WO2012057125A1 - 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の製造方法 Download PDFInfo
- Publication number
- WO2012057125A1 WO2012057125A1 PCT/JP2011/074531 JP2011074531W WO2012057125A1 WO 2012057125 A1 WO2012057125 A1 WO 2012057125A1 JP 2011074531 W JP2011074531 W JP 2011074531W WO 2012057125 A1 WO2012057125 A1 WO 2012057125A1
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- WIPO (PCT)
- Prior art keywords
- solar cell
- resin adhesive
- sheet
- cushion sheet
- pressing member
- Prior art date
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Images
Classifications
-
- 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
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
-
- 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
- H01L31/02—Details
- H01L31/0224—Electrodes
- H01L31/022408—Electrodes for devices characterised by at least one potential jump barrier or surface barrier
- H01L31/022425—Electrodes for devices characterised by at least one potential jump barrier or surface barrier for solar cells
- H01L31/022433—Particular geometry of the grid contacts
-
- 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
-
- 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
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
- H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
-
- 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
Definitions
- the present invention relates to a method for manufacturing a solar cell module including a solar cell string in which a wiring material is connected to a solar cell using a resin adhesive film.
- Solar cells are expected as a new energy source because they can directly convert clean and infinitely supplied sunlight into electricity.
- the output per solar cell is about several watts. For this reason, when a solar cell is used as a power source for a house, a building, or the like, a solar cell module whose output is increased by connecting a plurality of solar cells is used.
- the solar cell module includes a solar cell string including a plurality of solar cells electrically connected by a wiring material.
- Patent Document 1 As a method for connecting a wiring material to a solar cell, a method using a resin adhesive film is known (see, for example, Patent Document 1). This prior art describes a technique for preventing the occurrence of cracks that occur when the positions of the front and back electrodes are shifted.
- the manufacturing yield may be reduced.
- the present invention has been made in view of the above-described conventional circumstances, and an object thereof is to provide a method for manufacturing a solar cell module with a high yield.
- the present invention relates to a method for manufacturing a solar cell module in which a wiring material is electrically connected to electrodes provided on the front and back surfaces of a solar cell using a resin adhesive film.
- a resin adhesive film is disposed on the front and back electrodes of the solar cell, the total area of the electrodes being smaller than the total area of the electrodes provided on the back side, and the first cushion sheet, After the side pressing members are arranged in this order and the second cushion sheet and the upper pressing member are arranged in this order on the upper resin adhesive film, the lower pressing member And pressurizing the upper pressing member in a direction facing each other to crimp the resin adhesive film on the front and back electrodes of the solar cell, releasing the pressing of both the pressing members and separating them, Serial first and second cushion sheet is separated from the resin adhesive film, to adhere respectively the resin adhesive film on both of the electrodes of the solar cell.
- the resin adhesive film can be affixed to the front and back electrodes of the solar cell with good adhesiveness.
- FIG. 1 is a cross-sectional view schematically showing the solar cell module according to the first embodiment
- FIG. 2 is a side view showing a process of attaching a conductive resin adhesive film according to the first embodiment
- FIG. It is the typical sectional view which expanded the principal part about the pasting process of the conductive resin adhesive film concerning a 1st embodiment.
- FIG. 4 is a schematic cross-sectional view showing the conductive resin adhesive film used in the first embodiment.
- the conductive resin adhesive film 5 includes at least a resin adhesive component 5c and conductive particles 5b dispersed therein.
- a resin adhesive component 5c having conductive particles 5b dispersed therein is provided on a base film 5d made of PET (Polyethylene terephthalate) or the like.
- the resin adhesive component 5c is made of a composition containing a thermosetting resin.
- a thermosetting resin for example, an epoxy resin, a phenoxy resin, an acrylic resin, a polyimide resin, a polyamide resin, or a polycarbonate resin can be used.
- These thermosetting resins are used singly or in combination of two or more, and one or more thermosetting resins selected from the group consisting of epoxy resins, phenoxy resins and acrylic resins are preferable.
- conductive particles 5b for example, metal particles such as gold particles, silver particles, copper particles and nickel particles, or the surfaces of conductive or insulating core particles such as gold plated particles, copper plated particles and nickel plated particles are used. Conductive particles formed by coating with a conductive layer such as a metal layer are used.
- PET is used as the base film 5d.
- a resin adhesive layer 5a composed of a resin adhesive component 5c and conductive particles 5b is provided on the base film 5d, and the thickness of the resin adhesive layer 5a is about 0.02 mm.
