JP2014183149A - Solar cell module and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module capable of suppressing a defect in insertion of a lead wire into an insertion hole in a terminal plate even if the lead wire shifts in position, and a method of manufacturing the same.SOLUTION: A solar cell module 100 and the solar cell module 100 manufactured by a method of manufacturing the solar module 100 each include: a plurality of solar battery cells; a base part 122 which is electrically connected to the solar battery cell; a lead wire 120 including a tip part 121 formed thinner than the base part 122; and a terminal box 130 which includes a terminal plate 131 electrically connected to the lead wire 120, the terminal plate 131 having an insertion hole 131a into which the lead wire 120 is inserted from the side of the tip part 121.

Description

  The present invention relates to a solar cell module including a plurality of solar cells, a lead wire electrically connected to the solar cell, and a terminal box including a terminal plate electrically connected to the lead wire, and a manufacturing method thereof. About.

  The solar cell module is, for example, a plurality of crystalline solar cells made of single crystal silicon / polycrystalline silicon attached on a light transmissive substrate such as a glass substrate, or a thin film photoelectric conversion layer formed on the light transmissive substrate. The thin film solar cell made of is sealed with a resin material or a protective film.

  In a general solar battery module, when taking out the electric power generated by the solar battery cell, the lead wire connected to the solar battery cell is pulled out to the back side through a resin material or a protective film, and a terminal having an output cable Electrically connected to the box. The terminal box is fixed to the back surface of the solar cell module (see, for example, Patent Document 1).

  As a conventional terminal box, there is one that has an insertion hole through which a lead wire connected to a solar cell in the solar cell module body is inserted, and is electrically connected to a terminal plate by inserting the lead wire into the insertion hole ( For example, see Patent Document 2).

  Moreover, as a lead wire in a solar cell module main body, the lead wire which made the shape of the front-end | tip part rectangular shape is normally used (for example, refer patent document 3, 4).

JP 2001-102616 A JP 2005-353734 A JP-A-2005-236206 JP 2010-129853 A

  However, when the leading end portion of the lead wire having a rectangular tip shape is inserted toward the insertion hole of the terminal plate of the terminal box as described in Patent Document 2, the position of the leading end portion of the lead wire is If it deviates from the normal position, the leading end portion of the lead wire may be caught by the peripheral portion of the insertion hole in the terminal board, resulting in poor insertion. In particular, in the case where the length in the width direction of the insertion hole and the length in the width direction of the lead wire are approximately the same, when the position of the lead wire is laterally shifted, the lead wire is easily caught by the peripheral portion of the insertion hole in the terminal plate, It tends to be poor insertion.

  Accordingly, an object of the present invention is to provide a solar cell module and a method for manufacturing the same that can suppress poor insertion of the lead wire into the insertion hole even if the lead wire is displaced. To do.

  In order to solve the above problems, the present invention provides the following solar cell module and method for manufacturing the solar cell module.

(1) Solar cell module A plurality of solar cells, a lead wire including a base part electrically connected to the solar battery cell and a tip formed narrower than the base part, and electrically connected to the lead wire A terminal box including a terminal board, wherein the terminal board includes a terminal box having an insertion hole through which the lead wire is inserted from the tip end side.

(2) Manufacturing method of solar cell module The solar cell module has a plurality of solar cells, a base part electrically connected to the solar battery cells, and a lead wire including a tip formed narrower than the base part. A terminal box including a solar cell module body drawn from a back surface opposite to a light receiving surface that receives light, and a terminal plate electrically connected to the lead wire, the terminal plate being on the tip side A terminal box having an insertion hole through which the lead wire is inserted, and a step of preparing the solar cell module body in which the lead wire is laid along the back surface And a step of raising the lead wire of the solar cell module body in a state where the lead wire is laid along the back surface from the back surface. Receiving the lead wire in the terminal box from the bottom surface and installing the terminal box on the back surface; and inserting the lead wire housed in the terminal box into the insertion hole in the terminal plate. A method for producing a solar cell module, comprising:

  In this invention, the said insertion hole is formed in the magnitude | size which can penetrate the said base, and the aspect by which the said lead wire is penetrated by the said insertion hole until it reaches at least the said base can be illustrated.

  In the present invention, it is possible to exemplify an embodiment in which the lead wire is formed so that the width of the tip end portion gradually decreases toward the tip end side.

  In the present invention, the lead wire can be exemplified by a form in which the outer peripheral surface of the tip is formed into a curved surface having no corners.

  According to the solar cell module and the manufacturing method thereof according to the present invention, even if the lead wire is misaligned, poor insertion of the lead wire into the insertion hole in the terminal plate can be suppressed.

