JP2013026378A - Solar cell, solar cell module and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To arrange solar cells densely and closely to each other, by preventing a folding part of an output terminal from projecting to the outside of the periphery of a surface member and a rear surface member.SOLUTION: A solar cell 1 includes an element mounting substrate 2 where a solar cell element 12 is mounted on a wiring base material 11 and an output terminal 17 formed on the wiring base material 11 is projecting outward thereof, a filling sheet 41 and a surface sheet 51 which are laminated on the surface side of the element mounting substrate 2, and a filling sheet 41 and a rear surface sheet 61 which are laminated on the rear surface side of the element mounting substrate 2. Notches 41, 61 are formed at a part on the periphery of at least the filling sheet 41 and the rear surface sheet 61 where the output terminal 17 is located. The output terminal 17 is folded to the rear surface side at the root of the notches 41, 61.

Description

  The present invention relates to a solar cell having a structure in which a filling member and a surface member are laminated on the front surface side of the solar cell element mounting substrate, and a filling member and a back member are laminated on the back surface side. A solar cell using a solar cell and a solar cell that achieves high efficiency of the mounting area of the solar cell element by devising the structure of the bent portion of the output terminal part formed on the wiring substrate on which the solar cell element is mounted The present invention relates to a battery module and a manufacturing method thereof.

  In recent years, so-called back electrode type solar cells (back contact type solar cells) in which both a p-type electrode and an n-type electrode are formed on the back surface of a semiconductor substrate such as a silicon substrate have been developed.

  As for the back contact type solar cell, a method in which a large number of solar cell elements are mounted on a single wiring sheet to form a module is generally employed (see, for example, Patent Documents 1 and 2).

  However, when a large number of solar cell elements are mounted on a single wiring sheet, there is a problem that if even one of the mounted solar cell elements is defective, the entire sheet becomes defective.

  Therefore, a small number of solar cell elements are mounted on a small-sized wiring sheet to produce an element mounting substrate, and a filling member, a front surface member, and a filling member and a back surface member are laminated on both the front and back surfaces of the element mounting substrate. It is considered that a small-sized solar cell is manufactured, and a plurality of solar cells manufactured in this manner are arranged adjacent to each other, and the output terminal portions facing each other are connected to form a final-type solar cell module. It is done.

  The feature of this configuration is that it is possible to configure the solar cell module of the final form after confirming that each small-sized solar cell operates normally, so the yield in the final form is very high and should be Even if there is a solar cell, it is easy to replace.

  FIGS. 16A to 16E show a manufacturing procedure of a solar cell module using a small-sized wiring sheet, where FIG. 16A is a plan view and FIGS. 16B to 16E are cross-sectional views.

  First, as shown in FIG. 16A, the solar cell element 101 is mounted on the wiring substrate 102 to produce the element mounting substrate 100. Each output terminal portion 103 is provided on the wiring base material 102 so as to protrude outward from the peripheral portion of the wiring base material 102 (four corners in the diagonal direction in FIG. 16A).

  Next, as shown in FIG. 16B, the filling member 105 and the surface member 106 are disposed on the front surface side of the element mounting substrate 100, and the filling member 105 and the back surface member 107 are disposed on the back surface side. Is laminated. Thereby, as shown in FIG.16 (c), the small sized solar cell 110 is produced.

  Next, as shown in FIG. 16 (d), each output terminal portion 103 is bent into a substantially U shape on the back side of the wiring substrate 102.

  Next, as shown in FIG. 16 (e), a plurality of solar cells 110 (two in FIG. 16 (e)) are arranged adjacent to each other, and the adjacent (opposing) output terminal portions 103 are connected to each other by soldering or the like. To do. The solar cell module of the last form is produced by the above.

JP 2011-114205 A JP 2011-091327 A

  In the solar cell module having the above configuration, when a plurality of small-sized solar cells 110 are arranged adjacent to each other, the adjacent solar cells 110 cannot be arranged densely.

  That is, as shown in FIG. 16C, the filling member 105 and the surface member 106 are disposed on the front surface side of the element mounting substrate 100, and the filling member 105 and the back surface member 107 are disposed on the bare surface side. When the laminating process is performed, the filling member 105 is melted and greatly protrudes from the outer peripheral portions of the front surface member 106 and the back surface member 107. The protruding portion can be eliminated by cutting in a later process, but in the output terminal portion 103 portion, the filling member 105 sticks to the surface of the output terminal portion 103 and protrudes. It is difficult. Therefore, when the output terminal portion 103 is bent in this state, as shown in FIG. 16D, the filling member 105 is attached to the output terminal portion 103, so that it is difficult to bend and a large R is attached. That is, the bent portion 103 a of the output terminal portion 103 protrudes greatly outward from the outer peripheral portions of the front surface member 106 and the back surface member 107.

  For this reason, even if a plurality of solar cells 110 are arranged adjacent to each other in this state, they are arranged densely to the extent that the bent portions 103a of the adjacent output terminal portions 103 get in the way and contact the outer peripheral portions of the front surface member 106 and the back surface member 107 There was a problem that I could not do it.

  The present invention has been devised to solve such a problem, and its purpose is to prevent the bent portion of the output terminal portion from protruding outside the outer peripheral portion of the front surface member and the back surface member. It is providing the solar cell which can be arrange | positioned adjacent to, a solar cell module, and its manufacturing method.

