JP4698410B2 - Solar cell module manufacturing method and solar cell module manufacturing apparatus - Google Patents

Description

  The present invention relates to a solar cell module manufacturing method and a solar cell module for manufacturing a solar cell module in which a solar cell array in which a plurality of solar cells are connected is sealed by connecting solar cells with an interconnector. It relates to a manufacturing apparatus.

  As a countermeasure against environmental problems, the use of solar cell modules in which a solar cell array in which a large number of solar cells are connected is mounted (sealed) is increasing. In particular, it is desired to provide a large-sized solar cell module capable of generating large electric power with high reliability and at low cost.

  From such a background, development for manufacturing a highly reliable solar cell module efficiently and inexpensively is desired.

  A conventional solar cell module manufacturing method and manufacturing apparatus will be described.

  FIG. 10 is an explanatory diagram for partially explaining a process of manufacturing a solar cell array constituting a solar battery module according to a conventional example. FIG. 10 (A) shows a manufacturing process of the solar cell array according to Conventional Example 1. (B) shows the manufacturing process of the photovoltaic cell row | line | column which concerns on the prior art example 2. FIG.

  First, the process in the case of manufacturing the photovoltaic cell row | line | column of the solar cell module which concerns on the prior art example 1 shown to the figure (A) is demonstrated. A solar cell module according to Conventional Example 1 is disclosed in Patent Document 1, for example.

  After the interconnector wire 101 is pulled out by a roller or a chuck (not shown) from the wire supply reel 102 around which the interconnector wire 101 is wound and passed through a guide groove (not shown) of the feed base 103, the distortion is corrected. The interconnector wire 101 is supplied to the cell 110, and the interconnector wire 101 is set on an electrode (not shown) on the surface side of the solar battery cell 110.

  Next, the interconnector wire rod 101 is provided with a length for connecting to an electrode (not shown) on the back surface side of the adjacent solar battery cell 110, and is cut and bent by the tab cut portion 104 to form the interconnector 111. Then, it is temporarily placed on the electrode on the surface side of the solar battery cell 110. The solar battery cell 110 on which the interconnector 111 is temporarily placed is transported on the stage 105.

  Similarly, the next adjacent solar battery cell is processed, and an electrode (not shown) on the back surface side is overlapped with the interconnector 111 that the previous solar battery cell 110 extends.

  The continuously stacked solar cells 110 are further transported on the stage 105 and heated by the heating unit 106 so that the solder coated on the surface of the interconnector 111 and the solder formed on the electrodes of the solar cells 110 Melt.

  By melting the solder, the interconnector 111 is connected to the electrodes of the solar battery cells (solder bonding), and a solar battery array in which the plurality of solar battery cells 110 are connected by the interconnector 111 is formed.

  Next, the process in the case of manufacturing the photovoltaic cell row | line | column of the solar cell module which concerns on the prior art example 2 shown to the same figure (B) is demonstrated. A solar cell module according to Conventional Example 2 is disclosed in Patent Document 2, for example.

  The surface of the interconnector wire 101 is coated by drawing the interconnector wire 101 from the wire supply reel 102 around which the interconnector wire 101 is wound, and contacting the interconnector wire 101 with the electrode on the surface side of the solar battery cell 110 and heating it. The solder formed on the electrode of the solar cell 110 is melted and the interconnector wire 101 is connected to the electrode on the surface side of the solar cell 110 (solder bonding), and then the adjacent solar cell 110 is connected. The interconnector wire 111 is provided with a length for connecting to the electrode on the back surface of the interconnector, and the interconnector 111 is formed by cutting along the cutting line DL.

  Thereafter, the solar battery cell 110 to which the interconnector 111 is connected is inverted, and the interconnector 111 is connected to the electrode on the back surface side of the adjacent solar battery cell 110 to which the interconnector 111 has been previously connected. A solar battery cell row connecting the battery cells 110 is formed (not shown).

In both Conventional Example 1 and Conventional Example 2, a solar cell module is formed by subjecting the formed solar cell array to a sealing process by an appropriate sealing process.
JP-A-10-93120 JP 2003-298095 A

  However, in the method for manufacturing a solar cell array (solar cell module) according to Conventional Example 1, when interconnector wire 101 that is a copper wire formed in a ribbon shape is supplied from wire supply reel 102, interconnector wire 101 is used. Is pulled out in the horizontal direction by a roller or a chuck (not shown), an excessive force may be applied to the interconnector wire 101 when it is pulled out, and the interconnector wire 101 is hard due to deformation caused by deformation (bending or extending). There was a problem of fear of becoming.

  Moreover, since it is set as the structure which eliminates distortion of the interconnector wire 101 only by pressing the interconnector wire 101 with the guide groove of the feed stand 103, it was not easy to eliminate the curl of the interconnector wire 101.

  In the manufacturing method of the photovoltaic cell row (solar cell module) according to Conventional Example 2, the interconnector wire 101 wound around the wire supply reel 102 is wound around bobbins that form a plurality of planes. When the interconnector wire 101 is pulled out, the interconnector wire 101 disposed on both the left and right sides of the bobbin receives a force in the twisting direction with respect to the direction of the interconnector 111, which may cause deformation. there were.

