TW201711538A - 撓性印刷配線板，聚光型太陽光發電模組，聚光型太陽光發電面板，及撓性印刷配線板的製造方法 - Google Patents

撓性印刷配線板，聚光型太陽光發電模組，聚光型太陽光發電面板，及撓性印刷配線板的製造方法 Download PDF

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TW201711538A
TW201711538A TW105118581A TW105118581A TW201711538A TW 201711538 A TW201711538 A TW 201711538A TW 105118581 A TW105118581 A TW 105118581A TW 105118581 A TW105118581 A TW 105118581A TW 201711538 A TW201711538 A TW 201711538A
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wiring board
printed wiring
flexible printed
layer
power generation
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Kazumasa Toya
Youichi Nagai
Kenji Saito
Takashi Iwasaki
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Sumitomo Electric Industries
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Abstract

提高撓性印刷配線板的製造性。 本發明之聚光型太陽光發電用之撓性印刷配線板(12)，具備供發電元件(121)連接之導電層(127)、及具有絕緣性之絕緣層(126)、及補強此絕緣層(126)之補強層(124)，導電層、絕緣層、及補強層依此順序被接合。撓性印刷配線板(12)中，補強層(124)，和導電層(127)藉由同一材料所形成。

Description

撓性印刷配線板，聚光型太陽光發電模組，聚光型太陽光發電面板，及撓性印刷配線板的製造方法
本發明有關用於令太陽光聚光至發電元件而發電之聚光型太陽光發電(CPV：Concentrated Photovoltaic)的撓性印刷配線板、聚光型太陽光發電模組、及聚光型太陽光發電面板，另有關撓性印刷配線板的製造方法。
以往，已知有一種聚光型太陽光發電裝置，是設計成藉由令多數個聚光型太陽光發電模組縱橫排列而成之聚光型太陽光發電面板，來獲得期望的發電電力(例如，參照專利文獻1)。
專利文獻1記載之發電裝置中使用的發電模組，是在容器形狀的框體的內部，具備具有發電元件之撓性印刷配線板，並藉由設於框體的表面側之聚光透鏡來將太陽光聚集至發電元件，以在發電元件進行發電。
[先前技術文獻] [專利文獻]
[專利文獻1]日本特開2013-80760號公報
專利文獻1記載之撓性印刷配線板，具備連接至發電元件之銅製的導電層、及將此導電層與框體側絕緣之絕緣層，並且具有一定程度的柔軟性以便能夠對於框體密合地安裝。此外，為便於製造時等的取用，在絕緣層的背面側設有補強板，以使撓性印刷配線板帶有一定程度的剛性。此補強板，為了將來自發電元件或導電層的熱往框體側逸散，係由具有散熱性之鋁材所形成。
但，由鋁材所構成之補強板，為了確保足夠的散熱性不得不做成較厚，撓性印刷配線板的輕量化等會變得困難。