- the solar cell module 100 includes a plurality of plate-like solar cells 1.
- the solar cell 1 is made of, for example, a crystalline semiconductor substrate made of single crystal silicon, polycrystalline silicon, or the like having a thickness of about 0.15 mm, and has a substantially square shape with one side of 104 mm or a square with one side of 125 mm.
- the present invention is not limited to this, and other solar cells may be used.
- an n-type region and a p-type region are formed, and a junction for forming an electric field for carrier separation is formed at an interface portion between the n-type region and the p-type region.
- the n-type region and the p-type region can be formed by single or a combination of semiconductor substrates used for solar cells such as single crystal silicon, polycrystalline silicon, and compound semiconductors such as GaAs and InP.
- a solar cell in which an intrinsic amorphous silicon layer is interposed between a single crystal silicon substrate and an amorphous silicon layer having opposite conductivity types is used. By adopting this configuration, defects at the interface between the single crystal silicon substrate and the amorphous silicon layer can be reduced, and the characteristics of the heterojunction interface can be improved.
- this solar cell 1 has electrodes 11 and 12 formed in predetermined regions on the front and back sides.
- the electrodes 11 and 12 are electrodes for collecting carriers generated by the photoelectric conversion unit in the solar cell 1.
- the electrodes 11 and 12 include, for example, a plurality of fine wire electrodes 11a and 12a formed in parallel with each other.
- the thin wire electrodes 11a provided on the surface side have a width of about 100 ⁇ m and a thickness of about 60 ⁇ m, for example, and are formed on the surface of the substrate by about 50 at intervals of about 2 mm.
- the thin wire electrodes 12a provided on the back surface side have an electrode width of 100 ⁇ m and a thickness of 10 ⁇ m, and about 240 wires are provided on the back surface of the substrate at intervals of about 0.5 mm.
- Such fine wire electrodes 11a and 12a are formed, for example, by screen printing a silver paste and curing it at a temperature of a few hundred degrees.
- the electrodes 11 and 12 may be provided with a polygonal bus bar electrode having the same thickness and the same width as the thin wire electrode.
- the number of fine wire electrodes 11a of the front surface side electrode 11 is made smaller than the number of thin wire electrodes 12a of the back surface side electrode 12. Yes. Further, the resistance of the surface-side electrode 11 is reduced by making the thickness of the front-side thin wire electrode 11a larger than the thickness of the back-side thin wire electrode 12a, thereby improving the solar cell characteristics.
- the wiring material 120 is electrically connected to the electrodes 11 and 12.
- the conductive resin adhesive film 5 is used.
- the conductive resin adhesive film 5 is pressure-bonded to the position where the wiring member 120 is bonded.
- a conductive resin adhesive film having the same width as or slightly narrower than the width of the wiring material 120 to be connected is used. For example, if the width of the wiring material 120 is 0.5 mm to 3 mm, the width of the conductive resin adhesive film 5 is within the range of 0.5 mm to 3 mm corresponding to the width of the wiring material 120. Below. In this embodiment, as shown in FIG.
- the three adhesive resin film layers 5 a are attached to the front and back of the solar cell 1 at the position where the wiring member 120 is bonded.
- the wiring material 120 is attached to the solar cell 1 by placing the resin adhesive films 5 on the front and back surfaces of the solar cell 1 and pressing the pressing members in directions facing each other.
- the number of the fine wire electrodes 11a on the front surface side of the solar cell 1 is smaller than the number of the fine wire electrodes 12a on the back surface side.
- the pressure applied to the resin adhesive film 5 is different between the front surface and the back surface side. Therefore, the inventor diligently studied a method for attaching the resin adhesive film 5 to the solar cell 1 on the front and back sides, and found a method for obtaining a good attachment state. This pasting method will be described later.
- the wiring material 120 is pressed onto the conductive adhesive film 5, heat treatment is performed while pressing, and the adhesive layer of the conductive resin adhesive film 5 is thermally cured to connect the wiring material 120 to the electrodes 11 and 12.
- the electrode 12 on the back surface side is described as an example of the thin wire electrode 12a.
- a metal is formed on the entire back surface.
- a structure having an electrode is used.
- each of the plurality of solar cells 1 is electrically connected to another solar cell adjacent to each other by a wiring member 120 formed of a flat copper foil or the like. Yes. That is, one end side of the wiring member 120 is connected to the electrode 11 on the upper surface side of the predetermined solar cell 1, and the other end side is connected to the electrode 12 on the lower surface side of another solar cell 1 adjacent to the predetermined solar cell 1. Connected. These solar cells 1 are connected in series with a wiring member 120, and are configured such that a predetermined output, for example, an output of 200 W, is taken out from the solar cell module 100 through a lead wire.
