Abstract:
The present invention provides a method of manufacturing a thin-film solar panel with a laser scribing process to perform linear groove processing by irradiating a thin-film layer formed on a substrate with laser light to be separated from adjacent structure, including steps of: specifying an accurate position, size, shape of a adhered foreign matter on a glass substrate, a glass scratch, an air-bubble in the glass substrate causing an imperfection by inspecting a scribe line; and performing repair processing to form a new scribe line to bypass a portion of the imperfection after a final scribe line is formed.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a laser scribing technology in a manufacturing process of a thin-film solar panel. 
         [0003]    2. Description of the Related Art 
         [0004]    Recently, solar panels are being extensively developed.  FIG. 10  illustrates a processed example with a scribing apparatus of a single-type amorphous silicon thin-film solar panel which is generally known and mass-produced by a number of manufacturers of solar panels.  FIG. 11  is an enlarged fragmentary sectional view taken along the line A-A in  FIG. 10 . After a transparent electrode layer  3  is formed on a glass substrate  1 , scribe lines  6  are scribed to form line-shaped grooves by a laser and the like in order to separate from an adjacent cell. Then, after an amorphous silicon layer  4  is formed thereon, scribe lines  7  are similarly scribed for separation. Further, after a back-side electrode layer  5  is formed thereon, scribe lines  8  are similarly scribed for separation. Normally, the distance between adjacent scribe line groups  2  is 6 to 12 mm, the distance between adjacent scribe lines is 100 to 150 μm, and the width of each scribe line is approximately 40 to 70 μm. 
         [0005]    First, an example of a laser beam machine (i.e., a laser scribing apparatus) to perform such scribing is illustrated in  FIGS. 12 to 14 .  FIG. 12  is a plan view of the laser scribing apparatus and  FIG. 13  is a front view thereof.  FIG. 14  is an operational flowchart. In the case of this scribing apparatus, a dust collector  109  is arranged right above a position of the glass substrate  1  to be irradiated with laser light through a condenser lens  108  so as to be configured to be capable of removing powder dust and the like generated by laser scribing. 
         [0006]    As the first process of the scribing of a thin-film solar panel with the laser scribing apparatus, the glass substrate  1  on which the transparent electrode layer  3  is formed as illustrated in  FIG. 11  is supplied on a conveying surface  102  of a laser scribing apparatus main body  100 . Here, in the present embodiment, a face of the glass substrate  1  not having the transparent electrode layer  3  formed is directed to the conveying surface  102  and the transparent electrode layer  3  is directed upward. Forming of the transparent electrode layer  3  can be performed with a known method such as a sputtering method, a CVD method or a vapor deposition method. As a method of supplying on the conveying surface  102 , the glass substrate  1  is supplied from a conveying loader portion in the case that the present apparatus is connected to an upstream apparatus via the conveying loader portion in a factory production line. In the case of not being connected via the conveying loader, the supplying may be performed by a conveying robot or the like. The glass substrate  1  supplied on the glass substrate conveying surface  102  is chucked by a glass substrate hold portion  104  which is attached to a conveyance drive portion  103 . The glass substrate  1  reciprocates on the conveying surface  102  along with reciprocating of the conveyance drive portion  103  on a conveyance drive portion guide  105 . The conveying surface  102  is constituted so as not to damage the glass substrate  1 , such as an air floating table or a table with resin-made free rollers. 
         [0007]    The glass substrate  1  is irradiated with laser light  110  deflected by reflection mirrors (i.e., a pair of galvanometer mirrors)  107  and through a condenser lens (i.e., an fθ lens)  108 , in a synchronized manner with the reciprocating motion of the glass substrate  1  on the conveying surface  102  so as to form scribe lines  111 . Dust is generated due to evaporation of the transparent electrode layer  3  at a position irradiated with the laser light  110  by the processing with the laser light  110 . The dust is collected by the dust collector  109 . Here, the reflection mirror  107  and the condenser lens  108  are arranged on a movable table  106 . Then, a predetermined number of lines are formed by sequential movement from a position for a scribe line formed to a position for the next scribe line to be formed, synchronized with the leftward and rightward motions of the glass substrate  1 . 
