WO2012077557A1 - 太陽電池モジュール、太陽電池モジュールの製造方法、太陽電池セル及びタブ線の接続方法 - Google Patents
太陽電池モジュール、太陽電池モジュールの製造方法、太陽電池セル及びタブ線の接続方法 Download PDFInfo
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- WO2012077557A1 WO2012077557A1 PCT/JP2011/077691 JP2011077691W WO2012077557A1 WO 2012077557 A1 WO2012077557 A1 WO 2012077557A1 JP 2011077691 W JP2011077691 W JP 2011077691W WO 2012077557 A1 WO2012077557 A1 WO 2012077557A1
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- tab wire
- solar cell
- electrode
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- solar
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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
- H01L31/04—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
-
- 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
-
- 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 solar cell module in which electrodes of a plurality of solar cells are connected by tab wires, a method for manufacturing a solar cell module, solar cells, and a method for connecting tab wires.
- 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.
- the tab wire is bonded to the surface electrode of one solar battery cell on one surface side of one end side, and to the back electrode of the adjacent solar battery cell on the other surface side of the other end side.
- 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 by a heating bonder from above the tab wire, so that the binder resin exhibits fluidity and the electrode and tab. While flowing out from between the wires, 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
- a width of about 50 to 200 ⁇ m for collecting current generated inside the solar cell by applying and baking Ag paste on the entire surface of the solar cell is formed, and then a plurality of bus bar electrodes having a width of about 1 to 3 mm for collecting the current collected by the finger electrodes are formed so as to cross the finger electrodes. Thereafter, a tab wire is connected on the bus bar electrode using a conductive adhesive film, and the solar cells are connected in series.
- the finger electrodes are crossed through the conductive adhesive film without providing the bus bar electrodes.
- a method of connecting tab wires directly has been proposed. In such a solar cell with a bus bar-less structure, the current collection efficiency is equal to or higher than that of the solar cell in which the bus bar electrode is formed.
- the adhesive region of the tab wire to the solar cell is offset from the outer edge of the solar cell toward the center of the cell, and the tab wire is heated at the outer edge of the cell. Measures not to be pressed are taken.
- the present invention prevents the occurrence of current collection loss while enjoying the above-mentioned advantages of the solar cells having the bus bar-less structure in which the tab wires are connected using the conductive adhesive film, and the photoelectric conversion efficiency is improved with the bus bar electrode. It aims at providing the solar cell module which can be equivalent to the used photovoltaic cell, the manufacturing method of a solar cell module, a photovoltaic cell, and the connection method of a tab wire.
- a solar cell module includes a plurality of solar cells in which a plurality of finger electrodes parallel to each other are provided over the entire surface and a back electrode is formed on the back surface, By being bonded across the plurality of finger electrodes and the back electrode, the tab wires that electrically connect the adjacent solar cells are interposed between the solar cells and the tab wires.
- an adhesive layer that adheres the tab wire to the finger electrode and the back electrode of the solar cell by being hot-pressed from above the tab wire, and the solar cell has an adhesive step of the tab wire In the non-thermal pressurization region, the non-thermal pressurization region where the tab wire is not hot-pressed and the hot-pressurization region where the tab wire is hot-pressed in the bonding step are formed. Collecting electrode intersecting the finger electrodes are formed.
- the method for manufacturing a solar cell module according to the present invention includes the above-described plurality of fingers of a plurality of solar cells in which a plurality of finger electrodes parallel to each other are provided over the entire surface and a back electrode is formed on the back surface.
- the method for manufacturing a solar cell module having a connection step of connecting a back electrode, a non-thermal pressurization region where the tab wire is not thermally pressurized in the tab wire bonding step, and a tab wire in the bonding step.
- the solar cell according to the present invention has a plurality of parallel finger electrodes formed over the entire surface and a back electrode formed on the back surface, and one of the adjacent solar cells.