- a predetermined output for example, an output of 200 W
- a plurality of solar cells 1 are electrically connected to each other by a wiring material 120 made of a conductive material such as a copper foil to form a solar cell string 100a.
- the solar cell string 100a is weatherproof between the surface member 41 which has translucency like glass and translucent plastic, and the back surface member 42 which consists of members, such as a weather-resistant film or glass, plastic. Further, it is sealed with a sealing material 43 such as EVA (ethyl vinylate) excellent in moisture resistance.
- EVA ethyl vinylate
- the solar cell module 100 is fitted into an outer frame (not shown) made of aluminum or the like using a sealing material on the outer periphery as necessary.
- the outer frame is formed of aluminum, stainless steel, a steel plate roll forming material, or the like.
- a terminal box (not shown) is provided, for example, on the surface of the back member 42 as necessary.
- the adhesive film 5 is disposed, and the lower pressing member 61 and the upper pressing member 62 are pressed in a direction facing each other.
- the first cushion sheet 63 is interposed between the lower pressing member 61 and the adhesive film 5 and the second cushion sheet 64 is interposed between the upper pressing member 62 and the adhesive film 5 so that pressure is applied on average.
- the adhesive film 5 is pressed against the electrodes 11 and 12 through the first and second cushion sheets 63 and 64.
- the conductive adhesive film 5 is pressed and pasted on the electrodes 11 and 12 on the front and back sides of the solar cell 1, the base film 5d is peeled off, and the resin adhesive layer 5a is pasted.
- a resin adhesive component of the conductive resin adhesive layer 5a a crosslinking accelerator is blended that has an epoxy resin as a main component and that is rapidly crosslinked by heating at 180 ° C. and cured in about 15 seconds. Resin adhesive is used.
- the thickness of the conductive resin adhesive film layer 5 is 0.01 to 0.05 mm, and the width is preferably equal to the wiring material 120 or narrower than the wiring material width in consideration of shielding of incident light.
- a conductive resin adhesive film 5 formed on a belt-like film sheet having a width of 1.5 mm and a thickness of 0.02 mm is used.
- the number of the fine wire electrodes 11a on the front surface side of the solar cell 1 is smaller than the number of the fine wire electrodes 12a on the back surface side. For this reason, when the pressing members are pressed in the direction facing each other, as shown in FIG. 10, the total surface area where the electrode 11 provided on the front surface side of the solar cell 1 and the resin adhesive layer 5a are in contact with each other, and the back surface side The sum of the surface areas where the electrode 12 and the resin adhesive layer 5a provided on the surface are in contact with each other is different.
- the pressure is applied unevenly to the resin adhesive film having the smaller surface area to be contacted.
- the resin adhesive layer 5a is cut at the portion of the electrode 11 and there is a problem in that poor adhesion occurs.
- the first cushion sheet 63 is interposed between the lower pressing member 61 and the adhesive film 5 and the second cushion is interposed between the upper pressing member 62 and the adhesive film 5 so that pressure is applied on average.
- the sheets 64 are respectively disposed, the total area in which the cushion sheets 63 and 64 and the electrodes are in contact with each other is different depending on the number of the thin wire electrodes 11a on the front surface side and the number of the thin wire electrodes 12a on the back surface side. Become.
- the area in contact with the cushion sheet 64 and the electrode 11 is smaller than the area in contact with the back surface side electrode 12 and the cushion sheet 63. Since the pressing members 61 and 62 are pressed in the direction facing each other, the pressure applied to each fine wire electrode is such that the fine wire electrode 11a on the surface side becomes higher if the cushion sheets 63 and 64 are the same material and have the same thickness. Due to the difference in pressure, the adhesive film 5 on the front surface side may be partially crimped to the thin wire electrode 11a, and the resin adhesive layer 5a may be thinned.
- the resin adhesive layer 5a is cut when the base film 5d is peeled off, and the fine wire electrode 11a is peeled off together with the base film 5d without being peeled off from the base film 5d.
- the inventor has examined the thickness of the cushion sheets 63 and 64 and found that the adhesion failure is eliminated by making the pressure uniform and applying the pressure to the thin wire electrode 11a.