此外，銅製的導電層與鋁製的補強板之熱膨脹率相異，因此會因為當藉由熱壓(hot press)等將它們接合時的熱膨脹差等，造成尺寸變得容易發生偏差。又，當進行將由導電層、絕緣層、及補強板接合而成的中間材料切割出期望形狀的撓性印刷配線板之加工的情形下，不能不考量材料相異之導電層與補強板雙方的切斷條件，故現況是採取將導電層及絕緣層、以及補強板各自分別地切斷成期望形狀，其後再將它們接合這樣的製造方法。在此情形下，製造所需之工程變多，並且接合時的對位也變得困難。
又，當補強板的剛性低的情形下，切斷後以熱壓等來做接合會變得困難，因此除了上述般來自散熱性的理由之外，基於製造上的理由也必須將補強板形成為較厚以提高剛性。
本發明之目的在於解決上述般製造上的問題等，提高製造性。
本發明之撓性印刷配線板，具備：供發電元件連接之導電層、及具有絕緣性之絕緣層、及補強此絕緣層之補強層，前述導電層、前述絕緣層、及前述補強層依此順序被接合，前述補強層，為和前述導電層藉由同一材料所形成之物。
本發明之聚光型太陽光發電模組，具備：具有安裝面之框體、及被接合於前述安裝面之上述撓性印刷配線板、及對應於前述發電元件而被安裝於前述框體，將太陽光聚光至前述發電元件之透鏡要素。
本發明之聚光型太陽光發電面板，係令上述聚光型太陽光發電模組集合複數個而成。
本發明之撓性印刷配線板的製造方法，包含：將供發電元件連接之導電層、及具有絕緣性之絕緣層、及和前述導電層由同一材料所形成而補強前述絕緣層之補強層予以接合，以形成聚光型太陽光發電模組用 的撓性印刷配線板的中間材料之工程；及將前述中間材料切斷加工成期望的形狀之工程。
按照本發明，能夠提高撓性印刷配線板的製造性。
1‧‧‧聚光型太陽光發電面板
1M‧‧‧聚光型太陽光發電模組
2‧‧‧支柱
3‧‧‧架台
11‧‧‧框體
11a‧‧‧底板
11b‧‧‧緣部
12‧‧‧撓性印刷配線板
12f‧‧‧撓性基板
13‧‧‧一次聚光部
13f‧‧‧菲涅爾透鏡
14‧‧‧連接器
100‧‧‧聚光型太陽光發電裝置
121‧‧‧發電元件
121a‧‧‧引線框
122‧‧‧二次聚光部
123‧‧‧接着層
123’‧‧‧接着層
124‧‧‧補強板(補強層)
124’‧‧‧補強板(補強層)
125‧‧‧接着層
125’‧‧‧接着層
126‧‧‧絕緣基材(絕緣層)
126’‧‧‧絕緣基材(絕緣層)
127‧‧‧圖樣(導電層)
127’‧‧‧圖樣(導電層)
128‧‧‧覆蓋膜(保護層)
128’‧‧‧覆蓋膜(保護層)
[圖1]本發明一實施形態之聚光型太陽光發電裝置示意立體圖。
[圖2]聚光型太陽光發電模組放大示意立體圖(部分裁斷)。
[圖3]圖2中的III部之放大圖。
[圖4]設有發電元件之部位中的聚光型太陽光發電模組的部分截面概要示意圖。
[圖5]實施形態與習知技術之撓性印刷配線板的截面比較示意說明圖。
〔實施形態之要旨〕
就本發明實施形態之要旨而言，至少包含下述者。
(1)實施形態之撓性印刷配線板， 係接合有供發電元件連接之導電層、及具有絕緣性之絕緣層、及補強此絕緣層之補強層之聚光型太陽光發電模組用的撓性印刷配線板，其中，前述補強層，為和前述導電層藉由同一材料所形成之物。
藉由這樣的構成，補強層與導電層之熱膨脹率會成為相同，故即使將包含它們在內之各層藉由熱壓等予以接合，仍難以發生尺寸的偏差。此外，能夠將補強層與導電層以相同的條件加工，故將包含它們在內之各層予以接合的狀態下，能夠容易加工成期望的形狀。另，本實施形態之撓性印刷配線板中，於導電層與絕緣層之間、絕緣層與補強層之間介著其他層並不會造成妨礙，例如在它們之間亦可設有接着層。
