provided on the photovoltaic layer II-4a. By configuring in this way, the electrodes of other laminates overlap and contact the portion where no other layer is provided, thereby forming a further series connection.

In the photovoltaic device 40, the 1-1 region, the 1-2 region, the 2-1 region, and the 2-2 region are based on the relative relationship (opposite relationship) between the first electrode and the second electrode contained in the first laminate. The 1-1 region, the 1-2 region, the 2-1 region, and the 2-2 region are based on the relative relationship (opposite relationship) between the first electrode and the second electrode contained in the second laminate. These regions are named based on the relative relationship (opposite relationship) between the first electrode and the second electrode contained in each laminate.

The electrically connected area is preferably equivalent to the overlapping portion 30 shown in FIG. 5. If this area is formed, a plurality of laminates with a power generation function can be attached to the device substrate, and the aforementioned plurality of laminates can be connected in series. As a result, even after the laminate with a power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with a power generation function provided in the device. In the first embodiment, since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. Since the overlapping portion has a fixed area, even if it is deformed by external force, it can stably perform its function for a long period of time, thereby improving the durability of the photovoltaic device.

In the first embodiment, the electrically connected region means that the first electrode I-3a of the first laminate I-6a and the second-2 region I-11b of the second electrode I-5b of the second laminate I-6b become regions that can be electrically energized. The first electrode I-3a of the first laminate I-6a and the second electrode I-5b of the second laminate I-6b are preferably in contact with each other in a manner that allows electrical conduction, and more preferably in contact through adhesion (adhesion) of the surface of the first electrode I-3a of the first laminate I-6a and/or the surface of the second electrode I-5b of the second laminate I-6b or the overlapping of a protective layer I-7, etc. The first electrode I-3a of the first laminate I-6a and the second electrode I-5b of the second laminate I-6b are preferably joined with an adhesive that can conduct electricity (e.g., conductive paste), and more preferably, the adhesive that can conduct electricity is provided in the first-2 region I-9a of the first laminate I-6a or the second-2 region I-11b of the second laminate I-6b. The adhesive that can conduct electricity can be applied using a dispenser.

In the second embodiment, the electrically connected region means that the photovoltaic layer II-4a of the first laminate II-6a and the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b become regions that can be electrically energized. The photovoltaic layer II-4a of the first laminate II-6a and the 1st-2nd region II-9b of the first electrode II-3b of the second laminate II-6b are preferably in contact with each other in a manner that allows electrical conduction, and more preferably in contact through the adhesion (adhesion) of the surface of the photovoltaic layer II-4a of the first laminate II-6a and/or the surface of the 1st-2nd region II-9b of the first electrode II-3b of the second laminate II-6b or the weight of the protective layer I-7. The photovoltaic layer II-4a of the first laminate II-6a and the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b are preferably bonded with an adhesive that can conduct electricity (such as a conductive paste), and more preferably, the photovoltaic layer II-4a of the first laminate II-6a or the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b are bonded with an adhesive that can conduct electricity. The adhesive that can conduct electricity can be applied using a dispenser.

As an adhesive capable of conducting electricity (e.g., conductive paste), a mixture of a conductive filler and a resin serving as the adhesive may be used. The conductive filler may be, for example, copper particles, silver particles, gold particles, nickel particles, copper particles coated with silver, copper alloy particles coated with silver, nickel particles coated with silver, etc. having a predetermined particle size. The resin serving as the adhesive may be, for example, an epoxy resin, a polyurethane resin, an acrylic resin, a phenolic resin, a polyimide resin, a fluororesin, etc.

The material of the device substrate 2a may be the same as the material of the substrate layer 2. The material of the device substrate 2a is preferably a rigid material. In the photovoltaic device 40, it is preferred that a first bonding layer is provided between the device substrate 2a and one or both of the first electrodes of the first laminate and the second laminate. This bonding layer may be derived from the long laminate 1, or may be provided on the device substrate 2a before the first laminate and the second laminate are attached, and is preferably derived from the long laminate 1.

