Method of manufacturing a solar cell module and apparatus of manufacturing a solar cell module

A method of manufacturing a solar cell, which includes an edge deletion step using a laser beam, and a manufacturing apparatus which is used in such a method, the method and the apparatus being capable of preventing a shunt and cracks from being generated are provided. By radiating a first laser beam to a multilayer body, which includes a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on a transparent substrate, from a side of the transparent substrate, the photoelectric conversion layer and the back electrode layer in a first region are removed, and by radiating a second laser beam into the region such that the second laser beam is spaced from a peripheral rim of the region, the transparent electrode layer in a second region is removed.

CROSS-REFERENCE TO A RELATED APPLICATIONS

This application is a U.S. national phase application filed under 35 U.S.C. §371 of International Application PCT/JP2010/005333, filed on Aug. 30, 2010, designating the United States, which claims priority from JP 2009-205323, filed on Sep. 4, 2009, which are hereby incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a method of manufacturing a solar cell module, which includes an edge deletion step, and to an apparatus of manufacturing a solar cell module, which is used in such a method.

BACKGROUND ART

The solar cell consists of a solar cell module obtained by forming on a single substrate a plurality of solar cells each being a minimum unit for performing photovoltaic power generation. Here, as one of manufacturing steps for a solar cell module, there is a step called “edge deletion.” The manufacturing steps for a solar cell module generally include a step of uniformly forming on a substrate made of a glass or the like thin films including a transparent electrode layer, a photoelectric conversion layer, a back electrode layer, and the like. Here, in the case where thin films are present on a peripheral rim portion (portion having a width from a peripheral rim) of the substrate, a short circuit of the thin films and a metal frame or the like attached to the peripheral rim portion may occur or moisture and the like may infiltrate the peripheral rim portion, resulting in low power generation performance. Therefore, after forming the thin films, edge deletion being a step of removing the thin films present on the peripheral rim portion of the substrate is needed.

For the edge deletion, there is, for example, a method of using sandblasting. In the sandblasting, by spraying powdered abrasives to the thin films on the peripheral rim portion using gas so as to physically remove the thin films. However, in the sandblasting, there are problems in that the powdered abrasives are dispersed also in a power generation region, resulting in low power generation performance, a great amount of dust is generated, and so on. Although other than the sandblasting, there are various methods including directly grinding with a rotating grinder, etching with chemicals, and the like, they have problems in terms of productivity and the like. In view of this, in recent years, edge deletion using a laser beam is considered.

For example, Japanese Patent Application Laid-open No. 2008-66453 (paragraph [0056], FIG. 7B) discloses a method of manufacturing a solar cell module using a laser. In such a manufacturing method, the laser is used to remove, from a transparent conductive layer, a photoelectric conversion layer, and a back electrode layer, which have been sequentially stacked on a translucent substrate, the back electrode layer and the photoelectric conversion layer so that a burr prevention groove is formed. Next, by using a laser to remove the transparent conductive layer, the photoelectric conversion layer, and the back electrode layer in an outside of the burr prevention groove (peripheral region), a peripheral rim isolation groove is formed. At this time, the laser is radiated so that an end portion of a laser beam pattern overlaps with the burr prevention groove and a center portion of the laser beam pattern reaches the outside of the burr prevention groove. By forming the peripheral rim isolation groove in this manner, a short circuit (shunt) between the back electrode layer and the transparent electrode layer, which occurs due to residues of the transparent conductive layer that adhere to the walls of the groove, is prevented from being generated.

However, in the method of manufacturing a solar cell module using a laser, which is described in Japanese Patent Application Laid-open No. 2008-66453(paragraph [0056], FIG. 7B), when the peripheral rim isolation groove is formed, the transparent conductive layer, the photoelectric conversion layer, and the back electrode layer are all removed in the center portion of the laser beam pattern. Here, when the transparent conductive layer, the photoelectric conversion layer, and the back electrode layer are all removed, there is a fear that cracks are generated in a portion of the translucent substrate, which is irradiated with the laser beam, because the laser radiated from the translucent substrate side is reflected by the back electrode layer and heat is accumulated therein. The cracks contribute to a change of the outer appearance of the manufactured solar cell. In addition, the cracks can cause damage and low quality of the solar cell panel, and particularly low power generation performance due to infiltration of moisture and the like over time, and so on.

SUMMARY OF THE INVENTION

In view of the above-mentioned circumstances, it is an object of the present invention to provide a method of manufacturing a solar cell, which includes an edge deletion step using a laser beam, and an apparatus of manufacturing a solar cell module, which is used in such a method, the method and the apparatus being capable of preventing a shunt and cracks from being generated.

In order to achieve the above-mentioned object, a method of manufacturing a solar cell module according to an aspect of the present invention includes radiating a first laser beam to a multilayer body, which includes a transparent substrate and a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on the transparent substrate, from a side of the transparent substrate, to thereby remove the photoelectric conversion layer and the back electrode layer in a first region irradiated with the first laser beam.

The transparent electrode layer in the second region irradiated with the second laser beam is removed by radiating a second laser beam having a property different from a property of the first laser beam into the first region such that the second laser beam is spaced from a peripheral rim of the first region.

In order to achieve the above-mentioned object, an apparatus of manufacturing a solar cell module according to an aspect of the present invention is an apparatus of manufacturing a solar cell module, that radiates a laser beam to a multilayer body including a transparent substrate and a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on the transparent substrate, and includes a laser beam oscillator, an output controller, a stage, and a position controller.

The laser beam oscillator generates a laser beam having a wavelength included in an infrared wavelength region.

The output controller forms, in order to remove the photoelectric conversion layer and the back electrode layer, a first laser beam by controlling an output of the laser beam and forms, in order to remove the transparent electrode layer, a second laser beam having an output larger than an output of the first laser beam by controlling the output of the laser beam.

On the stage, the multilayer body is disposed.

The position controller controls a relative position between the laser beam oscillator and the stage such that a first region includes a second region and a peripheral rim of the second region is spaced from a peripheral rim of the first region, the first region being a region in which the formed photoelectric conversion layer and the formed back electrode layer are removed by irradiating the multilayer body with the first laser, the second region being a region in which the formed transparent electrode layer is removed by irradiating the multilayer body with the second laser beam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A method of manufacturing a solar cell module according to an embodiment of the present invention includes radiating a first laser beam to a multilayer body, which includes a transparent substrate and a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on the transparent substrate, from a side of the transparent substrate, to thereby remove the photoelectric conversion layer and the back electrode layer in a first region irradiated with the first laser beam.

The transparent electrode layer in the second region irradiated with the second laser beam is removed by radiating a second laser beam having a property different from a property of the first laser beam into the first region such that the second laser beam is spaced from a peripheral rim of the first region.

The first laser beam removes the back electrode layer and the photoelectric conversion layer of the multilayer body and the second laser beam removes the transparent electrode layer not including the back electrode layer and the photoelectric conversion layer above it. By setting the property (wavelength or energy density) of the first laser beam to be different from the property of the second laser beam, it is possible that the first laser beam does not remove the transparent electrode layer and the second laser beam removes the transparent electrode layer. The first laser beam does not remove the transparent electrode layer, and hence in irradiation of the first laser beam, no cracks are generated in the transparent substrate. Further, when the second laser beam removes the transparent electrode layer, the photoelectric conversion layer and the back electrode layer have been removed, and hence the second laser beam is not reflected by the back electrode layer and cracks are prevented from being generated in the transparent substrate due to heat accumulation. In addition, by radiating the second laser beam into the first region such that the second laser beam is spaced from the peripheral rim of the first region, end surfaces of the photoelectric conversion layer and the back electrode layer, which have been formed due to the irradiation of the first laser beam, are spaced from a position in which the transparent electrode layer is removed by the second laser beam. Accordingly, when the transparent conductive layer is removed, it is possible to prevent the back electrode layer from being molten due to heat or a short circuit (shunt) between the back electrode layer and the transparent conductive layer, which occurs due to residues of the transparent conductive layer that adhere to the end surface, is prevented from being generated.

The first laser beam and the second laser beam may have the same wavelength included in an infrared wavelength region, and the second laser beam may be radiated to have an energy density higher than an energy density of the first laser beam.

The transparent electrode layer of the multilayer body exhibits a low absorptance with respect to a laser beam having an infrared wavelength. Therefore, by adjusting the energy density of a laser beam, whether or not to remove the transparent electrode layer can be selected. By setting the energy density of the first laser beam to be sufficiently low, that is, to be below a laser ablation threshold, it becomes possible to prevent the transparent electrode layer from being removed. In contrast, by setting the energy density of the second laser beam to be sufficiently high (even if most of the second laser beam passes through the transparent electrode layer), it is possible to remove the transparent electrode layer by laser ablation. Therefore, by adjusting the energy density of a laser having an infrared wavelength, a first laser and a second laser can be obtained. Accordingly, the laser beam irradiation apparatus to be used in edge deletion as a feature of the present invention needs only to include a laser beam generator capable of outputting a single infrared laser beam. Thus, the laser beam irradiation apparatus can be simplified. Further, an infrared laser beam generator is generally cheaper than a harmonic laser beam generator, and hence it is also possible to reduce the cost for the laser beam irradiation apparatus.

