JPH11330514A - Flexible solar cell module, its manufacture and method for connecting external lead - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module which reduces a manufacture fail of an elongated module, and facilitate wiring end part process works after cut out; its simple manufacture; and a method for connecting an external lead. SOLUTION: In a flexible solar cell module M in which a plurality of solar cell sub-modules (sub-modules) 1 comprising a flexible plastic base material and a photoelectric conversion element formed thereon and a main wiring 2 connected to an output of a different polarity of the sub-module 1 are pinched between at least thermally adhesive and contractive sealing films 4 to be covered and sealed, an interval in a longitudinal direction of the sealing film between the sub-modules 1 is set to 20 mm or less.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plurality of sub-modules comprising a flexible plastic substrate and a photoelectric conversion element formed thereon, and a main wiring connected to electrodes of different polarities of the photoelectric conversion element. And a flexible solar cell module covered with a long surface protective film via a heat-sealing sealing film, and a method for manufacturing the same.

[0002]

2. Description of the Related Art A flexible solar cell module using a solar cell sub-module in which a photoelectric conversion element is formed on a flexible plastic substrate is characterized by excellent mass productivity, flexibility of the module, and the like. The simplification of the installation work can be expected due to the weight reduction, and the cost can be reduced.

FIGS. 6A and 6B show a main part of a conventional flexible solar cell module, wherein FIG. 6A is a plan view, FIG. 6B is a sectional view taken along line XX in FIG. It is sectional drawing. One flexible plastic substrate and a sub-module 1 formed on the substrate and comprising a plurality of photoelectric conversion elements connected in series according to a required voltage, and via an output electrode of the photoelectric conversion element and a sub wiring 3 What is the main wiring 2 connected in parallel?
It is sealed with two insulating and heat-sealing sealing films 4 and further covered with two protective films 5 for improving weather resistance.

[0004] A roll-to-roll system in which the components of such a flexible solar cell module are wound up from a roll and supplied, and the manufactured solar cell module is again rolled into a roll state after bonding and sealing the components. Alternatively, a step-roll type manufacturing method has been proposed. FIG. 7 is a cross-sectional view of a conventional step-roll type manufacturing apparatus for a flexible solar cell module, taken along the transport direction. Sealing film 4
Is wound on a roll R (hereinafter referred to as a roll state).
And the solar cell sub-module 1, the main wiring 2 and the sub wiring 3 are separately supplied, and the other sealing film 4 is supplied.
Is rolled up from the roll Rb and supplied, the wiring connection and sealing are performed by the heating and pressing device H, and the modularized solar cell module is rolled up again by the roll Re.

A film of ethylene vinyl acetate (hereinafter referred to as EVA) is useful as such an insulating heat-sealing sealing film. The EVA film undergoes a remarkable shrinkage change after the adhesive sealing step in which the temperature is raised to around the melting point. In the case of the roll-to-roll method or the step-roll method in which the long EVA film is supplied in a roll state, Since the tension is applied in the direction, the film shrinks largely in the width direction of the long film.

However, conventional solar cell modules are generally of the panel type, and are used after being cut into single sheets from a roll state, so that the above-mentioned dimensional change is problematic in a roll-to-roll or step-roll system. Production has not been performed in which a long and wide EVA film is continuously supplied from a roll state.

[0007]

In order to mass-produce a flexible solar cell module having a large area, it is necessary that the sealing and protection film be long and wide. Then, the above dimensional change becomes a problem. In addition, the flexible solar cell module needs to be cut in accordance with a variety of uses and then be surely subjected to an end treatment of an external lead connection portion to a main wiring to prevent intrusion of moisture.

In addition, when an individual module is cut from a long module, if the cutting is performed on a sub-module, the photoelectric conversion element is cut.
The reliability is also reduced due to the intrusion of moisture from that part. To avoid this, cutting must be done between sub-modules. When cut in this manner, both surfaces of the main wiring 2 are adhered to the sealing film 4 as shown in FIG. 6C, and it is difficult to remove the sealing film 4 for wiring work. It is.

Even if the insulating sealing film 4 can be removed by an ultrasonic cutter, a heat cutter, or the like, in order to secure the electrical reliability and mechanical strength of the wiring connection portion,
It is indispensable to secure a space for wiring end processing. However, in the flexible solar cell module shown in FIG. 6, if the space between the sub-modules 1 is increased and the wiring end processing space is provided in order to secure the wiring end processing space, the space between the sub-modules 1 is increased. Insulating sealing film 4
Characteristic defects and molding defects due to the remarkable dimensional change of.