In the example of FIG. 7 and FIG. 8 of the first embodiment, the photovoltaic device I-40 includes a protective layer I-7a on the second electrode I-5a and the second electrode I-5b. In the example of FIG. 9 of the second embodiment, the photovoltaic device II-40 includes a protective layer II-7a on the second electrode II-5a and the second electrode II-5b. It is preferred that a second bonding layer is provided between the protective layer and one or both of the second electrodes. As described above, a release layer different from the second bonding layer may also be provided. As the material used for the second bonding layer, for example, the conductive filler listed in the above-mentioned bonding agent capable of conducting electricity and the resin serving as the bonding agent may be used.

In the photovoltaic device 40, the peeling force when peeling the device substrate 2a is preferably greater than the peeling force when peeling the protective layer. Such a peeling force is the same as the above, and is derived from the bonding layer and/or the peeling layer. For example, the peeling force when peeling the device substrate 2a can be adjusted by the presence or absence of silicon coating in the device substrate 2a. In the case where the photovoltaic device 40 has a protective layer, it is possible to peel only the protective layer from the photovoltaic device 40 without peeling the first electrode 3 from the device substrate 2a. This is advantageous when the protective layer is the protective layer 7 described above derived from the long-layer body 1, for example when a replacement layer or film is desired.

The photovoltaic device 40 (I-40, II-40) includes at least a first laminate (I-6a, II-6a) and a second laminate (I-6b, II-6b). The first laminate and the second laminate (I-6a, I-6b, II-6a, II-6b) include a first electrode (I-3a, I-3b, II-3a, II-3b), a photovoltaic layer, a photovoltaic layer (I-4a, I-4b, II-4a, II-4b), and a second electrode (I-5a, I-5b, II-5a, II-5b), respectively.

The first electrode of the first laminate and the first electrode of the second laminate may have the same structure or different structures, but preferably have the same structure. The second electrode of the first laminate and the second electrode of the second laminate may have the same structure or different structures, but preferably have the same structure.

From the perspective of increasing the size of the photovoltaic device, in the photovoltaic device 40, the number of laminates including the first laminate, the second laminate, etc. formed on the device substrate 2a is preferably greater than 3 and less than 1000, more preferably greater than 4 and less than 700, further preferably greater than 5 and less than 400, and further preferably greater than 10 and less than 100.

In the photovoltaic device 40, the device substrate 2a, the first electrode (1-1 region, 1-1 region, 1-2 region, 1-2 region), and the second electrode (2-1 region, 2-1 region, 2-2 region, 2-2 region) can be the same as the substrate layer 2, the first electrode 3 (1-1 region, 1-2 region), and the second electrode 5 (2-1 region, 2-2 region) shown in the long-layer body 1, respectively. The substrate layer 2 of the long stacked layer 1 is preferably a peelable substrate layer, more preferably a peelable substrate layer formed of an organic material. The device substrate 2a of the photovoltaic device 40 is preferably a device substrate to be attached, more preferably a device substrate formed of an organic material, paper, metal or glass.

In the photovoltaic device 1-40 of the first embodiment, from the viewpoint of the balance between the area of the overlapping portion and the area of the power generation layer, the length in the width direction of the overlapping portion 30 of the 1-2 region 1-9a of the 1st electrode 1-3a of the 1st laminate 1-6a and the 2-2 region 1-11b of the 2nd electrode 1-5b of the 2nd laminate 1-6b is preferably 0.1 mm to 5 mm, and more preferably 0.2 mm to 3 mm. With this configuration, a plurality of laminates having a power generation function can be connected in series. As a result, even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. Since the overlapping part has a fixed area, even if it is deformed by external force, it can still function stably for a long time, thereby improving the durability of the photovoltaic device.

In the second embodiment of the photovoltaic device II-40, from the viewpoint of the balance between the area of the overlapping portion and the area of the power generation layer, the length in the width direction of the overlapping portion 30 of the photovoltaic layer II-4a of the first laminate II-6a and the 1-2 region II-9b of the first electrode II-3b of the second laminate II-6b is preferably 1 mm to 100 mm, and more preferably 2 mm to 50 mm. With this structure, a plurality of laminates with power generation functions can be connected in series. As a result, even after the laminate with power generation functions is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation functions provided in the device. Since the overlapping portion has a fixed area, even if it is deformed by external force, it can still function stably for a long period of time, thereby improving the durability of the photovoltaic device.