- a solar battery cell in which a tab wire is bonded across the plurality of finger electrodes of the solar battery cell and the connection portion of the back electrode of the other solar battery cell, the solar battery cell is interposed between the solar battery cell and the tab wire.
- an adhesive layer that adheres the tab wire to the finger electrode and the back electrode of the solar cell by being hot-pressed from above the tab wire, and the tab wire is heated in the bonding step of the tab wire.
- the tab wire connecting method includes a plurality of finger electrodes of a plurality of solar cells in which a plurality of finger electrodes parallel to each other are provided over the entire surface and a back electrode is formed on the back surface.
- the tab wires are not subjected to heat pressure in the tab wire bonding step in advance.
- a collecting electrode that intersects the finger electrode formed in the non-thermal pressurization region is formed across the pressurization region and the hot pressurization region where the tab wire is thermally pressed in the bonding step.
- the collector electrode is formed over the region where the tab wire is not thermally pressed and the region where the tab wire is not heated, the occurrence of the current collection loss from the finger electrode provided in the region is prevented.
- the photoelectric conversion efficiency can be improved.
- 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 plan view showing a back electrode and a connection part of the solar battery cell.
- FIG. 4 is a cross-sectional view showing a conductive adhesive film.
- FIG. 5 is a diagram showing a conductive adhesive film wound in a reel shape.
- FIG. 6 is an exploded perspective view showing a solar battery cell to which the present invention is applied.
- FIG. 7 is a plan view showing a light receiving surface of a solar battery cell to which the present invention is applied.
- FIG. 8 is a cross-sectional view for explaining a formation region of the collecting electrode in a solar battery cell to which the present invention is applied.
- 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 plan view showing a back electrode and a connection part
- FIG. 9 is a side view showing a process in which the conductive adhesive film and the tab wire are temporarily press-bonded to the solar battery cell.
- FIG. 10 is a side view showing a process in which the conductive adhesive film and the tab wire are finally bonded to the solar battery cell.
- 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 a tab wire 3 serving as an interconnector.
- a matrix 5 in which a plurality of 4 are arranged 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.
- the photoelectric conversion element 10 is a single crystal silicon photoelectric conversion element, a crystalline silicon solar cell 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 a thin film silicon solar cell using the photoelectric conversion elements can be used.
- the photoelectric conversion element 10 is provided with finger electrodes 12 for collecting electricity generated inside on the light receiving surface side.
- the finger electrode 12 is formed by baking after the Ag paste is applied to the surface to be the light receiving surface of the solar battery cell 2 by screen printing or the like.
- the finger electrode 12 has a plurality of lines having a width of about 50 to 200 ⁇ m, for example, approximately parallel to each other at a predetermined interval, for example, every 2 mm, over the entire light receiving surface.
- 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 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 electrode 13 has a tab wire connecting portion 14 to which the tab wire 3 is connected via a conductive adhesive film 17 described later.
- the photovoltaic cell 2 is electrically connected to each finger electrode 12 formed on the surface by the tab wire 3 and the back electrode 13 of the adjacent photovoltaic cell 2, and thereby the strings connected in series. 4 is configured.
- the tab wire 3, the finger electrode 12 and the back electrode 13 are connected by a conductive adhesive film 17.
- the tab line 3 is made of a long conductive base material that electrically connects adjacent solar cells 2X, 2Y, and 2Z, and has a thickness of 50 to 300 ⁇ m, for example, which will be described later.
- a ribbon-like copper foil having substantially the same width as that of the conductive adhesive film 17 is used, and gold plating, silver plating, tin plating, solder plating, or the like is applied as necessary.
- the conductive adhesive film 17 is a thermosetting binder resin layer containing conductive particles 23 at a high density.