  In order to solve the above problems, the solar cell of the present invention has one or a plurality of solar cell elements mounted on a wiring substrate, and an output terminal portion formed on the wiring substrate is external to the wiring substrate. An element mounting board projectingly provided, a filling member and a surface member laminated on the front side of the element mounting board, and a filling member and a back member laminated on the back side of the element mounting board. In the solar cell provided, a notch portion is formed in a portion of the outer peripheral portion of the front surface member, the both filling members, and the back surface member where the output terminal portion is located.

  According to the present invention, even when the output terminal portion is bent from the root portion by forming a notch in the portion where the output terminal portion is located on the outer peripheral portion of the front surface member, both filling members and the back surface member, Since the bent portion can be positioned in the cutout portion, the bent output terminal portion can be prevented from protruding outside the outer peripheral portions of the front surface member, the filling member, and the back surface member.

  In the solar cell of the present invention, one or a plurality of solar cell elements are mounted on a wiring substrate, and an output terminal portion formed on the wiring substrate is provided so as to protrude from the wiring substrate. A solar cell comprising: an element mounting substrate; a filling member and a surface member stacked on the front side of the element mounting substrate; and a filling member and a back member stacked on the back side of the element mounting substrate. And the notch part is formed in the outer peripheral part of the both said filling member and the said back surface member, and the part in which the said output terminal part is located, It is characterized by the above-mentioned.

  According to the present invention, even when the output terminal portion is bent from the root portion by forming a notch in the outer peripheral portion of both the filling member and the back surface member and the output terminal portion is located, the bent portion Since the bent output terminal portion can be prevented from protruding outside the outer peripheral portion of the surface member.

  Moreover, according to this invention, the said output terminal part is bend | folded to the said back surface member side in the said notch part. When the output terminal portion is bent from the root portion to the back surface member side, the bent portion can be positioned at the notch portion, so that the bent output terminal portion does not protrude beyond the outer peripheral portion of the surface member.

  That is, the output terminal portion is bent inside the outer peripheral portion of the surface member. By bending the output terminal portion inside the outer peripheral portion of the surface member, the bent output terminal portion does not protrude outside the outer peripheral portion of the surface member. Therefore, the vertical and horizontal sizes of the entire solar cell when viewed from the light receiving surface side can be suppressed to the vertical and horizontal sizes of the outer peripheral portion of the surface member.

  Moreover, according to this invention, it is good also as a structure by which the area | region around the said solar cell element was coat | covered with the non-transparent member. Thus, by providing a non-transparent member in the area | region around a solar cell element, when a solar cell element is seen from the surface side, it becomes difficult to visually recognize an output terminal part from the surface side, and a quality improves.

  According to the present invention, the non-transparent member is formed of an insulating film in which a region around the solar cell element is printed with non-transparent ink, and the insulating film is attached to the surface member. A region around the solar cell element may be covered with the non-transparent ink. With such a configuration, it is possible to block the light transmitted through the area around the solar cell element on the surface member side only by attaching the insulating film printed with the non-transparent ink to the surface member. It is possible to make it difficult to visually recognize the output terminal portion from the surface side.

  Moreover, it is set as the structure by which the solar cell module of this invention and two or more solar cells of said each structure are adjacently arranged, and the said output terminal parts which the said adjacent solar cell opposes are connected.

  According to the said structure, the output terminal part is bend | folded in the notch part of a filling member and a back surface member, and does not protrude outside from the outer peripheral part of a surface member, a filling member, and a back surface member. Therefore, when connecting the output terminal portions facing each other by arranging a plurality of solar cells adjacent to each other, the connection terminal portions can be connected without protruding from the outer peripheral portions of the front surface member, the filling member, and the back surface member. When viewed from the surface side, the solar cell surface member can be placed in contact. That is, since it can arrange | position between the surface members of an adjacent solar cell without a clearance gap, it becomes possible to arrange | position a solar cell densely and can improve electric power generation efficiency in the solar cell module of the same size.

  In the method for manufacturing a solar cell module of the present invention, one or a plurality of solar cell elements are mounted on a wiring substrate, and an output terminal portion formed on the wiring substrate is externally provided from the wiring substrate. An element mounting board provided in a protruding manner, a filling member and a surface member that are stacked on the front side of the element mounting board, and a filling member and a back member that are stacked on the back side of the element mounting board are provided. A method of manufacturing a solar cell module using a solar cell, comprising: a filling member provided with a notch on the outer peripheral portion where the output terminal portion is located on the surface side of the element mounting substrate; and a surface member. And arranging the filling member provided with a notch in the outer peripheral portion where the output terminal portion is located on the back side of the element mounting substrate and laminating the whole, and the output terminal Part A plurality of solar cells are adjacent to each other so that the bent output terminal portions face each other and the outer peripheral portion of the surface member is in contact with each other, with the step of bending from the root portion to the back side of the element mounting substrate at the notch And a step of connecting the opposing output terminal portions of the adjacent solar cells.

  In the method for manufacturing a solar cell module of the present invention, one or a plurality of solar cell elements are mounted on a wiring substrate, and an output terminal portion formed on the wiring substrate is externally provided from the wiring substrate. An element mounting board provided in a protruding manner, a filling member and a surface member that are stacked on the front side of the element mounting board, and a filling member and a back member that are stacked on the back side of the element mounting board are provided. A solar cell module is manufactured using the solar cell, and includes a filling member in which a cutout portion is provided in an outer peripheral portion where the output terminal portion is located on the surface side of the element mounting substrate, and a cutout portion in the outer peripheral portion. A front surface member not provided with a notch is disposed, and a back surface member is provided with a filling member and a back surface member provided with a notch in the outer peripheral portion where the output terminal portion is located on the back surface side of the element mounting substrate. Laminate the whole A step of bending the output terminal portion from the root portion to the back side of the element mounting substrate at the notch, and the bent output terminal portions are opposed to each other, and the outer peripheral portion of the surface member is The method includes a step of arranging a plurality of solar cells adjacent to each other so as to be in contact with each other, and a step of connecting output terminal portions facing each other of the adjacent solar cells.