In the photovoltaic device 40, from the viewpoint of maximizing the power generation area relative to the total area of the laminate having the power generation function, the distance between the adjacent first laminate and the second laminate (preferably the distance between the side surface of the photovoltaic layer of the first laminate and the side surface of the second electrode of the second laminate) is preferably greater than 0.01 mm and less than 4 mm, more preferably greater than 0.02 mm and less than 3 mm, and further preferably greater than 0.05 mm and less than 2 mm.

In the photovoltaic device 40 (I-40, II-40), the photovoltaic layer and the photovoltaic layer (I-4a, I-4b, II-4a, II-4b) also preferably include an organic thin film. The photovoltaic layer (I-4a, I-4b, II-4a, II-4b) may be the same as the photovoltaic layer 4 described for the long-walled layer 1, and the material used to form the organic thin film may also be the same as that described for the long-walled layer.

The photovoltaic device 40 (I-40, II-40) preferably has a protective layer (I-7a, II-7a) on the second electrode (I-5a, II-5b) of the first laminate (I-6a, II-6a) and the second laminate (I-6b, II-6b). The protective layer may be the same as the protective layer 7 described in the long laminate 1. The protective layer may be derived from the protective layer 7 described in the long laminate 1, or may be different from the protective layer 7.

In any of the first and second aspects, the photovoltaic device 40 may also have a barrier layer to prevent degradation of the photovoltaic device (especially the first electrode 3, the photovoltaic layer 4, and the second electrode 5) due to water and oxygen. More specifically, the photovoltaic device 40 may also have a barrier layer provided on the first layer and the second layer in a manner covering the first layer and the second layer. The photovoltaic device 40 may also have a barrier layer on the device substrate 2a side across the region where the first layer and the second layer having a power generation function are provided. In this case, the barrier layer is preferably provided between the device substrate 2a and the first laminate and the second laminate having a power generation function. The barrier layer is preferably transparent, and the total light transmittance of the barrier layer is, for example, 80% or more, preferably 85% or more.

The barrier layer may be a barrier layer alone or a combination of a barrier layer and a resin layer.

As materials constituting the barrier layer, metals and inorganic compounds other than metals can be listed. As metals, metals such as aluminum, nickel, stainless steel, iron, copper, and titanium, and alloys containing the aforementioned metals can be listed. As inorganic compounds, oxides, oxynitrides, nitrides, oxycarbides, oxycarbide nitrides, etc. of metal elements or non-metal elements such as silicon, magnesium, calcium, potassium, sodium, tin, boron, lead, yttrium, zirconium, barium, and zinc can be listed. Specific examples of these include silicon oxide, aluminum oxide, titanium oxide, tin oxide, silicon zinc alloy oxide, indium alloy oxide, silicon nitride, aluminum nitride, titanium nitride, silicon nitride oxide, silicon zinc oxide, etc. These may be used alone or in combination of two or more.

The barrier layer may be a layer formed by evaporation or coating. From the viewpoint of adhesion to the resin and high water vapor barrier properties, a layer formed by evaporation is preferred. The barrier layer may be one layer or two layers or more. The dimension of the barrier layer in the thickness direction is, for example, 1 nm to 400 nm, preferably 5 nm to 300 nm, and more preferably 10 nm to 200 nm.

As the resin used for the barrier layer, the above-mentioned resin can be used. The thickness dimension of the resin used for the barrier layer is, for example, 100 nm to 10 μm, preferably 200 nm to 5 μm, and more preferably 300 nm to 3 μm.

The barrier layer is preferably formed at least on the entire protective layer, and more preferably formed on the entire protective layer and the entire device substrate. When the barrier layer is provided, it is not necessarily necessary to provide the protective layer.

In the photovoltaic device 40, the collector wire is preferably connected to the first electrode and the second electrode respectively exposed at the ends of a plurality of laminates connected in series.