- a silicon rubber sheet is used as the first and second cushion sheets 63, 64, and the thickness of the silicon rubber sheet is changed to change the state where the resin adhesive layer 5a is attached to the front and back electrodes 11, 12 of the solar cell 1. confirmed.
- the solar cell 1 used is made of a crystalline semiconductor substrate made of single crystal silicon having a thickness of 0.15 mm, and has a substantially square shape with one side of 125 mm. Electrodes 11 and 12 are formed in predetermined regions on the front and back of the solar cell 1.
- the electrodes 11 and 12 include, for example, a plurality of fine wire electrodes 11a and 12a formed in parallel with each other.
- the thin wire electrodes 11a provided on the surface side have, for example, a width of about 100 ⁇ m, a pitch of about 2 mm, and a thickness of about 60 ⁇ m, and 50 are formed on the surface of the substrate.
- the thin wire electrodes 12a provided on the back surface side have an electrode width of 100 ⁇ m, a pitch of 0.5 mm, and a thickness of 10 ⁇ m, and 240 are provided on the back surface of the substrate.
- a resin adhesive film 5 is disposed on the front and back electrodes 11 and 12 of the solar cell 1 described above, and a first cushion sheet 63 made of a silicon rubber sheet is provided below the lower resin adhesive film 5, and a lower pressing member. 61 is arranged in this order, and the second cushion sheet 64 made of a silicon rubber sheet and the upper pressing member 62 are arranged in this order on the upper resin adhesive film 5.
- the lower pressing member 61 and the upper pressing member 62 were pressed in directions facing each other, and the resin adhesive film 5 was pressed onto the electrodes 11 and 12 on the front and back of the solar cell 1.
- the lower pressing member 61 and the upper pressing member 62 were sandwiched at a pressure of 0.50 MPa.
- the first cushion sheet 63 is a 200 ⁇ m silicon rubber sheet
- the second cushion sheet 64 is changed, and the lower pressing is performed.
- the member 61 and the upper pressing member 62 were sandwiched and pressurized. The results are shown in Table 1.
- the pressure applied to the fine wire electrode 11a of the upper electrode 11 increases, and the resin adhesive layer 5a is stuck. Bad attachment occurred.
- the thickness of the upper second cushion sheet 64 is 300 ⁇ m, 400 ⁇ m, and 450 ⁇ m, which is greater than the thickness of the lower first cushion sheet 63, that is, 200 ⁇ m, the second cushion sheet 62 is the first one. Bending more than the cushion sheet 63, following the shape of the surface of the solar cell 1, the pressure applied to the thin wire electrode 11a was made uniform, and concentration of pressure could be prevented. As a result, it was confirmed that the resin adhesive layer 5a was reliably attached to the electrodes 11 and 12 on the front and back sides of the solar cell 1.
- the thickness of the upper second cushion sheet 64 is preferably 1.2 times or more, more preferably 1.5 times or more than the thickness of the lower first cushion sheet 63. Moreover, since the material ratio of a cushion sheet will become high when it becomes too thick, 1.5 times or more and 2.5 times or less are preferable.
- the silicon rubber sheet is used, but the same effect can be obtained by using other elastic sheets.
- the electrodes 11 and 12 are formed using a silver paste.
- the present invention is not limited to this, and the same effect can be obtained when the electrodes 11 and 12 are formed by plating or the like.
- the wiring members 120 are placed on the conductive resin adhesive layers 5a and 5a attached to the front and back of the solar cell 1, respectively. Then, as shown in FIG. 8, the wiring member 120 is crimped and temporarily fixed on the electrodes 11 and 12.
- the heater blocks 80 and 80 are pressed, for example, at a pressure of about 0.5 MPa, and the wiring members 120 and 120 are pressed against the solar cell 1 side. Then, the temperature of the heater blocks 80, 80 is low-temperature heated at a temperature at which the resin adhesive component does not thermally cure, for example, heated to a temperature of about 90 ° C. to temporarily fix the wiring material 120, and temporarily fix the wiring material 120.
- the solar cells 1 are arranged to form a string. The temporarily fixed solar cell 1 is sequentially sent by the conveyor 82.
- the wiring material 120 is again pressed against the solar cell 1 side and heated against the string on which the wiring material is temporarily fixed, thereby curing the resin adhesive component and finally crimping the wiring material 120.