  Therefore, in the conventional example 2, it is necessary to increase the distance between the bobbin and the processing position of the interconnector wire rod 101, or to provide a mechanism for moving the bobbin in the axial direction in order to pull out from the same direction. However, there is a problem that the apparatus becomes large and complicated control is required.

  Moreover, since the countermeasure against the curl of the interconnector wire 101 is not taken into consideration, it is not easy to eliminate the curl of the interconnector wire 101.

  The present invention has been made in view of such a situation, and since excessive tension does not reach the supplied interconnector wire, deformation (working distortion) such as twist due to tension can be suppressed and prevented, and the wire It is possible to connect the interconnector and solar cells in a state where distortion is suppressed and prevented by forming an interconnector with less processing distortion by adopting a configuration that can reduce winding of the interconnector wire by the supply reel or bobbin. An object is to provide a solar cell module manufacturing method and a solar cell module manufacturing apparatus capable of manufacturing a highly reliable solar cell module.

The solar cell module manufacturing method according to the present invention includes a step of supplying the interconnector wire from a wire supply reel or bobbin around which the interconnector wire is wound, and cutting the supplied interconnector wire into a connection unit length. forming a connector, the interconnector a solar cell module manufacturing method comprising a step of connecting the electrode of solar cell, in step of supplying the interconnector wire, the interconnector wire, the connection A slack portion having a slack is formed between the interconnector forming portion that is drawn out from the wire supply reel or the bobbin with a length longer than a unit length to form the interconnector and the wire supply reel or the bobbin, In the step of forming an interconnector, the length of the connection unit length When pulled out of the interconnector wire, the length of the interconnector wire in the slack portion, characterized in that there as a length longer than the connection unit length.

  With this configuration, excessive tension does not reach the interconnector wire that is supplied, so deformation (distortion) such as torsion due to tension can be suppressed, and an interconnector with less distortion can be formed, and distortion is also suppressed. Since the interconnector and the solar battery cell can be connected in a state where there is little processing distortion, it is possible to manufacture a highly reliable solar battery module.

Moreover, in the solar cell module manufacturing method which concerns on this invention, the said interconnector wire is made into J shape by the said slack part .

With this configuration, the length of the slack portion can be defined by a J-shaped portion .

Further, in the solar cell module manufacturing method according to the present invention, the length of the slack portion in a state with the sag, characterized in that it is adjusted by feeding the interconnector wire from the wire supply reel or the bobbin And

With this configuration, the wire supply reel or bobbin can be controlled and fed out, so that the interconnector wire can be supplied without applying excessive tension to the interconnector wire.

Further, in the solar cell module manufacturing method according to the present invention, the length of feed of the interconnector wire is characterized in that it is controlled by the state of the slack portion that is detected by the slack detection means.

  With this configuration, it is possible to accurately control the state of the slack portion (the length of the slack portion), it is possible to suppress the tension applied to the interconnector wire, and prevent the interconnector wire from being distorted. It becomes possible.

Moreover, in the solar cell module manufacturing method according to the present invention, after forming the interconnector in the step of forming the interconnector, the interconnector wire is held in the state where the end of the interconnector wire is held, or the wire supply reel or A step of pulling back in the direction of the bobbin is provided .

  With this configuration, it is possible to correct (straighten, flatten) the slack of the interconnector wire, and it can be cut in a state in which the slack is eliminated. It becomes possible to cut accurately.

Further, the solar cell module manufacturing apparatus according to the present invention, wound the wire supply reel or bobbin supplying interconnector wire are, cutting the wire supply reel or the interconnector wire material supplied from the bobbin to the connection unit length And an interconnector forming unit for forming an interconnector, wherein the wire supply reel or the bobbin is controlled to feed out the interconnector wire having a length longer than the connection unit length. The interconnector wire forms a slack portion having a length longer than the connection unit length between the wire supply reel or bobbin and the interconnector forming portion .
With this configuration, excessive tension is not applied to the supplied interconnector wire, so deformation (distortion) such as torsion due to tension can be suppressed, and curling of the interconnector wire due to the wire supply reel or bobbin is reduced (corrected) Therefore, it is possible to form an interconnector with less distortion, and to manufacture a highly reliable solar cell module because the interconnector and the solar cell can be connected in a state where distortion is suppressed. Is possible.

Moreover, in the solar cell module manufacturing apparatus according to the present invention, the interconnector wire is formed in a J shape at the slack portion . With this configuration, the length of the slack portion can be defined by a J-shaped portion.

In the solar cell module manufacturing apparatus according to the present invention, the wire supply reel or the bobbin is configured to feed out the interconnector wire from a side away from the interconnector forming portion.

  With this configuration, the curvature of the slack portion can be increased and the apparatus can be miniaturized, so that the distortion of the interconnector wire can be reliably reduced.

In the solar cell module manufacturing apparatus according to the present invention, a slack detecting means for detecting the slack state is provided between the wire supply reel or the bobbin and the interconnector forming portion .

