JP3605998B2 - Solar cell module and method of manufacturing the same - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a flexible solar cell module having a connection member for connecting external lead wires and a method for manufacturing the same.
[0002]
[Prior art]
A flexible solar cell element formed on a film substrate can be produced at low cost, and has excellent practical features such as being lightweight and being attachable to a curved portion. Indispensable for a solar cell presumed to be used outdoors is sealing of the solar cell element with a protective film for securing weather resistance and preventing damage, which is called modularization. Usually, a plurality of solar cell elements are connected by a main wiring, and they are connected to each other by a sealing film made of ethylene vinyl acetate (hereinafter, referred to as EVA) or a material having a surface with excellent weather resistance, for example, ethylene tetrafluoride copolymer. It is covered and sealed with a laminated film to which a weather-resistant film made of a united film (hereinafter referred to as ETFE) or the like is attached. Hereinafter, the sealing film and the laminated film are collectively referred to as a protective film.
[0003]
FIGS. 8A and 8B show a part of a conventional continuous solar cell module before being individualized. FIG. 8A is a plan view, and FIG. 8B is a sectional view taken along line YY in FIG. The photoelectric conversion layer and the output extraction electrode of the solar cell element 1 are located on opposite sides of the substrate. A plurality of solar cell elements 1 are arranged along a longitudinal direction of a long protective film 4 (a laminated film of a sealing film 41 and a weather-resistant film 42), and a long ribbon-shaped metal main wiring 2 is provided on both sides thereof. Both poles of the solar cell element 1 are connected to the main wiring 2 by the arranged and shorter ribbon-shaped auxiliary wirings 3 of the metal, and the solar cell elements 1 are connected in parallel. Then, it is covered with another long protective film 4 and sealed to form a continuous solar cell module. Then, it is cut by the cutting line C between the solar cell device 1 from the solar cell module continuum, individual solar cell module having one or more solar cell elements (hereinafter, simply referred to as modules) it is. Arrows indicate the direction of light incidence.
[0004]
FIG. 9 is a plan view showing a part of a conventional individualized solar cell module. In order to extract power from the module, it is necessary to electrically connect the main wiring 2 and the external lead wires 6. Conventionally, in order to connect the main wiring 2 and the external lead wires 6, first, the protective film 4 on the end of the main wiring 2 of the solar cell module 1 is cut using an ultrasonic cutter and a sharp blade such as a knife together. Then, the main wiring 2 is exposed. Next, an external lead wire 6 was connected to this exposed portion by soldering via a terminal fitting 7, and this was covered with a coating sheet 8 again to form an external lead wire take-out portion.
[0005]
[Problems to be solved by the invention]
However, the above method has the following problems. In the step of exposing the main wiring, the workability was poor because the wiring was cut by a knife, or the main wiring and the protective film had a strong adhesive force and were difficult to remove. In addition, when trying to increase the filling rate of the solar cell element, the space between the solar cell elements and the space between the wiring and the element cannot be unnecessarily widened, and the space for attaching the external lead wire is limited, It was very difficult to attach external leads with sufficient strength.
[0006]
In view of the above problems, an object of the present invention is to provide a solar cell module in which external leads can be easily attached and the attached external leads are strong, and a method of manufacturing the same.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, one or a plurality of solar cell elements including a flexible substrate and a solar cell formed thereon, and two main wirings arranged on both sides of these solar cell elements And a sub-wiring for individually connecting the solar cell element and the main wiring is connected to the main wiring in a solar cell module in which at least two or more protective films sandwich and cover and seal. A connection member extending along the solar cell element and having two connection electrodes wider than the main wiring formed on an insulating sheet, wherein the connection member is sealed between the protective films. It has been done.
[0008]
The insulation sheet is polyimide, aramid, may consist polymeric material such as polyethylene terephthalate or polyethylene naphthalate. The connecting electrode may the metal thin film, Ru is formed of a metal foil or a conductive resin film which is secured by a conductive adhesive or conductive adhesive. An adhesive sheet made of a metal film or a polymer film is preferably adhered to the surface of the connection electrode.
