JP2017183693A - Method of manufacturing solar battery module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a solar battery module capable of preventing a light reflecting member sticking step of sticking a light reflecting member from disturbing a series of manufacturing steps, and suppressing breakage of a solar battery string.SOLUTION: A method of manufacturing a solar battery module includes a light reflecting member arranging step (S4) of arranging a light reflecting member 30 so that the light reflecting member 30 straddles the gap between two adjacent solar battery cells 10 placed on a working table 90, and a light reflecting member sticking step (S5) for thermally crimping overlap areas of the light reflecting member 30 and the solar battery cell 10 by using a crimping head 110 having first and second thermally crimping portions 112 and 113 having a contact surface 115b in contact with the light reflecting member 30, and a thermally non-crimping portion 111 which is pinched by the first and second thermally crimping portions 112 and 113 and does not thermally crimp the light reflecting member 30, thereby sticking the light reflecting member 30 to the end portion of the solar battery cell 10.SELECTED DRAWING: Figure 5

Description

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

  Conventionally, a solar battery cell and a solar battery cell adjacent to the solar battery cell are fixed by a fixing member (an example of a light reflecting member) that has a gap and is bonded across both solar battery cells. A known solar cell module is known (see, for example, Patent Document 1).

JP 2014-183289 A

  However, in conventional solar cell modules, it is conceivable to provide a step of applying pressure or a step of heating when the light reflecting member is attached to the solar cell. The manufacturing process of the solar battery module includes a process of heating and pressurizing when connecting the wiring to the solar battery cell, and heating and pressurizing when the solar battery cell is sealed in a sealing material such as resin. Process may be included. Moreover, the manufacturing process of a solar cell also includes the process of conveying the components under manufacture between each process as mentioned above. Therefore, it is desired that the heating and pressurizing steps when the light reflecting member is attached to the solar battery cell not interfere with other manufacturing steps.

  An object of the present invention is to provide a method for manufacturing a solar cell module capable of suppressing the step of attaching a light reflecting member from interfering with a series of manufacturing steps and suppressing damage to the solar cell string. And

  In order to achieve the above object, one aspect of a method for manufacturing a solar cell module according to the present invention is to arrange a light reflecting member so as to straddle a gap between two adjacent solar cells placed on a workbench. A light reflecting member arranging step, two thermocompression bonding parts having a contact surface in contact with the light reflecting member, and a non-thermocompression bonding part that is sandwiched between the two thermocompression bonding parts and does not thermocompression bond the light reflecting member. A light reflecting member attaching step of attaching the light reflecting member to an end portion of the solar battery cell by thermocompression bonding of the overlapping region between the light reflecting member and the solar battery cell using a pressure-bonding head.

  ADVANTAGE OF THE INVENTION According to this invention, it can suppress that the process of sticking a light reflection member becomes a hindrance of a series of manufacturing processes, and can suppress the failure | damage of a solar cell string.

4 is a plan view of the solar cell module according to Embodiment 1. FIG. 4 is a partially enlarged plan view of the solar cell module according to Embodiment 1. FIG. It is sectional drawing of the solar cell module which concerns on Embodiment 1 in the III-III line of FIG. It is an expanded sectional view of the solar cell module which concerns on Embodiment 1 in the IV-IV line of FIG. It is a perspective view of the crimping | compression-bonding apparatus and solar cell string which concern on Embodiment 1. FIG. It is sectional drawing which shows the crimping | compression-bonding head of the crimping | bonding apparatus which concerns on Embodiment 1 in the VI-VI line of FIG. 3 is a block diagram showing a crimping apparatus in the method for manufacturing a solar cell module according to Embodiment 1. FIG. 3 is a flowchart showing a method for manufacturing the solar cell module according to Embodiment 1. It is explanatory drawing which shows the string formation process and pressing process of the manufacturing method of the solar cell module which concerns on Embodiment 1. FIG. FIG. 10A is an explanatory view showing the state of the solar cell string of the solar cell module according to Embodiment 1 taken along line XX of FIG. B of FIG. 10 is explanatory drawing which shows the pressing process of the manufacturing method of the solar cell module which concerns on Embodiment 1 in the XX of FIG. It is explanatory drawing which shows the light reflection member arrangement | positioning process and light reflection member sticking process of the manufacturing method of the solar cell module which concerns on Embodiment 1. FIG. It is explanatory drawing which shows the laminated body formation process and the lamination process of the manufacturing method of the solar cell module which concerns on Embodiment 1. FIG. It is sectional drawing which shows the crimping | compression-bonding head of the crimping apparatus which concerns on the modification of Embodiment 1 in the VI-VI line of FIG. FIG. 14A is an explanatory diagram showing a state in which a light reflecting member is thermocompression bonded to a solar battery cell using a pressure roller in the method for manufacturing a solar battery module according to Embodiment 2. 14B is a cross-sectional view showing the pressure roller of the pressure bonding apparatus according to the second embodiment taken along the line XIVB-XIVB in FIG. 14A. In the manufacturing method of the solar cell module which concerns on the modification of Embodiment 2, it is explanatory drawing which shows the state which thermocompression-bonds a light reflection member to a photovoltaic cell using a pressurizing roller. It is a perspective view of the crimping | compression-bonding apparatus which concerns on Embodiment 3, and a solar cell string. FIG. 17A is an enlarged perspective view showing a crimping head of the crimping apparatus according to the third embodiment. FIG. 17B is an enlarged perspective view showing the pressure-bonding head of the pressure-bonding apparatus according to the third embodiment. It is a perspective view of the preparation stand and light reflection member which concern on Embodiment 3. FIG. 10 is a flowchart of a method for manufacturing a solar cell module according to Embodiment 3. FIG. 10 is an explanatory diagram showing a moving process of the method for manufacturing a solar cell module according to Embodiment 3. It is explanatory drawing which shows the light reflection member arrangement | positioning process and lamination process of the manufacturing method of the solar cell module which concerns on Embodiment 3. FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Each of the embodiments described below shows a preferred specific example of the present invention. Therefore, the numerical values, shapes, materials, components, arrangement positions and connection forms of the components shown in the following embodiments are merely examples, and are not intended to limit the present invention. Therefore, among the constituent elements in the following embodiments, constituent elements that are not described in the independent claims showing the highest concept of the present invention are described as optional constituent elements.

  In addition, the description of “substantially **” is intended to include not only exactly the same, but also those that are recognized as being substantially the same, with “substantially identical” as an example.

  Each figure is a schematic diagram and is not necessarily illustrated strictly. Moreover, in each figure, the same code | symbol is attached | subjected to the substantially same structure, The overlapping description is abbreviate | omitted or simplified.

(Embodiment 1)
Hereinafter, the configuration of the solar cell module 1 according to Embodiment 1 will be described with reference to FIGS.

[Constitution]
FIG. 1 is a plan view of solar cell module 1 according to Embodiment 1. FIG. FIG. 2 is a partially enlarged plan view of solar cell module 1 according to Embodiment 1. FIG. FIG. 3 is a cross-sectional view of solar cell module 1 according to Embodiment 1 taken along line III-III in FIG. FIG. 4 is an enlarged cross-sectional view of solar cell module 1 according to Embodiment 1 taken along line IV-IV in FIG.

  In FIG. 1, a direction in which twelve solar cells 10 arranged at equal intervals along the row direction are aligned is defined as an X-axis direction. The direction in which the six solar cell strings 11 are arranged in the column direction so that the two adjacent solar cell strings 11 are parallel to each other is defined as the Y-axis direction. The vertical direction is defined as the Z-axis direction. In FIG. 1, the X-axis direction, the Y-axis direction, and the Z-axis direction change depending on the usage mode, and are not limited to this. The same applies to each figure after FIG.

  The “front surface” of the solar cell module 1 means a surface on which light on the “front surface” side of the solar battery cell can be incident, and the “back surface” of the solar cell module 1 means a surface on the opposite side. The “front surface” of the solar cell module 1 is the upper side (plus Z-axis direction), and the “back surface” of the solar cell module 1 is the lower side (minus Z-axis direction).

  A solar cell module 1 shown in FIG. 1 is a module that is installed in plural on the roof of a facility such as a house. The solar cell module 1 has a structure in which a plurality of solar cells 10 are sealed with a filling member 60 between a surface protection member 40 (an example of a light-transmitting substrate) and a back surface protection member 50 (an example of a light-transmitting substrate). It has become. For example, the solar cell module 1 has a substantially rectangular flat plate shape in XY plan view. As an example, the solar cell module 1 has a substantially rectangular shape with a length in the row direction of about 1600 mm and a length in the column direction of about 800 mm. In addition, the shape of the solar cell module 1 is not limited to a shape in which six solar cell strings 11 including 12 solar cells 10 are arranged, and is not limited to a rectangular shape.

  The solar cell module 1 includes a plurality of solar cells 10, a wiring member 20 (interconnector), a light reflecting member 30, a surface protection member 40, a back surface protection member 50, a filling member 60, and a frame 7. I have.

  The solar cell 10 is a photoelectric conversion element (photovoltaic element) that converts light such as sunlight into electric power. A plurality of solar cells 10 are arranged in a matrix (matrix shape) on the same plane to constitute a cell array.

  A plurality of solar cells 10 arranged in a straight line along one of the row direction and the column direction are connected to each other by two wiring cells 20 to form a solar cell string 11 (cell string). It is composed. A plurality of solar cells 10 in one solar cell string 11 are connected in series by a wiring member 20.

  The solar cell string 11 is an aggregate of solar cells 10 in which twelve solar cells 10 arranged at equal intervals along the row direction are connected by a wiring material 20. More specifically, each solar cell string 11 is configured by sequentially connecting two solar cells 10 adjacent in the row direction with three wiring members 20 and arranged along the row direction. All the solar cells 10 corresponding to one row are connected.

  A plurality of solar cell strings 11 are formed. The plurality of solar cell strings 11 (solar cell strings) are arranged along the other in the row direction or the column direction. In the present embodiment, six solar cell strings 11 are formed. The six solar cell strings 11 are arranged at equal intervals along the column direction so as to be parallel to each other.

  Two adjacent solar cell strings 11 are connected to the connection wiring 21 via the wiring member 20 at both ends in the row direction. The solar cell string 11 connected to the connection wiring 21 is connected to the solar cell string 11 on the other end side (plus X-axis side) by the connection wiring 21. The connection wiring 21 is a wiring member that connects the solar cell strings 11 together. Thus, a plurality of solar cell strings 11 are connected in series or in parallel to form a cell array. The connection wiring 21 is a wiring member that connects the solar cell strings 11 together. In the present embodiment, six adjacent solar cell strings 11 are connected in series to form one series connection body (a structure in which 72 solar cells 10 are connected in series).

  As shown in FIG. 2, the two photovoltaic cells 10 adjacent in the row direction and the column direction are arranged with a gap therebetween. As will be described later, the light reflecting member 30 is disposed across the gap.

  The solar battery cell 10 has a substantially rectangular flat plate shape in the XY plan view. Specifically, the solar battery cell 10 has a shape in which a 125 mm square substantially square corner is lacking, and a linear long side and a linear or non-linear short side are alternately connected. It is an octagonal shape. That is, one solar cell string 11 is configured such that one side of two adjacent solar cells 10 faces each other. In addition, the shape of the photovoltaic cell 10 is not restricted to a substantially rectangular shape.

  The solar cell 10 has a semiconductor pn junction as a basic structure, and as an example, the n-type single crystal silicon substrate that is an n-type semiconductor substrate and one main surface side of the n-type single crystal silicon substrate are sequentially formed. , An n-type amorphous silicon layer and an n-side electrode, and a p-type amorphous silicon layer and a p-side electrode sequentially formed on the other main surface side of the n-type single crystal silicon substrate. Note that a passivation layer such as an i-type amorphous silicon layer, a silicon oxide layer, or a silicon nitride layer may be provided between the n-type single crystal silicon substrate and the n-type amorphous silicon layer. Further, a passivation layer may be provided between the n-type single crystal silicon substrate and the p-type amorphous silicon layer. The n-side electrode and the p-side electrode are transparent electrodes such as ITO (Indium Tin Oxide).

  In addition, although the photovoltaic cell 10 is arrange | positioned so that an n side electrode may become the main light-receiving surface side (surface protection member 40 side) of the solar cell module 1, it does not restrict to this. Moreover, when the solar cell module 1 is a single-sided light receiving system, the electrode located in the back surface side (p-side electrode in this Embodiment) does not need to be transparent, for example, is a metal electrode which has reflectivity, Also good.

