JP2010040769A - Method of manufacturing solar-battery module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a solar-battery module that controls the degradation of the productivity of the solar-battery module. <P>SOLUTION: The method of manufacturing the solar-battery module 100 includes the steps of electrically connecting a light-receiving surface 10A of one solar cell 10 and the backside 10B of the other solar cell 10 using a linear first wiring member 11 and arranging a cushion member 4p on the other solar cell 10 side on the light-receiving surface 10A of one solar cell 10. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a solar cell module including a solar cell string.

  Solar cells are expected as new energy sources because they directly convert clean and inexhaustible sunlight into electricity. The output per solar cell is about several watts. Therefore, when using a solar cell as an electric power source (energy source) such as a house or a building, a solar cell module including a plurality of solar cells connected to each other by a wiring material is used.

  Each solar cell is sealed with a sealing material between the light-receiving surface side protective material and the back surface side protective material. The encapsulant repeats expansion and contraction according to temperature changes in the usage environment. Therefore, the wiring material that connects the solar cells to each other receives stress according to the expansion and contraction of the sealing material. As a result, when the wiring material is bent, the wiring material may be broken due to stress concentration on the bent portion.

Therefore, a method has been proposed in which the light receiving surface of one solar cell and the back surface of another solar cell adjacent to the one solar cell are electrically connected to each other by a linear wiring material (see Patent Document 1). ). According to this method, since the wiring material is not bent, it is possible to prevent the wiring material from being broken by expansion and contraction of the sealing material.

JP 2001-244491 A

  However, in the method described in Patent Document 1, since the light receiving surface of each solar cell is not provided on the same surface, it is necessary to form a sealing material in a complicated manner according to the arrangement angle of each solar cell. Specifically, in the laminating process of the solar cell module, when the sealing material and the plurality of solar cells are sequentially laminated on the light receiving surface side protective material, the surface of the sealing material is formed in a staircase shape. Therefore, the technique described in Patent Document 1 has a problem that the productivity of the solar cell module is lowered.

  This invention is made | formed in view of said problem, and it aims at providing the manufacturing method of the solar cell module which can suppress the fall of productivity of a solar cell module.

  A method for manufacturing a solar cell module according to a feature of the present invention includes a first solar cell and a second solar cell each having a first main surface and a second main surface provided on the opposite side of the first main surface. A method for manufacturing a module, the step A of electrically connecting the first main surface of the first solar cell and the second main surface of the second solar cell with a linear wiring material; The process B which arrange | positions a buffer material on the 2nd solar cell side on the 1st main surface, the 1st protective material, the 1st sealing material, and the 1st solar cell and the 2nd solar cell which were connected by the wiring material And a step C of forming a laminate by sequentially laminating a second sealing material and a second protective material, and a step D of laminating the laminate. In step C, the first solar cell The first main surface forms a predetermined angle with respect to the surface of the first sealing material facing the first solar cell. It is the gist of.

  According to the method for manufacturing a solar cell module according to the features of the present invention, the buffer material is arranged so as to fill a space formed between the light receiving surface of the first solar cell and the first sealing material. Therefore, in the post-process, when the first solar cell is pressure-bonded to the first sealing material, it is possible to suppress the end portion in contact with the wiring material of the first solar cell from being pressed and damaged. Moreover, since the buffer material is disposed on the light receiving surface of the first solar cell, it is not necessary to mold the first sealing material into a complicated shape.

  In step B according to the feature of the present invention, the buffer material may be temporarily fixed on the first main surface of the first solar cell.

Between the process A and the process C which concerns on the characteristic of this invention, it has the process E which arrange | positions a buffer material on the 1st solar cell side among the 2nd main surfaces of a 2nd solar cell, The 2nd main surface of a solar cell may comprise a predetermined angle with respect to the surface facing a 2nd solar cell among 2nd sealing materials.

