JP2014192481A - Metal foil lamination body for solar cell, solar cell module, and manufacturing method of metal foil lamination body for solar cell - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metal foil lamination body for a solar cell which easily makes secure electric connection with aluminium foils at low costs without performing chemical treatment to surfaces of the aluminium foils.SOLUTION: A metal foil lamination body 10 for a solar cell is used for arranging wiring in a solar cell 20 having a wiring connection electrode 21 and comprises: a flexible sheet-like base material 11; aluminum foils 13 which are laminated on one surface 11a of the base material through an insulative adhesive layer 12 and form a wiring pattern on the base material; and solder parts 14, each of which is provided at a position on the aluminum foil that may face the connection electrode. The solder part is formed so as to linearly extend on the aluminum foil when viewed in a thickness direction D of the base material.

Description

  The present invention relates to a metal foil laminate for solar cells, a solar cell module, and a method for producing a metal foil laminate for solar cells.

In recent years, solar power generation, which is a power generation system using natural energy, has been rapidly spread. A solar cell module for performing solar power generation is, for example, like a solar cell module 100 shown in FIG. 7, a translucent substrate 120 disposed on a light incident surface, and a solar cell module disposed on the back side thereof. Substrate (solar cell backsheet) 110, and a large number of solar cells 130 sealed between the translucent substrate 120 and the solar cell module substrate 110. Solar cell 130 is sandwiched and sealed between sealing films 140 formed of an ethylene / vinyl acetate copolymer (EVA) film or the like.
Conventionally, in a solar cell module, a large number of solar cells 130 are electrically connected in series with a wiring member 150. Since the solar battery cell 130 is provided with a negative electrode on the front surface side that is the sunlight receiving surface 130 a and a positive electrode on the rear surface side, when connected by the wiring member 150, wiring is performed on the light receiving surface 130 a of the solar battery cell 130. The material 150 overlapped, and there existed a fault which the area efficiency of photoelectric conversion fell.

Further, in the arrangement of the electrodes described above, the wiring member 150 has a structure that wraps around from the front surface side to the back surface side of the solar battery cell 130, and thus there is a possibility that the wiring member 150 is disconnected due to the difference in the thermal expansion coefficient of each member. It was.
Therefore, Patent Documents 1 and 2 propose a back contact type solar battery cell in which both a positive electrode and a negative electrode are installed on the back surface. Solar cells of this system can be connected in series on the back surface, and the light receiving area on the front surface is not sacrificed. Accordingly, it is possible to prevent a decrease in the light receiving rate and the area efficiency of photoelectric conversion. Moreover, since it is not necessary to have a structure in which the wiring material is wound around from the front surface side to the back surface side, disconnection of the wiring material due to the difference in the thermal expansion coefficient of each member can be prevented.

In such a solar cell module, a metal foil laminated body for a solar cell, in which a metal foil having a wiring pattern for connecting to a solar cell via an insulating adhesive layer is attached to the surface of an insulating base material, Parts that are laminated on a solar cell backsheet may be distributed to the market.
In addition, as described in Patent Document 3, it has been proposed to use an aluminum foil as the metal foil. Since aluminum foil is cheaper and relatively stable in price compared with general metal foil, the cost of metal foil can be reduced.

JP 2005-11869 A JP 2009-111122 A JP 2007-76288 A

However, in the solar battery metal foil laminate including the aluminum foil on which the wiring pattern described above is formed, when the aluminum foil and the solar battery cell are connected, the oxide film on the surface of the aluminum foil is insulative. There exists a subject which foil and a photovoltaic cell cannot electrically connect.
When the oxide film on the surface of the aluminum foil is deleted by means such as etching or plating, many chemical solutions and materials such as a plating solution, an etching solution, and a removal solution for each remaining chemical solution are required. For this reason, the process was complicated and the manufacturing cost was high.

  This invention is made in view of such a subject, Comprising: For solar cells which can connect an aluminum foil electrically reliably simply and at low cost, without carrying out the chemical | medical solution process of the surface of aluminum foil It aims at providing the solar cell module provided with the metal foil laminated body and this metal foil laminated body for solar cells. Moreover, it aims at providing the manufacturing method of the metal foil laminated body for solar cells which manufactures this metal foil laminated body for solar cells at low cost and high speed.

