WO2012043494A1 - 太陽電池モジュール及び太陽電池モジュールの製造方法 - Google Patents
太陽電池モジュール及び太陽電池モジュールの製造方法 Download PDFInfo
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- WO2012043494A1 WO2012043494A1 PCT/JP2011/071922 JP2011071922W WO2012043494A1 WO 2012043494 A1 WO2012043494 A1 WO 2012043494A1 JP 2011071922 W JP2011071922 W JP 2011071922W WO 2012043494 A1 WO2012043494 A1 WO 2012043494A1
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- Prior art keywords
- tab wire
- adhesive film
- solar cell
- solar
- electrode
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0512—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module made of a particular material or composition of materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
- H01L31/0547—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/52—PV systems with concentrators
Definitions
- the present invention relates to a solar cell module in which electrodes of a plurality of solar cells are connected by tab wires, and a method for manufacturing the solar cell module.
- a plurality of adjacent solar cells are connected by tab wires made of a ribbon-like copper foil or the like that is solder-coated as an interconnector.
- One end side of the tab wire is connected to the front surface electrode of one solar battery cell, and the other end side is connected to the back surface electrode of the adjacent solar battery cell, thereby connecting the solar battery cells in series.
- connection between the solar battery cell and the tab wire is made up of a bus bar electrode formed by screen printing of silver paste on the light receiving surface of the solar battery cell, an Ag electrode formed on the back surface connection portion of the solar battery cell, and a tab.
- the wires are connected by soldering (Patent Document 1).
- Al electrodes and Ag electrodes are formed in regions other than the connection portion on the back surface of the solar battery cell.
- a conductive adhesive film that can be connected by thermocompression treatment at a relatively low temperature is used to connect the front and back electrodes of the solar battery cell and the tab wire (Patent Document 2).
- a conductive adhesive film a film obtained by dispersing spherical or scaly conductive particles having an average particle size on the order of several ⁇ m in a thermosetting binder resin composition is used.
- the conductive adhesive film is interposed between the front electrode and the back electrode and the tab wire, and then thermally pressed from above the tab wire, so that the binder resin exhibits fluidity and between the electrode and the tab wire. As it flows out, the conductive particles conduct between the electrode and the tab wire, and in this state, the binder resin is thermally cured. Thereby, the string by which the several photovoltaic cell was connected in series by the tab wire is formed.
- a plurality of solar cells in which the tab wire and the front and back electrodes are connected using a conductive adhesive film are made of a surface protective material having translucency such as glass and translucent plastic, and PET (Poly Ethylene Terephthalate) ) And the like, and a back protective material made of a film such as ethylene vinyl acetate resin (EVA).
- a surface protective material having translucency such as glass and translucent plastic, and PET (Poly Ethylene Terephthalate)
- EVA ethylene vinyl acetate resin
- the tab line 100 is formed in a long shape, and an uneven portion 102 is formed on the surface 101a.
- the concavo-convex portion 102 is alternately provided with crest portions 102 a and trough portions 102 b extending in the longitudinal direction of the tab wire 100 in the width direction.
- the tab wire 100 is connected to the surface electrode 103a of the solar battery cell 103 through the conductive adhesive film 104 on the back surface 101b side.
- the binder resin of the conductive adhesive film 104 flows out in the thermal pressing process of the tab wire 100. May be hindered by the concavo-convex portion 102, and the electrical conductivity between the tab wire 100 and the back electrode may be lowered. That is, the conductive adhesive film 104 is provided with a crest 102a and a trough 102b continuously over the longitudinal direction of the tab wire 100 even when the binder resin exhibits fluidity by heating.
- the direction is limited to the direction along the valley portion 102b, and the outflow from between the peak portion 102a of the tab wire 100 and the connection portion of the back electrode becomes insufficient even by pressurization. Therefore, as shown in FIG. 16, in the solar battery cell 103, a large amount of binder resin remains between the tab wire 100 and the connection portion of the back electrode, and the contact between the crest 102 a and the back electrode or between the conductive particles If the contact is inhibited, the conductivity is lowered.
- this invention aims at providing the solar cell module which can ensure electroconductivity, and its manufacturing method in the solar cell module which connected the photovoltaic cell using the tab wire in which the uneven
- a solar cell module includes a plurality of solar cells each having electrodes formed on both sides thereof, and peaks and valleys continuous in the longitudinal direction on one side in the width direction. It has uneven portions formed alternately, tab wires connecting the plurality of solar cells in series, and interposed between the electrodes of the solar cells and the tab wires, the solar cells and the above
- An adhesive film for connecting a tab wire, and the solar battery cell is formed with an inflow portion into which a binder component of the adhesive film flows into a connection portion to which one surface provided with the uneven portion is connected It is.