  According to the manufacturing method of the present invention having such characteristics, the output terminal portion is bent in the notch portions of the filling member and the back member, and protrudes outward from the outer peripheral portions of the front member, the filling member, and the back member. There is nothing. Therefore, when connecting the output terminal portions facing each other by arranging a plurality of solar cells adjacent to each other, the connection terminal portions can be connected without protruding from the outer peripheral portions of the front surface member, the filling member, and the back surface member. When viewed from the surface side, the solar cell surface member can be placed in contact. That is, since it can arrange | position between the surface members of an adjacent solar cell without a gap, the solar cell module which arranged the solar cell closely can be manufactured by that much.

  According to the present invention, even when the output terminal portion is bent from the base portion by forming a notch portion at least in the outer peripheral portion of the filling member and the back surface member and where the output terminal portion is located, the bent portion Therefore, the bent output terminal portion can be prevented from protruding outside the outer peripheral portions of the front surface member and the back surface member.

(A) is the top view which looked at the solar cell which concerns on embodiment of this invention from the light-receiving surface side, (b) is sectional drawing. It is a typical top view of a wiring sheet. (A) is sectional drawing which shows typically an example of a photovoltaic cell, (b) is a top view which shows typically an example of the back surface of the semiconductor substrate of the photovoltaic cell shown by (a). It is a disassembled perspective view which shows the structural example 1 of a filling sheet, a surface sheet, and a back surface sheet. (A)-(e) is sectional drawing which shows each process of the manufacturing method of the solar cell using each sheet | seat of the structural example 1, and the manufacturing method of the solar cell module using this solar cell in multiple numbers, (f). Is a plan view. It is a disassembled perspective view which shows the structural example 2 of a filling sheet, a surface sheet, and a back surface sheet. (A)-(e) is sectional drawing which shows each process of the manufacturing method of the solar cell using each sheet | seat of the structural example 2, and the manufacturing method of the solar cell module using this solar cell in multiple numbers, (f). Is a plan view. It is the top view which looked at the solar cell which concerns on the other Example of embodiment of this invention from the light-receiving surface side. It is a typical top view of the vertically long wiring sheet used for the solar cell which concerns on another Example. It is a top view which shows a mode that a solar cell element is attached to a vertically long wiring sheet. It is a disassembled perspective view which shows the structural example 3 of the filling sheet used for the solar cell which concerns on another Example, a surface sheet, and a back surface sheet. It is a disassembled perspective view which shows the structural example 4 of the filling sheet used for the solar cell which concerns on another Example, a surface sheet, and a back surface sheet. It is a top view which shows an example of the solar cell module of the last form which used multiple solar cells which concern on another Example. (A), (b) is a top view which shows the application example of each solar cell which concerns on this invention. (A) is a top view of the solar cell of a conventional structure, (b) is sectional drawing. (A)-(e) has shown the preparation procedure of the solar cell module using a small-sized wiring sheet, (a) is a top view, (b)-(e) is sectional drawing.

  Embodiments of the present invention will be described below with reference to the drawings.

  1A and 1B are a plan view and a cross-sectional view of a solar cell according to an embodiment of the present invention as viewed from the light receiving surface side.

  In the solar cell 1 of this embodiment, a back electrode type solar cell element (hereinafter simply referred to as a solar cell element) 20 is mounted on a wiring sheet 10 formed in a square shape, and the element mounting substrate 2 is configured. . Then, a filling sheet (filling member) 41 and a surface sheet (surface member) 51 are laminated on the light receiving surface side (front surface side) of the element mounting substrate 2, and the filling sheet (filling member) 41 and the back sheet on the back surface side. (Back member) 61 is laminated and the solar cell 1 is configured.

  FIG. 2 is a schematic plan view of the wiring sheet 10.

  The wiring sheet 10 includes an insulating wiring base material 11 and a wiring material (wiring pattern) 12 formed on the surface of the wiring base material 11.

  The wiring material (wiring pattern) 12 includes a comb-shaped n-type wiring 13 and a comb-shaped p-type wiring 14, and a portion corresponding to a comb tooth of the comb-shaped n-type wiring 13 and a comb. The n-type wiring 13 and the p-type wiring 14 are arranged to face each other so that the portions corresponding to the comb teeth of the shaped p-type wiring 14 are alternately meshed one by one. That is, a portion corresponding to the comb teeth of the comb-shaped n-type wiring 13 and a portion corresponding to the comb teeth of the comb-shaped p-type wiring 14 are alternately spaced one by one, that is, Arranged in an insulated state.

  In addition, the output terminal 17 is connected to the wiring substrate 11 so as to protrude laterally on both the left and right sides of the upper end portion of the n-type wiring 13, and on the left and right sides of the lower end portion of the p-type wiring 14. The output terminal portion 17 is connected by protruding.

  Here, the material of the wiring substrate 11 can be used without particular limitation as long as it is an electrically insulating material. For example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide. A material containing at least one resin selected from (PPS: Polyphenylene sulfide), polyvinyl fluoride (PVF) and polyimide (Polyimide) can be used.

  Moreover, the thickness of the wiring base material 11 is not specifically limited, For example, it can be 25 micrometers or more and 200 micrometers or less.

