WO2013002243A1 - 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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- WO2013002243A1 WO2013002243A1 PCT/JP2012/066338 JP2012066338W WO2013002243A1 WO 2013002243 A1 WO2013002243 A1 WO 2013002243A1 JP 2012066338 W JP2012066338 W JP 2012066338W WO 2013002243 A1 WO2013002243 A1 WO 2013002243A1
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- Prior art keywords
- solar cell
- tab wire
- terminal box
- film
- current collecting
- 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
- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
- H01L31/0201—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising specially adapted module bus-bar structures
-
- 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
- H01L31/0445—PV modules or arrays of single PV cells including thin film solar cells, e.g. single thin film a-Si, CIS or CdTe solar cells
- H01L31/046—PV modules composed of a plurality of thin film solar cells deposited on the same substrate
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/10—Frame structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- 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 having a positive electrode and a negative electrode facing one side and provided with a terminal box tab wire, and more particularly, to a connection between a terminal box tab wire and a current collecting tab wire for electrode extraction. .
- This application claims priority on the basis of Japanese Patent Application No. 2011-141986 filed on Jun. 27, 2011 in Japan. This application is incorporated herein by reference. Incorporated.
- thin-film solar cells in which a semiconductor layer, which is a photoelectric conversion layer, is formed on a substrate such as glass or stainless steel will be thin and light, low in manufacturing cost, and easy to increase in area. It is considered to become the mainstream of solar cells.
- These thin-film solar cells are obtained by laminating a semiconductor layer or a metal electrode film on an inexpensive substrate with a large area using a forming apparatus such as a plasma CVD apparatus or a sputtering apparatus, and then producing the photoelectric conversion on the same substrate.
- the solar cell string is formed by separating and connecting the layers by laser patterning or the like.
- FIG. 7 shows an example of the configuration of a thin-film solar cell constituting a conventional solar cell string.
- the thin-film solar cell 100 includes a plurality of solar cells 102 in which a transparent electrode film made of a transparent conductive film (not shown), a photoelectric conversion layer, and a back electrode film are stacked on a light-transmitting insulating substrate 101.
- Each solar battery cell 102 has a long and narrow strip shape, and has a length extending over almost the entire width of the translucent insulating substrate 101.
- the thin-film solar battery 100 is configured such that a plurality of solar battery cells 102 are connected in series by connecting one transparent electrode film and the other back electrode film between adjacent solar battery cells 102 and 102. Has been.
- a linear P-type electrode terminal portion 103 having substantially the same length as the solar cell 102 is formed.
- a linear N-type electrode terminal portion 104 having substantially the same length as that of the solar battery cell 102 is formed.
- the P-type electrode terminal portion 103 and the N-type electrode terminal portion 104 are electrode extraction portions.
- the positive electrode current collecting tab wire 105 made of copper foil is electrically and mechanically bonded to the entire surface of the P-type electrode terminal portion 103 called a bus bar.
- a negative electrode current collecting tab wire 106 made of copper foil is electrically and mechanically bonded to the entire surface of the N-type electrode terminal portion 104 to the N-type electrode terminal portion 104.
- a terminal box 110 connected to the P-type electrode terminal portion 103 and the N-type electrode terminal portion 104 and outputting electricity to the outside, and this terminal A terminal box tab wire 111 that connects the box 110 to the P-type electrode terminal portion 103 and the N-type electrode terminal portion 104 is connected.
- the terminal box 110 is fixed to the center of the back surface of the thin-film solar cell 100 through an insulating adhesive, for example.
- the terminal box tab wire 111 is made of a long copper foil or Al foil, like the positive electrode current collecting tab wire 105 or the negative electrode current collecting tab wire 106, and the back surface of the thin film solar cell 100 and the insulating tape 112 are connected to each other. It is arranged via.
- the terminal box tab wire 111 has one end soldered to the terminal box 110 and the other end disposed on the P-type electrode terminal portion 103 or the N-type electrode terminal portion 104 via the insulating tape 112.
- connection portion between the terminal box tab wire 111 and the positive electrode current collecting tab wire 105 is connected to both sides of the insulating tape 112 and the terminal box tab wire 111.
- the third positive electrode current collecting tab wire 105c is connected across the insulating tape 112 and the terminal box tab wire 111 between the second positive electrode current collecting tab wires 105a and 105b.
- the third positive electrode current collecting tab wire 105 c is connected to the terminal box tab wire 111.