- the manufacturing method of the solar cell module according to the present invention includes an arraying step of arranging a plurality of solar cells, and peaks and valleys continuous in the longitudinal direction over the entire surface through an adhesive film alternately in the width direction. And temporarily connecting the one surface of the tab wire having the concavo-convex portion formed on the back surface electrode side of the solar cell, and the flat surface opposite to the one surface of the tab wire through the adhesive film Temporary crimping step for temporary connection to the surface electrode side of the cell, and a book for thermosetting the adhesive film from above the tab wire to connect the tab wire and each electrode of the solar battery cell.
- a pressure bonding step, and in the main pressure bonding step the binder component of the adhesive film flows into an opening provided in a connection portion to which one surface of the tab wire provided with the uneven portion is connected.
- the binder component of the adhesive film flows along the uneven portion and flows into the inflow portion formed in the connection portion. Therefore, since an excess binder component can be eliminated from the connection portion with the tab wire, the solar cell has conductivity without being obstructed by the binder component between the connection portion and the peak portion of the tab wire. Can be secured.
- FIG. 1 is an exploded perspective view showing a solar cell module.
- FIG. 2 is a cross-sectional view showing strings of solar cells.
- FIG. 3 is a bottom view showing a back electrode of a solar battery cell to which the present invention is applied.
- FIG. 4 is a plan view showing a state in which the tab wire is finally crimped to the back electrode of the solar battery cell to which the present invention is applied.
- FIG. 5 is a cross-sectional view showing the configuration of the conductive adhesive film.
- FIG. 6 is a diagram showing a conductive adhesive film.
- FIG. 7 is a diagram for explaining a temporary crimping process of the tab wire.
- FIG. 8 is a diagram for explaining the final crimping process of the tab wire.
- FIG. 1 is an exploded perspective view showing a solar cell module.
- FIG. 2 is a cross-sectional view showing strings of solar cells.
- FIG. 3 is a bottom view showing a back electrode of a solar battery cell to which the present
- FIG. 9A shows an embodiment to which the present invention is applied
- FIG. 9B is a cross-sectional view showing a comparative example
- FIG. 10 is a cross-sectional view showing a double-sided light receiving solar cell to which the present invention is applied.
- 11A and 11B are plan views showing a configuration in which an outflow portion is provided in the bus bar electrode 11.
- FIG. 12 is a side view showing a heating and pressing head in which an elastic body is provided on the pressing surface of the tab wire.
- FIG. 13 is a perspective view showing a tab line having a concavo-convex portion in which crests and troughs continuous in the longitudinal direction on the surface are alternately formed in the width direction.
- FIG. 14 is a cross-sectional view of the tab line.
- FIG. 14 is a cross-sectional view of the tab line.
- FIG. 15 is a cross-sectional view showing a solar battery cell using a tab line having a concavo-convex portion in which crests and troughs continuous in the longitudinal direction on the surface are alternately formed in the width direction.
- FIG. 16 is a cross-sectional view showing a solar battery cell connected to a tab line having a concavo-convex portion in which crests and troughs continuous in the longitudinal direction are formed in the width direction on the surface.
- a solar cell module 1 to which the present invention is applied has a string 4 in which a plurality of solar cells 2 are connected in series by tab wires 3 serving as interconnectors.
- An arrayed matrix 5 is provided.
- the solar cell module 1 is laminated together with the front cover 7 provided on the light receiving surface side and the back sheet 8 provided on the back surface side, with the matrix 5 sandwiched between the sealing adhesive sheets 6.
- a metal frame 9 such as aluminum is attached to the periphery.
- sealing adhesive for example, a translucent sealing material such as ethylene vinyl acetate resin (EVA) is used.
- EVA ethylene vinyl acetate resin
- surface cover 7 for example, a light-transmitting material such as glass or light-transmitting plastic is used.
- back sheet 8 a laminated body in which glass or aluminum foil is sandwiched between resin films is used.
- Each solar battery cell 2 of the solar battery module has a photoelectric conversion element 10 as shown in FIG.
- the photoelectric conversion element 10 includes a single crystal silicon photoelectric conversion element, a crystalline silicon solar cell module using a polycrystalline photoelectric conversion element, a cell made of amorphous silicon and a cell made of microcrystalline silicon or amorphous silicon germanium.
- Various photoelectric conversion elements 10 such as thin-film silicon solar cells using the photoelectric conversion elements can be used.
- the photoelectric conversion element 10 is provided with a bus bar electrode 11 serving as a surface electrode on the light receiving surface side and a finger electrode 12 which is a collector electrode formed in a direction substantially orthogonal to the bus bar electrode 11. Further, the photoelectric conversion element 10 is provided with a back electrode 13 made of aluminum or silver on the back side opposite to the light receiving surface.
