JP5356347B2 - 太陽電池モジュール及び太陽電池モジュールの製造方法 - Google Patents
太陽電池モジュール及び太陽電池モジュールの製造方法 Download PDFInfo
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Description
以下、本発明にかかる太陽電池モジュール及び太陽電池モジュールの製造方法について、図面を参照しながら詳細に説明する。
裏面電極13は、図3に示すように、アルミニウムや銀からなる電極が例えばスクリーン印刷やスパッタ等により太陽電池セル2の裏面に形成される。裏面電極13は、導電性接着フィルム15が仮貼りされた後タブ線3の凹凸部21が形成された表面20aが接続される接続部14を有する。接続部14は、後述するタブ線3の本圧着工程時において導電性接着フィルム15のバインダー樹脂が流入する流入部16が形成されている。流入部16は、裏面電極13の形成時に、マスク処理やエッチング処理を施すことにより形成され、例えば図3に示すように、開口部16aとして形成されている。すなわち、接続部14は、AlやAg部分からなりタブ線3との導通を図る導通部17と、本圧着工程時において余剰のバインダー樹脂が流入する流入部16とからなる。
タブ線3は、従来の太陽電池モジュールで使用されているタブ線と同様に、例えば、50〜300μm厚のリボン状銅箔を使用し、必要に応じて金メッキ、銀メッキ、スズメッキ、ハンダメッキ等が施されている。
導電性接着フィルム15は、図5に示すように、導電性粒子23が高密度に含有された熱硬化性のバインダー樹脂層である。また、導電性接着フィルム15は、押し込み性の観点から、バインダー樹脂の最低溶融粘度が、100〜100000Pa・sであることが好ましい。導電性接着フィルム15は、最低溶融粘度が低すぎると低圧着から本硬化の過程で樹脂が流動してしまい接続不良やセル受光面へのはみ出しが生じやすく、受光率低下の原因ともなる。また、最低溶融粘度が高すぎてもフィルム貼着時に不良を発生しやすく、接続信頼性に悪影響が出る場合もある。なお、最低溶融粘度については、サンプルを所定量回転式粘度計に装填し、所定の昇温速度で上昇させながら測定することができる。
次いで、太陽電池モジュール1の製造工程について説明する。太陽電池モジュール1は、バスバー電極11及び裏面電極13の接続部14に導電性接着フィルム15を仮貼りする仮貼り工程、太陽電池セル2を配列する配列工程、タブ線3を導電性接着フィルム15上に低温低圧で熱加圧することによりバスバー電極11上及び裏面電極13の接続部14上に配置する仮圧着工程、及びタブ線3上から熱加圧することにより導電性接着フィルム15を熱硬化させ、タブ線3とバスバー電極11及び裏面電極13の接続部14とを接続する本圧着工程とを備える。
なお、太陽電池セル2は、開口部16aを介して光電変換素子10を構成するSiを外方に露出させてもよい。これにより、太陽電池セル2は、導電性接着フィルム15のバインダー樹脂が裏面電極13の開口部16aを介して光電変換素子10の表面のSiと接触する。シリコン基板からなる太陽電池セルの表面と導電性接着フィルム15のバインダー樹脂とは、強固に接着することから、導電性接着フィルム15は、タブ線3と裏面電極13との接続において、導通部17(Al部分)で導通を図ると共に、開口部16aを介して露出されているSi部分でタブ線3と裏面電極13の接続部14との接続強度を確保することができる。
Claims (12)
- 両面に電極が形成された複数の太陽電池セルと、
一面に長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部を有し、上記複数の太陽電池セルを直列に接続するタブ線と、
上記太陽電池セルの電極と上記タブ線との間に介在され、上記太陽電池セルと上記タブ線とを接続する接着フィルムとを備え、
上記太陽電池セルは、上記凹凸部が設けられた一面が接続される接続部に上記接着フィルムのバインダー成分が流入する流入部が形成されている太陽電池モジュール。 - 上記タブ線は、上記凹凸部が設けられた一面と反対側の平坦面が、上記太陽電池セルの表面電極と接続され、上記一面が上記太陽電池セルの裏面電極と接続されている請求項1記載の太陽電池モジュール。
- 上記タブ線は、上記凹凸部が設けられた一面と反対側の面にも、長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部が形成されている請求項1記載の太陽電池モジュール。
- 上記太陽電池セルは、裏面電極がAlを用いて形成されている請求項1〜請求項3のいずれか1項に記載の太陽電池モジュール。
- 上記太陽電池セルは、結晶シリコン系太陽電池セルであり、上記流入部よりSiが外方へ露出している請求項4に記載の太陽電池モジュール。
- 上記流入部は、上記裏面電極の上記タブ線との接続部に設けられた開口部である請求項2〜請求項5のいずれか1項に記載の太陽電池モジュール。
- 上記流入部は、上記裏面電極の上記タブ線との接続部に設けられた切り欠き部である請求項2〜請求項5のいずれか1項に記載の太陽電池モジュール。
- 上記接続部は、上記タブ線と導通する導通部が上記流入部よりも大きな面積を有する請求項1〜請求項7のいずれか1項に記載の太陽電池モジュール。
- 上記接着フィルムは、導電性粒子を含有する請求項1〜請求項8のいずれか1項に記載の太陽電池モジュール。
- 上記接着フィルムは、導電性粒子を含有しない絶縁性接着フィルムである請求項1〜請求項8のいずれか1項に記載の太陽電池モジュール。
- 複数の太陽電池セルを配列する配列工程と、
接着フィルムを介して一面に長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部を有するタブ線の上記一面を上記太陽電池セルの裏面電極側に仮接続すると共に、接着フィルムを介して上記タブ線の上記一面と反対側の平坦面を上記太陽電池セルの表面電極側に仮接続する仮圧着工程と、
上記タブ線の上から熱加圧することにより、上記接着フィルムを熱硬化させて上記タブ線と上記太陽電池セルの各電極とを接続する本圧着工程とを備え、
上記本圧着工程では、上記接着フィルムのバインダー成分を、上記タブ線の上記凹凸部が設けられた一面が接続される接続部に設けられた開口部に流入する太陽電池モジュールの製造方法。 - 上記本圧着工程では、上記タブ線の押圧面に弾性体が設けられたヘッドによって上記タブ線を熱加圧する請求項11記載の太陽電池モジュールの製造方法の製造方法。
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EP11829048.5A EP2624311A1 (en) | 2010-09-29 | 2011-09-26 | Solar cell module and method for producing solar cell module |
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