In order to solve the above problems, the present invention proposes the following means.
The metal foil laminate for solar cells of the present invention is a metal foil laminate for solar cells for wiring to solar cells having connection electrodes for wiring, and has a sheet-like base material having flexibility, An aluminum foil laminated on one surface of the base material via an insulating adhesive layer and forming a wiring pattern on the base material, and provided on the aluminum foil at a position facing the connection electrode A solder part, and when viewed in the thickness direction of the base material, the solder part is formed to extend linearly on the aluminum foil.

In the solar cell metal foil laminate, the thickness of the solder part is more preferably 3 μm or more and 50 μm or less.
Moreover, in the metal foil laminate for a solar cell, when viewed in the thickness direction, it is more preferable that the plurality of solder portions are formed side by side at intervals in the width direction of the solder portions. .
Moreover, in said metal foil laminated body for solar cells, it is more preferable that the back sheet for solar cells is laminated | stacked on the other surface of the said base material.

  Moreover, the manufacturing method of the metal foil laminated body for solar cells of this invention is a manufacturing method of the metal foil laminated body for solar cells for wiring to the photovoltaic cell which has the connection electrode for wiring, Comprising: A base material portion is formed by laminating a sheet-like base material having an aluminum foil laminated on one surface of the base material with an insulating adhesive layer and forming a wiring pattern on the base material. In the state where the tip of the solder supply body melted and subjected to ultrasonic waves is pressed against the aluminum foil, the base portion and the tip end of the solder supply body are arranged in the thickness direction of the base. A solder part is formed at a position that can be opposed to the connection electrode on the aluminum foil by moving the solder supply body relatively in an orthogonal direction and solidifying the molten solder supply body.

Moreover, in the manufacturing method of said metal foil laminated body for solar cells, it is more preferable that the said solder supply body does not contain the flux.
Moreover, in the manufacturing method of the metal foil laminate for solar cell, in order to relatively move the base portion and the tip of the solder supply body in a direction perpendicular to the thickness direction of the base material, It is more preferable to use a roll-to-roll method in which the base material part is fed out from a roll formed by winding the base material part, and the solder part is formed on the base material part and then wound into a roll shape. preferable.

  Moreover, the solar cell module of the present invention includes the metal foil laminate for solar cell according to any one of the above and a connection electrode for wiring, and the connection electrode is the solder portion of the metal foil laminate for solar cell. And a solar cell connected via a conductive connecting material, a sealing material for sealing the solar battery cell, and a layer on the surface of the sealing material opposite to the metal foil laminate for solar battery And a light-transmitting substrate.

  According to the solar cell metal foil laminate and solar cell module of the present invention, the aluminum foil can be electrically and reliably connected easily and at low cost without subjecting the surface of the aluminum foil to chemical treatment. Moreover, according to the manufacturing method of the metal foil laminated body for solar cells of this invention, the metal foil laminated body for solar cells can be manufactured at low cost and at high speed.

It is sectional drawing of the side surface of the solar cell module of one Embodiment of this invention. It is a typical top view which shows schematic structure of the metal foil laminated body of the solar cell module. It is the schematic diagram which fractured | ruptured one part explaining the manufacturing method of the metal foil laminated body. It is a top view of the metal foil laminated body explaining the manufacturing method of the metal foil laminated body. It is the schematic diagram which fractured | ruptured one part explaining the manufacturing method of the metal foil laminated body. It is sectional drawing of the side surface of the solar cell module in embodiment of the modification of this invention. It is sectional drawing of the side surface of the conventional solar cell module.

Hereinafter, an embodiment of a solar cell module according to the present invention will be described with reference to FIGS. 1 to 6.
As shown in FIG. 1, the present solar cell module 1 includes a metal foil laminate 10 for solar cells of the present invention (hereinafter also abbreviated as “metal foil laminate 10”) and a connection electrode 21 for wiring. The connection electrode 21 is electrically connected to a later-described precoat solder (solder part) 14 of the metal foil laminate 10, a sealing material 30 for sealing the solar battery cell 20, and sealing. A translucent substrate 40 is provided on the surface of the stopper 30 opposite to the metal foil laminate 10.
In FIG. 1, the illustration is simplified and only two connection electrodes 21 of the solar battery cell 20 are shown.