- the solar cell 1 is between the surface member 41 which consists of glass, and the back surface member 42 which consists of members, such as a weather-resistant film or glass, and translucent plastic. , And sandwiched between light-transmitting sealing material sheets 43a and 43b such as EVA. And the solar cell 1 is sealed with the sealing material sheet between the surface member 41 and the back surface member 42 with a laminating apparatus. Then, put it in a furnace and heat it at a temperature of about 150 ° C. for about 10 minutes to advance the crosslinking reaction and increase the adhesion between the sealing material 43 (sealing material sheet), the front surface member 41 and the back surface member 42, The solar cell module shown in FIG. 1 is manufactured.
- the number of wiring members 120 is not limited to three, and the wiring members 120 are arranged on the front and back sides. In this case, the present invention can be applied regardless of the number.
- FIGS. 19 and 20 An example of a method of connecting a solar cell electrode and a wiring material using a conductive resin adhesive film as a resin adhesive will be described with reference to FIGS. 19 and 20.
- the conductive resin adhesive film 5 is pressed and applied to the electrodes 11 and 12 of the solar cell 1, respectively, the base film is peeled off, and the resin adhesive layers 5a and 5a are attached.
- the wiring members 120 and 120 are placed on the upper and lower sides of the solar cell 1 to which the resin adhesive layers 5 a and 5 a are attached, respectively, and pressed by the heater blocks 40 and 40. Press to the side.
- the temperature of the heater blocks 40, 40 is heated at a temperature at which the resin adhesive component of the resin adhesive layer 5a is not thermally cured, so that the wiring members 120, 120 are temporarily bonded to the solar cell 1, and the solar cells 1, 1 are arranged. .
- the process for carrying out this pressure bonding of the wiring material 120 is started. That is, as shown in FIG. 20, the solar cells 1, 1 to which the wiring member 120 is temporarily bonded are pressed by the heater blocks 40, 40 at a high temperature and a high pressure. Sheets 70 and 71 having a releasing action are arranged between the heater block 40 and the temporarily adhered solar cells 1 and 1. Using the heater blocks 40 and 40, the wiring material 120 is pressed against the solar cell 1 side by setting the temperature higher than the temperature at which the resin adhesive component is thermally cured, the resin adhesive component is thermally cured, and the electrode 11 of the solar cell 1 12 and the wiring material 120 are connected by the resin adhesive layer 5 to form a solar cell string. Further, as the sheets 70 and 71, PTFE (polytetrafluoroethylene) sheets can be used as the sheets 70 and 71.
- PTFE polytetrafluoroethylene
- the solar cell and the solar cell module according to the second embodiment are the same as the solar cell 1 and the solar cell module 100 according to the first embodiment.
- the plurality of solar cells 1 described above are electrically connected by a wiring member 120 made of a conductive material such as a flat copper foil using a conductive resin adhesive layer 5a as a resin adhesive.
- a wiring member 120 made of a conductive material such as a flat copper foil using a conductive resin adhesive layer 5a as a resin adhesive.
- the conductive resin adhesive layer 5 a is attached to the positions where the wiring members 120 on the front and back electrodes 11 and 12 of the solar cell 1 are connected.
- the conductive resin adhesive layer 5a is attached so as to cover all of the plurality of thin wire electrodes 11a and 12a.
- An anisotropic conductive adhesive film is used as the conductive resin adhesive layer 5a.
- the thickness of the conductive resin adhesive layer 5a is 0.01 mm to 0.05 mm, and the width is preferably equal to the wiring material 120 or narrower than the width of the wiring material 120 in consideration of shielding of incident light.
- an anisotropic conductive adhesive film formed on a belt-like film sheet having a width of 1.5 mm and a thickness of about 0.02 mm is used.
- each of the plurality of solar cells 1 is electrically connected to another solar cell 1 adjacent to each other by a wiring material 120. That is, one end side of the wiring member 120 is connected to the electrode 11 on the upper surface side of the predetermined solar cell 1, and the other end side is connected to the electrode 12 on the lower surface side of another solar cell adjacent to the predetermined solar cell 1.
- the wiring member 120 is placed on the conductive resin adhesive layers 5 a and 5 a attached to the front and back of the solar cell 1. Then, as shown in FIG. 14, the wiring member 120 is pressure-bonded to the conductive resin layers 5 a and 5 a and temporarily fixed on the electrodes 11 and 12.
- the heater blocks 80 and 80 are pressed, for example, at a pressure of about 0.5 MPa, and the wiring members 120 and 120 are pressed against the solar cell 1 side. Then, the temperature of the heater blocks 80, 80 is low-temperature heated at a temperature at which the resin adhesive component does not thermally cure, for example, heated to a temperature of about 90 ° C. to temporarily fix the wiring material 120, and temporarily fix the wiring material 120.