BRIEF DESCRIPTION OF THE DRAWINGS It is the top view which looked at the lead wire connected to the terminal box in the solar cell module which concerns on one Embodiment of this invention from the top, Comprising: (a) is a figure which shows an example of a lead wire, (b) FIG. 5 is a diagram showing another example of a lead wire. It is a schematic sectional drawing which shows the lead wire connected to the terminal box for solar cell modules shown in FIG. It is a schematic sectional drawing which shows the 1st process in the preparation process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 2nd process in the preparatory process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 3rd process in the preparatory process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 4th process in the preparatory process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 5th process in the preparatory process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 1st process in the lead wire raising process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the 3rd process in the lead wire raising process among the manufacturing processes which manufacture a solar cell module, Comprising: (a) shows the state which has inserted raising means, such as a squeegee (squeezing spatula), in the clearance gap. It is a figure and (b) is a figure which shows the state which raised the lead wire to the predetermined raising angle. It is a schematic sectional drawing which shows the terminal box installation process among the manufacturing processes which manufacture a solar cell module. It is a schematic sectional drawing which shows the lead wire penetration process among the manufacturing processes which manufacture a solar cell module. It is a schematic plan view which shows the state which affixed the adhesive tape on the base part side of a lead wire in the 4th process in the preparatory process among the manufacturing processes which manufacture a solar cell module, Comprising: (a) is FIG. (B) is a figure which shows the lead wire shown in FIG.1 (b). It is a schematic plan view which shows the state which affixed the adhesive tape on the base part side of the conventional lead wire which made the shape of the front-end | tip part rectangular. Schematic for explaining the difference in distance from the reference position between a lead wire in which the tip portion is located at a normal position without occurrence of tip lift and a lead wire in which the tip portion is displaced due to occurrence of tip lift It is a side view. It is a schematic sectional drawing which shows the state which raised the lead wire which the tip floating generate | occur | produced from the back surface of the solar cell module main body at the lead wire raising process. It is a schematic sectional drawing which shows the state by which the sheet-like buffer material was inserted | pinched between the adjacent solar cell module main bodies, and was loaded. FIG. 6 is a schematic plan view showing an example in which the outer peripheral surface of the tip portion is formed in a curved shape having no corners in the lead wire formed so that the width of the tip portion gradually decreases toward the tip side. Schematic plan view showing an example of a lead wire having one end portion in the longitudinal direction cut into a convex shape and the other end portion obtained by cutting one end portion of another lead wire into a convex shape. 1A is a diagram showing the case of the lead wires shown in FIGS. 1A and 12A, and FIG. 1B is a lead shown in FIGS. 1B and 12B. It is a figure which shows the case of a wire | line, (c) is a figure which shows the case of the lead wire shown in FIG.

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

  FIG. 1 is a plan view of a lead wire 120 connected to a terminal box 130 in a solar cell module 100 according to an embodiment of the present invention as viewed from above. FIG. 1A shows an example of the lead wire 120, and FIG. 1B shows another example of the lead wire 120. FIG. 2 is a schematic sectional view showing the lead wire 120 connected to the terminal box 130 for the solar cell module 100 shown in FIG.

[About solar cell module]
On the back surface 110a opposite to the light receiving surface that receives the light of the solar cell module body 110 (see FIG. 2), a sealing insulating member 111 (see FIG. 2), a back sheet for weather resistance and high insulation, and the like The back surface protection member 112 is laminated and sealed.

  In the terminal box 130, lead wires 120, 120, 120, 120 (output lead wires) led out from the back surface 110 a of the solar cell module body 110 through the sealing insulating member 111 and the back surface protection member 112 are in the terminal box 130. The terminal plates 131, 131, 131, 131 are electrically connected. The terminal box 130 includes a box case 132 (see FIG. 2) that is placed and fixed on the back surface protection member 112 of the solar cell module body 110, terminal plates 131 to 131 formed on the box case 132, and an upper lid 133 ( 2).

  The box case 132 includes a case main body 132a that is placed and fixed on the back surface protection member 112 of the solar cell module main body 110, and a terminal plate fixing portion 132b for mounting and fixing the terminal plates 131 to 131. The terminal plate fixing part 132b is fixed to the bottom plate 132c of the case main body 132a. In the present embodiment, the case main body 132a has a box shape, and the terminal plate fixing portion 132b has a rectangular parallelepiped shape. Note that reference numeral 134 in the figure indicates a bypass diode.

  The terminal plates 131 to 131 in the terminal box 130 are provided with insertion holes 131a, 131a, 131a, and 131a through which the lead wires 120 to 120 in the solar cell module body 110 are inserted.

  The bottom plate 132c (see FIG. 2) of the case main body 132a is provided with an opening 132d (see FIG. 2) for receiving the lead wires 120 to 120 from the back surface of the terminal box 130. And the terminal boards 131-131 penetrated the lead wires 120-120 in the solar cell module main body 110 diagonally from the outer side (upper side in FIG. 2) to the inner side (lower side in FIG. 2) through the insertion holes 131a-131a. It is set as the structure electrically connected in a state.

  Specifically, the lead wires 120 to 120 have a distal end portion 121 that is inserted into the insertion holes 131 a to 131 a in the terminal plates 131 to 131 and a base portion 122 that is proximal to the distal end portion 121.

  The lead wires 120 to 120 are obliquely upward on the terminal plate 131 to 131 side through the through holes 112a, 112a, 122a, 112a provided with the base portion 122 in the back surface protection member 112 and the opening 132d in the bottom plate 132c of the case body 132a. The front end 121 is inserted into the insertion holes 131a to 131a.

  In the present embodiment, solar cell module 100 is configured such that terminal box 130 is installed on back surface 110a of solar cell module body 110, but may be installed on the side surface.

