JP3448924B2 - Method for manufacturing thin-film solar cell module - Google Patents

Method for manufacturing thin-film solar cell module

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Publication number
JP3448924B2
JP3448924B2 JP29372793A JP29372793A JP3448924B2 JP 3448924 B2 JP3448924 B2 JP 3448924B2 JP 29372793 A JP29372793 A JP 29372793A JP 29372793 A JP29372793 A JP 29372793A JP 3448924 B2 JP3448924 B2 JP 3448924B2
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JP
Japan
Prior art keywords
film
solar cell
conductive
adhesive resin
module
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP29372793A
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Japanese (ja)
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JPH07147424A (en
Inventor
清雄 齋藤
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富士電機株式会社
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Application filed by 富士電機株式会社 filed Critical 富士電機株式会社
Priority to JP29372793A priority Critical patent/JP3448924B2/en
Publication of JPH07147424A publication Critical patent/JPH07147424A/en
Application granted granted Critical
Publication of JP3448924B2 publication Critical patent/JP3448924B2/en
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Application status is Expired - Fee Related legal-status Critical

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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin-film solar cell comprising a plurality of thin-film solar cell sub-modules each using a semiconductor thin film mainly composed of amorphous silicon or the like. The present invention relates to a method for manufacturing a module. 2. Description of the Related Art An amorphous semiconductor thin film formed by glow discharge decomposition of a source gas or photo-CVD can be formed by a vapor phase growth method. Since it is low, it can be formed on a flexible substrate such as a resin. A solar cell module using such an amorphous thin film electrically connects the sub-modules of the amorphous solar cell in series or in parallel, and is made of a weather-resistant material such as glass which does not deteriorate the solar cell outdoors and does not transmit moisture. The protective substrate and the solar cell are sealed with an adhesive resin such as ethylene vinyl acetate (EVA). [0003] As a method of connecting solar cells in series or in parallel to produce a module, a conductive film is conventionally used.
That is, the solder is fused to the solar cell electrode portion, a conductive film is further placed thereon, and the solder and the conductive film are thermally fused. Thereby, the conductive film and the solar cell electrode portion were electrically connected. However, in this method, it has been difficult to modularize a thin-film solar cell having a small electrode area and a large effective area, or a thin-film solar cell using a synthetic resin substrate having a low melting point. SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems and to interconnect thin-film solar cells having a small electrode area and a large effective area, and a thin-film solar cell using a substrate having a low melting point. It is an object of the present invention to provide a method of manufacturing a thin film solar cell module that can be manufactured. [0005] In order to achieve the above object, a reference means of a method of manufacturing a thin-film solar cell module according to the present invention is a solar cell module having a strip-shaped extraction electrode at both ends on an insulating substrate. A plurality of sub-modules having a battery structure are placed adjacent to each other on the side where the extraction electrode is not provided and placed on one protective substrate with an adhesive resin layer interposed therebetween. An adhesive resin film having a narrow width and including dispersed metal pieces whose both end surfaces are exposed, and a conductive film whose both ends protrude from above the sub-module at the end portion. By laminating an adhesive resin film that does not contain any other components, placing another protective substrate on them, and then applying heat and pressure, both surfaces of the solar cell submodule are bonded to the protective substrate and the extraction electrodes are led. It shall be electrically connected to the conductive film. It is preferable that the metal piece is a columnar body made of copper or made of gold-plated metal powder. According to the method of manufacturing a thin-film solar cell module of the present invention, a conductive projection is formed on an extraction electrode of a sub-module having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate. A plurality of modules are taken out and placed on one protective substrate via an adhesive resin layer so that they are adjacent to each other on the side where the extraction electrode is not provided, and each module is covered with an adhesive resin film. Place a conductive film protruding above the sub-module,