  As shown in FIG. 3, in each solar cell 10, this surface is a surface on the surface protection member 40 side (plus Z-axis direction side), and the back surface is a surface on the back surface protection member 50 side (minus Z-axis direction side). It is. In the solar battery cell 10, a front surface collecting electrode 12 and a back surface collecting electrode 13 are formed. The surface collection electrode 12 is electrically connected to the surface side electrode (for example, n side electrode) of the photovoltaic cell 10. The back surface collection electrode 13 is electrically connected to the back surface side electrode (for example, p side electrode) of the photovoltaic cell 10.

  Each of the front surface collecting electrode 12 and the back surface collecting electrode 13 includes, for example, a plurality of finger electrodes formed in a straight line so as to be orthogonal to the extending direction of the wiring member 20, and finger fingers connected to these finger electrodes It is comprised by the several bus-bar electrode formed in linear form along the direction (extension direction of the wiring material 20) orthogonal to an electrode. For example, the number of bus bar electrodes is the same as that of the wiring member 20 and is three in the present embodiment. The front collector electrode 12 and the rear collector electrode 13 have the same shape as each other, but are not limited thereto.

  The front surface collecting electrode 12 and the back surface collecting electrode 13 are made of a low resistance conductive material such as silver (Ag). For example, the front surface collecting electrode 12 and the back surface collecting electrode 13 can be formed by screen-printing a conductive paste (silver paste or the like) in which a conductive filler such as silver is dispersed in a binder resin in a predetermined pattern.

  In this solar cell 10, both the front surface and the back surface are light receiving surfaces. When light enters the solar battery cell 10, carriers are generated in the photoelectric conversion part of the solar battery cell 10. The generated carriers are collected by the front surface collecting electrode 12 and the back surface collecting electrode 13 and flow into the wiring member 20. In this solar cell 10, by providing the front collector electrode 12 and the rear collector electrode 13, carriers generated in the solar cell 10 can be efficiently taken out to an external circuit.

  As shown in FIG. 2, the wiring member 20 electrically connects two adjacent solar cells 10 in the solar cell string 11. In the present embodiment, two adjacent solar cells 10 are connected by three wiring members 20 arranged substantially in parallel with each other. Each wiring member 20 extends along the direction in which two adjacent solar cells 10 to be connected are arranged.

  The wiring member 20 is a long conductive wiring, and is, for example, a ribbon-like metal foil or a fine-line metal wire. The wiring member 20 is produced, for example, by cutting a metal foil such as a copper foil or a silver foil, which is covered with a solder material, silver, or the like into a strip having a predetermined length.

  For each wiring member 20, one end of the wiring member 20 is disposed on the surface of one of the two adjacent solar cells 10, and the other end of the wiring member 20 is adjacent to 2. It arrange | positions at the back surface of the other photovoltaic cell 10 among the two photovoltaic cells 10. FIG.

  Each wiring member 20 includes an n-side collector electrode (front-side collector electrode) of one solar cell 10 and a p-side collector electrode (rear surface side) of the other solar cell 10 in two adjacent solar cells 10. Are electrically connected to each other. Specifically, the wiring member 20 is joined to the bus bar electrode of the front surface collecting electrode 12 of one solar cell 10 and the bus bar electrode of the back surface collecting electrode 13 of the other solar cell 10. The wiring member 20 and the front surface collecting electrode 12 (back surface collecting electrode 13) are bonded by, for example, thermocompression bonding with a conductive adhesive interposed therebetween.

  As the conductive adhesive, for example, a conductive adhesive paste, a conductive adhesive film, or an anisotropic conductive film can be used. The conductive adhesive paste is, for example, a paste adhesive in which conductive particles are dispersed in a thermosetting adhesive resin material such as an epoxy resin, an acrylic resin, or a urethane resin. The conductive adhesive film and the anisotropic conductive film are formed in a film form by dispersing conductive particles in a thermosetting adhesive resin material.

  The wiring member 20 and the front surface collecting electrode 12 (back surface collecting electrode 13) may be joined by a solder material instead of the conductive adhesive. Moreover, it may replace with a conductive adhesive and may use the resin adhesive which does not contain electroconductive particle. In this case, by appropriately designing the application thickness of the resin adhesive, the resin adhesive softens during pressurization during thermocompression bonding, and the surface of the surface collector electrode 12 and the wiring member 20 are brought into direct contact to electrically Connect.

  As shown in FIG. 4, the solar battery cell 10 is provided with a light reflecting member 30. The light reflecting member 30 is provided in each of the plurality of solar cells 10.

  The light reflecting member 30 is disposed so as to be positioned in a gap between two adjacent solar battery cells 10. In the present embodiment, the light reflecting member 30 is provided in each of the two adjacent solar cells 10 so as to straddle the gap between the two adjacent solar cells 10 in the Y direction. Each gap between two adjacent solar cells 10 is between one side of one solar cell 10 and one side of the other solar cell 10 facing this side. That is, the gap between two adjacent solar cells 10 is long in the row direction and extends in a direction parallel to the solar cell string 11. That is, the light reflecting member 30 is provided so as to straddle from one solar battery cell 10 to the other solar battery cell 10 on the back side of two adjacent solar battery cells 10 arranged with a gap.

  In the present embodiment, the light reflecting member 30 is provided with two light reflecting members 30 in one solar battery cell 10 except for the solar battery cell 10 of the outermost solar cell string 11. The light reflecting member 30 has a tape shape extending in the row direction of the solar cell string 11, and has a long rectangular shape as an example. The light reflecting member 30 is attached along one side of the solar battery cell 10 so that one end in the width direction (Y-axis direction) and the end of the solar battery 10 overlap each other. That is, the light reflecting member 30 is affixed substantially parallel to the wiring member 20.

  The light reflecting member 30 includes a resin base material 31 and a reflective film 32 formed on the back surface of the resin base material 31 (the surface on the minus Z-axis side of the resin base material 31). The resin substrate 31 is made of, for example, polyethylene terephthalate (PET) or acrylic. The reflective film 32 is a metal film made of a metal such as aluminum or silver, and is an aluminum vapor deposition film in the present embodiment.

  Here, the uneven part 30a is formed in the back surface of the resin base material 31, and the reflective film 32 is formed in the uneven part 30a (back surface) of the resin base material 31 by vapor deposition. In this way, the resin base material 31 and the reflective film 32 are laminated, and the light reflecting member 30 having an uneven shape on the back surface is configured. When the light incident on the solar cell module 1 is incident on the surface of the light reflecting member 30, the concavo-convex portion 30a scatters the light, or the interface between the surface protective member 40 and the air layer or the surface protective member 40 and the filling member. It is possible to guide the solar cell 10 by reflecting it at the interface with the solar cell 60. Thereby, the light incident on the region of the gap between two adjacent solar cells 10 also effectively contributes to power generation, so that the power generation efficiency of the solar cell module 1 is improved.

  The light reflecting member 30 has a long rectangular shape, for example, a length of 100 mm to 130 mm, a width of 1 mm to 20 mm, and a thickness of 0.05 mm to 0.5 mm. In the present embodiment, the light reflecting member 30 has a length of 125 mm, a width of 5 mm, and a thickness of 0.1 mm.

  Moreover, the thickness of the resin base material 31 is 50 micrometers-500 micrometers, for example. In the concavo-convex portion 30a, for example, the height between the concave portion and the convex portion is 20 μm or more and 100 μm or less, and the interval (pitch) between adjacent convex portions is 20 μm or more and 400 μm or less. In this Embodiment, the height between a recessed part and a convex part is 12 micrometers, and the space | interval (pitch) of an adjacent convex part is 40 micrometers.

  In addition, although the shape of the concavo-convex portion 30a is a triangular groove shape along the longitudinal direction of the light reflecting member 30, it is not limited to this, and the light reflecting member can be used as long as it can scatter light. A triangular groove shape, a conical shape, a quadrangular pyramid shape, a polygonal pyramid shape, or a combination of these shapes along a direction intersecting the longitudinal direction of 30 may be used.

  The light reflecting member 30 is bonded to the surface of the resin base material 31 (the surface on the plus Z-axis side of the resin base material 31) and the negative Z-axis side surface of the solar battery cell 10 with the resin adhesive 33 to attach the solar battery cell 10. Is provided. For example, the light reflecting member 30 and the solar battery cell 10 are bonded by thermocompression bonding with the resin adhesive 33 interposed therebetween. The resin adhesive 33 is, for example, a heat-sensitive adhesive or a pressure-sensitive adhesive made of EVA, and may be provided in advance on the surface of the resin base material 31. That is, the light reflecting member 30 may be configured by the resin base material 31, the reflective film 32, and the resin adhesive 33. Thereby, the light reflection member 30 is bonded and fixed to the solar battery cell 10 by thermocompression bonding. Moreover, in this Embodiment, the light reflection member 30 is affixed on the back surface side of the solar cell module 1. FIG.

  The surface protection member 40 is a member that protects the surface of the solar cell module 1 and protects the inside of the solar cell module 1 (solar cell 10 or the like) from an external environment such as wind and rain or an external impact. The surface protection member 40 is disposed on the front surface side of the solar battery cell 10 and protects the light receiving surface on the front surface side of the solar battery cell 10.

  Since the surface protection member 40 is provided on the surface side of the solar battery cell 10, the surface protection member 40 is configured by a translucent member that transmits light in a wavelength band used for photoelectric conversion in the solar battery cell 10. The surface protection member 40 is, for example, a glass substrate (transparent glass substrate) made of a transparent glass material, or a resin substrate made of a hard resin material having a film-like or plate-like translucency and water shielding property.

  On the other hand, the back surface protection member 50 is a member that protects the back surface of the solar cell module 1 and protects the inside of the solar cell module 1 from the external environment. The back surface protection member 50 is disposed on the back surface side of the solar battery cell 10.

  In this Embodiment, the back surface of the photovoltaic cell 10 is also a light-receiving surface. Therefore, the back surface protection member 50 protects the light receiving surface on the back side of the solar battery cell 10 and is made of a translucent member. The back surface protection member 50 is a film-like or plate-like resin sheet made of a resin material such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN). In addition, as the back surface protection member 50, a glass sheet or a glass substrate made of a glass material may be used.

  In addition, when there is no light incident from the back surface side of the photovoltaic cell 10, the back surface protection member 50 is good also as an opaque board or film. In this case, as the back surface protection member 50, for example, an opaque member (light-shielding member) such as a black member or a laminated film such as a resin film having a metal foil such as an aluminum foil therein may be used.

  A filling member 60 is filled between the front surface protection member 40 and the back surface protection member 50. The front surface protection member 40 and the back surface protection member 50 and the solar battery cell 10 are bonded and fixed by the filling member 60.

  The filling member 60 (filler) is disposed between the front surface protection member 40 and the back surface protection member 50. In the present embodiment, the filling member 60 is filled so as to fill a space between the surface protection member 40 and the back surface protection member 50.

  The filling member 60 is made of a translucent resin material such as ethylene vinyl acetate (EVA). The filling member 60 is formed by sandwiching a plurality of solar cells 10 between the front surface side filling member 61 and the back surface side filling member 62. For example, the filling member 60 is formed by laminating (laminating) two resin sheets (EVA sheets) sandwiching six solar cell strings 11.

  The frame 7 is an outer frame that covers the peripheral edge of the solar cell module 1. The frame 7 in the present embodiment is an aluminum frame (aluminum frame) made of aluminum. Four frames 7 are used, and are mounted on each of the four sides of the solar cell module 1. The frame 7 is fixed to each side of the solar cell module 1 with an adhesive, for example.

  Note that the solar cell module 1 is provided with a terminal box (not shown) for taking out the electric power generated by the solar cells 10. The terminal box is fixed to the back surface protection member 50, for example. The terminal box contains a plurality of circuit components such as diodes for preventing the occurrence of hot spots.

[Manufacturing method: 1-1 Configuration of crimping apparatus]
In manufacturing the solar cell module 1, the crimping device 100 is used. First, the structure of the crimping | compression-bonding apparatus 100 is demonstrated using FIGS.