  Here, it is preferable that the insertion hole 131a has a width as small as possible through which the base portion 122 of the lead wire 120 can be inserted. As a result, the inserted lead wire 120 and the terminal plate 131 come into contact with each other, and a good electrical connection can be realized. If the insertion hole 131a is simply enlarged, the inserted lead wire 120 and the terminal plate 131 do not contact each other, and there is a high possibility that a connection failure will occur in electrical connection. In particular, in the solar cell module 100, outputs from a plurality of solar cells 116 to 116 (see FIGS. 4 to 7 to be described later) included in the solar cell module main body 110 are aggregated, and the lead wires 120 to 120 are connected to the terminal plates 131 to 131. Therefore, if there is an electrical connection failure, heat may be generated due to electrical resistance in the portion of the connection failure or a discharge due to leakage may occur, leading to the failure of the terminal box 130.

  In addition, the terminal box 130 may be filled with a filler to increase durability such as moisture resistance, but it is preferable to reduce the internal volume of the terminal box 130 in order to reduce the amount of filler used. It is preferable to reduce the size of the terminal board 131 and the insertion hole 131a.

  Since the output of the plurality of solar cells 116 to 116 included in the solar cell module body 110 is aggregated, the lead wire 120 is as thick as possible in order to reduce the electrical resistance and efficiently extract the output. If it is a conducting wire, it is preferable to use a wide wire.

  In addition, in the solar cell module 100 shown in FIG.1 and FIG.2, the part of the reference code which is not demonstrated among the attached reference codes is mentioned later.

[Solar cell module manufacturing process]
Next, a manufacturing process for manufacturing the solar cell module 100 according to the present embodiment will be described.

  The manufacturing process of the solar cell module 100 includes a preparation process, a lead wire raising process, a terminal box installation process, a lead wire insertion process, a lead wire insertion inspection process, a soldering process, and a finishing process.

  3-12 is explanatory drawing for demonstrating an example of the manufacturing process which manufactures the solar cell module 100. FIG. 3 to 7 are schematic cross-sectional views respectively showing the first to fifth steps in the preparation step. 8 and 9 are schematic cross-sectional views showing the first step and the third step in the lead wire raising step, respectively. FIG. 9A shows a state in which the raising means S such as a squeegee is inserted into the gap D, and FIG. 9B shows that the lead wires 120 to 120 are raised at a predetermined raising angle θ. It is a figure which shows a state. FIG. 10 is a schematic cross-sectional view showing the terminal box installation step, and FIG. 11 is a schematic cross-sectional view showing the lead wire insertion step. FIG. 12 is a schematic plan view showing a state where the adhesive tape T is attached to the base 122 side of the lead wires 120 to 120 in the fourth step in the preparation step.

(Preparation process)
In the preparation step (see FIGS. 3 to 7), the solar cell module body 110 is prepared in which the lead wires 120 to 120 are laid along the back surface 110a.

  Specifically, the preparation process includes a first process, a second process, a third process, a fourth process, and a fifth process.

  In the first step (see FIG. 3), a first light-receiving side sealing member made of resin on a light-transmitting substrate 113 such as a glass substrate placed on a mounting table 200 (for example, a heating mounting table). A filler 114 is placed.

  In the second step (see FIG. 4), after the first step, the solar cell string 117 in which a plurality of solar cells 116 to 116 are connected in series via the interconnector 115 is formed on the first filler 114. It arrange | positions so that the light-receiving surface 116a of the battery cells 116-116 may be located in the translucent board | substrate 113 side. At this time, lead wires 120 to 120 for taking out the electric power of the solar cell string 117 to the outside (at least two lead wires 120 and 120 of a positive electrode and a negative electrode, in this example, two lead wires are combined in two sets in total. The ends of the four lead wires 120 to 120 are projected outward (upward in FIG. 4).

  In this example, the lead wire 120 is illustrated as having four wires. However, since the lead wire 120 includes at least two lead wires 120 and 120 of a positive electrode and a negative electrode, two or more lead wires 120 are used. Can be an even number of books. Further, the lead wires 120 to 120 are strip-shaped metal flat plates (for example, a copper flat plate subjected to solder plating) having a predetermined width W (see FIG. 1) and a predetermined thickness H (see FIG. 2). Yes.

  In the third step (see FIG. 5), after the second step, the second filler 118, which is a back surface side sealing portion made of resin, is placed on the solar cell string 117. At this time, the end portions of the lead wires 120 to 120 are in a state of penetrating the second filler 118 and being drawn onto the second filler 118 and projecting outward (upward in FIG. 5).

  In the fourth step (see FIG. 6), a back surface protection member 112 such as a back sheet is disposed on the second filler 118 after the third step. At this time, the end portions of the lead wires 120 to 120 penetrate the back surface protection member 112 and are drawn onto the back surface protection member 112 to constitute the back surface 110a (see FIG. 7) of the solar cell module body 110. Is in a state of sleeping along.

  Then, if necessary, an adhesive tape T (see FIG. 12) as a fixed insulating member for fixing and insulating the lead wires 120 to 120 is attached to the base 122 side of the lead wires 120 to 120.

  FIG. 12A shows the lead wire 120 shown in FIG. FIG. 12B shows the lead wire 120 shown in FIG. In addition, in FIG.1 and FIG.2, the adhesive tape T is abbreviate | omitting illustration.

  Here, as the adhesive tape T, for example, a resin adhesive tape, in particular, an adhesive tape in which an adhesive material is applied to a polyimide film excellent in insulation and heat resistance can be exemplified.

  In the fifth step (cure treatment step) (see FIG. 7), after the fourth step, a pressurizing means (not shown) including a pressing film for applying pressure to the solar cell module body 110 and the solar cell module body 110 are provided. A solar cell string is obtained by heating the solar cell module body 110 while applying pressure to the solar cell module body 110 by heating, and melt-curing (curing) the first filler 114 and the second filler 118 into the sealing insulating member 111. 117 is sealed and laminated (for example, vacuum lamination).