- the conductive adhesive film 17 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 17 is too low, the resin flows in the process of low pressure bonding to main curing, and connection failure or protrusion to the cell light receiving surface is likely to occur, which causes a decrease in the 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 for the conductive adhesive film 17 are not particularly limited, and examples thereof include metal particles such as nickel, gold, silver, and copper, those obtained by applying gold plating to resin particles, and gold plating on resin particles. And the like. In addition, by containing flat flaky metal particles as the conductive particles 23, 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 17 preferably has a viscosity of about 10 to 10000 kPa ⁇ s, more preferably 10 to 5000 kPa ⁇ s at around room temperature.
- the conductive adhesive film 17 has a viscosity in the range of 10 to 10,000 kPa ⁇ s, when the conductive adhesive film 17 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 17 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. 5 is a diagram schematically showing an example of a product form of the conductive adhesive film 17.
- the conductive adhesive film 17 is formed in a tape shape by laminating a binder resin layer on the release substrate 24. 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 17 may have a configuration 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 17 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 17 is finger-fed.
- the tab wire 3 and each of the electrodes 12 and 13 are connected by sticking on the connection portion 14 of the electrode 12 or the back electrode 13.
- conductive adhesive film having a film shape has been described, but there is no problem even if it is in a paste form.
- a film or paste-like adhesive containing conductive particles is defined as “conductive adhesive”.
- a film or paste adhesive that does not contain conductive particles is defined as an “insulating adhesive”.
- the conductive adhesive film 17 is not limited to a reel shape, and may be a strip shape.
- the viscosity of the conductive adhesive film 17 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 17 are stacked in a strip shape, deformation can be prevented and a predetermined dimension can be maintained.
- the conductive adhesive film 17 described above dissolves the conductive particles 23, the film-forming resin, the liquid epoxy resin, the latent curing agent, and the silane coupling agent in a solvent.
- a solvent toluene, ethyl acetate or the like, or a mixed solvent thereof can be used.
- a conductive adhesive film 17 is obtained by applying a resin-generating solution obtained by dissolution onto a release sheet and volatilizing the solvent.
- the conductive adhesive film 17 is cut into a predetermined length for two of the front electrode and two for the back electrode, and is temporarily attached to a predetermined position on the front and back surfaces of the solar battery cell 2.
- the conductive adhesive film 17 is temporarily pasted so as to be substantially orthogonal to each of the finger electrodes 12 that are formed in a plurality substantially parallel to the surface of the solar battery cell 2.
- the tab wire 3 cut to a predetermined length is superimposed on the conductive adhesive film 17.
- the conductive adhesive film 17 is heated and pressed at a predetermined temperature and pressure from above the tab wire 3 by a heating bonder, whereby the binder resin is cured and the conductive particles 23 are formed on the tab wire 3 and the finger electrode 12. Alternatively, it is sandwiched between the back electrode 13. Thereby, the conductive adhesive film 17 can be electrically connected to the tab wires 3 on each electrode while being adhered.
- the solar cell 2 generates stress when the tab wire 3 and the conductive adhesive film 17 are hot-pressed, a difference in linear expansion coefficient between the solar cell 2 and the tab wire 3, and expansion and contraction due to heating and cooling.
- the thermal pressurization region of the tab wire 3 to the solar battery cell 2 by the heating bonder is the outer edge of the solar battery cell 2. It is offset from the portion 2a toward the center of the cell.
- the tab wire 3 is not heated and pressed on the outer edge 2a side, the finger electrode 12 provided on the outer edge 2a side and the tab wire 3 are not conductively connected.
- the solar battery cell 2 extends over the non-thermal pressure region 2c where the tab wire 3 is not thermally pressurized by the heating bonder and the end of the thermal pressure region 2b where the tab wire 3 is thermally pressurized by the heating bonder.
- a current collecting electrode 30 orthogonal to the finger electrode 12 provided in the vicinity of the outer edge 2a is formed.
- the current collecting electrode 30 is formed by applying and baking Ag paste at a predetermined position of the surface electrode by screen printing or the like, for example. Further, not only the Ag paste but also any paste containing a conductive material such as Cu, Ni, Al can be used.