  FIG. 5 is a perspective view of the crimping device 100 and the solar cell string 11 according to the first embodiment. 6 is a cross-sectional view showing the crimping head 110 of the crimping apparatus 100 according to the first embodiment taken along line VI-VI in FIG. FIG. 7 is a block diagram showing the crimping apparatus 100 in the method for manufacturing the solar cell module 1 according to Embodiment 1. FIG. 5 shows a state in which the pressure-bonding head 110 is moving while the pressure-bonding head 110 holds the light-reflecting member 30 in the light-reflecting member arrangement step (S4). In FIG. 5, the work table 90, the preparation table 91, the holding jig 70, and the like are omitted.

  As shown in FIG. 5, in the production of the solar cell module 1, the crimping device 100 is used to place the light reflecting member 30 in each of the two adjacent solar cells 10 and perform thermocompression bonding. The crimping apparatus 100 includes a transport unit 101 and an apparatus main body unit 102.

  The transport unit 101 includes a plurality of crimping heads 110, a plurality of heat source units 120, and an arm unit 130.

  The arm unit 130 is controlled by the apparatus main body 102 in FIG. 7 and is freely moved by the apparatus main body 102. In the present embodiment, the arm portion 130 includes a first support portion 131 that extends in the row direction parallel to the solar cell string 11, and a second support portion 132 that is orthogonal to the central portion of the first support portion 131. Yes.

  The first support portion 131 is provided with a plurality of crimping heads 110 on the solar cell string 11 side. In the present embodiment, twelve crimping heads 110 are provided on the first support portion 131.

  The crimping head 110 is a long casing extending in the row direction (longitudinal direction). The crimping heads 110 are fixed to the first support part 131 via the heat source part 120 and are arranged in a line at substantially equal intervals in the row direction. Specifically, in the XY plan view, the crimping head 110 is substantially disposed on the first support portion 131 so as to correspond to the arrangement region R1 in the solar cell string 11 arranged in the row direction of two adjacent solar cells 10. They are arranged in a line at equal intervals. The arrangement region R1 is a region where the gap between the two adjacent solar cells 10 and the light reflecting member 30 overlap with each other, and a region where a part of the light reflecting member 30 overlaps the end of the solar cell 10 in the XY plan view. (Overlapping region). When the pressure bonding head 110 is lowered toward the solar battery cell 10, the pressure bonding heads 110 are arranged in a row at substantially equal intervals on the first support portion 131 so as to substantially coincide with the arrangement region R <b> 1. That is, the light reflecting member 30 and the arrangement region R1 have substantially the same shape and the same size in the XY plan view. In the present embodiment, the crimping heads 110 are arranged in a row in the row direction, but when there are three or more solar cell strings, they are provided in two or more columns so as to correspond to all the arrangement regions R1. May be.

  As shown in FIG. 6, the crimping head 110 is held horizontally by the first support part 131 and has a non-thermocompression bonding part 111, a first thermocompression bonding part 112, and a second thermocompression bonding part 113. .

  The non-thermocompression bonding portion 111 has a long plate shape extending in the row direction. The non-thermocompression bonding portion 111 is a region that is not thermocompression bonded by the pressure bonding head 110 when the light reflecting member 30 is disposed in the arrangement region R1 of FIG. The non-thermocompression bonding part 111 corresponds to a gap between two adjacent solar battery cells 10. In the present embodiment, the inside of the groove 116 is hollow, but the inside may be filled with a material having low thermal conductivity so that the light reflecting member 30 is not bonded to the solar battery cell 10. In this case, a portion filled with a material having low thermal conductivity is also a non-thermocompression bonding portion.

  The 1st thermocompression bonding part 112 and the 2nd thermocompression bonding part 113 comprise the elongate plate shape extended in a row direction at the both ends in the column direction of the non-thermocompression bonding part 111, and are directed downward from the non-thermocompression bonding part 111. It extends. Specifically, the first thermocompression bonding part 112 is provided so as to extend downward from the plus Y-axis side of the non-thermocompression bonding part 111. The second thermocompression bonding part 113 is provided so as to extend downward from the negative Y-axis side of the non-thermocompression bonding part 111. The first thermocompression bonding part 112 and the second thermocompression bonding part 113 are in a substantially parallel relationship. That is, in the crimping head 110, the non-thermocompression bonding portion 111 forms the bottom of the groove 116 that is recessed upward from the lower end surface (minus Z-axis side surface) of the crimping head 110. The groove 116 penetrates in the row direction. That is, the crimping head 110 is formed in a U shape when viewed from the row direction. The crimping head 110 is made of a metal such as copper, iron, or aluminum, or an alloy containing these metals.

  The lower end surfaces of the first thermocompression bonding part 112 and the second thermocompression bonding part 113 are areas where the light reflecting member 30 is bonded to the solar battery cell 10. Specifically, the heated first thermocompression bonding part 112 and the second thermocompression bonding part 113 thermocompression bond (adhere) the light reflecting member 30 to the solar battery cell 10 via the elastic part 115. That is, the portion of the light reflecting member 30 that overlaps the end of the solar battery cell 10 in the XY plan view and the end of the solar battery cell 10 are bonded by thermocompression bonding with the resin adhesive 33. The thicknesses in the column direction of the first thermocompression bonding part 112 and the second thermocompression bonding part 113 are substantially the same as the thicknesses in the width direction in the overlapping region between the light reflecting member 30 and the solar battery cell 10.

  The first thermocompression bonding part 112 and the second thermocompression bonding part 113 have an elastic part 115 for thermocompression bonding the light reflecting member 30. The elastic part 115 is an elastic body such as silicon rubber. The elastic part 115 is provided along the lower end surfaces of the first thermocompression bonding part 112 and the second thermocompression bonding part 113. The elastic part 115 is configured to conduct heat of the heated first thermocompression bonding part 112 and the second thermocompression bonding part 113 so that the light reflecting member 30 can be thermocompression bonded to the solar battery cell 10. In other words, the lower end surface of the elastic portion 115 is a contact surface 115 b that contacts the reflective film 32 of the light reflecting member 30.

  The crimping head 110 has a plurality of intake holes 114. The intake holes 114 are formed in a row at substantially equal intervals in the non-thermocompression bonding part 111 of the groove part 116. The crimping head 110 sucks the light reflecting member 30 by sucking outside air from the suction hole 114. The adsorbed light reflecting member 30 is held horizontally. In the present embodiment, the outside air sucked from the intake hole 114 is directed to the apparatus main body 102 of the crimping apparatus 100, but is discharged from the discharge holes formed in the first support part 131, the second support part 132, and the like. May be. In this case, the pump 102b of FIG. 7 described later is provided in the first support part 131, the second support part 132, and the like.

  The heat source unit 120 is a heater that is provided on the upper surface of the crimping head 110 and heats the crimping head 110 at a constant temperature. The heat source unit 120 heats the pressure-bonding head 110 to a predetermined temperature in order to heat-press the light reflecting member 30 to the solar battery cell 10. The heat source unit 120 heats the crimping head 110 to a temperature at which the light reflecting member 30 can be thermocompression bonded to the solar battery cell 10. The temperature at which the heat source unit 120 heats the pressure-bonding head 110 is preferably a temperature from about 70 ° C. to about 80 ° C. In the present embodiment, twelve pressure-bonding heads 110 are provided with heat source sections 120, respectively.

  In the present embodiment, the first support portion 131 is provided in only one column in the row direction. However, when there are three or more solar cell strings as in the present embodiment, it corresponds to all the arrangement regions R1. As described above, two or more first support portions 131 may be provided.

  As shown in FIG. 7, the apparatus main body 102 controls a drive unit 102a that moves the arm unit 130 to a predetermined position, a pump 102b that adsorbs outside air, a drive unit 102a, a pump 102b, a heat source unit 120, and the like. A control unit 102c and the like are included.

  The drive unit 102a is driven by power supplied from the power unit 102d by the control unit 102c. For example, the drive unit 102a receives the operation start signal transmitted from the control unit 102c and starts the operation. The driving unit 102a receives the operation stop signal transmitted from the control unit 102c and stops the operation.

  The control unit 102c includes a control circuit for controlling a display unit (not shown) and a storage unit (not shown). The control unit 102c is configured by a processor, a microcomputer, or the like.

  As shown in FIGS. 5 and 7, the control unit 102c is configured to control the drive of the drive unit 102a, the drive of the pump 102b, the heating temperature of the heat source unit 120, and the like based on an operation program stored in advance. ing. The control unit 102c controls the drive unit 102a to cause the arm unit 130 to perform a predetermined operation. Specifically, the drive unit 102a moves the crimping head 110 and the like from the position where the light reflecting member 30 is attracted to the crimping head 110 of the arm unit 130 to the arrangement region R1. The control unit 102c controls the amount of intake air of the pump 102b in order to cause the light reflecting member 30 to be attracted to the pressure bonding head 110. The control unit 102c can execute control included in the operation program in accordance with a signal from a sensor unit including a position sensor.

[Manufacturing Method: 1-2 Manufacturing Method of Solar Cell Module]
Next, the manufacturing method of the solar cell module 1 is demonstrated using FIGS.

  FIG. 8 is a flowchart showing a method for manufacturing solar cell module 1 according to Embodiment 1. FIG. 9 is an explanatory diagram showing a pressing step (S2) of the method for manufacturing the solar cell module 1 according to Embodiment 1. FIG. 10A is an explanatory diagram showing the state of the solar cell string 11 of the solar cell module 1 according to Embodiment 1 taken along line XX of FIG. B of FIG. 10 is explanatory drawing which shows the pressing process (S2) of the manufacturing method of the solar cell module 1 which concerns on Embodiment 1 in the XX line of FIG. FIG. 11 is an explanatory diagram showing a light reflecting member arranging step (S4) and a light reflecting member attaching step (S5) of the method for manufacturing the solar cell module 1 according to Embodiment 1. FIG. 12 is an explanatory diagram showing a laminated body forming step (S6) and a laminating step (S7) in the method for manufacturing solar cell module 1 according to Embodiment 1.

  FIG. 10A shows the solar cell string 11 obtained in the string forming step (S1) before the pressing step (S2). FIG. 10B shows a state in which the pressing step (S2) is performed.

  Before the pressing step (S2), in the string forming step (S1), a solar cell string 11 in which a plurality of solar cells 10 are connected by the wiring member 20 is prepared. In the string forming step (S1), the plurality of solar cells 10 on which the front surface collecting electrode 12 and the back surface collecting electrode 13 of FIG.

  In this string forming step (S1), the wiring member 20 is attached to the solar battery cell 10 by thermocompression using a conductive adhesive. That is, in the present embodiment, the predetermined temperature is a heating temperature when the solar battery cell 10 is thermocompression bonded to the wiring member 20. For example, the wiring member 20 and the solar battery cell 10 are bonded together by performing thermocompression bonding (heating and pressurization) for 10 seconds at a predetermined temperature of 200 ° C.

  In this embodiment, a conductive adhesive paste is used as the conductive adhesive. In this case, a conductive adhesive paste is disposed on the surface of the solar cell 10 along the bus bar electrode of the front surface collecting electrode 12 (back surface collecting electrode 13) of FIG. 3, and the wiring member 20 is disposed on the bus bar electrode. Thereafter, the wiring member 20 and the solar battery cell 10 are thermally connected to each other by the crimping apparatus 100 to electrically connect the wiring member 20 and the solar battery cell 10.

  A plurality of solar cells 10 are sequentially connected by the wiring material 20 to produce a solar cell string 11 in which the plurality of solar cells 10 are connected in a row. In the present embodiment, twelve solar cells 10 are connected.

  As shown in FIG. 8 and FIG. 10A, the solar cell string 11 formed in the string forming step (S1) may be warped. Further, the solar cell 10 in the state of the solar cell string 11 may be bent and warped due to stress generated between the solar cell 10 and the connected wiring member 20. Therefore, before arranging the light reflecting member 30 on the solar battery cell 10, as shown in FIG. 10B, each solar battery cell 10 is pressed with a pressing jig 70 (an example of a pressing unit) (pressing process ( S2)).