  In this way, in the preparation step, it is possible to obtain the solar cell module main body 110 in which the leading ends 121 of the lead wires 120 to 120 are laid along the back surface 110a. That is, at the stage where the fifth process (curing process) is finished, the leading end portions 121 of the lead wires 120 to 120 are in contact with the back surface 110a of the solar cell module body 110.

(Lead wire raising process)
In the lead wire raising (starting up) step (see FIGS. 8 and 9), the lead wires 120 to 120 of the solar cell module body 110 are placed in a state in which the lead wires 120 to 120 are laid along the back surface 110a of the solar cell module body 110. 120 is raised (raised) at a predetermined raising angle (for example, about 90 °) with respect to the back surface 110a.

  Specifically, in the lead wire raising step, the first step (see FIG. 8) for inspecting the state of the lead wires 120 to 120 (sleeping) before waking up, and the position of the tip 121 of the lead wires 120 to 120 are measured. Using the second step and the raising means S such as a squeegee (see FIG. 9A), the lead wires 120 to 120 in the laid state are placed at a predetermined raising angle θ (for example, about 90 °) (see FIG. 9). 9 (b)) and a third step (see FIG. 9).

  This will be described with reference to an example in which a lead wire is raised by an automatic machine. First, in the first step (see FIG. 8), the state where the lead wires 120 to 120 are along the back surface 110a of the solar cell module main body 110 is shown as a camera. The photographing means 300 takes a picture from the back surface 110a (directly above). At this time, it is confirmed whether the lead wires 120 to 120 are not deformed (for example, whether they are bent or broken), and whether or not foreign matter is attached to the lead wires 120 to 120 (specifically, camera inspection). To do.

  Next, in the second step (not shown), the position of the tip 121 of the lead wires 120 to 120 is measured. At this time, the position where the lead wires 120 to 120 are raised, the installation position of the terminal box 130, and the lead wire inspection, soldering, and camera inspection positions are determined based on the position of the tip 121.

  Next, in the third step (see FIG. 9), the lead wires 120 to 120 are raised at the portion of the adhesive tape T and are raised with respect to the back surface 110 a of the solar cell module body 110. Specifically, the tip 121 side of the lead wires 120 to 120 is sucked by a suction means (not shown), and a gap D (see FIG. 5) is formed between the lead wires 120 to 120 and the back surface 110a of the solar cell module body 110. 9 (a)). Next, the raising means S such as a squeegee is inserted into the gap D, the lead wires 120 to 120 are part of the adhesive tape T, and both the lead wires 120 to 120 and the adhesive tape T are left at a predetermined bending angle. By bending the lead wires 120 to 120 to a predetermined raising angle θ (for example, about 90 °) (see FIG. 9B), for example, by bending it to 180 ° in consideration of the restoring force of the adhesive tape T. Deform.

  In this way, in the lead wire raising step, the lead wires 120 to 120 of the solar cell module body 110 with the lead wires 120 to 120 laid along the back surface 110a of the solar cell module body 110 with respect to the back surface 110a. It can be raised at a predetermined raising angle θ (for example, about 90 °).

(Terminal box installation process)
In the terminal box installation step (see FIG. 10), the lead wires 120 to 120 raised from the back surface 110a of the solar cell module body 110 are accommodated in the terminal box 130 from the bottom surface 130a and the terminal box 130 is installed on the back surface 110a.

  Specifically, the installation device 400 installs the terminal box 130 on the back surface 110a of the solar cell module main body 110 and adheres it via an adhesive (not shown) (for example, a silicone adhesive). At this time, the lead wires 120 to 120 in the solar cell module main body 110 are shaped to rise with respect to the back surface 110a. As the installation device 400, a conventionally known device can be used. Therefore, detailed description of the installation apparatus 400 is omitted here. Further, instead of the installation device 400, an operator may install the terminal box 130 on the back surface 110a of the solar cell module body 110.

(Lead wire insertion process)
In the lead wire insertion step (see FIG. 11), the lead wires 120 to 120 accommodated in the terminal box 130 are inserted into the insertion holes 131a to 131a in the terminal plates 131 to 131.

  Specifically, the lead wires 120 to 120 are bent toward the terminal plates 131 to 131, and the tip portions 121 of the lead wires 120 to 120 are inserted into the insertion holes 131 a to 131 a in the terminal plates 131 to 131 of the terminal box 130. . Regarding the insertion of the leading end portion 121 of the lead wires 120 to 120 into the insertion holes 131a to 131a, in this example, the lead wire insertion device 500 for inserting the lead wires 120 to 120 into the insertion holes 131a to 131a is used. The insertion device 500 includes an insertion device 510 that curves and inserts the lead wires 120 to 120 into the insertion holes 131 a to 131 a of the terminal plates 131 to 131 in the terminal box 130. The insertion device 510 is not limited thereto, but the lead wires 120 to 120 are bent toward the terminal plates 131 to 131 by a robot arm and inserted into the insertion holes 131a to 131a, or the lead wires 120 to 120 are used by a jig. Can be illustrated as being bent toward the terminal plates 131 to 131 and inserted into the insertion holes 131a to 131a. A conventionally known insertion device 510 can be used. Therefore, detailed description of the insertion device 510 is omitted here.