(2)前述導電層及前述補強層，亦可為銅製。
當補強層為銅製的情形下，相較於習知鋁製的補強層而言熱傳導率高，因此在確保散熱性的前提下能夠形成得較薄。是故，能夠謀求撓性印刷配線板的輕量化。
(3)較佳是在接合至前述絕緣層之前述補強層的一面，施加有黑化處理。
藉此，能夠提高補強層與絕緣層之接合強度。
(4)前述補強層的厚度，較佳是設定在30~140μm的範圍。
這是因為若比此範圍還小，則散熱性或補強的效果會 變小，若比此範圍還大，則輕量化或柔軟性、低成本化的效果會變小的緣故。
(5)在供前述發電元件連接之前述導電層的面，亦可設有保護層，其以避開前述發電元件的狀態覆蓋。
藉由這樣的構成，導電層會受到保護層保護，能夠提高耐久性，並且能夠防止漏電的發生。
(6)在和供前述絕緣層接合之面為相反側的前述補強層之面，亦可設有接着層，其用來接合至聚光型太陽光發電模組的框體。
藉由這樣的構成，能夠迅速且簡單地進行將撓性印刷配線板接着而安裝至聚光型太陽光發電模組的框體之作業。
(7)實施形態之聚光型太陽光發電模組，具備：具有安裝面之框體、及被接合於前述安裝面之上述(1)~(6)任一項所述之撓性印刷配線板、及對應於此撓性印刷配線板的發電元件而被安裝於前述框體，將太陽光聚光至前述發電元件之透鏡要素。
藉由這樣的構成，能夠提供製造性良好的聚光型太陽光發電模組。
(8)實施形態之聚光型太陽光發電面板，係令上述(7)所述之聚光型太陽光發電模組集合複數個而成。
藉由這樣的構成，能夠提供製造性良好的聚光型太陽 光發電面板。
(9)實施形態之撓性印刷配線板的製造方法，包含：將供發電元件連接之導電層、及具有絕緣性之絕緣層、及和前述導電層由同一材料所形成而補強前述絕緣層之補強層予以接合，以形成聚光型太陽光發電模組用的撓性印刷配線板的中間材料之工程；及將前述中間材料切斷加工成期望的形狀之工程。
按照此構成，導電層與補強層為相同材料，故在將包含它們在內之各層予以接合的狀態下態夠容易地切斷成期望的形狀，能夠減少製造工程，謀求製造成本的減低。此外，由於是在將包含導電層與補強層在內之各層事先接合的狀態下切斷成期望的形狀，故切斷時能夠降低對補強層要求之剛性，能夠謀求補強層的薄厚度化。
〔實施形態之細節〕
圖1為本發明一實施形態之聚光型太陽光發電裝置示意立體圖。
圖中，聚光型太陽光發電裝置100，具備聚光型太陽光發電面板1、及在背面中央支撐其之支柱2、及安裝支柱2之架台3。
聚光型太陽光發電面板1，例如，剔除與支柱2連接用的中央部，係令62個(縱7×橫9-1)聚光型太陽光發電模組1M縱橫集合而成。
1個聚光型太陽光發電模組1M的額定輸出例如約120W，就聚光型太陽光發電面板1全體而言，成為約7.5kW的額定輸出。
太陽光發電面板1，能夠藉由未圖示之旋轉機構以支柱2為軸而朝方位角及仰角的2方向旋動，能夠令聚光型太陽光發電面板1追蹤而總是面向太陽的方向。
圖2為聚光型太陽光發電模組(以下亦簡稱為模組)1M放大示意立體圖(部分裁斷)。
模組1M，就主要的構成要素而言具備：具有底板11a之容器狀(角皿狀)的框體11、及和底板11a的上面(安裝面)相接而設置之撓性印刷配線板12、及以堵塞框體11的開口部分之方式安裝於緣部(brim)11b之一次聚光部13。框體11為金屬製，較佳為鋁製。框體11，藉由金屬製而具有良好的熱傳導性。是故，從撓性印刷配線板12往框體11之散熱性特別好。模組1M的大小，例如，能夠將縱、橫、及深度的尺寸各自做成840mm、640mm、85mm。