         [0008]    The above operation will be described with reference to a flowchart of  FIG. 14 . The glass substrate  1  is conveyed and supplied on the conveying surface  102 . The glass substrate  1  supplied on the conveying surface  102  is chucked by the glass substrate hold portion  104  so as to be in a state of being capable of reciprocating on the conveying surface  102 . When the processing is started with an operator&#39;s instruction or the like, the movable table  106  having the reflection mirrors  107  and the condenser lens  108  (hereinafter, referred to collectively as “a processing head”) is moved to the position for processing the first scribe line and N is set to be one as the first line (step  301 ). Then, the glass substrate  1  is conveyed for leftward processing (step  302 ) and the leftward processing (for the first line) is performed as the glass substrate  1  passes above the laser light irradiation position at predetermined set speed (step  303 ). After the first scribe line is formed with the leftward processing, the glass substrate  1  stops moving on the conveying surface  102  and the movable table  106  is moved to the position for processing the next scribe line (step  304 ). Here, after checking whether or not being the final scribe line (step  305 ), the glass substrate  1  is conveyed back for return processing (step  306 ). Then, the return processing (for the second line as being N+1) is performed as the glass substrate  1  passes above the laser light irradiation position at the predetermined set speed (step  307 ) and the glass substrate  1  stops (step  308 ). Subsequently, processes of the leftward processing (for lines of N=3, 5, 7, . . . ) and the return processing (for lines of N+1=4, 6, 8, . . . ) are repeated until forming the final scribe line (steps  302  to  310 ). The operation ends when processing of the predetermined number of lines set by a program is completed. The above operation is described in the case of one processing head. In the case of a plural processing heads, the processing heads perform processing simultaneously in their respective assigned areas. The operation ends when processing of a predetermined number of lines for each processing head is completed. 
         [0009]    After the scribe lines  6  of the transparent electrode layer  3  as illustrated in  FIG. 11  are formed in the first process, the glass substrate  1  having the amorphous silicon layer  4  formed on the transparent electrode layer  3  is supplied on the conveying surface  102  of the laser scribing apparatus main body  100  as the second process. Here, in the present embodiment, a face of the glass substrate  1  not having the transparent electrode layer  3  and the amorphous silicon layer  4  formed is directed to the conveying surface  102 . That is, the transparent electrode layer  3  and the amorphous silicon layer  4  are directed upward. The scribe lines  7  are formed in the amorphous silicon layer  4  at positions not overlapping with the scribe lines  6  formed in the first process. The processing method is similar to that in the first process. 
         [0010]    After the scribe lines  7  of the amorphous silicon layer  4  are formed in the second process, the glass substrate  1  having the back-side electrode layer  5  formed on the amorphous silicon layer  4  is supplied on the conveying surface  102  of the laser scribing apparatus main body  100  as the third process. Here, in the present embodiment, a face of the glass substrate  1  not having the transparent electrode layer  3 , the amorphous silicon layer  4  and the back-side electrode layer  5  formed is directed to the conveying surface  2 . That is, the transparent electrode layer  3 , the amorphous silicon layer  4  and the back-side electrode layer  5  are directed upward. The scribe lines  8  are formed in the amorphous silicon layer  4  and the back-side electrode layer  5  at positions not overlapping with the scribe lines  6 ,  7  formed in the first and second processes. The processing method is similar to that in the first process. 
         [0011]      FIG. 15  being an enlarged fragmentary view taken within the circle B of a scribe line group  2  in  FIG. 10  illustrates scribe lines  6  to  8  formed with the above method. Circles in  FIG. 15  indicate laser spots (φ50 μm) used for the processing. During the formation process, there may be created a processing imperfection (hereinafter, referred to simply as “an imperfection”) that a scribe line is discontinued at some intermediate point where there exists a glass scratch  9 , a foreign matter  10  adhered to the substrate which cannot be removed in a cleaning process performed in an upstream process on the film formed side or the back side of the glass substrate  1 , or an air-bubble  15  in the glass substrate as illustrated in  FIGS. 16 and 17 , or the like. A scribe line  6   b  indicates an example of an imperfection of discontinuation in the transparent electrode layer  3  at which the laser processing is hindered by the adhered foreign matter  10 . A scribe line  8   b  indicates an example of an imperfection of discontinuation in the amorphous silicon layer  4  and the back-side electrode layer  5  at which the laser processing is hindered by the glass scratch  9 . 
         [0012]    In the case that an imperfection exists in a scribe line  6  formed in the transparent electrode layer  3  as described above, adjacent photovoltaic portions  11 ,  12  are connected electrically as illustrated in  FIG. 18  resulting in that photovoltaic efficiency is decreased. Further, also in the case that an imperfection exists in the scribe line  8  formed in the amorphous silicon layer  4  and the back-side electrode layer  5 , adjacent photovoltaic portions  13 ,  14  are connected electrically as illustrated in  FIG. 19  resulting in that photovoltaic efficiency is decreased. Here, the scribe line  7  formed only in the amorphous silicon layer  4  is to function as a passage for electrons from the back-side electrode layer  5  to the transparent electrode layer  3 . Accordingly, even when discontinuation occurs at some intermediate point due to a glass scratch  9 , an adhered foreign matter  10 , an air-bubble 15  in the glass substrate, or the like, electrons bypass through a portion which is normally scribed. Therefore, the influence to the decrease of photovoltaic efficiency is extremely small as being negligible compared to that in the scribe lines  6 ,  8 . 