(Lead wire insertion inspection process)
In the lead wire insertion inspection step (not shown), the insertion positions at the distal end portions 121 of the lead wires 120 to 120 inserted through the insertion holes 131a to 131a of the terminal plates 131 to 131 are inspected. In the lead wire insertion inspection step, if the insertion position is not located at the reference position, it is determined that the insertion is defective. In this case, the leading end portions 121 of the lead wires 120 to 120 are reinserted into the insertion holes 131a to 131a.

  The insertion inspection in the lead wire insertion inspection process may be a visual inspection by human eyes, but in this example, an insertion inspection device (not shown) such as a laser inspection machine is used. The insertion inspection device detects whether or not the insertion position is located at the reference position.

(Soldering process)
In the soldering step (not shown), the lead wires 120 to 120 are soldered at the contact portions with the insertion holes 131a to 131a of the terminal plates 131 to 131 in the terminal box 130.

  Thereby, the lead wires 120 to 120 can be electrically connected to the terminal plates 131 to 131 in the terminal box 130.

(Finishing process)
In a finishing step (not shown), a filler (not shown) is charged into the box case 132 of the terminal box 130 and filled, and an upper lid 133 (see FIG. 2) is attached.

  Thus, in the manufacturing process of the solar cell module 100, the plurality of solar cells 116 to 116 and the lead wires 120 to 120 electrically connected to the solar cells 116 to 116 are provided, and the lead wires 120 to 120 are included. 120 includes a solar cell module main body 110 pulled out from the back surface 110a and terminal plates 131 to 131 electrically connected to the lead wires 120 to 120. The terminal plates 131 to 131 are connected to the lead wires 120 to 120 from the tip 121 side. The solar cell module 100 including the terminal box 130 having insertion holes 131a to 131a through which the terminal 120 is inserted and having the terminal box 130 installed on the back surface 110a of the solar cell module main body 110 can be manufactured.

  In the present embodiment, the solar cell module 100 using the double-sided crystal solar cell having electrodes on the light receiving surface 116a (see FIGS. 4 to 7) and the back surface 116b (see FIGS. 4 to 7), respectively. Although it is applied, the present invention is not limited to this, and the present invention is also applied to a solar battery module using a so-called back contact type solar battery cell such as a back electrode type solar battery cell, an MWT (Metal Wrap Through) cell, or a thin film solar battery cell. be able to.

  FIG. 13 is a schematic plan view showing a state where the adhesive tape T is attached to the base portion 122A side of a conventional lead wire 120A in which the tip portion 121A has a rectangular shape.

  By the way, when the leading end portion 121A of the lead wires 120A to 120A having the rectangular shape of the leading end portion 121A is inserted into the insertion holes 131a to 131a in the terminal plates 131 to 131 of the terminal box 130 as in the prior art, the lead wires 120A to 120A. When 120A is deformed (for example, bent or broken) and the position of the tip 121A deviates from the normal position, the tip 121A of the deformed lead wires 120A to 120A is inserted into the insertion holes 131a to 131a of the terminal plates 131 to 131. The lead wire insertion that is caught on the peripheral edge of 131a and inspects the insertion of the lead wires 120A to 120A into the insertion holes 131a to 131a by an insertion inspection device (not shown) such as a laser inspection machine. There may be poor insertion in the inspection process.

  Here, the “regular position” means that, for example, when the lead wire 120A is inserted into the insertion hole 131a of the terminal plate 131, the insertion is performed within the range of the lateral width M of the insertion hole 131a of the terminal plate 131 shown in FIG. This refers to the positional relationship in which the entire leading end portion 121A of the lead wire 120A enters in the width direction X. As a result, when the lead wire 120A is inserted into the insertion hole 131a, the tip 121A of the lead wire 120A is caught on the side surface of the insertion hole 131a, or the terminal plate 121A is not inserted into the insertion hole. It is possible to prevent the 131 from being bent outward in the lateral direction when viewed from the upper surface.

  In this regard, for example, in the lead wire insertion step, when the leading end portion 121A of the lead wires 120A to 120A is inserted through the insertion holes 131a to 131a in the terminal plates 131 to 131 by the insertion device 500 shown in FIG. The lead wires 120A to 120A are deformed (for example, bent or broken) by hand to bend back to their original positions, for example, the state before the lead wire 120A shown in FIG. It is necessary to redo from one process and to pass through the insertion holes 131a to 131a in the terminal plates 131 to 131 of the terminal box 130. In this case, problems such as a decrease in productivity due to the need for manual work, a decrease in productivity of the entire production line due to stopping the insertion device 500, and a cost increase occur.

  Further, in the lead wire insertion step (see FIG. 11), when the leading end portions of the lead wires 120A to 120A are inserted into the insertion holes 131a to 131a in the terminal plates 131 to 131 by the insertion device 500, the insertion holes 131a to 131a are inserted. At the time of insertion, strong folds may be attached to the deformed portions of the lead wires 120A to 120A. As a result, even if the lead wire 120A is manually returned to the normal position, a crease remains in the lead wire 120A. For example, the crease is regarded as a foreign object by a camera inspection in the first step of the lead wire raising step shown in FIG. There is a possibility that an error is output (error detection) due to determination or determination that the lead wires 120A to 120A are broken.

  Furthermore, if the lead wire insertion process fails and the lead wire 120A has a strong crease, it is difficult to completely return the crease once attached due to the remaining crease. The possibility of causing poor insertion again increases.