- the photovoltaic cell 2 is electrically connected with the bus-bar electrode 11 of the surface, and the back surface electrode 13 of the adjacent photovoltaic cell 2 by the tab wire 3, Thereby, the string 4 connected in series is comprised. .
- the tab wire 3 is connected to the bus bar electrode 11 and the back electrode 13 by a conductive adhesive film 15.
- the bus bar electrode 11 is formed by applying Ag paste and heating.
- the bus bar electrode 11 formed on the light receiving surface of the solar battery cell 2 is formed in a line shape with a width of 1 mm, for example, in order to reduce the area that blocks incident light and suppress shadow loss.
- the number of bus bar electrodes 11 is appropriately set in consideration of the size and resistance of the solar battery cell 2.
- the bus bar electrode 11 is bonded to the flattened back surface 20b of the tab wire 3 after a conductive adhesive film 15 described later is temporarily attached.
- the finger electrode 12 is formed over almost the entire light receiving surface of the solar battery cell 2 so as to intersect the bus bar electrode 11 by the same method as the bus bar electrode 11.
- the finger electrodes 12 are formed with lines having a width of about 100 ⁇ m, for example, at a predetermined interval, for example, every 2 mm.
- the back electrode 13 is formed of an electrode made of aluminum or silver on the back surface of the solar battery cell 2 by, for example, screen printing or sputtering.
- the back surface electrode 13 has the connection part 14 to which the surface 20a in which the uneven
- the connecting portion 14 is formed with an inflow portion 16 into which the binder resin of the conductive adhesive film 15 flows in the final crimping process of the tab wire 3 described later.
- the inflow portion 16 is formed by performing a mask process or an etching process when the back electrode 13 is formed, and is formed as an opening 16a, for example, as shown in FIG. That is, the connecting portion 14 includes a conducting portion 17 that is made of Al or Ag and is intended to conduct with the tab wire 3, and an inflow portion 16 into which excess binder resin flows during the main crimping process.
- connection part 14 of the back surface electrode 13 is laminated
- the binder resin of the conductive adhesive film 15 flows along the concavo-convex portion 21 and flows into the opening 16 a, and excess binder resin can be excluded from the conductive portion 17. Therefore, the solar battery cell 2 ensures conductivity without contact between the conductive particles in the conductive portion 17 of the connection portion 14 or between the conductive particles and the tab wire 3 or the connection portion 14 by the binder resin. be able to.
- a plurality of openings 16 a are provided at predetermined intervals along the connection portion 14 of the back electrode 13.
- the solar battery cell 2 is electrically connected to the adjacent solar battery cell 2 via the tab wire 3 in the conductive portion 17 and mechanically connected to the tab wire 3.
- the solar battery cell 2 is mechanically connected to the tab wire 3 while allowing excess binder resin to flow through the opening 16a.
- the opening 16a may have any shape such as a circle or a square.
- the tab wire 3 uses, for example, a ribbon-like copper foil having a thickness of 50 to 300 ⁇ m as in the case of the tab wire used in the conventional solar cell module, and gold plating, silver plating, tin plating, solder plating, etc. as required. Is given.
- the tab wire 3 has a plurality of concave and convex portions that are continuous in the longitudinal direction on the surface in the width direction, like the tab wire 100 described above.
- the tab line 3 is formed in a long shape, and the uneven portion 21 is formed on the surface 20 a.
- the concavo-convex portions 21 are alternately provided with crest portions 21 a and trough portions 21 b provided continuously in the longitudinal direction of the tab wire 3 in the width direction of the tab wire 3.
- the uneven portion 21 is formed by, for example, press-molding the plated ribbon-like copper foil.
- the tab wire 3 is connected to the bus bar electrode 11 of the solar battery cell 2 through the conductive adhesive film 15 on the flattened back surface 20b side as shown in FIG.
- the uneven portion 21 is directed in the same direction as the light receiving surface, so that incident light is scattered by the uneven portion 21, and the scattered light is reflected by the protective glass surface and reenters the light receiving surface.
- the light receiving efficiency can be improved.
- the tab wire 3 is connected to the connection portion 14 of the back surface electrode 13 of the solar battery cell 2 through the conductive adhesive film 15 on the surface 20a side where the uneven portion 21 is formed.
- the conductive adhesive film 15 is a thermosetting binder resin layer containing conductive particles 23 at a high density.
- the conductive adhesive film 15 preferably has a minimum melt viscosity of 100 to 100,000 Pa ⁇ s from the viewpoint of indentability. If the minimum melt viscosity of the conductive adhesive film 15 is too low, the resin will flow in the process of low pressure bonding to main curing, and connection failure and protrusion to the cell light-receiving surface are likely to occur, causing a reduction in light receiving rate. Moreover, even if the minimum melt viscosity is too high, defects are likely to occur when the film is adhered, and the connection reliability may be adversely affected.
