JP5820976B2 - Manufacturing method of solar cell module - Google Patents

Description

The present invention is, you adhesive resin adhesive tape to the substrate, relates to the production how a solar cell module.

  Conventionally, a method of using a resin adhesive tape having conductivity is widely known when a wiring member is electrically connected to a printed wiring board or a solar cell substrate into which various elements are incorporated.

  For example, a wiring material for electrically connecting a plurality of solar cell substrates to each other is electrically connected to each solar cell substrate via a resin adhesive tape. Specifically, as shown in FIG. 1A, the resin adhesive tape 200 attached to the support film 150 is pressed against the solar cell substrate 10 by the crimping tool 300. At this time, by heating the crimping tool 300 to a predetermined temperature, the resin adhesive tape 200 can be peeled off from the support film 150 and attached to the solar cell substrate 10.

  Here, as shown in FIG. 1A, a method of forming a resin adhesive tape piece 200a by cutting the resin adhesive tape 200 at a predetermined interval from one end of the resin adhesive tape 200 has been proposed (Patent Literature). 1). According to such a method, since only the resin adhesive tape piece 200a can be affixed on the solar cell substrate 10, the resin adhesive tape 200 can be accurately arranged on the solar cell substrate 10.

The crimping tool 300 includes a crimping head 301, a crimping pad 302, and a heating mechanism 301a. A heating mechanism 301 a built in the pressure-bonding head 301 uniformly heats the entire pressure-bonding pad 302. The pressure pad 302 is made of an elastic member such as silicone rubber.
JP-A-7-101618

  Here, as the crimping tool 300 is repeatedly used, the crimping pad 302 is deformed as shown in FIG. Therefore, the resin adhesive tape 200 is excessively affixed on the solar cell substrate 10 by being heated across the cutting position X. As a result, there is a problem that it is difficult to peel off the support film 150 and it is difficult to continuously and accurately dispose the resin adhesive tape pieces 200a.

  The present invention has been made in view of the above problems, and provides a bonding method, a solar cell module manufacturing method, and an electronic component manufacturing method capable of accurately arranging resin adhesive tape pieces on a substrate. The purpose is to do.

  An adhesion method according to the feature of the present invention is an adhesion method in which a resin adhesive tape attached to a support film is adhered to a substrate, and the resin adhesion is performed on the support film at a predetermined interval from one end of the resin adhesive tape. Step A of forming a resin adhesive tape piece by cutting the tape and pressing the resin adhesive tape piece from the support film side to the substrate and heating the resin adhesive tape piece to bond the resin adhesive tape piece to the substrate The process B and the process C which peels the resin adhesive tape piece from the support film. In the process B, the first part which is the end part on the cutting position side of the resin adhesive tape piece is the first of the resin adhesive tape pieces. The gist is to heat at a temperature lower than the second part excluding the one part.

  Therefore, in the vicinity of the cutting position, the adhesive force of the resin adhesive tape to the substrate can be made smaller than the adhesive force of the resin adhesive tape to the support film. Therefore, even when the resin adhesive tape is heated across the cutting position, it is possible to suppress the resin adhesive tape from being excessively attached on the substrate 10. As a result, the resin adhesive tape pieces can be continuously arranged on the substrate with high accuracy.

  In one aspect of the present invention, in step B, the heating tool for heating the resin adhesive tape piece includes a first heating tool part for heating the first part and a second heating tool part for heating the second part. It may be.

  A method for manufacturing a solar cell module according to a feature of the present invention is a method for manufacturing a solar cell module including a plurality of solar cell substrates that are electrically connected to each other by a wiring material, the resin bonding being affixed to a support film A step of forming a resin adhesive tape piece by cutting the tape on a support film from one end of the resin adhesive tape at a predetermined interval, and a plurality of solar cells. A process B for bonding the resin adhesive tape piece to one solar cell substrate by pressing the resin adhesive tape piece and heating the resin adhesive tape piece among the substrates, and a process C for peeling the resin adhesive tape piece from the support film And the step D of arranging the wiring material on the resin adhesive tape piece bonded to one solar cell substrate, and heating the resin adhesive tape piece And in step B, the first part, which is the end part on the cutting position side, of the resin adhesive tape piece is at a temperature lower than the second part of the resin adhesive tape piece excluding the first part. The gist is to heat.