The first laser beam may have a wavelength included in a green light wavelength region, and the second laser beam may have a wavelength included in an infrared wavelength region.

The absorptance of the transparent electrode layer of the multilayer body with respect to a laser beam having a green light wavelength region is significantly smaller than the absorptance of the transparent electrode layer of the multilayer body with respect to a laser beam having an infrared wavelength. Therefore, by setting the laser beam having a green light wavelength region as the first laser beam, irrespective of the energy density, without removing the transparent electrode layer, the photoelectric conversion layer and the back electrode layer can be removed. Further, by setting the laser having an infrared wavelength as the second laser beam so as to set its energy density to be sufficiently high, the transparent electrode layer can be removed.

The second laser beam may be radiated to the multilayer body from the side of the transparent substrate.

During irradiation of the second laser beam, the irradiated region thereof is included in the first region and the back electrode layer that reflects the laser beam is not present, and hence the second laser beam is not limited to be radiated from the side of the transparent substrate of the multilayer body and can also be radiated from the opposite side. However, in the case where the second laser beam is radiated from the side of the transparent substrate, it is possible to use the same optical system as the first laser beam. Thus, in this case, the laser beam irradiation apparatus which is used in edge deletion can be simplified. Further, dispersion of removed films with respect to the optical system is prevented by the transparent substrate, and hence contamination of the optical system can be prevented.

The second region may include an end portion of the multilayer body.

The transparent electrode layer, the photoelectric conversion layer, and the back electrode layer in the end portion of the multilayer body are all removed. Thus, in the subsequent step, a sealant can be directly applied to the transparent substrate and the adhesion property in sealing can be improved. Therefore, a solar cell module more excellent in moisture resistance and weather resistance can be manufactured.

An apparatus of manufacturing a solar cell module according to an embodiment of the present invention is an apparatus of manufacturing a solar cell module, that radiates a laser beam to a multilayer body including a transparent substrate and a transparent electrode layer, a photoelectric conversion layer, and a back electrode layer sequentially formed on the transparent substrate, and includes a laser beam oscillator, an output controller, a stage, and a position controller.

The laser beam oscillator generates a laser beam having a wavelength included in an infrared wavelength region.

The output controller forms, in order to remove the photoelectric conversion layer and the back electrode layer, a first laser beam by controlling an output of the laser beam and forms, in order to remove the transparent electrode layer, a second laser beam having an output larger than an output of the first laser beam by controlling the output of the laser beam.

On the stage, the multilayer body is disposed.

The position controller controls a relative position between the laser beam oscillator and the stage such that a first region includes a second region and a peripheral rim of the second region is spaced from a peripheral rim of the first region, the first region being a region in which the formed photoelectric conversion layer and the formed back electrode layer are removed by irradiating the multilayer body with the first laser, the second region being a region in which the formed transparent electrode layer is removed by irradiating the multilayer body with the second laser beam.

The output controller controls the output of the laser beam, and hence a single optical system can be used. In addition, without changing a laser spot area in an irradiated surface and the moving speed of the stage, infrared laser beams having different energy densities, that is, the first laser beam and the second laser beam can be formed. Further, The position controller controls the laser spot position such that the first region in which the photoelectric conversion layer and the back electrode layer of the multilayer body have been removed by the first laser beam includes the second region in which the transparent electrode layer is removed by the second laser beam and that the peripheral rim of the second region is spaced from the peripheral rim of the first region. Accordingly, cracks and a shunt in the transparent substrate can be prevented from being generated.

Hereinafter, with reference to the drawings, embodiments of the present invention will be described.

First Embodiment

FIG. 1is a flowchart showing a method of manufacturing a solar cell module according to the first embodiment. As shown in the drawing, the method of manufacturing a solar cell module according to this embodiment includes a multilayer body producing step (St1), an edge deletion step (St2), and a modularization step (St3). It should be noted that the method of manufacturing a solar cell according to this embodiment may include steps other than those steps. In the following, each of the steps will be described.

The multilayer body producing step (St1) will be described.

FIG. 2is a sectional view showing a multilayer body1produced in this step.FIG. 3is a plan view showing the multilayer body1.

The multilayer body1is formed by stacking a transparent electrode layer3, a photoelectric conversion layer4, and a back electrode layer5on a transparent substrate2. The transparent substrate2is made of, for example, a white plate glass (glass from which Fe components are removed) that has a size of 1 m *1 m and 5 mm in thickness. It should be noted that in addition to this, the transparent substrate2may be made of various glasses such as a blue plate glass (glass from which Fe components are not removed), a borosilicate glass, a soda-lime glass, an alkali-free glass, a silica glass, and a lead glass, a synthetic resin, and the like and the size thereof is not limited thereto.

First, the transparent electrode layer3is stacked. The transparent electrode layer3can be formed by forming on the transparent substrate2an SnO2thin film having a thickness of 1 μm by a thermal CVD (Chemical Vapor Deposition) method. Other than SnO2, the transparent electrode layer3can be made of a conductive material having a high light transmittance, such as a transparent conductive oxide (TCO) including ZnO and ITO (Indium Tin Oxide). In addition, the thickness thereof can be appropriately changed. The film formation method is also not limited to the thermal CVD method, and a sputtering method, applying, or the like may be employed.

Next, the transparent electrode layer3is separated. By irradiating the transparent electrode layer3with an infrared laser beam (wavelength: 1,064 nm) using an Nd:YAG (Yttrium Aluminum Garnet) as a laser crystal, the transparent electrode layer3is linearly removed (laser scribing) to thereby form a separation line3s. Regarding the separation line3s, a plurality of separation lines3scan be formed to be arranged in parallel in one direction. The wavelength and output of the laser beam may be appropriately selected, and the laser beam may be a continuous wave. The separation of the transparent electrode layer3is performed for the purpose of connecting currents in series, the currents being generated by the photoelectric conversion layer4that will be described later. Regarding the separation line3s, for example, a plurality of separation lines3sare formed to be arranged in parallel in one direction. The method for the separation of the transparent electrode layer3is not limited to the laser scribing and other methods may be employed. Further, the separation of the transparent electrode layer3may be performed after another layer is formed on the transparent electrode layer3.

Next, the photoelectric conversion layer4is stacked. The photoelectric conversion layer4can be formed by sequentially forming, on the transparent electrode layer3by a plasma CVD method, a B-doped amorphous Si film (p-layer) having a thickness of 30 nm, an amorphous Si film (i-layer) having a thickness of 300 nm, and a P-doped microcrystalline Si (n-layer) having a thickness of 30 nm. It is sufficient for the photoelectric conversion layer4to have a structure allowing photoelectric conversion. Therefore, other than the above-mentioned structure, the photoelectric conversion layer4may have a structure of repeating pin junction, that is, a tandem type structure of pin/pin, a triple type structure of pin/pin/pin, or the like. Further, for example, a middle layer such as a buffer layer arranged between the p-layer and the i-layer or a TCO layer adjusting an optical refraction index may be included. The film formation method is also not limited to the plasma CVD method.

Next, the photoelectric conversion layer4is separated. By irradiating the photoelectric conversion layer4with a second harmonic green laser beam using an Nd:YAG as a laser crystal, the photoelectric conversion layer4is linearly removed, to thereby form a separation line4s. The wavelength and output of the laser beam may be appropriately selected, and the laser beam may be a continuous wave. The separation of the photoelectric conversion layer4is performed for the purpose of connecting the back electrode layer5, which will be described later, to the transparent electrode layer3. Regarding the separation line4s, for example, a plurality of separation lines4sare formed to be arranged in parallel to the separation line3sat positions different from the positions at which the separation lines3sare arranged. The method for the separation of the photoelectric conversion layer4is not limited to the laser scribing, and other methods can be employed. Further, the separation of the photoelectric conversion layer4may be performed after another layer is formed on the photoelectric conversion layer4.

Next, the back electrode layer5is stacked. The back electrode layer5can be formed by forming, on the photoelectric conversion layer4by a sputtering method, Ag having a thickness of 300 nm. Alternatively, the back electrode layer5may be made of a conductive material capable of reflecting a beam that has passed through the photoelectric conversion layer4, such as Al, Cr, Mo, W, or Ti, and the thickness thereof can be appropriately changed. The film formation method is also not limited to the sputtering method, and a CVD method, an application method, or the like may be employed.

Next, the photoelectric conversion layer4and the back electrode layer5are separated. By irradiating the photoelectric conversion layer4and the back electrode layer5with an infrared laser beam (wavelength: 1,064 nm) using an Nd:YAG as a laser crystal or a second harmonic green laser beam (wavelength: 532 nm) using an Nd:YAG as a laser crystal, the photoelectric conversion layer4and the back electrode layer5are linearly removed, to thereby form a cell separation line6.

Regarding the cell separation line6, a plurality of cell separation lines6can be formed to be arranged in parallel in one direction. The wavelength and output of the laser beam may appropriately selected, and the laser beam may be continuous wave.

Regarding the cell separation line6, a plurality of cell separation lines6are formed at positions different from the positions, at which the separation line3sand the separation line4sare arranged, in parallel to the separation line3sand the separation line4s. The laser beam is input from the transparent substrate2side to be prevented from being reflected by the back electrode layer5. By forming the cell separation line6, a current generated in the photoelectric conversion layer4is allowed to flow through the transparent electrode layer3and the back electrode layer5into the adjacent photoelectric conversion layer4, and the cell is separated. The method for the separation of the photoelectric conversion layer4and the back electrode layer5is not limited to the laser scribing, and other methods may be employed.