- the minimum melt viscosity can be measured while a sample is loaded in a predetermined amount of rotational viscometer and raised at a predetermined temperature increase rate.
- the conductive particles 23 used in the conductive adhesive film 15 are not particularly limited, and examples thereof include metal particles such as nickel, gold, and copper, resin particles that are gold-plated, and resin particles that are gold-plated.
- the outermost layer of the particles may be an insulating coating.
- the number of the conductive particles 23 that overlap each other can be increased, and good conduction reliability can be ensured.
- the conductive adhesive film 15 preferably has a viscosity of about 10 to 10,000 kPa ⁇ s, more preferably 10 to 5,000 kPa ⁇ s at around room temperature.
- the conductive adhesive film 15 has a viscosity in the range of 10 to 10000 kPa ⁇ s, when the conductive adhesive film 15 is wound in a tape-like reel, so-called protrusion can be prevented and a predetermined tack can be prevented. You can maintain power.
- composition of the binder resin layer of the conductive adhesive film 15 is not particularly limited as long as it does not impair the above-described characteristics, but more preferably a film-forming resin, a liquid epoxy resin, a latent curing agent, a silane cup Contains a ring agent.
- the film-forming resin corresponds to a high molecular weight resin having an average molecular weight of 10,000 or more, and preferably has an average molecular weight of about 10,000 to 80,000 from the viewpoint of film formation.
- various resins such as an epoxy resin, a modified epoxy resin, a urethane resin, and a phenoxy resin can be used.
- a phenoxy resin is preferably used from the viewpoint of the film formation state, connection reliability, and the like. .
- the liquid epoxy resin is not particularly limited as long as it has fluidity at room temperature, and all commercially available epoxy resins can be used.
- Specific examples of such epoxy resins include naphthalene type epoxy resins, biphenyl type epoxy resins, phenol novolac type epoxy resins, bisphenol type epoxy resins, stilbene type epoxy resins, triphenolmethane type epoxy resins, phenol aralkyl type epoxy resins.
- Resins, naphthol type epoxy resins, dicyclopentadiene type epoxy resins, triphenylmethane type epoxy resins, and the like can be used. These may be used alone or in combination of two or more. Moreover, you may use it combining suitably with other organic resins, such as an acrylic resin.
- the latent curing agent various curing agents such as a heat curing type and a UV curing type can be used.
- the latent curing agent does not normally react but is activated by some trigger and starts the reaction.
- the trigger includes heat, light, pressurization, etc., and can be selected and used depending on the application.
- a latent curing agent composed of imidazoles, amines, sulfonium salts, onium salts and the like can be used.
- silane coupling agent epoxy, amino, mercapto sulfide, ureido, etc. can be used.
- an epoxy-type silane coupling agent is used preferably. Thereby, the adhesiveness in the interface of an organic material and an inorganic material can be improved.
- an inorganic filler as another additive composition.
- an inorganic filler silica, talc, titanium oxide, calcium carbonate, magnesium oxide and the like can be used, and the kind of the inorganic filler is not particularly limited.
- FIG. 6 is a diagram schematically showing an example of a product form of the conductive adhesive film 15.
- the conductive adhesive film 15 has a binder resin layer laminated on a release substrate 24 and is molded into a tape shape. This tape-like conductive adhesive film is wound and laminated on the reel 25 so that the peeling substrate 24 is on the outer peripheral side.
- the release substrate 24 is not particularly limited, and PET (Poly Ethylene Terephthalate), OPP (Oriented Polypropylene), PMP (Poly-4-methlpentene-1), PTFE (Polytetrafluoroethylene), or the like can be used.
- the conductive adhesive film 15 may have a structure having a transparent cover film on the binder resin layer.
- the above-described tab wire 3 may be used as a cover film to be stuck on the binder resin layer.
- the tab wire 3 and the conductive adhesive film 15 are laminated and integrated in advance, so that the peeling substrate 24 is peeled off during actual use, and the binder resin layer of the conductive adhesive film 15 is used as a bus bar.
- the tab wire 3 and each of the electrodes 11 and 13 are connected by sticking on the connection part 14 of the electrode 11 or the back electrode 13.
- the conductive adhesive film 15 is not limited to a reel shape, and may be a strip shape.
- the viscosity of the conductive adhesive film 15 is set in the range of 10 to 10000 kPa ⁇ s. Deformation can be prevented and a predetermined dimension can be maintained. Similarly, when two or more conductive adhesive films 15 are stacked in a strip shape, deformation can be prevented and a predetermined dimension can be maintained.