- the connection (one place) with the tab wire 111 is performed by ultrasonic soldering.
- the connection between the negative electrode current collecting tab wire 106 and the terminal box tab wire 111 is the same.
- the P-type electrode terminal portion 103 and the N-type electrode terminal portion 104 are formed of various materials such as Al, Ag, and ZnO depending on the manufacturing method, configuration, and the like.
- the connection strength between the electric tab wire 105 and the negative electrode current collecting tab wire 106 cannot be maintained. For this reason, there exists a possibility of causing the raise of connection resistance value and the fall of power generation efficiency.
- connection between the first and second positive current collecting tab wires 105a and 105b and the third positive current collecting tab wire 105c, and the third positive current collecting tab wire 105c and the terminal box tab wire 111 are provided.
- the heat history in the high temperature region accompanying the solder connection is locally applied, so that the translucent insulating substrate 101 made of glass or the like may be warped or damaged.
- an object of the present invention is to provide a solar cell module and a method for manufacturing the solar cell module that can prevent the connection strength of the tab wire for the terminal box and the warp and breakage of the light-transmitting insulating substrate.
- a solar cell module includes a solar cell in which a positive electrode and a negative electrode are disposed on one surface, and a conductive adhesive layer containing conductive particles.
- a pair of power extraction tab wires connected on the positive electrode and the negative electrode and an insulating adhesive layer not containing conductive particles are provided on one surface of the solar cell, and one end is on the positive electrode and the negative electrode.
- the manufacturing method of the solar cell module which concerns on this invention is a pair of terminal box via the insulating adhesive layer which does not contain electroconductive particle on the said surface of the solar cell by which the positive electrode and the negative electrode are arrange
- end portions of the tab wires for the terminal box are disposed on the positive electrode and the negative electrode through the insulating adhesive layer, and a pair of power extraction tab wires are electrically conductive.
- the terminal box tab is connected to the positive electrode and the negative electrode of the solar cell via the conductive adhesive layer containing particles, and is connected to the positive electrode and the negative electrode via the conductive adhesive layer. Connect on the end of the wire.
- the contact area between the terminal box tab wire and the power extraction tab wire via the conductive adhesive layer Increase in connection strength and increase in resistance value can be prevented.
- FIG. 1 is a view showing a solar cell to which the present invention is applied, in which (A) is a perspective view showing a state before connection of tab wires, and (B) is a plan view showing a state in which tab wires are connected. It is.
- FIG. 2 is an exploded perspective view of the solar cell module.
- FIG. 3 is a cross-sectional view showing a connection portion between a current collecting tab line and a terminal box tab line.
- FIG. 4 is a cross-sectional view showing the configuration of the conductive adhesive film.
- FIG. 5 is a cross-sectional view showing a current collecting tab line to which a conductive adhesive film is attached.
- FIG. 6 is a cross-sectional view showing another configuration example of the insulating adhesive layer.
- FIG. 1 is a view showing a solar cell to which the present invention is applied, in which (A) is a perspective view showing a state before connection of tab wires, and (B) is a plan view showing a state in which tab wire
- FIG. 7 is an exploded perspective view showing an example of a conventional thin film solar cell.
- 8A and 8B are diagrams showing an example of a conventional thin film solar cell, where FIG. 8A is a plan view and FIG. 8B is a cross-sectional view at an electrode terminal portion.
- a thin film solar cell 1 to which the present invention is applied constitutes a solar cell string in which a plurality of solar cells 2 are connected by contact lines.
- the thin-film solar cell 1 having this string structure is composed of a single piece or a matrix in which a plurality of pieces are connected together with a sealant sheet 3 and a backsheet 5 provided on the back surface side.
- the solar cell module 6 is formed by laminating together.
- the solar cell module 6 is appropriately attached with a metal frame 7 such as aluminum around it.
- sealing agent for example, a translucent sealing material such as ethylene vinyl acetate resin (EVA) is used.
- EVA ethylene vinyl acetate resin
- back sheet 5 a laminated body in which glass or aluminum foil is sandwiched between resin films is used.
- a transparent electrode film made of a transparent conductive film, a photoelectric conversion layer, and a back electrode film are laminated in this order on a translucent insulating substrate 8 although not shown.
- This is a super-straight type solar cell in which light is incident from the translucent insulating substrate 8 side.
- a substrate type solar cell formed in order of the base material, the back surface electrode, the photoelectric converting layer, and the transparent electrode in the thin film solar cell.