- the current collection electrode 30 and the tab wire 3 were two, it may not be restricted to this but may be three or more.
- the hot-pressing region 2b and the non-hot-pressing region 2c refer to regions extending between the opposing outer edges 2a of the solar cells 2 where the conductive adhesive film 17 and the tab wire 3 are disposed and bonded.
- the heat pressurization region 2b is subjected to heat pressurization to the solar cells 2 of the tab wires 3 by the heating bonder in the region for reasons such as cell crack prevention.
- the region offset from the edge 2a to the inside of the cell is referred to, and the non-thermal pressure region 2c refers to a region on the outer edge 2a side of the thermal pressure region 2b.
- the current collecting electrode 30 collects current from the finger electrode 12 in the non-thermal pressure region 2c where the tab wire 3 is not thermally pressurized, and includes a non-thermal pressure region 2c and end portions of the thermal pressure region 2b. And is connected to a tab wire 3 bonded to the heat and pressure region 2b.
- the photovoltaic cell 2 performs the current collection from the finger electrode 12 in the thermal pressurization area
- the solar battery cell 2 prevents the occurrence of current collection loss in the non-thermal pressure region 2c, and forms the photoelectric conversion efficiency over the entire region of the thermal pressure region 2b and the non-thermal pressure region 2c with the bus bar electrode. It is possible to make it equal to or greater than the solar cell.
- the solar cell 2 offsets the thermal pressurization region 2b of the tab wire 3 from the outer edge portion, stress is applied to the outer edge of the cell and there is no possibility of causing cell cracking. Furthermore, the solar battery cell 2 uses the silver paste used as the material of the bus bar electrode, as compared with the solar battery cell in which the bus bar electrode is formed over the entire region of the heat pressurization region 2b and the non-heat pressurization region 2c. The manufacturing cost can be reduced.
- the collector electrode 30 has a pair of outer edge portions in both the regions 2b and 2c.
- the formation region from the opposite outer edge portion 2a of the solar cell 2 to the cell inner side in the non-thermal pressure region 2c The distance between 2a is defined as 100%, and the area is 10% to 50% from each outer edge 2a of the solar battery cell 2 toward the inside of the cell. That is, as shown in FIG. 8, when the collecting electrode 30 is formed in a region of 10% inward from the outer edge 2 a, the collecting electrode 30 is in a region entering 5% from the pair of outer edges 2 a respectively. Is formed.
- the current collecting electrode 30 when the current collecting electrode 30 is formed in a region of 30% inward from the outer edge 2a, the current collecting electrode 30 is formed in a region 15% inward from each of the pair of outer edges 2a, and the outer edge 2a. In the case of forming in a 50% region from the inside to the inside, the region is formed in a region entering 25% from the pair of outer edge portions 2a.
- the photoelectric conversion efficiency is improved as the formation region between the two regions 2b and 2c of the collecting electrode 30 is reduced to 50%, 30%, and 10%. This is because, when the formation area of the current collecting electrode 30 is 10%, the outer edge 2a is formed about 5%, and the remaining 90% is thermally pressed to the finger electrode 12 and the tab wire. This is because the current collector 3 is directly connected, so that the current can be collected with less loss than that in which the current collecting electrode 30 is formed to be 30% or 50%.
- the heat-pressing region 2b shrinks from the outer edge 2a to the inside of the cell. It is possible to improve resistance to stress generated inside the cell in the heat pressurizing process, particularly resistance on the outer edge 2a side.
- the formation region of the current collecting electrode 30 is appropriately set according to the photoelectric conversion efficiency and the cell strength. However, when it is formed to exceed 50%, the photoelectric conversion efficiency is higher than that of the conventional pressurization region 2b and the bus bar electrode. Since the solar cell formed over the entire region of the non-thermally pressurized region 2c falls to the level of less than 10%, the thermally pressurized region 2b expands to the vicinity of the outer edge 2a. There are also fears.
- the manufacturing process of the solar cell module 1 will be described.