- the conductive adhesive film 15 described above dissolves conductive particles 23, a film-forming resin, a liquid epoxy resin, a latent curing agent, and a silane coupling agent in a solvent.
- a solvent toluene, ethyl acetate or the like, or a mixed solvent thereof can be used.
- the conductive adhesive film 15 is obtained by applying the resin-generating solution obtained by dissolution onto a release sheet and volatilizing the solvent.
- the temporary bonding step of temporarily bonding the conductive adhesive film 15 to the connection portion 14 of the bus bar electrode 11 and the back electrode 13 the arranging step of arranging the solar cells 2, and the tab wire 3 are connected to the conductive adhesive film 15.
- the conductive adhesive film 15 is thermally cured by heat pressing from above the tab wire 3 and the temporary pressure bonding step that is arranged on the bus bar electrode 11 and the connection part 14 of the back electrode 13 by hot pressing at low temperature and low pressure.
- an uncured conductive adhesive film 15 is temporarily pasted on the connection portion 14 of the bus bar electrode 11 and the back electrode 13 of each solar battery cell 2.
- the temporary bonding step of the conductive adhesive film 15 is performed by transporting the conductive adhesive film 15 wound in a reel shape to a predetermined position on the front and back sides of the solar battery cell 2 and pressing it with a temporary bonding head.
- the temporary attachment head is heated by a predetermined time (for example, 1 to 5 seconds) at a temperature (for example, 40 to 60 ° C.) at which fluidity is generated in the conductive adhesive film 15 but main curing does not occur.
- the solar cells 2 to which the conductive adhesive film 15 is temporarily attached are arranged in the order in which they are connected in series.
- the tab wire 3 is temporarily pressure-bonded onto the conductive adhesive film 15 with respect to each solar cell 2 arranged at a predetermined position facing the pair of upper and lower temporary pressure-bonding heads 26.
- one end 3 a of the tab wire 3 is formed on the bus bar electrode 11 formed on the surface of the preceding one solar battery cell 2 a via an uncured conductive adhesive film 15.
- the other end 3b of the tab wire 3 is temporarily pressure-bonded to the connecting portion 14 of the back surface electrode 13 of another subsequent solar cell 2b through the uncured conductive adhesive film 15.
- uncured electrical conductivity is formed on the bus bar electrode 11 formed on the surface of the other solar battery cell 2b and the connection part 14 of the back electrode 13 of the solar battery cell 2c following the solar battery cell 2b.
- One end 3 a and the other end 3 b of the tab wire 3 are temporarily bonded via the adhesive film 15. In this way, adjacent solar cells 2 are connected in series with the tab wire 3.
- the tab wire 3 has a flat back surface 20b on the one end 3a side, which is temporarily crimped onto the bus bar electrode 11, and an uneven portion on the other end 3b side.
- the front surface 20 a on which 21 is formed is temporarily pressure-bonded onto the connection portion 14 of the back electrode 13.
- the temporary pressure bonding step is performed by the temporary pressure bonding head 26.
- the temporary pressure bonding head 26 is heated to a temperature at which the curing reaction of the conductive adhesive film 15 does not proceed and presses the tab wire 3. Therefore, the conductive adhesive film 15 temporarily fixes the tab wire 3 on the bus bar electrode 11 and the connection part 14 of the back electrode 13 when the binder resin exhibits fluidity and exerts an adhesive force.
- the tab wires 3 are solar cells by the heating and pressing head 28.
- the conductive adhesive film 15 is cured by press-bonding to each of the two electrodes 11 and 13.
- the plurality of solar cells 2 are configured so that the preceding solar cell 2a is moved up and down in synchronization with a pair of heating and pressing heads 28 provided above and below, so that the tab wire 3 is at a predetermined pressure. Pressed.
- the heating and pressing head 28 is heated to a predetermined temperature at which the conductive adhesive film 15 is cured. Therefore, in the conductive adhesive film 15, the binder resin is thermally cured, and the tab wire 3 and the connection portion 14 of the bus bar electrode 11 or the back electrode 13 are electrically and mechanically connected.
- the solar battery cell 2 has a binder resin that exhibits fluidity and the length of the tab wire 3. It flows through a trough portion 21 b continuous in the direction and flows into an opening portion 16 a formed in the connection portion 14 of the back electrode 13. Therefore, the solar battery cell 2 can exclude the excessive binder resin in the conduction
- the opening 16a may have a diameter equal to or larger than the width of the tab wire 3 and the conductive adhesive film 15. Thereby, the opening 16a can surely flow in the excess binder resin and can be removed from the conductive portion 17, and can also correspond to a sticking position shift between the tab wire 3 and the conductive adhesive film 15.
