JPH0918044A - Solar battery module and connection thereof - Google Patents

Abstract

PURPOSE: To make it possible to connect a solar battery module with external lead wires even if weather-resistance films are cut at arbitrary places by a method wherein wirings for connecting a solar battery formed on the surface of a flexible insulating substrate are formed of two sheets of superposed conductor tapes, and through holes common to both conductor tapes are provided in the conductor tapes and filled with a bonding agent. CONSTITUTION: Substrate rear electrodes, which are connected with a solar battery 1 formed on the surface of a flexible insulating substrate 3 using a resin film, are formed by soldering two sheets 100-μm thick and 15-μm wide copper tapes 51 and 52, which are superposed on both sides of the rear of the substrate 3, using solders 7. 3-mm diameter holes 6 common to the taped 51 and 52 are provided in the tapes 51 and 52, which are used as positive and negative wirings, at intervals of 30mm. A bonding agent 4 is made to interpose between weather-resistant films 2 on both surface of the substrate 3 and the cell 1, the holes 6 are filled with the agent 4 and the tapes 51 and 52 are made to closely adhere to each other, the films 2 are cut at desired places to extend the tapes 51 and 52 and outer lead terminals are inserted between the tapes 51 and 52 to connect with an external circuit. Thereby, a solar battery module is simply connected with the external lead terminals at arbitrary places.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar battery module in which a plurality of solar battery cells formed on a flexible insulating substrate are connected in series or in parallel using wiring, and a connecting method thereof.

[0002]

2. Description of the Related Art Solar cells have been attracting attention as clean energy, and their technological progress has been remarkable. In order to obtain desired power from a solar cell, a plurality of solar cells are connected in series or in parallel to form a module. Amorphous silicon (hereinafter referred to as a-Si) as a main material of the photoelectric conversion layer of a solar cell
The use of is advantageous in that large-area film formation is easy and the cost is low. Conventionally, glass substrates have been used for a-Si thin film solar cells, but they are thick and heavy, and have the drawbacks of being easily broken, and because of the improved workability for installation on an outdoor roof, etc. There is a strong demand for weight reduction.
In response to these demands, a flexible thin film solar cell using a flexible plastic film or a thin metal film as a substrate is being put into practical use.

FIG. 2 shows a conventional solar cell module.
As shown in (a) and (b), a plurality of solar battery cells 1 formed on an insulating substrate 21 whose periphery is reinforced by a frame 22 are connected to each other and to a terminal box 23 exposed on the back surface side. There is. In addition, as shown in FIG. 3, electrodes on the back surface of the substrate connected to cells formed on the front surface of the insulating substrate 3 are connected by thin film wiring 24 on the back surface of the substrate, and the weather resistant film 2 is attached to both surfaces of the adhesive 4 There are a type in which the wiring 24 is laminated through the ends and the wiring 24 is collected from the end and connected to an external lead wire, or a type in which a connector is coupled to the wiring.

[0004]

However, when the terminal box on the back side is used for connection, there is no invasion of water from the connection portion, which has a strong advantage against rain and the like, but has a drawback that the shape becomes thick. The method of connecting the connector to the thin film wiring is simple in connection, but has a drawback that the connector portion becomes high and the surface has irregularities. Further, in the structure shown in FIG. 3, when the adhesion between the thin-film wiring 24 and the adhesive layer 4 is poor, the wiring 24 is lifted and further peeled off. On the other hand, since the wiring 24 is in the form of a thin film, it is likely to be cut when connecting to an external lead wire, and there is a drawback that the connection becomes impossible. Further, when installing the solar cell module on the roof, the solar cell module formed on a long flexible substrate may be cut out according to the length of the roof and used. In such a case, it was difficult to connect the external lead wire to the thin film wiring exposed at the end.

It is an object of the present invention to provide a solar cell module having a wiring that does not float above the cell substrate, has sufficient mechanical strength, and that can be easily connected to an external lead wire even if it is cut at an arbitrary position, and its connection. Will provide a method.

[0006]

In order to achieve the above object, a first invention of the present invention is to provide a solar cell formed on the surface of a flexible insulating substrate, which is connected to a wiring, respectively, and is connected to both outer surfaces. In a solar cell module in which an exposed weatherproof material is sealed with an adhesive, the wiring consists of two conductor tapes, through holes are commonly formed in both conductor tapes, and the through holes are formed. It shall be filled with adhesive. The second aspect of the present invention is that a plurality of solar cells formed on the surface of a flexible insulating substrate are connected to wirings, respectively.
In a solar cell module sealed between weatherproof materials exposed on both outer surfaces, two conductor tapes in which wirings are superposed, one conductor tape of a solar battery cell on a substrate by a conductive adhesive. It is assumed that the conductor tape is adhered to the electrodes and the other conductor tape is adhered to the weather resistant material with an adhesive. The conductor of the conductor tape is preferably copper.