- the super straight type thin film solar cell 1 will be described as an example, but the present technology can also be used for a substrate type thin film solar cell.
- a heat resistant resin such as glass or polyimide can be used.
- the transparent electrode film for example, SnO 2 , ZnO, ITO or the like can be used.
- a silicon-based photoelectric conversion film such as amorphous silicon, microcrystalline silicon, or polycrystalline silicon, or a compound-based photoelectric conversion film such as CdTe, CuInSe 2 , or Cu (In, Ga) Se 2 can be used. .
- the back electrode film has a laminated structure of a transparent conductive film and a metal film.
- a transparent conductive film For the transparent electrode film, SnO 2 , ZnO, ITO, or the like can be used. Silver, aluminum, or the like can be used for the metal film.
- the thin-film solar cell 1 configured in this way has a plurality of rectangular solar cells 2 having a length extending over almost the entire width of the light-transmitting insulating substrate 8.
- Each solar battery cell 2 is separated by an electrode dividing line, and one transparent electrode film and the other back electrode film are connected to each other in the adjacent solar battery cells 2 and 2 by a contact line.
- a solar battery string in which the solar battery cells 2 are connected in series is configured.
- the thin-film solar cell 1 is formed with a linear P-type electrode terminal portion 9 having substantially the same length as the solar cell 2 on the end of the transparent electrode film of the solar cell 2 at one end of the solar cell string.
- a linear N-type electrode terminal portion 10 having substantially the same length as that of the solar battery cell 2 is formed on the end of the back electrode film of the solar battery cell 2 at the other end.
- the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 serve as an electrode extraction portion, and electricity is supplied to the terminal box 23 through the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15. Supply.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are formed by, for example, slitting a copper foil or aluminum foil rolled to a thickness of 50 to 300 ⁇ m, or rolling a thin metal wire such as copper or aluminum into a flat plate shape. By doing so, it is a rectangular wire having a width of 1 to 3 mm which is substantially the same width as the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10.
- the positive current collecting tab wire 11 is electrically and mechanically joined to the P-type electrode terminal portion 9 via the conductive adhesive layer 16, and the negative current collecting tab wire 15 is connected to the N-type electrode terminal portion 10. Electrically and mechanically joined through the conductive adhesive layer 16.
- the conductive adhesive layer 16 is provided on each surface 11 a, 15 a of the positive current collecting tab wire 11 and the negative current collecting tab wire 15.
- the conductive adhesive layer 16 is provided on the entire surfaces 11 a and 15 a of the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15, and is composed of, for example, a conductive adhesive film 17.
- the conductive adhesive film 17 includes a thermosetting binder resin layer 18 containing conductive particles 19 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 19 used for the conductive adhesive film 17 are not particularly limited.
- 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.
- the conductive particles may be a powder in which one particle or one particle exists individually, but it is preferable that the conductive particles have a chain shape in which primary particles are connected.
- An example of the former is a spherical nickel powder having spike-like protrusions, and an example of the latter that is preferably used is a filamentous nickel powder.
- the conductive particles 19 have elasticity, the connection reliability between the positive electrode current collector tab wire 11 and the P-type electrode terminal portion 9 having different physical properties, and the negative electrode current collector tab wire 15 and the N-type electrode. Connection reliability with the terminal portion 10 can be improved.
- the conductive adhesive film 17 preferably has a viscosity of about 10 to 10,000 kPa ⁇ s, more preferably 10 to 5,000 kPa ⁇ s near normal temperature. Since the conductive adhesive film 17 has a viscosity in the range of 10 to 10000 kPa ⁇ s, the conductive adhesive film 17 is provided on one surface 11a, 15a of the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 15, and the reel In the case of being wound around 21, blocking due to so-called protrusion can be prevented, and a predetermined tack force can be maintained.
- composition of the binder resin layer 18 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, and a silane. Containing a coupling 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 thermosetting latent curing agent is suitably used, and the main curing is performed by heating and pressing the bus bar electrode 11 and the back electrode 13.
- a latent curing agent made of imidazoles, amines, sulfonium salts, onium salts, or 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 18 on a peeling substrate 20.
- the tape-like conductive adhesive film 17 is wound and laminated on the reel 21 so that the peeling substrate 20 is on the outer peripheral side.
- the peeling base material 20 PET (Poly * Ethylene * Terephthalate), OPP (Oriented * Polypropylene), PMP (Poly-4-methlpentene-1), PTFE (Polytetrafluoroethylene) etc. can be used.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 described above are integrally laminated on the binder resin layer 18.
- the conductive adhesive film 17 is laminated by laminating a binder resin layer 18 on a wide ribbon copper foil, and further slitting it with a slitter.
- the electroconductive adhesive film 17 with a peeling base material is laminated
- the peeling substrate 20 is peeled off in actual use.
- the positive electrode current collecting tab wire 11, the negative electrode current collecting tab wire 15, and each electrode are obtained by sticking the binder resin layer 18 of the conductive adhesive film 17 onto the P-type electrode terminal portion 9 or the N-type electrode terminal portion 10. Temporary pasting with the terminal portions 9 and 10 is achieved.
- the conductive adhesive film 17 described above dissolves conductive particles 19, 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 solution for resin production obtained by dissolving is applied on the peeling substrate 20 and the solvent is volatilized to obtain the conductive adhesive film 17. Thereafter, as described above, the conductive adhesive film 17 is laminated and integrated on one surface 11a, 15a of the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 15, and the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 11 is integrated.
- the electric tab wire 15 is formed over the entire surface 11a, 15a.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are placed on the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 via the conductive adhesive film 17 provided on one surface 11a, 15a. Temporarily pasted. At this time, as will be described later, one end 24 a of the terminal box tab wire 24 is temporarily installed on the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 via the insulating adhesive layer 22. .
- the thin-film solar cell 1 has the conductive adhesive film 17, the positive electrode current collecting tab wire 11, the negative electrode current collecting tab wire 15, and the terminal.
- the box tab wires 24 are heat-pressed by a vacuum laminator and connected together.
- the conductive adhesive film 17 is thermally pressed at a predetermined temperature and pressure by a vacuum laminator, so that the binder resin becomes between the P-type electrode terminal portion 9 and the positive electrode current collecting tab wire 11 and N And the conductive particles 19 are sandwiched between the current collecting tab wires 11 and 15 and the electrode terminal portions 9 and 10 and are discharged from between the mold electrode terminal portion 10 and the negative electrode current collecting tab wire 15, In this state, the binder resin is cured. Thereby, the conductive adhesive film 17 adheres the current collecting tab wires 11 and 15 to the electrode terminal portions 9 and 10, and also collects the current collecting tab wires 11 and 15 and the electrode terminal portions 9 and 10. Can be electrically connected.
- the conductive adhesive layer 16 may not be laminated in advance on the one surface 11 a or 15 a of the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 15.
- the conductive adhesive layer 16 may use a paste-like conductive adhesive paste in addition to the film-like conductive adhesive film.
- the film-like conductive adhesive film 17 containing the conductive particles 19 and the paste-like conductive adhesive paste are defined as “conductive adhesive”.
- Such a conductive adhesive layer 16 has a predetermined length corresponding to the P-type electrode terminal portion 9 or the N-type electrode terminal portion 10 when the conductive adhesive film 17 is joined to the positive electrode current collecting tab wire 11 or the like. And is temporarily attached on the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 of the thin-film solar cell 1. Alternatively, the conductive adhesive layer 16 is applied with a conductive adhesive paste on the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10. Next, the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 cut to a predetermined length are placed on the conductive adhesive layer 16 so as to be conductively connected by being thermally pressurized.
- Terminal box On the back electrode film of the thin-film solar cell 1, a terminal box 23 that is electrically connected to the positive current collecting tab wire 11 and the negative current collecting tab wire 15 via the terminal box tab wire 24 is provided. ing. The terminal box 23 is electrically connected to an external output line, and supplies the power collected by the positive current collecting tab wire 11 and the negative current collecting tab wire 15 to the outside.
- the terminal box 23 is fixed on the back electrode film of the thin-film solar cell 1 through an insulating adhesive film 25 whose details are omitted.
- the insulating adhesive film 25 has substantially the same components as the above-described conductive adhesive film 17 except that the conductive particles 19 are not included, and the binder resin layer is thermally cured to make the terminal box 23 a thin film solar cell. 1 is fixed on the back electrode film. Insulating adhesive film 25 does not react with the back electrode film even when temporarily bonded on the back electrode film of thin-film solar cell 1 by mixing a chemically stable fluorine-based resin. Corrosion can be prevented.