  If even one lead wire 120A is deformed, the other lead wires 120A connected by the adhesive tape T are also affected, and when the lead wire 120A is inserted, the other lead wire 120A is also deformed and inserted as much. Defects are likely to occur.

  In addition, when the insertion is poor, an adhesive (for example, a silicone adhesive) for bonding the terminal box 130 may adhere to the lead wires 120A to 120A. If it does so, it will be disqualified at the lead wire insertion inspection process, and the solar cell module main body 110 will be temporarily paid out from the line, but then the silicone will be wiped off by the hand of the person (operator) and returned to the line. The line 120A can be inserted. However, in this case, even if a person (operator) wipes off the silicone, there may be a case where the silicone remains due to an operation mistake. Therefore, the possibility that the reliability of soldering is lowered due to the poor insertion itself increases. In particular, the compatibility between silicone and solder is poor, and the residual silicone may reduce the reliability of electrical connection by soldering.

  Further, in the process upstream of the lead wire raising process, there may be a case where the leading edge floating (bending) in which the leading end part 121A side of the lead wires 120A to 120A floats occurs.

  FIG. 14 shows a lead wire 120A to 120A in which the tip 121A is positioned at a normal position without occurrence of tip lifting, and a lead wire 120A to 120A in which the tip 121A is displaced due to tip lifting. It is a schematic side view for demonstrating the difference of distance D1, D2 with respect to the reference position (beta). In FIG. 14, solid lines indicate the lead wires 120A to 120A located at regular positions, and broken lines indicate the lead wires 120A to 120A at least one of which is displaced. In FIG. 14, the adhesive tape T is not shown.

  As shown in FIG. 14, for example, even if the deformation of the lead wires 120 </ b> A to 120 </ b> A is a deformation that passes the camera inspection, the lead 121 </ b> A is positioned at a normal position without the occurrence of floating of the tip. There is a difference between the distances D1 and D2 with respect to the reference position β between the wires 120A to 120A and the lead wires 120A to 120A in which the tip 121A is displaced due to the occurrence of the tip floating.

  FIG. 15 is a schematic cross-sectional view showing a state where the lead wires 120A to 120A in which the tip floating has occurred are raised from the back surface 110a of the solar cell module main body 110A in the lead wire raising step.

  As shown in FIG. 15, when the lead wires 120 </ b> A to 120 </ b> A are lifted (see the γ portion in FIG. 15), the lead wires 120 </ b> A to 120 </ b> A are bent too much when raised from the back surface 110 a of the solar cell module body 110 </ b> A. It becomes.

  Therefore, in the present embodiment, as shown in FIG. 1 and FIG. 12, the lead wires 120 to 120 have a distal end portion 121 inserted through the insertion holes 131 a to 131 a in the terminal plates 131 to 131 thinner than the base portion 122. ing. Here, in the lead wires 120 to 120, the distal end side is referred to as a distal end portion 121 and the proximal end side is referred to as a base portion 122 with a boundary portion Q (see FIG. 1) between a thick portion and a thin portion as a boundary. In this example, in the lead wires 120 to 120, the width W (see FIG. 1) of the distal end portion 121 is smaller than the width W of the base portion 122. Note that the lead wires 120 to 120 may have a thickness H (see FIG. 2) of the distal end portion 121 smaller than a thickness H of the base portion 122 instead of or in addition to such a configuration. The lead wires 120 to 120 have the base 122 electrically connected to the terminal plates 131 to 131 of the terminal box 130. That is, the lead wires 120 to 120 are configured such that at least the distal end portion 121 enters inside the insertion holes 131a to 131a in the terminal plates 131 to 131. A boundary portion Q is located on the same straight line between the lead wires 120 to 120.

  According to the present embodiment, even if the lead wires 120 to 120 are misaligned, the lead wires 120 to 120 have the tip portion 121 made thinner than the base portion 122, so that the lead wires 120 to 120 are correspondingly reduced. Can be prevented from being caught by the peripheral edge portions of the insertion holes 131a to 131a in the terminal plates 131 to 131 of the terminal box 130, whereby the lead wires 120 to 120 are inserted into the insertion holes 131a to 131a in the terminal plates 131 to 131a. Defects can be suppressed.

  In the present embodiment, as shown in FIGS. 1A and 12A, the lead wires 120 to 120 have an outer peripheral surface 121a (see FIG. 12A) of the tip 121 having no corners. It is formed in a curved surface shape. In this example, the outer peripheral surface 121a of the tip 121 of the lead wires 120 to 120 is along the thickness direction Z.

  As described above, the lead wires 120 to 120 are formed in a curved surface in which the outer peripheral surface 121a of the tip 121 has no corners, so that the lead wires 120 to 120 are in the terminal plates 131 to 131 of the terminal box 130. It is possible to further prevent the peripheral edge portions of the insertion holes 131a to 131a from being caught, thereby further suppressing poor insertion of the lead wires 120 to 120 into the insertion holes 131a to 131a in the terminal plates 131 to 131.

  By the way, as shown in FIG. 13, when the outer peripheral surface 121aA of the tip 121A of the lead wires 120A to 120A has a corner like the conventional lead wires 120A to 120A having a rectangular tip 121A, the following is performed. In addition, there is a problem that the lead wires 120A to 120A are deformed.