  A method of manufacturing an electronic component according to a feature of the present invention is a method of manufacturing an electronic component comprising a substrate and a wiring material that is electrically connected to an electrode provided on the substrate, and is attached to a support film. The resin adhesive tape is cut from the end of the resin adhesive tape at one predetermined cutting position on the support film to form a resin adhesive tape piece, and the resin adhesive tape piece from the support film side is an electrode. And pressing the resin adhesive tape piece to the electrode, heating the resin adhesive tape piece to the electrode, step B, peeling the resin adhesive tape piece from the support film, step C, and the resin adhesive tape piece adhered to the substrate And a step D for arranging the wiring material and a step E for heat-curing the resin adhesive tape piece. In step B, the end of the resin adhesive tape piece on the cutting position side The first portion is minute, summarized as heating at a temperature lower than the second portion is the other end portion side of the first portion of the resin adhesive tape strips.

  ADVANTAGE OF THE INVENTION According to this invention, the adhesion | attachment method, the manufacturing method of a solar cell module, and the manufacturing method of an electronic component which make it possible to arrange | position a resin adhesive on a board | substrate accurately can be provided.

  Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic and ratios of dimensions and the like are different from actual ones. Accordingly, specific dimensions and the like should be determined in consideration of the following description. Moreover, it is a matter of course that portions having different dimensional relationships and ratios are included between the drawings.

(Configuration of solar cell module)
A schematic configuration of the solar cell module 100 according to the embodiment of the present invention will be described with reference to FIGS. 2 and 3. FIG. 2 is a side view of the solar cell module 100 according to the present embodiment. FIG. 3 is a plan view of the solar cell string 1 according to the present embodiment.

  The solar cell module 100 includes a solar cell string 1, a light receiving surface side protective material 2, a back surface side protective material 3, and a sealing material 4. The solar cell module 100 is configured by sealing the solar cell string 1 with a sealing material 4 between the light receiving surface side protective material 2 and the back surface side protective material 3.

  The solar cell string 1 includes a plurality of solar cell substrates 10, a wiring material 11, and a resin adhesive layer 12. The solar cell string 1 is configured by connecting a plurality of solar cell substrates 10 to each other by a wiring material 11.

  The plurality of solar cell substrates 10 are arranged along the arrangement direction H. As shown in FIGS. 2 and 3, the solar cell substrate 10 includes a photoelectric conversion unit 20, a thin wire electrode 30, and a connection electrode 40. FIG. 4 is a plan view of the solar cell substrate 10 according to the present embodiment.

 The photoelectric conversion unit 20 generates photogenerated carriers (holes and electrons) by receiving light on the light receiving surface. The photoelectric conversion unit 20 includes a semiconductor junction such as a pn-type junction or a pin junction. The photoelectric conversion unit 20 can be formed using a general semiconductor material such as a crystalline semiconductor material such as single crystal Si or polycrystalline Si, or a compound semiconductor material such as GaAs or InP. The photoelectric conversion unit 20 may have a so-called HIT structure in which a substantially intrinsic amorphous silicon layer is sandwiched between a single crystal silicon substrate and an amorphous silicon layer.

  The thin wire electrode 30 is a collection electrode that collects photogenerated carriers from the photoelectric conversion unit 20. A plurality of fine wire electrodes 30 are formed on the photoelectric conversion unit 20 along an orthogonal direction T substantially orthogonal to the arrangement direction H. The thin wire electrode 30 can be formed by using a resin-type conductive paste, a sintered-type conductive paste (ceramic paste), or the like using, for example, a coating method or a printing method. The fine wire electrode 30 is electrically connected to the wiring member 11.

  The connection electrode 40 is an electrode for connecting the wiring material 11. The connection electrode 40 is formed along the arrangement direction H on the photoelectric conversion unit 20 and intersects with the plurality of thin wire electrodes 30. The connection electrode 40 can be formed of the same material as the thin wire electrode 30.