- the terminal box 23 is provided on the back electrode film of the thin-film solar cell 1 at a position along substantially the middle in the width direction orthogonal to the longitudinal direction of the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15. Accordingly, the terminal box tab wires 24 of the same size can be used on the positive electrode current collecting tab wire 11 side and the negative electrode current collecting tab wire 15 side.
- the terminal box tab wire 24 for connecting the terminal box 23 with the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 is the same as the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15.
- it is a rectangular wire obtained by slitting a copper foil or an aluminum foil rolled to a thickness of 50 to 300 ⁇ m, or by rolling a thin metal wire such as copper or aluminum into a flat plate shape.
- the terminal box tab wire 24 is provided on the back electrode film of the thin-film solar cell 1 through the insulating adhesive layer 22.
- the terminal box tab wire 24 is prevented from short-circuiting with the back electrode film of the thin film solar cell 1 by interposing the insulating adhesive layer 22 between the back electrode film of the thin film solar cell 1.
- the insulating adhesive layer 22 is provided over the entire surface in advance in contact with the back electrode film of the thin film solar cell 1 of the terminal box tab wire 24, for example, by an insulating adhesive film 25. Composed.
- the insulating adhesive film 25 has the same configuration as that of the conductive adhesive film 17 except that the binder resin layer does not contain conductive particles.
- the insulating adhesive layer 22 is constituted by a flexible substrate 31 with an insulating adhesive layer 30 or a film 33 with an insulating adhesive layer 32 as shown in FIG. 6 in addition to the insulating adhesive film 25. May be.
- the flexible substrate 31 and the film 33 are provided with insulating adhesive layers 30 and 32 on one surface to which at least the terminal box tab wire 24 is connected.
- the adhesive layer 34 it is optional to form the adhesive layer 34 on the other surface facing the back electrode film of the thin film solar cell 1, and the Si-based adhesive is used as the adhesive layer 34 formed on the other surface. You may make it lightly stop on the back surface electrode film of the thin film solar cell 1 using an agent.
- the insulating adhesive layer 22 such as the insulating adhesive film 25 preferably has a width equal to or larger than the width of the terminal box tab wire 24. Thereby, the insulating adhesive film 25 can insulate the tab wire 24 for terminal boxes and the back surface electrode film of the thin film solar cell 1 reliably.
- At least a pair of terminal box tab wires 24 are provided on the back electrode film of the thin-film solar cell 1, one of which connects the P-type electrode terminal 9 and the terminal box 23, and the other of which is the N-type electrode terminal 10 and the terminal.
- the box 23 is connected.
- the terminal box tab wire 24 has one end 24 a disposed on the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10, and the other end 24 b connected to the terminal box 23.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are superimposed on the one end 24 a via the conductive adhesive layer 16.
- the P-type electrode terminal portion 9 and the N-type electrode terminal portion. 10 is connected to one end 24a of a terminal box tab wire 24 via an insulating adhesive layer 22 such as an insulating adhesive film 25, and conductive adhesive such as the conductive adhesive film 17 on the side surface and upper surface of the one end 24a.
- the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 15 is connected through the agent layer 16.
- the thin-film solar cell 1 has the terminal box tab wire 24 and the positive electrode current collecting tab through the conductive adhesive film 17 as compared with the configuration in which the terminal box tab wire is connected to the current collecting tab wire.
- the contact area with the wire 11 or the negative electrode current collecting tab wire 15 is increased, so that the connection strength can be improved and the resistance value can be prevented from increasing.
- the thin film solar cell 1 connects the terminal box tab wire 24, the positive electrode current collector tab wire 11 and the negative electrode current collector tab wire 15 in a lump using a vacuum laminator, air bubbles are mixed in the connection location.
- the connection reliability can be improved over a long period of time.
- a terminal box tab wire 24 in which an insulating adhesive layer 22 such as an insulating adhesive film 25 is formed on one surface in advance is temporarily pasted on the back electrode film of the thin-film solar cell 1, and one end 24 a of the tab wire 24 is P This is performed by temporarily pasting on the mold electrode terminal portion 9 and the N-type electrode terminal portion 10. Further, in this step, after the insulating adhesive film 25 is temporarily attached along the connection portion of the terminal box tab wire 24 on the back electrode film of the thin film solar cell 1, the insulating film 25 is used on the insulating adhesive film 25. You may carry out by sticking the tab line 24 temporarily.
- the terminal box tab wire 24 to which the insulating adhesive film 25 is attached, and the temporary attachment of the insulating adhesive film 25 and the terminal box tab wire 24 are adhered to such an extent that the insulating adhesive film 25 is not fully cured by roll lamination. It is carried out by applying heat and pressure until it exhibits the characteristics. Further, the terminal box tab wire 24 is connected to the terminal box 23 after the other end 24b is made conductive by peeling off the insulating adhesive layer 22 by using a blade and heat.
- Insulating adhesive layer 22 such as insulating adhesive film 25 is formed to have a width equal to or larger than the width of terminal box tab wire 24, so that insulating adhesive layer 22 is formed into a thin film and terminal box tab wire 24.
- the back electrode film of the solar cell 1 can be reliably insulated.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are connected to the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 through the conductive adhesive layer 16, and the P-type.
- the terminal box tab wire 24 is connected to one end 24 a via the conductive adhesive layer 16.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 in which the conductive adhesive layer 16 such as the conductive adhesive film 17 is formed on one surface in advance are formed on the P-type electrode terminal portion 9 and the N-type.
- This is performed by temporarily attaching the conductive adhesive layer 16 on the electrode terminal portion 10 and on one end 24a of the terminal box tab wire 24 disposed on the electrode terminal portions 9 and 10.
- this process is performed by conducting conductive bonding on the P-type electrode terminal portion 9, the N-type electrode terminal portion 10, and one end 24 a of the terminal box tab wire 24 disposed on the electrode terminal portions 9, 10.
- the positive electrode current collecting tab wire 11 or the negative electrode current collecting tab wire 15 may be temporarily installed on the conductive adhesive film 17.
- the conductive adhesive film 17 is fully cured by roll lamination. It is carried out by applying heat and pressure until it exhibits tackiness to such an extent that it does not.
- the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are temporarily installed across the one end 24 a of the terminal box tab wire 24 through the conductive adhesive film 17.
- the thin film solar cell 1 to which the insulating adhesive film 25, the terminal box tab wire 24, the conductive adhesive film 17, the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 are temporarily attached is the back electrode.
- the sheet 3 and the back sheet 5 of a light-transmitting sealing material such as EVA provided on the film side they are laminated together by a vacuum laminator.
- the insulating adhesive film 25 is thermally cured to connect the terminal box tab wire 24 onto the back electrode film of the thin film solar cell 1.
- the one end 24 a is connected to the P-type electrode terminal portion 9 or the N-type electrode terminal portion 10.
- each binder resin of the conductive adhesive film 17 flows, and the conductive particles 19 are sandwiched between the positive electrode current collecting tab wire 11 and one end 24a of the P-type electrode terminal portion 9 and the terminal box tab wire 24. In this state, the binder resin is cured.
- the conductive particles 19 are sandwiched between the negative electrode current collecting tab wire 15 and one end 24a of the N-type electrode terminal portion 10 and the terminal box tab wire 24, and the binder resin is cured in this state.
- the conductive adhesive film 17 allows the positive electrode current collecting tab wire 11 and the negative electrode current collecting tab wire 15 to adhere to the P-type electrode terminal portion 9 and the N-type electrode terminal portion 10 and to be electrically connected.
- the positive current collecting tab wire 11 and the negative current collecting tab wire 15 can be electrically connected to the terminal box tab wire 24.
- the terminal box tab wire 24, the positive current collecting tab wire 11, and the negative current collecting tab wire 15 can be efficiently connected. Moreover, according to this technique, compared with the process connected by heat-pressing the positive electrode current collection tab wire 11 or the negative electrode current collection tab wire 15 with a heating press head etc., local thermal pressurization is applied. There is nothing. Therefore, there is no possibility that the translucent insulating substrate 10 is warped or damaged. In particular, as shown in FIG. 3, since the portion to which one end 24 a of the terminal box tab wire 24 is connected protrudes from the other portions, the terminal box tab is thermally pressed by a heat pressing head or the like.
- Sample 1 used was a tab wire made of an electrolytic copper foil having a width of 10 mm and a thickness of 35 ⁇ m.
- Sample 2 used a tab wire made of an electrolytic copper foil having a width of 10 mm and a thickness of 35 ⁇ m, in which a PET film having a thickness of 25 ⁇ m to 50 ⁇ m was pasted as an insulating adhesive layer on one side.
- Sample 3 was a tab wire made of an electrolytic copper foil having a width of 10 mm and a thickness of 120 ⁇ m solder-plated on both sides by about 15 ⁇ m.