  The metal foil laminate 10 is for wiring to the solar battery cell 20. The metal foil laminate 10 of the present embodiment was provided on a base 11, an aluminum foil 13 laminated on one surface 11 a of the base 11 via an insulating adhesive layer 12, and the aluminum foil 13. And a precoat solder 14.

The base material 11 is a material having flexibility and electrical insulation, and is formed in a film shape or a sheet shape. As a material of the base material 11, for example, a resin material such as acrylic, polycarbonate, polyethylene terephthalate, polyethylene naphthalate, polyimide, urethane, epoxy, melamine, styrene, or a resin material obtained by copolymerization thereof can be used. .
Moreover, the material of the base material 11 can also use the material which mixed the organic or inorganic filler etc. as needed for control of heat insulation, elasticity, or an optical characteristic. Moreover, the base material 11 can also employ a laminated film in which a plurality of the above resin materials are laminated.

The insulating adhesive layer 12 is formed, for example, by heating and curing a thermosetting resin such as urethane, acrylic, epoxy, polyimide, olefin, or a curable adhesive obtained by copolymerizing these. As the insulating adhesive layer 12, an adhesive layer that is not a step-curing type may be used.
This insulating adhesive layer 12 has poor wettability with a melted ultrasonic solder 50 described later, and repels the melted ultrasonic solder 50. When the aluminum foil 13 and the molten ultrasonic solder 50 are cooled and solidified, the angle formed by the aluminum foil 13 and the solidified ultrasonic solder 50 is preferably 1 ° or more and 30 ° or less. The ultrasonic solder 50 wets and spreads on the aluminum foil 13 while applying ultrasonic waves under heating, but has a property that the wet spreading stops when the action of ultrasonic waves is stopped.
The molten ultrasonic solder 50 does not stay on the insulating adhesive layer 12 and receives a force to be pushed out of the insulating adhesive layer 12.

Next, the configuration of the aluminum foil 13 will be described.
The aluminum foil 13 forms a wiring pattern for wiring the solar cells 20 on the substrate 11 and has an appropriate plan view shape according to the arrangement of the connection electrodes 21 of the solar cells 20. The aluminum foil 13 is laminated on the base material 11 via the insulating adhesive layer 12 and is integrally joined to the base material 11.
As a wiring pattern of the aluminum foil 13, for example, as shown in FIG. 2, an example of a pattern having a comb-like portion 16 and a comb-like portion 17 can be given. FIG. 2 is a view of the metal foil laminate 10 as viewed in the thickness direction D of the substrate 11, that is, a plan view of the metal foil laminate 10.

The comb-like portion 16 is formed to have a substantially constant line width, and is arranged in three linear portions 16a, 16b, and 16c (hereinafter referred to as linear portions 16a to 16c) that are arranged apart from each other. .) And is formed in a comb-like shape as a whole. The comb-like portion 17 is formed to have a substantially constant line width, and is arranged as three linear portions 17a, 17b, and 17c (hereinafter, referred to as linear portions 17a to 17c) that are arranged apart from each other. .) And is formed in a comb-like shape as a whole. The comb-like portions 16 and 17 penetrate into the gaps between the linear portions and are arranged in close proximity to each other.
That is, for example, the linear portion 16 a of the comb-like portion 16 is inserted into a gap between the linear portions 17 a and 17 b of the comb-like portion 17. The linear portion 17 b of the comb-like portion 17 is inserted into a gap between the linear portions 16 a and 16 b of the comb-like portion 16.
For the aluminum foil 13, it is desirable to use high-purity aluminum such as 1N30 material and 1100 material in order to ensure electrical conductivity.

In the case of this example, the comb-like portions 16 and 17 correspond to the positive electrode wiring and the negative electrode wiring of the power generation output, respectively. Further, on the translucent substrate 40 side of the comb-like portions 16 and 17, the sun is located at a position overlapping with the comb-like portions 16 and 17 in the thickness direction D as indicated by a two-dot chain line in FIG. Battery cell 20 is arranged. In such a connection position, the solar battery cell 20 includes three connection electrodes 21 (three in each in the position overlapping with the linear portions 16a to 16c and 17a to 17c in the thickness direction D in total). 2).
Note that the shape of the pattern of the aluminum foil 13 shown in FIG. 2 and the number and arrangement of the connection electrodes 21 of the solar battery cell 20 are merely examples, and the present invention is not limited thereto.