- the pair of heating and pressing heads 28 are separated from the tab wire 3, and the subsequent solar cell 2 b is connected to the pair of heating and pressing heads 28. It is transported directly below. In this way, the solar cells 2 are conveyed one by one directly below the heating and pressing head 28, and the tab wires 3 are sequentially bonded to the connection portions 14 of the bus bar electrodes 11 and the back electrode 13, and adjacent solar cells. The cell 2 is connected in series.
- connection part 14 and the tab wire 3 are connected by the conductive adhesive film 15, either Al or Ag can be used as the back surface electrode 13 of the solar battery cell 2,
- a back surface Al current collecting electrode as the back surface electrode 13
- electrical_connection part 17 of the connection part 14 and the tab wire 3 was performed using the electroconductive adhesive film 15, the insulating adhesive film which does not mix
- the uneven portion 21 of the tab wire 3 is connected to the connection portion 14 in which the conduction portion 17 and the opening portion 16a are formed via a conductive adhesive film 15 (trade name: SP100 series, manufactured by Sony Chemical & Information Device Co., Ltd.). An example of connecting the surface 20a on which the is formed will be described.
- Example 1 the conductive portion 17 was formed by Ag paste wiring at the connection portion of the glass substrate, and a plurality of openings having a diameter of 2 mm were formed at intervals of 2 mm.
- the conductive adhesive film 15 and the tab wire 3 were laminated
- the heat and pressure conditions were 180 ° C., 15 seconds, and 1 MPa.
- Comparative Example 1 only the conduction part 17 is formed by Ag paste wiring in the connection part of the glass substrate, and no opening is formed. And like Example 1, the same conductive adhesive film 15 and the tab wire 3 as Example 1 were laminated
- Example 1 When the connection cross sections of Example 1 and Comparative Example 1 were observed, as shown in FIG. 9A, in Example 1, the connection with the conduction part 17 was confirmed at all the ten peaks 21a. This is because the surplus binder resin B exhibiting fluidity due to thermal pressurization flows into the opening due to the provision of the opening, so that the surplus binder resin B is formed between the peak portion 21a and the conductive portion 17. By being eliminated.
- Comparative Example 1 only three of the ten peak portions 21a are connected to the conductive portion 17, and in other cases, the peak portion 21a and the conductive portion 17 are separated. It was. Moreover, in the comparative example 1, it was the extent which the top part of the peak part 21a was touching the conduction
- Example 2 a solar battery cell in which an Al electrode is formed over the entire surface is used as the back electrode, and a connection portion with the tab wire 3 is formed on the Al electrode. A plurality of openings were formed at intervals of 4 mm.
- the bus bar electrode on the light receiving surface side did not exist, and the finger electrode and the tab wire were connected.
- the same conductive adhesive film 15 and the tab wire 3 as Example 1 were laminated
- the heat and pressure conditions were 180 ° C., 15 seconds, and 1 MPa.
- Example 3 instead of the conductive adhesive film 15 of Example 2, connection was performed under the same conditions as in Example 2 except that an insulating adhesive film excluding conductive particles was used. As a result, the connection with the conductive portion 17 was confirmed at all the mountain portions 21a as in Example 1.
- Comparative Example 2 was connected in the same manner as Example 2 except that the opening was not formed.
- Example 3 Example 3 and Comparative Example 2
- ⁇ FF value immediately after connection of the tab wire 3 (a value obtained by dividing the maximum output of the solar cell by [open circuit voltage ⁇ short circuit current]) / tab
- the value of FF value before connection of line 3 ⁇ ⁇ 100 (%) was determined.
- 97.1% was shown in Example 2 and 97.0% in Example 3, whereas it was 96.2% in Comparative Example 2. It can be seen that the connection is stabilized by providing an opening. .
- the measuring method of the said FF value was performed based on JISC8913 (crystalline solar cell output measuring method).
- Example 2 Example 3 and Comparative Example 2 was laminated with tempered glass, EVA and a back sheet, and the completed solar cell module was subjected to a temperature cycle test.
- the temperature cycle test 1000 cycles of ⁇ 40 ° C. for 30 minutes to 100 ° C. for 30 minutes were performed. And the value of (FF value before test / FF value after test) ⁇ 100 (%) was determined. As a result, 98.5% was shown in Example 2 and 97.8% in Example 3, whereas it was 96% in Comparative Example 2.
- the measuring method of the said FF value was performed based on JISC8913 (crystalline solar cell output measuring method).
- the photovoltaic cell 2 may expose Si which comprises the photoelectric conversion element 10 outside through the opening part 16a.
- the binder resin of the conductive adhesive film 15 comes into contact with Si on the surface of the photoelectric conversion element 10 through the opening 16 a of the back electrode 13. Since the surface of the solar battery cell made of a silicon substrate and the binder resin of the conductive adhesive film 15 are firmly bonded, the conductive adhesive film 15 is connected to the conduction line 17 in the connection between the tab wire 3 and the back electrode 13. Conductivity can be achieved at the (Al portion), and connection strength between the tab wire 3 and the connecting portion 14 of the back electrode 13 can be secured at the Si portion exposed through the opening 16a.
- the tab wire 30 having the concavo-convex portions 21 formed on both sides is used, and the surplus binder is also applied to the bus bar electrode 11 provided on both light receiving surfaces.
- the inflow portion 16 is formed in a lump when the bus bar electrode 11 is printed.
- the inflow part 16 can be formed as the opening part 16a.
- the opening 16a is formed to have a smaller diameter than the width of the bus bar electrode 11.
- the inflow portion 16 may be formed as a notch portion 16b in which a part of the bus bar electrode 11 is notched as shown in FIG. 11B.
- a plurality of openings 16 a and notches 16 b provided in the bus bar electrode 11 are also formed at predetermined intervals in the bus bar electrode 11.
- the opening 16 a and the notch 16 b allow the binder resin to flow along the valley 21 b of the uneven portion 21 in the final crimping process of the tab wire 3, and remove excess binder resin from the conductive portion 17. Can do.
- the heating press head 28 which heat-presses the tab wire 3 may provide the elastic body 31 in the press surface 28a, as shown in FIG.
- the heating and pressing head 28 is provided with an elastic body 31 such as silicon rubber having a high thermal conductivity to absorb the uneven portion 21 of the tab wire 3 and keep the uneven portion on the surface of the tab wire and the pressing surface 26a and the tab wire. As the contact area with the wire 3 increases, the contact with the wire 3 is more closely adhered, and heat and pressure can be reliably transmitted to the tab wire 3 evenly.
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Abstract
Description
本出願は、日本国において2010年9月29日に出願された日本特許出願番号特願2010-219384を基礎として優先権を主張するものであり、この出願は参照されることにより、本出願に援用される。
以下、本発明にかかる太陽電池モジュール及び太陽電池モジュールの製造方法について、図面を参照しながら詳細に説明する。
裏面電極13は、図3に示すように、アルミニウムや銀からなる電極が例えばスクリーン印刷やスパッタ等により太陽電池セル2の裏面に形成される。裏面電極13は、導電性接着フィルム15が仮貼りされた後タブ線3の凹凸部21が形成された表面20aが接続される接続部14を有する。接続部14は、後述するタブ線3の本圧着工程時において導電性接着フィルム15のバインダー樹脂が流入する流入部16が形成されている。流入部16は、裏面電極13の形成時に、マスク処理やエッチング処理を施すことにより形成され、例えば図3に示すように、開口部16aとして形成されている。すなわち、接続部14は、AlやAg部分からなりタブ線3との導通を図る導通部17と、本圧着工程時において余剰のバインダー樹脂が流入する流入部16とからなる。
タブ線3は、従来の太陽電池モジュールで使用されているタブ線と同様に、例えば、50~300μm厚のリボン状銅箔を使用し、必要に応じて金メッキ、銀メッキ、スズメッキ、ハンダメッキ等が施されている。