- the solar cells 1 and 1 are arranged to form a string.
- the temporarily fixed solar cells 1 and 1 are sequentially sent by the conveyor 82.
- the pressure bonding and heating are performed by pressing a metal block with a built-in heater and heating to a predetermined pressure and temperature, and by heating a pressing member such as a pressing pin and hot air to heat to a predetermined pressure and temperature.
- a pressing member such as a pressing pin and hot air to heat to a predetermined pressure and temperature.
- the step of fixing the wiring member 120 by pressure bonding is performed by placing the temporarily fixed solar cell string 100 a on the conveyor belt 60 and performing an upper heater block 40 a as a pressing member for performing the pressure bonding step. It is conveyed to the position of the lower heater block 40b.
- the conveyor belt 60 is provided with a slit 61 at a position facing the wiring member 120, and a lower silicon rubber sheet 75 b and a lower heater block 40 b as a second cushion sheet are arranged facing the slit 61. Has been.
- an upper silicon rubber sheet 75a as a first cushion sheet is disposed between the solar cell string 100a and the upper heater block 40a.
- the lower silicon rubber sheet 75 and the lower heat block 40 b are inserted into the slit 61.
- the upper heater block 40a and the lower heater block 40b move to the arrow A direction, and apply pressure to the solar cell 1 through the silicon rubber sheets 75a and 75b, respectively.
- silicon rubber sheets 75a and 75b made of the same material are interposed between the upper and lower heater blocks 40a and 40b and the wiring member 120, respectively. Since the silicon rubber sheets 75a and 75b have cushioning properties, the sheets 75a and 75b absorb the influence of the unevenness of the electrodes 11 and 12, and the pressure is made uniform. Moreover, since the silicon rubber sheets 75a and 75b have cushioning properties, the solar cell 1 can be prevented from being damaged during the process.
- the upper and lower heater blocks 40a and 40b When transporting the temporarily fixed solar cell string 100 to the positions of the upper and lower heater blocks 40a and 40b, the upper and lower heater blocks 40a and 40b are moved from the solar cell 1 as shown in FIG. Separate.
- the silicon rubber sheets 75a and 75b are also separated from the solar cell 1 similarly to the upper and lower heater blocks 40a and 40b.
- the upper and lower heater blocks 40a and 40b move in the direction of arrow A in FIG.
- the wiring member 120 and the solar cell 1 are pressure-bonded via silicon rubber sheets 75a and 75b.
- the upper and lower heater blocks 40a and 40b are pressed through silicon rubber sheets 75a and 75b at a pressure higher than that at the time of temporary press-bonding, for example, a pressure of about 5 MPa, 120 and 120 are pressed against the solar cell 1 side, respectively.
- the lower heater block 40b and the silicon rubber sheet 75b located on the conveyance belt 60 side protrude from the slit 61 between the conveyance belts 60 to the solar cell 1 side, and the wiring member 120 and the solar cell 1 are pressed.
- the upper and lower heater blocks 40a and 40b are heated at a high temperature at which the resin adhesive component is thermally cured, for example, heated to a temperature of 120 ° C. or higher and 200 ° C. or lower to fix the wiring member 120 to the main pressure bonding.
- the wiring member 120 is fixed by the thermosetting resin adhesive layer 5 and the solar cells 1 and 1 are electrically connected and arranged.
- the upper and lower heater blocks 40a and 40b move in the direction of arrow B in the drawing and are separated from the solar cell 1, as shown in FIG.
- the silicon rubber sheets 75a and 75b also move in directions away from the solar cell 1, respectively.
- the upper and lower silicon rubber sheets 75a and 75b are attached to the front and back surfaces of the solar cell 1 with a certain amount of force, respectively. Therefore, when the upper and lower heater blocks 40a and 40b are moved in the direction of arrow B in FIG. 18 in order to separate them from the solar cell 1, the same force acts on the upper and lower sides of the solar cell 1, and the solar cell It is possible to prevent the string 100a from being lifted upward.
- sheets 70 and 71 having a releasing action are disposed between the heater block 40 and the temporarily bonded solar cells 1 and 1.
- a sheet made of PTFE Polytetrafluoroethylene
- a sheet made of such a material does not have sufficient cushioning properties, and there is a possibility that the solar cell 1 may be damaged during the main compression bonding.
- the sheet disposed between the heater blocks 40a and 40b and the solar cell 1 preferably has a cushioning property in order to suppress damage to the solar cell 1 in the main press bonding step.