When the precoat solder 14 is viewed in the thickness direction D shown in FIG. 2, the precoat solder 14 is on the comb-like portions 16 and 17 of the aluminum foil 13 along the creeping direction E parallel to the one surface 11 a of the substrate 11. It is formed so as to extend linearly. The six precoat solders 14 are formed in stripes in a line in the width direction F of the precoat solder 14 so as to be spaced from each other. Some of the plurality of precoat solders 14 extend linearly with the insulating adhesive layer 12 interposed therebetween.
The precoat solder 14 is provided at a position that can face the connection electrode 21. The thickness (length in the thickness direction D) L of the precoat solder 14 shown in FIG. 1 is not less than 3 μm and not more than 50 μm. When the thickness L of the precoat solder 14 is less than 3 μm, there arises a problem that application uniformity of the melted precoat solder 14 is deteriorated. On the other hand, when the thickness L of the precoat solder 14 exceeds 50 μm, there arises a problem that cracks occur in the precoat solder 14 that is a coating film.
The thickness of the precoat solder 14 is desirably equal to or greater than the surface roughness of the aluminum foil 13. Thereby, the precoat solder 14 and the aluminum foil 13 can be stably connected.
As shown in FIG. 2, in one solar battery cell 20, a plurality of connection electrodes 21 are arranged along the creeping direction E.

The precoat solder 14 is obtained by melting and solidifying an ultrasonic solder 50 described later. In this example, a solder having a known composition containing tin, silver, copper, bismuth, and lead and containing no flux can be appropriately selected and used as the precoat solder 14. In particular, in order to cope with the aluminum foil 13, it is desirable to use solder corresponding to aluminum as the precoat solder 14.
The melting conditions of the precoat solder 14 are based on the melting conditions of each material constituting the precoat solder 14. The precoat solder 14 functions as a rust preventive layer of the aluminum foil 13, and has an effect of improving the wettability of the conductive connection material 26 when a conductive connection material 26 described later is connected to the precoat solder 14 in a later process. is there.
When the conductive connecting material 26 is melted, if the precoat solder 14 is melted, it causes a failure. Therefore, the melting temperature of the precoat solder 14 needs to be higher than the melting temperature of the conductive connecting material 26. The melting temperature of the precoat solder 14 is desirably set to 170 ° C. or more and 200 ° C. or less in order to mitigate thermal damage to peripheral materials.

  In the metal foil laminate 10 thus configured, a base material portion 10a (see FIG. 1) in which an aluminum foil 13 is laminated on one surface 11a of the base material 11 with an insulating adhesive layer 12 interposed therebetween. It is integrated.

In the present embodiment, the metal foil laminate 10 includes a solar cell backsheet 18 laminated on the other surface 11 b of the substrate 11.
The solar cell backsheet 18 constitutes one outer surface in the thickness direction D of the metal foil laminate 10, and moisture, oxygen, and the like are present in the metal foil laminate 10 and in the solar cell module 1. It is a sheet-like member for suppressing intrusion. For this reason, the solar cell backsheet 18 has a barrier function as a shield material.
As a material of the solar cell backsheet 18, for example, an aluminum foil film having a moisture shielding property or an oxygen shielding property, or a composite laminated film of an aluminum foil film and a resin can be used.

  In addition, when forming a wiring pattern on the solar cell backsheet 18, the base material 11 mentioned above can also be used as the solar cell backsheet 18. FIG. In this case, the base material 11 may be a composite laminated film of an aluminum foil film or an aluminum foil film having a moisture shielding property or an oxygen shielding property and the above-mentioned resin material forming the base material 11.

