JP6039905B2 - 導電性接着剤、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
導電性接着剤、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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- JP6039905B2 JP6039905B2 JP2012029804A JP2012029804A JP6039905B2 JP 6039905 B2 JP6039905 B2 JP 6039905B2 JP 2012029804 A JP2012029804 A JP 2012029804A JP 2012029804 A JP2012029804 A JP 2012029804A JP 6039905 B2 JP6039905 B2 JP 6039905B2
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Description
太陽電池モジュールを構成する太陽電池としては、例えばガラスやステンレススチールなどの基板上に、光電変換層である半導体層を形成したいわゆる薄膜太陽電池1を用いることができる。薄膜太陽電池1は、図1(a)(b)に示すように、複数の太陽電池セル2がコンタクトラインによって接続された太陽電池ストリングを構成する。図2に示すように、このストリング構造を有する薄膜太陽電池1は、単体で、又は複数枚連結されたマトリクスを構成して、裏面側に設けられた封止接着剤のシート3及びバックシート4とともに一括してラミネートされることにより太陽電池モジュール6が形成される。なお、太陽電池モジュール6は、適宜、周囲にアルミニウムなどの金属フレーム7が取り付けられる。
本発明が適用された薄膜太陽電池1は、透光性絶縁基板8上に、図示は省略しているが、透明導電膜からなる透明電極膜、光電変換層、裏面電極膜がこの順に積層されて形成され、透光性絶縁基板8側から光を入射させるスーパーストレート型の太陽電池である。なお、薄膜太陽電池には、基材、裏面電極、光電変換層、透明電極の順で形成されたサブストレート型太陽電池もある。以下では、スーパーストレート型の薄膜太陽電池1を例に説明するが、本技術は、サブストレート型の薄膜太陽電池に用いることもできる。
タブ線11は、薄膜太陽電池1のP型電極9及びN型電極10に導通接続されることにより電極を取り出す端子となるものである。タブ線11は、図3に示すように、例えば一面11aに接着剤層21が積層一体化されることにより積層体20を構成して用いられる。
タブ線11とP型電極9及びN型電極10との間に挟持され、両者を導通接続させる導電性フィラーとなるフィラメント凝集体25は、細く長い柔軟な金属線、例えば線状ニッケルの凝集体が用いられる。導電性接着フィルム23は、フィラメント凝集体25を導電性フィラーとして用いることにより、タブ線11とP型電極9及びN型電極10との間に挟持された際の接触点を増加させることができ、導通抵抗を低下させ、変換効率の向上を図ることができる。また、導電性接着フィルム23は、フィラメント凝集体25を導電性フィラーとして用いることにより、タブ線11とP型電極9及びN型電極10との間に挟持された場合にも残留応力が発生せず、長期に亘る接続信頼性を確保することができる。
次いで、上述した薄膜太陽電池モジュール6の製造工程について説明する。薄膜太陽電池モジュール6の製造工程は、薄膜太陽電池1の製造工程と、薄膜太陽電池1のP型電極9及びN型電極端子10上に、タブ線11と導電性接着フィルム23との積層体20を配置する工程と、薄膜太陽電池1をモジュール化する工程とを有する。
なお、上記では太陽電池として薄膜太陽電池1を用いた場合を例に説明したが、シリコン系太陽電池を用いた場合も同様に、導電性接着フィルム23を用いてタブ線と電極とを接続し、また太陽電池セル同士を接続することができる。
次いで、上述したシリコン系太陽電池モジュール38の製造工程について説明する。シリコン系太陽電池モジュール38の製造工程も上記薄膜太陽電池モジュールの製造工程と同様に、シリコン系太陽電池セル30の製造工程と、この太陽電池セル30のフィンガー電極31及び裏面電極37上に、タブ線32を配置する工程と、太陽電池セル30をモジュール化する工程とを有する。
フェノキシ樹脂(YP50:新日鐵化学株式会社製);50質量部
エポキシ樹脂(エピコート630:三菱化学株式会社製);4質量部
液状エポキシ分散型イミダゾール型硬化剤樹脂(ノバキュア3941HP:旭化成イーマテリアルズ株式会社製);25質量部
シランカップリング剤(A−187:モメンティブパフォーマンスマテリアルズ製);1質量部
である。
Claims (9)
- 太陽電池の電極とタブ線とを接続する導電性接着剤において、
接着剤樹脂組成物と、上記接着剤樹脂組成物に含有された導電性フィラーとを有し、
上記導電性フィラーとして、導電性フィラメントの凝集体を用い、
上記導電性フィラメントの凝集体は、上記接着剤樹脂組成物80質量部に対して10〜40質量部含有されており、
上記導電性フィラメントの凝集体は、径が2μm〜8μmの金属線からなる導電性フィラメントが凝集され、導電性フィラメントの凝集体の径が2μm〜40μmの大きさのものであることを特徴とする導電性接着剤。 - 接着剤層の厚さが10〜30μmである請求項1に記載の導電性接着剤。
- 上記導電性フィラメントの凝集体の最大径と接着剤層の厚さとの比、[凝集体の最大径(μm)]/[接着剤層の厚さ(μm)]が、0.2〜2.0である請求項1〜2のいずれか1項に記載の導電性接着剤。
- 導電性フィラーとして、上記導電性フィラメントの凝集体に加え、球状及び/又は扁平状の導電性粒子も含有し、
上記導電性フィラメントの凝集体と上記導電性粒子とは99:1〜50:50の割合で含有されている請求項1〜3のいずれか1項に記載の導電性接着剤。 - フィルム状に成形されている請求項1〜4のいずれか1項に記載の導電性接着剤。
- 上記導電性フィラメントとして、ニッケルフィラメントを用いる請求項1〜5のいずれか1項に記載の導電性接着剤。
- 上記導電性フィラメントの凝集体は、径が2μm〜3μmの金属線からなる導電性フィラメントが凝集され、導電性フィラメントの凝集体の径が5μm〜20μmの大きさのものであり、上記導電性フィラメントの凝集体の最大径と、上記接着剤層の厚さとの比、[凝集体の最大径(μm)]/[接着剤層の厚さ(μm)]が0.8〜1.5である請求項1に記載の導電性接着剤。
- 太陽電池と、
上記太陽電池に形成された電極上に、接着剤層を介して接続されるタブ線と、
上記太陽電池を封止する封止材と、
上記太陽電池の表面及び裏面を保護する保護部材とを備え、
上記接着剤層が、請求項1〜7のいずれか1項に記載の導電性接着剤からなる接着剤層である太陽電池モジュール。 - 太陽電池の電極に導電性接着剤を介してタブ線を配置する工程と、
上記タブ線の上から加熱及び押圧することにより上記導電性接着剤を硬化させ、上記タブ線と前記電極とを電気的、及び機械的に接続する工程とを有し、
上記導電性接着剤が、請求項1〜7のいずれか1項に記載の導電性接着剤である太陽電池モジュールの製造方法。
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KR1020147025082A KR102041274B1 (ko) | 2012-02-14 | 2013-01-30 | 도전성 접착제, 태양 전지 모듈 및 태양 전지 모듈의 제조 방법 |
PCT/JP2013/051973 WO2013121877A1 (ja) | 2012-02-14 | 2013-01-30 | 導電性接着剤、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 |
CN201380009481.6A CN104137278B (zh) | 2012-02-14 | 2013-01-30 | 导电性粘接剂、太阳能电池模块及太阳能电池模块的制造方法 |
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TW102104414A TWI565784B (zh) | 2012-02-14 | 2013-02-05 | 導電性接著劑、太陽電池模組及太陽電池模組的製造方法 |
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