  This configuration makes it possible to accurately control the slack state.

In the solar cell module manufacturing apparatus according to the present invention, the solar cell module manufacturing apparatus includes a rotation control unit that controls the rotation of the wire supply reel or the bobbin based on the detection result of the slackness state by the slackness detection means. .

  With this configuration, it is possible to accurately control the length of the slack portion.

Further, in the solar cell module manufacturing apparatus according to the present invention, a regulation chuck for fixing the interconnector wire supplied to the interconnector forming portion, and the interconnector wire fixed by the regulation chuck as the wire supply reel or the And a return roller that pulls back in the direction of the bobbin .

  With this configuration, it is possible to cut the interconnector wire after correcting the looseness of the interconnector wire at the interconnector forming portion, and it is possible to form an interconnector without distortion. Moreover, since a moving space for pulling back the interconnector wire is not required, the apparatus can be miniaturized.

  In the solar cell module manufacturing apparatus according to the present invention, the return roller has a torque adjustment function.

  With this configuration, excessive tension is not applied to the interconnector wire at the time of pulling back, so that it is possible to correct the interconnector wire with high accuracy.

  A solar cell module manufacturing method and a solar cell module manufacturing apparatus according to the present invention are provided by connecting an interconnector formed by cutting an interconnector wire supplied from a wire supply reel into a connection unit length to a solar cell. A solar cell module manufacturing method or a solar cell module manufacturing apparatus for manufacturing a module, wherein the interconnector wire is supplied in a slack state, or the interconnector wire is provided between the wire supply reel and the interconnector forming portion. It is set as the structure provided with the slack formation area | region which has slack.

  Therefore, according to the solar cell module manufacturing method and the solar cell module manufacturing apparatus according to the present invention, since excessive tension does not reach the supplied interconnector wire, deformation (distortion) such as twist due to tension can be suppressed, and , Because it is possible to reduce (correct or eliminate) the winding of the interconnector wire due to the wire supply reel, it is possible to form an interconnector with less distortion, and with the interconnector and solar cell in a state where distortion is suppressed Can be connected, and thus it is possible to manufacture a highly reliable solar cell module.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<Embodiment 1>
Based on FIG. 1 thru | or FIG. 7, the solar cell module manufacturing method and solar cell module manufacturing apparatus which concern on Embodiment 1 of this invention are demonstrated.

  The solar cell module manufacturing apparatus according to the present embodiment (see FIGS. 1 to 6) includes a wire supply reel 2 around which an interconnector wire 1 is wound, and an interconnector wire 1 supplied from the wire supply reel 2 as a connection unit length. An interconnector forming section 3 for forming an interconnector 11 (see FIGS. 3 and 4) for connecting the adjacent photovoltaic cells 10 (see FIG. 7) by cutting into Lu (see FIGS. 3 and 4); A connection processing unit (not shown) for connecting the interconnector 11 to the solar battery cell 10 is provided.

  The interconnector wire 1 is made of, for example, a ribbon-like metal wire, and specifically is made of a copper wire. The interconnector wire 1 is provided with a solder coating having a thickness of about 20 to 60 μm on the surface (entire surface) of a copper wire having a width of about 1 to 3 mm and a thickness of about 100 to 300 μm. Therefore, the total thickness is about 100 to 300 μm + 40 to 120 μm.

  Since the wire supply reel 2 is wound around the interconnector wire 1, it is possible to accommodate the interconnector wire 1 having a long distance in a limited range. The wire supply reel 2 includes a rotation control unit 24 (see FIG. 6), and is controlled so that the interconnector wire 1 is fed out to the slack formation region 21 in accordance with the state of the process and the state of the slack portion 1s. Therefore, it is possible to accurately control the length of the slack portion 1s without applying excessive tension to the interconnector wire 1.

  The interconnector forming unit 3 is configured to cut the interconnector wire 1 supplied from the wire supply reel 2 to form the interconnector 11. The interconnector forming unit 3 changes the traveling direction of the interconnector wire 1 to a horizontal direction to make it processable, and pulls the interconnector wire 1 back toward the convertor roller 31 (and the wire supply reel 2). A return roller 32 for reducing the interconnector wire 1 by correcting (flattening, straightening) the distortion (slackness) of the interconnector wire 1, a regulation chuck 33 for regulating the tip of the interconnector wire 1, A cutter 34 for cutting the interconnector wire 1 to form an interconnector 11 having a connection unit length Lu, and transfer chucks 35 and 36 for transferring the interconnector wire 1 or the interconnector 11 (cut interconnector wire 1). Prepare.

  Further, between the wire supply reel 2 and the interconnector forming portion 3, a slack forming region 21 in which a slack portion 1 s where the interconnector wire 1 has a slack is formed. Since the interconnector wire 1 is supplied in a state in which the slack portion 1s is always provided by the slack formation region 21, excessive tension is not applied to the supplied interconnector wire 1, so that deformation (distortion) such as twist due to tension is applied. ) And the curling of the interconnector wire 1 by the wire supply reel 2 can be reduced (corrected or eliminated), so that the interconnector 11 with less distortion can be formed.