  The wiring substrate 11 may have a single-layer structure consisting of only one layer or a multi-layer structure consisting of two or more layers.

  The material for the n-type wiring 13 and the p-type wiring 14 can be used without particular limitation as long as it is made of an electrically conductive material. For example, at least one selected from copper, aluminum, and silver is used. The metal etc. which contain can be used. The material of the output terminal portion 17 can be used without particular limitation as long as it is an electrically conductive material. For example, a metal containing at least one selected from copper, aluminum, and silver can be used. However, in this embodiment, copper foil is used. Although the thickness of the output terminal part 17 is not specifically limited, For example, it can be 80 micrometers.

  Further, the thicknesses of the n-type wiring 13 and the p-type wiring 14 are not particularly limited, and may be, for example, 10 μm or more and 35 μm or less.

  Further, the shapes of the n-type wiring 13 and the p-type wiring 14 are not limited to the shapes described above, and can be set as appropriate.

  Further, on at least a part of the surface of the n-type wiring 13 and / or at least a part of the surface of the p-type wiring 14, for example, nickel (Ni), gold (Au), platinum (Pt), palladium (Pd) Alternatively, an electrically conductive material including at least one selected from silver (Ag), tin (Sn), SnPb solder, and ITO (Indium Tin Oxide) may be provided. In this case, the electrical connection between the n-type wiring 13 and the p-type wiring 14 and the electrode of the solar cell element 20 described later is improved, and the n-type wiring 13 and / or the p-type wiring 14 Weather resistance can be improved.

  Further, at least a part of the surface of the n-type wiring 13 and / or at least a part of the surface of the p-type wiring 14 may be subjected to a surface treatment such as a blackening process.

  Each of the n-type wiring 13 and the p-type wiring 14 may also have a single-layer structure consisting of only one layer or a multi-layer structure consisting of two or more layers.

  FIG. 3A is a cross-sectional view schematically showing an example of the solar cell element 20.

  The solar cell element 20 includes, for example, a semiconductor substrate 21 such as a silicon substrate having n-type or p-type conductivity, and an antireflection film formed on the uneven surface of the semiconductor substrate 21 that serves as a light-receiving surface of the solar cell element 20. 27 and a passivation film 26 formed on the back surface of the semiconductor substrate 21 which is the back surface of the solar cell element 20. As shown in FIG. 1, the planar shape is an octagonal shape in which each corner portion of a semiconductor substrate formed in a square shape is cut out in a tapered shape.

  Further, on the back surface of the semiconductor substrate 21, an n-type impurity diffusion region 22 formed by diffusing an n-type impurity such as phosphorus and a p-type impurity diffusion formed by diffusing a p-type impurity such as boron, for example. The regions 23 are alternately formed at predetermined intervals, and n-type electrodes 24 that are in contact with the n-type impurity diffusion regions 22 through contact holes provided in the passivation film 26 on the back surface of the semiconductor substrate 21. And a p-type electrode 25 in contact with the p-type impurity diffusion region 23.

  Here, on the back surface of the semiconductor substrate 21 having n-type or p-type conductivity, a plurality of pn junctions are formed at the interface between the n-type impurity diffusion region 22 or the p-type impurity diffusion region 23 and the inside of the semiconductor substrate 21. Will be. Regardless of whether the semiconductor substrate 21 has n-type or p-type conductivity, the n-type impurity diffusion region 22 and the p-type impurity diffusion region 23 are joined to the inside of the semiconductor substrate 21, respectively. The electrode 24 and the p-type electrode 25 are respectively electrodes corresponding to a plurality of pn junctions formed on the back surface of the semiconductor substrate 21. Regardless of the conductivity type of the semiconductor substrate 21, a pn junction may be formed by contact between the adjacent n-type impurity diffusion region 22 and the p-type impurity diffusion region 23.

  FIG.3 (b) is a top view which shows typically an example of the back surface of the semiconductor substrate 21 of the solar cell element 20 shown by Fig.3 (a).

  As shown in FIG. 3B, each of the n-type electrode 24 and the p-type electrode 25 is formed in a comb shape, and the comb-shaped n-type electrode 24 has a comb-shaped portion and a portion corresponding to the comb teeth. The n-type electrode 24 and the p-type electrode 25 are arranged so that the portions corresponding to the comb teeth of the p-type electrode 25 are alternately meshed one by one. That is, a portion corresponding to the comb teeth of the comb-shaped n-type electrode 24 and a portion corresponding to the comb teeth of the comb-shaped p-type electrode 25 are alternately spaced one by one, that is, Arranged in an insulated state.

  In addition, each shape and arrangement | positioning of the electrode 24 for n-types on the back surface of the solar cell element 20 and the electrode 25 for p-types are not limited to the structure shown in FIG.3 (b), The n-type of the wiring sheet 10 is used. Any shape and arrangement that can be electrically connected to the wiring 13 and the p-type wiring 14 may be used.

  In such a configuration of the wiring sheet 10 and the solar cell element 20, the n-type electrode 24 formed on the back surface of the solar cell element 20 on the n-type wiring 13 and the p-type wiring 14 on the surface of the wiring sheet 10. And the element mounting board | substrate 2 is producible by installing the solar cell element 20 on the wiring sheet 10 so that the position of the electrode 25 for p-types may match.

<Sheet configuration example 1>
FIG. 4 is an exploded perspective view illustrating a configuration example 1 of the filling sheet 41, the top sheet 51, and the back sheet 61.