         [0013]    For such an imperfection (i.e., a defect), Japanese Patent Application Laid-Open No. 2004-214565 discloses in paragraphs 0033-0034 a method to detect an imperfection portion with a microscope after performing scribe line processing and to repair by removing the portion with emitting an impelled mixture of ice and water onto the imperfect portion. 
         [0014]    Further, Japanese Patent Application Laid-Open No. 2009-195968 discloses a method to detect an imperfect portion by detecting transmitted laser light and measuring electric characteristics and to repair by re-performing the laser processing after performing removal of foreign matters from the detected portion with a second laser light source or performing removal with an air knife or a brush, at paragraphs 0029, 0035 and 0047 for imperfection detecting and paragraph 0039 to 0040, 0055 and 0058 for imperfection removal and repair processing. 
         [0015]    Further, Japanese Patent Application Laid-Open No. 2010-021517 discloses an inspection and repair method for a thin-film solar cell unit (photovoltaic portion) which a short-circuit is detected between the adjacent thin-film solar cell unit based on the resistance value measurement using probes, by scribing one or more new (linear) laser scribe lines for the unit by moving the glass substrate at a predetermined distance repeatedly until the short-circuit is not detected, at paragraphs 0039 to 0062 as the second and third embodiments. 
         [0016]    Regarding a viewpoint of imperfection inspection of a glass substrate, there has been an inspection method to detect the position of an imperfection in the direction of thickness of the glass substrate based on an illumination gradient index value calculated by processing an image of the imperfection in the glass substrate captured by a camera, as disclosed in Japanese Patent Application Laid-Open No. 2004-361384 at paragraphs 0013 to 0040. 
         [0017]    With the method of Japanese Patent Application Laid-Open No. 2004-214565, imperfect portions are to be detected manually using the microscope after performing the scribe line processing. Here, since every separation groove (scribe line) has to be inspected, it takes much time to detect all imperfect portions. In addition, there has been a problem that the other normal portions are being damaged when removing the imperfect portions by emitting an impelled mixture of ice and water to the imperfect portions. 
         [0018]    Further, with the method of Japanese Patent Application Laid-Open No. 2009-195968, although detection of imperfect portions can be performed simultaneously with the laser scribing, the apparatus therefor becomes extensive since the laser scribing is performed again after removing foreign matters from the imperfect portions with the second laser light source, the air knife, or the brush. Further, since transmitted light is used for the imperfection detection, it is difficult to detect an imperfection in the transparent electrode layer or the amorphous silicon layer, Ibid. paragraph 0031. In addition, there has been a problem that repair cannot be performed, because it is impossible to remove an imperfection caused by a scratch  9 , an air-bubble  15 , or the like in the glass substrate  1  illustrated in  FIGS. 16 and 17 , which are not adhered thereto. 
         [0019]    Further, with the method of Japanese Patent Application Laid-Open No. 2010-021517, since one or more (linear) scribe lines for a solar cell unit are repeatedly scribed until short-circuit is not detected by moving the glass substrate at a predetermined distance a when short-circuit exists, the processing time is to be prolonged. 
         [0020]    With the method of Japanese Patent Application Laid-Open No. 2004-361384, the inspection takes time since the whole glass substrate must be scanned including in the direction of the thickness for specifying imperfect portions. 
       SUMMARY OF THE INVENTION 
       [0021]    The present invention provides a method capable of repairing every imperfection easily and reliably by specifying the accurate position, size, shape of a scratch in the glass substrate  1  or the like causing the imperfection. 
         [0022]    To address the above issues, according to the present invention, an additional laser scribing is performed to bypass an imperfection portion after specifying the accurate position, size, shape of a scratch, or the like causing the imperfection, by inspecting scribe lines using a resistance tester and inspection cameras. 
         [0023]    Further, by shifting a focal point from a film formed side to a glass face side as changing the distance between the inspection camera and the glass substrate, it becomes possible to detect even an air-bubble or the like within the glass substrate. 
         [0024]    It is known that the sensitivity for an imperfection of an inspection camera by detecting a reflection light under epi-illumination is better than that by detecting a transmitted light. In addition, by an additional scribing to bypass the imperfect portion due to a foreign matter adhered to the glass substrate, an air-bubble therein, or the like, a reliable repair can be performed for every imperfection. 