- at least the adhesive strength of the sheet 75b provided on the lower side of the solar cell 1 is preferably equal to or higher than the adhesive strength of the sheet 75a provided on the upper side.
- the upper sheet 75a is a fluorine-based rubber sheet or PET sheet
- the lower sheet 75b is a silicon rubber.
- a sheet, an acrylic rubber sheet, or the like can be used.
- the force of sticking to the silicon rubber sheets 75a and 75b increases as the temperature during the press bonding increases. Therefore, the actual temperature of the lower heater block 40b is made higher than the actual temperature of the upper heater block 40a, and the force sticking to the lower silicon rubber sheet 75b is slightly increased so that it cannot be lifted upward. Is also preferable.
- the same sheet can be used for the upper sheet 75a and the lower sheet 75b by making the actual temperature of the lower heater block 40b higher than the actual temperature of the upper heater block 40a.
- the conveyance belt 60 is arrange
- the silicon rubber sheet 75b is peeled off, and the solar cell 1 does not move downward any further.
- the solar cell string 100a can be prevented from being lifted or moved below the conveyor belt 60.
- the heating temperature of the heater is the same, and the heat capacity of the lower heater block 40b is made larger than the heat capacity of the upper heater block 40a. Even if the heater temperature is the same, the larger the heat capacity, the higher the actual temperature, and the higher the actual temperature of the lower heater block 40b.
- an anisotropic conductive adhesive film is used as the resin adhesive film, but a resin film that does not include conductive particles can also be used.
- a resin adhesive that does not contain conductive particles is used, an electrical connection is made by bringing a part of the surface of the electrode 11 (12) into direct contact with the surface of the wiring agent 120.
- the wiring material 120 is formed by forming a conductive film softer than the electrode 11 (12) such as tin (Sn) or solder on the surface of a conductor such as a copper foil plate, and a part of the electrode 11 (12). It is preferable that the connection is made so as to be embedded in the conductive film.
- a paste adhesive paste can be applied.
- the wiring material can be connected using an anisotropic conductive paste.
- the 1st member 41 which consists of glass
- the 2nd member 42 which consists of members, such as a weather resistant film or glass, and translucent plastic.
- the sealing materials 43a and 43b having translucency such as EVA.
- the solar cell 1 is sealed with the sealing material sheet between the 1st member 41 and the 2nd member 42 with a laminating apparatus. Thereafter, heating is carried out at a temperature of about 150 ° C. for about 10 minutes, the crosslinking reaction is advanced, and the adhesion between the sealing material 43 (sealing material sheet), the front surface member 41 and the back surface member 42 is increased, and the sun shown in FIG.
- a battery module is manufactured.