2. (1) Configuration Example X of Photovoltaic Device Below, referring to FIG. 7, the configuration example X of the first laminate I-6a and the second laminate I-6b in the photovoltaic device I-40 of the first embodiment is described. In FIG. 7, the first laminate I-6a corresponding to laminate A is shown on the left side, and the second laminate I-6b corresponding to laminate B is shown on the right side.

The 2-2 region I-11b of the second electrode I-5b of the second laminate I-6b and the 1-2 region I-9a of the first electrode I-3a of the first laminate I-6a form an overlapping portion 30, thereby being electrically connected. In the example of FIG. 7 , in the overlapping portion 30, the 1-2 region I-9a of the first electrode I-3a of the first laminate I-6a and the portion of the 2-2 region I-11b of the second electrode I-5b of the second laminate I-6b extending on the device substrate I-2a as described above (corresponding to the above-mentioned 2-2z region) are overlapped and contacted. In the example of FIG. 7 , no other layer is provided between the overlapping portion and the height at which the second electrode I-5a and the second electrode I-5b are provided on the photovoltaic layer I-4a and the photovoltaic layer I-4b. The photovoltaic layer I-4b of the second laminate I-6b is also formed on the side surface of the first electrode I-3b and the device substrate I-2a.

2. (2) Configuration Example Y of Photovoltaic Device Next, referring to FIG8 , the configuration example Y of the first laminate I-6a and the second laminate I-6b in the photovoltaic device I-40 is described. In FIG8 , similarly to FIG7 , the first laminate I-6a corresponding to laminate A is shown on the left side, and the second laminate I-6b corresponding to laminate B is shown on the right side.

The 2-2 region I-11b of the second electrode I-5b of the second laminate I-6b and the 1-2 region I-9a of the first electrode I-3a of the first laminate I-6a form an overlapping portion 30, thereby being electrically connected. In the example of FIG8 , in the overlapping portion 30, the 1-2 region I-9a of the first electrode I-3a of the first laminate I-6a and the 2-2 region I-11b of the second electrode I-5b of the second laminate I-6b, which are arranged on the side surface of the photovoltaic layer I-4b as described above, and the portion extending on the device substrate I-2a (corresponding to the above-mentioned 2-2y region and 2-2z region) are arranged in contact with each other.

As described above, the configuration examples of the first laminate I-6a and the second laminate I-6b in the photovoltaic device I-40 are listed. When the photovoltaic device I-40 includes three or more laminates, it is preferable to use one or more configuration examples selected from the above configuration example X and the above configuration example Y. Specifically, the photovoltaic device can be manufactured by configuring each laminate 6 using a combination of only configuration example X, a combination of only configuration example Y, and a combination of configuration example X and configuration example Y. If this structure is adopted, the laminate 6 with power generation function can be connected in series, and even after the laminate with power generation function is manufactured, it can be adapted to the shape and size of the device, and the power generation area can be maximized relative to the total area of the laminate with power generation function provided in the device. Since the first electrode and the second electrode can be connected in a planar manner, the wiring resistance can be reduced. The electrical connection parts (overlapping parts) between the laminates can also withstand deformation caused by external forces. When a plurality of laminates 6 are used to manufacture a photovoltaic device 40, it is not limited to the combination of the above-mentioned structure example X and structure example Y, and the overlapping parts 30 between the laminates 6 can also have different structures.

3. Method for manufacturing a long-walled structure The method for manufacturing a long-walled structure may include the following steps.

First electrode forming step This step is a step of forming the first electrode on a substrate layer having a width direction and a length direction. This step can be performed by using a vacuum film forming method such as evaporation or sputtering, or a wet coating method in which a film is formed by coating an ink containing nanoparticles, etc., and a predetermined shape can be formed by etching, etc., as needed.

Photovoltaic coating forming step This step is a step of forming a photovoltaic coating on at least a portion of the first electrode. This step is preferably formed by coating, and more preferably by wet coating. As coating methods, there can be listed: rotary coating, reverse roll coating, gravure coating, light touch coating, spray coating, air knife coating, impregnation coating, curtain coating, etc.

Second electrode forming step This step is a step of forming a second electrode on at least a portion of the photovoltaic layer, for example, using the same method as the first electrode forming step.