- the photoelectric conversion element 10 which comprises the photovoltaic cell 2 is prepared, the finger electrode 12 and the current collection electrode 30 are formed in the predetermined position of this surface, and the back surface electrode 13 is formed in the whole back surface.
- the finger electrode 12 is baked after the Ag paste is applied by screen printing or the like, so that a line having a width of, for example, about 50 to 200 ⁇ m is formed over the entire surface of the light receiving surface.
- a plurality are formed substantially in parallel at intervals, for example, every 2 mm.
- the collector electrode 30 is fired after the Ag paste is applied by screen printing or the like, so that it is 5 to 25% from the outer edge 2a in the thermal pressurization region 2b and the non-thermal pressurization region 2c to the inside of the cell.
- an electrode made of aluminum or silver is formed on the back surface of the solar battery cell 2 by, for example, screen printing or sputtering.
- a conductive adhesive film 17 is temporarily attached to the heat and pressure region 2 b of the solar battery cell 2 and the tab wire connection portion 14 of the back electrode 13.
- the conductive adhesive film 17 is at a temperature (for example, 40 to 60 ° C.) at which the thermosetting reaction of the binder does not proceed by the heating bonder for a predetermined time (for example, 1 to 5).
- Second is temporarily attached to the solar battery cell 2 by being thermally pressurized.
- the conductive adhesive film 17 is temporarily attached to the heat pressurizing region 2b offset inward from the outer edge portion, so that the end portions of the non-heat pressurizing region 2c and the heat pressurizing region 2b are provided. Temporarily affixing also on the current collection electrode 30 formed over.
- the solar cells 2 to which the conductive adhesive film 17 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 17 with respect to each of the solar cells 2 arranged at a predetermined position facing the pair of upper and lower temporary pressure-bonding heads 26.
- one end 3a of the tab wire 3 is temporarily pressure-bonded onto the uncured conductive adhesive film 17 temporarily attached to the surface of the preceding one solar cell 2X
- the other end 3b of the tab wire 3 is temporarily pressure-bonded onto the uncured conductive adhesive film 17 that is temporarily attached to the connection portion 14 of the back electrode 13 of another subsequent solar cell 2Y.
- Such a temporary crimping process is performed by the temporary crimping head 26.
- the temporary crimping head 26 is heated to a temperature at which the curing reaction of the conductive adhesive film 17 does not proceed and presses the tab wire 3. Therefore, the conductive adhesive film 17 temporarily fixes the tab wire 3 when the binder resin exhibits fluidity and exerts an adhesive force.
- the tab wires 3 are connected to the solar cells by the heating and pressing head 28.
- the conductive adhesive film 17 is hardened by final pressure bonding to each of the two electrodes 12, 13, and 30.
- the plurality of solar cells 2 are configured so that the preceding solar cell 2X is moved up and down in synchronization with the 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 17 is cured. Therefore, in the conductive adhesive film 17, the binder resin is thermally cured, and the tab wire 3 is electrically and mechanically connected to the finger electrode 12, the connection portion 14 of the back electrode 13, and the current collecting electrode 30.
- the pair of heating and pressing heads 28 are separated from the tab wire 3, and the subsequent solar cell 2Y 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 finger electrodes 12, the connection portions 14 of the back electrode 13, and the current collecting electrodes 30. And are connected in series with the adjacent solar cells 2.
- connection portion 14 and the tab wire 3 are connected by the conductive adhesive film 17, either Al or Ag can be used as the back electrode 13 of the solar battery cell 2.
- Al electrode As the back electrode 13, it is not necessary to provide a conventional Ag electrode for solder connection, so that the manufacturing process of the solar battery cell is shortened, and there are production technical advantages.
- connection between the tab wire 3 and the finger electrode 12, the connection part 14 of the back electrode 13, and the current collecting electrode 30 is performed using the conductive adhesive film 17, but the conductive resin is used as the binder resin. You may carry out using the insulating adhesive which does not mix
- Example 1 is a solar cell 2 in which the formation region of the collecting electrode 30 is 50%
- Example 2 is a solar cell 2 in which the formation region of the collecting electrode 30 is 30%.