  For example, in the fifth process (curing process) (see FIG. 7) in the preparation process, the curing process for curing (curing) the sealing member by advancing the crosslinking reaction of the solar cell module body 110A by a long-time heat treatment is completed. When the product is stored in this state or shipped to another factory, the solar cell module body 110A may be stacked (stored) vertically or diagonally.

  Thus, when the solar cell module main body 110A is loaded, the solar cell module main body 110A is connected to the bus bar (not shown) joined to the electrode terminal portions (not shown) of the solar cells 116 to 116 and the bus bar. Between the adjacent solar cell module bodies 110A and 110A so that the lead wires 120A to 120A in the state of being laid along the back surface 110a are not damaged the back surface protection member 112 such as the back sheet of the adjacent solar cell module bodies 110A to 110A. In some cases, a sheet-like cushioning material (for example, a bubble cushioning material in which air is confined in a number of columnar protrusions in the resin sheet) is sandwiched.

  FIG. 16 is a schematic cross-sectional view showing a state in which the sheet-like cushioning material K is sandwiched and stacked between adjacent solar cell module main bodies 110A and 110A. In FIG. 16, illustration of the solar battery cells 116 to 116 is omitted.

  As shown in FIG. 16, when an operator removes the sheet-like cushioning material K, the lead wires 120A to 120A are caught by the cushioning material K, and the lead wires 120A to 120A are deformed (for example, bent or broken). There is.

  Specifically, the solar cell module body 110A is taken out from the line after the curing process and stood with the sheet-like cushioning material K sandwiched between the adjacent solar cell module body bodies 110A and 110A. When the buffer material K is removed from between the adjacent solar cell module main bodies 110A and 110A in order to put the module main body 110A into the line again, the leading end portion 121A of the lead wires 120A to 120A in the solar cell module main body 110A is the buffer material K. Get caught in. At this time, the corner portions (see FIG. 13) at the tip 121A of the lead wires 120A to 120A are easily caught by the buffer material K, and when the solar cell module body 110A is removed from the buffer material K, the lead wires 120A to 120A A load may be applied and the lead wires 120A to 120A may be deformed.

  Moreover, even if the loaded solar cell module main bodies 110A to 110A are displaced from each other in the vertical direction or from each other in the left and right direction, the lead wires 120A to 120A may be caught by the sheet-like buffer material K and deformed. is there.

  In this regard, in the present embodiment, the lead wires 120 to 120 are formed in a curved surface in which the outer peripheral surface 121a of the tip 121 has no corners, as shown in FIGS. 1 (a) and 12 (a). Therefore, deformation of the lead wires 120 to 120 can be suppressed. For example, in the case where the sheet-like buffer material K is sandwiched between the adjacent solar cell module bodies 110, 110, when the operator removes the buffer material K, the lead wires 120 to 120 may not be easily caught by the buffer material K. Thus, it is possible to suppress inconvenience that the lead wires 120 to 120 are deformed (for example, bent or broken). Moreover, even if the adjacent solar cell module main bodies 110, 110 are displaced from each other in the vertical direction or from each other in the left-right direction, it is possible to make it difficult for the leading ends 121 of the lead wires 120 to 120 to be caught by the buffer material K. In this case as well, it is possible to suppress the disadvantage that the lead wires 120 to 120 are deformed.

  By doing so, the frequency with which the lead wires 120 to 120 are caught by the peripheral portions of the insertion holes 131a to 131a in the terminal plates 131 to 131 of the terminal box 130 can be reduced, and accordingly the terminal plates 131 to 131 of the lead wires 120 to 120 are reduced. It is possible to suppress poor insertion into 131 through-holes 131a to 131a. In addition, the deformation of the lead wires 120 to 120 due to the displacement of the sheet-like buffer material K and the adjacent solar cell module main bodies 110 and 110 can be suppressed.

  In the present embodiment, the lead wires 120 to 120 have a tip 121 having an arc shape. Examples of such a shape include a circular partial shape and an elliptical partial shape.

  In the present embodiment, as shown in FIGS. 1B and 12B, in the lead wires 120 to 120, the width W of the tip 121 (see FIG. 1B) goes to the tip. It is formed so as to gradually become smaller. As such a shape, for example, the inclination angle φ of both sides (inclined sides) in the width direction X of the tip 121 with respect to both sides (sides in the longitudinal direction Y) in the width direction X of the base portion 122 (see FIG. 12B). ) Are the same angle. In this example, the outer peripheral surface 121a of the tip 121 of the lead wires 120 to 120 is along the thickness direction Z.

  In this way, the lead wires 120 to 120 are formed so that the width W of the distal end portion 121 gradually decreases toward the distal end side, so that the lead wires 120 to 120 are connected to the terminal plates 131 to 131 of the terminal box 130. Can be smoothly inserted through the insertion holes 131a to 131a.

  In particular, when the lateral width (length in the width direction) M (see FIG. 1) of the insertion holes 131a to 131a and the width W (see FIG. 1) of the lead wires 120 to 120 are approximately the same, the lead wires 120 to 120 When the position is laterally shifted in the width direction X, the lead wires 120 to 120 can be hardly caught by the peripheral portions of the insertion holes 131a to 131a in the terminal plates 131 to 131 of the terminal box 130, and the occurrence of poor insertion is reduced accordingly. It becomes possible to make it.