In the above-mentioned manner, the multilayer body1shown inFIGS. 2 and 3is formed. It should be noted that the method of producing the multilayer body1is not limited to the above-mentioned method and can be appropriately changed. Further, the multilayer body1may include layers other than the above-mentioned layers. As shown inFIG. 3, a portion having a certain width from the peripheral rim of the multilayer body1is referred to as a peripheral rim portion1a, and a portion other than the peripheral rim portion1aof the multilayer body1is referred to as a power generation portion1bcontributing to power generation.

The edge deletion step is a step of removing the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5, which are present on the peripheral rim portion1aof the multilayer body1. With this step, it becomes possible to prevent a short circuit of those layers and a metal frame or the like attached to the peripheral rim portion1ain modularization step (St3), which will be described later, from occurring, or moisture and the like from infiltrating through the peripheral rim portion1aafter they are completed as a solar cell module.

In the edge deletion step described in the following, first, by irradiating the peripheral rim portion1awith a first laser beam L1, a first region A1(FIG. 4) in which the photoelectric conversion layer4and the back electrode layer5are removed is formed. Next, by irradiating the first region A1with the second laser beam L2, a second region A2(FIG. 5) in which the transparent electrode layer3is removed is formed. In the edge deletion step of this embodiment, a case where the first laser beam L1and the second laser beam L2have the same wavelength will be described.

The irradiation of the multilayer body1with the first laser beam L1will be described.

FIG. 4is views for illustrating the first laser beam L1being radiated.

As shown inFIG. 4(a), the peripheral rim portion1aof the multilayer body1is irradiated with a first laser beam L1from the transparent substrate2side. The first laser beam L1is radiated to a predetermined range by scanning a laser spot shaped in a predetermined size and moving a relative position of the multilayer body1with respect to an irradiation position of the laser beam.

The first laser beam L1passes through the transparent electrode layer3and is absorbed by the photoelectric conversion layer4. As a result, the photoelectric conversion layer4is removed, and the back electrode layer5being a layer above it is also removed. The transparent electrode layer3remains without being removed. Thus, as shown inFIG. 4(b), on the first region A1being the region irradiated with the first laser beam L1, the transparent electrode layer3is exposed. Further, the photoelectric conversion layer4and the back electrode layer5are, in the first region A1, removed, and hence an end surface4tof the photoelectric conversion layer4and an end surface5tof the back electrode layer5are newly formed.FIG. 4(c) is a plan view showing the range of the first region A1irradiated with the first laser beam L1.

The first laser beam L1may be a laser beam (infrared laser beam) having a wavelength included in an infrared wavelength region. Although a little of the infrared laser beam is absorbed by the transparent electrode layer3, most of the infrared laser beam passes through the transparent electrode layer3, arrives at the photoelectric conversion layer4, and is absorbed by the photoelectric conversion layer4. Therefore, by setting the first laser beam L1to have a suitable energy density, without subjecting the transparent electrode layer3to laser ablation, only the photoelectric conversion layer4can be subjected to laser ablation. Further, as described above, typically, the photoelectric conversion layer4is stacked by a CVD method or the like, while the back electrode layer5is stacked by a sputtering method or the like. Therefore, the adhesion property of the photoelectric conversion layer4with respect to the transparent electrode layer3is smaller than the adhesion property of the back electrode layer5with respect to the photoelectric conversion layer4. Consequently, it is quite possible to selectively remove the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5.

Specifically, as the first laser beam L1, an infrared laser beam having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the first laser beam L1may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the materials for the transparent electrode layer3and the photoelectric conversion layer4. For such a laser beam, there are solid laser beams using Er:YAG (wavelength of 2940 nm), Ho:YAG (wavelength of 2,098 nm), Yb:YAG (wavelength of 1,030 nm), Nd:YVO4(wavelength of 1,064, 1,342 nm), Nd:GdVO4(wavelength of 1,063 nm), Ti-sapphire (wavelength of 700 to 1,000 nm), and the like as a laser crystal. In addition to them, a gas laser beam or a semi-conductor laser beam may be used as the first laser beam L1. Further, the laser beam may be pulsed or a continuous wave.

The energy density of the first laser beam L1is appropriately selected within such a range that the photoelectric conversion layer4and the back electrode layer5can be removed without removing the transparent electrode layer3, although the transmittance of the transparent electrode layer3and the absorptance of the photoelectric conversion layer4are varied depending on the wavelength of the laser beam. For example, in the case of an infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to range from 0.5 to 1.5 J/cm2.

It should be noted that the energy density of the first laser beam L1and the second laser beam L2is a time integral value of a peak output density (W/cm2) per unit area in an irradiated surface.

The transparent electrode layer3is not subjected to ablation using the first laser beam L1, and hence it is possible to prevent generation of cracks in the transparent substrate2in the phase where the first laser beam L1is irradiated. Further, the end surface4tand the end surface5tthat are newly formed due to the irradiation of the first laser beam L1are insusceptible to thermal damage and contamination due to residues.

Irradiation of the multilayer body1with the second laser beam L2will be described.

FIG. 5is views for illustrating the second laser beam L2being radiated.

As shown inFIG. 5(a), the first region A1is irradiated with the second laser beam L2. Similar to the first laser beam L1, the second laser beam L2may be radiated from the transparent substrate2side. Alternatively, the back electrode layer5that reflects the laser beam has been removed, and hence the second laser beam L2may be radiated from a side opposite to the transparent substrate2side. The second region A2being the region irradiated with the second laser beam may be a region having a peripheral rim spaced from the peripheral rim of the first region A1. The second laser beam L2is radiated to a predetermined range by scanning a laser spot shaped in a predetermined size and moving a relative position of the multilayer body1with respect to the irradiation position of the laser beam.

The second laser beam L2is absorbed by the exposed transparent electrode layer3on the first region A1. As a result, the transparent electrode layer3is removed. Accordingly, as shown inFIG. 5(b), on the second region A2being the region irradiated with the second laser beam L2, the transparent substrate2is exposed, and an end surface3tof the transparent electrode layer3is newly formed after the transparent electrode layer3is removed on the second region A2. The position of the end surface3tis spaced from the positions of the end surface4tand the end surface5tthat have been formed due to the irradiation of the first laser beam L1.FIG. 5(c) is a plan view showing the range of the second region A2irradiated with the second laser beam L2. The range of the second region A2formed on the first region A1is denoted by A1+A2.

The second laser beam L2may be a laser having the same wavelength as the first laser beam L1. As described above, most of the infrared laser beam passes through the transparent electrode layer3, but a little of the infrared laser beam is absorbed by the transparent electrode layer3. Therefore, even if the second laser beam L2have the same wavelength as the first laser beam L1, by setting the energy density of the second laser beam L2to be sufficiently high, it is possible to apply to the transparent electrode layer3energy enough to remove the transparent electrode layer3.

Specifically, the second laser beam L2may be an infrared laser having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal. The second laser beam L2may be one that has the same wavelength as the first laser beam L1and an energy density higher than that of the first laser beam L1.

The energy density of the second laser beam L2is appropriately selected within such a range that the transparent electrode layer3can be removed, although the absorptance of the transparent electrode layer3varies depending on the wavelength of the laser beam. For example, in the case of an infrared laser having a wavelength of 1,064 nm, its energy density may be 5 J/cm2or more. As the second laser beam L2, a laser beam having an output larger than that of the first laser beam L1or a laser spot area smaller than that of the first laser beam L1may be used. The second laser beam L2is not limited to be pulsed and may be a continuous wave. Even if the first laser beam L1is a continuous wave, the second laser beam L2may be set to be pulsed.

During the irradiation of the second laser beam L2, the first region A1does not include anymore the back electrode layer5(and the photoelectric conversion layer4) that reflect the second laser beam L2and contributes to accumulation of heat, and hence the accumulation of heat due to the irradiation of the second laser beam L2does not occur, and generation of cracks in the transparent substrate2is prevented.

Further, by setting the second region A2to be a region having a peripheral rim spaced from the first region A1, the end surface4tand the end surface5tthat have been formed due to the first laser beam L1are spaced from a position in which the transparent electrode layer3is to be removed. Accordingly, a shunt, which is generated due to the residues of the transparent electrode layer3removed by the second laser beam L2that adhere to the end surfaces of the back electrode layer5and the photoelectric conversion layer4, can be prevented.

As described above, in the edge deletion of this embodiment, by using the first laser beam L1to remove the photoelectric conversion layer4and the back electrode layer5and the second laser beam L2to remove the transparent electrode layer3, it is possible to reduce heat to be applied to the transparent substrate2and to prevent generation of cracks. Further, the end surfaces4tand5tformed due to the first laser beam L1and the end surface3tformed due to the second laser beam L2can be suppressed from being molten, adhesion of the residues of those end surfaces can be suppressed, and a shunt can be prevented. In addition, the first laser beam L1and the second laser beam L2have the same infrared wavelength, and hence a single laser beam generator for generating the first laser beam L1and the second laser beam L2may be used.

As described above, the multilayer body1is subjected to edge deletion.