- the formation region of the collecting electrode 30 in the solar battery cell 2 is 10%
- no conductive particles are contained as an adhesive layer connecting the tab wire 3 and the solar battery cell 2.
- the configuration was the same as in Example 2 except that an insulating adhesive film (NCF: Non-Conductive Film) provided with a binder resin was used.
- NCF Non-Conductive Film
- the photoelectric conversion efficiency was calculated based on JIS C8913 (Crystal solar cell output measurement method).
- Table 1 shows the measurement results. As shown in Table 1, in Examples 1 to 3, the photoelectric conversion efficiency (%) tended to increase as the formation region of the collecting electrode 30 decreased (50% ⁇ 30% ⁇ 10%). In addition, Example 4 in which the tab wire 3 was bonded using NCF also showed relatively good photoelectric conversion efficiency.
- the comparative example 1 is disadvantageous in that the amount of Ag paste used to form the bus bar electrode is increased and the manufacturing cost is increased as compared with the examples.
- the photoelectric conversion efficiency was further reduced as compared with each Example and Comparative Example 1.
- Comparative Example 2 in order to prevent so-called cell cracking, the thermal pressurization region of the tab wire by the heating bonder to the solar cell is offset from the outer edge of the solar cell toward the center of the cell. . Therefore, in the solar cell according to Comparative Example 2, since the tab wire is not heated and pressed on the outer edge side, the finger electrode provided on the outer edge side and the tab wire are not conductively connected, and the finger This is thought to be due to current collection loss from the electrodes.
- 1 solar cell module 1 solar cell module, 2 solar cells, 3 tab wires, 4 strings, 5 matrix, 6 sheets, 7 surface cover, 8 back sheet, 9 metal frame, 10 photoelectric conversion elements, 12 finger electrodes, 13 back electrodes, 14 tabs Wire connection part, 17 conductive adhesive film, 23 conductive particles, 24 peeling substrate, 25 reel, 26 temporary crimping head, 28 heating press head, 30 current collecting electrode
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Abstract
Description
本出願は、日本国において2010年12月7日に出願された日本特許出願番号特願2010-272837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。
本発明が適用された太陽電池モジュール1は、図1~図3に示すように、複数の太陽電池セル2がインターコネクタとなるタブ線3によって直列に接続されたストリングス4を有し、このストリングス4を複数配列したマトリクス5を備える。そして、太陽電池モジュール1は、このマトリクス5が封止接着剤のシート6で挟まれ、受光面側に設けられた表面カバー7及び裏面側に設けられたバックシート8とともに一括してラミネートされ、最後に、周囲にアルミニウムなどの金属フレーム9が取り付けられることにより形成される。
導電性接着フィルム17は、図4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17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17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。
ここで、太陽電池セル2は、加熱ボンダーによってタブ線3が熱加圧されない非熱加圧領域2cと加熱ボンダーによってタブ線3が熱加圧される熱加圧領域2bの端部とに亘って、外側縁部2a付近に設けられたフィンガー電極12と直交する集電電極30が形成されている。集電電極30は、例えばAgペーストがスクリーン印刷等により表面電極の所定位置に塗布、焼成されることにより形成される。また、Agペーストに限らず、Cu、Ni、Alなど導電性を有する材料を含有したペーストであれば使用可能である。なお、本実施の形態では、集電電極30及びタブ線3は、2本としたが、これに限らず、3本以上としてもよい。
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。先ず、太陽電池セル2を構成する光電変換素子10を用意し、この表面の所定の位置にフィンガー電極12及び集電電極30を形成し、裏面全面に裏面電極13を形成する。
Claims (16)
- 表面の全面に亘って互いに平行な複数のフィンガー電極が設けられるとともに裏面に裏面電極が形成された複数の太陽電池セルと、
複数の上記フィンガー電極と上記裏面電極とに亘って接着されることにより、隣接する上記各太陽電池セルを電気的に接続するタブ線と、
上記太陽電池セルと上記タブ線との間に介在され、上記タブ線上から熱加圧されることにより、上記タブ線を上記太陽電池セルの上記フィンガー電極及び上記裏面電極に接着する接着層とを備え、
上記太陽電池セルは、上記タブ線の接着工程において上記タブ線が熱加圧されない非熱加圧領域と、上記接着工程においてタブ線が熱加圧される熱加圧領域とに亘って、上記非熱加圧領域に形成された上記フィンガー電極と交差する集電電極が形成されている太陽電池モジュール。 - 上記集電電極は、上記太陽電池セルの対向する外側縁からの形成領域が、該太陽電池セルの上記外側縁部から内側に向かって10%~50%の領域となる請求項1記載の太陽電池モジュール。
- 上記接着層は、導電性粒子が分散されている導電性接着剤である請求項1又は請求項2に記載の太陽電池モジュール。
- 上記接着層は、導電性粒子を有しない絶縁性接着剤である請求項1又は請求項2に記載の太陽電池モジュール。
- 表面の全面に亘って互いに平行な複数のフィンガー電極が設けられるとともに裏面に裏面電極が形成された複数の太陽電池セルの、上記複数のフィンガー電極上及び上記裏面電極の接続部上に、接着剤を介してタブ線を配置する工程と、
上記タブ線上から熱加圧することにより上記接着剤を硬化させ、上記タブ線と上記フィンガー電極及び上記裏面電極とを接続する接続工程とを有する太陽電池モジュールの製造方法において、
予め、上記タブ線の接着工程において上記タブ線が熱加圧されない非熱加圧領域と、上記接着工程においてタブ線が熱加圧される熱加圧領域とに亘って、上記非熱加圧領域に形成された上記フィンガー電極と交差する集電電極を形成する工程を有する太陽電池モジュールの製造方法。 - 上記集電電極は、上記太陽電池セルの対向する外側縁からの形成領域が、該太陽電池セルの上記外側縁から内側に向かって10%~50%の領域となる請求項5記載の太陽電池モジュールの製造方法。
- 上記接着剤は、導電性粒子が分散されている導電性接着剤である請求項5又は請求項6に記載の太陽電池モジュールの製造方法。
- 上記接着剤は、導電性粒子を有しない絶縁性接着剤である請求項5又は請求項6に記載の太陽電池モジュールの製造方法。
- 表面の全面に亘って形成された互いに平行な複数のフィンガー電極と、
裏面に形成された裏面電極とを有し、
隣接する太陽電池セルのうち一方の太陽電池セルの上記複数のフィンガー電極と他方の太陽電池セルの上記裏面電極の接続部とに亘ってタブ線が接着される太陽電池セルにおいて、
上記太陽電池セルと上記タブ線との間に介在され、上記タブ線上から熱加圧されることにより、上記タブ線を上記太陽電池セルの上記フィンガー電極及び上記裏面電極に接着する接着層を備え、
上記タブ線の接着工程において上記タブ線が熱加圧されない非熱加圧領域と、上記接着工程においてタブ線が熱加圧される熱加圧領域とに亘って、上記非熱加圧領域に形成された上記フィンガー電極と交差する集電電極が形成されている太陽電池セル。 - 上記集電電極は、上記太陽電池セルの対向する外側縁からの形成領域が、該太陽電池セルの上記外側縁から内側に向かって10%~50%の領域となる請求項9記載の太陽電池セル。
- 上記接着層は、導電性粒子が分散されている導電性接着剤である請求項9又は請求項10に記載の太陽電池セル。
- 上記接着層は、導電性粒子を有しない絶縁性接着剤である請求項9又は請求項10に記載の太陽電池セル。
- 表面の全面に亘って互いに平行な複数のフィンガー電極が設けられるとともに裏面に裏面電極が形成された複数の太陽電池セルの、上記複数のフィンガー電極上及び上記裏面電極の接続部上に、接着剤を介してタブ線を熱加圧することにより接続する接続方法において、
予め、上記タブ線の接着工程において上記タブ線が熱加圧されない非熱加圧領域と、上記接着工程においてタブ線が熱加圧される熱加圧領域とに亘って、上記非熱加圧領域に形成された上記フィンガー電極と交差する集電電極を形成するタブ線の接続方法。 - 上記集電電極は、上記太陽電池セルの対向する外側縁からの形成領域が、該太陽電池セルの上記外側縁から内側に向かって10%~50%の領域となる請求項13記載のタブ線の接続方法。
- 上記接着剤は、導電性粒子が分散されている導電性接着剤である請求項13又は請求項14に記載のタブ線の接続方法。
- 上記接着剤は、導電性粒子を有しない絶縁性接着剤である請求項13又は請求項14に記載のタブ線の接続方法。
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP11847010.3A EP2650927A4 (en) | 2010-12-07 | 2011-11-30 | SOLAR CELL MODULE, METHOD FOR PRODUCING SOLAR CELL MODULE, SOLAR CELL, AND METHOD FOR CONNECTING LANGUAGE ELECTRIC WIRE |
KR1020137009546A KR101441264B1 (ko) | 2010-12-07 | 2011-11-30 | 태양전지 모듈, 태양전지 모듈의 제조 방법, 태양전지 셀 및 탭선의 접속 방법 |
CN201180057948.5A CN103222070B (zh) | 2010-12-07 | 2011-11-30 | 太阳能电池模块、太阳能电池模块的制造方法、太阳能电池单元以及接头线的连接方法 |
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JP2014232864A (ja) * | 2013-04-30 | 2014-12-11 | 日立化成株式会社 | 太陽電池モジュールの製造方法 |
JP2016100437A (ja) * | 2014-11-20 | 2016-05-30 | 日立化成株式会社 | 結晶系太陽電池モジュール及びその製造方法 |
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WO2015008610A1 (ja) * | 2013-07-19 | 2015-01-22 | 三洋電機株式会社 | 太陽電池モジュール |
JP6511736B2 (ja) * | 2014-06-20 | 2019-05-15 | 日立化成株式会社 | 太陽電池モジュールの製造方法 |
KR102233889B1 (ko) * | 2014-07-07 | 2021-03-30 | 엘지전자 주식회사 | 태양 전지 모듈과 그 제조 방법 |
EP3198655A4 (en) * | 2014-10-31 | 2017-11-22 | BYD Company Limited | Solar cell array, solar cell module and manufacturing method thereof |
WO2016131222A1 (zh) * | 2015-02-16 | 2016-08-25 | 保定市易通光伏科技有限公司 | 光伏组件及其制造方法 |
CN104701418A (zh) * | 2015-03-17 | 2015-06-10 | 福建铂阳精工设备有限公司 | 一种晶硅电池组件的互联方法 |
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JP2014232864A (ja) * | 2013-04-30 | 2014-12-11 | 日立化成株式会社 | 太陽電池モジュールの製造方法 |
JP2016100437A (ja) * | 2014-11-20 | 2016-05-30 | 日立化成株式会社 | 結晶系太陽電池モジュール及びその製造方法 |
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EP2650927A1 (en) | 2013-10-16 |
JP2012124277A (ja) | 2012-06-28 |
TWI495122B (zh) | 2015-08-01 |
KR101441264B1 (ko) | 2014-09-18 |
CN103222070B (zh) | 2016-08-10 |
EP2650927A4 (en) | 2016-02-24 |
KR20130056338A (ko) | 2013-05-29 |
JP5480120B2 (ja) | 2014-04-23 |
CN103222070A (zh) | 2013-07-24 |
TW201230363A (en) | 2012-07-16 |
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