[0009]
The insulating sheet is, it has itself or at least one surface is colored, the can in the same direction and the light-receiving surface of the solar cell element towards the connecting electrode is coordinated to the connecting member to the direction memorial in the opposite direction Good to be.
[0010]
A connection member for two modules is mounted for every twice as many solar cell elements as a predetermined number of one module, and these are sealed between the protective films to manufacture a continuous solar cell module. The body is cut between a cutting line for dividing the connection member for the two modules into two and a predetermined solar cell element .
[0011]
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
2A and 2B show an example of a continuous solar cell module according to the present invention, wherein FIG. 2A is a plan view, and FIG. 2B is a sectional view taken along line YY in FIG. The connection members 5 are arranged for every twice as many solar cell elements as a predetermined number of one module. The connection member 5 is formed by forming a connection electrode 52 on a flexible insulating sheet 51 . The connection member 5 is a connection member for two modules. The connection electrode 52 is symmetrical with respect to the cutting line C, and is divided into two corresponding to the main wiring 2. Between the portion and the main wiring 2 close to the main wiring 2 of the connection electrode 52 is connected by the auxiliary wirings 32 made of metal tape with a conductive adhesive-attached metal tape or soldering. Thereafter, the protective film 4 is covered with the sealing film 41 made of EVA or the laminated film of the sealing film 41 made of EVA and the weather-resistant film 42 made of a fluorine-based ETFE film, and sealed by a laminating process.
[0013]
In the process, the mounting of the connecting member 5 and the sub wiring 31 and the connecting process thereof are added. However, these are the mounting of the solar cell element 1 and the sub wiring 31 in the manufacturing process of the conventional module continuum and the mounting thereof. Almost the same as the connection process. The present invention can be applied even when the connection electrode 52 is provided on the light incident side surface as the solar cell element 1 .
[0014]
1A and 1B are plan views of a solar cell module according to the present invention, in which FIG. 1A shows a state after cutting, and FIG. 1B shows a case where external lead wires are connected. This module is separated from the above-mentioned continuous solar cell module (FIG. 2) by cutting along the cutting line C and a predetermined solar cell element. A part of the protective film 4 covering the connection electrode 52 is removed, and an external connection member made of a cover sheet 8 to which the external lead wires 6 and the terminal fittings 7 connected thereto are fixed in advance, is covered with a conductive adhesive. To connect the terminal fitting 7 to the connection electrode 52. The connection electrode 52 has a larger area than the main wiring 2, and this connection operation can be easily performed.
[0015]
The insulating sheet 51 is preferably made of the same material as the substrate of the solar cell element 1 , such as a polyimide film having a thickness of about 50 μm. In addition, other materials satisfying conditions such as module flexibility, sealing property , mechanical strength, and good electrode adhesion , such as aramid, polyethylene terephthalate (PET), and polyethylene naphthalate (PEN), may be used. Can be used.
[0016]
As the connection electrode 52, a metal film such as Cu, Al or Ag formed by adhesion of metal foil, vapor deposition or sputtering can be used. The terminal fitting 7 of the external connection member can also be formed by attaching a metal foil with an adhesive material cut in a predetermined shape in advance to the insulating sheet 51 , or by mask vapor deposition of a metal film or sputtering.
[0017]
As the connection electrode 52 formed on the insulating sheet 51 , some shapes other than the above example can be considered. FIG. 3 is a plan view showing another example of the shape of the connection electrode 52 according to the present invention. Since the cutting line C does not cut the connection electrode 52, the connection electrode 52 is easily deteriorated due to moisture or the like. Therefore, the connection electrode 52 is completely exposed to the sealing film 41 without being exposed to the cut surface.
[0018]
In addition, another form of the connection electrode 52 can be used in consideration of the simplicity of the connection operation with the external lead wire 6 . FIGS. 4A and 4B are plan views showing examples of another connection electrode 52 according to the present invention. FIG. 4A shows a case where the electrode is cut by a cutting line, and FIG. 4B shows a case where the electrode is not cut by a cutting line. is there. An adhesive sheet 53 made of a metal film or a resin film having an adhesive layer on both surfaces is attached to a portion of the connection electrode 52 connected to the external lead wire 6 .