  Specifically, as shown in A of FIG. 10 and B of FIG. 10, the solar cell 10 is directed from one end side (minus X axis side) of the solar cell string 11 toward the other end side (plus X axis side). Are pressed one by one by the holding jig 70. In other words, one end side of the solar cell string 11 is a reference side. First, the first solar battery cell 10 on one end side of the solar battery string 11 is fixed with the first pressing jig 70. Thereafter, the second solar battery cell 10 adjacent in the row direction is fixed by the second pressing jig 70. And this process is performed for the number of sheets corresponding to the solar cells 10. And all the photovoltaic cells 10 in the photovoltaic string 11 will be in the state pressed by the work table 90. FIG. When the light reflecting member 30 is pasted so as to straddle the gap between two adjacent solar battery strings 11, there are 24 solar battery cells 10, and therefore, 24 pressing jigs 70 form one solar battery cell 10. Press in order. In addition, you may hold | suppress in the column direction, after pressing the photovoltaic cell 10 located in the center part of the solar cell string 11. FIG.

  In the present embodiment, in the pressing step (S2), the solar battery cell 10 is pressed by the pressing jig 70 as an example of the pressing means, but the present invention is not limited to this. Specifically, a suction hole corresponding to the solar battery cell 10 may be formed in the work table 90 on which the solar battery string 11 is placed. In other words, the solar battery cell 10 is disposed on the suction hole of the work table 90. The controller 102c may adsorb the solar cells 10 by causing the pump 102b to suck outside air from the suction holes so as to press the solar cells 10 against the work table 90. In this case, the solar battery cell 10 is fixed to the work table 90.

  As shown in FIGS. 8, 9 and 11, the light reflecting member 30 is prepared in advance on the preparation table 91 so that the resin adhesive 33 is on the lower surface. The light reflecting members 30 are arranged in a line at substantially equal intervals so that the longitudinal direction of the light reflecting members 30 is substantially parallel to the column direction in the XY plan view. In other words, the light reflecting member 30 is placed on the preparation table 91 in a state of being arranged in a line at substantially equal intervals so as to correspond to the crimping head 110 of the arm portion 130 (light reflecting member preparing step (S3)). More specifically, the interval between one end of the light reflecting member 30 in the plus X-axis direction and the other end of the different light reflecting member 30 adjacent to the light reflecting member 30 in the plus X-axis direction is in the plus X-axis direction. The distance between one end of the pressure-bonding head 110 and the other end of the different pressure-bonding head 110 adjacent to the pressure-bonding head 110 in the plus X-axis direction is substantially equal. For this reason, also in arrangement | positioning area | region R1, it is substantially equal similarly to these space | intervals.

  As shown in FIG. 9, the light reflecting member 30 is vacuum-sucked on the preparation table 91. Specifically, air is sucked from a plurality of suction holes (not shown) formed on the preparation base 91, and the light reflecting member 30 is fixed so as to stick to the preparation base 91. Intake from the suction holes is performed by a pump or the like. The light reflecting member 30 is disposed at a position corresponding to the suction hole.

  In this embodiment, the light reflecting member preparation step (S3) is performed after the pressing step (S2), but the light reflecting member preparation step (S3) is performed before the light reflecting member arrangement step (S4). And may be performed before the string forming step (S1) or the pressing step (S2). In this case, the pressing step (S2) is continuously performed between the light reflecting member preparation step (S3) and the light reflecting member sticking step (S5).

  As shown in FIGS. 8, 9, and 11, the crimping device 100 is used to arrange the light reflecting member 30 in the arrangement region R <b> 1 in the two adjacent solar cell strings 11. The crimping apparatus 100 arranges the light reflecting member 30 so as to straddle the gap between two adjacent photovoltaic cells 10 placed on the work table 90 in a state where the photovoltaic cells 10 are pressed by the holding jig 70. (Light reflecting member arrangement step (S4)). Further, the non-thermocompression bonding part 111 corresponds to a gap between two adjacent solar battery cells 10. Specifically, when the solar battery cell 10 is viewed from the XY plane, the first thermocompression bonding part 112 and the second thermocompression bonding part 113 overlap with the overlapping region, and the two solar battery cells adjacent to the non-thermocompression bonding part 111. The pressure-bonding head 110 is arranged so as to overlap with the 10 gap region.

  The specific operation in the light reflecting member arranging step (S4) is to move the pressure-bonding head 110 of the arm portion 130 so that the driving unit 102a comes into contact with the upper surface of the light reflecting member 30 arranged on the preparation base 91. When the pump 102b sucks outside air, the light reflecting member 30 is adsorbed by the pressure-bonding head 110. At this time, the light reflecting member 30 is held substantially horizontally in contact with the first thermocompression bonding part 112 and the elastic part 115 of the second thermocompression bonding part 113 in the pressure bonding head 110. In this state, the control unit 102c operates the drive unit 102a to move the arm unit 130 substantially parallel to the column direction. Specifically, the drive unit 102a is configured such that the solar cell string 11 placed on the work table 90 from the preparation table 91 in a state where the pressure-bonding head 110 holds the light reflecting member 30 substantially horizontally via the arm unit 130. The light reflecting member 30 is moved substantially parallel to the column direction up to the arrangement region R1. In other words, the crimping head 110 moves substantially parallel to the row direction and is positioned in the arrangement region R1 corresponding to the light reflecting member 30.

  The pressure bonding head 110 places the light reflecting member 30 in the arrangement region R1. At this time, the control unit 102c operates the heat source unit 120, and the crimping head 110 is heated to a predetermined temperature by the heat source unit 120. The control part 102c drives the drive part 102a, and the drive part 102a pressurizes the crimping head 110 via the arm part 130 downward. The light reflecting member 30 is bonded to the solar battery cell 10 by thermocompression bonding by the first thermocompression bonding part 112 and the second thermocompression bonding part 113. In a state where the solar battery cell 10 is pressed by the holding jig 70, the light reflecting member 30 is attached to the end of the solar battery cell 10 (light reflecting member attaching step (S5)). Thus, when viewed in the XY plane, the overlapping region between the light reflecting member 30 and the solar battery cell 10 is thermocompression bonded, and the region where the non-thermocompression bonding part 111 and the gap region between the two solar battery cells 10 overlap is overlapped. Not thermocompression bonded. In this way, as shown in FIG. 11, the solar cell string 11 with the light reflecting member 30 attached thereto is obtained.

  The crimping device 100 measures the attaching accuracy of the light reflecting member 30 when aligning the crimping head 110 and the light reflecting member 30 and aligning the light reflecting member 30 and the arrangement region R1. The measured pasting accuracy may be fed back to the light reflecting member arranging step (S4) and the light reflecting member pasting step (S5). In this case, the pasting accuracy of the light reflecting member 30 can be measured by image recognition using an imaging device such as a camera.

  The controller 102c determines that the adhesion between the light reflecting member 30 and the solar battery cell 10 is completed after a predetermined time has elapsed. Thus, the solar cell string 11 in which the light reflecting member 30 is bonded to the arrangement region R1 is obtained in the light reflecting member attaching step (S5). Then, the holding jig 70 is removed.

  As shown in FIGS. 8 and 12, the solar cell string 11 to which the light reflecting member 30 is bonded is placed on a stacking table 93 different from the work table 90. With this stacking table 93, a stacked body 80 including the surface protection member 40, the front surface side resin sheet 6, the solar cell string 11 to which the light reflecting member 30 is bonded, the back surface side resin sheet 6, and the back surface protection member 50 is formed. (Laminated body formation process (S6)). Specifically, the surface protection member 40, the resin sheet 6, the solar cell string 11 to which the light reflecting member 30 is bonded, the resin sheet 6, and the back surface protection member 50 are stacked in this order from the upper surface of the stacking table 93.

  Prior to the laminated body forming step (S6), it is preferable to connect the connecting wiring 21 to the adjacent solar cell string 11 obtained in the light reflecting member attaching step (S5) via the wiring member 20. The connection wiring 21 may be connected before the light reflecting member attaching step (S5), after the light reflecting member attaching step (S5), or with the light reflecting member attaching step (S5). It may be simultaneous. Thus, a plurality of solar cell strings 11 are connected in series or in parallel to form a cell array. And the laminated body 80 is obtained using the solar cell string 11 to which the connection wiring 21 and the light reflection member 30 were connected.

  The laminate 80 formed in the laminate formation step (S6) is thermocompression bonded (laminate step (S7)). And this laminated body 80 is thermocompression-bonded (heating and crimping | compression-bonding) in the vacuum at the temperature of 100 degreeC or more, for example. By this thermocompression bonding, the resin sheet 6 is heated and melted to become a filling member 60 that seals the solar battery cell 10. In this way, the solar cell module 1 is produced.

  A frame 7 is attached to the solar cell module 1. Specifically, the frame 7 is fixed to the peripheral edge of each of the four sides of the solar cell module 1 with an adhesive such as silicon resin.

[Function and effect]
Next, the effect of the manufacturing method of the solar cell module 1 in Embodiment 1 will be described.

  As described above, in the method for manufacturing solar cell module 1 according to Embodiment 1, the light reflecting member 30 is arranged so as to straddle the gap between two adjacent solar cells 10 placed on the work table 90. The light reflecting member placement step (S4), the first thermocompression bonding part 112 and the second thermocompression bonding part 113 having the contact surface 115b in contact with the light reflecting member 30, and the first thermocompression bonding part 112 and the second thermocompression bonding part. The overlapping region between the light reflecting member 30 and the solar battery cell 10 is thermocompression bonded using the pressure bonding head 110 having the non-thermocompression bonding portion 111 that is sandwiched between 113 and does not thermally bond the light reflecting member 30. A light reflecting member attaching step (S5) for attaching 30 to the end of the solar battery cell 10.

  According to this manufacturing method, the first thermocompression bonding part 112 and the second thermocompression bonding part 113 are thermocompression bonded in the overlapping region between the light reflecting member 30 and the solar battery cell 10, and the first thermocompression bonding part 112 and the second thermocompression bonding are performed. The non-thermocompression bonding part 111 which is an area other than the part 113 does not thermocompression-bond the light reflecting member 30. For this reason, when the light reflecting member 30 is attached to the solar battery cell 10, it is difficult for the light reflecting member 30 to adhere to the work table 90 in the gap between two adjacent solar battery cells 10. For this reason, in a light reflection member sticking process (S5), it does not become a hindrance to other manufacturing processes. As a result, even if the solar cell string 11 to which the light reflecting member 30 is bonded is moved from the work table 90, the solar cell string 11 is hardly damaged by the light reflecting member 30 being bonded to the work table 90.

  Therefore, it can suppress that the light reflection member sticking process (S5) which sticks the light reflection member 30 becomes a hindrance to a series of manufacturing processes, and can suppress damage to the solar cell string 11. If breakage of the solar cell string 11 is suppressed, a decrease in yield can be suppressed.

  Moreover, in the manufacturing method of the solar cell module 1 according to Embodiment 1, in the light reflecting member pasting step (S5), when the solar cell 10 is viewed in the XY plane, the first thermocompression bonding part 112 and the second thermocompression bonding are performed. The light reflecting member 30 is placed in the solar cell 10 by arranging the pressure-bonding head 110 so that the portion 113 overlaps the overlapping region, and the non-thermocompression bonding portion 111 and the gap region between the two adjacent solar cells 10 overlap. Paste to the end of the.

  According to this manufacturing method, the first thermocompression bonding part 112 and the second thermocompression bonding part 113 overlap with the overlapping region, and the non-thermocompression bonding part 111 and the gap region between the two adjacent solar cells 10 overlap. . That is, since the non-thermocompression bonding part 111 corresponds to the gap between two adjacent solar battery cells 10, the light reflecting member 30 corresponding to the non-thermocompression bonding part 111 is difficult to adhere to the work table 90. For this reason, it is possible to reliably prevent the light reflecting member 30 from adhering to the work table 90.

  Moreover, the manufacturing method of the solar cell module 1 which concerns on Embodiment 1 further wiring the several photovoltaic cell 10 arranged in linear form along the row direction before a light reflection member arrangement | positioning process (S4). A string forming step (S1) in which the solar cell string 11 is formed by being connected with the material 20, and a pressing step (in which the solar cell 10 of the solar cell string 11 formed in the string forming step (S1) is pressed with a pressing jig 70 ( S2) and the pressing step (S2) is continuously performed between the light reflecting member preparation step (S3) and the light reflecting member attaching step (S5).

  According to this manufacturing method, the solar battery cell 10 is pressed by the holding jig 70, so that the warp of the solar battery string 11 can be suppressed and the solar battery string 11 can be fixed to the work table 90. As a result, spots due to warpage of each solar cell string 11 are eliminated, so that the light reflecting member 30 can be attached with high precision so as to straddle the gap between two adjacent solar cell strings 11.