導電性接着フィルム15は、図5に示すように、導電性粒子23が高密度に含有された熱硬化性のバインダー樹脂層である。また、導電性接着フィルム15は、押し込み性の観点から、バインダー樹脂の最低溶融粘度が、100~100000Pa・sであることが好ましい。導電性接着フィルム15は、最低溶融粘度が低すぎると低圧着から本硬化の過程で樹脂が流動してしまい接続不良やセル受光面へのはみ出しが生じやすく、受光率低下の原因ともなる。また、最低溶融粘度が高すぎてもフィルム貼着時に不良を発生しやすく、接続信頼性に悪影響が出る場合もある。なお、最低溶融粘度については、サンプルを所定量回転式粘度計に装填し、所定の昇温速度で上昇させながら測定することができる。
次いで、太陽電池モジュール1の製造工程について説明する。太陽電池モジュール1は、バスバー電極11及び裏面電極13の接続部14に導電性接着フィルム15を仮貼りする仮貼り工程、太陽電池セル2を配列する配列工程、タブ線3を導電性接着フィルム15上に低温低圧で熱加圧することによりバスバー電極11上及び裏面電極13の接続部14上に配置する仮圧着工程、及びタブ線3上から熱加圧することにより導電性接着フィルム15を熱硬化させ、タブ線3とバスバー電極11及び裏面電極13の接続部14とを接続する本圧着工程とを備える。
なお、太陽電池セル2は、開口部16aを介して光電変換素子10を構成するSiを外方に露出させてもよい。これにより、太陽電池セル2は、導電性接着フィルム15のバインダー樹脂が裏面電極13の開口部16aを介して光電変換素子10の表面のSiと接触する。シリコン基板からなる太陽電池セルの表面と導電性接着フィルム15のバインダー樹脂とは、強固に接着することから、導電性接着フィルム15は、タブ線3と裏面電極13との接続において、導通部17(Al部分)で導通を図ると共に、開口部16aを介して露出されているSi部分でタブ線3と裏面電極13の接続部14との接続強度を確保することができる。
Claims (12)
- 両面に電極が形成された複数の太陽電池セルと、
一面に長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部を有し、上記複数の太陽電池セルを直列に接続するタブ線と、
上記太陽電池セルの電極と上記タブ線との間に介在され、上記太陽電池セルと上記タブ線とを接続する接着フィルムとを備え、
上記太陽電池セルは、上記凹凸部が設けられた一面が接続される接続部に上記接着フィルムのバインダー成分が流入する流入部が形成されている太陽電池モジュール。 - 上記タブ線は、上記凹凸部が設けられた一面と反対側の平坦面が、上記太陽電池セルの表面電極と接続され、上記一面が上記太陽電池セルの裏面電極と接続されている請求項1記載の太陽電池モジュール。
- 上記タブ線は、上記凹凸部が設けられた一面と反対側の面にも、長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部が形成されている請求項1記載の太陽電池モジュール。
- 上記太陽電池セルは、裏面電極がAlを用いて形成されている請求項1~請求項3のいずれか1項に記載の太陽電池モジュール。
- 上記太陽電池セルは、結晶シリコン系太陽電池セルであり、上記流入部よりSiが外方へ露出している請求項4に記載の太陽電池モジュール。
- 上記流入部は、上記裏面電極の上記タブ線との接続部に設けられた開口部である請求項2~請求項5のいずれか1項に記載の太陽電池モジュール。
- 上記流入部は、上記裏面電極の上記タブ線との接続部に設けられた切り欠き部である請求項2~請求項5のいずれか1項に記載の太陽電池モジュール。
- 上記接続部は、上記タブ線と導通する導通部が上記流入部よりも大きな面積を有する請求項1~請求項7のいずれか1項に記載の太陽電池モジュール。
- 上記接着フィルムは、導電性粒子を含有する請求項1~請求項8のいずれか1項に記載の太陽電池モジュール。
- 上記接着フィルムは、導電性粒子を含有しない絶縁性接着フィルムである請求項1~請求項8のいずれか1項に記載の太陽電池モジュール。
- 複数の太陽電池セルを配列する配列工程と、
接着フィルムを介して一面に長手方向に亘って連続する山部及び谷部が幅方向に交互に形成されてなる凹凸部を有するタブ線の上記一面を上記太陽電池セルの裏面電極側に仮接続すると共に、接着フィルムを介して上記タブ線の上記一面と反対側の平坦面を上記太陽電池セルの表面電極側に仮接続する仮圧着工程と、
上記タブ線の上から熱加圧することにより、上記接着フィルムを熱硬化させて上記タブ線と上記太陽電池セルの各電極とを接続する本圧着工程とを備え、
上記本圧着工程では、上記接着フィルムのバインダー成分を、上記タブ線の上記凹凸部が設けられた一面が接続される接続部に設けられた開口部に流入する太陽電池モジュールの製造方法。 - 上記本圧着工程では、上記タブ線の押圧面に弾性体が設けられたヘッドによって上記タブ線を熱加圧する請求項11記載の太陽電池モジュールの製造方法の製造方法。
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EP2787539A4 (en) * | 2011-11-30 | 2015-06-10 | Sanyo Electric Co | PHOTOVOLTAIC MODULE AND METHOD FOR MANUFACTURING THE SAME |
WO2014033829A1 (ja) * | 2012-08-28 | 2014-03-06 | 三洋電機株式会社 | 太陽電池モジュール |
JP5485434B1 (ja) * | 2013-02-28 | 2014-05-07 | 海彬 郭 | 太陽電池セル |
WO2014155415A1 (ja) * | 2013-03-26 | 2014-10-02 | 三洋電機株式会社 | 太陽電池モジュール |
JP2015076446A (ja) * | 2013-10-07 | 2015-04-20 | 日立化成株式会社 | 太陽電池セル |
JP2015233095A (ja) * | 2014-06-10 | 2015-12-24 | 日立化成株式会社 | 太陽電池ユニット及び太陽電池ユニットの製造方法 |
TWI619262B (zh) * | 2016-01-04 | 2018-03-21 | 有成精密股份有限公司 | 高功率太陽能電池模組 |
WO2017179523A1 (ja) * | 2016-04-14 | 2017-10-19 | 株式会社カネカ | 太陽電池用配線材および太陽電池モジュール |
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