[0019]
After cutting the module, adhesive cut the sealing film 41 along the outer periphery of the sheet 53 to expose the connection electrode 52 surface peeled by the sealing film 41 pressure-sensitive adhesive sheet 53. Here, the external lead wires 6 are soldered, and then the portions are sealed with a cover sheet 8 with a weather-resistant filler or adhesive. Since the stripped portion is located on the inner side of the module from the cutting line C , this sealing is an extremely simple operation, and the sealing property is high.
[0020]
Assuming that the width of the insulating sheet 51 is the same as that of the solar cell element 1, for example, the solar cell element 1 and the insulating sheet 51 on the sealing film 41 at the time of manufacturing a continuous solar cell module of a roll-to-roll system are provided. Mounting can be simplified. However, when the cutting line C is at the center, the area efficiency of the module is slightly impaired, which can be improved.
[0021]
FIGS. 5A and 5B are plan views of a connecting member according to the present invention with increased area efficiency. FIG. 5A shows a case where two cutting lines are used, and FIG. 5B shows a case where the width of the connecting member is reduced. In the former, the width W of the connection member 5 is made equal to the width of the solar cell element 1 , and the mounting of the connection member 5 on the sealing film 41 is simple. The portion between the two cutting lines C is discarded. Although the latter eliminates the loss of the laminated portion, the mounting of the connection member 5 on the sealing film 41 is slightly complicated, but does not pose a practical problem.
[0022]
6A and 6B show a solar cell module using a connection member which does not require an auxiliary wiring according to the present invention, wherein FIG. 6A is a plan view, and FIG. 6B is a sectional view taken along line YY in FIG. The length of the insulating sheet 51 is equal to the distance between the outside of the main wiring 2, and the connection electrode 51 is directly connected to the main wiring 2. The auxiliary wiring 32 for connecting the main wiring 2 and the connection electrode 52 becomes unnecessary, and the manufacturing process of the module is slightly simplified.
[0023]
There is another perspective. There is also a connection member 5 that can solve the aesthetic problem in the case of installing a module. 7A and 7B show a solar cell module using the colored insulating sheet according to the present invention, wherein FIG. 7A is a plan view, FIG. 7B is a YY cross-sectional view in FIG. It is XX sectional drawing. If the connection electrode 52 is on the side opposite to the light incident surface, the same applies to some of the cross-sectional views described above, but if the connection electrode 52 is on the light incident surface, the length of the solar cell element 1, the auxiliary wiring 32, etc. It is necessary to change the order of mounting on the length protection film 3 . The insulating sheet 51 itself of the connection member 5 is made of a coloring material, or the side of the insulating sheet 51 opposite to the surface on which the connection electrode 52 is formed is colored. Then, when a module is manufactured with the surface on which the connection electrodes 52 are formed facing away from the light incidence surface of the solar cell element 1 , the appearance of the module viewed from the incidence surface is such that the connection electrodes 52 of the insulating sheet 5 are It is invisible and the reflection unique to the connection electrode 52 is not seen, so that the whole can be made a uniform color or some color design.
[0024]
【The invention's effect】
According to the present invention, in the modularization (lamination with a protective film) process, the solar cell elements are successively sandwiched between the protective films in an automated process, so that the connection electrodes are formed on the insulating sheet. The connected member thus mounted can be mounted in the same process as mounting the solar cell element, and no special labor is required. Also, after modularization is completed, if this section is cut, sufficient space for connecting the external lead wires for extracting the generated power can be secured, and by changing the pattern of the connection electrodes on the insulating sheet Since the distance between the anode and the cathode can be freely changed, the dielectric strength between the two electrodes is ensured, and the degree of freedom in designing the external lead wire connection is greatly improved. Also, the mechanical strength of the external lead wire connection can be significantly improved by increasing the strength of the insulating sheet as compared to the case where only the protective film is used. Further, a portion where the connection electrode is not formed can be used for a fixing portion of the solar cell module, and the usability in construction is improved.