  Moreover, in the manufacturing method of the solar cell module 1 according to Embodiment 1, in the pressing step (S2), the solar cells 10 are sequentially pressed by the pressing jig 70 in the row direction of the solar cell strings 11.

  According to this manufacturing method, the holding jig 70 sequentially presses the solar cells 10 from one end side to the other end side of the solar cell string 11 (in the column direction). It becomes easier to suppress warpage. For this reason, it becomes easy to eliminate the spot by the curvature for every solar cell string 11, and the light reflection member 30 can be affixed on the photovoltaic cell 10 more accurately. In particular, since the holding jig 70 presses the solar battery cells 10 in order, it is difficult to give stress to the solar battery string 11.

  Moreover, the manufacturing method of the solar cell module 1 which concerns on Embodiment 1 further has the surface protection member 40, the resin sheet 6, the solar cell string 11, the resin sheet 6, and back surface protection after a light reflection member sticking process (S5). It includes a laminating step (S7) in which the members 50 are laminated in this order, and the laminated body 80 is thermocompression bonded.

  According to this manufacturing method, the front surface protection member 40, the resin sheet 6, the solar cell string 11, the resin sheet 6, and the back surface protection member 50 are stacked in this order on the solar cell string 11 to which the light reflecting member 30 is bonded. Since the body 80 is formed, the light reflecting member 30 is difficult to adhere to the front surface protection member 40, the back surface protection member 50, and the resin sheet 6. For this reason, even if the stack 80 is moved from the work table 90 to another stack 93 to form the stacked body 80, the solar cell string 11 is hardly damaged by the adhesion of the light reflecting member 30. In particular, since the light reflecting member sticking step (S5) is performed before the stacked body 80 is formed, even if the solar battery cell 10 is damaged, the damaged portion can be replaced. For this reason, the fall of a yield can be suppressed.

  In the method for manufacturing the solar cell module 1 according to Embodiment 1, the crimping head 110 has the intake holes 114 that attract the light reflecting member 30. In the light reflecting member arrangement step (S4), the light reflecting member 30 is adsorbed to the intake holes 114, and the light reflecting member 30 is arranged so as to straddle the gap between two adjacent solar cells 10.

  According to this manufacturing method, when the light reflecting member 30 is moved from the preparation base 91 to a position straddling the gap between two adjacent solar cells 10, the light reflecting member 30 is easily arranged.

  In the method for manufacturing the solar cell module 1 according to Embodiment 1, the first thermocompression bonding part 112 and the second thermocompression bonding part 113 have an elastic part 115 that contacts the light reflecting member 30.

  According to this manufacturing method, even if the pressure-bonding head 110 attracts the light reflecting member 30, the elastic portion 115 is hardly damaged by the light reflecting member 30. For this reason, the fall of a yield can be suppressed more.

  Moreover, in the manufacturing method of the solar cell module 1 according to Embodiment 1, the pressure-bonding head 110 has a long shape, and is a non-thermo-compression bonding portion with respect to the two first thermocompression bonding portions 112 and the second thermocompression bonding portion 113. 111 has a groove 116 that is recessed.

  According to this manufacturing method, if the crimping head 110 having the groove 116 is used, the light reflecting member 30 can be easily thermocompression bonded to the solar battery cell 10 so as to straddle the gap between two adjacent solar battery cells 10. it can. For this reason, manufacturing cost can be reduced.

  In particular, the crimping head 110 is U-shaped, and it is easy to produce such a member.

(Modification of Embodiment 1)
In the modification of the first embodiment, the other configuration of the solar cell module 1 is the same as that of the solar cell module 1 of the first embodiment, and the same configuration is denoted by the same reference numeral and detailed description regarding the configuration is given. Is omitted.

[Production Method: 1-1-1 Configuration of Crimping Device]
The difference between the first embodiment and the modification of the first embodiment is that the crimping head 110 in the crimping apparatus 100 is different. Hereinafter, the configuration of the crimping head 110 in the crimping apparatus 100 will be described with reference to FIG.

  FIG. 13 is a cross-sectional view showing the crimping head 110 of the crimping apparatus 100 according to the modification of the first embodiment taken along the line VI-VI in FIG.

  As shown in FIG. 13, the plurality of intake holes 114 formed in the crimping head 110 are formed in the non-thermocompression bonding part 111, the first thermocompression bonding part 112, and the second thermocompression bonding part 113.

  Specifically, the intake hole 114 has a first communication hole 111 a and a second communication hole 111 b in the non-thermocompression bonding part 111. The first communication hole 111 a extends downward from the upper surface of the non-thermocompression bonding portion 111. The second communication hole 111b communicates with the first communication hole 111a and extends from the lower end of the first communication hole 111a in the column direction.

  In the first thermocompression bonding part 112 and the second thermocompression bonding part 113, the intake hole 114 has a third communication hole 112a and a fourth communication hole 113a. The third communication hole 112a extends upward from the lower end surface of the first thermocompression bonding part 112 and is connected to the plus Y-axis end side of the second communication hole 111b. The fourth communication hole 113a extends upward from the lower end of the second thermocompression bonding part 113 and is connected to the minus Y-axis end side of the second communication hole 111b.

  The intake hole 114 has a through hole 115 a in the elastic portion 115. The through hole 115a is formed to correspond to the third communication hole 112a and the fourth communication hole 113a.

  Thus, when the pump 102b sucks air, the light reflecting member 30 is held substantially horizontally by the first and second thermocompression bonding parts 112 and 113 via the elastic part 115.

  The method for manufacturing solar cell module 1 is the same as the method for manufacturing solar cell module 1 of Embodiment 1, and detailed description of the same method is omitted.

  Moreover, the effect in this solar cell module 1 is the same effect as the solar cell module 1 of Embodiment 1, and detailed description is abbreviate | omitted about the same effect.

(Embodiment 2)
In the second embodiment, the other configuration of the solar cell module 1 is the same as that of the solar cell module 1 of the first embodiment. The same components are denoted by the same reference numerals, and detailed description thereof is omitted. .

[Manufacturing method: Configuration of 2-1 crimping apparatus]
In manufacturing the solar cell module 1, the crimping device 200 is used. First, the configuration of the crimping apparatus 200 will be described with reference to FIG.

  14A is an explanatory diagram showing a state in which the light reflecting member 30 is thermocompression bonded to the solar battery cell 10 using the pressure roller 210 in the method for manufacturing the solar battery module 1 according to Embodiment 2. FIG. 14B is a cross-sectional view illustrating the pressure roller 210 of the pressure bonding apparatus 200 according to the second embodiment taken along line XIVB-XIVB in FIG. 14A. 14A is a thermocompression bonding of the light reflecting member 30 to the solar cell 10 using the pressure roller 210 to the solar cell string 11 to which the light reflecting member 30 of FIG. 11 is bonded, along the line XIVA-XIVA of FIG. It is a state to do.

  In the second embodiment, the other configuration of the crimping apparatus 200 is the same as that of the crimping apparatus 100 of the first embodiment. The same components are denoted by the same reference numerals, and detailed description thereof is omitted.

  The difference between the crimping device 100 according to the first embodiment and the crimping device 200 according to the second embodiment is that the crimping head 110 according to the first embodiment is a long member having a U-shaped cross section. 2 is different in that the head for performing thermocompression bonding is a roller. Further, the pressure-bonding head 110 according to the first embodiment performs the light reflecting member arranging step (S4), but the pressure roller 210 according to the second embodiment does not perform the light reflecting member arranging step (S4).

  As shown in FIGS. 7 and 14, the crimping apparatus 200 includes a transport unit 101 and a device main body 102.

  The transport unit 101 includes a plurality of moving heads and an arm unit. The moving head has the same configuration as that of the crimping head 110 of the first embodiment, except that the heat source 120 of the first embodiment is not provided on the moving head. For this reason, the light reflecting member 30 is arranged so that the moving head straddles the gap between two adjacent solar battery cells 10. Moreover, the arm part of this Embodiment is the structure similar to the arm part 130 of Embodiment 1. FIG.

  The apparatus main body 102 includes a pressure roller 210, a drive unit 102a, a control unit 102c that controls the heat source unit 120, and the like.

  The pressure roller 210 has a non-thermocompression bonding part 211, a first thermocompression bonding part 212, and a second thermocompression bonding part 213. The pressure roller 210 has a housing portion 210a.

  The non-thermocompression bonding portion 211 has an annular shape and has a housing portion 210a on the inner peripheral side. The non-thermocompression bonding portion 211 is provided so as to be rotatable around the rotation axis X1. A heat source part 120 is provided in the housing part 210 a of the non-thermocompression bonding part 211. The heat source part 120 is provided so that the inner peripheral surface of the non-thermocompression bonding part 211 can be heated. The pump 102b may be housed in the housing portion 210a.

  An annular first thermocompression bonding part 212 and an annular second thermocompression bonding part 213 are formed on the outer peripheral surface of the non-thermocompression bonding part 211. The first thermocompression bonding part 212 is an annular shape that protrudes radially outward from the outer peripheral edge on one side of the non-thermocompression bonding part 211. The second thermocompression bonding part 213 has an annular shape that protrudes radially outward from the outer peripheral edge on the other side of the non-thermocompression bonding part 211. An annular groove 210 b is formed between the first thermocompression bonding part 212 and the second thermocompression bonding part 213 and the outer peripheral surface of the non-thermocompression bonding part 211. In other words, the first thermocompression bonding part 212, the second thermocompression bonding part 213, and the non-thermocompression bonding part 211 form an annular groove 210b that is recessed in an annular shape. In the present embodiment, the annular groove 210b is hollow, but the light reflecting member 30 may be filled with a material having low thermal conductivity so that the light reflecting member 30 is not thermocompression bonded to the solar battery cell 10. In this case, the portion filled with the material having low thermal conductivity also becomes the non-thermocompression bonding portion 211.

  The drive unit 102a moves the crimping apparatus 200 in the row direction at a constant speed. The pressure roller 210 of the pressure bonding device 200 moves so as to roll on the upper surface of the solar cell string 11 on which the light reflecting member 30 is arranged from one end side to the other end side of the solar cell string 11. In addition, in FIG. 14, although it moves toward the other end side from the one end side of the solar cell string 11, the reverse direction may be sufficient. In addition, the driving unit 102a may move the crimping apparatus 200 in the row direction by moving the work table 90 without moving the crimping apparatus 200 in the row direction.

[Manufacturing method: manufacturing method of 2-2 solar cell module]
Next, the manufacturing method of the solar cell module 1 is demonstrated.

  In the second embodiment, the other method in the method for manufacturing the solar cell module 1 is the same as the method for manufacturing the solar cell module 1 in the first embodiment, and the same method is denoted by the same reference numeral. Detailed description is omitted.

  In this Embodiment, it is the same method from the string formation process (S1) of the manufacturing method of the solar cell module 1 of Embodiment 1 to the pressing process (S2), The description is abbreviate | omitted.

  After the pressing step (S2), the pressure roller 210 moves so as to roll from one end side to the other end side of the solar cell string 11 on which the light reflecting member 30 is disposed (light reflecting member attaching step (S5)). In the present embodiment, the pressure roller 210 moves so as to roll from the minus X-axis side of the solar cell string 11 toward the plus X-axis side.

  Specifically, the pressure roller 210 is positioned on one end side of the solar cell string 11 on which the light reflecting member 30 is disposed. Further, when the pressure roller 210 moves, the first thermocompression bonding portion 212 of the pressure roller 210 is disposed so as to pass through a portion where the solar cell 10 and the light reflecting member 30 on one side overlap in the row direction. To do. Further, the second thermocompression bonding part 213 of the pressure roller 210 is disposed so as to pass through the part where the other side solar cell 10 and the light reflecting member 30 overlap in the row direction. In other words, in the XY plan view, the light reflecting member 30 substantially coincides with the portion (overlapping portion) straddling the two adjacent solar cells 10 and is not heated with the gap between the two adjacent solar cells 10. The pressure roller 210 is disposed so that the pressure roller 211 passes while substantially matching the pressure roller 211.

  The pressure-bonding roller 210 of the pressure-bonding device 200 moves from one end side to the other end side of the solar cell string 11 on which the light-reflecting member 30 is disposed while thermocompressing the solar cells 10 and the light-reflecting member 30 (light). Reflecting member sticking step (S5)). In this manner, the light reflecting member 30 and the portion of the solar battery cell 10 that overlaps the light reflecting member 30 are bonded to obtain the solar cell string 11 to which the light reflecting member 30 is bonded.

