WO2013014723A1 - Solar cell module and method for producing same - Google Patents

Solar cell module and method for producing same Download PDF

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Publication number
WO2013014723A1
WO2013014723A1 PCT/JP2011/066669 JP2011066669W WO2013014723A1 WO 2013014723 A1 WO2013014723 A1 WO 2013014723A1 JP 2011066669 W JP2011066669 W JP 2011066669W WO 2013014723 A1 WO2013014723 A1 WO 2013014723A1
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WO
WIPO (PCT)
Prior art keywords
solar cell
resin composition
wiring
cell module
resin
Prior art date
Application number
PCT/JP2011/066669
Other languages
French (fr)
Japanese (ja)
Inventor
俊行 佐久間
Original Assignee
三洋電機株式会社
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Filing date
Publication date
Application filed by 三洋電機株式会社 filed Critical 三洋電機株式会社
Priority to PCT/JP2011/066669 priority Critical patent/WO2013014723A1/en
Publication of WO2013014723A1 publication Critical patent/WO2013014723A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • 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
    • H01L31/02—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
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • 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 and a manufacturing method thereof.
  • Patent Document 1 discloses a form in which an insulator is disposed on the outer peripheral portion of one of the stacked wiring members to prevent electrical contact between one wiring member and the other wiring member.
  • the solar cell and the wiring material are sealed with a filler to prevent moisture from entering them.
  • a solar cell module uses two resin films as fillers, and laminates the solar cells with the film. When laminating, the resin film melts and adheres to the surface of the solar cell or wiring material, but if there are gaps along the surface direction of the resin film, such as between overlapping wiring materials, the solar cell is less likely to contain the filler. Gaps may remain inside the module. If it does so, there exists a possibility that the reliability of a solar cell module may fall.
  • the solar cell module according to the present invention includes a plurality of solar cells, a plurality of first wiring members that connect the solar cells, and a plurality of first wiring members that are connected to the first wiring member and guide the output of the solar cells to the outside.
  • 2 wiring material and a filler for sealing the solar cell, the first wiring material, and the second wiring material, the second wiring material is disposed so that a part thereof overlaps, and the filling material overlaps the first It is provided between the two wiring members without a gap.
  • a method for manufacturing a solar cell module according to the present invention is connected to a plurality of solar cells, a plurality of first wiring members that connect solar cells to each other, and a first wiring member, and guides the output of the solar cells to the outside.
  • a method for manufacturing a solar cell module comprising a plurality of second wiring members and a solar cell, a first wiring member, and a filler for sealing the second wiring member, wherein a part of the second wiring members overlap each other.
  • a step of arranging the second wiring material a step of inserting a resin member constituting a part of the filler between the overlapping second wiring materials, and a part of the filler on the light receiving surface of the solar cell
  • a step of laminating the first resin film constituting the second resin film constituting a part of the filler on the back surface of the solar cell, the resin member, the first resin film, and the second resin film Are thermocompression bonded to each other so that the solar cell, the first wiring material, and And a step of sealing the second wiring member.
  • the solar cell module according to the present invention it is possible to suppress a decrease in reliability.
  • FIG. 4 is an enlarged view of a part B in FIG. 3, illustrating an example of a configuration of a filler. It is the B section enlarged view of Drawing 3, and is a figure showing other examples of composition of a filler. It is a figure for demonstrating the manufacturing method of the solar cell module which is embodiment which concerns on this invention.
  • the solar cell module 10 which is embodiment which concerns on this invention is demonstrated in detail.
  • the present invention is not limited to the following embodiments.
  • the drawings referred to in the embodiments are schematically described, and the dimensional ratios of the components drawn in the drawings may be different from the actual products. Specific dimensional ratios and the like should be determined in consideration of the following description.
  • FIG. 1 is a plan view of the solar cell module 10 viewed from the light receiving surface side
  • FIG. 2 is a plan view of the solar cell module 10 viewed from the back surface side
  • FIG. 3 is a view showing a part of a cross section taken along the line AA of FIGS. 1 and 2 and showing a cross section of a portion where the second wiring members 19 overlap each other.
  • the solar cell module 10 includes a plurality of solar cells 11, a first protective member 12 disposed on the light receiving surface side of the solar cell 11, and a second protective member 13 disposed on the back surface side of the solar cell 11. That is, the solar cell 11 is sandwiched between the first protective member 12 and the second protective member 13.
  • the light receiving surfaces of the plurality of solar cells 11 are arranged side by side on the same plane.
  • the “light receiving surface” means a surface on which sunlight mainly enters from the outside of the solar cell 11. For example, more than 50% to 100% of the sunlight incident on the solar cell 11 enters from the light receiving surface side.
  • the “back surface” means a surface opposite to the light receiving surface.
  • the solar cell 11 includes a photoelectric conversion unit 30 which generates carriers (electrons and holes) by receiving sunlight, a light receiving surface electrode 31 provided on the light receiving surface of the photoelectric conversion unit 30, and the photoelectric conversion unit 30. And a back electrode 32 provided on the back surface. In the solar cell 11, carriers generated by the photoelectric conversion unit 30 are collected by the light receiving surface electrode 31 and the back surface electrode 32.
  • the photoelectric conversion unit 30 includes, for example, a semiconductor substrate such as a crystalline silicon substrate, a gallium arsenide (GaAs) substrate, or an indium phosphide (InP) substrate.
  • a semiconductor substrate such as a crystalline silicon substrate, a gallium arsenide (GaAs) substrate, or an indium phosphide (InP) substrate.
  • B p-type amorphous material doped with boron
  • a silicon layer was sequentially formed, and an i-type amorphous silicon layer and an n-type amorphous silicon layer doped with phosphorus (P) or the like were sequentially formed on the back surface of the n-type
  • An i-type amorphous silicon layer and an n-type amorphous silicon layer doped with phosphorus (P) or the like are sequentially formed on the light-receiving surface of the n-type single crystal silicon substrate.
  • a structure in which an i-type amorphous silicon layer and a p-type amorphous silicon layer doped with boron (B) or the like are sequentially formed on the back surface of the substrate.
  • the light receiving surface electrode 31 preferably includes a transparent conductive layer formed on the light receiving surface of the photoelectric conversion unit 30.
  • a transparent conductive layer As the transparent conductive layer, a transparent conductive oxide (TCO) in which tin (Sn), antimony (Sb), or the like is doped into a metal oxide such as indium oxide (In 2 O 3 ) or zinc oxide (ZnO) is applied. it can.
  • TCO transparent conductive oxide
  • the transparent conductive layer is preferably formed on the entire front and back surfaces of the photoelectric conversion unit 30.
  • the light receiving surface electrode 31 includes a plurality of (for example, 50) finger electrodes 33 and a plurality (for example, two) of bus bar electrodes 34.
  • the finger electrode 33 and the bus bar electrode 34 are preferably formed on the transparent conductive layer.
  • the finger electrode 33 is a thin line electrode that collects carriers from the entire photoelectric conversion unit 30.
  • the bus bar electrode 34 is an electrode wider than the finger electrode 33 and mainly collects carriers from the finger electrode 33.