A laser beam irradiation apparatus10to be used in the edge deletion step (St2) will be described.

FIG. 6is a view showing a schematic configuration of the laser beam irradiation apparatus10.

As shown in the drawing, the laser beam irradiation apparatus10includes an oscillator11, a variable attenuator12, a condenser lens17, a homogenizer13, a scanner14, an fθ lens15, and a stage16. In the laser beam irradiation apparatus10, the oscillator11, the condenser lens17, the homogenizer13, the scanner14, and the fθ lens15correspond to a laser beam oscillator. The variable attenuator12corresponds to an output controller. The configuration of the laser beam irradiation apparatus10is not limited to the configuration as described in the following.

The oscillator11outputs an infrared laser which becomes the first laser beam L1and the second laser beam L2. The oscillator11installs a laser crystal such as an Nd:YAG laser rod (not shown), a laser diode for photo-excitation, or the like. The oscillator11may include a mechanical or electrochemical Q-switch mechanism for pulsed oscillation. By setting the first laser beam L1and the second laser beam L2to be infrared laser beams having the same wavelength, the oscillator11can be configured to be capable of outputting a single infrared laser beam.

The variable attenuator12attenuates the infrared laser beam output from the oscillator11, to thereby control the output. As the variable attenuator12, a Fresnel-reflection-type variable attenuator or a beam-split-type variable attenuator may be used. The beam-split-type variable attenuator is used when the laser beam is a linear polarized beam and consists of a λ/2 wave plate and a polarizing beam splitter. The λ/2 wave plate rotates the direction of polarization of a laser beam and the polarizing beam splitter separates the laser beam into a p-polarized beam and an s-polarized beam for attenuation. The Fresnel-reflection-type variable attenuator is used when the laser beam is non-polarized beam and consisting of a mirror with reflective coating and a compensator (optical axis compensating plate) with anti-reflective coating. By changing the angle of the reflective mirror, the transmittance of an incident laser beam is changed for attenuation.

The condenser lens17collects the laser beam output from the variable attenuator12, to the homogenizer13. The homogenizer13converts the shape of a cross-section of beam of the incident laser to obtain an even light intensity distribution. The laser beam irradiation apparatus10includes an optical fiber having a 0.6 mm square-shaped cross-section as the homogenizer13. The homogenizer13converts the incident infrared laser beam into a laser having a square-shaped cross-section having an even light intensity distribution. The configuration of the homogenizer13is not limited thereto and a refraction-type homogenizer (micro lens array, aspheric lens, etc) or a reflection-type homogenizer (light pipe, aspheric mirror, etc) may be used.

The scanner14scans the laser beam by changing the direction of the reflected laser beam. As the scanner14, it is possible to select one of various scanners such as a polygon scanner consisting of a rotating polyhedral mirror, a galvano scanner consisting of a mirror vibrating due to the external magnetic field, and a resonant scanner consisting of a mirror vibrating due to oscillation.

The fθ lens15corrects the scanning speed and the laser spot shape of the laser beam scanned by the scanner14. Regarding the laser beam scanned by the scanner14, although the scanning speed and the laser spot shape thereof when the laser beam is radiated to an irradiation target (multilayer body1) are varied depending on the angle of reflection thereof, the fθ lens15can correct this.

The stage16defines an irradiation position of the laser beam with respect to the multilayer body1. The stage16is configured to be movable in an X-direction being one direction parallel to a surface (laser-irradiated surface) of the multilayer body1and a Y-direction orthogonal to the X-direction. The stage16freely allows a laser beam to be radiated onto an X-Y plane. The laser beam irradiation apparatus10includes a position controller (not shown) that controls the movement of the stage16.

One example of edge deletion performed by the laser beam irradiation apparatus10configured as described above will be described.

When the multilayer body1is disposed on the stage16, the stage16moves to adjust the position of the multilayer body1so that any point on the peripheral rim portion1aof the multilayer body1can be irradiated with a laser beam. The oscillator11outputs an infrared laser beam having a wavelength of 1,064 nm and a predetermined output and the variable attenuator12controls the output. The laser beam is converted by the homogenizer13to have a 0.6 mm square-shaped laser cross-section and made to even.

The laser beam is scanned by the scanner14, corrected through the fθ lens15, and radiated to the above-mentioned point of the multilayer body1. Further, using the area of its laser spot, the output density is defined. The stage16moves and thus the laser beam is radiated to a predetermined range. Using the moving speed of the stage16, the repeat frequency of the laser beam is defined. Here, the laser beam is adjusted to be a laser beam (the first laser beam L1) having such an energy density that the transparent electrode layer3is not removed and the photoelectric conversion layer4and the back electrode layer5are removed. By the position controller controlling the movement of the stage16, the first region A1being the region irradiated with the first laser beam L1is formed within the peripheral rim portion1a.

Next, by moving the stage16, the position of the multilayer body1is adjusted so that any point on the first region A1is irradiated with the laser beam. The variable attenuator12changes the output, and the moving speed of the stage16defines the repeat frequency of the laser beam. The laser beam is adjusted to be a laser beam (second laser beam L2) having such an energy density that the transparent electrode layer3is removed. By the position controller controlling the movement of the stage16, the second region A2being the region irradiated with the second laser beam within the first region A1is formed.

The position controller may control the movement of the stage16such that the peripheral rim of the second region A2is spaced from the peripheral rim of the first region A1. In this case, the areas of the first region A1and the second region A2can be reduced, and hence a laser beam scan time can be reduced, which contributes to an improvement of throughput. Alternatively, in the case where the first region portion extends up to the end of the multilayer body1, that is, in the case where the first region A1includes the end portion of the multilayer body1, the second region A2may also include the same end portion of the multilayer body1. In this case, the layers in the end portion of the multilayer body1are all removed, and hence in the subsequent step, a sealant for the substrate can be directly applied to the multilayer body1and the adhesion property in sealing can be improved. Thus, a solar cell panel more excellent in moisture resistance and weather resistance can be manufactured.

FIG. 7is a view showing irradiation positions of laser beams, which are controlled by the position controller.

For example, when performing edge deletion on one side of the multilayer body1, the position controller uses the scanner14to scan the first laser beam L1on an end portion of the first region A1on a center side of the multilayer body1by a predetermined distance a from a scan start position S in an X-axis direction. When one scan is completed, the position controller moves the scan start position by a predetermined distance β in the X-axis direction. After that, the scanner14moves an irradiation position of the first laser beam L1by a distance equal to the width of the laser beam in an opposite direction to the center side of the substrate in a Y-axis direction. Thus, in the subsequent scan, the scanner14scans, in the X-axis direction again by a predetermined distance α from a position deviated by a predetermined distance β from the scan start position S in the X-axis direction and deviated by a distance equal to the width in the Y-axis direction of the laser beam from the scan start position S in the Y-axis direction. By repeating the process, when in the Y-axis direction, irradiations in a predetermined range are completed, the position controller moves the scan start position of the laser beam L1by a predetermined distance a and a distance equal to the width in the X-axis direction of the laser beam from the above-mentioned scan start position S in the X-axis direction.

As described above, while using the scanner14and the position controller, the stage16is moved such that the irradiation position of the first laser beam L1goes around the power generation portion1b. In other words, the first laser beam L1is radiated to scan over the range of the region A1. Further, the stage16can be moved while using a scan by the scanner14and the position controller such that similar to the first laser beam L1, the second laser beam L2goes around a portion which is located on the outer peripheral side of the multilayer body1in the region A1and which is in contact with the outer periphery in order to form the region A2. In this manner, edge deletion of the multilayer body1can be performed.

As described above, as the laser beam output from the oscillator11, the infrared laser beam is used, and hence by adjusting the energy density, the first laser beam L1and the second laser beam L2can be formed and the laser beam irradiation apparatus including a single-laser beam generator may be used.

FIG. 8is a view showing the multilayer body1modularized in the modularization step.

The modularization step St3is a step of completing the multilayer body1as the solar cell module. It should be noted that before this step, a step of cleaning the multilayer body1may be adopted. With the method of manufacturing a solar cell module according to this embodiment, unlike the case where the sandblasting is used, the powdered abrasives and the like are not generated, and hence the step of cleaning the multilayer body1may be omitted.

To the multilayer body1, wires (not shown) to be connected to each of the transparent electrode layer3and the back electrode layer5are attached. The wires can be formed, for example, by methods such as reflow with a soldering paste, sealing with a conductive adhesion, and plating.

Next, on the back electrode layer5, an insulating layer7made of an insulating resin is formed. The insulating resin can be made of, for example, EVA (Ethylene Vinyl Acetate Copolymer). Next, on the insulating layer7, a protective layer8made of a material excellent in moisture resistance is formed. The protective layer8can be made of PET (Polyethylene Terephthalate), Al, and PET which are sequentially stacked. The insulating layer7and the protective layer8can be formed by covering the back electrode layer5side of the multilayer body1with a EVA sheet and a PET/Al/PET sheet and laminating it under decreased pressure. Next, a frame (not shown) is attached onto the protective layer8and thus the multilayer body1is modularized. Such a modularization step is merely one example and the present invention is not limited thereto.

As described above, the solar cell module is manufactured.