[0025]
Using a colored insulating sheet, the connection electrode is formed on one surface and this surface is turned to the opposite side to the light receiving surface of the solar cell module, so that the connection electrode can be made inconspicuous when the module is installed. In addition, since the connection electrode surface is not exposed to sunlight, there is also an advantage that the deterioration of the sealing resin on this surface due to ultraviolet rays is reduced and the durability is improved.
[0026]
Since the adhesive sheet made of a metal film or a polymer film is stuck on the surface of the connection electrode and sealed with a resin, the connection electrode can be easily exposed. As a result, the connection of the external lead wire becomes easy, and the working time and the defective rate are greatly improved.
[Brief description of the drawings]
FIG. 1 is a plan view of a solar cell module according to the present invention, in which (a) is after cutting and (b) is a case where an external lead wire is connected. FIG. 2 is a continuous solar cell module according to the present invention. FIG. 3A is a plan view, and FIG. 3B is a sectional view taken along line YY in FIG. 3A. FIG. 3 is a plan view showing another example of the shape of the connection electrode according to the present invention. FIGS. 5A and 5B are plan views showing examples of another connection electrode according to the present invention. FIG. 5A is a case where the electrode is cut by a cutting line, and FIG. 5B is a case where the electrode is not cut by a cutting line. It is a top view of the connection member which made such area efficiency high, (a) is a case where two cutting lines are used, and (b) is a case where the width of a connection member is narrowed. 2A shows a solar cell module using a connecting member that does not require wiring, FIG. 2A is a plan view, and FIG. FIG. 7 shows a solar cell module using the colored insulating sheet according to the present invention, wherein (a) is a plan view, (b) is a YY sectional view in (a), and (c) Fig. 8 shows a part of a conventional long continuous solar cell module continuum before being individualized, (a) is a plan view, and (b) is (a). FIG. 9 is a plan view showing a part of a conventional individualized solar cell module.
DESCRIPTION OF SYMBOLS 1 Solar cell element 2 Main wiring 31 Secondary wiring 32 Auxiliary wiring 4 Protective film 41 Sealing film 42 Weatherproof film 5 Connecting member 51 Insulating sheet 52 Connecting electrode 53 Adhesive sheet 6 External lead wire 7 Terminal fitting 8 Covering sheet

Claims (6)

A flexible substrate and one or more solar cell elements formed of solar cells formed thereon, two main wirings arranged on both sides of these solar cell elements, the solar cell element and the main cell; In a solar cell module in which sub-wirings for individually connecting wirings are sandwiched between at least two or more protective films and covered and sealed, each of the sub- wirings is connected to the main wiring and extends along the solar cell element. A solar cell comprising: a connection member having two connection electrodes, each of which is wider than the main wiring and which is formed on an insulating sheet, wherein the connection member is sealed between the protective films. module. The insulating sheet is a solar cell module according to claim 1, wherein the polyimide, aramid, that it is a polymeric material such as polyethylene terephthalate or polyethylene naphthalate. The connection electrode, the solar cell module according to claim 1 or 2, characterized in that it is formed of a metal thin film, a conductive adhesive or a conductive metal foil which is fixed by adhesive material or a conductive resin film. The solar cell module according to claim 1, wherein an adhesive sheet made of a metal film or a polymer film is adhered to a surface of the connection electrode. The insulating sheet is, it has itself or at least one surface is colored, the can in the same direction and the light-receiving surface of the solar cell element towards the connecting electrode be arranged the connecting member to the direction memorial in the opposite direction The solar cell module according to claim 1, wherein: A connection member for two modules is mounted for every twice as many solar cell elements as a predetermined number of one module, and these are sealed between the protective films to manufacture a continuous solar cell module. The method for manufacturing a solar cell module according to any one of claims 1 to 5, wherein the body is cut between a cutting line that divides the connection member for the two modules into two and a predetermined solar cell element.

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