         [0025]    In amorphous silicon thin-film solar panels, the thickness of the glass substrate is generally in a range of 2 to 4 mm. Therefore, in inspecting scribe lines formed in films with an inspection camera, when discontinuation of a scribe line is caused by a scratch existing in a glass face side (the opposite side to a film formed side), the position, size and shape of the scratch or the like cannot be accurately viewed due to the focal depth of the camera (normally, being in the order of μm). 
         [0026]    According to the present invention, a repair processing of an additional scribing to bypass an imperfect portion can be reliably performed with the same apparatus by specifying the accurate position, size, shape of the glass scratch  9 , the adhered foreign matter  10 , the air-bubble  15 , or the like causing the imperfection, while the decrease of photovoltaic efficiency is suppressed to the minimum. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  is a plane view of a laser scribing apparatus according to apparatus example 1 of the present invention; 
           [0028]      FIG. 2  is a side view of the laser scribing apparatus according to apparatus example 1 of the present invention; 
           [0029]      FIG. 3  is an operational flowchart of laser scribing processing according to apparatus example 1 of the present invention; 
           [0030]      FIG. 4  is a plane view of a laser scribing apparatus according to apparatus example 2 of the present invention; 
           [0031]      FIG. 5  is a side view of the laser scribing apparatus according to apparatus example 2 of the present invention; 
           [0032]      FIG. 6  is an operational flowchart of laser scribing processing according to apparatus example 2 of the present invention; 
           [0033]      FIG. 7  is the first repair processing example with the laser scribing processing according to the present invention; 
           [0034]      FIG. 8  is the second repair processing example with the laser scribing processing according to the present invention; 
           [0035]      FIG. 9  is the third repair processing example with the laser scribing processing according to the present invention; 
           [0036]      FIG. 10  is an example of a thin-film solar panel to which laser scribing is performed; 
           [0037]      FIG. 11  is an enlarged fragmentary sectional view taken along the line A-A of  FIG. 10 ; 
           [0038]      FIG. 12  is a plane view of a laser scribing apparatus in the related art; 
           [0039]      FIG. 13  is a side view of a laser scribing apparatus in the related art; 
           [0040]      FIG. 14  is an operational flowchart of laser scribing processing in the related art; 
           [0041]      FIG. 15  is an enlarged fragmentary view taken within the circle B of  FIG. 10 ; 
           [0042]      FIG. 16  illustrates an example of imperfect portions; 
           [0043]      FIG. 17  is a sectional view illustrating positional relation between a glass substrate and an inspection camera; 
           [0044]      FIG. 18  is a sectional view of a case that a imperfection occurs in a transparent electrode layer  3 ; and 
           [0045]      FIG. 19  is a sectional view of a case that a imperfection occurs in a back-side electrode layer  5 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0046]    In the following, apparatuses and methods therewith for specifying imperfect positions preferable for the present invention will be described as apparatus example 1 and apparatus example 2, and then, repair methods will be described as processing example 1, processing example 2 and processing example 3. 
       APPARATUS EXAMPLE 1 
       [0047]      FIGS. 1 and 2  illustrate a laser scribing apparatus preferable for a laser describing method according to apparatus example 1 of the present invention.  FIG. 1  is a plan view and  FIG. 2  is a front view. The same numeral is given to the similar element of an apparatus in the related art of  FIGS. 12 and 13  and description thereof will not be repeated. 
         [0048]    A laser scribing apparatus of apparatus example 1 of the present invention is provided with inspection cameras  112 ,  113  disposed respectively right before and right after of the processing head. Two or more inspection cameras  112 ,  113  are fixed respectively on both sides of a camera table  114  movable in the direction (i.e, the direction of a vertical arrow in  FIG. 1 ) perpendicular to the substrate conveying direction (i.e., the direction of a leftward arrow in  FIG. 1 ) as being synchronized with the movable table  106  to which the condenser lens  108  is disposed. The substrate surface image can be captured right before and right after the scribing with the processing head by the inspection cameras  112 ,  113 . The inspection cameras  112 ,  113  are each provided with an epi-illumination device (not illustrated) of a coaxial type or an oblique type such as ring-shaped illumination. 