  The interconnector wire 1 is configured to be drawn out from the side farther than the axis of the wire supply reel 2 (position outside the axis of the wire supply reel 2) with respect to the slack formation region 21. That is, the wire supply reel 2 is configured to feed out the interconnector wire 1 from the side away from the interconnector forming portion 3. With this configuration, the curvature of the slack (slack portion 1s) can be increased, and the solar cell module manufacturing apparatus can be downsized.

  FIG. 1 is a process explanatory view showing a state immediately before an interconnector wire is transferred by a transfer chuck in the solar cell module manufacturing method according to Embodiment 1 of the present invention.

  The interconnector wire 1 whose tip is cut by the cutter 34 is held by the transfer chucks 35 and 36. In order to perform the transfer, the return roller 32, the regulation chuck 33, and the cutter 34 are opened. The interconnector wire 1 is transferred in the direction of arrow A while being held by the transfer chucks 35 and 36. Along with this, the slack portion 1s also starts to move (rise) in the direction of the arrow B. Note that the length of the slack portion 1s can be defined by a portion having a “J” shape.

  That is, FIG. 1 shows a process for preparing the transfer of the interconnector wire 1.

  The wire supply reel 2 viewed from the arrow X direction will be described with reference to FIG.

  FIG. 2 is a process explanatory view showing a state where the interconnector wire is transferred by the transfer chuck and prepared for cutting after the process of FIG.

  The interconnector wire 1 held by the transfer chucks 35 and 36 is transferred to the outside of the regulating chuck 33 and the cutter 34 (on the connection processing unit side) by the transfer chucks 35 and 36.

  Further, as the interconnector wire 1 is transferred, in the slack formation region 21, the slack portion 1s moves (rises) in the direction of arrow B while maintaining the tension corresponding to the weight of the interconnector wire 1, and the interconnector 1 The interconnector wire 1 is supplied to the forming unit 3. At this time, since only the tension of its own weight is applied to the interconnector wire 1 (slack portion 1s), excessive tension does not reach and deformation (distortion) such as torsion due to tension can be suppressed.

  That is, FIG. 2 shows a step of preparing for cutting by transferring (drawing out) the interconnector wire 1 so that it can be cut.

  FIG. 3 is a process explanatory view showing a state in which the interconnector wire is cut after the process of FIG.

  The interconnector 11 having the connection unit length Lu is formed by fixing the interconnector wire 1 with the restriction chuck 33 and cutting with the cutter 34 provided adjacent to the restriction chuck 33. The movement positions of the transfer chucks 35 and 36 are set in advance so that the interconnector wire 1 is transferred to a position corresponding to the connection unit length Lu.

  That is, FIG. 3 shows a process of forming the interconnector 11 by cutting the supplied interconnector wire 1 into the connection unit length Lu.

  In addition, when the interconnector wire 1 is supplied in the process of forming the interconnector 11 by cutting the interconnector wire 1 into the connection unit length Lu, the length of the slack portion 1s in the state having the slack is the connection unit. The length is longer than the length Lu. In addition, the length of the slack portion 1s having a slack is adjusted by feeding the interconnector wire 1 from the wire supply reel 2.

  With this configuration, when the interconnector wire 1 is supplied in the process of forming the interconnector 11 by cutting the interconnector wire 1 into the connection unit length Lu, the interconnector wire 1 can be supplied while maintaining slack. It is possible to reliably form the interconnector 11 having a small amount.

  At this time, since there is a gap between the regulation chuck 33 of the interconnector forming portion 3 and the conversion roller 31, the interconnector wire 1 may be loosened due to its own weight.

  FIG. 4 is a process explanatory view showing a state in which the cut interconnector is transferred and the interconnector wire is pulled back after the process of FIG. 3.

  The interconnector 11 formed by cutting the interconnector wire 1 is transferred in the direction of the arrow C by the transfer chucks 35 and 36 and is transported to the connection processing unit arranged next to the interconnector forming unit 3. Note that the transfer chucks 35 and 36 may be used as they are for transfer to the connection processing unit, but it is preferable that the transfer chucks 35 and 36 be transferred and transferred appropriately by a separately provided transfer means (not shown).

  On the other hand, the interconnector wire 1 held and fixed by the regulating chuck 33 is sandwiched by the return roller 32, and the return roller 32 is rotated in the direction of the arrow D, whereby the interconnector wire 1 is moved in the direction of the arrow E (conversion roller). Reduction is made by pulling back in the 32 direction and the wire supply reel 2 direction. Accordingly, the interconnector wire 1 can proceed to the step of cutting the interconnector 11 in a state where the slack is corrected (straightened, flattened), and the interconnector wire 1 is cut in a state in which the distortion is eliminated. Therefore, the interconnector 11 without distortion can be formed.

  That is, the interconnector wire 1 is removed from slackness by reduction, and further corrected (flattened, straightened). In response to the reduction, the slack formation region 21 moves (lowers) in the direction of arrow F, and the tension due to the weight of the slack portion 1s is maintained on the interconnector wire 1 so that excessive tension acts. There is nothing.