  In the process B according to the feature of the present invention, the first solar cell may be disposed on the buffer material placed on the placing table.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the solar cell module which can suppress the productivity fall of a solar cell module can be provided.

  Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic and ratios of dimensions and the like are different from actual ones. Accordingly, specific dimensions and the like should be determined in consideration of the following description. Moreover, it is a matter of course that portions having different dimensional relationships and ratios are included between the drawings.

(Configuration of solar cell module)
Below, the structure of the solar cell module which concerns on embodiment of this invention is demonstrated, referring drawings. FIG. 1 is a side view showing a configuration of a solar cell module 100 according to the present embodiment. FIG. 2 is a plan view showing the configuration of the solar cell module 100 according to this embodiment.

  As shown in FIGS. 1 and 2, the solar cell module 100 includes four solar cell strings 1, a light receiving surface side protective material 2, a back surface side protective material 3, and a sealing material 4.

  The four solar cell strings 1 are sealed by the sealing material 4 between the light receiving surface side protective material 2 and the back surface side protective material 3. The solar cell string 1 includes three solar cells 10 arranged along the arrangement direction H, a first wiring member 11 that electrically connects the solar cells 10 to each other, and electricity at both ends of each solar cell string 1. And a second wiring member 12 connected to each other. As shown in FIG. 2, the solar cell strings 1 are arranged in parallel in an orthogonal direction T that is substantially orthogonal to the arrangement direction H, and are electrically connected by a crossover wiring member 13.

  As shown in FIG. 1, each solar cell 10 has a light receiving surface 10A for receiving light and a back surface 10B provided on the opposite side of the light receiving surface 10A. Moreover, although not shown in figure, each solar cell 10 has a photoelectric conversion part which produces | generates a light generation carrier by light reception, and a collection electrode which collects a light generation carrier from a photoelectric conversion part. The collection electrodes are formed on the light receiving surface and the back surface, respectively, and are electrically connected to the first wiring member 11. In addition, although the dimension of each solar cell 10 can be set arbitrarily, it can be set to, for example, 70 mm × 90 mm square and 300 μm thickness.

  Here, each solar cell 10 is not parallel to the light receiving surface side protective material. Specifically, as shown in FIG. 1, the light receiving surface 10 </ b> A of each solar cell 10 forms a predetermined angle α with the back surface facing surface 2 </ b> A facing the back surface protecting material 3 of the light receiving surface protecting material 2. . The back surface 10 </ b> B of each solar cell 10 forms a predetermined angle α with the light receiving surface side facing surface 3 </ b> A facing the light receiving surface side protecting material 2 of the back surface side protecting material 3.

  The first wiring member 11 is formed using a conductive material such as copper formed in a thin plate shape or a twisted wire shape. The surface of such a conductive material may be plated with eutectic solder or the like. The dimensions of the first wiring material 11 can be arbitrarily set. For example, the width in the orthogonal direction T can be 1 mm, the conductive material can be 200 μm thick, and the plating layer can be 40 μm thick.

The first wiring member 11 is electrically connected to each solar cell 10 by a conductive adhesive such as solder or resin adhesive. The light receiving surface 10A of each solar cell 10 has one conductivity type, and the back surface 10B of each solar cell 10 has another conductivity type. Therefore, the first wiring member 11 is formed on the collecting electrode formed on the light receiving surface of one solar cell 10 and the collecting electrode formed on the back surface of another solar cell 10 adjacent to the one solar cell 10. By connecting, one solar cell 10 and another solar cell 10 are electrically connected in series.

  Here, in this embodiment, as shown in FIG. 1, the first wiring member 11 is formed in a straight line and is not bent between one solar cell 10 and another solar cell 10. Should be noted. Accordingly, the first wiring member 11 is disposed in parallel with each of the light receiving surface 10 </ b> A and the back surface 10 </ b> B of the solar cell 10.

  The second wiring member 12 and the transition wiring member 13 are formed of the same material as the first wiring member 11.