  Solar cell module 1 is manufactured by the same method as the laminating step (S7) of the method for manufacturing solar cell module 1 of the first embodiment.

  In the light reflecting member pasting step (S5) of the present embodiment, the pressure roller 210 moves in the row direction to thermally press the light reflecting member 30 and the solar battery cell 10, but the pressure roller 210 is moved. Instead, the work table 90 may be moved in the row direction, and the solar battery cell 10 and the light reflecting member 30 may be thermocompression bonded. In this case, it is realized by a belt conveyor provided with a driving device for moving the work table 90.

[Function and effect]
Next, the effect of the solar cell module 1 in this Embodiment is demonstrated.

  As described above, in the method for manufacturing solar cell module 1 according to Embodiment 2, the pressure-bonding head 110 is a roller (pressure-bonding roller 210), and the non-thermo-compression bonding part 211 includes the first thermo-compression bonding part 212 and the second heat-bonding part 212. An annular groove 210b that is annularly recessed with respect to the thermocompression bonding part 213 is formed.

  According to this manufacturing method, the apparatus including the pressure roller 210 can be downsized as compared with the pressure bonding apparatus 200 using the long pressure bonding head 110.

  The effect in this solar cell module 1 is the same effect as the solar cell module 1 of Embodiment 1, and detailed description is abbreviate | omitted about the same effect.

(Modification of Embodiment 2)
In the modification of the second embodiment, the other configuration of the solar cell module 1 is the same as that of the solar cell module 1 of the second embodiment, and the same components are denoted by the same reference numerals and detailed description regarding the configuration is given. Is omitted.

[Manufacturing method: Configuration of 2-1-1 crimping apparatus]
In manufacturing the solar cell module 1, the crimping device 200 is used. First, the configuration of the crimping apparatus 200 will be described with reference to FIG.

  FIG. 15 is an explanatory view showing a state in which the light reflecting member 30 is thermocompression bonded to the solar battery cell 10 using the pressure roller 210 in the method for manufacturing the solar battery module 1 according to the modification of the second embodiment. FIG. 15 shows a state in which the light reflecting member 30 is thermocompression bonded to the solar battery cell 10 using the pressure roller 210 to the solar cell string 11 in which the light reflecting member 30 of FIG. is there.

  In the modification of the second embodiment, the other configuration of the crimping apparatus 200 is the same as that of the crimping apparatus 200 of the second embodiment, and the same components are denoted by the same reference numerals and detailed description of the configuration is omitted. To do.

  The difference between the crimping apparatus 200 according to the second embodiment and the crimping apparatus 200 according to the modification of the second embodiment is that the light reflecting tape 3 that is the basis of the light reflecting member 30 is added to the crimping apparatus 200 according to the modification according to the second embodiment. Is different in that it has a bobbin 221, a supply roller 222, a pair of transport rollers 223, a cutter 224, and the like. The crimping apparatus 200 according to the modification of the second embodiment is also different in that it does not have the transport unit 101 of the second embodiment.

  As illustrated in FIG. 15, the pressure bonding apparatus 200 includes a conveyance unit 201, a housing 202, a bobbin 221, and a cutter 224 in addition to the pressure roller 210, the drive unit 102 a, and the control unit 102 c. The housing 202 accommodates the pressure roller 210, the drive unit 102a, the control unit 102c, the transport unit 201, the bobbin 221, the cutter 224, and the discharge roller 226.

  A transport path P <b> 1 is formed in the transport unit 201. Further, the transport unit 201 includes a supply roller 222, a pair of transport rollers 223, a cutter 224, a placement pad 225, and a discharge roller 226. The supply roller 222, the pair of transport rollers 223, and the discharge roller 226 are rotatably supported by the housing 202 by the drive unit 102a.

  The conveyance path P1 includes a path from the bobbin 221 around which the light reflecting tape 3 is wound to the supply roller 222, a path from the supply roller 222 to the pair of conveyance rollers 223, and a pair of conveyance rollers 223 to the cutter 224. A path and a path from the cutter 224 to the mounting pad 225 and the discharge roller 226. In the conveyance path P1, the bobbin 221 side is the upstream side, and the mounting pad 225 and the discharge roller 226 are the downstream side. In the transport path P1, the light reflecting tape 3 is transported in the transport direction (the direction of the arrow).

  The bobbin 221 is provided on the upstream side of the transport path P1. The light reflecting tape 3 is wound around the bobbin 221. A supply roller 222 is provided on the downstream side of the bobbin 221. The supply roller 222 rotates so as to transport the light reflecting tape 3 wound around the bobbin 221 in the transport direction. A pair of transport rollers 223 is provided on the downstream side of the supply roller 222. The pair of transport rollers 223 rotate so as to transport the light reflecting tape 3 transported from the supply roller 222 toward the transport direction. A cutter 224 for cutting the light reflecting tape 3 is provided on the downstream side of the pair of transport rollers 223. The cutter 224 cuts the light reflecting tape 3 into a predetermined length to form the light reflecting member 30. On the downstream side of the cutter 224, there are provided a mounting pad 225 and a discharge roller 226 for arranging the light reflecting member 30 in the arrangement region R1 of FIG. The light reflecting member 30 is discharged by the mounting pad 225 and the discharge roller 226.

  A light sensor (not shown) that detects the length of the light reflecting member 30 is provided near the cutter 224. The optical sensor transmits the detected signal to the control unit 102c. The controller 102c controls the length of the light reflecting member 30 to be cut into a predetermined length based on the signal detected by the optical sensor. In the present embodiment, the length of the light reflecting member 30 is set to be cut substantially evenly.

  The control unit 102c controls the moving speed of the crimping apparatus 200 by the driving unit 102a. The crimping device 200 moves at a constant speed in the scanning direction on the solar cell string 11 pressed in the pressing step (S2) placed on the work table 90. In the present embodiment, the scanning direction is a direction in which the crimping apparatus 200 travels, and is a direction parallel to the row direction. In FIG. 15, the solar cell string 11 moves from the other end side (plus X axis side) toward one end side (minus X axis side), but may be in the opposite direction.

  Further, in the pressing step (S2), the control unit 102c can arrange the light reflecting members 30 in a line at substantially equal intervals in the arrangement region R1 in FIG. 11 of the solar cell string 11 pressed by the pressing jig 70. The rotation of the pressure roller 210, the supply roller 222, the pair of transport rollers 223 and the discharge roller 226, and the cutting operation of the cutter 224 are also controlled via the drive unit 102a. For example, when the light reflecting member 30 is arranged in the arrangement region R1 of FIG. 11 from the mounting pad 225 and the discharge roller 226, the control unit 102c moves the rotation speed of the crimping device 200 and the outer peripheral surface of the discharge roller 226. Are controlled to be substantially the same as each other, or in a region between two adjacent arrangement regions R1 in FIG. 11 in the row direction, the driving of the discharge roller 226 and the like is stopped. The region between two adjacent arrangement regions R1 in FIG. 11 is a region where the light reflecting member 30 is not attached, and four solar cells excluding the solar cell 10 of the outermost solar cell string 11. 10 is a corner side portion of the solar battery cell 10 surrounded by 10.

  If the solar cell module 1 is manufactured using such a crimping device 200, the light reflecting members 30 are adjacent to each other without preparing the light reflecting members 30 on the preparation base 91 of FIG. 11 according to the first embodiment. It can arrange | position so that the clearance gap between the photovoltaic cells 10 may be straddled. Further, the crimping apparatus 200 does not need to include the arm portion of FIG. 5 according to the first embodiment. For this reason, in the crimping | compression-bonding apparatus 200, the process which prepares the light reflection member 30 on the preparation stand 91 can be omitted, and an apparatus can be reduced in size.

  In the modification of Embodiment 2, the other methods in the manufacturing method of the solar cell module 1 are the same as the manufacturing method of the solar cell module 1 of Embodiment 2, and about the same method, detailed description regarding the method is given. Omitted.

  Moreover, in the modification of Embodiment 2, the effect in this solar cell module 1 is the same effect as the solar cell module 1 of Embodiment 1, and detailed description is abbreviate | omitted about the same effect. .

(Embodiment 3)
In the third embodiment, the other configuration of the solar cell module 1 is the same as that of the solar cell module 1 of the first embodiment. The same components are denoted by the same reference numerals, and detailed description thereof is omitted. .

  In manufacturing the solar cell module 1, the crimping device 300 is used. First, the configuration of the crimping apparatus 300 will be described with reference to FIGS. 16 and 17.

  FIG. 16 is a perspective view of the crimping device 300 and the solar cell string 11 according to the third embodiment. FIG. 17A is an enlarged perspective view showing the crimping head 310 of the crimping apparatus 300 according to the third embodiment. FIG. 17B is an enlarged perspective view showing the crimping head 310 of the crimping apparatus 300 according to the third embodiment. 17A is a perspective view of the pressure-bonding head 310 viewed from an oblique upper side, and FIG. 17B is a perspective view of the pressure-bonding head 310 viewed from an oblique lower side.

  In the present embodiment, the contact surfaces 312a and 313a of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 of each crimping head 310 are different from those of the first embodiment and the like in that they are provided discretely. . Further, the present embodiment is different from the first embodiment in that a movable table 401 is used instead of the preparation table 91.

[Manufacturing method: Configuration of 3-1 crimping apparatus]
In the present embodiment, the other configuration of the crimping apparatus 300 is the same as that of the crimping apparatus 100 of the first embodiment, and the same components are denoted by the same reference numerals and detailed description of the configuration is omitted.

  The first thermocompression bonding part 312 and the second thermocompression bonding part 313 of each crimping head 310 extend from the end surface in the minus Z-axis direction (contact surfaces 312a and 313a described later) in the plus Z-axis direction and penetrate in the Y-axis direction. A notch 310a is formed. That is, by forming the notches 310a, a plurality of columnar structures extending in the Z-axis direction are formed in the first thermocompression bonding part 312 and the second thermocompression bonding part 313 of the crimping head 310. The columnar structures of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 are arranged discretely.

  The cutout 310 a is cut out at the first thermocompression bonding portion 312 and the second thermocompression bonding portion 313 so as to communicate the outside of the pressure bonding head 310 and the groove portion 116 of the pressure bonding head 310. The columnar structures of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 may be two or more. That is, the cutout 310a may be one or more. In the present embodiment, each of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 is provided with three columnar structures.

  In the present embodiment, the columnar structure of the first thermocompression bonding part 312 is provided on the edge side of the heat source part 120 in the negative Y-axis direction so as to be arranged at equal intervals in the X-axis direction. The columnar structure of the second thermocompression bonding part 313 is provided on the edge side in the plus Y-axis direction of the heat source part 120 so as to be arranged at equal intervals in the X-axis direction. An elastic part 315 is provided on the lower end surface of the columnar structure in the first thermocompression bonding part 312 and the second thermocompression bonding part 313. The elastic part 315 is provided so as to correspond to the shapes of the first thermocompression bonding part 312 and the second thermocompression bonding part 313, and is otherwise the same as the elastic part 115 of the first embodiment.

  In the first thermocompression bonding part 312 and the second thermocompression bonding part 313, the elastic part 315 (contact surfaces 312a, 313a) provided on the lower end surface of the columnar structure is subjected to the light reflecting member 30 in the light reflecting member pasting step (S5). And contact with the overlapping region of the solar battery cell 10. In the overlapping region, the regions that do not contact the plurality of first thermocompression bonding portions 312 and the plurality of second thermocompression bonding portions 313 become non-contact surfaces 312b and 313b. That is, the lower surface of the elastic portion 315 becomes the contact surfaces 312a and 313a, and the portions where the notches 310a are formed in the first thermocompression bonding portion 312 and the second thermocompression bonding portion 313 become non-contact surfaces 312b and 313b.

  In the present embodiment, the columnar structures of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 are provided on both ends of the crimping head 310 in the X-axis direction. In other words, the notch 310 a is formed in a portion other than both end sides of the first thermocompression bonding part 312 and the second thermocompression bonding part 313. The first thermocompression bonding part 312 and the second thermocompression bonding part 313 are thermocompression bonded at both end sides of each overlapping region during the light reflecting member attaching step (S5).