  By setting the return roller 32 to have a torque adjustment function, it is possible to adjust the tension applied to the interconnector wire 1 when the return roller 32 is pulled back. Therefore, by setting the tension to such an extent that the slack can be removed, the interconnector wire 1 can be corrected with high accuracy and without distortion.

  That is, FIG. 4 shows a process of reducing and flattening and straightening the supplied interconnector wire 1.

  In addition, since the return roller 32 pulls back the interconnector wire 1 by rotation, a moving space for pulling back is not necessary as compared with a case where the interconnector wire 1 is moved back linearly, and thus the apparatus can be miniaturized.

  FIG. 5 is a process explanatory view showing a state in which the interconnector wire is supplied in preparation for transferring the reduced interconnector wire after the process of FIG.

  The interconnector wire 1 is reduced and held by the regulation chuck 33 and the return roller 32. In this state, the transfer chucks 35 and 36 that have completed the transfer of the interconnector 11 are returned to their original positions (between the return roller 32 and the restricting chuck 33), and are held again.

  Next, the rotation control unit 24 (see FIG. 6) is controlled so that the wire supply reel 2 is rotated in the feed-out direction (arrow G direction) of the interconnector wire 1 and is set appropriately according to the connection unit length Lu. The interconnector wire 1 corresponding to the length is fed out. Since the slack formation region 21 moves (lowers) in the direction of the arrow H while maintaining the tension due to the weight of the slack portion 1s, excessive tension does not act on the interconnector wire 1. Therefore, the length of the slack portion 1 s is adjusted by feeding the interconnector wire 1 from the wire supply reel 2.

  At this time, the change in the length of the slack portion 1s of the interconnector wire 1 is necessary to form the interconnector 11 by adjusting the slack so as to change with a length longer than the length of the connection unit length Lu. The length of the interconnector wire 1 can be supplied to the interconnector forming portion 3, and the interconnector 11 without distortion can be reliably formed. Note that the length of the slack portion 1s can be defined by the portion having the “J” shape in the slack formation region 21 as described above.

  Since the rotation control unit 24 is composed of, for example, a stepping motor or the like, the rotation of the wire supply reel 2 can be controlled with high accuracy. Therefore, the feeding length of the interconnector wire 1 (length of the slack portion 1s) can be accurately and accurately. Can be controlled (adjusted).

  That is, FIG. 5 shows a process of supplying the interconnector wire 1 from the wire supply reel 2.

  FIG. 6 is an explanatory diagram of a wire rod supply reel showing a state in which the wire rod supply reel is viewed from the direction of the arrow X shown in FIG. 1, and (A) shows a wire rod supply reel having an interconnector wire rod wound as a ribbon. B) shows a wire supply reel in which the interconnector wire is wound around a bobbin. The wire supply reel shown in FIG. 4B is also called a bobbin.

  In the present embodiment, the interconnector wire 1 fed out from the wire supply reel 2 forms a slack portion 1 s in the slack formation region 21 arranged in front of the interconnector formation portion 3. Any form of winding can be applied.

  In other words, the winding rod added to the interconnector wire 1 by the wire supply reel 2 can be reduced (corrected or eliminated) in the slack formation region 21, so that the wire rod can be in any form of ribbon winding or bobbin winding. The supply reel 2 can also be applied.

  In addition, since the rotation control part 24 which controls rotation of the wire supply reel 2 is connected with the axis | shaft of the wire supply reel 2, rotation of the wire supply reel 2 can be controlled easily and correctly.

  In the present embodiment, when the winding diameter of the wire supply reel 2 is 200 mm and the maximum is 500 mm, the interconnector wire 1 having the shape (thickness) described above can be wound by about 600 m.

  FIG. 7: is explanatory drawing which shows the photovoltaic cell row | line | column sealed by the solar cell module manufactured with the solar cell module manufacturing method which concerns on Embodiment 1 of this invention, (A) is a top view, (B) Is a side view.

  The solar battery cell 10 has an electrode 10e formed on the surface of a semiconductor substrate on which an appropriate junction is formed. The thickness of the semiconductor substrate is about 200 to 400 μm, and the size is about 100 to 200 mm. The electrode 10e is formed on the front surface side (FIG. A) and the back surface side (not shown), and the electrode on the front surface side is formed in a comb shape so as to improve current collection efficiency and power generation efficiency. Further, the electrode on the back side (not shown) has a shape that covers, for example, the entire back side in order to reduce connection resistance.

  The electrode 10e is subjected to solder coating, and is transferred to the connection processing unit in a state of being in contact with the interconnector 11 to which the solder coating is similarly applied. By heating in this state and melting the solder, solder joining between the electrode 10e (solar cell 10) and the interconnector 11 is performed (step of connecting the interconnector 11 to the solar cell 10).