  In the configuration example 1, each of the filling sheet 41, the top sheet 51, and the back sheet 61 is formed in a square shape according to the shape of the element mounting substrate 2, and is an outer peripheral portion of each sheet. Cutout portions 41a, 51a, and 61a are formed at portions where the ten output terminal portions 17 are located, that is, at four corner portions in the diagonal direction.

  Next, the solar cell 1 shown in FIG. 1 is manufactured using the element mounting substrate 2 having the above configuration and the filling sheet 41, the top sheet 51, and the back sheet 61 of the above configuration example 1, and a plurality of the solar cells 1 are manufactured. A method of manufacturing a solar cell module using the method will be described with reference to each step diagram of the manufacturing method shown in FIGS. 4 and 5A to 5F. 5A to 5E are sectional views, and FIG. 5F is a plan view.

  First, as shown in FIG. 4 and FIG. 5A, the front surface of the element mounting substrate 2 and the surface of the filling sheet 41 provided with notches 41a and 51a on the outer peripheral portion where the output terminal portion 17 is located, respectively. The sheet 51 and the back sheet 61 are disposed on the back surface side of the element mounting substrate 2, and the filling sheet 41 and the back sheet 61 provided with notches 41 a and 61 a on the outer peripheral portion where the output terminal portion 17 is located, respectively. The solar cell 1 shown in FIG.5 (b) is produced by laminating.

  Thereafter, the filling member (filling sheet portion) 41b protruding by the laminating process is cut at the outer peripheral portions other than the cutout portions 51a and 61a of the topsheet 51 and the backsheet 61 where the output terminal portion 17 is located. Note that the protruding filling member (filling sheet portion) 41 c sticks to the output terminal portion 17 also in the cutout portions 51 a and 61 a of the topsheet 51 and the backsheet 61.

  Next, in this state, as shown in FIG. 5C, the output terminal portion 17 is bent so as to be folded back from the root portion to the back surface side of the element mounting substrate 2. At this time, as shown in part enlarged in FIG. 5 (d), the filling member 14 c is also attached to the output terminal portion 17, so that it is difficult to bend at the root portion, but with a slightly larger R Even if the output terminal portion 17 is bent to the back surface side, the outer peripheral portions of the top sheet 51 and the back sheet 61 protrude outwardly from the outer surface. That is, the output terminal portion 17 can be bent (in the notches 51a and 61a of the top sheet 51 and the back sheet 61).

  However, the output terminal portion 17 is actually bent along the outer peripheral surfaces of the top sheet 51 and the back sheet 61 in order to connect to the output terminal portion 17 of another adjacent solar cell 1.

  Thereafter, as shown in FIGS. 5 (e) and 5 (f), a plurality (two in the figure) are formed so that the bent output terminal portions 17 are opposed to each other and the outer peripheral portion of the topsheet 51 is in contact. The solar cells 1 and 1 are arranged adjacent to each other, and the opposed output terminal portions 17 of the adjacent solar cells 1 and 1 are connected by soldering or the like. Thereby, the solar cell module of the last form which connected multiple solar cells 1 can be produced.

  Here, the filling sheet 41 can be used without particular limitation as long as it is a resin transparent to sunlight, and more preferably, ethylene vinyl acetate resin, epoxy resin, acrylic resin, urethane resin, It is preferable to use at least one transparent resin selected from olefin resins, polyester resins, silicone resins, polystyrene resins, polycarbonate resins, and rubber resins.

  Moreover, as the surface sheet 51, if it is a board | substrate transparent with respect to sunlight, it can be used without being specifically limited, For example, a glass substrate etc. can be used.

  Moreover, as the back surface sheet 61, what can protect the back surface of the filling sheet 41 should just be used, for example, conventionally used weathering films, such as PET, can be used.

  According to the manufacturing method of the present invention, the output terminal portion 17 is bent in the notches 51 a and 61 a of the top sheet 51 and the back sheet 61, and protrudes outward from the outer peripheral portions of the top sheet 51 and the back sheet 61. There is nothing. Therefore, when connecting the output terminal parts 17 facing each other by arranging a plurality of solar cells 1 adjacent to each other, the connection terminal parts 17 can be connected without protruding from the outer peripheral parts of the top sheet 51 and the back sheet 61. When it sees from the light-receiving surface side, it can arrange | position in the state which the surface sheet 51 of the solar cell 1 was made to contact. That is, since it can arrange | position between the surface sheets 51 of the adjacent solar cell 1 without a gap, the solar cell module which arrange | positioned the solar cell 1 closely can be produced by that much.

<Sheet configuration example 2>
FIG. 6 is an exploded perspective view showing a configuration example 2 of the filling sheet 41, the top sheet 51, and the back sheet 61.

  In the configuration example 2, each of the filling sheet 41, the top sheet 51, and the back sheet 61 is formed in a square shape according to the shape of the element mounting substrate 2, but the filling sheet 41 and the back sheet excluding the top sheet 51. 61 is formed with notches 41a and 61a at the outer periphery of the wiring sheet 10 where the output terminal portion 17 is located, that is, at four corners in the diagonal direction. That is, the surface sheet 51 has a simple square shape with no notch.

  Next, the solar cell 1 shown in FIG. 1 is manufactured using the element mounting substrate 2 having the above configuration and the filling sheet 41, the topsheet 51, and the backsheet 61 of the above configuration example 2, and a plurality of the solar cells 1 are manufactured. A method of manufacturing a solar cell module using the method will be described with reference to each step diagram of the manufacturing method shown in FIGS. 6 and 7A to 7F. 7A to 7E are cross-sectional views, and FIG. 7F is a plan view.