In addition, another protective substrate is placed on the exposed surface of the conductive film and the adhesive resin film, and both surfaces of the solar cell module are bonded to the protective substrate by heating and pressure bonding, and a conductive electrode that has pierced the extraction electrode through the adhesive resin film. It shall be electrically connected to the conductive film via the projection. Another aspect of the present invention is to provide a solar cell structure having a strip-shaped extraction electrode at both ends on an insulating substrate. Placed via a layer, the top of each module is covered with an adhesive resin film, a conductive film having a projection formed on one surface is placed on both extraction electrodes, facing the extraction electrode, and further placed on the extraction film. Another protective substrate is placed on the exposed surface of the adhesive resin film, and both sides of the solar cell module are bonded to the protective substrate by heating and pressure bonding, and the extraction electrodes are made conductive through conductive protrusions that have broken through the adhesive resin film. It shall be electrically connected to the film. Preferably, the conductive protrusions are made of solder. In any case, it is effective that the adhesive resin is ethylene vinyl acetate. When the thin-film solar cell sub-module is bonded to the protective substrates on both sides with an adhesive resin, a conductive film, a sub-module and an end portion are used for connection between the sub-modules and for taking out generated power to the outside. The electrodes are electrically connected to each other by a conductive protrusion formed on a metal piece or end electrode included in the adhesive resin or on the conductive film and penetrating the adhesive resin film. This avoids connection with the conductive film by soldering. Next, reference examples and embodiments of the present invention will be described with reference to the drawings. In the reference examples shown in FIGS. 1A and 1B, the adhesive resin between the thin-film solar cell and the weather-resistant substrate contains a metal piece. Flexible thickness of 50 μm for solar cell substrate 1
m of polyethylene naphthalate film was used. An ITO film was formed on the surface of the substrate to a thickness of 1000 mm by a sputtering method, and the ITO film was separated into strips by a laser scribe method. Thereafter, an amorphous silicon (hereinafter referred to as a-Si) film was formed by a plasma CVD method, and this was again separated into strips by a laser scribe method. Further, on this, silver was formed to a thickness of 2000 mm by a sputtering method and separated into strips by a laser scribe method, whereby an a-Si solar cell submodule 2 was produced. And a glass plate that is a transparent weather-resistant protective substrate
A through an EVA4 film which is an adhesive resin
The substrate 1 on which the -Si solar cell submodule 2 was mounted was placed. Then, an EVA4 film containing a copper piece as the metal piece 5 such as an anisotropic conductive film Anisorm and a copper foil having the same width as the transparent electrode part are provided on the electrode part of each submodule. A conductive film 6 coated with a conductive adhesive on one side, and EVA4 on other portions.
Only the film was placed thereon, and a glass plate 32 was further placed thereon, followed by thermocompression bonding. EVA4 as an adhesive resin is melted by heat at the time of thermocompression bonding, and the a-Si solar cell submodule 2 and the glass plates 31 and 32 are bonded. At the same time, through the copper piece 5,
The extraction electrode of the a-Si solar cell sub-module 2 and the conductive film 6 are electrically connected, the connection between the a-Si solar cell sub-modules 2 is established, and the power generated from the end 61 to the outside is generated. Unloading can be performed. As described above, the output of the a-Si solar cell sub-module 2 is extracted to the outside by connecting the extraction electrode of each sub-module to the conductive film 6 via the copper piece 5 dispersed in the EVA 4. I have. The connection of each sub-module is performed in series and in parallel according to the required voltage. EVA4
Here, the copper pieces 5 dispersed in the inside are 50 μm in diameter and height.
Although they are randomly dispersed at a pitch of about 50 μm in a columnar shape of 100 μm, a spherical or rivet-shaped copper piece has the same effect. In order to prevent the a-Si solar cells from being short-circuited by the copper pieces 5, the width of the EVA film 6 containing the copper pieces 5 should be slightly smaller than the patterning width of the silver electrode that is the back electrode of the submodule 2. is important. E
The material of the metal pieces 5 dispersed in the VA 4 is not limited to copper, and may be any material that can make a good connection with the extraction electrode of the solar cell submodule 2 and the conductive film 6. Those coated with gold on the surface are also effective. The thickness of the EVA4 film containing the metal powder is such that the metal powder is exposed from the EVA film,
It is necessary to reduce the thickness so as to sufficiently contact the extraction electrode of the solar cell submodule 2 and the conductive film 6.
For this reason, in this prototype, the film thickness of the EVA4 film was set to 100 μm. Further, in this reference example, a conductive film 6 having a conductive adhesive applied on one side was used.
By fixing the conductive film 6 to the film or the glass plate 32, the conductive film 6 is prevented from being displaced during thermocompression bonding. With this structure, series or parallel connection between the solar cell submodules 2 and power extraction to the outside can be easily performed without soldering to the extraction electrode of the solar cell submodule 2. Further, by making the width of the conductive film 6 smaller than the width of the back surface electrode of the solar cell sub-module 2, precise positioning is not required, so that the extraction electrode area is small and the area efficiency is high.
-Si solar cell module may be produced. As a structure having the same effect, there is a structure shown in FIGS. 2A and 2B according to an embodiment of the present invention. In this embodiment, a flexible polyretylene naphthalate film having a thickness of 50 μm was used for the substrate 1. An ITO film is formed on this substrate to a thickness of 1000 mm by a sputtering method.