  Since the interconnector 11 is formed by cutting the interconnector wire 1 with a connection unit length Lu, the interconnector 11 has a so-called strip shape. When the size of the solar cell 10 is about 150 mm square, the connection unit length Lu is about 300 mm, about half of the connection unit length Lu is connected to the electrode 10e on the surface side, and the other half is adjacent to the solar cell. 10 is connected to the electrode on the back surface side.

  In the interconnector 11, a bent portion is appropriately formed in the middle of the interconnector 11 in order to correspond to the thickness of the semiconductor substrate, and the adjacent solar cells 10 are connected in series. Become. That is, one side in the length direction of the connection unit length Lu is connected to the electrode on the front surface side of the solar battery cell 10, and the other side in the length direction of the connection unit length Lu is connected to the electrode on the back surface side of the adjacent solar battery cell 10. Is done. The step of bending the interconnector 11 can be appropriately set before the interconnector 11 is transferred and aligned with the electrode 10e of the solar battery cell 10.

  A plurality of solar cells 10 connected continuously by the interconnector 11 constitute a solar cell array 15. A solar cell module (not shown) can be manufactured by sealing the solar cell rows 15 with an appropriate sealing means. The sealing means includes, for example, a frame body (not shown) that surrounds the periphery of the solar cell row 15 and a sealing portion (not shown) that seals the front surface side and the back surface side of the solar cell row 15. The

  In the following second and third embodiments, the slackness detecting means is used to detect the slackness state (the slackness portion 1s state), and the length of the slackness portion 1s is adjusted based on the detection result. However, regardless of the slack detection means, the length of the extension of the interconnector wire 1 is calculated in advance, and the rotation of the rotation control unit 24 is controlled based on the calculation result, thereby controlling the slack portion 1s. It is also possible to adjust and control the length (sag state).

<Embodiment 2>
Based on FIG. 8, the solar cell module manufacturing method and solar cell module manufacturing apparatus which concern on Embodiment 2 of this invention are demonstrated.

  FIG. 8 is an explanatory diagram schematically illustrating the operation of the conductive detection unit that detects the state of the slack portion in the solar cell module manufacturing method and the solar cell module manufacturing device according to Embodiment 2 of the present invention. A) shows a state where the length of the slack portion is maximized, and (B) shows a state where the length of the slack portion is minimized.

  Corresponding to the slack formation region 21, a conductive detection unit 22 as a slack detection means is arranged. The conductivity type detection unit 22 has an arm-shaped contact terminal 22a having appropriate conductivity. In the present embodiment, for example, when the arm-shaped contact terminal 22a is positioned in the horizontal direction, a position where the length of the slack portion 1s becomes a predetermined maximum length is detected (A in the figure), and the arm-shaped contact terminal 22a is detected. Is positioned by rotating the angle θ from the horizontal direction to the upward direction to detect the position where the length of the slack portion 1s becomes a predetermined minimum length (B in the figure).

  For example, in the step of supplying the interconnector wire 1 from the wire supply reel 2 (see FIG. 5), since the interconnector wire 1 is fed out from the wire supply reel 2, the slack portion 1s descends in the direction of the arrow H. Then, the arm-shaped contact terminal 22a is contacted (FIG. 8A). Since both the interconnector wire 1 and the arm-shaped contact terminal 22a have conductivity, when the interconnector wire 1 comes into contact with the arm-shaped contact terminal 22a, the ammeter 22s of the conductive detector 22 detects the current.

  That is, by detecting a change in current, it is possible to detect that the interconnector wire 1 has been lowered to a predetermined position (horizontal direction) and has become a slack portion 1s having a maximum length (a slack state).

  For example, in the process of preparing for cutting by transferring (drawing) the interconnector wire 1 so that it can be cut (see FIG. 2), the interconnector wire 1 is transferred in the direction of the arrow K, so Part 1s will rise in the direction of arrow B. When the arm-shaped contact terminal 22a is rotated upward in a state of being in contact with the slack portion 1s in synchronization with the rise of the slack portion 1s, and the arm-shaped contact terminal 22a is stopped at the position of the angle θ, The interconnector wire 1 to be transferred is separated from the arm-shaped contact terminal 22a at the position of the angle θ (FIG. 8B). When the arm-shaped contact terminal 22a and the interconnector wire 1 are separated from each other, no current flows through the ammeter 22s of the conductive detection unit 22.

  That is, by detecting a change in current, the interconnector wire 1 is raised to a predetermined position (position rotated by an angle θ from the horizontal direction to the upward direction) to become a slack portion 1s having a minimum length (a slack state). ) Can be detected. The slack portion 1s having the minimum length can be maintained by feeding the interconnector wire 1 by appropriately controlling the rotation of the wire supply reel 2 so that the slack portion 1s having the minimum length is not further shortened. .

  As described above, the extension length of the interconnector wire 1 can be controlled (adjusted) by the rotation control unit 24 in accordance with the state of the slack portion 1s detected by the slack detection means (conductivity detection unit 22). . With this configuration, it is possible to accurately control the state of slack according to the state of each process, so that it is possible to prevent the occurrence of distortion when the interconnector wire 1 is supplied.