  First, as shown in FIG. 6 and FIG. 7A, a filling sheet 41 in which a notch 41 a is provided on the outer peripheral portion where the output terminal portion 17 is located and a notch are provided on the surface side of the element mounting substrate 2. A front sheet 51 that is not provided is disposed, and on the back side of the element mounting substrate 2, a filling sheet 41 and a back sheet 61 each provided with notches 41 a and 61 a on the outer peripheral portion where the output terminal portion 17 is located, Is placed and the whole is laminated to produce the solar cell 1 shown in FIG.

  Thereafter, the filling member (filling sheet portion) 41b protruding by the laminating process is cut at the outer peripheral portion other than the notches 41a and 61a of the filling sheet 41 and the back sheet 61 where the output terminal portion 17 is located. Note that the protruding filling member (filling sheet portion) 41 c sticks to the output terminal portion 17 in the cutout portions 41 a and 61 a of the filling sheet 41 and the back sheet 61.

  Next, in this state, as shown in FIG. 7C, the output terminal portion 17 is bent into a substantially U shape so as to be folded back from the root portion to the back surface side of the element mounting substrate 2. At this time, as shown in a partly enlarged view in FIG. 7 (d), the filling member 41c is also attached to the output terminal portion 17, so that it is difficult to bend at the root portion, but with a slightly larger R Even if the output terminal portion 17 is bent to the back surface side, the outer peripheral portions of the top sheet 51 and the back sheet 61 protrude outwardly from the outer surface. That is, the output terminal portion 17 can be bent (in the notch portion 61 a of the back sheet 61).

  However, the output terminal portion 17 is actually bent along the outer peripheral surfaces of the top sheet 51 and the back sheet 61 in order to connect to the output terminal portion 17 of another adjacent solar cell 1.

  Thereafter, as shown in FIGS. 7E and 7F, a plurality (two in the figure) are formed so that the bent output terminal portions 17 face each other and the outer peripheral portion of the topsheet 51 is in contact with each other. The solar cells 1 and 1 are arranged adjacent to each other, and the opposed output terminal portions 17 of the adjacent solar cells 1 and 1 are connected by soldering or the like. Thereby, the solar cell module of the last form which connected multiple solar cells 1 can be produced.

  According to the manufacturing method of the present invention, the output terminal portion 17 is bent in the notch 61 a of the back sheet 61 and does not protrude outward from the outer peripheral portions of the top sheet 51 and the back sheet 61. Therefore, when connecting the output terminal parts 17 facing each other by arranging a plurality of solar cells 1 adjacent to each other, the connection terminal parts 17 can be connected without protruding from the outer peripheral parts of the top sheet 51 and the back sheet 61. When it sees from the light-receiving surface side, it can arrange | position in the state which the surface sheet 51 of the solar cell 1 was made to contact. That is, since it can arrange | position between the surface sheets 51 of the adjacent solar cell 1 without a gap, the solar cell module which arrange | positioned the solar cell 1 closely can be produced by that much.

<Other Examples of Solar Cell>
FIG. 8 shows another example of the solar cell according to this embodiment.

  In the embodiment shown in FIG. 1, the solar cell 1 has one solar cell element 20 mounted on the wiring sheet 10, but the solar cell 1 </ b> A of another embodiment has five solar cells on the wiring sheet 10 </ b> A. The battery element 20 is mounted.

  That is, as shown in FIG. 9, the wiring sheet 10 </ b> A has a wiring pattern 12 that is a combination of one comb-shaped n-type wiring 13 and one comb-shaped p-type wiring 14. Five wiring patterns 12 are arranged side by side in the vertical direction, and each wiring pattern 12 is electrically connected to another wiring pattern 12 disposed adjacent thereto.

  Further, the output terminal portion 17 is connected to the wiring substrate 11 so as to protrude laterally on both left and right sides of the upper end portion of the n-type wiring 13 of the uppermost wiring pattern 12, and the p of the lowermost wiring pattern 12 is connected. Output terminal portions 17 are connected to the left and right sides of the lower end of the mold wiring 14 so as to project laterally.

  Then, as shown in FIG. 10, the n-type wiring 13 and the p-type wiring 14 of each wiring pattern 12 on the wiring sheet 10A are connected to the n-type electrode 24 and the p-type for the solar cell element 20 shown in FIG. By mounting the solar cell elements 20 on the wiring patterns 12 so that the positions of the electrodes 25 are aligned, as shown in FIG. 8, a vertically long element mounting substrate 2A is manufactured.

<Sheet configuration example 3>
FIG. 11 is an exploded perspective view showing a configuration example 3 of the filling sheet 41A, the top sheet 51A, and the back sheet 61A.

  In the configuration example 3, each of the filling sheet 41A, the top sheet 51A, and the back sheet 61A is formed in a rectangular shape in accordance with the shape of the element mounting substrate 2A, and is an outer peripheral portion of each sheet. Cutout portions 41Aa, 51Aa, and 61Aa are formed at the portion where the output terminal portion 17 of 10A is located, that is, at four corner portions in the diagonal direction.

  A solar cell 1A shown in FIG. 8 is manufactured by using the element mounting substrate 2A having the above configuration and the filling sheet 41A, the top sheet 51A, and the back sheet 61A of the above configuration example 3, and a plurality of the solar cells 1A ( The method of manufacturing the solar cell module of the final form shown in FIG. 13 using three in this example) is basically the same as the manufacturing method shown in FIG. 4 and FIGS. Therefore, the description is omitted here.

<Sheet configuration example 4>
FIG. 12 is an exploded perspective view showing a configuration example 4 of the filling sheet 41A, the top sheet 51A, and the back sheet 61A.