  • the finger electrode 33 and the bus bar electrode 34 are arranged so as to cross each other and are electrically connected. These are formed, for example, by screen-printing a conductive paste in which conductive particles such as silver (Ag) are dispersed in a binder resin in a desired pattern on the light receiving surface of the photoelectric conversion unit 30.
  • the back surface electrode 32 preferably includes a plurality of finger electrodes 35, a plurality of bus bar electrodes 36, and a transparent conductive layer.
  • the number of the finger electrodes 35 may be set larger than that of the finger electrodes 33 and the interval may be set narrower.
  • a metal film such as a silver (Ag) thin film may be formed instead of the finger electrode 35.
  • the first protective member 12 a transparent substrate or film, for example, a glass substrate, a resin substrate, a resin film, or the like can be used.
  • the second protective member 13 the same glass substrate, resin substrate, resin film and the like as the first protective member 12 can be used.
  • the second protection member 13 may be an opaque substrate or film, and may be a metal substrate such as an aluminum plate, for example.
  • a filler 14 is provided between the first protective member 12 and the second protective member 13.
  • the filler 14 has a function of sealing the solar cell 11 and the like.
  • the filler 14 includes a first resin composition 15, a second resin composition 16, and a third resin composition 17, which will be described in detail later.
  • the solar cell module 10 further includes a first wiring member 18 that electrically connects the solar cells 11, and a second wiring member 19 that is electrically connected to the first wiring member 18 (part of which is the solar cell 11. ), A terminal portion 20 for electrically connecting the second wiring member 19 and an external device (not shown), and the first protection member 12 and the second protection. A frame 21 or the like attached to the end of the member 13 is provided.
  • the four second wiring members 19 (19a to 19d) and the lead wires extending from the external device are electrically connected.
  • the first wiring member 18 electrically connects the solar cells 11 together to form the string S.
  • the string S is a plurality of solar cells 11 connected in series and arranged in a row.
  • the solar cell module 10 includes a plurality of strings S, and FIG. 1 shows a configuration in which six strings S (S1 to S6) each having four solar cells 11 connected in series are arranged in parallel with each other. ing.
  • the first wiring member 18 is connected to, for example, the light receiving surface electrode 31 of one of the solar cells 11 disposed adjacent to the first wiring member 18 and connected to the back surface electrode 32 of the other solar cell 11. More specifically, the first wiring member 18 is soldered or resin-bonded to the bus bar electrode 34 of the light receiving surface electrode 31 of one solar cell 11 and the bus bar electrode 36 of the back surface electrode 32 of the other solar cell 11. Connected. That is, the 1st wiring material 18 bends in the thickness direction of the solar cell module 10 between the adjacent solar cells 11, and connects the adjacent solar cells 11 in series.
  • the second wiring member 19 includes second wiring members 19e to 19g for connecting adjacent strings S and the second wiring members 19a to 19d for electrically connecting the string S and the terminal portion 20.
  • Each of the plurality of second wiring members 19 is arranged close to the end of the string S so as to intersect the longitudinal direction of each string S and not touch the string S.
  • the first wiring member 18 and the second wiring member 19 are orthogonal to each other, the end of the first wiring member 18 extending from each string S, the second wiring member 19, Is connected.
  • the connection between the first wiring member 18 and the second wiring member 19 is made by soldering or a resin adhesive.
  • the second wiring material 19e connects the strings S1 and S2, the second wiring material 19f connects the strings S3 and S4, and the second wiring material 19g connects the strings S5 and S6.
  • the second wiring member 19a connects the string S1 and the terminal portion 20, and the second wiring member 19d connects the string S6 and the terminal portion 20, respectively.
  • the second wiring member 19b connects the string S2 and the string S3 and is also connected to the terminal unit 20.
  • the second wiring member 19c connects the string S4 and the string S5 and is also connected to the terminal portion 20.
  • the second wiring members 19a to 19d have a shape in which one end connected to the terminal portion 20 is bent in an L shape.
  • An insulating member 22 such as an insulating tape is attached to the portion bent in the L shape, and the insulation between the second wiring members 19a to 19d and the solar cell 11 is ensured.
  • the second wiring member 19 is arranged so that a part thereof overlaps with each other in order to increase the power generation amount per unit area and improve the module efficiency.
  • the second wiring members 19 connected to the terminal portion 20 are arranged so as to overlap each other, and the second wiring member 19a and the second wiring member 19b, and the second wiring member 19c and the second wiring member 19d. Respectively overlap in the thickness direction of the module.
  • the width of each of the second wiring members 19 can be set to be the same, and a portion where the second wiring members 19 overlap (hereinafter also referred to as “overlapping portion”) is viewed in plan view from the light receiving surface side and the back surface side. It is preferable to arrange them so that they appear as one when they are.
  • the filler 14 is inserted between the second wiring material 19a and the second wiring material 19b, and between the second wiring material 19c and the second wiring material 19d so as to be in close contact with each wiring material without any gap.
  • the terminal portion 20 is formed with openings for drawing out the second wiring members 19a to 19d to the outside. That is, a through hole is formed in the second protection member 13.
  • the terminal portion 20 includes, for example, a terminal block for connecting the second wiring members 19a to 19d and lead wires extending from the external device, and a terminal box that covers the terminal block and the opening. The opening is sealed with an appropriate sealing material as necessary so that moisture does not enter.
  • FIGS. 4 and 5 are both enlarged views of part B in FIG.
  • the form illustrated in FIG. 4 is different from the form illustrated in FIG. 5 only in the shape of the layer made of the third resin composition 17.
  • the filler 14 is provided in close contact not only with the solar cell 11 but also with the first wiring member 18 and the second wiring member 19.
  • the filler 14 includes a first resin composition 15 that covers the light receiving surface side of the solar cell 11, a second resin composition 16 that covers the back surface side of the solar cell 11, and an overlapping second wiring material 19. It is comprised including the 3rd resin composition 17 inserted without gap between them. Then, the second resin composition 16, the third resin composition 17, and the first resin composition 15 are laminated in this order from the second protective member 13 side. As will be described later, by using an appropriate resin composition, there is no gap at the interface of each layer, and good adhesiveness is exhibited.
  • the “gap” is a gap that can be detected by cross-sectional observation with a scanning electron microscope (SEM). Specifically, it means a gap having a maximum length of 50 nm or more. That is, in the solar cell module 10, it means that there is no gap of at least a maximum length of 50 nm or more between the overlapping second wiring members 19.
  • SEM scanning electron microscope
  • the first resin composition 15 is provided in layers so as to cover the light receiving surface side of all the solar cells 11.
  • the layer made of the first resin composition 15 has substantially the same area as the first protective member 12.
  • the 2nd resin composition 16 covers the back side of all the solar cells 11, and is provided in layered form.
  • the layer made of the second resin composition 16 has substantially the same area as the second protective member 13. Further, the thickness of each layer is preferably about 0.2 mm to 1.0 mm, for example, about 0.4 mm to 0.8 mm.