(Other embodiments)
In the present embodiment, as shown in FIGS. 1B and 12B, in the lead wires 120 to 120 formed so that the width W of the distal end portion 121 gradually decreases toward the distal end side. The outer peripheral surface 121a of the front end portion 121 may be formed in a curved shape having no corners.

  In FIG. 17, in the lead wires 120 to 120 formed so that the width W of the distal end portion 121 gradually decreases toward the distal end side, the outer peripheral surface 121 a of the distal end portion 121 is formed in a curved shape having no corners. It is a schematic plan view showing an example.

  As shown in FIG. 17, the shape of the tip 121 of the lead wires 120 to 120 is an elliptical curved surface whose long axis is along the longitudinal direction Y. Therefore, in this example, the boundary portion Q between the tip portion 121 and the base portion 122 is also formed in a curved surface shape.

  Here, the lead wires 120 to 120 may be formed by cutting a long lead wire to produce a short lead wire 120. In this case, from the viewpoint of minimizing the number of times of cutting in the long lead wire before cutting, one end portion in the longitudinal direction Y which is the tip portion 121 is cut into a convex shape, and the other end portion on the opposite side is Examples of the other concave shape obtained by cutting one end of the lead wire 120 to be produced into a convex shape can be given.

  In FIG. 18, one end 120a in the longitudinal direction Y is cut into a convex shape, and the other end 120b is formed into a concave shape on the other side obtained by cutting one end 120a of another lead wire 120 into a convex shape. 2 is a schematic plan view showing an example of a lead wire 120. FIG. 18A shows the case of the lead wire 120 shown in FIGS. 1A and 12A, and FIG. 18B shows the case shown in FIGS. 1B and 12B. The case of the lead wire 120 is shown, and FIG. 18C shows the case of the lead wire 120 shown in FIG.

  As shown in FIG. 18, one end 120a in the longitudinal direction Y, which is the tip 121 of the lead wires 120 to 120, is cut into a convex shape, and the other end 120b is connected to another (adjacent) lead wire 120. By making the other end concave shape obtained by cutting the one end 120a into a convex shape, the number of times of cutting is reduced when the long lead wire before cutting is cut into the short lead wire 120 to produce one lead wire 120. It is possible to do it only once, and the shape (cutting die) of the cutting blade can be made only one type in the same type of lead wire. In addition, although the front-end | tip of the other end part 120b of the lead wires 120-120 is sharpened, the other end part 120b enters inside the back surface 110a of the solar cell module main body 110 when the solar cell module main body 110 is completed. Because it is not exposed to the outside, there is no problem.

  The present invention is not limited to the embodiment described above, and can be implemented in various other forms. Therefore, such an embodiment is merely an example in all respects and should not be interpreted in a limited manner. The scope of the present invention is shown by the scope of claims, and is not restricted by the text of the specification. Further, all modifications and changes belonging to the equivalent scope of the claims are within the scope of the present invention.

DESCRIPTION OF SYMBOLS 100 Solar cell module 110 Solar cell module main body 110a Back surface 111 Sealing insulating member 112 Back surface protection member 112a Through-hole 113 Translucent substrate 114 1st filler 115 Interconnector 116 Solar cell 116a Light-receiving surface 116b Back surface 117 Solar cell string 118 Second filler 120 Lead wire 120a One end portion 120b The other end portion 121 The front end portion 121a The outer peripheral surface 122 The base portion 130 The terminal box 130a The bottom surface 131 The terminal plate 131a The insertion hole 132 The box case 132a The case main body 132b The terminal plate fixing portion 132c The bottom plate 132d The opening 133 The upper lid 134 Bypass diode 200 Mounting table 300 Imaging means 400 Installation device 500 Insertion device 510 Insertion device D Gap D1 Distance D2 Distance H Thickness K Buffer material M Width Q Boundary portion S Raising means T It raised wearing tape width W X width direction Y longitudinal direction β reference position θ angle φ tilt angle

Claims (5)

A plurality of solar cells,
A lead wire including a base part electrically connected to the solar battery cell and a tip part formed narrower than the base part;
A terminal box including a terminal plate electrically connected to the lead wire, wherein the terminal plate has an insertion hole through which the lead wire is inserted from the distal end side;
A solar cell module comprising: The insertion hole is formed in a size that allows the base to be inserted;
The solar cell module according to claim 1, wherein the lead wire is inserted through the insertion hole until at least the base portion is reached.   3. The solar cell module according to claim 1, wherein the lead wire is formed such that a width of the tip end portion gradually decreases toward the tip end side.   The solar cell module according to any one of claims 1 to 3, wherein the lead wire is formed in a curved shape in which an outer peripheral surface of the tip portion has no corners. A plurality of solar cells, a base portion electrically connected to the solar cells, and a lead wire including a tip portion formed narrower than the base portion, wherein the lead wire is opposite to a light receiving surface that receives light; A solar cell module body pulled out from the back of the side,
A terminal box including a terminal plate electrically connected to the lead wire, wherein the terminal plate has an insertion hole through which the lead wire is inserted from the distal end side;
A solar cell module manufacturing method comprising:
Preparing the solar cell module main body in a state in which the lead wire is laid along the back surface;
Waking up the lead wire of the solar cell module main body from the back surface in a state where the lead wire is laid along the back surface;
Receiving the lead wire raised from the back surface in the terminal box from the bottom surface and installing the terminal box on the back surface;
A step of inserting the lead wire accommodated in the terminal box through the insertion hole in the terminal plate.

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