  In Configuration Example 4, each of the filling sheet 41A, the top sheet 51A, and the back sheet 61A is formed in a rectangular shape according to the shape of the element mounting substrate 2A, and the filling sheet 41A and the back surface excluding the top sheet 51A In the sheet 61A, notches 41Aa and 61Aa are formed at the outer peripheral portion of the wiring sheet 10A where the output terminal portion 17 is located, that is, at four corners in the diagonal direction. That is, the top sheet 51A has a simple rectangular shape without a notch.

  A solar cell 1A shown in FIG. 8 is manufactured by using the element mounting substrate 2A having the above configuration and the filling sheet 41A, the top sheet 51A, and the back sheet 61A of the above configuration example 4, and a plurality of the solar cells 1A ( For the method of manufacturing the solar cell module of the final form shown in FIG. 13 using three in this example, the manufacturing method shown in FIG. 6 and FIGS. Since it is basically the same, the description is omitted here.

<Application examples of solar cells>
FIGS. 14A and 14B are plan views showing application examples of the solar cells 1 and 1A and the solar cell modules of the present invention (however, the solar cell modules are not shown). .

  In this application example, a region around each solar cell element 20 is covered with a non-transparent member 71 (dots are attached to the covered portions). Thus, by providing the non-transparent member 71 in the area | region around each solar cell element 20, when the solar cell 1, 1A and a solar cell module are seen from the surface side, the output terminal part 17 is visually recognized from the surface side. It becomes difficult and the quality improves.

  In the case of using a dark-colored material (for example, black) as the non-transparent member 71, when the solar cells 1, 1A and the solar cell module are viewed from the surface sheet 51 side, the entire surface excluding the solar cell element 20 is A single color (for example, dark black) can be unified. Note that the surface on which the non-transparent member 71 is provided may be either the front surface side or the back surface side of the top sheet 51.

  As a material of the non-transparent member 71, a resin material (paint) such as polyester resin / melamine resin or acrylic resin / melamine resin can be used, but is not particularly limited to these resin materials. .

  When the resin material (paint) as described above is used as the non-transparent member 71, the non-transparent member 71 is uniformly provided on the entire surface of the solar cell 1, 1A and the surface sheet 51 of the solar cell module except for the region of the solar cell element. What is necessary is just to apply | coat to. Thereby, the non-transparent member 71 is apply | coated to the whole surface of the surface sheet 51 except the area | region of the solar cell element 20 at a film | membrane form.

  As a method for applying the non-transparent member 71, for example, while maintaining a state where a certain amount of paint (non-transparent member 71) is always adhered to the roll, the roller is used while the region of the solar cell element 20 is masked. It can implement by what is called roll coating which transfers on the surface sheet 51 at a fixed speed from one direction. In the case of roll coating, the coating thickness of the coating is generally accurate to about several tens of μm, but the coating thickness is not particularly limited. The method of applying the non-transparent member 71 is not limited to such roll coating, and other conventionally known methods can be employed.

  On the other hand, the non-transparent member 71 is formed of a transparent insulating film in which the area around the solar cell element 20 is printed with non-transparent ink, and the solar cell element is attached to the top sheet 51 by sticking the insulating film to the top sheet 51. The area around 20 may be configured to be covered with non-transparent ink. With such a configuration, it is possible to block the light transmitted through the area around each solar cell on the surface sheet side only by attaching the insulating film on which the non-transparent ink is printed to the surface sheet. The output terminal portion can be made difficult to visually recognize from the surface side.

  As a material of the non-transparent member 71 and the insulating film, a resin material such as a polyester resin / melamine resin or an acrylic resin / melamine resin can be used. However, the material is not particularly limited to these resin materials. Absent.

  The concept of the solar cell in the present invention is not limited to the back electrode type solar cell in which both the n-type electrode and the p-type electrode are formed only on one surface (back surface) of the semiconductor substrate. , MWT (Metal Wrap Through) (a solar cell having a configuration in which a part of an electrode is disposed in a through hole provided in a semiconductor substrate) and so-called back contact type solar cells (current from the back surface opposite to the light receiving surface of the solar cell) A solar cell having a structure for extracting

  Further, the solar cell of the present invention is not limited to the above-described back electrode type solar cell, but as a double-sided electrode type solar cell having electrodes on both the front and back surfaces as shown in FIGS. 15 (a) and 15 (b). Can also be applied. 15A is a plan view of a double-sided electrode type solar cell, and FIG. 15B is a cross-sectional view. However, in FIG.15 (b), the output terminal part mentioned later is shown in the bent state.

  In the double-sided electrode type solar cell 80, two surface electrodes 82 are arranged in parallel on the surface of a square-shaped semiconductor substrate 81, and one end of the surface electrode 82 is connected orthogonally to the surface electrode 82. A front-side bus bar electrode 83 is disposed. In addition, two back electrodes 84 are disposed on the back surface of the semiconductor substrate 81 in parallel with the front surface electrode 82, and one end portion of the back surface electrode 84 (on the side opposite to the one end portion of the front surface electrode 82). The back side bus bar electrode 85 connected orthogonally to the back side electrode 84 is disposed at the end). Then, both end portions of the front-side bus bar electrode 83 and both end portions of the back-side bus bar electrode 85 that are arranged in parallel as described above are connected to the outer peripheral portion of the semiconductor substrate 81 (more precisely, the top sheet covering the entire semiconductor substrate 81) 86, outer peripheral portions of the filling sheet 87 and the back sheet 88) are extended to the outside to constitute output terminal portions 83a and 85a.