         [0049]    The operation of the laser scribing apparatus of apparatus example 1 of the present invention will be described with reference to a flowchart of  FIG. 3 . Steps  201  to  210  are approximately similar to those in the flowchart of the related art described in  FIG. 14 . The glass substrate  1  on which a transparent electrode layer  3 , or additionally an amorphous silicon layer  4  and a back-side electrode layer  5  (hereinafter, referred to collectively as “a film-formed layer”  21 ) is formed is conveyed and supplied on the conveying surface  102 . In this processing apparatus, a dust collector  109  is arranged right above a position of the glass substrate  1  irradiated with laser light through a condenser lens  108  so as to remove powder dust and the like generated by the laser processing. The glass substrate  1  supplied to the conveying surface  102  is chucked by the glass substrate hold portion  104  so as to be reciprocated on the conveying surface  102 . When the processing is started with an operator&#39;s instruction or the like, the movable table  106  having the processing head mounted and the camera table  114  are moved to a position for the first scribe line and N is set to be one as the first line (step  201 ). The glass substrate  1  is conveyed for leftward processing and the surface image thereof is captured by the inspection camera  112  (i.e., IN-side) right before entering the processing head portion, and then, the image data is recorded in an image processing and recording device  120  (step  202 ). The leftward processing (for the first line) is performed as the glass substrate  1  passes above the laser light irradiation position (i.e., the processing head) at a predetermined set speed, and then, the surface image thereof (i.e., the result of the processing) is captured by the inspection camera  113  (i.e., OUT-side) right thereafter. After being recorded in an image processing and recording device  121 , the image data thereof is compared to the image data at the same portion recorded in the image processing and recording device  120  at an arithmetic device  130 . When an imperfection exists, the imperfect portion thereof is recorded in an imperfect portion recording device  140  (step  203 ). After the first scribe line is formed with the leftward processing, the glass substrate  1  stops moving on the conveying surface  102  and the movable table  106  and the camera table  114  are moved to the position for the next scribe line (step  204 ). Here, after checking whether or not being the final scribe line (step  205 ), the glass substrate  1  is conveyed for return processing and the surface image thereof is captured by the inspection camera  113  (i.e., IN-side this time) right before entering the processing head portion, and then, the image data is recorded in the image processing and recording device  121  (step  206 ). The return processing (for the second line as being N+1) is performed as the glass substrate  1  passes above the laser light irradiation position at the predetermined set speed, and then, the surface image thereof (i.e., the result of the processing) is captured by the inspection camera  112  (i.e., OUT-side this time) right thereafter. After being recorded in the image processing and recording device  120 , the image data thereof is compared to the image data at the same portion recorded in the image processing and recording device  121  at the arithmetic device  130 . When an imperfection exists, the imperfect portion thereof is recorded in the imperfect portion recording device  140  (step  207 ) and the glass substrate  1  stops (step  208 ). Subsequently, processes of the leftward processing (for lines of N=3, 5, 7, . . . ) and the return processing (for lines of N+1=4, 6, 8, . . . ) are repeated until the final line is formed (steps  202  to  210 ). After processing of the predetermined number of lines set by a program is determined as being completed is step  205  or step  209 , the number of imperfections such as discontinuation or swell of the scribe lines and the imperfect positions thereof are displayed on an operational monitor (step  211 ). Based on automatic comparison with a threshold value of the number of imperfections previously set in an inspection program, instructions of categorization for ranking, no-processing, repair-processing or the like for the substrate having the final scribe line formed are displayed on the operational monitor (step  212 ). Then, it is determined whether or not the repair processing is performed (step  213 ). If required (i.e., in the case of “Yes”), a scribe line to bypass the position of the glass scratch  9 , the adhered foreign matter  10  or the like is formed (step  214 ) and the operation ends. 
         [0050]    Here, in step  203  or step  207 , an example to compare the image data of the inspection cameras of the IN-side to the image data of the OUT-side is described. However, if the image of the OUT-side is sufficiently clear, it is also possible to determine the imperfect portions only by the images of the OUT-side. 
       APPARATUS EXAMPLE 2 
       [0051]      FIGS. 4 and 5  illustrate a laser scribing apparatus preferable for a laser describing method according to apparatus example 2 of the present invention.  FIG. 4  is a plan view and  FIG. 5  is a front view. The same numeral is given to the similar element of an apparatus in the related art in  FIGS. 12 and 13  and description thereof will not be repeated. 
         [0052]    A laser scribing apparatus of apparatus example 2 of the present invention is provided with a resistance tester  115  between adjacent solar cell units facing the film formed side of the glass substrate  1  and the inspection camera by one side of the processing head facing the glass face side of the glass substrate. One or more inspection cameras  116  are fixed on the camera table  117  movable in the same direction as the movable table  106  (i.e., the direction perpendicular to the scribe lines  111 ). Resistance values between the adjacent scribe lines can be measured by the resistance tester  115  and the image of substrate surface after the final scribe line is formed can be captured by the inspection cameras  116 . The inspection cameras  116  are each provided with an epi-illumination device (not illustrated) of a coaxial type or an oblique type such as ring-shaped illumination. 