  As shown in FIG. 1, the thin wire electrode 30 and the connection electrode 40 are similarly formed on the light receiving surface and the back surface of the photoelectric conversion unit 20. The dimensions and the number of each of the thin wire electrode 30 and the connection electrode 40 can be set to an appropriate number in consideration of the size and physical properties of the photoelectric conversion unit 20. For example, when the photoelectric conversion unit 20 is about 100 mm square, about 50 thin wire electrodes 30 and two connection electrodes 40 having a width of about 1.5 mm can be formed.

  The wiring member 11 electrically connects the plurality of solar cell substrates 10 to each other. Specifically, the wiring member 11 is connected to the connection electrode 40 of one solar cell substrate 10 and the connection electrode of another solar cell substrate 10 adjacent to the one solar cell substrate 10. The wiring member 11 is connected to the connection electrode 40 through the resin adhesive layer 12. The wiring member 11 is formed by performing lead-free solder plating or tin plating on copper, silver, gold, tin, nickel, aluminum, or an alloy thereof in a thin plate shape or a twisted wire shape.

The resin adhesive layer 12 is interposed between the wiring member 11 and the connection electrode 40. The resin adhesive layer 12 is preferably cured at a temperature equal to or lower than the melting point of general Pb-free solder (for example, SnAg _3.0 Cu _0.5 ), that is, approximately 200 ° C. or lower. As the resin adhesive layer 12, for example, a two-component reaction type adhesive in which a curing agent is mixed with an epoxy resin, an acrylic resin, or a urethane resin in addition to a thermosetting resin adhesive such as an acrylic resin or a highly flexible polyurethane type. An agent or the like can be used. The width of the resin adhesive layer 12 may be substantially the same as the width of the wiring material 11 or may be narrower than the width of the wiring material 11.

Further, the resin adhesive layer 12 may be conductive or insulating. When the resin adhesive layer 12 is conductive, the resin adhesive layer 12 may contain a plurality of conductive particles. As the conductive particles, nickel, nickel with gold coating, or the like can be used. On the other hand, when the resin adhesive layer 12 is insulative, the resin adhesive layer 12 may include a plurality of insulating particles (for example, Al ₂ O ₃ particles). When the resin adhesive layer 12 is insulative, at least a part of the wiring material 11 comes into contact with the connection electrode 40, whereby the wiring material 11 and the connection electrode 40 are electrically connected.

  The light receiving surface side protective material 2 is disposed on the light receiving surface side of the sealing material 4 and protects the surface of the solar cell module 100. As the light-receiving surface side protective material 2, glass having translucency and water shielding properties, translucent plastic, or the like can be used.

  The back surface side protective material 3 is disposed on the back surface side of the sealing material 4 and protects the back surface of the solar cell module 100. As the back surface side protective material 3, a resin film such as PET (Polyethylene Terephthalate), a laminated film having a structure in which an Al foil is sandwiched between resin films, and the like can be used.

  The sealing material 4 seals the solar cell string 1 between the light receiving surface side protective material 2 and the back surface side protective material 3. As the sealing material 4, a translucent resin such as EVA, EEA, PVB, silicon, urethane, acrylic, or epoxy can be used.

  An Al frame (not shown) can be attached to the outer periphery of the solar cell module 100 having the above configuration.

(Method for manufacturing solar cell module)
Below, the manufacturing method of the solar cell module which concerns on embodiment of this invention is demonstrated, referring drawings.

  First, as shown in FIG. 5, the resin adhesive tape 55 is cut by a cutter 60 at a cutting position Y at a predetermined interval L from one end of the resin adhesive tape 55 attached to the support film 50.

  Next, as shown in FIG. 6, the resin adhesive tape piece 55 a affixed to the support film 50 is thermocompression bonded to the solar cell substrate 10 with the crimping tool 70. Specifically, the resin adhesive tape piece 55 a attached to the support film 50 is pressed onto the connection electrode 40 of the solar cell substrate 10 from the support film 50 side by the crimping tool 70.

Here, as shown in FIG. 6, the crimping tool 70 includes a crimping head 71, a crimping pad 72, a first heating mechanism 71 a _1, and a second heating mechanism 71 a ₂ . Bonding head 71 incorporates a first heating mechanism 71a ₁ and the second heating mechanism 71a _2. The first heating mechanism 71a ₁ and the second heating mechanism 71a ₂ respectively, via the bonding pads 72, heating the resin adhesive tape strip 55a.