  In such a configuration, cutout portions 87a and 88a are formed at least at the outer peripheral portions of the filling sheet 87 and the back sheet 88 and where the output terminal portions 83a and 85a are located. Thereby, even when the output terminal portions 83a and 85a are bent from the root portion, the bent portions can be positioned at the cutout portions 87a and 88a. It can be prevented from protruding outside the outer peripheral portion.

  In addition, embodiment disclosed this time is an illustration in all the points, Comprising: It does not become the basis of limited interpretation. Therefore, the technical scope of the present invention is not interpreted only by the above-described embodiments, but is defined based on the description of the scope of claims. Moreover, all the changes within the meaning and range equivalent to a claim are included.

DESCRIPTION OF SYMBOLS 1,1A Solar cell 2,2A Element mounting substrate 10 Wiring sheet 11 Wiring base material 12 Wiring material (wiring pattern)
13 Wiring for n-type 14 Wiring for p-type 17 Output terminal part 20 Solar cell element (rear electrode type solar cell element)
21 Semiconductor substrate 22 n-type impurity diffusion region 23 p-type impurity diffusion region 24 n-type electrode 25 p-type electrode 26 passivation film 27 antireflection film 32 element mounting substrate 41, 41A filling sheet (filling member)
51, 51A Surface sheet (surface member)
61, 61A Back sheet (back member)
71 Non-transparent member 80 Double-sided electrode type solar cell 81 Semiconductor substrate 82 Surface electrode 83 Front side bus bar electrode 83a Output terminal part 84 Back side electrode 85 Back side bus bar electrode 85a Output terminal part 86 Top sheet 87 Filling sheet 87a Notch part 88 Back sheet 88a Notch

Claims (9)

An element mounting substrate on which one or a plurality of solar cell elements are mounted on a wiring base material, and an output terminal portion formed on the wiring base material protrudes from the wiring base material; A solar cell comprising a filling member and a front surface member laminated on the front surface side of the mounting substrate, and a filling member and a back surface member laminated on the back surface side of the element mounting substrate,
A solar cell, wherein a cutout portion is formed in a portion of the outer peripheral portion of the front surface member, the two filling members, and the back surface member where the output terminal portion is located. An element mounting substrate on which one or a plurality of solar cell elements are mounted on a wiring base material, and an output terminal portion formed on the wiring base material protrudes from the wiring base material; A solar cell comprising a filling member and a front surface member laminated on the front surface side of the mounting substrate, and a filling member and a back surface member laminated on the back surface side of the element mounting substrate,
A notch part is formed in the outer peripheral part of both the said filling member and the said back surface member, and the said output terminal part is located, The solar cell characterized by the above-mentioned. The solar cell according to claim 1 or 2, wherein
The said output terminal part is bent in the said notch part at the said back surface member side, The solar cell characterized by the above-mentioned. The solar cell according to claim 3,
The said output terminal part is bent inside the outer peripheral part of the said surface member, The solar cell characterized by the above-mentioned. The solar cell according to claim 3 or 4, wherein
A solar cell, wherein a region around the solar cell element is covered with a non-transparent member. The solar cell according to claim 5,
The non-transparent member is formed of an insulating film in which a region around the solar cell element is printed with a non-transparent ink, and the region around the solar cell element is adhered to the surface member. Is coated with the non-transparent ink.   A plurality of the solar cells according to any one of claims 3 to 6 are arranged adjacent to each other, and the output terminal portions facing each other of the adjacent solar cells are connected to each other. module. An element mounting substrate on which one or a plurality of solar cell elements are mounted on a wiring base material, and an output terminal portion formed on the wiring base material protrudes from the wiring base material; Method for manufacturing a solar cell module using a solar cell comprising a filling member and a front member laminated on the front side of the mounting substrate, and a filling member and a back member laminated on the back side of the element mounting substrate Because
On the surface side of the element mounting substrate, a filling member provided with a notch in the outer peripheral portion where the output terminal portion is located and a surface member are arranged, and on the back side of the element mounting substrate, the output terminal portion is A step of laminating the whole by disposing a filling member and a back surface member provided with a notch in the outer peripheral part located;
Bending the output terminal portion from the root portion to the back side of the element mounting substrate at the notch,
A step of arranging a plurality of solar cells adjacent to each other so that the bent output terminal portions are opposed to each other and the outer peripheral portion of the surface member is in contact with each other;
Connecting the output terminal portions facing each other in adjacent solar cells, and a method for manufacturing a solar cell module. An element mounting substrate on which one or a plurality of solar cell elements are mounted on a wiring base material, and an output terminal portion formed on the wiring base material protrudes from the wiring base material; Method for manufacturing a solar cell module using a solar cell comprising a filling member and a front member laminated on the front side of the mounting substrate, and a filling member and a back member laminated on the back side of the element mounting substrate Because
On the surface side of the element mounting substrate, a filling member provided with a notch in the outer peripheral part where the output terminal part is located and a surface member not provided with a notch in the outer peripheral part are arranged, and the element mounting On the back side of the substrate, a step of laminating the whole by placing a filling member and a back surface member provided with a notch in the outer periphery where the output terminal portion is located;
Bending the output terminal portion from the root portion to the back side of the element mounting substrate at the notch,
A step of arranging a plurality of solar cells adjacent to each other so that the bent output terminal portions are opposed to each other and the outer peripheral portion of the surface member is in contact with each other;
Connecting the output terminal portions facing each other in adjacent solar cells, and a method for manufacturing a solar cell module.

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