         [0053]    The operation of the laser scribing apparatus of apparatus example 2 of the present invention will be described with reference to a flowchart of  FIG. 6 . Steps  201  to  210  are approximately similar to those in the flowchart of the related art described in  FIG. 14 . The glass substrate  1  having a film-formed layer  21  is conveyed and supplied to the conveying surface  102 . In this processing apparatus, the dust collector  109  is arranged right above a position of the glass substrate  1  irradiated with laser light through a condenser lens  108  so as to be configured to be capable of removing powder dust and the like generated by the laser processing. The glass substrate  1  supplied on the conveying surface  102  is chucked by the glass substrate hold portion  104  so as to be in a state of being capable of reciprocating on the conveying surface  102 . When the processing is started with an operator&#39;s instruction or the like, the movable table  106  having the processing head mounted is moved to a position for the first scribe line and N is set to be one as the first line (step  201 ). The glass substrate  1  is conveyed for leftward processing (step  222 ) and the leftward processing (for the first line) is performed as the glass substrate  1  passes above the laser light irradiation position at a predetermined set speed (step  223 ). After the first scribe line is formed with the leftward processing, the glass substrate  1  stops moving on the conveying surface  102  and the movable table  106  is moved to the position for the next scribe line (step  204 ). Here, after checking whether or not being the final scribe line (step  205 ), the glass substrate  1  is conveyed for return processing (step  226 ). The return processing (for the second line as being N+1) is performed as the glass substrate  1  passes above the laser light irradiation position at the predetermined set speed (step  227 ) and the glass substrate  1  stops (step  208 ). Subsequently, processes of the leftward processing (for lines of N=3, 5, 7, . . . ) and the return processing (for lines of N+1=4, 6, 8, . . . ) are repeated until the final line is formed (steps  222  to  210 ). The operation ends when processing of the predetermined number of lines set by a program is completed. 
         [0054]    After the final scribe line is formed, the resistance values between adjacent scribe lines are measured with the resistance tester  115  disposed facing the film face side of the glass substrate  1 , so that presence or absence of short-circuit is detected (step  231 ). The measured data is recorded at a recording device  123 . After obtaining the result of the resistance value measurement, the operational monitor displays presence or absence of a short-circuited line (i.e., an imperfect line) and the number and positions of short-circuited lines in the case of presence (step  232 ). Based on automatic comparison with a threshold value of the number of imperfections previously set in an inspection program, instructions of categorization for ranking, no-processing, repair-processing or the like for the substrate having the final scribe line formed are displayed on the operational monitor (step  233 ). Then, it is determined whether or not a short-circuited line exists (step  234 ). The operation ends when a short-circuited line does not exist. 
         [0055]    When a short-circuited line exists (in the case of “Yes”), it is determined whether or not the repair processing is performed if necessary (step  235 ). In the case of performing, proceeding to a repair processing step  240  consists of the following three steps, the position information of the short-circuited line detected by the resistance tester  115  recorded in the recording device  123  is transmitted via the arithmetic device  130  to a drive portion of the movable table  117  to which the inspection cameras  116  are mounted. The inspection camera  116  is moved to the position of the short-circuited line based on the position information from the arithmetic device  130 . First, the inspection camera  116  is focused on the scribe line formed on the film formed side, that is, formed in the corresponding layer and the short-circuited line image is captured as conveying and moving the glass substrate  1 , so that the imperfect portion is found based on the image information recorded in the image processing and recording device  122  (step  236 ). Next, when images are captured at the found imperfect portion as the focal point of the inspection camera  116  is shifted from the film formed side to the glass face side, the focal point is to be matched to a cause creating the imperfection such as a glass scratch  9 , a adhered foreign matter  10 , an air-bubble  15 , or the like. In this manner, the cause is detected (step  237 ). Then, the position, size, shape and the like thereof are recorded in the image processing and recording device  122  and the detecting operation ends. At that time, the focal point, which is at the focal length  20  from the camera, is to be adjusted by automatically moving the inspection camera  116  in the vertical direction (upward and downward) against the glass substrate (as illustrated as A to D in  FIG. 17 ). Then, the imperfect portion is displayed on the operational monitor (step  238 ). The repair processing is performed with the same apparatus to form a new scribe line to bypass the position of the glass scratch  9 , the adhered foreign matter  10 , the air-bubble, or the like based on the information from the image processing and recording device  122  (step  239 ) and the operation ends. By utilizing the present repair step  240 , the size of the air-bubble  15  in the glass substrate can be measured as well as the size of the glass scratch  9  or the adhered foreign matter  10  on the glass substrate surface. 