Laminated body winding step This step is to roll up the long laminated body including the obtained laminated body into a roll. This step is implemented, for example, using a previously known film winding device. In addition to the above steps, the method for manufacturing the long laminated body may also include a follower layer forming step, an electron transport layer forming step, a protective layer forming step, etc. By this manufacturing method, a long laminated body including a plurality of photovoltaic elements can be manufactured at low cost without the need for large-scale manufacturing equipment.

4. Method for manufacturing photovoltaic device The method for manufacturing photovoltaic device may include the following steps: peeling off the substrate layer from the stack of the long stack of layers as described above; and transferring the stack of the long stack of layers to the device substrate in such a manner that the first-second region of the first electrode or the second-second region of the second electrode in the stack of the first state and the portion below the second-second region in the photovoltaic stack of the second state overlap and contact with the electrodes of other stacks on the device substrate. By repeating such steps any number of times, a photovoltaic device consisting of a desired number of stacks connected in series can be manufactured on the device substrate. The details of each step that may be included in the manufacturing method of a photovoltaic device are described below.

Substrate layer peeling step This step is a step of peeling the substrate layer from a certain layer of the long-layer body. The peeling of the substrate layer can be performed manually or mechanically. In the first embodiment, it is preferred to peel the substrate layer to expose the first electrode and the 2-2 region of the second electrode. In the second embodiment, it is preferred to peel the substrate layer to expose the first electrode.

Laminate attaching step (1) This step is, for example, attaching the exposed first electrode surface of a certain laminate (also referred to as the first laminate) in the long laminate to the device substrate, thereby forming the first laminate including the first electrode, the photovoltaic layer and the second electrode on the device substrate. Through this step, the first laminate is formed on the device substrate.

Laminate attaching step (2) This step is, for example, to attach the exposed first electrode surface of another laminate (also referred to as the second laminate) of the long laminate to the device substrate in a manner parallel to and partially overlapping the long side of the first laminate, thereby forming the second laminate including the first electrode, the photovoltaic layer and the second electrode on the device substrate. In either the first embodiment or the second embodiment, it is preferred to form an overlapping portion of the first laminate and the second laminate. In the first embodiment, it is preferred to attach the second laminate to the device substrate by overlapping the 1st-2 region of the 1st electrode of the second laminate and the 2nd-2 region of the 2nd electrode of the first laminate attached to the device substrate. In the second embodiment, it is preferred to attach the second laminate to the device substrate by overlapping the photovoltaic layers of different laminates and the 1st-2 region of the 1st electrode of the laminate attached to the device substrate. The above description is focused on the first laminate and the second laminate. The above steps can be appropriately repeated to manufacture a photovoltaic device in which a plurality of laminates are connected in series in a desired number on the device substrate. At this time, since the defective parts in the laminate contained in the long laminate can be removed and transferred to the device substrate, the yield rate of the manufactured photovoltaic device can be improved.

The long stacked layer and photovoltaic device of the present invention can be suitably used in vehicles such as aircraft, four-wheeled vehicles (such as cars), two-wheeled vehicles (such as motorcycles and bicycles); building-related objects such as the outer walls, pipelines, tiles, windows, etc. of buildings; clothing such as clothes, bags, shoes, belts, hats, etc.; various containers such as bottles and cups made of plastic, glass or metal; various electronic devices such as clocks, watches, personal computers, mobile phones, chargers, etc.

This application claims the benefit of priority based on Japanese Patent Application No. 2022-159812 filed on October 3, 2022. The entire contents of the specification of Japanese Patent Application No. 2022-159812 filed on October 3, 2022 are incorporated herein by reference.

1,I-1,II-1: long stack 1a,1b,1c,1d: long stack 2,I-2,II-2: substrate layer 2a,I-2a,II-2a: device substrate 3,I-3,II-3: first electrode I-3a,II-3a: first electrode of first stack I-3b,II-3b: first electrode of second stack 4,I-4,II-4: photovoltaic layer I-4a,II-4a: photovoltaic layer of first stack I-4b,II-4b: photovoltaic layer of second stack 5,I-5,II-5: second electrode I-5a, II-5a: Second electrode of the first laminate I-5b, II-5b: Second electrode of the second laminate 6, I-6, II-6: Laminated body I-6a, II-6a: First laminate I-6b, II-6b: Second laminate 7, I-7, II-7: Protective layer I-7a, II-7a: Protective layer I-8, II-8: First-1 region I-8a, I-8b, II-8a, II-8b: First-1 region I-9, II-9: First-2 region I-9a, I-9b, II-9a, II-9b: First-2 region I-10, II-10: Second-1 region I-10a, I-10b, II-10a, II-10b: Region 2-1 I-15, II-15: Laminated body formed by peeling off the substrate layer from the long laminate 30: Overlapping portion of the long laminate 40, I-40, II-40: Photovoltaic device A: First laminate (laminated body) B: Second laminate (laminated body) I-11, II-11, I-11a, I-11b, II-11a, II-11b: Region 2-2 I-11xh, I-11yh, I-11zh, I-11xI, I-11yI, I-11zI: Symbols II-12:Electron transmission layer

[FIG. 1] is a three-dimensional diagram showing a stacked layer according to an embodiment of the present invention. [FIG. 2] is a cross-sectional diagram showing a direction perpendicular to the length direction of the stacked layer according to an embodiment of the present invention (the first embodiment). [FIG. 3] is a cross-sectional diagram showing a direction perpendicular to the length direction of the stacked layer according to another embodiment of the present invention (the second embodiment). [FIG. 4] is a diagram showing a method of manufacturing a photovoltaic device by sequentially attaching a plurality of stacked layers having a power generation function provided on a stacked layer according to an embodiment of the present invention to a device substrate. [FIG. 5] is a plan view showing a photovoltaic device of the present invention obtained by sequentially attaching a plurality of stacked layers having a power generation function provided in an embodiment of the present invention to a device substrate. [FIG. 6] is an example of a cross-sectional view of a photovoltaic device according to an embodiment (the first embodiment) of the present invention. [FIG. 7] is another example of a cross-sectional view of a photovoltaic device according to an embodiment (the first embodiment) of the present invention. [FIG. 8] is another example of a cross-sectional view of a photovoltaic device according to an embodiment (the first embodiment) of the present invention. [FIG. 9] is an example of a cross-sectional view of a photovoltaic device according to another embodiment (the second embodiment) of the present invention.

Claims (14)

A long stacked layer, comprising: a substrate layer having a width direction and a length direction; and a stacked layer, comprising a first electrode formed on the substrate layer, a photovoltaic layer at least partially formed on the first electrode, and a second electrode at least partially formed on the photovoltaic layer; the second electrode having a 2-1 region opposite to the first electrode and a 2-2 region not opposite to the first electrode; the 2-2 region exists on one side of the substrate layer in the width direction and does not exist on the other side of the substrate layer in the width direction; the long stacked layer is rolled into a roll shape. The long-layer body as described in claim 1, wherein the aforementioned first electrode has a 1-1 region opposite to the aforementioned second electrode, and a 1-2 region not opposite to the aforementioned second electrode; the aforementioned 1-2 region exists on the aforementioned other side in the aforementioned width direction, and does not exist on the aforementioned one side in the aforementioned width direction. The long-layer body as described in claim 2, wherein the aforementioned 1-2 region has: a portion where no other layer is provided between the aforementioned 1-2 region and the height at which the aforementioned second electrode is provided on the aforementioned photovoltaic layer; The aforementioned 2-2 region has: a portion where no other layer is provided between a portion extending on the aforementioned substrate layer through the side surface of the aforementioned photovoltaic layer and the height at which the aforementioned second electrode is provided on the aforementioned photovoltaic layer; or the aforementioned photovoltaic layer has: a portion provided below the aforementioned 2-2 region and where no electrode exists below. A long stacked body, comprising: a substrate layer; and a stacked body, comprising a first electrode on the substrate layer, a second electrode above the first electrode, and a photovoltaic layer between the first electrode and the second electrode; the first electrode has a portion that is not opposite to the second electrode and has no other layer between the first electrode and the height at which the second electrode is provided on the photovoltaic layer; The second electrode has a portion extending on the substrate layer through the side of the photovoltaic layer, and no other layer is provided between the extending portion and the height at which the second electrode is provided on the photovoltaic layer; or the photovoltaic layer has a portion provided below the second electrode, and no electrode exists below the second electrode. The long-layer body as recited in any one of claims 1 to 4, comprising the aforementioned first electrode, the aforementioned photovoltaic layer and the aforementioned second electrode, wherein the aforementioned long-layer body exists in plurality in the length direction of the aforementioned substrate layer. A long-layer body as described in any one of claims 1 to 4, wherein a protective layer is further provided on the aforementioned second electrode at least through a bonding layer; The aforementioned first electrode is formed on the aforementioned substrate layer at least through the aforementioned bonding layer; The peeling force when the aforementioned protective layer is peeled off from the aforementioned second electrode is greater than the peeling force when the aforementioned substrate layer is peeled off from the aforementioned first electrode. The long-layer structure as recited in any one of claims 1 to 4, wherein the photovoltaic layer comprises an organic thin film. A photovoltaic device comprises: a device substrate, a first laminate and a second laminate; The first laminate and the second laminate each comprise: a first electrode at least partially formed on the device substrate, a photovoltaic layer at least partially formed on the first electrode, and a second electrode at least partially formed on the photovoltaic layer; The first laminate and the second laminate are formed in parallel on the device substrate; In each of the first laminate and the second laminate, the second electrode has a 2-1 region opposite to the first electrode and a 2-2 region not opposite to the first electrode; In each of the aforementioned first laminate and the aforementioned second laminate, the aforementioned first electrode has a 1-1 region opposite to the aforementioned second electrode, and a 1-2 region not opposite to the aforementioned second electrode; In the aforementioned photovoltaic device: The aforementioned 1-2 region of the aforementioned first electrode of the aforementioned first laminate overlaps with the aforementioned 2-2 region of the aforementioned second electrode of the aforementioned second laminate and is electrically connected; or The aforementioned photovoltaic layer of the aforementioned first laminate has: a portion disposed below the aforementioned 2-2 region of the aforementioned second electrode of the aforementioned first laminate and overlapping and electrically connected to the aforementioned 1-2 region of the aforementioned first electrode of the aforementioned second laminate; and the aforementioned 1-2 region of the aforementioned first electrode of the aforementioned second laminate has a portion where no other layers are disposed between the portion overlapping with the aforementioned photovoltaic layer and the aforementioned 1-1 region of the aforementioned first electrode of the aforementioned second laminate, from above the aforementioned first electrode to the height at which the aforementioned second electrode is disposed on the aforementioned photovoltaic layer of the aforementioned second laminate. The photovoltaic device as recited in claim 8, wherein a first contact layer is provided between the device substrate and the first electrode of one or both of the first laminate and the second laminate. A photovoltaic device as recited in claim 9, wherein a protective layer is provided on the second electrode of one or both of the first laminate and the second laminate via a second bonding layer, and in the photovoltaic device, a peeling force when peeling off the device substrate is greater than a peeling force when peeling off the protective layer. The photovoltaic device as recited in any one of claims 8 to 10, wherein a barrier layer is provided above the first layer and the second layer in a manner of covering the first layer and the second layer. A photovoltaic device as recited in any one of claims 8 to 10, wherein the photovoltaic layer comprises an organic thin film. A photovoltaic device is provided, wherein the long-layer structure described in any one of claims 1 to 4 is transferred onto a device substrate and electrically connected. A method for manufacturing a photovoltaic device, using a long stacked body as described in claim 2 or 3 to manufacture a photovoltaic device, comprising the following steps: Peeling off the substrate layer from the stacked body before the long stacked body; and Transferring the stacked body before the long stacked body to the device substrate in such a manner that the 1-2 region of the 1st electrode or the 2-2 region of the 2nd electrode in the stacked body before the long stacked body, or when the photovoltaic layer has a portion disposed below the 2-2 region, such portion overlaps and contacts the electrode disposed on the device substrate of other stacked bodies.