With the method of manufacturing a solar cell module according to this embodiment, in the edge deletion step St2, the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5in the peripheral rim portion1aare removed, and hence the frame and these layers can be surely insulated. Further, the peripheral rims of the transparent substrate2, the insulating layer7, and the protective layer8are spaced from the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5, and hence it is possible to prevent moisture and the like from infiltrating through the peripheral rims of the transparent substrate2, the insulating layer7, and the protective layer8, resulting in low power generation performance.

Second Embodiment

Description of the same content as that of the first embodiment will be omitted.

A method of manufacturing a solar cell module according to this embodiment includes a multilayer body producing step (St1), an edge deletion step (St2), and a modularization step (St3). The multilayer body producing step (St1) and the modularization step (St3) are the same as in the method of manufacturing a solar cell module according to the first embodiment, and hence the description thereof will be omitted.

The edge deletion step of the second embodiment is different from the edge deletion step of the first embodiment in that the first laser beam L1and the second laser beam L2have different frequencies.

The first laser beam L1can be a laser beam (green laser beam) having a wavelength included in a green light wavelength region. The green laser beam passes through the transparent electrode layer3, arrives at the photoelectric conversion layer4, and is absorbed by the photoelectric conversion layer4. The transmittance of the green laser beam with respect to the transparent electrode layer3is significantly larger than the transmittance of the infrared laser beam with respect to the transparent electrode layer3. Therefore, by setting the first laser beam L1to be the green laser beam, without removing the transparent electrode layer3, only the photoelectric conversion layer4can be removed. Further, as described above, typically, the photoelectric conversion layer4is stacked by a CVD method or the like, while the back electrode layer5is stacked by a sputtering method or the like. Therefore, the adhesion property of the photoelectric conversion layer4with respect to the transparent electrode layer3is larger than the adhesion property of the back electrode layer5with respect to the photoelectric conversion layer4. Consequently, by setting the first laser beam L1to be the green laser beam, it is quite possible to remove the photoelectric conversion layer4and the back electrode layer5without removing the transparent electrode layer3.

Specifically, as the first laser beam L1, a green laser beam being a second harmonic wave (wavelength 532 nm) using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the first laser beam L1may be selected from the green light wavelength region (500 nm to 570 nm) exhibiting a high transmittance with respect to the transparent electrode layer3, depending on the materials for the transparent electrode layer3and the photoelectric conversion layer4. For such a laser beam, there are, for example, solid-state laser beams (each having a wavelength of 532 nm) having Nd:YVO4(wavelength 1,064 nm) and Nd:GdVO4(wavelength 1,064 nm) as laser crystals, the solid-state laser beams being subjected to second-harmonic conversion, a solid-state laser beam of GaN (wavelength 531 nm), an Ar ion laser beam (wavelength 515 nm), a gas laser beam such as a copper vapor laser beam (wavelength 511 nm), and a semi-conductor laser beam having ZnCdSe as an active layer. Further, the laser beam may be pulsed or a continuous wave.

Regarding the energy density of the first laser beam L1, although the absorptance of the photoelectric conversion layer4is varied depending on the wavelength of the laser beam, the first laser beam L1is hardly absorbed by the transparent electrode layer3, and hence the energy density of the first laser beam L1can be set to be enough to remove the photoelectric conversion layer4and the back electrode layer5. For example, in the case of the green laser beam having a wavelength of 532 nm, its energy density can be set to be 0.5 J/cm2or more.

The second laser beam L2can be set to be a laser beam (infrared laser beam) having a wavelength included in an infrared wavelength region. As described above, most of the infrared laser beam passes through the transparent electrode layer3, but a little of the infrared laser beam is absorbed by the transparent electrode layer3. Therefore, by setting the energy density to be sufficiently high, it is possible to apply to the transparent electrode layer3energy enough to remove the transparent electrode layer3.

Specifically, as the second laser beam L2, an infrared laser beam having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the first laser beam L1may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the material for the transparent electrode layer3. For such a laser beam, there are solid laser beams using Er:YAG (wavelength of 2940 nm), Ho:YAG (wavelength of 2,098 nm), Yb:YAG (wavelength of 1,030 nm), Nd:YVO4(wavelength of 1,064, 1,342 nm), Nd:GdVO4(wavelength of 1,063 nm), Ti-sapphire (wavelength of 700 to 1,000 nm), and the like as a laser crystal. In addition to them, a gas laser beam and a semi-conductor laser beam may be used as the first laser beam L1. Further, the laser beam may be pulsed or a continuous wave.

The energy density of the second laser beam L2is appropriately selected within such a range that the transparent electrode layer3can be removed, although the absorptance of the transparent electrode layer3is varied depending on the wavelength of the laser beam. For example, in the case of the infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to 5 J/cm2or more. The second laser beam L2is not limited to be pulsed and may be a continuous wave.

During the irradiation of the second laser beam L2, the first region A1does not include anymore the back electrode layer5(and the photoelectric conversion layer4) that reflect the second laser beam L2and contributes to accumulation of heat, and hence the accumulation of heat due to the irradiation of the second laser beam L2does not occur, and generation of cracks in the transparent substrate2is prevented.

Further, by setting the second region A2to be a region having a peripheral rim spaced from the first region A1, the end surface4tand the end surface5tthat have been formed due to the first laser beam L1are spaced from a position in which the transparent electrode layer3is to be removed. Accordingly, a shunt, which is generated due to the residues of the transparent electrode layer3removed by the second laser beam L2that adhere to the end surfaces of the back electrode layer5and the photoelectric conversion layer4, can be prevented.

As described above, in the edge deletion of this embodiment, by using the first laser beam L1to remove the photoelectric conversion layer4and the back electrode layer5and the second laser beam L2to remove the transparent electrode layer3, it is possible to reduce heat to be applied to the transparent substrate2and to prevent generation of cracks. Further, the end surfaces4tand5tformed due to the first laser beam L1and the end surface3tformed due to the second laser beam L2can be suppressed from being molten, adhesion of the residues of those end surfaces can be suppressed, and a shunt can be prevented.

As described above, the multilayer body1is subjected to edge deletion.

A laser beam irradiation apparatus20to be used in the edge deletion step (St2) will be described.

FIG. 9is a view showing a schematic configuration of the laser beam irradiation apparatus20.

As shown in the drawing, the laser beam irradiation apparatus20includes an oscillator21, a condenser lens27, a homogenizer23, a scanner24, an fθ lens25, and a stage26. In the laser beam irradiation apparatus20, the oscillator21, the condenser lens27, the homogenizer23, the scanner24, and the fθ lens25correspond to the laser beam oscillator. The configuration of the laser beam irradiation apparatus20is not limited to the configuration as described in the following.

The laser beam irradiation apparatus20includes the oscillator has a different configuration from that in the laser beam irradiation apparatus10according to the first embodiment. Further, the laser beam irradiation apparatus20does not include a variable attenuator. Hereinafter, different points from the laser beam irradiation apparatus10according to the first embodiment will be mainly described.

The oscillator21of the laser beam irradiation apparatus20according to this embodiment outputs a green laser beam which becomes the first laser beam L1and an infrared laser beam which becomes the second laser beam L2. The oscillator21installs a laser crystal such as an Nd:YAG laser rod, a laser diode for photo-excitation, or the like. The oscillator21includes a non-linear crystal (not shown) that changes a laser beam (1,064 nm) generated from a laser crystal to a second harmonic wave (wavelength 532 nm). The oscillator21can be configured to be capable of switching the infrared laser beam and the green laser beam and output it.

The laser beam irradiation apparatus20according to this embodiment does not include the variable attenuator.

Unlike the laser beam irradiation apparatus10according to the first embodiment, it is unnecessary to control the output of the laser beam generated from the oscillator21, and hence the variable attenuator can be omitted.

The configurations (the homogenizer23, the scanner24, the fθ lens25, the stage26) other than those configurations may be the same as the configurations as in the laser beam irradiation apparatus10according to the first embodiment.

One example of edge deletion by the laser beam irradiation apparatus20configured as described above will be described.

When the multilayer body1is disposed on the stage26, the stage26moves to adjust the position of the multilayer body1so that any point on the peripheral rim portion1aof the multilayer body1can be irradiated with a laser beam. The oscillator21outputs an infrared laser beam having a wavelength of532nm and a predetermined output. The output laser beam is collected by the condenser lens27to the homogenizer23. The laser beam is converted by the homogenizer23to have a 0.6 mm square-shaped laser cross-section and made to even.

The green laser beam is scanned by the scanner24, corrected through the fθ lens25, and radiated to the above-mentioned point of the multilayer body1as the first laser beam L1. By the position controller controlling the movement of the stage26, the first region A1being the region irradiated with the first laser beam L1is formed within the peripheral rim portion1a.

Next, by moving the stage26, the position of the multilayer body1is adjusted so that any point on the first region A1is irradiated with the laser beam. The oscillator21outputs an infrared laser beam having a wavelength of 1,064 nm and a predetermined output. The laser beam is converted by the homogenizer23to have a 0.6 mm square-shaped laser cross-section and made to even.

The infrared laser is scanned by the scanner24, corrected through the fθ lens25, and radiated to the above-mentioned point of the multilayer body as the second laser beam L2. When the position controller controls the movement of the stage26, the second region A2being the region irradiated with the second laser beam is formed within the first region A1.

