JP5409908B2 - 太陽電池用のフィルム状電気コネクタを製造する方法、このようにして製造された接続エレメント、及び少なくとも2つの太陽電池を1つのソーラーモジュールへと電気的に接続する方法 - Google Patents
太陽電池用のフィルム状電気コネクタを製造する方法、このようにして製造された接続エレメント、及び少なくとも2つの太陽電池を1つのソーラーモジュールへと電気的に接続する方法 Download PDFInfo
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Description
太陽電池の個数に対応する予め決められた所定の長さの積層体の後に、切断箇所が形成される。切断箇所の部分には、より幅の広い横路が設けられている。
フィルムコネクタ又はフィルムTABに基づいている。太陽電池の幅にほぼ等しい、例えば6’’の幅を有するフィルムシートが使用される。フィルムコネクタは、銅材料でコーティングされたプラスチックフィルムに基づいており、被覆層としてさらに別のプラスチックフィルムが設けられており、しかも積層体を形成している。フィルムは次々と構造化され、接着され、ロールに巻き取られる。
図1a及び1bによれば、支持フィルムには図示されていないパンチングツールによってパンチングが施されていることが明らかである。このパンチングツールは同時に側帯101及び103上に穿孔102及び104も形成する。
Claims (16)
- 複数の太陽電池を1つのモジュールへと接続するための、太陽電池用のフィルム状電気コネクタを製造する方法であって、前記コネクタは1つの導電平面層と少なくとも1つの絶縁平面層とを有している方法において、
まず、接続すべき太陽電池の幅に実質的に等しい幅の絶縁性の支持フィルムを用意し、
前記支持フィルムの、後のはんだ箇所の領域に、はんだ用の開口部を設けるとともに、前記支持フィルムの側帯領域に、調節及び輸送のための穿孔として開口部を設け、
前記支持フィルムに合わせた幅を有する導電フィルムシートを用意し、その際に、前記支持フィルムと同様に前記導電フィルムシートの縁部に調節及び輸送のための穿孔を設け、さらに後の電気接続フィンガとして櫛歯構造を形成し、その際、当該櫛歯構造の位置を固定するために、前記調節及び輸送のための穿孔の方向に保持バーが残るようにし、
輸送ベルト又は輸送ローラのピン状の突起部によって前記支持フィルム上に前記導電フィルムシートを位置決めし、その際、前記突起部が前記調節及び輸送のための各穿孔に入り込み、
前記支持フィルムを接着結合により前記導電フィルムシートと接続し、
前記側帯を切り離し、前記保持バーを切断し、
前記支持フィルムと前記導電フィルムシートとの積層体上に、絶縁性の被覆フィルムを、前記被覆フィルムの縁部で貼り付け、ラミネートし、前記被覆フィルムは、前記積層体から広く張り出しており、
側方に張り出した前記被覆フィルムの縁部の張り出しを前記積層体下面へと折り返し固定し、
後の処理のために、得られたフィルム積層体の供給ロールを形成し、
前記導電フィルムシートの接点部材は、前記支持フィルムのはんだ用の開口部を通して露出している、
ことを特徴とする方法。 - 前記開口部と前記穿孔をパンチングまたはレーザ光線によって形成し、同時に別の開口部を接触させるべき疑似正方形太陽電池の面取り部に設ける、請求項1記載の方法。
- 前記櫛歯構造は太陽電池モジュールの接点構成と予想される電流強度比とに適した平面形状を有する、請求項1又は2記載の方法。
- 前記支持フィルムは接着剤層を有している、又はそのような層を既に備えている、請求項1から3までのいずれか1項記載の方法。
- 前記被覆フィルムを貼り付ける前に、前記被覆フィルムに接着剤層を設ける、請求項1から4までのいずれか1項記載の方法。
- 前記積層体をロールに巻き取る前に前記接着剤の硬化を行い、露出している導電表面をフラックス及び/又ははんだで濡らす、請求項1から5までのいずれか1項記載の方法。
- x個の太陽電池に相当する予め決められた所定の長さの前記積層体の後に、切断箇所を形成し、該切断箇所の部分には、導電性の横路が設けられており、
前記横路は、nを1〜x−1としたとき、n番目の太陽電池用の積層体と、n+1番目の太陽電池用の積層体と、の間の幅より広い、
請求項1から6までのいずれか1項記載の方法。 - 前記導電フィルムシートは銅材料からできており、前記はんだ箇所の領域に開口部を有しており、当該開口部は前記支持フィルムのはんだ用の開口部の寸法よりも小さな寸法を有している、請求項1から7までのいずれか1項記載の方法。
- 前記被覆フィルムも同様に前記はんだ箇所の領域に開口部を有しており、当該開口部の寸法は前記導電フィルムシートの開口部の寸法よりも大きい、請求項8記載の方法。
- 前記支持フィルムと前記被覆フィルムは圧力と温度とによって活性化される接着剤層を備えており、貼り合わせステップにおいて前記フィルム層の接続を行い、前記側方の被覆フィルムの縁部の張り出しを折り返し固定する前記ステップは炉室内で行われ、前記貼り合わせは当該炉室内で実行される、請求項1、2、8及び9のいずれか1項記載の方法。
- 前記支持フィルムを前記導電フィルムシートと接触させる前に、前記支持フィルムを接着剤で濡らし、向かい合わされた前記シートを軽い圧力で貼り合わせる、請求項1から9までのいずれか1項記載の方法。
- 前記折り返しの前に、前記被覆フィルムの縁部に外部から前記積層体の中心の方向に向かって切り込みを入れる又は切断する、請求項1から11までのいずれか1項記載の方法。
- 前記ウェッティングをウェーブはんだ浴により行う、請求項6記載の方法。
- 請求項1から13までのいずれか1項記載の方法によって製造されたフィルム状電気コネクタ。
- 少なくとも2つの太陽電池を請求項14記載のコネクタによって1つのソーラーモジュールへと接続する電気的接続方法において、ロールの動作を行い、その際、はんだ付けによって前記太陽電池のはんだ箇所を前記支持フィルムのパンチ孔を通して露出している接触箇所に接触させることによって、巻き取られた部分において前記太陽電池をx個ずつストリングに接続し、つぎに、このようにしてできたストリングを、カプセル化材料を備えた透明板上で以前のストリングに対して180°回転して位置決めし、その際、所定の横コネクタによって前記ストリングを互いに直列接続することを特徴とする、電気的接続方法。
- はんだ貫通開口部を該はんだ貫通開口部を通して見える太陽電池上の残留はんだで覆うことにより、前記x個の太陽電池を前記コネクタの構造と整列させ、つづいてはんだ付けを行う、請求項15記載の方法。
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DE102010004112A DE102010004112A1 (de) | 2009-06-29 | 2010-01-07 | Verfahren zur Herstellung eines folienartigen elektrischen Verbinders für Solarzellen, derartig hergestelltes Verbindungselement sowie Verfahren zum elektrischen Verbinden von mindestens zwei Solarzellen zu einem Solarmodul |
DE102010004112.2 | 2010-01-07 | ||
PCT/EP2010/056899 WO2011000629A2 (de) | 2009-06-29 | 2010-05-19 | Verfahren zur herstellung eines folienartigen elektrischen verbinders für solarzellen, derartig hergestelltes verbindungselement sowie verfahren zum elektrischen verbinden von mindestens zwei solarzellen zu einem solarmodul |
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WO2011000629A2 (de) | 2011-01-06 |
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