Specifically, as shown in FIG. 6, the first heating mechanism 71a ₁ heats the first portion 55a ₁ which is one end portion of the cutting position Y side of the resin adhesive tape piece 55a to the first temperature T ₁ of . The second heating mechanism 71a ₂ heats the second portion 55a ₂ of the other end portion side of the first portion 55a ₁ of the resin adhesive tape piece 55a to the second temperature _{T 2.} The first temperature T ₁ and the second temperature T ₂ has a softening temperature or higher of the resin adhesive tape strip 55a, and is preferably lower than the curing temperature of the resin adhesive tape strip 55a. Therefore, the resin adhesive tape piece 55a is softened and bonded to the solar cell substrate 10 (connection electrode 40). In the present embodiment, the first temperature _{T 1} of the lower than the second temperature _{T 2.} The higher the heating temperature, the greater the adhesive force of the resin adhesive tape piece 55a. Therefore, adhesion to the solar cell substrate 10 of the first portion 55a ₁ is less than the adhesive strength to the solar cell substrate 10 of the second portion 55a _2.

Incidentally, as shown in FIG. 6, in the arrangement direction H, the length of the first heating mechanism 71a ₁ is smaller than the length of the second heating mechanism 71a _2. Thus, in the arrangement direction H, the length of the first portion 55a ₁ is smaller than the length of the second portion 55a _2. The pressure-bonding pad 72 is made of an elastic member such as silicone rubber having a thickness of about 1 mm. Such a pressure-bonding pad 72 is deformed as it is repeatedly used (see FIG. 1B).

  Next, as shown in FIG. 7, the resin adhesive tape piece 55 a is peeled from the support film 50 by moving the crimping tool 70 and the support film 50 upward. Thereby, the resin adhesive layer 12 is formed on the solar cell substrate 10 (connection electrode 40).

  Next, one end of the wiring member 11 is disposed on the resin adhesive layer 12 (resin adhesive tape piece 55a). Subsequently, the resin adhesive layer 12 is cured by heating the resin adhesive layer 12 to a curing temperature or higher. As a result, the wiring member 11 is connected to the solar cell substrate 10 via the resin adhesive layer 12.

  By repeating the above process on the light receiving surface and the back surface of each of the plurality of solar cell substrates 10, the above-described solar cell string 1 is formed.

  Next, the sealing material 4, the solar cell string 1, the sealing material 4, and the back surface side protective material 3 are sequentially laminated on the light receiving surface side protective material 2 to form a laminate.

  Next, the laminate is laminated using a laminating apparatus 80 shown in FIG. The laminating apparatus 80 includes a lower housing 81, a heater plate 82, an upper housing 83, and a diaphragm 84. Specifically, the heater plate 82 is heated to about 150 to 200 ° C. while evacuating the inside of the lower housing 81. As a result, as shown in FIG. 9, the laminate is thermocompression bonded by the diaphragm 84 and the heater plate 82 to form the solar cell module 100.

(Function and effect)
In the bonding method of the resin adhesive tape 55 according to this embodiment, the resin adhesive tape piece 55a is pressed against the solar cell substrate 10 and heated to heat the resin adhesive tape piece 55a to the solar cell substrate. heating the first portion 55a ₁ which is one end portion of the cutting position Y side of the piece 55a at a lower temperature than the second portion 55a _2.

  Therefore, in the vicinity of the cutting position Y, the adhesive force of the resin adhesive tape 55 to the solar cell substrate 10 can be made smaller than the adhesive force of the resin adhesive tape 55 to the support film 50. Therefore, even when the resin adhesive tape 55 is heated across the cutting position Y by the crimping tool 70 (see FIG. 1B), the resin adhesive tape 55 is excessively attached on the solar cell substrate 10. This can be suppressed. As a result, since the resin adhesive tape piece 55a can be continuously arranged on the solar cell substrate 10 with high accuracy, the productivity of the solar cell module 100 can be improved.

On the other hand, although the first portion 55a ₁ is strongly bonded to the support film 50, the first portion 55a ₁ is easily pulled off from the support film 50 because it is pulled by the second portion 55a ₂ that is strongly bonded to the solar cell substrate 10. It is secured.