  The light receiving surface side protective material 2 is a flat plate member that is disposed on the light receiving surface side of each solar cell 10 and protects the surface of the solar cell module 100. As the light-receiving surface side protective material 2, glass having translucency and water shielding properties, translucent plastic, or the like can be used.

  The back surface side protective material 3 is a flat member that is disposed on the back surface side of each solar cell 10 and protects the back surface of the solar cell module 100. As the back surface side protective material 3, a resin film such as PET (Polyethylene Terephthalate), a laminated film having a structure in which an Al foil is sandwiched between resin films, and the like can be used.

The sealing material 4 seals the solar cell string 1 between the light receiving surface side protective material 2 and the back surface side protective material 3. As the sealing material 4, a translucent resin such as EVA, EEA, PVB, silicon, urethane, acrylic, or epoxy can be used. Note that the sealing material 4 contains a crosslinking agent.

  Note that an Al frame or a terminal box may be attached to the solar cell module having the above configuration.

(Method for manufacturing solar cell module)
Below, the manufacturing method of the solar cell module which concerns on embodiment of this invention is demonstrated, referring drawings.

  First, the three solar cells 10 arranged along the arrangement direction H are electrically connected to each other by the linear first wiring material 11. Specifically, the first wiring member 11 is connected to the light receiving surface 10 </ b> A of one solar cell 10 and the back surface 10 </ b> B of another solar cell 10. Further, the second wiring member 12 is connected to the solar cells 10 located at both ends of the three solar cells 10. Four solar cell strings 1 manufactured in this way are prepared.

  Next, as shown in FIG. 3A, each solar cell string 1 is mounted on the mounting table 20. Subsequently, the buffer material 4p is disposed on the light receiving surface 10A of the one solar cell 10 on the other solar cell 10 side adjacent to the one solar cell 10. Specifically, as shown in FIG. 3B, the buffer material 4p is disposed so as to eliminate the step formed between the light receiving surface 10A of one solar cell 10 and the back surface 10B of the other solar cell 10. To do. The buffer material 4p is formed of the same material as the sealing material 4 described above. The first wiring member 11 is connected to the light receiving surface 10A of one solar cell 10 and the back surface 10B of another solar cell 10.

  In addition, when arrange | positioning the buffer material 4p on 10 A of light reception surfaces of the one solar cell 10, it is preferable to heat the one solar cell 10. FIG. Specifically, the solar cell string 1 is heated to about 100 ° C. by a heating mechanism built in the mounting table 20. Thereby, the buffer material 4p is softened and bonded (temporarily fixed) to the light receiving surface 10A of the one solar cell 10.

  Next, as shown in FIG. 4A, each solar cell string 1 is turned upside down and placed on the mounting table 20. Then, the buffer material 4q is arrange | positioned in the other solar cell 10 side adjacent to the one solar cell 10 among the back surfaces 10B of the one solar cell 10. FIG. Specifically, as shown in FIG. 4B, the buffer material 4q is disposed so as to eliminate the step formed between the back surface 10B of one solar cell 10 and the light receiving surface 10A of the other solar cell 10. To do. The buffer material 4q is formed of the same material as the buffer material 4p described above.

  In addition, when arrange | positioning the buffer material 4q on the back surface 10B of the one solar cell 10, it is preferable to heat the one solar cell 10 similarly to the case where the buffer material 4p is arrange | positioned. Thereby, the buffer material 4q is softened and bonded (temporarily fixed) to the back surface 10B of the one solar cell 10.

  Next, the wiring member 13 is solder-connected to the second wiring member 12 of each solar cell string 1.