一次聚光部13，為菲涅爾透鏡(Fresnel lens)陣列，身為將太陽光聚光的透鏡要素之菲涅爾透鏡13f，是形成為以矩陣狀並排複數個(例如縱16×橫12，共192個)。這樣的一次聚光部13，例如能夠做成以玻璃板為基材，在其背面(內側)形成有矽氧樹脂膜之物。菲涅爾透鏡13f，形成於該樹脂膜。在框體11的外面，設有用來將模組1M的輸出予以取出之連接器14。
圖3為圖2中的III部之放大圖。圖3中，撓性印刷配線板12，具備帶狀之撓性基板12f、及設於其上面之發電元件(太陽電池)121、及設置成罩住該發電元件121之二次聚光部122。發電元件121及二次聚光部122的組合(set)，是在一次聚光部13的對應於各菲涅爾透鏡13f之位置，恰好設有相同個數。二次聚光部122，將從各菲涅爾透鏡13f入射的太陽光聚集至發電元件121上。二次聚光部122，例如為透鏡。本實施形態中，是使用球形的透鏡，但亦可為球形以外的形狀。此外，亦可替換透鏡，而為一面將光漫射一面往下方引導之反射鏡。
圖4為設有發電元件121之部位中的模組1M的部分截面概要示意圖。
撓性基板12f，若把接着層等也想成其一部分，則從下方開始依序由接着層123、補強板(補強層)124、接着層125、絕緣基材(絕緣層)126、圖樣(導電層)127、覆蓋膜(coverlay)(保護層)128所構成。又，撓性印刷配線板12，係構成撓性基板12f之各層與發電元件121及二次聚光部122成為一體，藉此構成。另，圖4所示之各層123~128的厚度，與實際尺寸大致成比例。
發電元件121，具有輸出端子亦即引線框121a，該引線框121a和圖樣127的規定部位電性連接。此外，圖4中的122a，為在發電元件121上支撐二次聚光部122之支撐體。
圖樣127，例如由銅箔所構成，是在絕緣基材126上藉由蝕刻等而形成。
絕緣基材126，例如為耐熱性優良之聚醯亞胺製。藉由絕緣基材126，圖樣127與框體11絕緣。
最下方的接着層123，將框體11的底板11a與補強板124互相接着。該接着層123，具有導電性以便將框體11與補強板124保持在相同電位(接地電位)。此外，該接着層123，例如由雙面膠帶所構成，是在撓性印刷配線板12尚未被安裝於框體11之單體的狀態下，事先被安裝於補強板124的下面。
另一接着層125，將補強板124與絕緣基材126互相接着。具體而言，補強板124與絕緣基材126係隔著接着層125藉由熱壓而接合。絕緣基材126與圖樣127，構成為狹義的撓性基板12f。
將圖樣127覆蓋之覆蓋膜128，為絕緣材料之層，耐電壓優良。覆蓋膜128，例如能夠做成聚醯亞胺等合成樹脂製。覆蓋膜128，藉由熱熔接而以密合至圖樣127之狀態被接合。覆蓋膜128，藉由覆蓋圖樣127而加以保護，並且防止漏電的發生。
覆蓋膜128，熱傳導率被訂為0.2〔W/m．K〕程度。像這樣，覆蓋膜128的熱傳導率被設定地相對較低，藉此能夠抑制太陽光的熱傳導。由此觀點，覆蓋膜128，較佳是做成太陽光的反射率高之「白色」系。
補強板124，是在不喪失柔軟性的程度，使撓 性印刷配線板12帶有若干的剛性。因此，於發電模組1M之製造時等能使撓性印刷配線板12的取用變得容易。此外，藉由補強板124，會獲得撓性印刷配線板12全體的變形防止效果，能夠保持圖樣127的形狀。
本實施形態之補強板124，訂為銅製。因此，具有用來使發電元件121或圖樣127等的熱往框體11的底板11a散熱之優良熱傳導性(散熱性)。
表1中，針對撓性印刷配線板12各層的厚度，分別揭示其推薦值及可適用之範圍。另，表1中各層的上下方向的記載順序，對應於圖4中各層的上下方向的層積順序。