(Other embodiments)
Although the present invention has been described according to the above-described embodiments, it should not be understood that the descriptions and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples and operational techniques will be apparent to those skilled in the art.

For example, in the above embodiment, the crimping tool 70 has been set to be equipped with the first heating mechanism 71a ₁ and the second heating mechanism 71a _2, the invention is not limited thereto. Crimping tool 70 may have a configuration that can be heated at a lower temperature than the first portion 55a ₁ of the resin adhesive tape piece 55a second portion 55a _2. For example, as shown in FIG. 10, the crimping tool 70 is separated into a first heating tool part 711 that heats the first part 55a ₁ and a second heating tool part 712 that heats the second part 55a _2. Also good. The first heating tool part 711 heats the first part 55a ₁ to the first temperature T ₁ via the first heating pad part 721. Second heating tool 712, through the second heating pad section 722 to heat the second portion 55a ₂ to the second temperature _{T 2.}

  In the above embodiment, the solar cell substrate 10 has been described as an example. However, the resin adhesive tape 55 is bonded to an electronic substrate such as a printed wiring board and an electrode provided on the electronic substrate. It can apply to the manufacturing method of an electronic component provided with the wiring material connected to. For example, it can be used when a wiring material for connecting to an external circuit is bonded to an electrode of a liquid crystal display element. Specifically, the resin adhesive tape piece 55a may be bonded to the electrode by pressing the resin adhesive tape piece 55a against the electrode and heating the resin adhesive tape piece 55a from the support film 50 side.

  As described above, the present invention naturally includes various embodiments not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

  Hereinafter, the bonding method according to the present invention will be specifically described with reference to examples. However, the present invention is not limited to those shown in the following examples, and can be implemented with appropriate modifications within a range not changing the gist thereof.

Example 1
In Example 1, the adhesion layer was formed on the solar cell substrate by the following adhesion method.

First, an adhesive tape mainly composed of an epoxy resin in which Ni particles having a diameter of about 10 μmφ were mixed at a density of about 1000 particles / 1 mm ³ was attached on a PET film. Next, on the PET film, the adhesive tape was cut with a cutter at cutting positions at predetermined intervals from one end of the adhesive tape. Thus, an adhesive tape piece was formed.

  Next, the adhesive tape piece was heat-bonded onto the solar cell substrate with a crimping tool. Specifically, as shown in FIG. 6, the adhesive tape piece was pressed onto the solar cell substrate 10 with a pressure bonding tool including a pressure bonding head, a pressure bonding pad, a first heating mechanism, and a second heating mechanism. In this case, the temperature of the first heating mechanism was set to 60 ° C., and the temperature of the second heating mechanism was set to 100 ° C. In addition, about 1 mm-thick silicone rubber was used as a pressure-bonding pad.

  Next, the adhesive tape piece was peeled off from the support film by moving the support film upward.

(Example 2)
In Example 2, the adhesive layer was formed on the solar cell substrate in the same manner as the adhesive method according to Example 1 above. The difference between Example 1 and Example 2 is that the crimping tool is separated into a first heating tool part and a second heating tool part as shown in FIG. In this case, the temperature of the first heating mechanism built in the first heating tool part was set to 60 ° C., and the temperature of the second heating mechanism built into the second heating tool part was set to 100 ° C.

(Comparative example)
In the comparative example, the adhesive layer was formed on the solar cell substrate in the same manner as the adhesive method according to Example 1 above. The difference between Example 1 and the comparative example is that the crimping tool includes a heating mechanism for uniformly heating the entire crimping tool as shown in FIG. In this case, the temperature of the heating mechanism was set to 100 ° C.

(Comparison of poor adhesion)
The adhesion failure occurrence rates when the adhesion methods of Example 1, Example 2, and Comparative Example were repeated 10,000 times were compared. The adhesion failure is a state in which an adhesive tape heated across a cutting position by a deformed crimping tool (see FIG. 1B) is excessively adhered on the solar cell substrate.

  In Example 1 and Example 2, adhesion failure did not occur even when the crimping tool was repeatedly used 10,000 times. This is because the adhesive force of the adhesive tape to the solar cell substrate could be made smaller than the adhesive force of the adhesive tape to the PET film because the vicinity of the cutting position was heated at about 60 ° C.

  On the other hand, in the comparative example, adhesion failure occurred when the crimping tool was repeatedly used about 5000 times, and the adhesion failure rate when it was repeatedly used about 7000 times was 1% or more. This is because the adhesive force of the adhesive tape to the solar cell substrate is larger than the adhesive force of the adhesive tape to the PET film because the vicinity of the cutting position is heated at about 100 ° C.

  From the above, it has been confirmed that defective bonding can be reduced by heating the cutting position side of the adhesive tape piece at a temperature lower than the other portions.

It is a figure for demonstrating the adhesion | attachment method of the conventional resin adhesive tape. It is a side view of the solar cell module 100 which concerns on this embodiment of this invention. It is a top view of the solar cell string 1 which concerns on this embodiment of this invention. It is a top view of the solar cell substrate 10 which concerns on embodiment of this invention. It is a figure for demonstrating the adhesion method of the resin adhesive tape which concerns on embodiment of this invention (the 1). It is a figure for demonstrating the adhesion method of the resin adhesive tape which concerns on embodiment of this invention (the 2). It is a figure for demonstrating the adhesion method of the resin adhesive tape which concerns on embodiment of this invention (the 3). It is a figure for demonstrating the adhesion method of the resin adhesive tape which concerns on embodiment of this invention (the 4). It is a figure for demonstrating the adhesion method of the resin adhesive tape which concerns on embodiment of this invention (the 5). It is a figure which shows the structure of the crimping | compression-bonding tool which concerns on embodiment of this invention.

Explanation of symbols

X ... cutting position, Y ... cutting position, 1 ... solar cell string, 2 ... light receiving surface side protective material, 3 ... back surface side protective material, 4 ... sealing material, 10 ... solar cell substrate, 11 ... wiring material, 12 ... Resin adhesive layer, 20 ... photoelectric conversion part, 30 ... fine wire electrode, 40 ... connecting electrode, 50 ... support film, 55 ... resin adhesive tape, 55a ... resin adhesive tape piece, 60 ... cutter, 70 ... crimping tool, 71 ... Crimping head, 71a ₁ ... 1st heating mechanism, 71a ₂ ... 2nd heating mechanism, 72 ... Crimp pad, 80 ... Laminating device, 81 ... Lower housing, 82 ... Heater plate, 83 ... Upper housing, 84 ... Diaphragm, 100 DESCRIPTION OF SYMBOLS ... Solar cell module, 150 ... Support film, 200 ... Resin adhesive tape, 200a ... Resin adhesive tape piece, 300 ... Crimping tool, 301 ... Crimp head, 301a ... Heating mechanism, 3 02 ... Crimp pad, 711 ... First heating tool part, 712 ... Second heating tool part, 721 ... First heating pad part, 722 ... Second heating pad part

Claims (1)

A method for producing a solar cell module comprising a plurality of solar cell substrates electrically connected to each other by a wiring material,
Step A of forming a resin adhesive tape piece by cutting the resin adhesive tape attached to the support film on the support film at a predetermined interval from the one end of the resin adhesive tape;
The resin adhesive tape piece is pressed against one solar cell substrate among the plurality of solar cell substrates from the support film side, and the resin adhesive tape piece is heated to heat the resin adhesive tape piece to the one solar cell substrate. Step B for bonding to the battery substrate;
Step C of peeling the resin adhesive tape piece from the support film;
Step D of arranging the wiring material on the resin adhesive tape piece bonded to the one solar cell substrate;
Heating the resin adhesive tape piece, and attaching the wiring material to the one solar cell substrate,
In step B,
Heating the first portion that is one end portion on the cutting position side of the resin adhesive tape piece at a temperature lower than the second portion that is on the other end side than the first portion of the resin adhesive tape piece,
The heating tool for heating the resin adhesive tape piece includes a first heating tool part for heating the first part to a first temperature, and a second heating for heating the second part to a second temperature different from the first temperature. With a tool part,
The length of the first heating tool part is smaller than the length of said second heating tool unit,
The manufacturing method of the solar cell module characterized by the above-mentioned.

Images