For example, when performing edge deletion on one side of the multilayer body1, as shown inFIG. 7, the position controller uses the scanner24to scan the first laser beam L1on an end portion of the first region A1on a center side of the multilayer body1by a predetermined distance from a scan start position in the X-axis direction. At the same time, the position controller moves it by a predetermined distance in the X-axis direction. After that, the scanner24moves an irradiation position of the first laser beam L1by a distance equal to the width of the laser beam in an opposite direction to the center side of the substrate in the Y-axis direction. After that, the scanner24moves back to the scan start position in the X-axis direction and scans by a predetermined distance in the X-axis direction again. As described above, while using the scanner24and the position controller, the stage26is moved such that the irradiation position of the first laser beam L1goes around the power generation portion1b. Further, the stage26is moved while using a scan by the scanner24and the position controller such that similar to the first laser beam L1, the second laser beam L2goes around the outer peripheral side. In this manner, the multilayer body1is subjected to edge deletion.

As described above, the edge deletion step St2according to the second embodiment is implemented.

After that, the solar cell module is manufactured as in the method of manufacturing a solar cell module according to the first embodiment.

With the method of manufacturing a solar cell module according to this embodiment, in the edge deletion step St2, the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5in the peripheral rim portion1aare removed, and hence the frame and these layers can be surely insulated. Further, the peripheral rims of the transparent substrate2, the insulating layer7, and the protective layer8are spaced from the transparent electrode layer3, the photoelectric conversion layer4, and the back electrode layer5, and hence it is possible to prevent moisture and the like from infiltrating through the peripheral rims of the transparent substrate2, the insulating layer7, and the protective layer8, resulting in low power generation performance.

Third Embodiment

A third embodiment of the present invention will be described.

Description of the same content as that of the first embodiment will be omitted.

The method of manufacturing a solar cell module according to this embodiment includes a multilayer body producing step (St1), an edge deletion step (St2), and a modularization step (St3). The multilayer body producing step (St1) and the modularization step (St3) are the same as in the method of manufacturing a solar cell module according to the first embodiment, and hence the description thereof will be omitted.

In the first embodiment and the second embodiment, after the irradiation of the multilayer body1with the first laser beam L1by an amount of one substrate to be an irradiation target is completed, the irradiation of the second laser beam L2is performed. Meanwhile, in the third embodiment, when the irradiation of the multilayer body1with the first laser beam L1by an amount of one substrate to be an irradiation target is not completed, the irradiation of the second laser beam L2is started. In this point, the edge deletion step of the third embodiment is different from the edge deletion step of the second embodiment.

As the first laser beam L1, an infrared laser beam having a wavelength of 1,064 nm with an Nd:YAG crystal as a laser crystal may be used. The wavelength of the first laser beam L1may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the materials for the transparent electrode layer3and the photoelectric conversion layer4. The energy density of the first laser beam L1is appropriately selected within such a range that the photoelectric conversion layer4and the back electrode layer5can be removed without removing the transparent electrode layer3, although the transmittance of the transparent electrode layer3and the absorptance of the photoelectric conversion layer4are varied depending on the wavelength of the laser beam. For example, in the case of an infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to range from 0.5 to 1.5 J/cm2.

As the second laser beam L2, an infrared laser beam having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the second laser beam L2may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the material for the transparent electrode layer3. The energy density of the second laser beam L2is appropriately selected within such a range that the transparent electrode layer3can be removed, although the absorptance of the transparent electrode layer3is varied depending on the wavelength of the laser beam. For example, in the case of an infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to 5 J/cm2or more.

A laser beam irradiation apparatus30to be used in the edge deletion step (St2) will be described.

FIG. 10is a view showing a schematic configuration of the laser beam irradiation apparatus30.

As shown in the drawing, the laser beam irradiation apparatus30includes an oscillator31, a variable attenuator32, a λ/2 wave plate38, a polarizing beam splitter39, condenser lenses37aand37b, homogenizers33aand33b, scanners34aand34b, fθ lenses35aand35b, and a stage36. In the laser beam irradiation apparatus30, the oscillator31, the condenser lenses37aand37b, the homogenizers33aand33b, the scanners34aand34b, and the fθ lenses35aand35bcorrespond to the laser beam oscillator. The variable attenuator32, the λ/2 wave plate38, and the polarizing beam splitter39correspond to the output controller. The configuration of the laser beam irradiation apparatus30is not limited to the configuration as described in the following.

The oscillator31outputs an infrared laser beam which becomes a first laser beam L1and a second laser beam L2, the infrared laser beam being a linear polarized beam. The oscillator31installs a laser crystal such as an Nd:YAG laser rod (not shown), a laser diode for photo-excitation, or the like. The oscillator31may include a mechanical or electrochemical Q-switch mechanism for pulsed oscillation. The oscillator31may output a laser beam being a linear polarized beam. Further, the oscillator41having an output of 500 W may be used.

The variable attenuator32attenuates the infrared laser beam output from the oscillator31, to thereby control the output. The λ/2 wave plate38rotates the direction of polarization of the laser beam. The rotation of the λ/2 wave plate38can reverse the output rate of the laser beam to be sorted by the polarizing beam splitter39as will be described later. The polarizing beam splitter39allows one part of the laser beam which has passed through the λ/2 wave plate38to passes therethrough and reflects the other part. For example, the polarizing beam splitter39can allow 70% of the incident laser beam to pass therethrough and reflect 30% of the incident laser beam.

The laser beam which the polarizing beam splitter39has allowed to pass therethrough passes through a first laser beam path consisting of the condenser lens37a, the homogenizer33a, the scanner34a, and the fθ lens35aand is radiated to the multilayer body1. Further, the laser beam which the polarizing beam splitter39has reflected passes through a second laser beam path consisting of the condenser lens37b, the homogenizer33b, the scanner34b, and the fθ lens35band is radiated to the multilayer body1. For example, in the case where the polarizing beam splitter39allows 30% of the incident laser beam to pass therethrough (reflects 70%), the laser beam which passes through the first laser beam path becomes a low-intensity laser beam and the laser beam which passes through the second laser beam path becomes a high-intensity laser beam. In this case, when the above-mentioned λ/2 wave plate38is rotated, the polarizing beam splitter is set to allow 70% of the incident laser beam (reflects 30%) to pass therethrough. As a result, the laser beam which passes through the first laser beam path becomes a high-intensity laser beam and the laser beam which passes through the second laser beam path becomes a low-intensity laser beam.

The condenser lens37acollects the laser beam, which the polarizing beam splitter39has allowed to pass therethrough, to the homogenizer33aand the condenser lens37bcollects the laser beams, which the polarizing beam splitter39has reflected, to the homogenizer33b. The homogenizers33aand33bconvert the incident laser beams into a square-shaped laser spot having an even light intensity distribution. The scanners34aand34bscans the laser beams by changing the direction of the reflected laser beams. The fθ lenses35aand35bcorrect the scanning speed and the laser spot shape of the laser beams scanned by the scanners34aand34b.

The stage36defines irradiation positions of the laser beams with respect to the multilayer body1. The stage36is configured to be movable in an X-direction being one direction parallel to a surface (laser beam-irradiated surface) of the multilayer body1and a Y-direction orthogonal to the X-direction. The stage36freely allows the laser beams to be radiated onto an X-Y plane. The laser beam irradiation apparatus30includes a position controller (not shown) that controls the movement of the stage36.

It should be noted that the laser beam irradiation apparatus30may include two oscillators31that generate the laser beams which respectively pass through the first laser beam path and the second laser path and two variable attenuators32that attenuate these laser beams. In the case where the laser beam irradiation apparatus30outputs a non-polarized laser beam, the polarizing beam splitter39is unnecessary.

One example of edge deletion performed by the non-polarized laser beam irradiation apparatus30configured as described above will be described.

When the multilayer body1is disposed on the stage36, the stage36moves to adjust the position of the multilayer body1so that any point on the peripheral rim portion1aof the multilayer body1can be irradiated with a laser beam which has passed through the first laser beam path and that one point on the peripheral rim portion1aafter irradiated with the low-intensity laser beam is irradiated with a laser beam which has passed through the second laser beam path. The oscillator31outputs an infrared laser beam having a wavelength of 1,064 nm and a predetermined output (e.g., 500 W) and the variable attenuator32controls the output. The infrared laser beam goes through the λ/2 wave plate38and passes through the polarizing beam splitter39or is reflected with the result that the infrared laser beam is separated into the first laser beam path and the second laser beam path. It should be noted that the λ/2 wave plate38is set to have a transmittance of 30% (reflectance 70%) and thus the laser beam which passes through the first laser beam path becomes a low-intensity laser and the laser beam which passes through the second laser beam path becomes a high-intensity laser beam. The low-intensity laser beam passes through the condenser lens37aand the homogenizer33aso as to be converted to have a 0.6 mm square-shaped laser cross-section and made to even. The high-intensity laser beam passes through the condenser lens37band the homogenizer33bso as to be similarly converted and made to even.