  • the third resin composition 17 is inserted without a gap between portions where the first resin composition 15 and the second resin composition 16 cannot enter, that is, between the overlapping second wiring members 19. Has the function of preventing mechanical contact. Moreover, the 3rd resin composition 17 has a function which prevents that the gap
  • the third resin composition 17 is provided so as to protrude from between the overlapping second wiring material 19a and the second wiring material 19b and between the overlapping second wiring material 19c and the second wiring material 19d. Is preferred. That is, the third resin composition 17 is provided in a wider range than the range where the second wiring members 19 overlap each other. In the present embodiment, the width (length in the short direction) and the length (length in the longitudinal direction) of the layer made of the third resin composition 17 are larger than the width and length of the overlapping portion, and from the entire periphery of the overlapping portion. It protrudes (see FIG. 1).
  • the width of the layer made of the third resin composition 17 is wider than the width of the second wiring member 19, for example, within a range not in contact with the string S and the frame 21.
  • the width of the material 19 is preferably 1.1 times or more, more preferably 1.5 times or more, and more than 2.0 times.
  • the layer made of the third resin composition 17 is arranged substantially parallel to the surface direction of the module. This form is formed, for example, when the melting point of the third resin composition 17 is higher than that of the first resin composition 15 and the second resin composition 16. Further, the second wiring members 19a and 19b are embedded in the third resin composition 17 and are in close contact with each other. In this embodiment, for example, the third resin composition 17 having a thickness larger than the distance between the second wiring member 19a and the second wiring member 19b that is overlapped is pushed into the third resin composition 17 in the thermocompression bonding step. Obtained by melting.
  • a part of the layer made of the third resin composition 17 is bent or curved toward the first protective member 12 side. More specifically, the portion protruding from the overlapping portion is unevenly distributed on the layer side made of the first resin composition 15.
  • the contact area between the portion protruding from the overlapping portion and the first resin composition 15 is larger than the contact area between the portion protruding from the overlapping portion and the second resin composition 16. This form is formed by arranging and laminating the first resin composition 15 on the vertically lower side, for example.
  • the solubility parameter (SP value) of both compositions is close, at least It is preferable that the main components are the same. In other words, it is preferable that the portion of the third resin composition 17 that protrudes from the overlapping portion is unevenly distributed on the resin composition side where the SP value is close to the first resin composition 15 and the second resin composition 16. .
  • Each resin composition constituting the filler 14 is, for example, a resin having high adhesion to the solar cell 11, the first wiring member 18, and the second wiring member 19 without melting in an environment irradiated with sunlight. It is preferable to use as a main component. Moreover, it is preferable that the resin as the main component is difficult to contain water.
  • the “main component” means a component having the largest weight ratio (% by weight) in the resin composition.
  • Each resin composition may be a composition composed of a plurality of resins, but from the viewpoint of productivity, etc., the resin as the main component (hereinafter also simply referred to as “main component”) is 50% by weight. % Or more of the composition is preferred. Furthermore, since it is suitable that the SP value of the composition is close, the proportion of the main component in the resin composition is more preferably 70% by weight or more, and particularly preferably 90% by weight or more.
  • Each resin composition can contain various additives. Additives include antioxidants, ultraviolet absorbers, weather resistance imparting agents, silane coupling agents, crosslinking agents, crosslinking aids (catalysts), tackifiers, white pigments such as titanium oxide (TiO 2 ), and the like. It can be illustrated. When light reception from the back surface side is not assumed, for example, by adding titanium oxide (TiO 2 ) to the second resin composition 16, the reflectance of light on the back surface side of the solar cell 11 is increased and the solar cell 11. The light receiving efficiency can be improved.
  • Additives include antioxidants, ultraviolet absorbers, weather resistance imparting agents, silane coupling agents, crosslinking agents, crosslinking aids (catalysts), tackifiers, white pigments such as titanium oxide (TiO 2 ), and the like. It can be illustrated. When light reception from the back surface side is not assumed, for example, by adding titanium oxide (TiO 2 ) to the second resin composition 16, the reflectance of light on the back surface
  • Each resin composition preferably has an SP value of 7.0 to 11.0, more preferably 7.3 to 10.0, from the viewpoint of moisture content and adhesion to the solar cell 11 and the like. It is particularly preferably 7.5 to 9.0. And the difference of each SP value of each resin composition is preferably less than 1.5, more preferably less than 1, and particularly preferably less than 0.5. If the difference in the SP value is within this range, the adhesiveness between the resin compositions is further improved, so that generation of a gap due to peeling of the layer interface or the like can be highly suppressed.
  • Each resin composition further preferably has a softening temperature of 60 ° C. to 150 ° C., particularly 65 ° C. to 130 ° C., from the viewpoints of heat resistance and productivity that do not melt in the use environment. preferable. And it is preferable that the softening temperature of each resin composition is mutually substantially the same.
  • the “softening temperature” is defined as a temperature at which a predetermined deformation occurs when a certain load is applied to the test sample.
  • the “substantially the same” softening temperature means that they can be regarded as the same or substantially the same, and specifically means that the difference in softening temperature is within a range of about 10%.
  • the melting points of the resin compositions are preferably substantially the same (the difference in melting point is within a range of about 10%).
  • the main component of the third resin composition 17 is preferably substantially the same as at least one of the main component of the first resin composition 15 and the main component of the second resin composition 16.
  • the main component of the first resin composition 15 and the main component of the third resin composition 17 are substantially the same, and the main component of the second resin composition 16 and the main component of the third resin composition 17 are different.
  • the main components of each resin composition are substantially the same. From the viewpoint of productivity, it is preferable that the main components of each resin composition are substantially the same.
  • the third resin composition 17 can be substantially the same as at least one of the first resin composition 15 and the second resin composition 16, that is, the entire composition including the additive can be made substantially the same.
  • the 1st resin composition 15 and the 3rd resin composition 17 are substantially the same, and the 2nd resin composition 16 and the 3rd resin composition 17 differ, or each resin composition is mutually substantially the same.
  • the filler 14 is composed of a single resin composition, and exhibits, for example, a single layer structure. Even when the filler 14 is composed of a single resin composition, as will be described later, if the filler 14 is formed by laminating three members, the interface of each member remains and the same kind of laminated structure is formed. May present.
  • the phrase “substantially the same” for the resin composition or its main component means that it can be regarded as the same or substantially the same as described above.
  • the difference in the copolymerization ratio of monomers constituting the main component is within a range of about 5%, and the difference in molecular weight (for example, weight average molecular weight). Is within the range of about 5%.
  • the case where the resin compositions can be regarded as substantially the same can be exemplified by the fact that the difference in the proportion of the weight of each constituent component is within the range of about 5%.