For this reason, it has been a challenge to improve the manufacturing defect of the long module and to simplify the wiring end processing.
As a solution, a solar cell module in which a film with wiring is arranged between submodules has been proposed. FIG.
1 shows a conventional solar cell module having a film with wiring, (a) is a plan view, and (b) is an XX cross-sectional view in (a). In a state where the film 1e with the wiring in which the wiring ee is formed is arranged in place of the submodule in advance at the cutting portion and the portion where the wiring end processing is performed, and the main wiring 2 and the wiring ee are connected using the sub wiring 3. Seal. However, separate production of the film with wiring 1e is required, which complicates the production method and leads to an increase in cost.

SUMMARY OF THE INVENTION An object of the present invention is to provide a solar cell module capable of reducing defective manufacturing of a long module, easily performing a wiring end processing after cutting, a simple manufacturing method thereof, and a method of connecting external leads. is there.

[0012]

In order to achieve the above object, a solar cell sub-module (hereinafter abbreviated as sub-module) comprising a flexible plastic substrate and a photoelectric conversion element formed thereon is provided. In a flexible solar cell module, a plurality and a main wiring connected to outputs of different polarities of the sub-module are sandwiched between at least a heat-adhesive and heat-shrinkable sealing film and covered and sealed. The distance between the modules in the longitudinal direction of the sealing film is 20 mm or less.

A plurality of sub-modules each comprising a flexible plastic substrate and a photoelectric conversion element formed thereon;
A flexible solar cell module in which a main wiring connected to outputs of different polarities of the submodule is sandwiched between at least a heat-adhesive and heat-shrinkable sealing film and covered and sealed, wherein a photoelectric conversion element is provided. A dummy sub-module, which is a flexible film not to be used, is disposed between the sub-modules so as to overlap with the main wiring, and is covered and sealed with an adhesive film.

The distance between the sub-module and the dummy sub-module in the longitudinal direction of the sealing film is preferably 20 mm or less. The dummy submodule is preferably made of a polyimide, aramid, or polyethylene insulating plastic. A heat-shrinkable and heat-shrinkable sealing film comprising a plurality of sub-modules comprising a flexible plastic substrate and a photoelectric conversion element formed thereon and main wirings connected to outputs of different polarities of the sub-modules In the method for manufacturing a flexible solar cell module that is sandwiched, covered, and sealed, the individual sub-modules are cut into individual solar cell modules.

A plurality of sub-modules each including a flexible plastic base material and a photoelectric conversion element formed thereon, and dummy sub-modules arranged for every arbitrary number of sub-modules, and connected to outputs of different polarities of the sub-modules In a method for manufacturing a flexible solar cell module in which the formed main wiring is sandwiched and covered and sealed with a heat-adhesive and heat-shrinkable sealing film, the dummy sub-module is cut into individual solar cell modules. It is preferable that the connection of the external lead to the main wiring after the individualization of the solar cell module is performed in a portion of the main wiring overlapping the dummy sub-module.

According to the present invention, the distance between the sub-modules or the distance between the sub-modules and the dummy sub-module is set to 20 mm or less as described above, so that the substrate of the sub-module suppresses the thermal shrinkage of the sealing film in the peripheral portion. However, the occurrence of molding defects such as deterioration of characteristics and wrinkles caused by distortion of the main wiring due to heat shrinkage is suppressed, and a long and wide solar cell module is manufactured by a roll-to-roll method or a step roll method. It can be expected that it can be manufactured and that the connection and end portions of the external leads to the solar cell module can be easily implemented.

Further, dummy sub-modules are arranged for every arbitrary number of sub-modules and cut at dummy sub-module portions, or cut between sub-modules when there is no dummy sub-module. Since the external leads are connected at the wiring part, the removal of the sealing film becomes easy, and the connection work becomes simple,
The wiring end processing space can be widened, and the electrical reliability and mechanical strength of the wiring connection can be improved.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is based on the following experimental data for manufacturing a solar cell module. FIG. 4 is an enlarged plan view showing the position of the width change amount of the solar cell module.
When the interval between the submodules 1 is D, the end width change amount w1 of the width of the submodule 1 along the extension of the end line
And the center width change amount w2 on the center line between the sub-modules 1.

FIG. 5 is a graph showing the dependence of the width variation of the solar cell module on the sub-module interval. The width of the sealing resin is 800 mm. As is clear from FIG. 5, as the distance X between the sub-modules 1 increases, a dimensional change occurs in the width of the sealing film between the sub-modules 1. The variation in the width W1 along the extension of the line at the end of the submodule 1 is also large. Such a difference in width depending on the position can be understood as follows. Although the adhesive strength of the submodule and the protective film is secured by the cross-linking reaction of EVA, the sealing film has the property of shrinking isotropically during the cross-linking reaction, and the length in the length direction is maintained by the transport roll. As a result, the substrate of the sub-module suppresses the shrinkage that occurs particularly in the width direction perpendicular to the transport direction. Therefore, the smaller the sub-module interval, the smaller the amount of change.