The low-intensity laser beam is scanned by the scanner34aand corrected through the fθ lens35a. The high-intensity laser beam is scanned by the scanner34band corrected through the fθ lens35b. The low-intensity laser beam is radiated to one point on the peripheral rim portion1a. The high-intensity laser beam is radiated to one point on the peripheral rim portion1aafter irradiated with the low-intensity laser beam. The stage36moves and thus the laser beam is radiated to a predetermined range. Using the moving speed of the stage36, the repeat frequencies of the low-intensity laser beam and the high-intensity laser beam are defined. Here, the low-intensity laser beam is adjusted to be a laser beam (first laser beam L1) having such an energy density that without removing the transparent electrode layer3, the photoelectric conversion layer4and the back electrode layer5can be removed. The high-intensity laser beam is adjusted to be a laser beam (second laser beam L2) having such an energy density that the transparent electrode layer3can be removed. When the stage36is moved, following the first laser beam L1, the second laser beam L2is radiated. In this case, the region to be irradiated with the second laser beam L2is adjusted to be located within the region irradiated with the first laser beam. By the position controller controlling the movement of the stage36, the first region A1being the region irradiated with the first laser beam L1is formed within the peripheral rim portion1aand the second region A2being the region irradiated with the second laser beam L2is formed within the first region A1.

For example, when performing edge deletion on one side of the multilayer body1, as shown inFIG. 7, the position controller uses the scanner34ato scan the first laser beam L1and the scanner34bto scan the second laser beam L2on an end portion of the first region A1on a center side of the multilayer body1by a predetermined distance α from a scan start position S in an X-axis direction. When one scan is completed, the position controller moves the scan start position by a predetermined distance β in the X-axis direction. After that, the scanners34aand34bmove irradiation positions of the first laser beam L1and the second laser beam L2by a distance equal to the width of the laser beam in an opposite direction to the center side of the substrate in a Y-axis direction. Thus, in the subsequent scan, the scanners34aand34bscan, in the X-axis direction again by a predetermined distance α from a position deviated by a predetermined distance β from the scan start position S in the X-axis direction and deviated by a distance equal to the width in the Y-axis direction of the laser beam from the scan start position S in the Y-axis direction. By repeating the process, when in the Y-axis direction, irradiations in a predetermined range are completed, the position controller moves the scan start positions of the laser beam L1and the laser beam L2by a predetermined distance a and a distance equal to the width in the X-axis direction of the laser beam from the above-mentioned scan start position S in the X-axis direction. As described above, while using the scanners34aand34band the position controller, the stage36is moved such that the irradiation positions of the first laser beam L1and the second laser beam L2go around the power generation portion1b. At this time, every time edge deletion of one side of the multilayer body1is completed, the stage36is moved or rotated. Here, the λ/2 wave plate38performs switching so that the second laser beam L2is radiated from the scanner34aor the first laser beam L1is radiated from the scanner34b. Thus, while moving the stage36in an opposite direction to the moving direction of the stage36before switching, the first laser beam L1and the second laser beam L2can be radiated to the multilayer body1. Accordingly, as will be described in the following, the time required for moving or rotating the multilayer body1can be reduced and thus, the time required for edge deletion can be reduced.

A specific example of a method of moving the multilayer body1by the stage36will be described.

FIG. 11is views showing moving paths for the multilayer body1in the case where laser beam paths through which a high-intensity laser beam and a low-intensity laser beam are output cannot be switched. It is assumed that the entire periphery (first to fourth sides) of the multilayer body1is subjected to edge deletion and that the position in which a laser beam is radiated is not changed. The X1denotes an irradiation position of the first laser beam path and the X2denotes an irradiation position of the second laser beam path. Here, in the irradiation position X1, the first laser beam L1is radiated and in the irradiation position X2, the second laser beam L2is radiated.

As shown inFIG. 11(a), the multilayer body1is originally located in the position (1). With the multilayer body1being irradiated with a laser beam (with a first laser beam L1in the irradiation position X1and with the second laser beam L2in the irradiation position X2), the multilayer body1is moved by the stage36to the position (2). Thus, the first side of the multilayer body1is subjected to edge deletion. Next, when in the position (2), the stage36rotates 90 degrees to the right with the center of the multilayer body1being as a center of rotation, the multilayer body1takes the position (3). Due to the movement of the stage36, the multilayer body1is moved from the position (3) to the position (4).

Subsequently, as shown inFIG. 11(b), with the multilayer body1being irradiated with a laser beam, the stage36moves to the position (5). Thus, the second side of the multilayer body1is subjected to edge deletion. Next, the multilayer body1is rotated by the stage36and takes the position (6). Next, the multilayer body1is moved by the stage36to the position (7). With the multilayer body1being irradiated with a laser beam, the multilayer body1is moved to the position (8). Thus, the third side of the multilayer body1is subjected to edge deletion.

Subsequently, as shown inFIG. 11(c), the multilayer body1is rotated by the stage36and takes the position (9). The multilayer body1is moved by the stage36to the position (10). With the multilayer body1being irradiated with a laser beam, the multilayer body1is moved to the position (11). Thus, the fourth side of the multilayer body1is subjected to edge deletion. Here, during the rotation from the position (2) to the position (3), the movement from the position (3) to the position (4), the rotation from the position (5) to the position (6), the movement from the position (6) to the position (7), the rotation from the position (8) to the position (9), and the movement from the position (9) to the position (10), edge deletion is not performed.

On the other hand,FIG. 12is views showing moving paths for the multilayer body1in the case where laser beam paths through which a high-intensity laser beam and a low-intensity laser beam are output can be switched. It is assumed that the entire periphery (first to fourth sides) of the multilayer body1is subjected to edge deletion and that the position in which a laser beam is irradiated is not changed. The X1denotes the irradiation position of the first laser beam L1and the X2denotes the irradiation position of the second laser beam L2. Here, in the irradiation position X1, the first laser beam L1is radiated and in the irradiation position X2, the second laser beam L2is radiated. Further, when the low-intensity laser beam and the high-intensity laser beam are switched, in the irradiation position X1, the second laser beam L2is radiated and in the irradiation position X2, the first laser beam L2is radiated.

As shown inFIG. 12(a), the multilayer body i is originally located in the position (1). With the multilayer body1being irradiated with a laser beam (with a first laser beam L1in the irradiation position X1and with the second laser beam L2in the irradiation position X2), the multilayer body1is moved by the stage36to the position (2). The first side of the multilayer body1is subjected to edge deletion. Next, the multilayer body1is moved by the stage36to the position (3) and the low-intensity laser beam and the high-intensity laser beam are switched. With the multilayer body1being irradiated with a laser beam (with a first laser beam in the irradiation position X2and with a second laser beam in the irradiation position X1), the multilayer body1is moved by the stage36from the position (3) to the position (4). Thus, the second side of the multilayer body1is subjected to edge deletion.

Subsequently, as shown inFIG. 12(b), the multilayer body1is rotated by the stage36, takes the position (5), and is moved to the position (6). Here, the low-intensity laser beam and the high-intensity laser beam are switched again. With the multilayer body1being irradiated with a laser beam (with a first laser beam L1in the irradiation position X1and with a second laser beam L2in the irradiation position X2), the multilayer body1is moved by the stage36from the position (6) to the position (7). Thus, the third side of the multilayer body1is subjected to edge deletion.

Subsequently, as shown inFIG. 12(c), the multilayer body1is moved by the stage36to the position (8). Here, the low-intensity laser and the high-intensity laser are switched. With the multilayer body1being irradiated with a laser beam (with a first laser beam in the irradiation position X2and with a second laser beam in the irradiation position X1), the multilayer body1is moved by the stage36from the position (8) to the position (9). Thus, during the fourth side of the multilayer body1is subjected to edge deletion. Here, during the movement from the position (2) to the position (3), the rotation from the position (4) to the position (5), the movement from the position (5) to the position (6), and the movement from the position (7) to the position (8), edge deletion is not performed.

As described above, in the case where the laser beam paths through which the high-intensity laser beam and the low-intensity laser beam are output cannot be switched, three movements and three rotations by the stage36are needed for edge deletion of the four sides of the multilayer body1. In contrast, in the case where the laser beam paths through which the high-intensity laser beam and the low-intensity laser beam are output can be switched, by only three movements and one rotation by the stage36, the four sides of the multilayer body1can be subjected to edge deletion. Thus, the takt time can be reduced.

In this manner, the multilayer body1is subjected to edge deletion.

With the method of manufacturing a solar cell module according to this embodiment, in the edge deletion step (St2), the multilayer body1can be irradiated with the first laser beam L1and the second laser beam L2at the same time. Therefore, in comparison with the case where the first laser beam L1and the second laser beam L2are individually radiated, the time required for the edge deletion step can be reduced.

Fourth Embodiment

A fourth embodiment of the present invention will be described.

Description of the same content as that of the first embodiment will be omitted.

The method of manufacturing a solar cell module according to this embodiment includes a multilayer body producing step (St1), an edge deletion step (St2), and a modularization step (St3). The multilayer body producing step (St1), the edge deletion step (St2), and the modularization step (St3) are the same as in the method of manufacturing a solar cell module according to the first embodiment, and hence the description thereof will be omitted.

As in the third embodiment, in the edge deletion step of the fourth embodiment, the first laser beam L1and the second laser beam L2are radiated at the same time.