  • a polyolefin resin obtained by polymerizing at least one selected from ⁇ -olefins having 2 to 20 carbon atoms (for example, polyethylene (PE), polypropylene (PP), ethylene, etc.) And other ⁇ -olefin random or block copolymers), polyester resins (eg, polycondensates of polyols with polycarboxylic acids or their acid anhydrides / lower alkyl esters), polyurethane resins (eg, polyisocyanates) And active hydrogen group-containing compounds (such as polyaddition products of diols, polyol riols, dicarboxylic acids, polycarboxylic acids, polyamines, polythiols, etc.), epoxy resins (for example, polyepoxide ring-opening polymers, polyepoxides and active hydrogen groups) Polyaddition product with compound) And a copolymer (e.g., EVA or ion
  • those suitable as the main component are polyolefin resins, copolymers of alpha olefins with vinyl carboxylates, acrylate esters, or other vinyl monomers (for example, EVA and ionomers), especially polyolefins. Resins are preferred.
  • polyethylene including copolymers of ethylene and other ⁇ -olefins is particularly preferable.
  • each resin composition for example, all are composed mainly of polyolefin resin, all are composed mainly of polyolefin resin, and only second resin composition 16 contains titanium oxide (TiO 2 ).
  • Configuration, or configuration in which second resin composition 16 and third resin composition 17 contain titanium oxide (TiO 2 ), first resin composition 15 and second resin composition 16 are polyolefin resins, and third resin composition The structure etc. which make the thing 17 crosslinkable resin, such as EVA, can be illustrated.
  • FIG. 6 is a cross-sectional view showing each member constituting the solar cell module 10.
  • FIG. 6 shows a state in which the third resin composition 17 is inserted and laminated between the overlapping second wiring members 19.
  • the solar cell module 10 is preferably manufactured by a laminating process in which the constituent members are laminated and thermocompression bonded.
  • the first resin composition 15 and the second resin composition 16 are in the form of a film having a thickness of about 0.1 mm to 1.0 mm (hereinafter referred to as a first resin film 15p and a second resin film 16p, respectively).
  • the third resin composition 17 is supplied in the form of a small resin piece (hereinafter referred to as a resin member 17p) larger than the overlapping portion.
  • the solar cell 11 is manufactured by a known method (a detailed description of the manufacturing process of the solar cell 11 is omitted).
  • the 1st wiring material 18 is attached to the light-receiving surface electrode 31 and the back surface electrode 32 of the solar cell 11, and the several solar cell 11 arrange
  • a plurality of strings S are obtained.
  • the second wiring member 19 is attached to the first wiring member 18 extending from the end of the string S, and the strings S are electrically connected.
  • a part of the strings S and the terminal block of the terminal portion 20 are electrically connected by the second wiring member 19.
  • a part of the second wiring member 19a and a part of the second wiring member 19b, and a part of the second wiring member 19c and a part of the second wiring member 19d are overlapped in the thickness direction of the module. Be placed. In this way, a structure is obtained in which a part of the second wiring material 19 is arranged to overlap each other.
  • the resin member 17p is inserted between the overlapping second wiring material 19a and the second wiring material 19b and between the overlapping second wiring material 19c and the second wiring material 19d.
  • the resin member 17p a member larger than the overlapping portion is used, and a part thereof is inserted so as to protrude from the periphery between the overlapping second wiring members 19. If inserted in this way, even if the resin member 17p or the second wiring member 19 is misaligned in the laminating process or the like, the third resin composition 17 has no gap between the overlapping second wiring members 19. Can be filled.
  • the first resin film 15p is laminated on the first protective member 12, and the solar cell 11 is laminated on the first resin film 15p.
  • the second resin film 16p is laminated on the solar cell 11, and the second protective member 13 is laminated on the second resin film 16p. And it laminates by applying a pressure from the 2nd protective member 13 side, heating at the temperature which the 1st resin film 15p, the 2nd resin film 16p, and the resin member 17p fuse
  • the first resin film 15p, the second resin film 16p, and the resin member 17p are in close contact with each other without gaps, and the solar cell 11, the first protection member 12, the second protection member 13, and the first wiring member. 18 and the second wiring member 19 are also in close contact with each other without a gap.
  • a structure in which the solar cell 11 and the like are sealed with the filler 14 is obtained.
  • the first protective member 12 / first resin film 15p / solar cell 11 / second resin film 16p / second protective member 13 are stacked in this order to form a laminate, for example, in a vacuum state,
  • the laminate is integrated by thermocompression bonding.
  • the temperature of the hot plate for compressing the laminate is set to be equal to or higher than the melting temperature of each resin composition (for example, about 150 ° C.). Since the resin member 17p is inserted between the second wiring member 19a and the second wiring member 19b and between the second wiring member 19c and the second wiring member 19d, there is a gap between the overlapping portions.
  • a filler 14 is provided.
  • the solar cell module 10 a part of the second wiring material 19 is arranged so as to overlap in the thickness direction of the module. Thereby, the power generation amount per unit area can be increased and the module efficiency can be improved.
  • the filler 14 is inserted between the overlapping second wiring members 19 in close contact with the second wiring members 19 without any gaps. Thereby, while being able to ensure the insulation of the 2nd wiring materials 19 which overlap, mixing of impurities, such as a water
  • the solar cell 11 may have a so-called back junction structure in which the light receiving surface electrode 31 is not provided and an electrode is formed only on the back surface of the photoelectric conversion unit 30. Also in this case, a plurality of second wiring members 19 for guiding the output of the solar cell 11 to the outside are used. Then, a part of the second wiring material 19 is arranged so as to overlap each other in the thickness direction of the module, and a structure in which the filler 14 is inserted between the overlapping second wiring materials 19 without a gap can be formed.
  • the third resin composition 17 is described as protruding from the entire periphery of the overlapping portion.
  • the third resin composition 17 is provided so as to protrude from a part of the periphery of the overlapping portion. Form may be sufficient.

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Abstract

In order to minimize the occurrence of gaps that can become paths for humidity and the like in a module in a structure in which wiring materials for increasing the production of electricity per unit area are disposed in an overlapping manner, a solar cell module (10) is provided with: a plurality of solar cells (11); a plurality of first wiring materials (18) that electrically connect the solar cells (11); a plurality of second wiring materials (19) that are electrically connected to the first wiring materials (18), and lead the output of the solar cells (11) to the outside; and a filler (14) for sealing the solar cells (11), the first wiring materials (18), and the second wiring materials (19). The second wiring materials (19) are disposed in such a manner that a portion of the second wiring materials (19) are overlapping. The filler (14) is provided to the second wiring materials (19) such that there are no gaps between the overlapping second wiring materials (19).

Description

太陽電池モジュール及びその製造方法Solar cell module and manufacturing method thereof
　本発明は、太陽電池モジュール及びその製造方法に関する。 The present invention relates to a solar cell module and a manufacturing method thereof.
　太陽電池モジュールには、単位面積当たりの発電量を高めてモジュール効率を向上させることが求められている。このような状況に鑑みて、太陽電池のストリング同士を接続する配線材を互いに重ね合わせて配置した太陽電池モジュールが提案されている（例えば、特許文献１参照）。特許文献１では、重ね合わせた一方の配線材の外周部に絶縁物を配置して、一方の配線材と他方の配線材との電気的な接触を防止する形態が開示されている。 Solar cell modules are required to increase the power generation per unit area and improve module efficiency. In view of such a situation, a solar cell module in which wiring materials for connecting strings of solar cells are arranged so as to overlap each other has been proposed (for example, see Patent Document 1). Patent Document 1 discloses a form in which an insulator is disposed on the outer peripheral portion of one of the stacked wiring members to prevent electrical contact between one wiring member and the other wiring member.