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Abstract
Description
また、平均して圧力が加わるように、下側押圧部材61と接着フィルム5との間には第1のクッションシート63、上側押圧部材62と接着フィルム5との間には、第2のクッションシート64をそれぞれ配置しているが、表面側の細線電極11aの本数と裏面側の細線電極12aの本数との違いにより、クッションシート63、64と電極とが接触する総面積が相違することになる。
11、12 電極
11a、12a 細線電極
5 樹脂接着フィルム
5a 樹脂接着層 40a 上側ヒートブロック
40b 下側ヒートブロック
61 下側押圧部材
62 上側押圧部材
63 第1のクッションシート
64 第2のクッションシート 75a、75b シリコンラバーシート
120 配線材
Claims (14)
- 太陽電池の表裏に設けられた電極に樹脂接着層を用いて配線材を電気的に接続させる太陽電池モジュールの製造方法であって、前記電極は、基板の表裏にそれぞれ設けられ、表面側に設けられる前記電極の総面積が裏面側に設けられる前記電極の総面積より小さく、前記太陽電池モジュールの製造方法は、
前記電極上に、それぞれ樹脂接着層を配置し、下側の樹脂接着層の下に第1のクッションシート、下側押圧部材をこの順序で配し、上側の樹脂接着層の上に前記第1のクッションシートより厚みが厚い第2のクッションシート、上側押圧部材をこの順序で配する工程と、
前記下側押圧部材及び前記上側押圧部材を互いに向き合う方向に加圧して前記樹脂接着層を太陽電池の表裏の電極上に圧着させ、前記両押圧部材の加圧を解除して前記第1、第2のクッションシートを樹脂接着層より離間させ、前記樹脂接着フィルムを太陽電池の表裏の電極にそれぞれ粘着させる工程と、を含む。 - 請求項1に記載の太陽電池モジュールの製造方法であって、前記第1、第2のクッションシートはシリコンラバーシートからなる。
- 請求項1又は請求項2に記載の太陽電池モジュールの製造方法であって、前記第2のクッションシートは、第1のクッションシートの1.2倍以上の厚みを有する。
- 請求項2に記載の太陽電池モジュールの製造方法であって、前記第1のクッションシートの厚みは200μmであり、前記第2のクッションシートの厚みは300μm以上450μmである。
- 請求項1ないし請求項4のいずれか1項に記載の太陽電池モジュールの製造方法であって、前記樹脂接着層は、基材フィルム上に前記樹脂接着層を設けた樹脂接着フィルムから供給され、太陽電池へ前記接着層を張り付けたあとに前記基材フィルムを巻き取る巻き取り手段が設けられている。
- 太陽電池の表面電極及び裏面電極に樹脂接着剤を用いて配線材を電気的に接続させる工程を備える太陽電池モジュールの製造方法は、
前記太陽電池の表面電極上に樹脂接着剤、第1の配線材、第1のクッションシート、上側押圧部材をこの順序に配し、前記太陽電池の裏面電極上に樹脂接着剤、第2の配線材、第2のクッションシート、下側押圧部材をこの順序に配する工程と、
前記上側押圧部材及び下側押圧部材を互いに向き合う方向に加圧し、前記樹脂接着剤の硬化温度以上の温度で加熱して前記樹脂接着剤を熱硬化させて前記表面電極及び前記裏面電極と前記配線材とを固定する工程と、
前記押圧部材の加圧を解除し、少なくとも前記第2のクッションシートを前記太陽電池に粘着させながら前記上側押圧部材を上方に移動させ、前記第1のクッションシートを前記太陽電池から剥がす工程と、
を備える。 - 請求項6に記載の太陽電池モジュールの製造方法であって、前記第1のクッションシート及び第2のクッションシートはシリコンラバーシートからなる。
- 請求項6または請求項7に記載の太陽電池モジュールの製造方法であって、前記太陽電池は、前記上側押圧部材及び下側押圧部材の位置まで搬送ベルトにより送られる。
- 請求項6ないし請求項8のいずれか1項に記載の太陽電池モジュールの製造方法であって、前記上側押圧部材及び下側押圧部材は、前記太陽電池の上側に位置する上側のヒートブロックと前記太陽電池の下側に位置する下側のヒートブロックで構成され、前記表面電極及び前記裏面電極と前記配線材とを固定する工程において、前記上側のヒートブロック及び前記下側のヒートブロックで前記配線材を加圧すると共に加熱する。
- 請求項8に記載の太陽電池モジュールの製造方法であって、前記搬送ベルトは、前記第2のクッションシートと前記下側のヒートブロックが挿入可能なスリットを有する。
- 請求項9に記載の太陽電池モジュールの製造方法であって、前記表面電極及び前記裏面電極と前記配線材とを固定する工程において、前記下側のヒートブロックの実温度を前記上側のヒートブロックの実温度をより高くして前記太陽電池と前記配線材を固定する。
- 請求項10または請求項11に記載の太陽電池モジュールの製造方法であって、前記第1のクッションシートを前記太陽電池から剥がす工程において、前記搬送ベルトにより、前記第2のクッションシートを太陽電池から引き剥がす。
- 請求項9に記載の太陽電池モジュールの製造方法であって、前記第2のクッションシートが前記太陽電池に貼りつく粘着力は、前記第1のクッションシートが前記太陽電池に貼りつく粘着力より大きい。
- 請求項13に記載の太陽電池モジュールの製造方法であって、前記第1のクッションシートはフッ素系のゴムシートまたはPETシートであり、前記第2のクッションシートはシリコンラバーシート、アクリル系のゴムシートである。
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JP5934985B2 (ja) * | 2012-07-31 | 2016-06-15 | パナソニックIpマネジメント株式会社 | 太陽電池モジュールの製造方法及び太陽電池モジュール |
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Also Published As
Publication number | Publication date |
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JP6064177B2 (ja) | 2017-01-25 |
US9530924B2 (en) | 2016-12-27 |
EP2634818A1 (en) | 2013-09-04 |
JP2016026406A (ja) | 2016-02-12 |
US20130237000A1 (en) | 2013-09-12 |
EP2634818B1 (en) | 2017-02-08 |
EP2634818A4 (en) | 2016-04-27 |
JP5899400B2 (ja) | 2016-04-06 |
JPWO2012057125A1 (ja) | 2014-05-12 |
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