  It should be noted that the control of the conductive type slack detecting means can be easily synchronized with the operation of the other components in each process, so that accurate detection is possible and the length of the slack portion 1s of the interconnector wire 1 is accurately obtained. Can be adjusted.

  In addition, the conductive slack detecting means detects the state of the slack portion 1s by electrically detecting the contact between the arm-shaped contact terminal 22a and the interconnector wire 1, so that it can be detected with a simple configuration. There are advantages.

<Embodiment 3>
Based on FIG. 9, the solar cell module manufacturing method and solar cell module manufacturing apparatus which concern on Embodiment 3 of this invention are demonstrated.

  FIG. 9 is an explanatory diagram schematically illustrating the operation of a photoelectric conversion detection unit that detects the state of the slack portion in the solar cell module manufacturing method and the solar cell module manufacturing device according to Embodiment 3 of the present invention. (A) shows a state where the length of the slack portion is maximized, and (B) shows a state where the length of the slack portion is minimized.

  Corresponding to the slack formation region 21, a photoelectric conversion type detector 23 as a slack detection means is arranged. The photoelectric conversion detection unit 23 has a lower limit detection optical path SLb and an upper limit detection optical path SLu. A position where the slack portion 1s has a predetermined maximum length is detected by the lower limit detection light path SLb (FIG. A), and a position where the slack portion 1s reaches a predetermined minimum length is detected by the upper limit detection light path SLu (FIG. B). ) As a configuration.

  The lower limit detection optical path SLb is configured by the light emitting element 23eb and the light receiving element 23rb, and the upper limit detection optical path SLu is configured by the light emitting element 23eu and the light receiving element 23ru.

  For example, in the step of supplying the interconnector wire 1 from the wire supply reel 2 (see FIG. 5), since the interconnector wire 1 is fed out from the wire supply reel 2, the slack portion 1s descends in the direction of the arrow H. When the position of the lower limit detection optical path SLb is reached, the lower limit detection optical path SLb is changed from the light state to the light shielding state (FIG. 9A).

  That is, the light receiving element 23rb detects the light shielding in the lower limit detection optical path SLb, thereby detecting that the interconnector wire 1 is lowered to a predetermined position and becomes the slack portion 1s having the maximum length (sagging state). Can do.

  For example, in the process of preparing for cutting by transferring (drawing) the interconnector wire 1 so that it can be cut (see FIG. 2), the interconnector wire 1 is transferred in the direction of the arrow K, so The part 1s rises in the direction of the arrow B, and when it reaches the position of the upper limit detection optical path SLu, the upper limit detection optical path SLu is changed from the light shielding state to the light passing state (FIG. 9B).

  That is, the light receiving element 23ru detects light incident on the upper limit detection optical path SLu, thereby detecting that the interconnector wire 1 has been raised to a predetermined position and has become the slack portion 1s having the minimum length (sagging state). be able to. The slack portion 1s having the minimum length can be maintained by feeding the interconnector wire 1 by appropriately controlling the rotation of the wire supply reel 2 so that the slack portion 1s having the minimum length is not further shortened. .

  As described above, the extension length of the interconnector wire 1 can be controlled (adjusted) by the rotation control unit 24 in accordance with the state of the slack portion 1s detected by the slack detection means (photoelectric conversion type detection unit 23). it can. With this configuration, it is possible to accurately control the state of slack according to the state of each process, so that it is possible to prevent the occurrence of distortion when the interconnector wire 1 is supplied.

  The control of the photoelectric conversion type slack detection means can be easily synchronized with the operation of each component in each step, so that accurate detection is possible and the length of the slack portion 1s of the interconnector wire 1 is accurately determined. Can be adjusted.

  In addition, the photoelectric conversion type slack detection means does not need to use a mechanism portion, and thus has an advantage that it can be configured mechanically stable.

  In the first to third embodiments described above, the interconnector wire 1 is supplied by the wire supply reel 2. However, as shown in FIG. 6B, the interconnector wire 1 may be supplied while being wound around a bobbin. Absent. Needless to say, no extra force is applied to the interconnector wire 1 at the time of supply because the supply part (slack formation region 21) is kept slack even when supplied by a bobbin.

  In the present embodiment, a metal wire is used as an example of an interconnector wire, but a conductive member such as a thermoplastic molding material based on plastic other than metal may be used.