特開平９‐２６０７０７号公報JP-A-9-260707
　ところで、太陽電池モジュールでは、太陽電池や配線材を充填材で封止して、これらに水分が浸入することを防止している。一般的に、太陽電池モジュールは、充填材として２枚の樹脂フィルムを使用し、該フィルムで太陽電池をラミネートする。ラミネート時に樹脂フィルムが溶融して太陽電池や配線材の表面に密着するが、重なり合う配線材の間など、樹脂フィルムの面方向に沿った間隙が存在すると、そこには充填材が入り込み難く太陽電池モジュールの内部に隙間が残る場合がある。そうすると、太陽電池モジュールの信頼性が低下する恐れがある。 By the way, in the solar cell module, the solar cell and the wiring material are sealed with a filler to prevent moisture from entering them. Generally, a solar cell module uses two resin films as fillers, and laminates the solar cells with the film. When laminating, the resin film melts and adheres to the surface of the solar cell or wiring material, but if there are gaps along the surface direction of the resin film, such as between overlapping wiring materials, the solar cell is less likely to contain the filler. Gaps may remain inside the module. If it does so, there exists a possibility that the reliability of a solar cell module may fall.
　本発明に係る太陽電池モジュールは、複数の太陽電池と、太陽電池同士を接続する複数の第１配線材と、第１配線材と接続され、太陽電池の出力を外部に導くための複数の第２配線材と、太陽電池、第１配線材、及び第２配線材を封止する充填材とを備え、第２配線材は、その一部同士が重なり合って配置され、充填材は、重なり合う第２配線材の間に隙間なく設けられる。 The solar cell module according to the present invention includes a plurality of solar cells, a plurality of first wiring members that connect the solar cells, and a plurality of first wiring members that are connected to the first wiring member and guide the output of the solar cells to the outside. 2 wiring material and a filler for sealing the solar cell, the first wiring material, and the second wiring material, the second wiring material is disposed so that a part thereof overlaps, and the filling material overlaps the first It is provided between the two wiring members without a gap.
　本発明に係る太陽電池モジュールの製造方法は、複数の太陽電池と、太陽電池同士を接続する複数の第１配線材と、第１配線材と接続され、太陽電池の出力を外部に導くための複数の第２配線材と、太陽電池、第１配線材、及び第２配線材を封止する充填材とを備える太陽電池モジュールの製造方法であって、第２配線材の一部同士が重なり合うように、第２配線材を配置する工程と、重なり合う第２配線材の間に、充填材の一部を構成する樹脂部材を挿入する工程と、太陽電池の受光面上に充填材の一部を構成する第１の樹脂フィルムを、太陽電池の裏面上に充填材の一部を構成する第２の樹脂フィルムを、それぞれ積層する工程と、樹脂部材、第１樹脂フィルム、及び第２樹脂フィルムを互いに熱圧着して、太陽電池、第１配線材、及び第２配線材を封止する工程とを含む。 A method for manufacturing a solar cell module according to the present invention is connected to a plurality of solar cells, a plurality of first wiring members that connect solar cells to each other, and a first wiring member, and guides the output of the solar cells to the outside. A method for manufacturing a solar cell module comprising a plurality of second wiring members and a solar cell, a first wiring member, and a filler for sealing the second wiring member, wherein a part of the second wiring members overlap each other. As described above, a step of arranging the second wiring material, a step of inserting a resin member constituting a part of the filler between the overlapping second wiring materials, and a part of the filler on the light receiving surface of the solar cell A step of laminating the first resin film constituting the second resin film constituting a part of the filler on the back surface of the solar cell, the resin member, the first resin film, and the second resin film Are thermocompression bonded to each other so that the solar cell, the first wiring material, and And a step of sealing the second wiring member.
　本発明に係る太陽電池モジュールによれば、信頼性の低下を抑制できる。 According to the solar cell module according to the present invention, it is possible to suppress a decrease in reliability.
本発明に係る実施形態である太陽電池モジュールを受光面側から見た図である。It is the figure which looked at the solar cell module which is embodiment which concerns on this invention from the light-receiving surface side. 本発明に係る実施形態である太陽電池モジュールを裏面側から見た図である。It is the figure which looked at the solar cell module which is embodiment which concerns on this invention from the back surface side. 図１，２のＡ‐Ａ線断面の一部を模式的に示す図である。It is a figure which shows typically a part of AA line cross section of FIGS. 図３のＢ部拡大図であって、充填材の構成の一例を示す図である。FIG. 4 is an enlarged view of a part B in FIG. 3, illustrating an example of a configuration of a filler. 図３のＢ部拡大図であって、充填材の構成の他の一例を示す図である。It is the B section enlarged view of Drawing 3, and is a figure showing other examples of composition of a filler. 本発明に係る実施形態である太陽電池モジュールの製造方法を説明するための図である。It is a figure for demonstrating the manufacturing method of the solar cell module which is embodiment which concerns on this invention.
　図面を参照して、本発明に係る実施形態である太陽電池モジュール１０を詳細に説明する。
　本発明は、以下の実施形態に限定されない。また、実施形態において参照する図面は、模式的に記載されたものであり、図面に描画された構成要素の寸法比率などは、現物と異なる場合がある。具体的な寸法比率等は、以下の説明を参酌して判断されるべきである。 With reference to drawings, the solar cell module 10 which is embodiment which concerns on this invention is demonstrated in detail.
The present invention is not limited to the following embodiments. The drawings referred to in the embodiments are schematically described, and the dimensional ratios of the components drawn in the drawings may be different from the actual products. Specific dimensional ratios and the like should be determined in consideration of the following description.
　図１～図３を参照して、太陽電池モジュール１０の構成を詳説する。
　図１は、太陽電池モジュール１０を受光面側から見た平面図であり、図２は、太陽電池モジュール１０を裏面側から見た平面図である。図３は、図１，２のＡ‐Ａ線断面の一部を示す図であって、第２配線材１９同士が重なり合う部分の断面を示す。 The configuration of the solar cell module 10 will be described in detail with reference to FIGS.
FIG. 1 is a plan view of the solar cell module 10 viewed from the light receiving surface side, and FIG. 2 is a plan view of the solar cell module 10 viewed from the back surface side. FIG. 3 is a view showing a part of a cross section taken along the line AA of FIGS. 1 and 2 and showing a cross section of a portion where the second wiring members 19 overlap each other.
　太陽電池モジュール１０は、複数の太陽電池１１と、太陽電池１１の受光面側に配置される第１保護部材１２と、太陽電池１１の裏面側に配置される第２保護部材１３とを備える。つまり、太陽電池１１は、第１保護部材１２及び第２保護部材１３により挟み込まれている。太陽電池モジュール１０において、複数の太陽電池１１の受光面が同一平面上に並んで配置されている。 The solar cell module 10 includes a plurality of solar cells 11, a first protective member 12 disposed on the light receiving surface side of the solar cell 11, and a second protective member 13 disposed on the back surface side of the solar cell 11. That is, the solar cell 11 is sandwiched between the first protective member 12 and the second protective member 13. In the solar cell module 10, the light receiving surfaces of the plurality of solar cells 11 are arranged side by side on the same plane.