  The first thermocompression bonding portion 312 and the second thermocompression bonding portion 313 of each of the pressure bonding heads 310 are contact surfaces 312a and 313a that are in contact with the overlapping region between the light reflecting member 30 and the solar battery cell 10, and the light reflecting member 30 and the sun. Non-contact surfaces 312b and 313b that do not contact the overlapping area with the battery cell 10 are provided.

  The contact surface 312 a is a lower end surface of the elastic portion 315 provided on the lower end surface of the first thermocompression bonding portion 312 and is in contact with an overlapping region between the light reflecting member 30 and the solar battery cell 10. The contact surface 313 a is a lower end surface of the elastic portion 315 provided on the lower end surface of the second thermocompression bonding portion 313 and is in contact with the overlapping region between the light reflecting member 30 and the solar battery cell 10. The non-contact surfaces 312 b and 313 b are upper end surfaces (end surfaces in the plus Z-axis direction) of the first thermocompression bonding parts 312 and the second thermocompression bonding parts 313, and the light reflection member 30 and the solar battery cell 10 Touch the overlapping area. In the present embodiment, the non-contact surfaces 312b and 313b are flush with the non-thermocompression bonding portion 111.

  In the present embodiment, in the first thermocompression bonding part 312, a region between one columnar member and another adjacent columnar member is the non-contact surface 312b. Further, in the second thermocompression bonding part 313, a region between one second thermocompression bonding part 313 and another adjacent second thermocompression bonding part 313 is a non-contact surface 313b.

  When the contact surfaces 312a and 313a are brought into contact with the overlapping region and the light reflecting member 30 is thermocompression bonded to the solar battery cell 10, in this pressure bonding head 310, a part of the overlapping region is thermocompression bonded, and the remaining part of the overlapping region is The part is not thermocompression bonded. That is, in the region where the contact surfaces 312a and 313a overlap with the overlapping region, the light reflecting member 30 is thermocompression bonded to the solar battery cell 10, and in the region where the non-contact surfaces 312b and 313b overlap with the overlapping region, the light reflecting member 30 is It is not thermocompression bonded to the solar battery cell 10.

  The first thermocompression bonding part 312 and the second thermocompression bonding part 313 have three or more contact surfaces 312a and 313a, respectively. Each of the contact surfaces 312a and 313a may have a different temperature. For example, the contact surfaces 312a and 313a located on both ends of each overlapping region may have a higher temperature than the contact surfaces 312a and 313a other than both ends. And contact surface 312a, 313a located in the both ends side of each overlap region is hotter than the other contact surfaces 312a, 313a. That is, the columnar structures of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 provided on both ends of the crimping head 310 in the X-axis direction have a higher temperature than the other columnar structures. The contact surfaces 312a and 313a located at both ends of each overlapping region may be about 180 ° C., and the other contact surfaces 312a and 313a may be about 70 ° C. to 120 ° C. In this case, the corner portion side of the light reflecting member 30 is bonded to the solar battery cell 10 in the light reflecting member attaching step (S5).

  When the both ends in the X-axis direction of the pressure-bonding head 310 are heated to a high temperature, for example, by using the plurality of heat source portions 120, the both ends in the X-axis direction are heated to a high temperature and the others are cooled to the individual contact surfaces 312a. The temperature of 313a may be changed. When one heat source unit 120 is used, the material of the columnar structure of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 on both end sides in the X-axis direction is used as the other first thermocompression bonding part 312 and second thermocompression bonding part 312. A material having better thermal conductivity than the columnar structure of the thermocompression bonding part 313 may be used.

  In the present embodiment, the columnar structures that are a part of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 are provided at both ends in the X-axis direction of the crimping head 310, and thus contact surfaces 312a and 313a. Are also provided on both ends of the overlap region (both ends in the X-axis direction). In this case, the corners of the light reflecting member 30 can be thermocompression bonded during the light reflecting member attaching step (S5). Note that the columnar structures that are part of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 are provided on both ends in the X-axis direction of the pressure bonding head 310, but are not limited thereto. The position where the structure is provided is not particularly limited.

  Each first thermocompression bonding part 312 is formed with a third communication hole 312c. The third communication hole 312c communicates with the second communication hole 111b of the non-thermocompression bonding part 111 in FIG. Each second thermocompression bonding part 313 has a fourth communication hole 313a. The fourth communication hole 313a communicates with the second communication hole 111b of the non-thermocompression bonding part 111.

  Instead of forming the notches 310a, the elastic portions 315 may be provided discretely on the first thermocompression bonding portion 312 and the second thermocompression bonding portion 313. That is, the plurality of elastic parts 315 are discretely provided on the lower end surfaces of the first thermocompression bonding part 312 and the second thermocompression bonding part 313. In this case, the area of the load which affixes the light reflection member 30 on the photovoltaic cell 10 can be reduced only by providing the elastic part 315 discretely.

[Manufacturing method: Configuration of 3-2 preparation stand]
In manufacturing the solar cell module 1, the preparation table 400 is used. Next, the configuration of the preparation base 400 will be described with reference to FIG. FIG. 18 is a perspective view of the preparation base 400 and the light reflecting member 30 according to the third embodiment. In FIG. 18, a single row of moving bases 401 is described, but the present invention is not limited to this, and the moving base 401 may have a plurality of rows.

  The preparation table 400 includes a plurality of moving tables 401, a main body 402, and a drive mechanism.

  The plurality of movable bases 401 are provided on the upper surface of the main body 402 and are a base on which a plurality of light reflecting members 30 can be arranged. These movable tables 401 are arranged in a line in the X-axis direction. The plurality of light reflecting members 30 are arranged one-on-one on the plurality of moving bases 401. In the present embodiment, the moving table 401 has substantially the same shape as the light reflecting member 30 when the moving table 401 on which the light reflecting member 30 is placed is viewed from above. The plurality of moving bases 401 perform a desired movement on the upper surface of the main body 402. For example, the plurality of moving platforms 401 move so that the light reflecting member 30 and the arrangement region R1 overlap (correspond) on the Y axis.

  Each moving base 401 moves in the X-axis direction so that one light reflecting member 30 and another adjacent light reflecting member 30 are spaced apart from each other. The predetermined interval is an interval between two adjacent arrangement regions R1 in the X-axis direction. The plurality of moving platforms 401 move so as to have substantially the same interval as the interval between two adjacent arrangement regions R1 in the X-axis direction. In other words, the interval between the two adjacent movable platforms 401 is adjusted in accordance with the interval between the arrangement regions R1.

  In the present embodiment, the preparation table 400 is provided in the plus Y-axis direction of the work table 90, but the preparation table 400 may be provided in the X-axis direction of the work table 90. In this case, the plurality of moving bases 401 move on the main body 402 so that the light reflecting member 30 and the arrangement region R1 correspond on the X axis. Specifically, in the plurality of moving platforms 401, in the arrangement direction of the arrangement region R1, the interval between the two adjacent arrangement regions R1 and the interval between the two adjacent light reflecting members 30 in the X-axis direction are substantially the same. It moves on the main-body part 402 so that it may become. In other words, the plurality of moving bases 401 adjust the arrangement of the two adjacent light reflecting members 30 in accordance with the intervals in the arrangement of the plurality of pressure bonding heads 310 provided in the pressure bonding apparatus 100.

  In addition, the moving table 401 may be provided with an intake hole that suppresses the positional deviation of the mounted light reflecting member 30.

  The main body 402 is a base that supports the moving table 401, and houses a drive mechanism, a control unit, a power supply unit, and the like that move the plurality of moving tables 401. Note that the drive mechanism, the control unit, and the power supply unit may be built in the movable table 401.

  The drive mechanism is a device that moves the movable table 401 by a desired amount, and is, for example, an electric actuator. In the drive mechanism, the moving amount, moving speed, and the like of the moving table 401 are adjusted by the control unit or the like.

[Manufacturing method: 3-3 Manufacturing method of solar cell module]
Next, the manufacturing method of the solar cell module 1 is demonstrated using FIGS. FIG. 19 is a flowchart of the method for manufacturing the solar cell module 1 according to Embodiment 3. FIG. 20 is an explanatory diagram showing a moving step (S11) of the method for manufacturing the solar cell module 1 according to Embodiment 3. FIG. 21 is an explanatory diagram showing a light reflecting member arranging step (S4) and a laminating step (S7) in the method for manufacturing the solar cell module 1 according to Embodiment 3. In addition, about the manufacturing method of the solar cell module 1, the same code | symbol is attached | subjected about the process same as Embodiment 1, and the description is abbreviate | omitted.

  As shown in FIGS. 19 and 20, the light reflecting member preparation step (S3) is performed through the string formation step (S1) and the pressing step (S2). In the light reflecting member preparation step (S3), the plurality of light reflecting members 30 are placed on the plurality of moving bases 401 on a one-to-one basis. In the present embodiment, a diagram in which the light reflecting member 30 and the movable table 401 are provided in one row in the X-axis direction is used, but a plurality of these may exist. In the solar cell module 1 of the present embodiment, 12 arrangement regions R1 in the X-axis direction are provided in five rows in the Y-axis direction, and thus the light reflecting member 30 is provided in these 60 arrangement regions R1 at a time. 60 moving bases 401 may be provided so that can be arranged.

  Next, after the light reflecting member preparation step (S3), the movable table 401 moves so as to correspond to the plurality of arrangement regions R1 in which the plurality of light reflecting members 30 are arranged. Specifically, one light reflecting member 30 is placed on one moving table 401, and the plurality of moving tables 401 correspond to the arrangement region R1 arranged according to the interval in the arrangement in the X-axis direction. As shown, it moves on the main body 402 (moving step (S11)). Thus, in the plurality of light reflecting members 30, the interval between the two adjacent light reflecting members 30 in the X-axis direction is adjusted in accordance with the interval in the arrangement region R <b> 1 arranged. That is, as for the interval between the two adjacent light reflecting members 30, the two adjacent intervals (widths) and the interval between the arrangement regions R1 are substantially the same in the X-axis direction.

  When a plurality of light reflecting members 30 are provided, one light reflecting member 30 is placed on one moving table 401. The plurality of moving tables 401 includes a plurality of light reflecting members 30 arranged in a matrix. It may move on the main body 402 so as to correspond to the arrangement region R1 arranged in a shape (movement step (S11)). The plurality of light reflecting members 30 may be arranged in a matrix. Thus, since the plurality of light reflecting members 30 are arranged in accordance with the interval in the arrangement of the plurality of pressure bonding heads 310 provided in the pressure bonding apparatus 300 in the X-axis direction and the Y-axis direction, the light reflection member arranging step (S4). Thus, the plurality of pressure-bonding heads 310 can adsorb the plurality of light reflecting members 30 on a one-to-one basis. Thus, the light reflecting member 30 can be arranged in the arrangement region R <b> 1 so as to straddle the gap between the two adjacent solar cells 10.

  Next, after performing a light reflection member arrangement | positioning process (S4), as shown in FIG. 21, in a light reflection member sticking process (S5), the light reflection member 30 is arrange | positioned to arrangement | positioning area | region R1 of two adjacent photovoltaic cells 10. FIG. Is attached so that the pressure bonding head 310 does not crush the resin adhesive 33 of the light reflecting member 30. In the light reflecting member arrangement step (S4), when the light reflecting member 30 is attached to the arrangement region R1 of the two adjacent solar cells 10, the force applied by the pressure-bonding head 310 to the light reflecting member 30 is as follows. The force is the same as in Form 1 and the like. For this reason, in the light reflecting member arrangement step (S4), the area of the load applied to the overlapping region is reduced by the amount of the non-contact surfaces 312b and 313b compared to the first embodiment.

  Next, in the laminating step (S7) that has undergone the laminated body forming step (S6), the laminated body formed in the laminated body forming step (S6) is thermocompression bonded. At that time, the resin adhesive 33 of the light reflecting member 30 is crushed, and the resin adhesive 33 further ensures the adhesion between the light reflecting member 30 and the solar battery cell 10.

  As described above, the light reflecting member 30 is locally bonded to the solar battery cell 10 in the light reflecting member attaching step (S5), and the light reflecting member 30 is reliably attached to the solar battery cell 10 in the laminating step (S7). . And the solar cell module 1 is obtained.

[Function and effect]
Next, the effect of the manufacturing method of the solar cell module 1 in the present embodiment will be described.