  Next, as shown in FIG. 5, the flat light-receiving surface side protective material 2, the sheet-like first sealing material 4a, the four solar cell strings 1, the sheet-like second sealing material 4b, and the flat plate shape. The back surface side protective material 3 is sequentially laminated to form a laminate. Here, the light receiving surface 10 </ b> A of each solar cell 10 forms an angle α with respect to the surface of the first sealing material 4 a that faces each solar cell 10. Further, the back surface 10B of each solar cell 10 forms an angle α with respect to the surface of the second sealing material 4b that faces each solar cell 10. Therefore, a space is formed between the light receiving surface 10A of each solar cell 10 and the first sealing material 4a, and between the back surface 10B of each solar cell 10 and the second sealing material 4b. In the present embodiment, the buffer material 4p and the buffer material 4q are arranged so as to fill the space.

  Next, the laminate is laminated by a laminating apparatus. Specifically, the laminate is pressure-bonded while being heated to about 150 to 200 ° C. Thereby, the first sealing material 4a, the second sealing material 4b, the buffer material 4p, and the buffer material 4q are cured. By the above, the above-mentioned sealing material 4 is formed, and the solar cell module 100 is completed.

(Function and effect)
In the method for manufacturing the solar cell module 100 according to the present embodiment, the light receiving surface 10A of one solar cell 10 and the back surface 10B of the other solar cell 10 are electrically connected by the linear first wiring member 11. And a step of arranging the buffer material 4p on the other solar cell 10 side on the light receiving surface 10A of the one solar cell 10.

  Therefore, when the solar cell string 1 is arranged on the first sealing material 4a, the light receiving surface 10A of one solar cell 10 is opposed to the surface of the first sealing material 4a that faces the one solar cell 10. To form an angle α. The buffer material 4p is disposed so as to fill a space formed between the light receiving surface 10A of the one solar cell 10 and the first sealing material 4a. Therefore, when the solar cell string 1 is pressure-bonded to the first sealing material 4 a in a subsequent process, the first wiring member 11 can be prevented from damaging the contact end portion of the one solar cell 10. Moreover, since the buffer material 4p is arrange | positioned on the light-receiving surface 10A of the solar cell 10, it is not necessary to shape | mold the 1st sealing material 4a in a complicated step shape.

  Moreover, the manufacturing method of the solar cell module 100 according to the present embodiment further includes a step of arranging the buffer material 4q on the one solar cell 10 side among the back surfaces 10B of the other solar cells 10. Therefore, when the 2nd sealing material 4b is arrange | positioned on the solar cell string 1, the back surface 10B of the other solar cell 10 is with respect to the surface facing the other solar cell 10 among the 2nd sealing materials 4b. The angle α is formed. The buffer material 4q is disposed so as to fill a space formed between the back surface 10B of the other solar cell 10 and the second sealing material 4b. Therefore, in the subsequent process, when the second sealing material 4b is pressure-bonded to the solar cell string 1, the pressure is concentrated on a part of the back surface 10B of the one solar cell 10, so that one solar cell 10 is cracked or chipped. Can be suppressed. Moreover, since the buffer material 4q is arrange | positioned on the back surface 10B of the other solar cell 10, it is not necessary to shape | mold the 2nd sealing material 4b in a complicated step shape.

  In the method for manufacturing the solar cell module 100 according to the present embodiment, the buffer material 4p is temporarily fixed to the light receiving surface 10A of the one solar cell 10 by heating the one solar cell 10. The buffer material 4q is temporarily fixed to the back surface 10B of the other solar cell 10 by heating the other solar cell 10. Therefore, when moving the solar cell string 1, it can suppress that the buffer material 4p and the buffer material 4q fall.

(Other embodiments)
Although the present invention has been described with reference to the above-described embodiments and modifications thereof, it should not be understood that the descriptions and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples and operational techniques will be apparent to those skilled in the art.