In the method of connecting the solar cell module of the present invention, a gap is provided between the ends of the two conductor tapes, and the terminal of the external lead wire is inserted into the gap. The terminal of the external lead wire may be fixed by a weather resistant material and a stud that penetrates the terminal, and the head of the stud may be covered with a sealing material. Alternatively, the terminal of the external lead may be fixed by a staple penetrating the weather resistant material and straddling the terminal.

[0008]

By forming the wiring with the two conductive tapes superposed on each other, the increase in the thickness of the module at that portion can be reduced. Then, the gap between the two conductor tapes can be widened at the end of the wiring to provide a gap, and by inserting the terminal of the external lead wire into the gap, the wiring and the external lead wire can be easily connected by crimping. Wiring is fixed by filling the through hole with the adhesive used to seal the solar cells in common to the conductor tape, or connecting one conductor tape to the electrodes of the solar cells on the substrate and the electrodes. Is fixed by a conductive adhesive that can be used for the above, and the other conductor tape is adhered to the weather resistant material. Even when the wiring is fixed by filling the adhesive in the through holes, the adhesive does not enter into portions other than the portions close to the through holes, so that it is easy to provide a gap between the conductor tapes. The external lead wire can be crimped to the terminal by fixing it with a tack or a staple from above the weather resistant material. For electrical connection by crimping, the conductor of the conductor tape is preferably copper. By covering the head of the stud that penetrates the module with a sealing material,
Improve reliability.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. Example 1 FIGS. 1A and 1B are a plan view and a cross-sectional view taken along the line AA of a solar cell module according to an example of the present invention. An electrode (not shown) on the back surface of the substrate connected to the solar cell 1 formed on the front surface of the flexible insulating substrate 3 using a resin film has two thicknesses of 100 μm which are superposed on both sides of the back surface of the substrate 3. 15 mm wide copper tape 51, 52
It is connected by soldering with a solder 7. +
-In the copper tapes 51 and 52 which will be the wiring, holes 6 having a diameter of 3 mm and commonly passing therethrough are formed at intervals of 30 mm. In order to seal this module, the adhesive 4 interposed between the weather resistant film 2 on both surfaces and the cell 1 also fills these holes 6, so that the copper tapes 51, 52 adhere to the back surface of the substrate 3 closely. And is fixed. To connect the solar cell module and the external lead wire, as shown in FIG.
As shown in (b), the copper tape 5 exposed on the cut surface 10
The space between the first and the second spaces 52 was widened, and the crimp terminal 81 attached to the end of the external lead wire 8 was inserted into the space 50 in the direction of the arrow 82. After that, as shown in FIG. 5, a through hole 9 which is concentric with the hole of the crimp terminal 81 is formed by punching at the end of the solar module, and a locking stud 11 is inserted into the through hole 9,
Fasten with a snap punch. The head of the rivet tack 11 was sealed with a one-component silicone rubber as the sealing material 12. In the above embodiment, after the crimp terminal 81 was inserted, the through hole 9 for fastening the tack was opened. However, after cutting the solar cell module, a hole penetrating the ends of the copper tapes 51 and 52 was opened, and then the external lead wire was formed. The crimp terminal 8 may be inserted. Example 2: In place of the copper tapes 51, 52 having the structure shown in FIG. 6 and having the holes 6 in Example 1, copper tapes 53, 54 having a conductive adhesive 41 on one surface were used without adhesive. The surfaces were used together. The electrode on the back surface of the substrate 1 connected to the solar cell 1 is a copper tape 5 for wiring with a conductive adhesive 41.
3 is connected. The copper tape 54 is EVA which is used as the adhesive 4 in this case by the conductive adhesive 41 on one surface.
(Ethylene vinyl acetate copolymer) Adhesive to the film,
Fixed. However, in this case, the adhesive on the copper tape 54 need not be conductive. Then, as shown in FIG. 6, the crimp terminal 81 at the tip of the flat external lead wire 8 is inserted into the space 50 between the back-to-back copper tapes 53, 54, and the through hole 9 is punched at the hole position of the crimp terminal. After inserting the eyelet stud 11 into the through hole 9, the eyelet was fixed with the eyelet punch. Although not shown, the head portion of the dowel stud 11 was sealed with a one-component silicone rubber in the same manner as in Example 1. Example 3: Similar to Example 1, perforated copper tapes 51, 52
However, as shown in FIG. 7, a staple 13 was used for connection with the external lead wire 8. That is, after inserting the crimp terminal 81 at the tip of the external lead wire 8, the staple 13 was fixed across the two-layer wiring 51, 52. Comparative Example: Only one copper tape having the structure shown in FIG. 3 but similar to the copper tapes 51 and 52 of Example 1 was used for the wiring 24. The electrode layer on the back surface of the substrate 3 connected to the solar cell and the wiring 24 were connected by a point connection method using solder. It was also connected to external leads by soldering and reinforced with insulating tape.