Since there is no particular advantage that the adjacent submodules actually overlap, the lower limit of the submodule interval is 0 mm, that is, the ends of the submodules are abutted. FIG. 1 shows a main part of a flexible solar cell module according to the present invention, wherein (a) is a plan view and (b) is (a).
FIG. 13 is a sectional view taken along line XX in FIG.
It is a Y sectional view.

A sub-module 1 composed of a flexible plastic base material and a plurality of photoelectric conversion elements connected in series according to a required voltage formed thereon, via an output electrode of the photoelectric conversion element and a sub wiring 3 The main wirings 2 connected in parallel are sealed with an insulating, heat-adhesive, heat-shrinkable sealing film 4 and further covered with a protective film 5 for improving weather resistance.

On the other hand, as a result of the appearance inspection of the manufactured flexible solar cell module, when the dimensional change amount of the end portion of the sub-module was within 1 mm, no molding failure occurred. Example 1 Based on the above data, the interval between submodules was set to 20 mm.
As a result of trial production of a flexible solar cell module with 100 submodules set as follows, no failure such as molding failure or characteristic deterioration due to dimensional change in the width direction between the submodules was observed. The production yield was good. Example 2 A trial production of a solar cell module in which a dummy sub-module, which is an insulating and flexible plastic film, was inserted between sub-modules.

FIGS. 2A and 2B show a solar cell module having a dummy sub-module according to the present invention, wherein FIG. 2A is a plan view, and FIG. 2B is a sectional view taken along line XX in FIG. In the portion to be cut for each predetermined number of solar cell modules, the distance between the sub-module 1 and the dummy sub-module 1d is 20
Place it within mm. Dummy sub module 1
The size of d may be any size as long as the two main wirings 2 are covered by one dummy submodule 1d, and a portion where the dummy submodule 1d and the main wiring 2 overlap is formed. The cut portion is in a state where the dummy submodule 1 d and the main wiring 2 are covered with the sealing film 4.

The material of the dummy submodule 1 is as follows.
Insulating plastic films represented by polyimide, aramid, and polyethylene can be used.
FIG. 3 is an enlarged cross-sectional view along XX in FIG. 2 of the main wiring portion of the solar cell module according to the present invention. Since the surface C of the main wiring 2 overlapping with the dummy sub-module 1d is not bonded to the insulating sealing film 1d, the surface C is easily exposed. The same cross section can be obtained regardless of which part is cut, not limited to the center of the dummy submodule 1d. Further, since there is no other member on the periphery of the main wiring 2, the work of electrically connecting the external leads to the main wiring 2 can be easily performed.

The method of connecting external leads will be described below. First, a thin metal flat plate is inserted from the cross section after cutting into the surface C of the main wiring 2 and the flat plate of the dummy sub-module 1d facing each other. The film 1d is cut by a mold blade. At this time, the main wiring 2 is not cut because the metal flat plate exists. Next, the exposed surface of the main wiring 2 and the end of the external lead are soldered to make an electrical connection. The soldering area depends on the size of the dummy submodule and
It can be changed depending on the cutting position. Finally, the soldered portion and the cut cross-section are covered with a protective sheet via a sealing film 4 or another insulating adhesive and sealed.

As the protective sheet, a sheet of a fluororesin or silicone resin or a rubber sheet of ethylene propylene diene monomer (EPDM) is used. Also,
As the insulating adhesive, a silicone adhesive or a cyanoacrylate adhesive is used. In addition, the mechanical strength of the connection part can be enhanced by placing a reinforcing member such as soft or hard vinyl chloride resin, acrylic resin, polycarbonate resin, polyester resin or epoxy resin on the outer surface of the electrical wiring connection part. It is.

[0027]

According to the present invention, a plurality of sub-modules comprising a flexible plastic substrate and a photoelectric conversion element formed thereon, and a main wiring connected to outputs of different polarities of the sub-modules In a flexible solar cell module that is covered and sealed by sandwiching at least a heat-adhesive sealing film, the distance between the sub-modules in the longitudinal direction of the sealing film is set to 20 mm or less. The substrate suppresses the heat shrinkage of the sealing film in the peripheral portion thereof, and the occurrence of molding defects such as deterioration of characteristics and wrinkles caused by distortion of the main wiring due to the heat shrinkage is suppressed, and the roll-to-roll method and A long and wide solar cell module can be manufactured by the step roll method, and the connection and the end of the external lead to the solar cell module can be easily performed. It made.