- Sample 4 was a tab wire made of an electrolytic copper foil having a width of 10 mm and a thickness of 150 ⁇ m solder-plated on both sides by about 15 ⁇ m.
- an electrolytic copper foil having a thickness of 35 ⁇ m and a width of 2.0 mm coated with a conductive adhesive resin was used.
- the coated surface of the conductive adhesive resin is subjected to a surface roughening treatment with a surface roughness Rz of 7 to 9 ⁇ m (GTS-MP: manufactured by Furukawa Electric Co., Ltd.).
- GTS-MP manufactured by Furukawa Electric Co., Ltd.
- each of the above samples was temporarily attached to a glass substrate with a pressure-sensitive adhesive by roll lamination while being heated to about 95 ° C., and then the current collecting tab wire was temporarily attached to the glass substrate by roll lamination while being heated to about 95 ° C. . At this time, the current-collecting tab wires are in contact with each other so as to straddle each sample through the conductive adhesive resin.
- the glass substrate is vacuum laminated with a sealing resin (EVA), and each sample is connected to the current collecting tab wire (connection area: 2). .0 mm ⁇ 10 mm), four connected body samples were prepared.
- EVA sealing resin
- connection resistance value in a state where 1 A was energized was measured in each connection body sample, all were 10 m ⁇ or less. That is, it has been found that the connection between the current collecting tab wire and the terminal box tab wire via the conductive adhesive resin is a connection method that can be replaced with a conventional solder connection.
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Abstract
Description
本出願は、日本国において2011年6月27日に出願された日本特許出願番号特願2011-141986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薄膜太陽電池1は、図1(A)(B)に示すように、複数の太陽電池セル2がコンタクトラインによって接続された太陽電池ストリングを構成する。図2に示すように、このストリング構造を有する薄膜太陽電池1は、単体で、又は複数枚連結されたマトリクスを構成して、裏面側に設けられた封止剤のシート3およびバックシート5とともに一括してラミネートされることにより太陽電池モジュール6が形成される。なお、太陽電池モジュール6は、適宜、周囲にアルミニウムなどの金属フレーム7が取り付けられる。
本発明が適用された薄膜太陽電池1は、透光性絶縁基板8上に、図示は省略しているが、透明導電膜からなる透明電極膜、光電変換層、裏面電極膜がこの順に積層されて形成され、透光性絶縁基板8側から光を入射させるスーパーストレート型の太陽電池である。なお、薄膜太陽電池には、基材、裏面電極、光電変換層、透明電極の順で形成されたサブストレート型太陽電池もある。以下では、スーパーストレート型の薄膜太陽電池1を例に説明するが、本技術は、サブストレート型の薄膜太陽電池に用いることもできる。
正極集電用タブ線11及び負極集電用タブ線15は、例えば厚さ50~300μmに圧延された銅箔やアルミ箔をスリットし、あるいは銅やアルミなどの細い金属ワイヤーを平板状に圧延することにより、P型電極端子部9やN型電極端子部10とほぼ同じ幅の1~3mm幅の平角線である。
図3に示すように、導電性接着剤層16は、正極集電用タブ線11及び負極集電用タブ線15の各一面11a,15aに設けられている。導電性接着剤層16は、正極集電用タブ線11及び負極集電用タブ線15の一面11a,15aの全面に設けられ、例えば導電性接着フィルム17によって構成される。
また、導電性接着剤層16は、正極集電用タブ線11や負極集電用タブ線15の一面11a,15aに予め積層されていなくともよい。この場合、導電性接着剤層16は、フィルム状の導電性接着フィルムの他、ペースト状の導電性接着ペーストを用いてもよい。
また、薄膜太陽電池1の裏面電極膜上には、正極集電用タブ線11及び負極集電用タブ線15と端子ボックス用タブ線24を介して電気的に接続する端子ボックス23が設けられている。端子ボックス23は、外部出力線が電気的に接続され、正極集電用タブ線11及び負極集電用タブ線15が集電した電力を外部に供給する。
端子ボックス23と正極集電用タブ線11及び負極集電用タブ線15とを接続する端子ボックス用タブ線24は、上記正極集電用タブ線11や負極集電用タブ線15と同様に、例えば厚さ50~300μmに圧延された銅箔やアルミ箔をスリットし、あるいは銅やアルミなどの細い金属ワイヤーを平板状に圧延した平角線である。
次いで、正極集電用タブ線11、負極集電用タブ線15と及び端子ボックス用タブ線24の接続工程について説明する。先ず、薄膜太陽電池1の裏面電極膜上に絶縁性接着剤層22を介して一対の端子ボックス用タブ線24を配設するとともに、絶縁性接着剤層22を介して端子ボックス用タブ線24の一端24aをP型電極端子部9上及びN型電極端子部10上に配設する。
Claims (11)
- 一面に正極及び負極が配置されている太陽電池と、
導電性粒子を含有した導電性接着剤層を介して上記太陽電池の正極上及び負極上に接続された一対の電力取出し用タブ線と、
導電性粒子を含有しない絶縁性接着剤層を介して上記太陽電池の一面上に設けられるとともに、一端が上記正極上及び負極上に配設され、端子ボックスと一対の上記電力取出し用タブ線とを接続する一対の端子ボックス用タブ線とを備え、
電力取出し用タブ線は、上記正極上及び負極上において、端子ボックス用タブ線の上記一端に、上記導電性接着剤層を介して接続されている太陽電池モジュール。 - 一対の上記端子ボックス用タブ線は上記正極上又は負極上に設けられ、
一対の上記電力取出し用タブ線は、上記端子ボックス用タブ線の端部上を跨って設けられている請求項1記載の太陽電池モジュール。 - 上記導電性粒子は、フィラメント状の導電性粒子である請求項1又は請求項2に記載の太陽電池モジュール。
- 上記電力取出し用タブ線と、上記端子ボックス用タブ線とは、ラミネートにより一括して接続される請求項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。
- 上記絶縁性接着剤層は、接着剤付きフィルム又は接着剤付きフレキシブル基板である請求項1~請求項4のいずれか1項に記載の太陽電池モジュール。
- 上記端子ボックス用タブ線は、上記絶縁性接着剤層の幅以下の幅である請求項1~請求項5のいずれか1項に記載の太陽電池モジュール。
- 上記導電性接着剤層は、フッ素系樹脂を含有する請求項1~請求項6のいずれか1項に記載の太陽電池モジュール。
- 一面に正極及び負極が配置されている太陽電池の上記一面上に、導電性粒子を含有しない絶縁性接着剤層を介して一対の端子ボックス用タブ線を配設するとともに、上記絶縁性接着剤層を介して上記正極上及び負極上に上記端子ボックス用タブ線の端部を配設し、
一対の電力取出し用タブ線を、導電性粒子を含有した導電性接着剤層を介して、上記太陽電池の上記正極上及び負極上に接続するとともに、上記正極上及び負極上において、上記導電性接着剤層を介して上記端子ボックス用タブ線の上記端部上に接続する太陽電池モジュールの製造方法。 - 上記一面に端子ボックスを固定し、
一対の上記端子ボックス用タブ線の各端部を上記端子ボックスに接続する請求項8記載の太陽電池モジュールの製造方法。 - 上記電力取出し用タブ線と、上記端子ボックス用タブ線とは、ラミネートにより一括して接続される請求項8又は請求項9に記載の太陽電池モジュールの製造方法。
- 上記電力取出し用タブ線は、予め上記導電性接着剤層が設けられ、
上記端子ボックス用タブ線は、予め上記絶縁性接着剤層が設けられている請求項8~請求項10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。
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US14/127,626 US20140124034A1 (en) | 2011-06-27 | 2012-06-27 | Solar cell module and solar cell module manufacturing method |
EP12805080.4A EP2725626A1 (en) | 2011-06-27 | 2012-06-27 | Solar cell module and solar cell module manufacturing method |
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US10790777B2 (en) * | 2017-08-17 | 2020-09-29 | Tesla, Inc. | Flexible solar roofing modules |
US10862420B2 (en) | 2018-02-20 | 2020-12-08 | Tesla, Inc. | Inter-tile support for solar roof tiles |
JP7373658B2 (ja) * | 2019-10-25 | 2023-11-02 | ファースト・ソーラー・インコーポレーテッド | 光起電力デバイスおよび製作方法 |
CN114664953B (zh) * | 2020-11-30 | 2024-03-29 | 晶科能源(海宁)有限公司 | 太阳能电池组件、太阳能电池片及其制造方法 |
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EP2725626A1 (en) | 2014-04-30 |
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JP5745349B2 (ja) | 2015-07-08 |
JP2013008922A (ja) | 2013-01-10 |
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