　ここで、「受光面」とは、太陽電池１１の外部から太陽光が主に入射する面を意味する。例えば、太陽電池１１に入射する太陽光のうち５０％超過～１００％が受光面側から入射する。また、「裏面」とは、受光面と反対側の面を意味する。 Here, the “light receiving surface” means a surface on which sunlight mainly enters from the outside of the solar cell 11. For example, more than 50% to 100% of the sunlight incident on the solar cell 11 enters from the light receiving surface side. The “back surface” means a surface opposite to the light receiving surface.
　太陽電池１１は、太陽光を受光することでキャリア（電子及び正孔）を生成する光電変換部３０と、光電変換部３０の受光面上に設けられた受光面電極３１と、光電変換部３０の裏面上に設けられた裏面電極３２とを備える。太陽電池１１では、光電変換部３０で生成されたキャリアが受光面電極３１及び裏面電極３２により収集される。 The solar cell 11 includes a photoelectric conversion unit 30 which generates carriers (electrons and holes) by receiving sunlight, a light receiving surface electrode 31 provided on the light receiving surface of the photoelectric conversion unit 30, and the photoelectric conversion unit 30. And a back electrode 32 provided on the back surface. In the solar cell 11, carriers generated by the photoelectric conversion unit 30 are collected by the light receiving surface electrode 31 and the back surface electrode 32.
　光電変換部３０は、例えば、結晶系シリコン基板、ガリウム砒素（ＧａＡｓ）基板、又はインジウム燐（ＩｎＰ）基板等の半導体基板を有する。光電変換部３０としては、ｎ型単結晶シリコン基板の受光面上に、真性非晶質シリコン層であるｉ型非晶質シリコン層と、ボロン（Ｂ）等がドープされたｐ型非晶質シリコン層とが順に形成され、ｎ型単結晶シリコン基板の裏面上に、ｉ型非晶質シリコン層と、リン（Ｐ）等がドープされたｎ型非晶質シリコン層とが順に形成された構造を適用できる。なお、ｎ型単結晶シリコン基板の受光面上にｉ型非晶質シリコン層と、リン（Ｐ）等がドープされたｎ型非晶質シリコン層とが順に形成され、ｎ型単結晶シリコン基板の裏面上に、ｉ型非晶質シリコン層と、ボロン（Ｂ）等がドープされたｐ型非晶質シリコン層とが順に形成された構造でもよい。 The photoelectric conversion unit 30 includes, for example, a semiconductor substrate such as a crystalline silicon substrate, a gallium arsenide (GaAs) substrate, or an indium phosphide (InP) substrate. As the photoelectric conversion unit 30, an i-type amorphous silicon layer, which is an intrinsic amorphous silicon layer, and a p-type amorphous material doped with boron (B) or the like on the light-receiving surface of an n-type single crystal silicon substrate. A silicon layer was sequentially formed, and an i-type amorphous silicon layer and an n-type amorphous silicon layer doped with phosphorus (P) or the like were sequentially formed on the back surface of the n-type single crystal silicon substrate. Structure can be applied. An i-type amorphous silicon layer and an n-type amorphous silicon layer doped with phosphorus (P) or the like are sequentially formed on the light-receiving surface of the n-type single crystal silicon substrate. A structure in which an i-type amorphous silicon layer and a p-type amorphous silicon layer doped with boron (B) or the like are sequentially formed on the back surface of the substrate.
　受光面電極３１は、光電変換部３０の受光面上に形成される透明導電層を含むことが好ましい。透明導電層としては、酸化インジウム（Ｉｎ2Ｏ3）や酸化亜鉛（ＺｎＯ）等の金属酸化物に、錫（Ｓｎ）やアンチモン（Ｓｂ）等をドープした透明導電性酸化物（ＴＣＯ）を適用できる。透明導電層は、光電変換部３０の表裏面の全体に形成されることが好適である。 The light receiving surface electrode 31 preferably includes a transparent conductive layer formed on the light receiving surface of the photoelectric conversion unit 30. As the transparent conductive layer, a transparent conductive oxide (TCO) in which tin (Sn), antimony (Sb), or the like is doped into a metal oxide such as indium oxide (In 2 O 3 ) or zinc oxide (ZnO) is applied. it can. The transparent conductive layer is preferably formed on the entire front and back surfaces of the photoelectric conversion unit 30.
　さらに、受光面電極３１は、複数（例えば、５０本）のフィンガー電極３３と、複数（例えば、２本）のバスバー電極３４とを含んで構成される。フィンガー電極３３及びバスバー電極３４は、透明導電層上に形成されることが好適である。フィンガー電極３３は、光電変換部３０の全体からキャリアを収集する細線状の電極である。バスバー電極３４は、フィンガー電極３３よりも幅が太い電極であって、主にフィンガー電極３３からキャリアを収集する。フィンガー電極３３及びバスバー電極３４は、互いに交差して配置され電気的に接続されている。これらは、例えば、バインダー樹脂中に銀（Ａｇ）等の導電性粒子が分散した導電性ペーストを、光電変換部３０の受光面上に所望のパターンでスクリーン印刷して形成される。 Further, the light receiving surface electrode 31 includes a plurality of (for example, 50) finger electrodes 33 and a plurality (for example, two) of bus bar electrodes 34. The finger electrode 33 and the bus bar electrode 34 are preferably formed on the transparent conductive layer. The finger electrode 33 is a thin line electrode that collects carriers from the entire photoelectric conversion unit 30. The bus bar electrode 34 is an electrode wider than the finger electrode 33 and mainly collects carriers from the finger electrode 33. The finger electrode 33 and the bus bar electrode 34 are arranged so as to cross each other and are electrically connected. These are formed, for example, by screen-printing a conductive paste in which conductive particles such as silver (Ag) are dispersed in a binder resin in a desired pattern on the light receiving surface of the photoelectric conversion unit 30.
　裏面電極３２は、受光面電極３１と同様に、複数のフィンガー電極３５と、複数のバスバー電極３６と、透明導電層とを含んで構成されることが好ましい。フィンガー電極３５は、フィンガー電極３３と比べて、本数をより多く、間隔をより狭く設定してもよい。なお、裏面側からの受光を想定しない場合、フィンガー電極３５の代わりに、銀（Ａｇ）薄膜等の金属膜を形成してもよい。 Like the light receiving surface electrode 31, the back surface electrode 32 preferably includes a plurality of finger electrodes 35, a plurality of bus bar electrodes 36, and a transparent conductive layer. The number of the finger electrodes 35 may be set larger than that of the finger electrodes 33 and the interval may be set narrower. When light reception from the back side is not assumed, a metal film such as a silver (Ag) thin film may be formed instead of the finger electrode 35.
　第１保護部材１２としては、透明な基板やフィルム、例えば、ガラス基板や樹脂基板、樹脂フィルム等を用いることができる。第２保護部材１３としては、第１保護部材１２と同様のガラス基板や樹脂基板、樹脂フィルム等を用いることができる。なお、裏面側からの受光を想定しない場合、第２保護部材１３は、不透明な基板やフィルムとしてもよく、例えば、アルミ板等の金属基板であってもよい。 As the first protective member 12, a transparent substrate or film, for example, a glass substrate, a resin substrate, a resin film, or the like can be used. As the second protective member 13, the same glass substrate, resin substrate, resin film and the like as the first protective member 12 can be used. When light reception from the back side is not assumed, the second protection member 13 may be an opaque substrate or film, and may be a metal substrate such as an aluminum plate, for example.
　第１保護部材１２と第２保護部材１３との間には、充填材１４が設けられる。充填材１４は、太陽電池１１等を密封する機能を有する。充填材１４は、詳しくは後述するが、第１樹脂組成物１５と、第２樹脂組成物１６と、第３樹脂組成物１７とを含む。 A filler 14 is provided between the first protective member 12 and the second protective member 13. The filler 14 has a function of sealing the solar cell 11 and the like. The filler 14 includes a first resin composition 15, a second resin composition 16, and a third resin composition 17, which will be described in detail later.
　太陽電池モジュール１０は、さらに、太陽電池１１同士を電気的に接続する第１配線材１８、第１配線材１８と電気的に接続された第２配線材１９（その一部は、太陽電池１１の出力をモジュールの外部に導くためのものである。）、第２配線材１９と外部装置（図示せず）とを電気的に接続する端子部２０、及び第１保護部材１２及び第２保護部材１３の端部に取り付けられるフレーム２１等を備える。本実施形態では、端子部２０において、４本の第２配線材１９（１９ａ～１９ｄ）と、外部装置から延びるリード線とが電気的に接続される。 The solar cell module 10 further includes a first wiring member 18 that electrically connects the solar cells 11, and a second wiring member 19 that is electrically connected to the first wiring member 18 (part of which is the solar cell 11. ), A terminal portion 20 for electrically connecting the second wiring member 19 and an external device (not shown), and the first protection member 12 and the second protection. A frame 21 or the like attached to the end of the member 13 is provided. In the present embodiment, in the terminal portion 20, the four second wiring members 19 (19a to 19d) and the lead wires extending from the external device are electrically connected.
　第１配線材１８は、太陽電池１１同士を電気的に接続してストリングＳを形成する。ストリングＳとは、複数の太陽電池１１を直列に接続して列状に配置したものである。太陽電池モジュール１０は、複数のストリングＳを備えており、図１では、各々４つの太陽電池１１を直列に接続した６つのストリングＳ（Ｓ１～Ｓ６）が互いに平行に整列配置された形態を示している。 The first wiring member 18 electrically connects the solar cells 11 together to form the string S. The string S is a plurality of solar cells 11 connected in series and arranged in a row. The solar cell module 10 includes a plurality of strings S, and FIG. 1 shows a configuration in which six strings S (S1 to S6) each having four solar cells 11 connected in series are arranged in parallel with each other. ing.
　第１配線材１８は、例えば、隣接して配置される一方の太陽電池１１の受光面電極３１に接続され、他方の太陽電池１１の裏面電極３２に接続される。より詳しくは、第１配線材１８は、一方の太陽電池１１の受光面電極３１のバスバー電極３４と、他方の太陽電池１１の裏面電極３２のバスバー電極３６とに、半田付けや樹脂接着剤により接続される。つまり、第１配線材１８は、隣り合う太陽電池１１の間で太陽電池モジュール１０の厚み方向に折れ曲がり、隣り合う太陽電池１１同士を直列に接続する。 The first wiring member 18 is connected to, for example, the light receiving surface electrode 31 of one of the solar cells 11 disposed adjacent to the first wiring member 18 and connected to the back surface electrode 32 of the other solar cell 11. More specifically, the first wiring member 18 is soldered or resin-bonded to the bus bar electrode 34 of the light receiving surface electrode 31 of one solar cell 11 and the bus bar electrode 36 of the back surface electrode 32 of the other solar cell 11. Connected. That is, the 1st wiring material 18 bends in the thickness direction of the solar cell module 10 between the adjacent solar cells 11, and connects the adjacent solar cells 11 in series.
　第２配線材１９は、隣り合うストリングＳ同士を接続する第２配線材１９ｅ～１９ｇと、ストリングＳと端子部２０とを電気的に接続する上記第２配線材１９ａ～１９ｄとを含む。複数の第２配線材１９は、いずれも、各ストリングＳの長手方向に交差して、ストリングＳに触れない範囲で、その端部に近接して配置されている。図１に例示する形態では、第１配線材１８と第２配線材１９とが互いに直交しており、各ストリングＳから延出する第１配線材１８の端部と、第２配線材１９とが接続されている。第１配線材１８と第２配線材１９との接続は、半田付けや樹脂接着剤によりなされる。 The second wiring member 19 includes second wiring members 19e to 19g for connecting adjacent strings S and the second wiring members 19a to 19d for electrically connecting the string S and the terminal portion 20. Each of the plurality of second wiring members 19 is arranged close to the end of the string S so as to intersect the longitudinal direction of each string S and not touch the string S. In the form illustrated in FIG. 1, the first wiring member 18 and the second wiring member 19 are orthogonal to each other, the end of the first wiring member 18 extending from each string S, the second wiring member 19, Is connected. The connection between the first wiring member 18 and the second wiring member 19 is made by soldering or a resin adhesive.
　第２配線材１９ｅは、ストリングＳ１とストリングＳ２を、第２配線材１９ｆは、ストリングＳ３とストリングＳ４を、第２配線材１９ｇは、ストリングＳ５とストリングＳ６をそれぞれ接続する。第２配線材１９ａは、ストリングＳ１と端子部２０を、第２配線材１９ｄは、ストリングＳ６と端子部２０とをそれぞれ接続する。第２配線材１９ｂは、ストリングＳ２とストリングＳ３を接続すると共に、端子部２０にも接続される。同様に、第２配線材１９ｃは、ストリングＳ４とストリングＳ５を接続すると共に、端子部２０にも接続される。 The second wiring material 19e connects the strings S1 and S2, the second wiring material 19f connects the strings S3 and S4, and the second wiring material 19g connects the strings S5 and S6. The second wiring member 19a connects the string S1 and the terminal portion 20, and the second wiring member 19d connects the string S6 and the terminal portion 20, respectively. The second wiring member 19b connects the string S2 and the string S3 and is also connected to the terminal unit 20. Similarly, the second wiring member 19c connects the string S4 and the string S5 and is also connected to the terminal portion 20.