       PROCESSING EXAMPLE 1 
       [0056]      FIG. 7  is an example of the first repair processing with the laser scribing according to the present invention. For a scribe line  8   b  having an imperfect portion  9 , an appropriate distance between a repair line and the scribe line  8   b  is determined by the accurate position, size, shape and the like of the imperfect portion  9  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, a linear scribe line  8   c  for repairing is newly formed at a position shifted by the determined distance from the imperfect portion  9 . For a scribe line  6   b  having an imperfect portion  10 , an appropriate distance between a repair line and the scribe line  6   b  is determined by the accurate position, size, shape and the like of the imperfect portion  10  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, a linear scribe line  6   c  for repairing is newly formed at a position shifted by the determined distance from the imperfect portion  10 . Here, in order to avoid overlapping with the scribe line  7 , the bypass (repair) scribe lines  8   c,    6   c  are preferably formed each near the side of the corresponding scribe line opposite to the scribe line  7 . The repair processing of the present example only forms a new linear scribe line as being easily controlled. Accordingly, since the operation of moving and stopping of the glass substrate to the repair processing position is not required, repair processing time can be shortened in the case that a plural repair lines are necessary on the same line. However, in the present example, effective photovoltaic area of the amorphous silicon layer is decreased a little. 
       PROCESSING EXAMPLE 2 
       [0057]      FIG. 8  is an example of the second repair processing with the laser scribing according to the present invention. For the scribe line  8   b  having an imperfect portion  9 , a length of a repair line  8   d  and a distance between the repair line  8   d  and the scribe line  8   b  are appropriately determined by the accurate position, size, shape and the like of the imperfect portion  9  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, the rectangular scribe line  8   d  for repairing is formed to bypass the imperfect portion  9 . For the scribe line  6   b  having an imperfect portion  10 , a length of a repair line  6   d  and a distance between the repair line  6   d  and the scribe line  6   b  are appropriately determined by the accurate position, size, shape and the like of the imperfect portion  10  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, the rectangular scribe line  6   d  for repairing is formed to bypass the imperfect portion  10 . Here, in order to avoid overlapping with the scribe line  7 , the bypass scribe lines  8   d,    6   d  are preferably formed each near the side of the corresponding scribe line opposite to the scribe line  7 . The repair processing of the present example only forms a rectangular scribe line to bypass the imperfect portion. Accordingly, the repair processing time can be shortened, and the decrease in photovoltaic efficiency can be suppressed to the minimum because the present example causes little decrease in effective photovoltaic area of the amorphous silicon layer. 
       PROCESSING EXAMPLE 3 
       [0058]      FIG. 9  is an example of the third repair processing with laser scribing according to the present invention. For the scribe line  8   b  having an imperfect portion  9 , an appropriate diameter of a repair line  8   e  is determined by the accurate position, size, shape and the like of the imperfect portion  9  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, the circular scribe line  8   e  is formed for repairing so that the imperfect portion  9  is to be the center thereof. For the scribe line  6   b  having an imperfect portion  10 , an appropriate diameter of a repair line is determined by the accurate position, size, shape and the like of the imperfect portion  10  recorded in the imperfect portion recording device  140  or the image processing and recording device  122 . Then, the circular scribe line  6   e  is formed for repairing so that the imperfect portion  10  is to be the center thereof. In the present example, the circular scribe line  8   e  being centered on the imperfect portion  9  overlaps with the imperfect portion  9  in the lower side of the circle, for example. However, since the scribe line is only required to be connected through either side of the circle, there is no problem in this case due to connection in the upper side. Here, in order to avoid overlapping with the scribe line  7 , the circular scribe lines  8   e,    6   e  are each required to have a radius being smaller than the distance between the corresponding scribe line and the scribe line  7  when the center of the trepanning circle is set on the scribe line. Meanwhile, when the center of the trepanning circle is not set on the scribe line, the diameter is only required to avoid overlapping with the scribe line  7 . Since the repair processing of the present example may employ trepanning which is an often used control method of a pair of galvanometer mirrors being as the reflection mirrors  107 , the decrease in photovoltaic efficiency can be suppressed to the minimum as being easily controlled. The present example also causes little decrease in effective photovoltaic area of the amorphous silicon layer  4 . 
         [0059]    Here, in apparatus example 1 illustrated in  FIGS. 1 and 2 , by further disposing the image processing and recording device  122 , one or more inspection cameras  116  and the movable table  117 , and replacing step  214  in  FIG. 3  with step  240  in  FIG. 6 , it also becomes possible to perform repairing as measuring the size of the air-bubble  15  in the glass substrate.