As the first laser beam L1, an infrared laser beam having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the first laser beam L1may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the materials for the transparent electrode layer3and the photoelectric conversion layer4. The energy density of the first laser beam L1is appropriately selected within such a range that the photoelectric conversion layer4and the back electrode layer5can be removed without removing the transparent electrode layer3, although the transmittance of the transparent electrode layer3and the absorptance of the photoelectric conversion layer4are varied depending on the wavelength of the laser beam. For example, in the case of an infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to range from 0.5 to 1.5 J/cm2.

As the second laser beam L2, an infrared laser beam having a wavelength of 1,064 nm using an Nd:YAG crystal as a laser crystal may be used. The wavelength of the second laser beam L2may be selected from an infrared wavelength region (700 nm to 2,500 nm) exhibiting a low optical absorptance with respect to the transparent electrode layer3and a high optical absorptance with respect to the photoelectric conversion layer4, depending on the material for the transparent electrode layer3. The energy density of the second laser beam L2is appropriately selected within such a range that the transparent electrode layer3can be removed, although the absorptance of the transparent electrode layer3is varied depending on the wavelength of the laser beam. For example, in the case of an infrared laser beam having a wavelength of 1,064 nm, its energy density can be set to 5 J/cm2or more.

A laser beam irradiation apparatus40to be used in the edge deletion step (St2) will be described.

FIG. 13is a view showing a schematic configuration of the laser beam irradiation apparatus40.

As shown in the drawing, the laser beam irradiation apparatus40includes an oscillator41, a non-polarizing beam splitter49, variable attenuators42aand42b, condenser lenses47aand47b, homogenizers43aand43b, scanners44aand44b, fθ lenses45aand45b, and a stage46. In the laser beam irradiation apparatus40, the oscillator41, the non-polarizing beam splitter49, the condenser lenses47aand47b, the homogenizers43aand43b, the scanners44aand44b, and the fθ lenses45aand45bcorrespond to the laser beam oscillator. The variable attenuators42aand42bcorrespond to the output controller. The configuration of the laser beam irradiation apparatus40is not limited to the configuration as described in the following.

The oscillator41outputs an infrared laser beam which becomes a first laser beam L1and a second laser beam L2. The oscillator41installs a laser crystal such as an Nd:YAG laser rod (not shown), a laser diode for photo-excitation, or the like. The oscillator31may include a mechanical or electrochemical Q-switch mechanism for pulsed oscillation. The oscillator41may output a laser beam being a non-polarized beam. Further, the oscillator41having an output of 800 W may be used.

The non-polarizing beam splitter49allows one part of the laser beam output from the oscillator41to pass therethrough and reflects the other part. For example, the non-polarizing beam splitter may be set to allow 50% of the incident laser beam to pass therethrough and reflect 50% of the incident laser beam. The laser beam which the non-polarizing beam splitter49has allowed to pass therethrough passes through a first laser beam path consisting of the variable attenuator42a, the condenser lens47a, the homogenizer43a, the scanner44a, and the fθ lens45aand is radiated to the multilayer body1. Further, the laser beam which the non-polarizing beam splitter49has reflected passes through a second laser beam path consisting of the condenser lens47b, the homogenizer43b, the scanner44b, and the fθ lens45band is radiated to the multilayer body1.

The variable attenuator42ais provided on the first laser beam path to attenuate an incident infrared laser beam, to thereby control the output. The variable attenuator42bis provided on the second laser beam path to attenuate an incident infrared laser beam, to thereby control the output. By setting the attenuation rate of the variable attenuator42ato be larger than the attenuation rate of the variable attenuator42b, the laser beam which passes through the first laser beam path becomes a low-intensity laser beam and the laser beam which passes through the second laser beam path becomes a high-intensity laser beam.

The condenser lens47acollects the incident laser beam to the homogenizer43aand the condenser lens47bcollects the incident laser beam to the homogenizer43b. The homogenizers43aand43bconvert the incident laser beams into a square-shaped laser spot having an even light intensity distribution. The scanners44aand44bscan the incident laser beams by changing the direction of the reflected laser beams. The fθ lenses45aand45bcorrect the scanning speed and the laser spot shape of the laser beams scanned by the scanners44aand44b.

The stage46defines the irradiation positions of the laser beams with respect to the multilayer body1. The stage46is configured to be movable in an X-direction being one direction parallel to a surface (laser beam-irradiated surface) of the multilayer body1and a Y-direction orthogonal to the X-direction. The stage46freely allows the laser beams to be radiated onto an X-Y plane. The laser beam irradiation apparatus40includes a position controller (not shown) that controls the movement of the stage46.

One example of edge deletion performed by the laser beam irradiation apparatus40configured as described above will be described.

When the multilayer body1is disposed on the stage46and the stage46moves to adjust the position of the multilayer body1so that any point on the peripheral rim portion1aof the multilayer body1can be irradiated with a laser beam which has passed through the first laser beam path and that one point on the peripheral rim portion1aafter irradiated with the low-intensity laser beam is irradiated with a laser beam which has passed through the second laser beam path. The oscillator41outputs an infrared laser beam having a wavelength of 1,064 nm and a predetermined output (e.g., 800 W). The infrared laser beam passes through the non-polarizing beam splitter49(transmittance of 50%) or reflected (reflectance of 50%), with the result that the infrared laser beam is separated into the first laser beam path and the second laser beam path. The laser beam separated into the first laser beam path is attenuated by the variable attenuator42ato have a predetermined output density (e.g., 30%) and becomes a low-intensity laser beam. Further, the laser beam separated into the second laser beam path is attenuated by the variable attenuator42bby an attenuation rate smaller than that of the variable attenuator42ato have a predetermined output density (e.g., 70%) and becomes a high-intensity laser beam. The low-intensity laser beam passes through the condenser lens47aand the homogenizer43aso as to be converted to have a 0.6 mm square-shaped laser cross-section and made to even. The high-intensity laser beam passes through the condenser lens47band the homogenizer43bso as to be similarly converted and made to even.

The low-intensity laser beam is scanned by the scanner44aand corrected through the fθ lens45a. The high-intensity laser beam is scanned by the scanner44band corrected through the fθ lens45b. The low-intensity laser beam is radiated to one point on the peripheral rim portion1a. The high-intensity laser beam is radiated to one point on the peripheral rim portion1aafter irradiated with the low-intensity laser beam. The stage46moves and thus the laser beam is radiated to a predetermined range. Using the moving speed of the stage46, the repeat frequencies of the low-intensity laser beam and the high-intensity laser beam are defined. Here, the low-intensity laser beam is adjusted to be a laser beam (first laser beam L1) having such an energy density that without removing the transparent electrode layer3, the photoelectric conversion layer4and the back electrode layer5can be removed. The high-intensity laser beam is adjusted to be a laser beam (second laser beam L2) having such an energy density that the transparent electrode layer3can be removed. When the stage46is moved, following the first laser beam L1, the second laser beam L2is irradiated. In this case, the region to be irradiated with the second laser beam L2is adjusted to be located within the region irradiated with the first laser beam. By the position controller controlling the movement of the stage46, the first region A1being the region irradiated with the first laser beam L1is formed within the peripheral rim portion1aand the second region A2being the region irradiated with the second laser beam L2is formed within the first region A1.

For example, when performing edge deletion on one side of the multilayer body1, as shown inFIG. 7, the position controller uses the scanner44ato scan the first laser beam L1and the scanner44bto scan the second laser beam L2on an end portion of the first region A1on a center side of the multilayer body1by a predetermined distance α from a scan start position S in an X-axis direction. When one scan is completed, the position controller moves the scan start position by a predetermined distance β in the X-axis direction. After that, the scanners44aand44bmove the irradiation positions of the first laser beam L1and the second laser beam L2by a distance equal to the width of the laser beam in an opposite direction to the center side of the substrate in a Y-axis direction. Thus, in the subsequent scan, the scanners44aand44bscan, in the X-axis direction again by a predetermined distance α from a position deviated by a predetermined distance β from the scan start position S in the X-axis direction and deviated by a distance equal to the width in the Y-axis direction of the laser beam from the scan start position S in the Y-axis direction. As described above, while using the scanners44aand44band the position controller, the stage36is moved such that the irradiation positions of the first laser beam L1and the second laser beam L2go around the power generation portion1b. In this manner, the multilayer body1is subjected to edge deletion.

With the method of manufacturing a solar cell module according to this embodiment, in the edge deletion step (St2), the multilayer body1can be irradiated with the first laser beam L1and the second laser beam L2at the same time. Therefore, in comparison with the case where the first laser beam L1and the second laser beam L2are individually radiated, the time required for the edge deletion step can be reduced.

The present invention is not limited only to the above-mentioned embodiments and can be modified without departing from the gist of the present invention.

Although in each of the above-mentioned embodiments, the single laser beam irradiation apparatus is used, a plurality of laser beam irradiation apparatuses may be used at the same time in order to perform edge deletion. For example, if one laser beam irradiation apparatus is used for one side of a multilayer body in order to perform edge deletion, then in comparison with the case where four sides of the multilayer body1are subjected to edge deletion one by one, the edge deletion step can be completed for a shorter time.

Further, although in each of the above-mentioned embodiments, the positional relation between the irradiation position X1of the first laser beam path and the irradiation position X2of the second laser beam path is fixed, this relation may be variable. For example, if the irradiation position X2of the second laser beam path is configured to be rotatable by 90 degrees with the irradiation position X1of the first laser beam path being as the center, then the rotation of the multilayer body can be omitted.