It is process explanatory drawing which shows the state just before transferring an interconnector wire with a transfer chuck about the solar cell module manufacturing method which concerns on Embodiment 1 of this invention. It is process explanatory drawing which shows the state which transferred the interconnector wire by the transfer chuck and prepared the cutting after the process of FIG. It is process explanatory drawing which shows the state which cut | disconnects an interconnector wire after the process of FIG. It is process explanatory drawing which shows the state which transfers the cut interconnector and pulls back the other interconnector wire after the process of FIG. It is process explanatory drawing which shows the state which supplies an interconnector wire as preparation for transferring the reduced interconnector wire after the process of FIG. It is explanatory drawing of the wire supply reel which shows the state which looked at the wire supply reel from the arrow X direction shown in FIG. 1, (A) is a wire supply reel which used the interconnector wire as ribbon winding, (B) The wire supply reel which has the connector wire rod wound as a bobbin is shown. It is explanatory drawing which shows the photovoltaic cell row | line | column sealed by the solar cell module manufactured with the solar cell module manufacturing method which concerns on Embodiment 1 of this invention, (A) is a top view, (B) is a side view. is there. It is explanatory drawing which illustrates typically operation | movement of the electroconductive type detection part which detects the state of a slack part with the solar cell module manufacturing method and solar cell module manufacturing apparatus which concern on Embodiment 2 of this invention, (A) is slack. The state where the length of the part is maximized is shown, and (B) shows the state where the length of the slack part is minimized. It is explanatory drawing which illustrates typically the operation | movement of the photoelectric conversion type detection part which detects the state of a slack part with the solar cell module manufacturing method which concerns on Embodiment 3 of this invention, and a solar cell module manufacturing apparatus, (A) is The state where the length of the slack portion is maximized is shown, and (B) shows the state where the length of the slack portion is minimized. It is explanatory drawing partially explaining the process of manufacturing the photovoltaic cell row | line | column which comprises the photovoltaic module which concerns on a prior art example, (A) is the manufacturing process of the photovoltaic cell row | line | column which concerns on the prior art example 1, (B). These show the manufacturing process of the photovoltaic cell row | line | column which concerns on the prior art example 2. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Interconnector wire 1s Slack part 2 Wire supply reel 3 Interconnector formation part 10 Solar cell 10e Electrode 11 Interconnector 15 Solar cell row 21 Slack formation area 22 Conduction type detection part (slack detection means)
22a Arm-shaped contact terminal 23 Photoelectric conversion type detection unit (slack detection means)
23eu upper limit light emitting element 23eb lower limit light emitting element 23ru upper limit light receiving element 23rb lower limit light receiving element 24 rotation controller 31 conversion roller 32 return roller 33 regulating chuck 34 cutter 35 transfer chuck 36 transfer chuck Lu connection unit length SLu upper limit detection optical path SLb lower limit detection optical path

Claims (12)

A step of supplying the interconnector wire from a wire supply reel or bobbin around which the interconnector wire is wound, a step of forming the interconnector by cutting the supplied interconnector wire into a connection unit length, and the interconnector. A method of manufacturing a solar cell module comprising a step of connecting to an electrode of a solar cell,
In the step of supplying the interconnector wire, the interconnector wire is fed from the wire supply reel or the bobbin with a length longer than the connection unit length to form the interconnector and the wire supply A slack portion having a slack is formed between the reel and the bobbin,
In the step of forming the interconnector, when the interconnector wire having the length of the connection unit length is pulled out, the length of the interconnector wire at the slack portion is longer than the connection unit length. A method for manufacturing a solar cell module. The solar cell module manufacturing method according to claim 1, wherein the interconnector wire has a J shape at the slack portion . The length of the slack portion in a state with the slack, the sun according to claim 1 or claim 2, characterized in that it is adjusted by feeding the interconnector wire from the wire supply reel or the bobbin Battery module manufacturing method. The length of the feeding of the previous SL interconnector wire, a solar cell module manufacturing method according to claim 3, characterized in that it is controlled by the state of the slack portion that is detected by the slack detection means. After forming the interconnector in the step of forming the interconnector, the method includes a step of pulling back the interconnector wire in the direction of the wire supply reel or the bobbin in a state where the tip of the interconnector wire is held. The method for manufacturing a solar cell module according to any one of claims 1 to 4 . A wire supply reel or bobbin supplying interconnector wire that is wound, the interconnector forming portion for forming an inter connector by cutting the wire supply reel or the interconnector wire material supplied from the bobbin to the connection unit length A solar cell module manufacturing apparatus comprising:
The wire supply reel or the bobbin is controlled to feed out the interconnector wire having a length longer than the connection unit length,
The solar cell module is characterized in that the interconnector wire forms a slack portion having a length longer than the connection unit length between the wire supply reel or bobbin and the interconnector forming portion. Manufacturing equipment. The solar cell module manufacturing apparatus according to claim 6, wherein the interconnector wire has a J shape at the slack portion . The solar cell module manufacturing apparatus according to claim 6 or 7, wherein the wire supply reel or the bobbin is configured to feed out the interconnector wire from a side away from the interconnector forming portion. . The sun according to any one of claims 6 to 8 , further comprising a slack detecting means for detecting the slack state between the wire supply reel or the bobbin and the interconnector forming portion. Battery module manufacturing equipment. 10. The solar cell module manufacturing apparatus according to claim 9, further comprising a rotation control unit configured to control rotation of the wire rod supply reel or the bobbin based on a detection result of the slack state by the slack detection unit. A regulation chuck that fixes the interconnector wire supplied to the interconnector forming portion, and a return roller that pulls back the interconnector wire fixed by the regulation chuck toward the wire supply reel or the bobbin. The solar cell module manufacturing apparatus according to any one of claims 6 to 10.   The solar cell module manufacturing apparatus according to claim 11, wherein the return roller has a torque adjustment function.

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