Further, since dummy sub-modules are arranged for every arbitrary number of sub-modules and cut at the dummy sub-module portion, a wiring end processing space can be widened, and the electrical reliability and mechanical strength of the wiring connection portion can be reduced. improves. Since cutting is performed at the dummy sub-module portion and connection of external leads is performed at the main wiring portion where the dummy sub-module overlaps, removal of the sealing film is facilitated, connection work is simplified, and reliability is improved.

[Brief description of the drawings]

FIG. 1 shows a main part of a flexible solar cell module according to the present invention, wherein (a) is a plan view and (b) is XX in (a).
It is sectional drawing, (c) is YY sectional drawing in (a).

FIGS. 2A and 2B show a solar cell module having a dummy sub-module according to the present invention, wherein FIG.
FIG. 2 is a sectional view taken along line XX in FIG.

FIG. 3 is an enlarged cross-sectional view taken along the line XX of FIG. 2 of a main wiring portion of the solar cell module according to the present invention.

FIG. 4 is an enlarged plan view showing a position of a width change amount of the solar cell module.

FIG. 5 is a graph showing a sub-module interval dependency of a width change amount of a solar cell module.

6 (a) is a plan view, FIG. 6 (b) is a sectional view taken along line XX in FIG. 6 (a), and FIG. 6 (c) is a sectional view taken along line YY in FIG. 6 (a). It is.

FIG. 7 is a cross-sectional view along a transport direction of a conventional step-roll type manufacturing apparatus for a flexible solar cell module.

8A and 8B show a conventional solar cell module having a connection electrode forming film, wherein FIG. 8A is a plan view, and FIG. 8B is a cross-sectional view taken along line XX in FIG.

[Explanation of symbols]

 M Solar cell module 1 Solar cell sub-module 2 Main wiring 3 Secondary wiring 4 Sealing film 5 Surface protection film H Module curing device 1e Dummy sub-module with wiring 1d Dummy sub-module C Cutting line D Sub-module interval w1 Edge width change w2 Central part width change amount L1 Module end line L2 Center line between modules Ra Sending roll Rb Sending roll Re Winding roll

Claims (7)

[Claims] 1. A plurality of solar cell sub-modules (hereinafter abbreviated as sub-modules) each comprising a flexible plastic substrate and a photoelectric conversion element formed thereon, and connected to outputs of different polarities of the sub-modules. In a flexible solar cell module, the main wiring and the heat-adhesive, heat-shrinkable sealing film are sandwiched at least by covering and sealing.
The space between the sub-modules in the longitudinal direction of the sealing film is 20 mm or less. 2. A plurality of sub-modules each comprising a flexible plastic substrate and a photoelectric conversion element formed thereon,
A flexible solar cell module in which a main wiring connected to outputs of different polarities of the submodule is sandwiched between at least a heat-adhesive and heat-shrinkable sealing film and covered and sealed, wherein a photoelectric conversion element is provided. A flexible sub-module, which is a flexible film not to be provided, is disposed between the sub-modules so as to overlap with the main wiring, and is covered and sealed with an adhesive film. Battery module. 3. The flexible solar cell module according to claim 2, wherein the distance between the sub-module and the dummy sub-module in the longitudinal direction of the sealing film is 20 mm or less. 4. The flexible solar cell module according to claim 3, wherein said dummy sub-module is made of a polyimide-based, aramid-based or polyethylene-based insulating plastic. 5. A plurality of sub-modules each comprising a flexible plastic substrate and a photoelectric conversion element formed thereon, and a main wiring connected to outputs of different polarities of the sub-modules, which are thermally contracted and thermally contracted. In the method for manufacturing a flexible solar cell module sandwiched and covered and sealed by a flexible sealing film,
A method for manufacturing a flexible solar cell module, comprising cutting individual sub-modules into individual solar cell modules. 6. A plurality of sub-modules each comprising a flexible plastic base material and a photoelectric conversion element formed thereon and dummy sub-modules arranged for every arbitrary number of sub-modules and sub-modules different from each other. In a method for manufacturing a flexible solar cell module for sandwiching and covering a main wiring connected to a polar output with a heat-adhesive and heat-shrinkable sealing film, cutting the dummy sub-module, A method for manufacturing a flexible solar cell module, which is provided as individual solar cell modules. 7. The connection of the external lead to the main wiring after the individualization of the solar cell module according to claim 2 is performed on a portion of the main wiring overlapping the dummy sub-module. A method for connecting external leads, characterized in that: