WO2011093450A1

WO2011093450A1 - Solar cell module and method for producing solar cell module

Info

Publication number: WO2011093450A1
Application number: PCT/JP2011/051752
Authority: WO
Inventors: 悠丸山; 裕幸神納
Original assignee: 三洋電機株式会社
Priority date: 2010-01-29
Filing date: 2011-01-28
Publication date: 2011-08-04
Also published as: JP2011159646A; JP5377347B2

Abstract

Disclosed is a solar cell module that splits into solar cells when pressure is applied, suppresses the occurrence of chips and cracks, and can increase yield. In this solar cell module, the end on the side of a second solar cell of a second wiring material is disposed in a manner so as to either nearly match the end on the side of the second solar cell of a first wiring material when seen in a planar manner, or be positioned on the reverse side from the side of the second solar cell with respect to the end on the side of the second solar cell of the first wiring material.

Description

Solar cell module and method for manufacturing solar cell module

The present invention relates to a solar cell module and a method for manufacturing the solar cell module, and more particularly to a solar cell module provided with a wiring material and a method for manufacturing the solar cell module.

Conventionally, a solar cell module provided with a wiring material and a method for manufacturing the solar cell module are known. Such a solar cell module and its manufacturing method are disclosed in, for example, Japanese Patent Application Laid-Open No. 2004-281797.

JP-A-2004-281797 discloses a first solar cell and a second solar cell that are arranged adjacent to each other, and a connection tab (wiring material) that connects the first solar cell and the second solar cell. A solar cell module provided is disclosed. In the solar cell module disclosed in Japanese Patent Application Laid-Open No. 2004-281797, connection tabs on the light receiving surface side are arranged on the upper surfaces of the first solar cell and the second solar cell, respectively. In addition, connection tabs on the non-light-receiving surface side are arranged on the lower surfaces of the first solar cell and the second solar cell, respectively. The connection tab on the light receiving surface side of the second solar cell is provided so as to extend to the lower surface side of the first solar cell, and the connection tab on the non-light receiving surface side disposed on the lower surface of the first solar cell. And are connected by solder on the lower surface side of the first solar cell.

JP 2004-281797 A

However, in the solar cell module disclosed in Japanese Unexamined Patent Application Publication No. 2004-281797, the positional relationship between the end of the connection tab on the light receiving surface side and the end of the connection tab on the non-light receiving surface side is described and illustrated. Not. For this reason, when pressure is applied to the solar cell module disclosed in Japanese Patent Application Laid-Open No. 2004-281797, the end of the connection tab on the light receiving surface side and the end of the connection tab on the non-light receiving surface side Depending on the positional relationship, the first solar cell may be cracked, chipped, or cracked due to pressure concentration on the surface of the first solar cell corresponding to the end of the connection tab on the light receiving surface side. There seems to be a problem.

The present invention has been made to solve the above-described problems, and one object of the present invention is to suppress the occurrence of cracks, chips and cracks in a solar cell when pressure is applied. It is to provide a solar cell module capable of improving the yield and a method for manufacturing the solar cell module.

Means for Solving the Problems and Effects of the Invention

To achieve the above object, the solar cell module according to the first aspect of the present invention is arranged on the first solar cell and the second solar cell arranged adjacent to each other and on one surface side of the first solar cell. The first wiring member, the second wiring member disposed on the other surface side of the first solar cell, and the second wiring member disposed on the one surface side of the second solar cell, and second on the other surface side of the first solar cell. A third wiring member connected to the wiring member, and an end of the second wiring member on the second solar cell side substantially coincides with an end of the first wiring member on the second solar cell side in plan view Or, it is arranged so as to be located on the side opposite to the second solar cell side from the end of the first wiring member on the second solar cell side.

In the solar cell module according to the first aspect of the present invention, as described above, the end of the second wiring member on the second solar cell side when viewed in plan is the end of the first wiring member on the second solar cell side. Or the second wiring material second by disposing the first wiring material so as to be located on the opposite side of the second solar cell side from the end of the first wiring material on the second solar cell side. Since the first wiring member is present in the portion on the one surface side of the first solar cell corresponding to the portion where the end portion on the solar cell side is disposed, the second wiring side is second from the other surface side of the first solar cell. Even when pressure is applied to the wiring material, the pressure applied to the second wiring material can be received at the end of the first wiring material on the second solar cell side or in the plane portion near the end of the first wiring material. it can. Thereby, it can suppress that a pressure concentrates on the part of the surface of the 1st solar cell in which the edge part by the side of the 2nd solar cell of the 1st wiring material is located. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 1st solar cell resulting from the pressure from the other surface side. The third wiring member is connected to the second wiring member on the other surface side of the first solar cell, so that the pressure applied to the first wiring member from the one surface side is connected to the second wiring member. Since it can receive with a wiring material, it can suppress that a pressure concentrates on the part of the surface of the 1st solar cell corresponding to the edge part by the side of the 2nd solar cell of a 2nd wiring material. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 1st solar cell resulting from the pressure from the one surface side. As a result, the yield of the solar cell module can be improved.

In the solar cell module according to the first aspect, preferably, an end of the second wiring member on the second solar cell side is closer to the second solar cell side than an end of the first wiring member on the second solar cell side. Are arranged on the opposite side. If comprised in this way, while the pressure from the other surface side can be reliably received in the plane part near the edge part of a 1st wiring material, the pressure from one surface side can be received by a 3rd wiring material. Therefore, it can suppress more that a pressure concentrates on the surface of a 1st solar cell.

In this case, preferably, the interval between the second solar cell side end of the second wiring member and the second solar cell side side surface of the first solar cell is the end of the first wiring member on the second solar cell side. 2 mm or more than the distance between the first solar cell and the side surface of the first solar cell on the second solar cell side. If comprised in this way, while being able to receive the pressure from the other surface side more reliably in the plane part formed by the length of at least about 2 mm near the edge part of the 1st wiring material, Since the pressure can be received by the third wiring member, the concentration of pressure on the surface of the first solar cell can be effectively suppressed.

In the solar cell module in which the end of the second wiring member is located on the opposite side of the end of the first wiring member from the second solar cell side, preferably the end of the second wiring member on the second solar cell side The distance between the second solar cell side of the first solar cell and the second solar cell side end of the first wiring member and the second solar cell side surface of the first solar cell, and It is larger than the thickness of the first solar cell. If comprised in this way, by making the space | interval of the edge part by the side of the 2nd solar cell of the 2nd wiring material and the side surface by the side of the 2nd solar cell of the 1st solar cell larger than the thickness of the 1st solar cell, An end of the first wiring member on the second solar cell side while suppressing the difficulty of joining the second wiring member and the first solar cell in the vicinity of the side surface of the first solar cell on the second solar cell side. By making it larger than the distance between the first solar cell and the side surface of the first solar cell on the second solar cell side, it is possible to further suppress the concentration of pressure on the surface of the first solar cell.

In the solar cell module according to the first aspect, preferably, the distance between the end portion of the second wiring member on the second solar cell side and the side surface of the first solar cell on the second solar cell side is that of the first wiring member. It is not less than the distance between the end portion on the second solar cell side and the side surface on the second solar cell side of the first solar cell, and is 6 mm or less. If comprised in this way, while being able to suppress a pressure concentrating on the surface of the 1st solar cell corresponding to the edge part by the side of the 2nd solar cell of the 1st wiring material, it is 2nd of the 2nd wiring material. Since it can suppress that a pressure concentrates on the surface of the 1st solar cell corresponding to the edge part by the side of a solar cell, it suppresses that a crack, a chip, and a crack arise in a 1st solar cell resulting from pressure. be able to. Further, by setting the distance between the end of the second wiring member on the second solar cell side and the side surface of the first solar cell on the second solar cell side to 6 mm or less, the second wiring member on the second solar cell side The distance between the end portion and the side surface of the first solar cell on the second solar cell side becomes too large, and the surface area of the first solar cell on which the second wiring member is not disposed increases, resulting in poor current collection efficiency. It is possible to suppress a decrease in the output of the first solar cell due to the fact. In addition, the point which can suppress the fall of the output of a 1st solar cell is confirmed by the simulation which this inventor performed.

In the solar cell module according to the first aspect described above, preferably, the third wiring member is arranged in the second wiring member so as to overlap in a plan view in a state of being arranged on the opposite side of the second wiring member from the first solar cell. Connected to wiring material. If comprised in this way, the part with which the 2nd wiring material and the 3rd wiring material mutually overlapped can be easily connected with solder etc.

In the solar cell module according to the first aspect, the third solar cell is preferably disposed on the opposite side of the second solar cell from the first solar cell and adjacent to the second solar cell, and one of the third solar cells. A fourth wiring member disposed on the side surface and extending to the other surface side of the second solar cell; a fourth wiring member disposed on the other surface side of the second solar cell; A third solar cell side end of the fifth wiring member substantially coincides with an end portion of the third wiring member on the third solar cell side in plan view. Or it arrange | positions so that it may be located in the opposite side to the 3rd solar cell side rather than the edge part by the side of the 3rd solar cell of the 3rd wiring material. If comprised in this way, the 3rd wiring material exists in the part by the side of the one surface side of the 2nd solar cell corresponding to the part by which the edge part by the side of the 3rd solar cell of the 5th wiring material is arrange | positioned. Therefore, even when pressure is applied to the fifth wiring member from the other surface side of the second solar cell, the pressure applied to the fifth wiring member is changed to the end of the third wiring member on the third solar cell side or the second wiring member. It can be received in the plane portion near the end of the three wiring members. Thereby, it can suppress that a pressure concentrates on the part of the surface of the 2nd solar cell in which the edge part by the side of the 3rd solar cell of a 3rd wiring material is located. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 2nd solar cell resulting from the pressure from the other surface side. The fourth wiring member is connected to the fifth wiring member on the other surface side of the second solar cell, so that the pressure applied to the third wiring member from the one surface side is connected to the fifth wiring member. Since it can receive with a wiring material, it can suppress that a pressure concentrates on the part of the surface of the 2nd solar cell corresponding to the edge part by the side of the 3rd solar cell of a 5th wiring material. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 2nd solar cell resulting from the pressure from the one surface side. As a result, the yield of the solar cell module can be improved.

In this case, preferably, the end of the fifth wiring member on the third solar cell side is located on the opposite side of the third solar cell side from the end of the third wiring member on the third solar cell side. Has been placed. If comprised in this way, while the pressure from the other surface side can be reliably received in the plane part near the edge part of a 3rd wiring material, the pressure from one surface side can be received by a 4th wiring material. Therefore, it can suppress more that a pressure concentrates on the surface of a 2nd solar cell.

In the solar cell module in which the end portion of the fifth wiring member is located on the side opposite to the third solar cell side with respect to the end portion of the third wiring member, preferably the end of the second wiring member on the second solar cell side The part is located on the opposite side of the second solar cell side from the end of the first wiring member on the second solar cell side, and the end of the fifth wiring member on the third solar cell side is the third wiring. It is located on the opposite side to the third solar cell side from the end of the material on the third solar cell side. If comprised in this way, it can suppress that a pressure concentrates on both the surface of a 1st solar cell and the surface of a 2nd solar cell.

In the solar cell module further including the third solar cell, the fourth wiring member, and the fifth wiring member, preferably, the fourth wiring member is disposed on the opposite side of the fifth wiring member from the second solar cell. Thus, they are connected to the fifth wiring member so as to overlap in plan view. If comprised in this way, the part in which the 4th wiring material and the 5th wiring material overlapped each other can be easily connected with solder etc. FIG.

In the solar cell module according to the first aspect, preferably, a first cover and a second cover disposed on each of the one surface side and the other surface side of the first solar cell and the second solar cell by lamination, The laminate further includes a filler disposed between the first cover and the first solar cell and between the second cover and the second solar cell by laminating. Thus, even when pressure is applied from the other surface side or one surface side of the first solar cell by the laminating process when arranging the first cover and the second cover and the filler, the surface of the first solar cell It is possible to suppress the pressure from being concentrated on the portion.

In the solar cell module according to the first aspect, preferably, the thickness of the first solar cell and the second solar cell is 150 μm or less. Thus, since the first solar cell having a thickness of 150 μm or less is relatively easily cracked with respect to pressure, in this case, if the configuration according to the first aspect is applied, the first wiring member on the second solar cell side The pressure can be suppressed from concentrating on the surface of the first solar cell corresponding to the end of the second solar cell, and the pressure on the surface of the first solar cell corresponding to the end of the second wiring member on the second solar cell side. Can be concentrated.

The manufacturing method of the solar cell module according to the second aspect of the present invention includes a first solar cell and a defective solar cell that are arranged adjacent to each other, and a first wiring that is arranged on one side of the first solar cell. In a solar cell group comprising a material and a second wiring material disposed on the one surface side of the defective solar cell, the defective solar cell is repaired. A method for manufacturing a solar cell module comprising a step of replacing the solar cell module with a second solar cell for the first wiring material on the other surface side of the first solar cell and the first wiring material when viewed in plan Cut at a position substantially coincident with the end of the defective product on the solar cell side, or at a position opposite to the end of the defective product of the first wiring member on the solar cell side. And a second wiring material after cutting disposed on the other surface side of the first solar cell, The third solar cell is disposed on one side of the second solar cell disposed at the position where the defective solar cell is disposed, and extends to the other surface of the first solar cell. Connecting on the other surface side.

In the method for manufacturing a solar cell module according to the second aspect of the present invention, as described above, the second wiring member is disposed on the other surface side of the first solar cell, and the first wiring member is not seen as viewed in plan. Cutting at a position substantially coincident with the end of the non-defective solar cell side, or at a position opposite to the solar cell side of the defective product from the end of the defective first solar cell side of the wiring material, By connecting the second wiring material after cutting and the third wiring material on the other surface side of the first solar cell, the second wiring material corresponding to the portion where the end portion on the second solar cell side of the second wiring material is disposed. Since the first wiring member is present on the one surface side portion of the one solar cell, the second wiring member and the third wiring member after being cut are connected to each other from the other surface side of the first solar cell. Even when pressure is applied to the second wiring material, the pressure applied to the second wiring material is changed to the second value of the first wiring material. It can be received in the end portion or end plane portion in the vicinity of the first wiring member for solar cell side. Thereby, it can suppress that a pressure concentrates on the part of the surface of the 1st solar cell in which the edge part by the side of the 2nd solar cell of the 1st wiring material is located. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 1st solar cell resulting from the pressure from the other surface side. The third wiring member is connected to the second wiring member on the other surface side of the first solar cell, so that the pressure applied to the first wiring member from the one surface side is connected to the second wiring member. Since it can receive by a wiring material, it can suppress that a pressure concentrates on the surface of the 1st solar cell corresponding to the edge part by the side of the 2nd solar cell of a 2nd wiring material. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in a 1st solar cell resulting from the pressure from the one surface side. As a result, the yield of the solar cell module can be improved.

In the manufacturing method of the solar cell module according to the second aspect, preferably, after the step of connecting the second wiring material after cutting and the third wiring material, one side of the first solar cell and the second solar cell. And a step of laminating the filler and the cover on each of the other surface side in this order and laminating by applying pressure. Thus, in the method for manufacturing a solar cell module in which pressure is applied during laminating, if the configuration according to the second aspect is applied, the concentration of pressure on the surfaces of the first solar cell and the second solar cell is suppressed. can do.

In the method for manufacturing a solar cell module according to the second aspect, preferably, the step of cutting the second wiring member includes a step of drawing and cutting the second wiring member to the other surface side of the first solar cell, Formed by cutting the second wiring material after the step of cutting the two wiring materials and prior to the step of connecting the second wiring material and the third wiring material after cutting. The method further includes a step of applying a pressure to the folded portion of the second wiring member after being cut to form a straight line. If comprised in this way, if the structure by the said 2nd aspect is applied in the manufacturing method of the solar cell module in which a pressure is applied at the time of a folding correction, it will suppress that a pressure concentrates on the surface of a 1st solar cell. Can do.

In the method for manufacturing a solar cell module according to the second aspect, preferably, the step of connecting the second wiring member after cutting and the third wiring member includes the step of connecting the third wiring member to the second wiring member after cutting. It includes a step of connecting to the second wiring member from the side opposite to the first solar cell so as to overlap in plan view. If comprised in this way, the 2nd wiring material after the cutting | disconnection of the 1st solar cell provided in the solar cell group from the 3rd wiring material of the 2nd solar cell inserted after the defective solar cell will be provided. Can be easily stacked. In addition, the portion where the second wiring material and the third wiring material after cutting overlap each other can be easily connected with solder or the like.

In the method for manufacturing a solar cell module according to the second aspect, preferably, the step of cutting the second wiring member is configured such that the second wiring member is made less than the end of the defective first wiring member on the solar cell side. It includes a step of cutting at a position opposite to the non-defective solar cell side. If comprised in this way, the pressure from the other surface side added after connecting the 2nd wiring material and 3rd wiring material after a cutting | disconnection will be received reliably in the plane part near the edge part of a 1st wiring material. In addition, since the pressure from one side can be received by the third wiring member, it is possible to further suppress the pressure from being concentrated on the surface of the first solar cell.

In the method for manufacturing a solar cell module according to the second aspect, preferably, in the step of cutting the second wiring member, the second wiring member is made of a defective product from a side surface on the solar cell side of the defective product of the first solar cell. It includes a step of cutting at a position having a distance of 6 mm or less on the side opposite to the solar cell side. If comprised in this way, while being able to suppress a pressure concentrating on the surface of the 1st solar cell corresponding to the edge part by the side of the 2nd solar cell of the 1st wiring material, it is 2nd of the 2nd wiring material. It can suppress that a pressure concentrates on the surface of the 1st solar cell corresponding to the edge part by the side of a solar cell. Further, the second wiring member is cut at a position having a distance of 6 mm or less from the side of the defective first solar cell on the solar cell side to the side opposite to the defective solar cell side. The distance between the second solar cell side end of the first solar cell and the side surface of the first solar cell on the second solar cell side becomes too large, and the surface area of the first solar cell in which the second wiring member is not arranged increases. Thus, it is possible to suppress a decrease in the output of the first solar cell due to the deterioration of the current collection efficiency.

In the method for manufacturing a solar cell module according to the second aspect, preferably, the solar cell group is disposed on the opposite side of the defective solar cell from the first solar cell, and is adjacent to the defective solar cell. The step of cutting the second wiring member is further provided with a solar cell and a fourth wiring member disposed on the one side of the third solar cell and extending to the other side of the defective solar cell. The wiring member is located on the other surface side of the defective solar cell and at a position substantially coincident with the end of the third wiring member on the third solar cell side in plan view, or the third wiring member Including a step of cutting at a position opposite to the third solar cell side with respect to the end portion on the third solar cell side, and after the step of cutting the second wiring material and the fourth wiring material, While removing from the solar cell group, the second thick plate is located at the position where the defective solar cell was placed. A step of arranging a battery, and the step of connecting the second wiring member after cutting and the third wiring member includes a step of connecting the fourth wiring member after cutting disposed on one side of the third solar cell, A step of connecting the fifth wiring member disposed on the other surface side of the second solar cell disposed at the position where the non-defective solar cell has been disposed on the other surface side of the second solar cell. If comprised in this way, it can suppress that a pressure concentrates on both the surface of a 1st solar cell and the surface of a 2nd solar cell.

In this case, preferably, in the step of cutting the second wiring material and the fourth wiring material, the second wiring material is disposed on the defective solar cell side with respect to the defective solar cell side end of the first wiring material. Has a step of cutting the fourth wiring member at a position opposite to the third solar cell side from the end of the third wiring member on the third solar cell side while cutting at a position on the opposite side. If comprised in this way, it can suppress more that pressure concentrates on both the surface of a 1st solar cell and the surface of a 2nd solar cell.

It is a top view of the surface side of the solar cell module by one Embodiment of this invention. It is a top view of the back surface side of the solar cell module by one Embodiment of this invention. FIG. 3 is a cross-sectional view of the vicinity of a solar cell group not including a replacement solar cell of the solar cell module taken along line 1000-1000 in FIGS. 1 and 2; FIG. 3 is an enlarged cross-sectional view of a solar cell group not including a replacement solar cell of the solar cell module taken along line 1000-1000 in FIGS. 1 and 2; FIG. 3 is a cross-sectional view of the vicinity of a solar cell group including a replacement solar cell for a solar cell module taken along the line 2000-2000 in FIGS. 1 and 2; FIG. 3 is an enlarged cross-sectional view of a solar cell group including a solar cell for replacement of a solar cell module along the line 2000-2000 in FIGS. 1 and 2. It is the expanded sectional view which showed the state in which the defective solar cell exists in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the state which removes the defective solar cell in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the state which corrects a return in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the state which inserts the solar cell for replacement | exchange in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the state which soldered the solar cell for replacement | exchange in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the state laminated in the replacement | exchange operation | work of the solar cell module by one Embodiment of this invention. It is the expanded sectional view which showed the cutting position in Example 1 and 2 of this invention. It is the expanded sectional view which showed the cutting position in Example 3 and 4 of this invention. It is the expanded sectional view which showed the cutting position in the comparative example of this invention. It is the table | surface which showed the measurement result regarding generation | occurrence | production of the crack of the solar cell by the Example and comparative example of this invention. It is the graph which showed the result of the simulation of the output fall rate in the solar cell module of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

As shown in FIGS. 1 and 2, a solar cell module 1 according to an embodiment of the present invention includes a plate-like solar cell panel 2 and a terminal box 3 fixed to the back side of the solar cell panel 2 (see FIG. 2). ) And a metal frame 4 that supports the side surface of the solar cell panel 2. As shown in FIGS. 3 and 5, the solar cell panel 2 includes a front cover 21 made of a transparent member such as a glass plate or an acrylic plate, and a weather resistant back made of a resin film such as polyethylene terephthalate (PET).

Solar cell groups

23, 24, 25, 26, 27, and 28 including a plurality of solar cells 40 that are disposed between the side cover 22, the front-side cover 21, and the back-side cover 22 and are electrically connected in series. (See FIG. 1) and a filler 29 provided between the front surface side cover 21 and the solar cell 40 and between the back surface side cover 22 and the solar cell 40. Moreover, the terminal box 3 shown in FIG. 2 is provided in order to collect the electricity generated in the solar cell panel 2. The front cover 21 and the back cover 22 are examples of the “first cover” and the “second cover” in the present invention, respectively.

Here, the solar cell module 1 according to the present embodiment includes a replacement solar cell 42 in addition to the normal

solar cells

40, 41, and 43. The replacement solar cell 42 refers to a solar cell disposed by replacement work at a position where a defective solar cell 44 (see FIG. 7) described later is disposed. As shown in FIGS. 4 and 6, the thickness t in the Z direction between the

solar cells

40, 41 and 43 and the replacement solar cell 42 is about 100 μm. In addition, it is preferable that the thickness t of the

solar cells

40, 41 and 43 and the replacement solar cell 42 in the Z direction is about 150 μm or less. The replacement solar cell 42 is an example of the “second solar cell” in the present invention.

Further, as shown in FIG. 1, a plurality of finger electrodes 40a extending in the X direction are provided on the upper surface of the solar cell 40 (the arrow Z1 direction side in FIG. 3). As shown in FIG. 2, a plurality of finger electrodes 40b extending in the X direction are provided on the lower surface of the solar cell 40 (arrow Z2 direction side in FIG. 3). Further, as shown in FIGS. 4 and 6, bus bar electrodes 30 extending in the direction (Y direction) substantially orthogonal to the finger electrodes 40 a and the finger electrodes 40 b are provided on the upper surface and the lower surface of the solar cell 40. Since the bus bar electrode 30 has a small thickness, the bus bar electrode 30 is not shown in FIGS. 3 and 5.

Next, the structure of the solar cell group 24 will be described.

As shown in FIG. 3, in the solar cell group 24, the upper surface side (the arrow Z1 direction side in FIG. 3) of one solar cell 40 among the solar cells 40 adjacent to each other and the lower surface side of the other solar cell 40 ( 3 are connected in series by a wiring material (tab electrode) 50a made of solder-plated copper wire or the like via the bus bar electrode 30.

Moreover, as shown in FIG. 1, it connects with the wiring material 50a connected in the lower surface side of the solar cell 40 located in the arrow Y1 direction side, and the upper surface side of the solar cell 40 located in the arrow Y2 direction side. Each wiring member 50a is connected to a connecting member 3a for connecting to an adjacent solar cell group or terminal box 3 (see FIG. 2).

As shown in FIG. 4, the end of the wiring member 50a arranged on the upper surface side of the plurality of solar cells 40 on the arrow Y2 direction side is a predetermined distance L1 from the side surface of the solar cell 40 on the arrow Y2 direction side. It is located at a distance. Here, the distance L1 is about 1 mm. As shown in FIG. 1, the

solar cell groups

23, 25, 26 and 27 arranged in parallel with the solar cell group 24 also have the same structure as the solar cell group 24.

Next, the structure of the solar cell group 28 in which the replacement solar cell 42 is arranged after the replacement operation of the defective solar cell 44 (see FIG. 7) is performed will be described.

As shown in FIG. 5, in the solar cell group 28, the solar cell 41, the replacement solar cell 42, the solar cell 43, and the solar cell 40 are arranged in this order from the arrow Y1 direction side in the Y direction. ing. The solar cell 41 is an example of the “first solar cell” in the present invention, and the solar cell 43 is an example of the “third solar cell” in the present invention.

Further, as shown in FIG. 6, in the solar cell group 28, the wiring member (tab electrode) 50 b is disposed on the upper surface side of the solar cell 41 and is cut off on the lower surface side of the solar cell 41. A wiring material (tab electrode) 50c is arranged. A wiring member (tab electrode) 50d is disposed on the upper surface side of the replacement solar cell 42. The wiring member 50c and the wiring member 50d are connected by the solder 80 in a state where they overlap each other on the lower surface side of the solar cell 41 (overlapping state). At this time, the wiring member 50d is connected to the wiring member 50c in a state where it overlaps below (Z2 side) the wiring member 50c. The wiring member 50b is an example of the “first wiring member” in the present invention. The wiring member 50c is an example of the “second wiring member” and the “second wiring member after cutting” in the present invention, and the wiring member 50d is an example of the “third wiring member” in the present invention.

Further, a wiring member (tab electrode) 50e is disposed on the lower surface side of the replacement solar cell 42. Further, a cut wiring member (tab electrode) 50 f is disposed on the upper surface side of the solar cell 43. The wiring member 50e and the wiring member 50f are connected by the solder 80 in a state where they overlap each other on the lower surface side of the replacement solar cell 42 (overlapping state). At this time, the wiring member 50f is connected to the wiring member 50e in a state where it overlaps below the wiring member 50e (Z2 side). The wiring member 50e is an example of the “fifth wiring member” in the present invention, and the wiring member 50f is an example of the “fourth wiring member” in the present invention.

Further, the lower surface side of the solar cell 43 and the upper surface side of the solar cell 40 are connected by the wiring member 50a. As shown in FIGS. 1 and 2, the wiring member 50b connected on the upper surface side of the solar cell 40 located on the arrow Y1 direction side and the lower surface side of the solar cell 40 located on the arrow Y2 direction side are connected. The connected wiring members 50a are respectively connected to the connecting members 3a for connecting to the adjacent solar cell group 27 or the terminal box 3 (see FIG. 2).

Here, in this embodiment, as shown in FIG. 6, the

wiring members

50b, 50d and 50f arranged on the upper surface side (arrow Z1 direction side) of the solar cell 41, the replacement solar cell 42 and the solar cell 43, respectively. The ends on the arrow Y2 direction side are respectively disposed at positions separated from the ends on the arrow Y2 direction side of the solar cell 41, the replacement solar cell 42 and the solar cell 43 by a distance L1 (about 1 mm) in the arrow Y1 direction. Yes.

In the present embodiment, the end portions on the arrow Y2 direction side of the

wiring members

50c and 50e arranged on the lower surface side (arrow Z2 direction side) of the solar cell 41 and the replacement solar cell 42 are respectively the solar cell 41. And it is arrange | positioned in the position which left | separated distance L2 (about 3 mm) larger by about 2 mm than the distance L1 (about 1 mm) in the arrow Y1 direction from the edge part of the arrow Y2 direction side of the solar cell 42 for replacement | exchange. That is, the end on the arrow Y2 direction side of the wiring member 50c located on the lower surface side of the solar cell 41 is disposed closer to the arrow Y1 direction than the end on the arrow Y2 direction side of the wiring member 50b. In addition, the end of the wiring member 50e on the lower surface side of the replacement solar cell 42 on the arrow Y2 direction side is disposed on the arrow Y1 direction side of the end of the wiring member 50d on the arrow Y2 direction side. The distance L2 may be not less than the distance L1 (about 1 mm) and not more than about 6 mm.

Next, with reference to FIG. 1, FIG. 2 and FIGS. 5 to 12, the replacement operation of the solar cell group 28 of the solar cell module 1 in one embodiment of the present invention will be described.

First, as shown in FIG. 7, before the replacement work is performed, the lower surface side of the solar cell 41 and the upper surface side of the defective solar cell 44 are connected by the wiring member 50c. Further, the lower surface side of the defective solar cell 44 and the upper surface side of the solar cell 43 are connected by the wiring member 50f. Here, the ends of the

wiring members

50b and 50c on the arrow Y2 direction side are separated from the ends of the solar cell 41 and the defective solar cell 44 on the arrow Y2 direction side by a distance L1 (about 1 mm) in the arrow Y1 direction. It is arranged at the position.

Here, when replacing the defective solar cell 44, first, as shown in FIG. 7, the wiring member 50c is disposed on the lower surface side (arrow Z2 direction side) of the solar cell 41 and the wiring. The defective part of the material 50f is cut with a nipper at predetermined positions A and B, respectively, on the lower surface side of the solar cell 44.

In this case, in the present embodiment, the wiring member 50c is cut at a position A away from the end of the solar cell 41 on the arrow Y2 direction side by a distance L2 (about 3 mm) in the arrow Y1 direction, and the wiring member 50f is The non-defective solar cell 44 is cut at a position B away from the end on the arrow Y2 direction side by a distance L2 in the arrow Y1 direction. That is, the wiring member 50c is cut on the arrow Y1 direction side from the end of the wiring member 50b on the arrow Y2 direction side, and the wiring member 50f is cut on the arrow Y2 direction side of the wiring member 50c in the arrow Y1 direction. Cut by side. At this time, solder (not shown) is dissolved to remove the connection between the bus bar electrode 30 on the lower surface of the solar cell 41 and the wiring member 50c, and to connect the bus bar electrode 30 on the lower surface of the defective solar cell 44 to the wiring member 50f. Then, the

wiring members

50c and 50f are pulled out in the direction of the arrow Z2 and cut.

At this time, as shown in FIG. 8, the wiring material 50c in the vicinity of the position to be cut is cut in a state of being drawn downward (in the direction of arrow Z2), whereby the side of the wiring material 50c in the direction of arrow Z2 is folded. As a result, a folded portion 50g is formed in the wiring member 50c. Thereafter, the defective solar cell 44 is removed.

Then, as shown in FIG. 9, the upper surface side (arrow Z1 direction side) of the solar cell 41 is placed on the stage, and the folded portion 50g extends along the Z direction from the lower surface side (arrow Z2 direction side) of the solar cell 41. By applying the applied pressure, the folded portion 50g is corrected to a straight line that is the state before the folded portion 50g occurs (folded correction). At this time, since the end of the wiring member 50c on the arrow Y2 direction side is arranged closer to the arrow Y1 direction side than the end of the wiring member 50b on the arrow Y2 direction side, the pressure applied to the folded portion 50g is Since the pressure from the lower surface side applied by the folding correction can be received in the plane portion in the vicinity of the end portion of the wiring member 50b, it corresponds to the end portion on the arrow Y2 side of the wiring member 50b on the upper surface side of the solar cell 41. Concentration on the surface portion of the solar cell 41 is suppressed.

Thereafter, as shown in FIG. 10, the defective solar cell 44 is positioned in the replacement solar cell 42 in which the wiring member 50d is disposed on the upper surface side and the wiring member 50e is disposed on the lower surface side. Insert at the position. At this time, the end of the wiring member 50d on the arrow Y2 direction side is disposed at a position away from the end of the replacement solar cell 42 on the arrow Y2 direction side by a distance L1 (about 1 mm) in the arrow Y1 direction. Then, as shown in FIG. 11, the wiring material 50c and the wiring material 50d are soldered on the lower surface side of the solar cell 41 in a state where the wiring material 50d is superimposed on the wiring material 50c from the lower side (Z2 side) of the wiring material 50c. Connect by 80. In addition, the wiring member 50e and the wiring member 50f are connected to the lower surface side of the replacement solar cell 42 by the solder 80 in a state where the wiring member 50f is overlapped on the wiring member 50e from the lower side (Z2 side) of the wiring member 50e. Thereby, the solar cell group 28 in which the replacement work shown in FIGS. 5 and 6 is performed is formed.

Then, as shown in FIG. 12, the filler 29 and the front cover 21 are sequentially laminated on the upper surface side (arrow Z1 direction side) of the solar cell group 28, and the filler 29 on the lower surface side (arrow Z2 direction side). And the back cover 22 are laminated in order. Thereafter, the front surface side cover 21 is placed on the stage, and laminating is performed by applying pressure from the rear surface side cover 22 side (arrow Z2 direction side).

At this time, the end of the wiring member 50c on the arrow Y2 direction side is arranged closer to the arrow Y1 direction side than the end of the wiring member 50b on the arrow Y2 direction side. Based on the fact that it is possible to receive pressure at a plane portion formed with a length of about 2 mm in the vicinity of the end of the wiring member 50b and to receive pressure from the upper surface side by the wiring member 50d. The pressure is suppressed from concentrating on the surface portion of the solar cell 41. Further, the end of the wiring member 50e on the arrow Y2 direction side is arranged closer to the arrow Y1 direction side than the end of the wiring member 50d on the arrow Y2 direction side, whereby pressure from the lower surface side is applied to the end of the wiring member 50d. Based on the fact that it can be received in the plane portion formed with a length of about 2 mm in the vicinity of the portion and the pressure from the upper surface side can be received by the wiring member 50f, the replacement solar cell 42 Concentration of pressure on the surface portion is suppressed. Thereby, the solar cell panel 2 is formed. Finally, the metal frame 4 (see FIGS. 1 and 2) is disposed on the side surface of the solar cell panel 2.

In the present embodiment, as described above, the end of the wiring member 50c on the lower surface side of the solar cell 41 on the arrow Y2 direction side is closer to the arrow Y1 direction side than the end of the wiring member 50b on the arrow Y2 direction side. Arranged. As a result, the wiring material 50b is present in the portion on the upper surface side of the solar cell 41 corresponding to the portion where the end of the wiring material 50c on the arrow Y2 direction side is disposed. Even when pressure is applied to the wiring member 50c, the pressure applied to the wiring member 50c can be received at the end of the wiring member 50b on the arrow Y2 direction side or in the plane portion near the end of the wiring member 50b. Thereby, it can suppress that a pressure concentrates on the part of the surface of the solar cell 41 in which the edge part by the side of the arrow Y2 of the wiring material 50b is located. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in the solar cell 41 resulting from the pressure from the lower surface side. In addition, since the wiring material 50d is connected to the wiring material 50c on the lower surface side of the solar cell 41, the pressure applied to the wiring material 50b from the upper surface side can be received by the wiring material 50d connected to the wiring material 50c. The pressure can be prevented from concentrating on the surface portion of the solar cell 41 corresponding to the end of the wiring member 50c on the arrow Y2 direction side. Thereby, it can suppress that a crack, a chip | tip, and a crack arise in the solar cell 41 resulting from the pressure from the upper surface side. As a result, the yield of the solar cell module 1 can be improved.

In the present embodiment, as described above, the distance (distance L2) between the end of the wiring member 50c on the arrow Y2 direction side and the side surface of the solar cell 41 on the arrow Y2 direction side is set to about 3 mm. The distance between the end of the material 50b on the arrow Y2 direction side and the side surface on the arrow Y2 direction side of the solar cell 41 (distance L1: about 1 mm) is increased by about 2 mm, and the thickness t (about 100 μm of the solar cell 41). ). Thereby, the space | interval (distance L2) between the edge part of the arrow Y2 direction side of the wiring material 50c and the side surface of the arrow Y2 direction side of the solar cell 41 becomes large too much, and the surface of the solar cell 41 in which the wiring material 50c is not arrange | positioned It is possible to suppress a decrease in the output of the solar cell 41 due to the deterioration of the current collection efficiency due to the increase in the area. In addition, the pressure from the lower surface side of the solar cell 41 can be more reliably received in the plane portion formed with a length of about 2 mm in the vicinity of the end of the wiring member 50b on the arrow Y2 direction side. Since the pressure from the upper surface side can be received by the wiring member 50d, it is possible to effectively suppress the pressure from being concentrated on the surface portion of the solar cell 41. Further, by making the distance L2 larger than the thickness t of the solar cell 41, it is possible to suppress the difficulty in joining the wiring member 50c and the solar cell 41 near the side surface of the solar cell 41 on the arrow Y2 direction side. In addition, the concentration of pressure on the surface of the solar cell 41 can be further suppressed.

In the present embodiment, as described above, the end on the arrow Y2 direction side of the wiring member 50e located on the lower surface side of the replacement solar cell 42 is indicated by an arrow from the end on the arrow Y2 direction side of the wiring member 50d. It arranged on the Y1 direction side. Thereby, since the wiring material 50d exists in the upper surface side portion of the replacement solar cell 42 corresponding to the portion where the end of the wiring material 50e on the arrow Y2 direction side is arranged, the replacement solar cell Even when pressure is applied to the wiring member 50e from the lower surface side of 42, the pressure applied to the wiring member 50e is received at the end of the wiring member 50d on the arrow Y2 direction side or in the plane portion near the end of the wiring member 50d. be able to. Thereby, it can suppress that a pressure concentrates on the part of the surface of the solar cell 42 for replacement | exchange which the edge part of the arrow Y2 direction side of the wiring material 50d is located. Thereby, it can suppress that the crack, a chip | tip, and a crack arise in the solar cell 42 for replacement | exchange due to the pressure from the lower surface side. The wiring member 50f is connected to the wiring member 50e on the lower surface side of the replacement solar cell 42, whereby the pressure applied to the wiring member 50d from the upper surface side is received by the wiring member 50f connected to the wiring member 50e. Since it can do, it can suppress that a pressure concentrates on the surface part of the solar cell 42 for replacement | exchange corresponding to the edge part of the arrow Y2 direction side of the wiring material 50e. Thereby, it can suppress that the crack, a chip | tip, and a crack arise in the solar cell 42 for replacement | exchange resulting from the pressure from the upper surface side. As a result, the yield of the solar cell module 1 can be improved.

In the present embodiment, as described above, the end on the arrow Y2 direction side of the wiring member 50c located on the lower surface side of the solar cell 41 is in the direction of the arrow Y1 rather than the end of the wiring member 50b on the arrow Y2 direction side. And the end of the wiring member 50e located on the lower surface side of the replacement solar cell 42 on the arrow Y2 direction side is arranged closer to the arrow Y1 direction side than the end of the wiring member 50d on the arrow Y2 direction side. . Thereby, it can suppress that a pressure concentrates on both the surface of the solar cell 41 and the surface of the solar cell 42 for replacement | exchange.

In the present embodiment, as described above, the thickness t of the solar cell 41 in the Z direction is set to about 100 μm. Thereby, in the solar cell 41 which has a thickness of about 100 μm and is relatively fragile with respect to pressure, it is possible to suppress the concentration of pressure on the surface of the solar cell 41.

In the present embodiment, as described above, the wiring member 50c and the wiring member 50d are connected in a state where the wiring member 50d is overlapped (overlapped) below the wiring member 50c (on the Z2 side). The wiring member 50e and the wiring member 50f were connected in a state where the wiring member 50f was overlapped below the wiring member 50e (Z2 side). Thereby, the wiring material 50d of the replacement solar cell 42 inserted after the defective solar cell 44 is easily overlapped with the wiring material 50c after the cutting of the solar cell 41 originally provided in the solar cell group 28. be able to. In addition, the wiring material 50f after the cutting of the solar cell 43 originally provided in the solar cell group 28 can be easily overlapped with the wiring material 50e of the replacement solar cell 42. Further, the portion where the wiring member 50c and the wiring member 50d overlap each other and the portion where the wiring member 50e and the wiring member 50f overlap each other can be easily connected with solder or the like.

In the present embodiment, as described above, the filler 29 and the surface side cover 21 are sequentially laminated on the upper surface side (arrow Z1 direction side) of the solar cell group 28, and on the lower surface side (arrow Z2 direction side). The filler 29 and the back surface side cover 22 were laminated in order. Thereafter, the front surface side cover 21 was placed on the stage and laminated by applying pressure from the rear surface side cover 22 side (arrow Z2 direction side). Thus, even when a pressure is applied from the lower surface side or the upper surface side of the solar cell 41 by laminating, it is possible to suppress the pressure from being concentrated on the surface portion of the solar cell 41.

[Example]
Next, with reference to FIG. 9 and FIGS. 13 to 17, an experiment relating to the occurrence of cracks in the solar cell in the folding correction and the laminating process was performed in order to confirm the effect of the solar cell module according to the present embodiment described above. The output reduction rate simulation will be described.

(Experiment on cracking of solar cells)
In the experiment relating to the occurrence of cracks in the solar cell described below, as shown in FIGS. 13 to 15, in the above-described embodiment, the distance L1 (the end of the wiring member arranged on the upper surface side of the solar cell and the solar cell) The distance L2 (space between the side of the battery) and the distance L2 (space between the end of the wiring member arranged on the lower surface side of the solar battery and the side of the solar battery) are equal or the distance L2 is greater than the distance L1. Using the solar cell modules corresponding to Examples 1 to 4 and the comparative example in which the distance L2 is smaller than the distance L1, the folding correction and the lamination process were performed. Then, the difficulty of cracking the solar cell in the folding correction and the rate of occurrence of cracking of the solar cell that occurred in the lamination were measured.

Specifically, as shown in FIG. 13, in Example 1, the distance L1 was set to 1 mm and the distance L2 was set to 3 mm. In Example 2, the distance L1 was 3 mm, and the distance L2 was 5 mm. That is, in Example 1 and 2, the space | interval (distance L2) of the edge part of the wiring material arrange | positioned at the lower surface side of a solar cell and the side surface of a solar cell is made into the edge of the wiring material arrange | positioned at the upper surface side of a solar cell. It was made larger than the space | interval (distance L1) of a part and the side surface of a solar cell.

Further, as shown in FIG. 14, in Example 3, the distance L1 was set to 1 mm and the distance L2 was set to 1 mm. In Example 4, the distance L1 was 3 mm, and the distance L2 was 3 mm. That is, in Example 3 and 4, the space | interval (distance L2) of the edge part of the wiring material arrange | positioned at the lower surface side of a solar cell and the side surface of a solar cell, and the edge of the wiring material arrange | positioned at the upper surface side of a solar cell. The distance (distance L1) between the portion and the side surface of the solar cell was made equal.

On the other hand, as shown in FIG. 15, in the comparative example, the distance L1 was 3 mm and the distance L2 was 1 mm. That is, unlike Examples 1 to 4, in the comparative example, the distance (distance L2) between the end of the wiring member arranged on the lower surface side of the solar cell and the side surface of the solar cell is arranged on the upper surface side of the solar cell. It was made smaller than the space | interval (distance L1) of the edge part of the made wiring material, and the side surface of a solar cell. The thickness of the solar cell was set to 100 μm in all of Examples 1 to 4 and the comparative example.

(Experiment of cracking when turning back)
After the wiring material arranged on the lower surface side of the solar cell corresponding to Examples 1 to 4 and the comparative example described above is drawn and cut to the lower surface side, the upper surface side of the solar cell is placed on the stage, and the solar cell By applying pressure to the folded portion from the lower surface side, the folded portion was corrected to a straight line (folded correction). In addition, the wiring material was arrange | positioned 3 places with respect to one solar cell, and all the wiring materials of 3 places were pulled out and cut | disconnected. The crack of the solar cell at this time was measured.

In the table of solar cell crack measurement at the time of folding correction shown in FIG. 16, a circle (◯) indicates that the solar cell was not substantially cracked, and a triangle (Δ) indicates a solar cell crack. Indicates that some have occurred, and a cross mark (×) indicates that cracking has occurred in all the solar cells.

At the time of the folding correction, as shown in FIG. 16, in Examples 1 and 2, the solar cell was hardly cracked. In Examples 3 and 4, the solar cell was somewhat cracked. On the other hand, in the comparative example, cracks occurred in all the solar cells. Thus, the distance L2 (the distance between the end of the wiring member disposed on the lower surface side of the solar cell and the side surface of the solar cell) is changed to the distance L1 (the end of the wiring member disposed on the upper surface side of the solar cell and the solar cell). By making the distance smaller than the distance from the battery side surface (comparative example), cracks are likely to occur in the solar cell at the time of folding correction, while the distance L2 is the same as or larger than the distance L1 (Examples 1 to 4). Thus, it was confirmed that it was possible to suppress the occurrence of cracks in the solar cell at the time of correction of folding. This is because the pressure from the lower surface side can be received at the end portion of the wiring material arranged on the upper surface side of the solar cell or the planar portion near the end portion, so that the wiring material arranged on the upper surface side of the solar cell This is considered to be because the pressure can be suppressed from concentrating on the portion of the surface of the solar cell where the end portion is located.

In addition, by making the distance L2 larger than the distance L1 (Examples 1 and 2), the solar cell is cracked at the time of the folding correction as compared with the case where the distance L2 is made equal to the distance L1 (Examples 3 and 4). It has been found that it is possible to further suppress the occurrence of. This is because the pressure from the lower surface side can be received in the plane portion near the end portion of the wiring material arranged on the upper surface side of the solar cell, so that the end portion of the wiring material arranged on the upper surface side of the solar cell This is considered to be because it was possible to further suppress the concentration of pressure on the surface of the corresponding solar cell.

In the comparative example, since cracks occurred in all the solar cells at the time of folding correction, the measurement of cracks in the solar cells at the time of laminating described later is not performed.

(Experiment on cracking during laminating)
After the return correction, the wiring material of the replacement solar cell and the cut wiring material were connected by solder. And while laminating | filling a filler and a surface side cover in order on the upper surface side, the filler and the back surface side cover were laminated | stacked in order on the lower surface side. And the surface side cover was mounted on the stage, and it laminated by applying a pressure from the back side cover side. At this time, the crack of the solar cell at the position of the wiring material was measured, and the crack occurrence rate was calculated.

In the measurement table of solar cell cracks during lamination shown in FIG. 16, the total number of wiring members indicates the number of connected wiring members. Further, the number of positions where cracks occur indicates the number of cracks at the position where the wiring material of the solar cell is disposed. Further, the crack occurrence rate indicates the ratio of the number of wiring members arranged at the position where the solar cell is cracked to the total number of wiring members.

At the time of laminating, as shown in FIG. 16, in Examples 1 and 2 in which the distance L2 was larger than the distance L1, no crack was generated, and the crack occurrence rate was 0%. On the other hand, in Example 3 in which the distance L2 was the same as the distance L1 (1 mm), the crack occurred only in one wiring material, and the crack occurrence rate was 6.7%. In Example 4 in which the distance L2 was the same as the distance L1 (3 mm), the cracks occurred in four wiring members, and the crack generation rate was 26.7%. Thus, the distance L2 (the distance between the end of the wiring member disposed on the lower surface side of the solar cell and the side surface of the solar cell) is changed to the distance L1 (the end of the wiring member disposed on the upper surface side of the solar cell and the solar cell). (Spacing with the side surface of the battery) (Examples 3 and 4), the solar cell is somewhat cracked during lamination, while the distance L2 is made larger than the distance L1 (Examples 1 and 2). Thus, it was found that cracking of the solar cell during the lamination process can be further suppressed. This is because the pressure from the lower surface side can be received in the plane portion near the end portion of the wiring material arranged on the upper surface side of the solar cell, so that the end portion of the wiring material arranged on the upper surface side of the solar cell The pressure from the upper surface side can be further suppressed from being concentrated on the surface portion of the corresponding solar cell, and the pressure is received by the wiring material connected to the wiring material arranged on the lower surface side of the solar cell. Therefore, it is considered that it was possible to further suppress the pressure from being concentrated on the surface portion of the solar cell corresponding to the end portion of the wiring member arranged on the lower surface side of the solar cell.

Further, when both the distances L1 and L2 are 1 mm (Example 3), the solar cell is more cracked during the lamination process than when the distances L1 and L2 are both 3 mm (Example 4). It turned out to be difficult. This is considered that when pressure is applied from the lower surface side, the solar cell from the side surface to the end of the wiring member is bent and deformed with the end of the wiring member as a fulcrum. At this time, by reducing the distance from the side surface of the solar cell to the end of the wiring member, the moment based on the bending deformation can be reduced, so that it is considered that the solar cell is less likely to be cracked during lamination. .

(Simulation of output reduction rate)
In the simulation of the output reduction rate, with respect to the reference distance L2 (= 0 mm) when the distance L2 (the distance between the end of the wiring member arranged on the lower surface side of the solar cell and the side surface of the solar cell) is changed. The rate of decrease in the output of the solar cell was calculated as the output decrease rate. Specifically, the output reduction rate when the distance L2 is 1 mm, 2 mm, 3 mm, 4 mm, 5 mm and 6 mm was calculated.

In the simulation of the output reduction rate, as shown in FIG. 17, when the distance L2 is 1 mm, the output reduction rate is 0.00%. In addition, when the distance L2 was 2 mm, the output reduction rate was 0.00% (0.002%). Further, when the distance L2 was 3 mm, the output reduction rate was 0.01%. When the distance L2 was 4 mm, the output reduction rate was 0.03%. When the distance L2 was 5 mm, the output reduction rate was 0.06% (0.058%). When the distance L2 was 6 mm, the output reduction rate was 0.10% (0.098%). As described above, the reason why the output decreases as the distance L2 increases is considered to be that the current collection efficiency deteriorates due to an increase in the surface area of the solar cell on which the wiring member is not disposed. Further, although measurement is not performed for the case where the distance L2 is larger than 6 mm, it can be estimated from the graph of FIG. 21 that the output decrease rate increases in a quadratic function as the distance L2 is increased. Here, when the output reduction rate exceeds 0.10%, it is considered that the performance of the solar cell is insufficient and unacceptable, and therefore it has been found that the distance L2 is preferably 6 mm or less.

In addition, it should be thought that embodiment disclosed this time is an illustration and restrictive at no points. The scope of the present invention is shown not by the above description of the embodiments but by the scope of claims for patent, and further includes all modifications within the meaning and scope equivalent to the scope of claims for patent.

For example, in the above-described embodiment, the example in which the replacement work is performed only on the solar cell group 28 among the

solar cell groups

23, 24, 25, 26, 27, and 28 is shown, but the present invention is not limited thereto. Absent. In the present invention, replacement work may be performed in a plurality of solar cell groups.

Moreover, in the said embodiment, although the example which replaced | exchanged the solar cell 40 was shown only in one place (position of the solar cell 42 for replacement | exchange, and the defective solar cell 44) of the solar cell group 28, this invention is shown to this. Not limited. In the present invention, a plurality of solar cells may be replaced in one solar cell group.

In the above embodiment, the example in which the defective solar cell 44 is replaced with the replacement solar cell 42 in the solar cell group 28 is shown, but the present invention is not limited thereto. For example, when manufacturing a solar cell module, the present invention is also applicable to a case where a pair of wiring members provided to adjacent solar cells and arranged to overlap on the lower surface side of one solar cell are connected to each other. Is applicable.

In the above-described embodiment, the case where the pressure is applied to the solar cell is shown as an example of the folding correction and the laminating process, but the present invention is not limited to this. For example, even when a pressure is applied during soldering, it is possible to prevent the solar cell from being cracked, chipped and cracked.

Claims

A first solar cell and a second solar cell arranged adjacent to each other;
A first wiring member disposed on one side of the first solar cell;
A second wiring member disposed on the other surface side of the first solar cell;
A third wiring member disposed on one side of the second solar cell and connected to the second wiring member on the other side of the first solar cell;
An end of the second wiring member on the second solar cell side substantially coincides with an end of the first wiring member on the second solar cell side as viewed in a plan view, or the first wiring member. The solar cell module which is arrange | positioned so that it may be located in the opposite side to the said 2nd solar cell side rather than the edge part of the said 2nd solar cell side.
The end of the second wiring member on the second solar cell side is disposed so as to be located on the opposite side of the second solar cell side of the end of the first wiring member on the second solar cell side. The solar cell module according to claim 1, wherein
The interval between the end of the second wiring member on the second solar cell side and the side surface of the first solar cell on the second solar cell side is the end of the first wiring member on the second solar cell side. The solar cell module according to claim 2, wherein the distance between the first solar cell and the side surface of the first solar cell on the second solar cell side is 2 mm or more.
The interval between the end of the second wiring member on the second solar cell side and the side surface of the first solar cell on the second solar cell side is the end of the first wiring member on the second solar cell side. The solar cell module according to claim 2, wherein the distance between the first solar cell and a side surface of the first solar cell on the second solar cell side is larger than the thickness of the first solar cell.
The interval between the end of the second wiring member on the second solar cell side and the side surface of the first solar cell on the second solar cell side is the end of the first wiring member on the second solar cell side. 2. The solar cell module according to claim 1, wherein the solar cell module has a size greater than or equal to an interval between the first solar cell and a side surface on the second solar cell side and 6 mm or less.
The third wiring member is connected to the second wiring member so as to overlap in a plan view in a state where the third wiring member is arranged on a side opposite to the first solar cell of the second wiring member. 1. The solar cell module according to 1.
A third solar cell disposed on the opposite side of the second solar cell from the first solar cell and adjacent to the second solar cell;
A fourth wiring member disposed on one side of the third solar cell and extending to the other side of the second solar cell;
A fifth wiring member disposed on the other surface side of the second solar cell and connected to the fourth wiring member on the other surface side of the second solar cell;
An end portion of the fifth wiring member on the third solar cell side substantially coincides with an end portion of the third wiring member on the third solar cell side in plan view, or the third wiring member. The solar cell module according to claim 1, wherein the solar cell module is disposed so as to be located on an opposite side of the third solar cell side from an end of the third solar cell side.
The end of the fifth wiring member on the third solar cell side is disposed so as to be located on the opposite side of the third solar cell side of the end of the third wiring member on the third solar cell side. The solar cell module according to claim 7, wherein
An end of the second wiring member on the second solar cell side is located on a side opposite to the second solar cell side with respect to an end of the first wiring member on the second solar cell side, and The end portion on the third solar cell side of the fifth wiring member is located on the side opposite to the third solar cell side than the end portion on the third solar cell side of the third wiring member. The solar cell module according to.
The said 4th wiring material is connected to the said 5th wiring material so that it may overlap seeing planarly in the state arrange | positioned on the opposite side to the said 2nd solar cell of the said 5th wiring material. 8. The solar cell module according to 7.
A first cover and a second cover disposed on each of one side and the other side of the first solar cell and the second solar cell by laminating;
2. The filler according to claim 1, further comprising a filler disposed between the first cover and the first solar cell and between the second cover and the second solar cell by the laminating process. Solar cell module.
The solar cell module according to claim 1, wherein the first solar cell and the second solar cell have a thickness of 150 μm or less.
A first solar cell and a defective solar cell that are arranged adjacent to each other, a first wiring member that is arranged on one side of the first solar cell, and a second side of the first solar cell. And a step of replacing the defective solar cell with a second solar cell for repair in a solar cell group including a second wiring member disposed on one side of the defective solar cell. A solar cell module manufacturing method comprising:
The second wiring member is positioned on the other surface side of the first solar cell and substantially coincides with the end of the defective product of the first wiring member on the solar cell side, or Cutting at a position opposite to the solar cell side of the defective product from the end of the defective product of the first wiring material on the solar cell side;
Arranged on one surface side of the second solar cell disposed at the position where the second wiring member after cutting disposed on the other surface side of the first solar cell and the defective solar cell were disposed. And a step of connecting a third wiring member extending to the other surface side of the first solar cell on the other surface side of the first solar cell.
After the step of connecting the second wiring material after cutting and the third wiring material, a filler and a cover are respectively provided on one side and the other side of the first solar cell and the second solar cell. The method for manufacturing a solar cell module according to claim 13, further comprising a step of laminating by laminating in this order and applying pressure.
The step of cutting the second wiring material includes a step of drawing and cutting the second wiring material to the other surface side of the first solar cell,
After the step of cutting the second wiring material and prior to the step of connecting the second wiring material after the cutting and the third wiring material, the cutting is performed with the second wiring material drawn out. The method for manufacturing a solar cell module according to claim 13, further comprising a step of applying a pressure to a folded portion of the second wiring member after cutting formed by being formed.
In the step of connecting the second wiring material after cutting and the third wiring material, the third wiring material is planarized from the side of the second wiring material after cutting opposite to the first solar cell. The method for manufacturing a solar cell module according to claim 13, comprising a step of connecting to the second wiring member so as to overlap with each other.
In the step of cutting the second wiring material, the second wiring material is positioned at a position on the opposite side of the defective product from the solar cell side than the end portion of the defective product on the solar cell side. The manufacturing method of the solar cell module of Claim 13 including the process to cut | disconnect.
The step of cutting the second wiring member is a distance of 6 mm or less from the side surface of the first solar cell on the solar cell side of the defective product to the side opposite to the solar cell side of the defective product. The manufacturing method of the solar cell module of Claim 13 including the process cut | disconnected in the position which has.
The solar cell group is disposed on the opposite side of the defective solar cell from the first solar cell, the third solar cell adjacent to the defective solar cell, and one surface side of the third solar cell. And a fourth wiring member extending to the other surface side of the defective solar cell,
The step of cutting the second wiring member includes the fourth wiring member on the other surface side of the defective solar cell and on the third solar cell side of the third wiring member when viewed in plan. Cutting at a position substantially coincident with the end, or at a position opposite to the third solar cell side than the end of the third wiring member on the third solar cell side,
After the step of cutting the second wiring member and the fourth wiring member, the defective solar cell is removed from the solar cell group, and the second solar cell is disposed at a position where the defective solar cell is disposed. Further comprising the step of arranging solar cells,
The step of connecting the second wiring member after cutting and the third wiring member includes the fourth wiring member after cutting disposed on one side of the third solar cell, and the defective solar cell. A step of connecting, on the other surface side of the second solar cell, a fifth wiring member disposed on the other surface side of the second solar cell disposed at a position where the second solar cell is disposed. The manufacturing method of the solar cell module of description.
In the step of cutting the second wiring material and the fourth wiring material, the second wiring material is disposed on the defective solar cell side with respect to the defective solar cell side end of the first wiring material. Cutting at a position on the opposite side and cutting the fourth wiring material at a position on the opposite side of the third solar cell side from the end of the third wiring material on the third solar cell side. The manufacturing method of the solar cell module of Claim 19 which has these.