As shown in FIG. 1, the solar battery cell 20 generates electricity by photoelectrically converting light incident from the light receiving surface 22, which is a so-called back contact in which the connection electrode 21 is provided on the back surface 23. If it is a solar cell of a method, the thing of a suitable method is employable. The number of the connection electrodes 21 provided in the solar battery cell 20 can be an appropriate number of 2 or more as necessary.
Moreover, as shown in a two-dot chain line in FIG. 2, for example, an appropriate shape such as a rectangular shape in a plan view can be adopted as the plan view shape of the solar battery cell 20. Although not shown in FIGS. 1 and 2, a plurality of solar cells 20 in the solar cell module 1 are arranged side by side along the creeping direction E and the width direction F with a space therebetween. Generally, the number of solar cells included in the solar cell module is, for example, about 50 to 70.

As shown in FIG. 1, each connection electrode 21 of the solar battery cell 20 and the precoat solder 14 are connected via a conductive connection material 26.
The conductive connecting material 26 is preferably made of solder or silver paste. As solder, the thing containing tin, silver, copper, bismuth, lead, a flux component, etc. can be used. As the silver paste, a paste containing a silicone-based cured resin, an epoxy-based cured resin, a urethane-based cured resin, an acrylic-based cured resin, silver particles, copper particles, nickel particles, or an appropriate meltable conductive member is used. can do. The melting temperature of the conductive connecting material 26 is preferably 150 ± 10 ° C., that is, 140 ° C. or more and 160 ° C. or less in order to match the temperature of the manufacturing process of the solar cell module 1.

The curing conditions for the solder and the silver paste are in accordance with the curing conditions for each material constituting the solder and the silver paste. In general, techniques such as hot air reflow, IR reflow, oven heating, hot plate heating, and vacuum pressure lamination can be used to cure the solder and silver paste.
By providing the precoat solder 14 on the aluminum foil 13, it is possible to reliably connect the conductive connection material 26 that is thermally melted to the aluminum foil 13 through the precoat solder 14 as described later.

If the sealing material 30 can seal and insulate the photovoltaic cell 20 on the aluminum foil 13 and the insulating adhesive layer 12, it can be comprised from an appropriate material. Examples of suitable materials for the sealing material 30 include an ethylene / vinyl acetate copolymer (EVA) film.
When the sealing material 30 is composed of an EVA film, the sealing material 30 may be formed by laminating two or more EVA films so as to sandwich the solar battery cell 20.

  The translucent substrate 40 is a member that guides incident light to the light receiving surface 22 of the solar battery cell 20 and forms an outer surface on the opposite side of the solar battery backsheet 18 in the solar battery module 1. In the present embodiment, the translucent substrate 40 employs a configuration in which a glass panel is bonded to the surface of the sealing material 30.

Next, the manufacturing method of the metal foil laminated body 10 of this embodiment which manufactures the metal foil laminated body 10 of the solar cell module 1 comprised as mentioned above is demonstrated.
First, an aluminum foil 13 for forming a wiring pattern is laminated and bonded onto the base material 11 via an insulating adhesive layer 12. A resist is patterned on the surface of the obtained aluminum foil 13 laminate, and after etching the aluminum foil 13 by chemical etching, the resist is removed.

When the etching solution residue of the aluminum foil 13 remains on the insulating adhesive layer 12 at the time of chemical solution etching, it causes electric migration. Further, the wiring pattern of the aluminum foil 13 may be formed by punching with a mold.
The base material part 10a is formed by the above process.

Next, a method for laminating the precoat solder 14 on the aluminum foil 13 will be described. In this example, as shown in FIG. 3, the base material portion 10a is placed in the thickness direction D of the base material 11 with respect to the ultrasonic solder (solder supply body) 50 and the ultrasonic soldering iron 51 using a roll-to-roll method. A case of moving in a creeping direction E perpendicular to the direction will be described. In this example, although not shown, six sets of ultrasonic solders 50 and ultrasonic soldering irons 51 are provided corresponding to the number of precoat solders 14 to be formed.
In the roll-to-roll method, the base material portion 10a is sent out from a roll 10b formed by winding the base material portion 10a by rotating the roll 10b with a motor (not shown), etc., and after a predetermined treatment, The material part 10a is wound into a roll shape.

The ultrasonic solder 50 is formed in a rod shape having a constant thickness, and is sent out at a constant speed in the thickness direction D on the base member 10a side by a feed mechanism (not shown). The ultrasonic solder 50 becomes the above-mentioned precoat solder 14 when solidified after being heated and melted at a temperature equal to or higher than the melting point of the ultrasonic solder 50. That is, the ultrasonic solder 50 has almost the same composition as the precoat solder 14.
Although not shown, the ultrasonic soldering iron 51 is provided with a known heating device and ultrasonic generator. The tip 50a of the ultrasonic solder 50 is melted by the heating device. On the other hand, when an ultrasonic wave is applied to the tip 50a of the ultrasonic solder 50 by the ultrasonic generator, bubbles (not shown) generated in the melted portion of the ultrasonic solder 50 are ruptured.

  In a state where the tip 50a of the ultrasonic solder 50 in such a state is pressed against the aluminum foil 13, as shown in FIGS. 4 and 5, the base material portion 10a is opposed to the tip 50a of the ultrasonic solder 50. Is moved in the creeping direction E. At this time, the molten ultrasonic solder 50 is supplied to the region R on the insulating adhesive layer 12, but the ultrasonic solder 50 in which the insulating adhesive layer 12 is melted is repelled. Oxide films and dirt on the surface of the aluminum foil 13 are removed by the cavitation effect caused by the burst of bubbles generated in the molten ultrasonic solder 50. The six precoat solders 14 formed by cooling and solidifying the molten ultrasonic solder 50 are disposed only on the aluminum foil 13. Each precoat solder 14 is formed at a position that can face the connection electrode 21 of the solar battery cell 20 based on the arrangement of the ultrasonic solder 50 and the ultrasonic soldering iron 51.

The precoat solder 14 needs to be formed so as to face the connection electrode 21 of the solar battery cell 20. Since the precoat solder 14 has good wettability and connection reliability with the conductive connection material 26, it is possible to reduce the connection electrical resistance between the precoat solder 14 and the conductive connection material 26.
Thus, after the process which forms the precoat solder 14 in the base material part 10a, the base material part 10a is wound again, and it is made roll shape.
The metal foil laminated body 10 is manufactured by the above process.

In addition, when manufacturing the solar cell module 1 using this metal foil laminated body 10, the electroconductive connection material 26 is mounted on the precoat solder 14 of the metal foil laminated body 10, and it heat-melts, or it heat-melts. The conductive connecting material 26 is dropped on the precoat solder 14. In this state, the molten conductive connecting material 26 is connected to the precoat solder 14 having good wettability with good adhesion.
Then, the connection electrode 21 of the solar battery cell 20 is placed on the conductive connection member 26 attached to the aluminum foil 13 and cooled. Thereby, the wiring pattern of the aluminum foil 13 and the connection electrode 21 of the solar battery cell 20 are fixed in a conductive state.

As described above, according to the metal foil laminate 10 and the method for manufacturing the metal foil laminate 10 of the present embodiment, the tip 50a of the ultrasonic solder 50 that is melted and subjected to ultrasonic waves is applied to the aluminum foil 13. In the pressed state, the base material portion 10 a is moved in the creeping direction E with respect to the ultrasonic solder 50. And the precoat solder 14 is formed by solidifying the molten ultrasonic solder 50. By applying ultrasonic waves to the melted ultrasonic solder 50, an oxide film or the like on the surface of the aluminum foil 13 is removed, and the surface of the aluminum foil 13 is easily and pre-coated on the aluminum foil 13 without chemical treatment. 14 can be provided.
By removing the oxide film on the surface of the aluminum foil 13, the aluminum foil 13 and the precoat solder 14 can be electrically connected reliably.

The precoated solder 14 is formed along the creeping direction E on the aluminum foil 13 by solidifying the molten ultrasonic solder 50 while moving the base material portion 10 a in the creeping direction E with respect to the ultrasonic solder 50. The melted ultrasonic solder 50 is repelled from the insulating adhesive layer 12, so that the precoat solder 14 can be formed linearly only on the aluminum foil 13 without forming the precoat solder 14 on the insulating adhesive layer 12. it can.
Thus, in the present invention, when the precoat solder 14 is formed, there is no need to move the ultrasonic solder 50 or the ultrasonic soldering iron 51 up and down (to approach or separate from the base material portion 10a). .
If the amount of the precoat solder 14 used is large, the manufacturing cost of the solar cell module 1 becomes high. Therefore, it is desirable that the area for applying the precoat solder 14 is as small as possible and that the thickness of the precoat solder 14 is reduced. For this reason, the ultrasonic solder 50 is drawn and applied in stripes using an ultrasonic soldering iron 51 instead of a technique of immersing the entire metal foil laminate 10 in a solder bath.
When the thickness of the precoat solder 14 is 3 μm or more and 50 μm or less, a uniform and crack-free solder film can be formed.

When viewed in the thickness direction D, a plurality of precoat solders 14 are formed side by side in the width direction F so as to be spaced from each other. By comprising in this way, the some precoat solder 14 connected with each connection electrode 21 of the photovoltaic cell 20 can be comprised compactly as a whole.
The precoat solder 14 contains no flux. Thereby, the water washing process after precoat solder 14 formation can be omitted, and the manufacturing cost of the solar cell module 1 can be reduced.

A roll-to-roll method is used to move the base material portion 10 a in the creeping direction E with respect to the ultrasonic solder 50. For this reason, the base material part 10a can be continuously sent out and the precoat solder 14 can be continuously formed on the aluminum foil 13. Even when the area of the aluminum foil 13 is large, the precoat solder 14 can be applied and installed at an arbitrary position on the aluminum foil 13 with high positional accuracy, high speed and low cost.
Moreover, according to the solar cell module 1 of the present embodiment, the cost can be reduced and the reliability of electrical connection can be increased.

  In the solar cell module 1, a plurality of solar cells 20 including the connection electrodes 21 arranged side by side along the creeping direction E are arranged side by side along the creeping direction E and the width direction F, respectively. For this reason, a large number of connection electrodes 21 are arranged along the creeping direction E in the solar cell module 1. By forming the precoat solder 14 linearly, the precoat solder 14 connected to the connection electrode 21 can be efficiently formed.

In the metal foil laminate 10 of this embodiment, the insulating adhesive layer 12 may also be applied and disposed on the substrate 11 in the same pattern as the wiring pattern of the aluminum foil 13.
Moreover, in the manufacturing method of the metal foil laminated body 10 of this embodiment, in order to improve the wettability of the ultrasonic solder 50 and the aluminum foil 13, after preheating the aluminum foil 13 or the whole base-material part 10a, it is aluminum. A molten ultrasonic solder 50 may be applied onto the foil 13. In this case, the preheating is desirably performed at a temperature lower by about 20 ° C. to 30 ° C. than the melting point of the ultrasonic solder 50.

The precoat solder 14 may be laminated on the aluminum foil 13 of the base material portion 10a by a roll-to-roll method in a state where the solar cell backsheet 18 is laminated on the base material portion 10a.
When the conductive connecting material 26 is cured, it is possible to reduce the process cost by using the lamination lamination process of the solar cell module 1.

Although one embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and modifications and combinations of configurations within the scope not departing from the gist of the present invention are also possible. included.
For example, in the said embodiment, you may form the pattern of the black or white insulating resin 60 in the arbitrary parts on the aluminum foil 13, like the solar cell module 2 shown in FIG. This insulating resin 60 needs to have electrical insulation.
When the insulating resin 60 is black, the color difference between the black color of the solar cell module 2 and the aluminum foil 13 is alleviated, and the appearance from the upper surface (from the translucent substrate 40 side) is black and the design is black. Improves. On the other hand, when the insulating resin 60 is white, sunlight is reflected by the insulating resin 60 from the lower side of the solar cell module 2 (the solar cell backsheet 18 side). This has the effect of improving efficiency.

Moreover, in the said embodiment, in the embodiment, each precoat solder 14 was formed so that it might extend linearly. However, the shape of each precoat solder 14 is not limited to this, and for example, the precoat solder may be formed to extend in a curved shape such as an arc shape.
The metal foil laminate 10 has six pre-coated solders 14. However, the number of precoat solders 14 included in the metal foil laminate 10 is not limited to this, and can be set to one or more desired numbers according to the number of connection electrodes 21 included in the solar battery cell 20.
The metal foil laminate 10 is assumed to include the solar cell backsheet 18. However, when using the base material 11 as the solar cell backsheet 18 as described above, the metal foil laminate 10 may be configured not to include the solar cell backsheet 18.