The film was separated into strips by a laser scribe method. Thereafter, an a-Si film was formed by a plasma CVD method, and this was again separated into strips by a laser scribe method.
Further thereon, silver was formed to a thickness of 2000 mm by a sputtering method, and separated into strips by a laser scribe method to form a back electrode, thereby forming an a-Si solar cell submodule 2. Here, the conductive protrusions 7 were formed on the electrode extraction portion of the silver electrode serving as the back surface electrode by ultrasonic soldering. This conductive projection can be similarly formed by a method of screen-printing a conductive paste or a method of dropping solder or a conductive paste with a dispenser. Then, the thus-processed solar cell submodule 2 was placed on a glass plate 31 as a transparent weather-resistant protective substrate via an EVA4 as an adhesive resin. An EVA4 film, a conductive film 6 having a conductive adhesive applied to one side of a copper foil, and a glass plate 32 were placed thereon and thermocompression bonded. EVA4, which is an adhesive resin, is melted by heat at the time of thermocompression bonding, and the solar cell submodule 2 and the glass plates 31, 32 are bonded. At this time, the conductive protrusions 7 formed on the silver electrode portions of the solar cell sub-module 2 break through the EVA4 film on top,
Since it is electrically connected to the conductive film 6 thereon, the solar cell sub-modules 2 are connected to each other and used for taking out generated power to the outside. What is important in this structure is that the tip of the conductive projection 7 is sharpened so that the film of the EVA 4 can be broken through. In this example,
Soldering was performed so that the solder became conical. Further, by applying a low-melting-point solder to the conductive projections 52 and the conductive film 6, the low-melting-point solder is melted during thermocompression bonding, and a method of soldering the conductive projections 7 and the conductive film 6 is also effective. FIG. 3 shows a thin film solar cell module manufactured according to another embodiment of the present invention, in which conductive protrusions are formed on a conductive film 6 for connecting thin film solar cell submodules in series or in parallel. . In this case, a flexible polyethylene naphthalate film having a thickness of 50 μm was used for the substrate 1 of the solar cell. An ITO film is formed on this substrate to a thickness of 1000 mm by a sputtering method.
The film was separated into strips by a laser scribe method. Thereafter, an a-Si film was formed by a plasma CVD method, and this was again separated into strips by a laser scribe method.
Further, on this, silver was formed to a thickness of 2000 mm by a sputtering method and separated into strips by a laser scribe method, whereby an a-Si solar cell submodule 2 was produced. Then, the solar cell sub-module 2 is provided with a glass plate 31 as a transparent weather-resistant protective substrate and an EVA as an adhesive resin.
4 on top. On top of this, a film of EVA 4 and a conductive film 6 with conductive protrusions 7 were placed with the protrusions 7 on the lower side, and a glass plate 32 was further placed thereon and thermocompression-bonded. As a method for attaching the conductive protrusions 7 to the conductive film 6, FIG.
In the same manner as in the embodiment described above, the method can be performed by a method of ultrasonic soldering, a method of screen-printing a conductive paste, or a method of dropping solder or a conductive paste with a dispenser. EVA4, which is an adhesive resin, is melted by heat at the time of thermocompression bonding, and the solar cell submodule 2 and the glass plates 31, 32 are bonded. At this time, the conductive projections 7 formed on the lower surface of the conductive film 6 break through the underlying EVA 4 film and are electrically connected to the extraction electrodes of the solar cell sub-module 2. It is also used to take out generated power to the outside. What is important in this structure is that the tip of the conductive protrusion 7 is sharpened so that the film of the EVA 4 can be broken through. In this embodiment, the soldering is performed so that the solder has a conical shape. Further, by applying a low-melting-point solder to the conductive protrusions, the low-melting-point solder melts during thermocompression bonding, and a method of soldering the conductive protrusions 7 and the conductive film 6 is also effective. According to the present invention, the conductive film and the end electrode are electrically connected by pressing the end electrode of the solar cell sub-module or the conductive projection formed on the conductive film. This eliminates the need for a soldering process,
It has an advantage that a thin film solar cell using a small electrode area or a synthetic resin substrate can be connected. By using this method, the power generated per unit area of the thin-film solar cell module can be easily increased.
Further, since a complicated wiring process is not required, the manufacturing cost of the thin-film solar cell module can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a thin film solar cell module according to a reference example of the present invention, wherein (a) is a cross-sectional view and (b) is a plan view. 3A and 3B show a thin film solar cell module according to another embodiment of the present invention, in which FIG. 3A is a cross-sectional view, FIG. 3B is a plan view, and FIG. [Description of reference numerals] 1 solar cell substrate 2 solar cell submodules 31, 32 glass plate 4 EVA 5 copper piece 6 conductive film 7 conductive protrusion