本實施形態之補強板124為銅製，由散熱性及補強的觀點，理想的厚度是做成105μm。另一方面，習知(例如參照專利文獻1)之撓性基板的補強板是做成鋁 製。鋁的熱傳導率為240W/mK，比銅的熱傳導率400W/mK還小，因此若欲獲得期望的散熱性則不得不將厚度更增大。
具體而言，本實施形態之銅製的補強板124，厚度為105μm，相對於此，習知之鋁製的補強板厚度做成800μm。其結果，本實施形態之撓性印刷配線板12，相較於將補強板124以外的各層的厚度均設為相同之情形下的習知之撓性印刷配線板，約成為1/5的厚度。圖5視覺地表現了本實施形態與習知技術中撓性印刷配線板12的厚度差異。圖5中，習知技術中，與本實施形態對應之層係標上附「’」之符號。
另一方面，銅的比重約9.0，比鋁的比重約2.7還大。然而，本實施形態之補強板124的厚度(105μm)，自習知之鋁製的補強板的厚度(800μm)大幅減少，故其重量成為約一半。是故，本實施形態之補強板124，厚度及重量均比習知還小，能夠減低材料費。
此外，補強板124的厚度及重量變小，因此能夠謀求撓性印刷配線板12全體的薄厚度化及輕量化。因此，撓性印刷配線板12的取用變得更容易，能夠使製造太陽光發電模組時的作業性提升。
鋁的莫氏硬度約2.5，相對於此，銅的莫氏硬度約3.0，比鋁還稍大。但，本實施形態之補強板124，厚度比習知還變小，因此能夠充分地確保撓性印刷配線板12所要求之柔軟性。
另，如表1所示，補強板124的厚度，能夠設定在30μm~140μm的範圍。這是因為若補強板124的厚度比30μm還小，則就散熱性或補強而言的效果會變小，若比140μm還大，則撓性印刷配線板12的輕量化或柔軟性、低成本化的效果會變小的緣故。另，當重視補強板124的輕量化、柔軟性、及低成本化的情形下，補強板124的厚度更佳是設定在30μm~110μm的範圍。
撓性印刷配線板12，是在形成有圖樣127之絕緣基材126上，隔著接着層125將補強板124接合後，利用加壓等而被切斷加工(沖孔加工)成規定的形狀(細長帶狀)。或是，在形成有圖樣127之絕緣基材126上接合補強板124後，在圖樣127上安裝發電元件121及二次聚光部122，在補強板124安裝接着層123，其後被切斷加工成規定的形狀。
本實施形態中，圖樣127與補強板124皆為銅製，因此能夠以幾乎相同的條件將它們做切斷加工。是故，即使不將形成了圖樣127之絕緣基材126與補強板124予以分別切斷，也能夠在接合了的狀態下同時進行切斷加工，相較於分別切斷的情形能夠減少製造工程。
此外，圖樣127與補強板124為相同材料，熱膨脹率亦相同，因此會變得不易因它們藉由熱壓被接合時的熱膨脹差、或接合後受到冷卻時的熱收縮差而發生尺寸偏差。因此，便可提高製品的尺寸精度，能使製品不良減少，使良率提升。
又，當將形成了圖樣127之絕緣基材126與補強板124予以分別切斷後再藉由熱壓接合的情形下，若補強板124的剛性低則會變得難以藉由熱壓適當地接合，但本實施形態中，是將形成了圖樣127之絕緣基材126與補強板124予以事先接合再進行切斷，故對補強板124要求之剛性變低，相對比便能將補強板124薄厚度化。此外，本實施形態中，相較於習知之鋁製的補強板而言是使用加工性好的銅製之補強板124，故能夠提高用於切斷之模具的壽命。此外，薄厚度的銅板流通量大，因此能夠抑制成本。
補強板124，在接着層125側之面被施加黑化處理，於表面形成有微細的凹凸。如此一來，能夠提高對於絕緣基材126之接着力，並且能夠抑制氣泡的發生。本實施形態中，成功地將接着力提高大約3~5倍。此外，補強板124的接着層123側之面受到鏡面加工。此面，只要透過接着層123與框體11的底板11a做成同電位即足夠，因此亦可不施加黑化處理。