  As described above, in the method for manufacturing the solar cell module 1 according to Embodiment 3, each of the first thermocompression bonding part 312 and the second thermocompression bonding part 313 further has a non-contact surface 312b, 313b that does not contact the overlapping region. Have In the light reflecting member affixing step (S5), a part of each overlapping area is thermocompression bonded by the first thermocompression bonding part 312 and the second thermocompression bonding part 313, and the remaining of each overlapping area is made by the non-thermocompression bonding part 111. Is not thermocompression-bonded.

  In the light reflecting member attaching step (S5), when the first thermocompression bonding part 312 and the second thermocompression bonding part 313 perform thermocompression bonding on the entire surface of the overlapping region, the load applied to the light reflecting member 30 and the solar battery cell 10 causes the solar battery. The cell 10 may be damaged. Thus, the area of the load applied to the solar battery cell 10 can be reduced to reduce the load applied to the crimping head 310, and the solar battery cell 10 can be prevented from being damaged.

  In particular, in the light reflecting member pasting step (S5), for example, if the load applied when the light reflecting member 30 is thermocompression bonded in the overlapping region of the solar battery cell 10 is 100 N or less, the damage of the solar battery cell 10 is further suppressed. can do. Since this crimping head 310 has contact surfaces 312a and 313a and non-contact surfaces 312b and 313b, when the light reflecting member 30 is thermocompression bonded to the overlapping area of the solar cells 10 in the light reflecting member pasting step (S5). The area of such a load can be reduced. For this reason, damage to the solar battery cell 10 is suppressed, and a decrease in the yield of the solar battery module 1 can be suppressed.

  Moreover, in the manufacturing method of the solar cell module 1 according to Embodiment 3, a plurality of the contact surfaces 312a and 313a are provided in each of the first thermocompression bonding part 312 and the second thermocompression bonding part 313, and a light reflecting member attaching step ( In the case of S5), the contact surfaces 312a and 313a overlap with the overlapping region.

  According to this manufacturing method, the light reflecting member 30 is thermocompression bonded to the solar battery cell 10 by the plurality of contact surfaces 312a and 313a in the overlapping region where the solar battery cell 10 and the light reflecting member 30 overlap. For this reason, when the crimping head 310 adsorbs the light reflecting member 30 on the preparation base 91 and moves to the arrangement region R1, the light reflecting member 30 is not easily detached from the crimping head 310.

  Moreover, in the manufacturing method of the solar cell module 1 which concerns on Embodiment 3, the contact surfaces 312a and 313a are contact surfaces 312a and 313a in the both ends of each overlap area | region in the light reflection member sticking process (S5). And the overlapping area overlap.

  According to this manufacturing method, the light reflecting member 30 is thermocompression bonded to the solar battery cell 10 by the plurality of contact surfaces 312a and 313a at both ends of the overlapping region where the solar battery cell 10 and the light reflecting member 30 overlap. For this reason, when the crimping head 310 sucks the light reflecting member 30 of the preparation base 91 and moves to the arrangement region R1, the light reflecting member 30 is more difficult to separate from the crimping head 310. It can arrange | position reliably by R1.

  In particular, the corner portion side of the light reflecting member 30 is attached to the solar battery cell 10 during the light reflecting member attaching step (S5). When the corner portion side of the light reflecting member 30 is attached to the solar battery cell 10, the light reflecting member 30 is difficult to peel off from the solar battery cell 10.

  Moreover, in the manufacturing method of the solar cell module 1 according to Embodiment 3, the plurality of light reflecting members 30 are further mounted on the plurality of movable bases 401 on a one-to-one basis before the light reflecting member arranging step (S4). Two solar cells adjacent to each other in the light reflecting member arranging step (S4) before the light reflecting member preparing step (S3) and the light reflecting member arranging step (S4) and after the light reflecting member preparing step (S3). A moving step (S11) in which the two adjacent moving bases 401 adjust the interval between the two adjacent light reflecting members 30 in accordance with the respective intervals in the arrangement of the plurality of arrangement regions R1 across the ten gaps.

  According to this manufacturing method, after the plurality of light reflecting members 30 are mounted on the plurality of moving bases 401 one by one, the plurality of moving bases 401 are arranged in the main body in accordance with the intervals in the arrangement of the plurality of arrangement regions R1. Move on part 402. For this reason, since the plurality of light reflecting members 30 are aligned with the positions corresponding to the plurality of pressure bonding heads 310 on a one-to-one basis, it is not necessary to arrange the light reflecting members 30 with high accuracy. For this reason, according to this manufacturing method, manufacture of the solar cell module 1 can be performed more simply.

(Other variations)
As mentioned above, although the solar cell module which concerns on this invention was demonstrated based on the modification of Embodiment 1, 2 and Embodiment 1, 2, this invention is the said Embodiment 1, 2, and Embodiment 1. FIG. However, the present invention is not limited to the second modification.

  For example, in Embodiment 1 described above, the longitudinal direction of the pressure-bonding heads are arranged in a line at substantially equal intervals in the row direction, but may be arranged so as to be orthogonal to the row direction. That is, the crimping heads may be arranged in the row direction. In this case, when three or more solar cell strings are arranged, the crimping head may be moved while being crimped in order in the row direction when the light reflecting member is thermocompression bonded.

  In the first embodiment, five first support portions having 60 crimping heads are provided so as to correspond to the arrangement regions of two adjacent solar cells in the six solar cell strings. It may be. In this case, in the six solar cell strings that have undergone the pressing step, the light reflecting member arranging step and the light reflecting member attaching step can be performed at a time.

  Moreover, in said embodiment, you may arrange | position a light reflection member in the surface side of a photovoltaic cell. In this case, it arrange | positions so that the uneven | corrugated | grooved part of the insulating member in a light reflection member may face upwards, and the surface on the opposite side to the uneven | corrugated | grooved part in an insulating member is adhere | attached on the surface of a photovoltaic cell with a resin adhesive. That is, the light reflecting member in FIG. 4 may be arranged in plane symmetry with respect to a plane defined by the X-axis direction and the Y-axis direction.

  In the above-described embodiment, two light reflecting members are provided in one solar cell except for the solar cell of the outermost string cell. However, the present invention is not limited to this. For example, you may provide two light reflection members in each of all the photovoltaic cells. Moreover, the number of the light reflection members provided in one solar battery cell may be one or three or more instead of two. For example, a light reflecting member may be provided on each of the four sides of the solar battery cell, or a plurality of light reflecting members may be provided on each side.

  Moreover, in said embodiment, you may affix a light reflection member on the wiring material which connects two adjacent photovoltaic cells. In this case, the uneven portion of the light reflecting member may be provided so as to be substantially orthogonal to the wiring material.

  Further, in the above embodiment, the semiconductor substrate of the solar battery cell is an n-type semiconductor substrate, but may be a p-type semiconductor substrate.

  Moreover, in said embodiment, although the solar cell module was a double-sided light-receiving system in which both the surface protection member and the back surface protection member are light-receiving surfaces, it is not restricted to this. For example, a single-sided light receiving method in which only one of the surface protecting member and the back surface protecting member (for example, the surface protecting member) is the light receiving surface may be used. In the case of the single-sided light receiving method, the p-side electrode does not need to be transparent, and may be a reflective metal electrode, for example.

  Moreover, in said embodiment, although the semiconductor material of the photoelectric conversion part of a photovoltaic cell was silicon, it is not restricted to this. As a semiconductor material of the photoelectric conversion portion of the solar battery cell, gallium arsenide (GaAs), indium phosphide (InP), or the like may be used.

  In addition, Embodiments 1 and 2 and Embodiments 1 and 2 within a range that does not depart from the gist of the present invention, or forms obtained by making various modifications conceivable by those skilled in the art to the modifications of Embodiments 1 and 2 And the form implement | achieved by combining arbitrarily the component and function in the modification of Embodiment 1, 2 is also contained in this invention.

DESCRIPTION OF SYMBOLS 1 Solar cell module 6 Resin sheet 10 Solar cell 11 Solar cell string 20 Wiring material 30 Light reflection member 40 Surface protection member (translucent substrate)
50 Back surface protection member (translucent substrate)
70 Pressing jig (pressing means)
80 Laminated body 90 Work table 110, 310 Crimp head 111, 211 Non-thermocompression bonding part 112, 212, 312 First thermocompression bonding part (thermocompression bonding part)
113, 213, 313 Second thermocompression bonding part (thermocompression bonding part)
114 Intake hole 115, 315 Elastic part 116 Groove part 210b Annular groove 312a, 313a Contact surface 312b, 313b Non-contact surface 401 Moving table R1 Arrangement area S1 String formation process S2 Holding process S3 Light reflection member preparation process S4 Light reflection member arrangement process S5 Light reflecting member pasting process S7 Laminating process S11 Moving process

Claims (13)

A light reflecting member arranging step of arranging a light reflecting member so as to straddle a gap between two adjacent solar cells placed on the workbench;
The light using a pressure-bonding head having two thermocompression-bonding portions having contact surfaces in contact with the light-reflecting member and a non-thermo-compression-bonding portion sandwiched between the two thermocompression-bonding portions and not thermocompression-bonding the light-reflecting member. The manufacturing method of a solar cell module including the light reflection member sticking process of sticking the said light reflection member on the edge part of the said photovoltaic cell by thermocompression-bonding the overlapping area | region of a reflection member and the said photovoltaic cell. In the light reflecting member affixing step, when the solar battery cell is viewed in plan, the two thermocompression bonding portions and the overlapping region overlap, and a gap between the two solar battery cells adjacent to the non-thermocompression bonding portion is overlapped. The method for manufacturing a solar cell module according to claim 1, wherein the light reflecting member is attached to an end portion of the solar battery cell by arranging the pressure-bonding head so as to overlap an area. Each of the two thermocompression bonding parts is
Furthermore, it has a non-contact surface that does not contact the overlapping region,
2. In the light reflecting member attaching step, a part of each overlapping region is thermocompression bonded by the two thermocompression bonding portions, and the remaining part of each overlapping region is not thermocompression bonded by the non-thermocompression bonding portion. Or the manufacturing method of the solar cell module of 2. The method for manufacturing a solar cell module according to claim 3, wherein a plurality of the contact surfaces are provided in each of the thermocompression bonding portions, and the contact surface and the overlapping region overlap during the light reflecting member attaching step. The manufacturing method of the solar cell module according to claim 4, wherein the contact surface overlaps the contact surface and the overlap region at both end sides of each overlap region during the light reflecting member pasting step. further,
Before the light reflecting member placement step, a light reflecting member preparation step of placing a plurality of the light reflecting members on a plurality of moving bases one-to-one,
Before the light reflecting member arranging step and after the light reflecting member preparing step, each interval in the arrangement of a plurality of arranging regions straddling the gaps between two solar cells adjacent in the light reflecting member arranging step The manufacturing method of the solar cell module of any one of Claims 1-5 including the movement process in which the said two said moving stand adjusts the space | interval of the two said adjacent light reflection members according to. Furthermore, before the light reflecting member arrangement step,
A string forming step of forming a solar cell string by connecting a plurality of the solar cells arranged linearly along the row direction with a wiring material;
A pressing step of pressing the solar cells of the solar cell string formed in the string forming step with a pressing means,
The method for manufacturing a solar cell module according to claim 1, wherein the pressing step is continuously performed between the light reflecting member arranging step and the light reflecting member attaching step. The method for manufacturing a solar cell module according to claim 7, wherein in the pressing step, the solar cells are sequentially pressed by the pressing means toward the row direction of the solar cell string. Furthermore, after the light reflecting member attaching step,
The manufacturing method of the solar cell module of Claim 7 or 8 including the lamination process which laminates | stacks a translucent board | substrate, a resin sheet, and the said solar cell string in this order, and thermocompression-bonds the laminated body laminated | stacked. The pressure-bonding head has an intake hole for adsorbing the light reflecting member;
The light reflecting member is arranged so that the light reflecting member is attracted to the intake hole and straddles the gap between two adjacent solar cells in the light reflecting member arranging step. The manufacturing method of the solar cell module of 1 item | term. The method for manufacturing a solar cell module according to claim 1, wherein the thermocompression bonding portion includes an elastic portion that contacts the light reflecting member. The crimping head has a long shape,
The manufacturing method of the solar cell module of any one of Claims 1-11 which has the groove part which the said non-thermocompression bonding part dents with respect to two said thermocompression-bonding parts. The crimping head is a roller;
The method for manufacturing a solar cell module according to claim 1, wherein the non-thermocompression bonding part forms an annular groove that is annularly recessed with respect to the thermocompression bonding part.

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