As a result of repeating the bending test for the solar cell modules of the respective Examples and Comparative Examples thus formed, no abnormality occurred in the modules of the respective Examples, but in the modules of Comparative Examples. , The lead wire part was lifted and peeled off. Further, when the lead wire was pulled, no abnormality occurred in the module of each example, but the copper tape wiring was cut in the module of the comparative example. Next, as a result of cutting the solar cells halfway and attempting wiring, in the module of each example, a gap was formed using a jig between the wirings of two sheets and the terminals of the external lead wires were formed. It could be easily inserted by mechanical insertion and mechanical stapling. However, in the cutting part of the module of the comparative example,
Could not connect to the external lead wire.

In the above-mentioned embodiment, the conductor tape is connected to the electrode on the back surface of the insulating substrate of the solar cell, but the conductor tape is fixed on the surface on the same side as the cell and the connection is made on that surface. May be.

[0012]

According to the present invention, two layers of conductor tape are used for the wiring connected to each solar cell of the solar cell module, and the through holes through which the adhesive used for cell sealing penetrates are formed on the conductor tape. The conductor tape can be fixed so as not to float by leaving it open or by adhering one surface of the conductor tape to the electrode of the solar cell and the weather resistant material on the module surface with an adhesive. In addition, there is no fear of disconnecting the wiring. Then, you can easily form a gap in the mating part of the wiring end that is not adhered with a jig, insert the terminal of the external lead wire into it and crimp the terminal between the conductor tapes with studs or staples from the outside of the module,
By fixing, the solar cell module manufactured using a long substrate can be surely connected by a simple method no matter where it is cut.

[Brief description of the drawings]

1 shows a solar cell module according to an embodiment of the present invention, (a) is a plan view, (b) is a sectional view taken along the line AA of (a).

FIG. 2 shows an example of a conventional solar cell module,
(A) is a top view, (b) is a bottom view

FIG. 3 is a sectional view showing another example of a conventional solar cell module.

FIG. 4 is a perspective view showing a method of connecting external lead wires to a solar cell module according to an embodiment of the present invention in the order of (a) and (b).

FIG. 5 is a cross-sectional view after connecting external lead wires to a solar cell module according to an embodiment of the present invention.

FIG. 6 is a cross-sectional view after connecting external lead wires to a solar cell module according to another embodiment of the present invention.

7 is a cross-sectional view after connecting external lead wires to the same solar cell module as in FIG. 6 by a staple method.

[Explanation of symbols]

 1 Solar Cell 2 Weatherproof Film 3 Flexible Substrate 4 Adhesive 41 Conductive Adhesive 51, 52, 53, 54 Copper Tape 50 Void 7 Solder 8 External Lead Wire 81 Crimping Terminal 9 Through Hole 10 Cut Surface 11 Tack 12 Sealant 13 Staple

Claims (7)

[Claims] 1. A plurality of solar cells formed on the surface of a flexible insulating substrate are connected to wirings, respectively, and sealed with an adhesive between weatherproof materials exposed on both outer surfaces. A solar cell module, comprising: two conductor tapes having wirings superposed on each other, a common through hole is opened in both conductor tapes, and the through hole is filled with an adhesive. 2. A solar cell module in which a plurality of solar cells formed on the surface of a flexible insulating substrate are respectively connected to wiring and sealed between weatherproof materials exposed on both outer surfaces, It is two conductor tapes with wiring overlapped,
A solar cell module, wherein one conductor tape is adhered to an electrode of a solar battery cell on a substrate with a conductive adhesive, and the other conductor tape is adhered to a weather resistant material with an adhesive. 3. The solar cell module according to claim 1, wherein the conductor of the conductor tape is copper. 4. A gap is provided between the end portions of two conductor tapes,
4. The method for connecting a solar cell module according to claim 1, wherein a terminal of an external lead wire is inserted into the space. 5. The method of connecting a solar cell module according to claim 4, wherein the terminal of the external lead wire is fixed with a weather resistant material and a stud that penetrates the terminal. 6. The method of connecting a solar cell module according to claim 5, wherein the head of the stud is covered with a sealing material. 7. The method of connecting a solar cell module according to claim 4, wherein the terminal of the external lead wire is fixed by a staple penetrating the weather resistant material and straddling the terminal.