另，上述實施形態中，框體11訂為金屬製，但並非限定於金屬製，亦可訂為樹脂製。在此情形下，框體11變得尤其輕量，就聚光型太陽光發電模組1M全體而言也變得尤其輕量。另，即使為樹脂亦有熱傳導性，故會獲得一定的散熱性。尤其是，添加了具有高熱傳導性之絕緣性填料(例如氧化鋁、矽石、炭化矽、氧化鎂等)的樹脂，其熱傳導性優良，散熱性提升，故為合適。此外，藉由在樹脂的表面施加金屬塗布，也能將表面的熱傳導性 提高至和金屬同等。
此外，上述實施形態中，二次聚光部122是和發電元件121一起組裝至撓性基板12f上，但亦可將二次聚光部122和撓性基板12f分開設置，此外，也可將二次聚光部本身省略。
圖樣127與補強板124，只要是相同材料，則亦可由銅以外的金屬來形成。
表1所示各層的推薦值或適用範圍為一例，未必受到限定，也會依各層的素材而變化。尤其是，針對補強板，由散熱性、輕量化、柔軟性、成本的觀點，只要厚度或其範圍被設定成和習知之鋁製的補強板大致同等、或至少1者獲得優良結果即可。
另，本次揭示之實施形態中，應認為所有特點均為示例，並非限制性的事項。本發明之範圍意圖包括申請專利範圍所揭示，與申請專利範圍之意義均等及其範圍內的所有變更。
11‧‧‧框體
11a‧‧‧底板
12‧‧‧撓性印刷配線板
12f‧‧‧撓性基板
121‧‧‧發電元件
121a‧‧‧引線框
122‧‧‧二次聚光部
122a‧‧‧支撐體
123‧‧‧接着層
124‧‧‧補強板(補強層)
125‧‧‧接着層
126‧‧‧絕緣基材(絕緣層)
127‧‧‧圖樣(導電層)
128‧‧‧覆蓋膜(保護層)

Claims (10)

  1. 一種撓性印刷配線板，具備：供發電元件連接之導電層、及具有絕緣性之絕緣層、及補強此絕緣層之補強層，前述導電層、前述絕緣層、及前述補強層依此順序被接合，前述補強層，和前述導電層藉由同一材料所形成。
  2. 如申請專利範圍第1項所述之撓性印刷配線板，其中，前述導電層及前述補強層為銅製。
  3. 如申請專利範圍第1項所述之撓性印刷配線板，其中，在接合至前述絕緣層之前述補強層的一面，施加有黑化處理。
  4. 如申請專利範圍第2項所述之撓性印刷配線板，其中，在接合至前述絕緣層之前述補強層的一面，施加有黑化處理。
  5. 如申請專利範圍第2項所述之撓性印刷配線板，其中，前述補強層的厚度設定在30~140μm的範圍。
  6. 如申請專利範圍第1項至第5項中任一項所述之撓性印刷配線板，其中，設有保護層，將供前述發電元件連接之前述導電層的面，以避開前述發電元件的狀態予以覆蓋。
  7. 如申請專利範圍第1項至第5項中任一項所述之撓性印刷配線板，其中，在和供前述絕緣層接合之面為相反側的前述補強層之面，設有接着層，其用來接合至聚光型太陽光發電模組的框體。
  8. 一種聚光型太陽光發電模組，具備：具有安裝面之框體、及被接合於前述安裝面之申請專利範圍第1項至第5項中任一項所述之撓性印刷配線板、及對應於此撓性印刷配線板的發電元件而被安裝於前述框體，將太陽光聚光至前述發電元件之透鏡要素。
  9. 種聚光型太陽光發電面板，係令申請專利範圍第8項所述之聚光型太陽光發電模組集合複數個而成。
  10. 一種撓性印刷配線板的製造方法，包含：將供發電元件連接之導電層、及具有絕緣性之絕緣層、及和前述導電層由同一材料所形成而補強前述絕緣層之補強層予以接合，以形成聚光型太陽光發電模組用的撓性印刷配線板的中間材料之工程；及將前述中間材料切斷加工成期望的形狀之工程。
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