In the embodiment, the base material portion 10 a is moved in the creeping direction E with respect to the tip portion 50 a of the ultrasonic solder 50 in a state where the tip portion 50 a of the ultrasonic solder 50 is pressed against the aluminum foil 13. However, in this pressed state, the ultrasonic solder 50 and the ultrasonic soldering iron 51 may be moved in the creeping direction E with respect to the base material portion 10a.
A solder containing no flux was used as the ultrasonic solder. However, solder containing flux in ultrasonic solder may be used.
The base material portion 10a was moved in the creeping direction E with respect to the ultrasonic solder 50 by a roll-to-roll method. However, the base material portion 10a may be moved with respect to the ultrasonic solder 50 by placing the base material portion 10a on the conveyance path and sending out the base material portion 10a.

In the said embodiment, although the thickness of the precoat solder 14 was 3 micrometers or more and 50 micrometers or less, the thickness of the precoat solder 14 may be less than 3 micrometers and may exceed 50 micrometers.
Moreover, the metal foil laminated body 10 by embodiment of this invention can also be used not only as the solar cell module 1, but as what comprises various conductive patterns, such as an antenna of an IC tag, a conductor, and a circuit pattern. . The use of the metal foil laminate 10 in the present invention is arbitrary.

1, 2 Solar cell module 10 Metal foil laminate (metal foil laminate for solar cell)
DESCRIPTION OF SYMBOLS 10a Base part 10b Roll 11 Base 11a One side 11b The other side 12 Insulating adhesive layer 13 Aluminum foil 14 Precoat solder (solder part)
18 Solar cell back sheet 20 Solar cell 21 Connection electrode 30 Sealing material 40 Translucent substrate 50 Ultrasonic solder (solder supply body)
50a Tip D Thickness direction F Width direction L Thickness

Claims (8)

A metal foil laminate for a solar battery for wiring to a solar battery cell having a connection electrode for wiring,
A sheet-like base material having flexibility;
Aluminum foil laminated on one surface of the base material via an insulating adhesive layer, and forming a wiring pattern on the base material,
On the aluminum foil, a solder part provided at a position that can be opposed to the connection electrode;
With
When viewed in the thickness direction of the base material, the solder part is formed on the aluminum foil so as to extend linearly.   The thickness of the said solder part is 3 micrometers or more and 50 micrometers or less, The metal foil laminated body for solar cells of Claim 1 characterized by the above-mentioned.   3. The metal for solar cells according to claim 1, wherein when viewed in the thickness direction, a plurality of the solder portions are formed side by side in the width direction of the solder portions at intervals. Foil laminate.   The solar cell metal foil laminate according to any one of claims 1 to 3, wherein a solar cell backsheet is laminated on the other surface of the substrate. A method for producing a solar battery metal foil laminate for wiring to solar cells having connection electrodes for wiring,
A base formed by laminating a flexible sheet-like base material and an aluminum foil laminated on one surface of the base material via an insulating adhesive layer and forming a wiring pattern on the base material Forming the material part,
In a state where the tip of the solder supply body that is melted and subjected to ultrasonic waves is pressed against the aluminum foil, the base portion and the tip of the solder supply body are orthogonal to the thickness direction of the base material. A metal foil laminate for a solar cell, wherein a solder part is formed at a position that can be opposed to the connection electrode on the aluminum foil by moving the solder supply body relatively in a direction and solidifying the molten solder supply body Manufacturing method.   The method for producing a metal foil laminate for a solar cell according to claim 5, wherein the solder supplier does not contain a flux.   From the roll formed by winding the base material part to move the base material part and the tip of the solder supply body relatively in the direction orthogonal to the thickness direction of the base material. A roll-to-roll method using a roll-to-roll system in which a part is fed out and wound after forming the solder part on the base part is used. Production method. The metal foil laminate for solar cells according to any one of claims 1 to 4,
A solar battery cell having a connection electrode for wiring, the connection electrode being connected to the solder portion of the metal foil laminate for solar battery via a conductive connection material,
A sealing material for sealing the solar battery cell;
A translucent substrate laminated on the surface opposite to the solar cell metal foil laminate of the encapsulant;
A solar cell module comprising:

Images