  For example, in the above embodiment, the buffer material 4p is arranged only on the other solar cell 10 side in the light receiving surface 10A of one solar cell 10, but the present invention is not limited to this. The buffer material 4p may be disposed so as to fill a space formed between the first sealing material 4a and the light receiving surface 10A of the one solar cell 10. Therefore, the buffer material 4p may cover substantially the entire light receiving surface 10A of one solar cell 10, for example. Similarly, in the above embodiment, the buffer material 4q is disposed only on the one solar cell 10 side of the back surface 10B of the other solar cell 10, but the present invention is not limited to this. The buffer material 4q may cover substantially the entire back surface 10B of the other solar cell 10, for example.

  In the above embodiment, the buffer material 4p and the buffer material 4q are temporarily fixed by heating each solar cell 10. However, the buffer material 4p and the buffer material 4q may not be temporarily fixed. .

  Moreover, in the said embodiment, in the manufacturing method of the solar cell module 100, although each of the buffer material 4p and the buffer material 4q was used, you may use only any one.

  Moreover, in the said embodiment, although the buffer material 4p was arrange | positioned on the one solar cell 10 mounted in the mounting base 20, it is not restricted to this. For example, the buffer material 4p may be bonded to the single solar cell 10 by disposing one solar cell 10 on the buffer material 4p mounted on the mounting table 20. Similarly, the buffer material 4q may be bonded to the other solar cell 10 by disposing another solar cell 10 on the buffer material 4q placed on the mounting table 20.

  Moreover, in the said embodiment, although each of the buffer material 4p and the buffer material 4q is formed in the substantially triangular prism shape, it is not restricted to this. Each of the buffer material 4p and the buffer material 4q may be formed in a substantially triangular prism shape by combining a plurality of members.

  As described above, the present invention naturally includes various embodiments not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

It is a side view of the solar cell module 100 which concerns on embodiment of this invention. It is a top view of the solar cell module 100 which concerns on embodiment of this invention. It is a figure for demonstrating the manufacturing method of the solar cell module 100 which concerns on embodiment of this invention. It is a figure for demonstrating the manufacturing method of the solar cell module 100 which concerns on embodiment of this invention. It is a figure for demonstrating the manufacturing method of the solar cell module 100 which concerns on embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Solar cell string, 2 ... Light-receiving surface side protective material, 2A ... Back surface side opposing surface, 3 ... Back surface side protective material, 3A ... Light-receiving surface side opposing surface, 4 ... Sealing material, 4a ... 1st sealing material, 4b ... second sealing material, 4p ... buffer material, 4q ... buffer material, 10 ... solar cell, 10A ... light receiving surface, 10B ... back surface, 11 ... first wiring material, 12 ... second wiring material, 13 ... transition wiring Material, 20 ... mounting table, 100 ... solar cell module

Claims (4)

A method for producing a solar cell module comprising a first solar cell and a second solar cell each having a first main surface and a second main surface provided on the opposite side of the first main surface,
Step A of electrically connecting the first main surface of the first solar cell and the second main surface of the second solar cell by a linear wiring material;
Step B of disposing a buffer material on the second solar cell side of the first main surface of the first solar cell;
The first protective material, the first sealing material, the first solar cell and the second solar cell connected by the wiring material, the second sealing material, and the second protective material are sequentially stacked. Step C for forming a laminate,
Step D for laminating the laminate,
In step C,
The method of manufacturing a solar cell module, wherein the first main surface of the first solar cell forms a predetermined angle with respect to a surface of the first sealing material facing the first solar cell. In step B,
The method for manufacturing a solar cell module according to claim 1, wherein the buffer material is temporarily fixed on the first main surface of the first solar cell. Between Step A and Step C,
A step E of arranging a buffer material on the first solar cell side of the second main surface of the second solar cell;
In step C,
The said 2nd main surface of a said 2nd solar cell makes a predetermined angle with respect to the surface facing the said 2nd solar cell among the said 2nd sealing material, The Claim 1 or 2 characterized by the above-mentioned. Manufacturing method for solar cell module. In step B,
4. The method for manufacturing a solar cell module according to claim 1, wherein the first solar cell is disposed on the buffer material placed on a mounting table. 5.

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