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. 7 , DB name) H01L 31/00-31/12

Claims (1)

  1. (57) Claims 1. A submodule having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate, wherein a conductive projection is formed on an extraction electrode, Are mounted on one protective substrate via an adhesive resin layer adjacent to the side on which the extraction electrode is not provided, and each module is covered with an adhesive resin film. A conductive film that protrudes above the module is placed, and another protective substrate is placed on the exposed surface of the conductive film and the adhesive resin film, and both sides of the solar cell module are bonded to the protective substrate by heating and pressing. Characterized in that an extraction electrode is electrically connected to a conductive film through a conductive protrusion that has penetrated the adhesive resin film, . 2. An adhesive resin layer is formed on one protective substrate adjacent to a plurality of sub-modules having a solar cell structure provided with strip-shaped extraction electrodes at both ends on an insulating substrate on a side where no extraction electrodes are provided. The module is covered with an adhesive resin film, and a conductive film having a projection formed on one surface is placed on both extraction electrodes so as to face the projection, and the conductive film and the adhesive are further mounted. Another protective substrate is placed on the exposed surface of the resin film, and both sides of the solar cell module are adhered to the protective substrate by heat-pressing, and the take-out electrodes are connected to the conductive film via conductive protrusions that have broken through the adhesive resin film. A method for manufacturing a thin-film solar cell module, wherein the method is electrically connected to a thin-film solar cell module. 3. The method according to claim 1, wherein the conductive projections are made of solder. 4. The method for manufacturing a thin-film solar cell module according to claim 1, wherein the adhesive resin is ethylene vinyl acetate.
JP29372793A 1993-11-25 1993-11-25 Method for manufacturing thin-film solar cell module Expired - Fee Related JP3448924B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP29372793A JP3448924B2 (en) 1993-11-25 1993-11-25 Method for manufacturing thin-film solar cell module

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP29372793A JP3448924B2 (en) 1993-11-25 1993-11-25 Method for manufacturing thin-film solar cell module

Publications (2)

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JPH07147424A JPH07147424A (en) 1995-06-06
JP3448924B2 true JP3448924B2 (en) 2003-09-22

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WO2008026356A1 (en) 2006-08-29 2008-03-06 Hitachi Chemical Company, Ltd. Conductive adhesive film and solar cell module
WO2008044696A1 (en) 2006-10-13 2008-04-17 Hitachi Chemical Company, Ltd. Solar battery cell connection method and solar battery module
WO2008044357A1 (en) 2006-10-10 2008-04-17 Hitachi Chemical Company, Ltd. Connected structure and method for manufacture thereof
DE102011081551A1 (en) 2010-08-26 2012-03-01 Hitachi Chemical Co., Ltd. Adhesive film for solar cell electrode and method of manufacturing a solar cell module with its use
KR101514844B1 (en) * 2007-12-27 2015-04-23 산요덴키가부시키가이샤 Solar cell module and manufacturing method thereof
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WO2008026356A1 (en) 2006-08-29 2008-03-06 Hitachi Chemical Company, Ltd. Conductive adhesive film and solar cell module
WO2008044357A1 (en) 2006-10-10 2008-04-17 Hitachi Chemical Company, Ltd. Connected structure and method for manufacture thereof
US9123835B2 (en) 2006-10-10 2015-09-01 Hitachi Chemical Company, Ltd. Connected structure and method for manufacture thereof
WO2008044696A1 (en) 2006-10-13 2008-04-17 Hitachi Chemical Company, Ltd. Solar battery cell connection method and solar battery module
US8809102B2 (en) 2006-10-13 2014-08-19 Hitachi Chemical Company, Ltd. Solar battery cell connection method and solar battery module
KR101514844B1 (en) * 2007-12-27 2015-04-23 산요덴키가부시키가이샤 Solar cell module and manufacturing method thereof
US9059358B2 (en) 2007-12-27 2015-06-16 Panasonic Intellectual Property Management Co., Ltd. Solar cell module and method of manufacturing the same
DE102011081551A1 (en) 2010-08-26 2012-03-01 Hitachi Chemical Co., Ltd. Adhesive film for solar cell electrode and method of manufacturing a solar cell module with its use
DE202011110111U1 (en) 2010-08-26 2013-01-10 Hitachi Chemical Company, Ltd. Adhesive film for solar cell electrode

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