     FIG. 3     START     202  CONVEY GLASS SUBSTRATE FOR LEFTWARD PROCESSING (“N”TH LINE) AND CAPTURE SUBSTRATE SURFACE IMAGE WITH INSPECTION CAMERA ABOVE GLASS SUBSTRATE IN-SIDE     203  PERFORM LEFTWARD PROCESSING (“N”TH LINE) AND CAPTURE SCRIBE LINE IMAGE WITH INSPECTION CAMERA ABOVE GLASS SUBSTRATE OUT-SIDE     204  COMPLETE LEFTWARD PROCESSING (“N”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     205  BEFORE FINAL SCRIBE LINE?     206  CONVEY GLASS SUBSTRATE FOR RETURN PROCESSING (“N+1”TH LINE) AND CAPTURE SUBSTRATE SURFACE IMAGE WITH INSPECTION CAMERA ABOVE GLASS SUBSTRATE IN-SIDE     207  PERFORM RETURN PROCESSING (“N+1”TH LINE) AND CAPTURE SCRIBE LINE IMAGE WITH INSPECTION CAMERA ABOVE GLASS SUBSTRATE OUT-SIDE     208  COMPLETE RETURN PROCESSING (“N+1”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     209  FINAL SCRIBE LINE FORMED?     211  DISPLAY ON OPERATIONAL MONITOR NUMBER AND POSITION OF IMPERFECTION AND COMPARE TO INSPECTION PROGRAM     212  DISPLAY ON OPERATIONAL MONITOR INSTRUCTIONS OF CATEGORIZATION FOR RANKING, NO-PROCESSING, REPAIR-PROCESSING OR THE LIKE FOR FINAL-SCRIBE-LINE-FORMED SUBSTRATE     213  PERFORM REPAIR PROCESSING?     214  PERFORM REPAIR PROCESSING   END     FIG. 6     START     222  CONVEY GLASS SUBSTRATE FOR LEFTWARD PROCESSING (“N”TH LINE)     223  PERFORM LEFTWARD PROCESSING (“N”TH LINE)     204  COMPLETE LEFTWARD PROCESSING (“N”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     205  BEFORE FINAL SCRIBE LINE?     226  CONVEY GLASS SUBSTRATE FOR RETURN PROCESSING (“N+1”TH LINE)     227  PERFORM RETURN PROCESSING (“N+1”TH LINE)     208  COMPLETE RETURN PROCESSING (“N+1”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     209  FINAL SCRIBE LINE FORMED?     231  MEASURE RESISTANCE VALUE (SHORT-CIRCUIT) BETWEEN ADJACENT SCRIBE LINES     232  DISPLAY ON OPERATIONAL MONITOR NUMBER AND POSITION OF SHORT-CIRCUITED LINE AND COMPARE TO INSPECTION PROGRAM     233  DISPLAY ON OPERATIONAL MONITOR INSTRUCTIONS OF CATEGORIZATION FOR RANKING, NO-PROCESSING, REPAIR-PROCESSING OR THE LIKE FOR FINAL-SCRIBE-LINE-FORMED SUBSTRATE     234  SHORT-CIRCUITED LINE EXISTS?     235  PERFORM REPAIR PROCESSING?     236  INSPECT SHORT-CIRCUITED LINE AS ADJUSTING FOCAL POINT OF INSPECTION CAMERA ON FILM FORMED SIDE AND FIND IMPERFECT PORTION     237  INSPECT SUBSTRATE STATE AS SHIFTING FOCAL POINT TOWARD GLASS FACE SIDE ABOUT THE IMPERFECT PORTION FOUND BY INSPECTION CAMERA     238  DETECT AND DISPLAY CAUSE CREATING THE IMPERFECTION     239  PERFORM REPAIR PROCESSING   END     FIG. 14     START     302  CONVEY GLASS SUBSTRATE FOR LEFTWARD PROCESSING (“N”TH LINE)     303  PERFORM LEFTWARD PROCESSING (“N”TH LINE)     304  COMPLETE LEFTWARD PROCESSING (“N”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     305  BEFORE FINAL SCRIBE LINE?     306  CONVEY GLASS SUBSTRATE FOR RETURN PROCESSING (“N+1”TH LINE)     307  PERFORM RETURN PROCESSING (“N+1”TH LINE)     308  COMPLETE RETURN PROCESSING (“N+1”TH LINE) AND STOP CONVEYING GLASS SUBSTRATE     309  FINAL SCRIBE LINE FORMED?   END