　第２配線材１９ａ～１９ｄは、端子部２０に接続される一端側がＬ字状に折り曲げられた形状を有する。このＬ字状に折り曲げられた部分には、絶縁テープ等の絶縁部材２２が装着され、第２配線材１９ａ～１９ｄと太陽電池１１との絶縁性を確保している。 The second wiring members 19a to 19d have a shape in which one end connected to the terminal portion 20 is bent in an L shape. An insulating member 22 such as an insulating tape is attached to the portion bent in the L shape, and the insulation between the second wiring members 19a to 19d and the solar cell 11 is ensured.
　また、第２配線材１９は、単位面積当たりの発電量を高めてモジュール効率を向上させるため、その一部同士が重なり合って配置されている。本実施形態では、端子部２０に接続される第２配線材１９同士が重なり合って配置されており、第２配線材１９ａと第２配線材１９ｂ、及び第２配線材１９ｃと第２配線材１９ｄがそれぞれモジュールの厚み方向に重なっている。各第２配線材１９の幅は、いずれも同じに設定することができ、第２配線材１９同士が重なり合う部分（以下、「重なり部」とも称する）は、受光面側及び裏面側から平面視したときに１本に見えるように配置されることが好適である。そして、重なり合う第２配線材１９ａと第２配線材１９ｂの間、及び第２配線材１９ｃと第２配線材１９ｄとの間には、各配線材に密着して隙間なく充填材１４が挿入される。 In addition, the second wiring member 19 is arranged so that a part thereof overlaps with each other in order to increase the power generation amount per unit area and improve the module efficiency. In the present embodiment, the second wiring members 19 connected to the terminal portion 20 are arranged so as to overlap each other, and the second wiring member 19a and the second wiring member 19b, and the second wiring member 19c and the second wiring member 19d. Respectively overlap in the thickness direction of the module. The width of each of the second wiring members 19 can be set to be the same, and a portion where the second wiring members 19 overlap (hereinafter also referred to as “overlapping portion”) is viewed in plan view from the light receiving surface side and the back surface side. It is preferable to arrange them so that they appear as one when they are. The filler 14 is inserted between the second wiring material 19a and the second wiring material 19b, and between the second wiring material 19c and the second wiring material 19d so as to be in close contact with each wiring material without any gap. The
　本実施形態において、端子部２０には、第２配線材１９ａ～１９ｄを外部に引き出すための開口部が形成される。つまり、第２保護部材１３に貫通孔が形成される。端子部２０は、例えば、第２配線材１９ａ～１９ｄと外部装置から延びるリード線とを接続するための端子台と、端子台及び開口部をカバーする端子ボックスとを有する。なお、開口部は、水分が浸入しないように、必要により適当なシーリング材を用いて密閉される。 In the present embodiment, the terminal portion 20 is formed with openings for drawing out the second wiring members 19a to 19d to the outside. That is, a through hole is formed in the second protection member 13. The terminal portion 20 includes, for example, a terminal block for connecting the second wiring members 19a to 19d and lead wires extending from the external device, and a terminal box that covers the terminal block and the opening. The opening is sealed with an appropriate sealing material as necessary so that moisture does not enter.
　次に、図４及び図５をさらに参照して、充填材１４の構成を詳説する。
　図４及び図５は、いずれも、図３のＢ部拡大図である。図４に例示する形態と、図５に例示する形態とは、第３樹脂組成物１７からなる層の形状のみが相違している。 Next, the configuration of the filler 14 will be described in detail with further reference to FIGS. 4 and 5.
4 and 5 are both enlarged views of part B in FIG. The form illustrated in FIG. 4 is different from the form illustrated in FIG. 5 only in the shape of the layer made of the third resin composition 17.
　図４及び図５に示すように、充填材１４は、太陽電池１１だけでなく、第１配線材１８及び第２配線材１９にも密着して設けられている。本実施形態において、充填材１４は、太陽電池１１の受光面側を覆う第１樹脂組成物１５と、太陽電池１１の裏面側を覆う第２樹脂組成物１６と、重なり合う第２配線材１９の間に隙間なく挿入される第３樹脂組成物１７とを含んで構成されている。そして、第２保護部材１３側から、第２樹脂組成物１６、第３樹脂組成物１７、第１樹脂組成物１５の順に積層されている。後述するように、適切な樹脂組成物を用いることで、各層の界面にも隙間が存在することなく、互いに良好な密着性を発現する。 As shown in FIGS. 4 and 5, the filler 14 is provided in close contact not only with the solar cell 11 but also with the first wiring member 18 and the second wiring member 19. In the present embodiment, the filler 14 includes a first resin composition 15 that covers the light receiving surface side of the solar cell 11, a second resin composition 16 that covers the back surface side of the solar cell 11, and an overlapping second wiring material 19. It is comprised including the 3rd resin composition 17 inserted without gap between them. Then, the second resin composition 16, the third resin composition 17, and the first resin composition 15 are laminated in this order from the second protective member 13 side. As will be described later, by using an appropriate resin composition, there is no gap at the interface of each layer, and good adhesiveness is exhibited.
　ここで、「隙間」とは、走査型電子顕微鏡（ＳＥＭ）による断面観察で検出できる隙間である。具体的には、最大長が５０ｎｍ以上の隙間を意味する。つまり、太陽電池モジュール１０において、重なり合う第２配線材１９の間には、少なくとも最大長５０ｎｍ以上の隙間は存在しないことを意味する。 Here, the “gap” is a gap that can be detected by cross-sectional observation with a scanning electron microscope (SEM). Specifically, it means a gap having a maximum length of 50 nm or more. That is, in the solar cell module 10, it means that there is no gap of at least a maximum length of 50 nm or more between the overlapping second wiring members 19.
　第１樹脂組成物１５は、全ての太陽電池１１の受光面側を覆って層状に設けられる。第１樹脂組成物１５からなる層は、第１保護部材１２と略同一の面積を有する。同様に、第２樹脂組成物１６は、全ての太陽電池１１の裏面側を覆って層状に設けられる。第２樹脂組成物１６からなる層は、第２保護部材１３と略同一の面積を有する。また、各層の厚みは、例えば、０．２ｍｍ～１．０ｍｍ程度が好ましく、０．４ｍｍ～０．８ｍｍ程度である。 The first resin composition 15 is provided in layers so as to cover the light receiving surface side of all the solar cells 11. The layer made of the first resin composition 15 has substantially the same area as the first protective member 12. Similarly, the 2nd resin composition 16 covers the back side of all the solar cells 11, and is provided in layered form. The layer made of the second resin composition 16 has substantially the same area as the second protective member 13. Further, the thickness of each layer is preferably about 0.2 mm to 1.0 mm, for example, about 0.4 mm to 0.8 mm.
　第３樹脂組成物１７は、第１樹脂組成物１５及び第２樹脂組成物１６が入り込めない部分、即ち重なり合う第２配線材１９の間に隙間なく挿入され、第２配線材１９同士の電気的接触を防止する機能を有する。また、第３樹脂組成物１７は、重なり合う第２配線材１９の間に水分の通り道となり得る隙間が発生することを防止する機能を有し、信頼性が低下するのを抑制できる。 The third resin composition 17 is inserted without a gap between portions where the first resin composition 15 and the second resin composition 16 cannot enter, that is, between the overlapping second wiring members 19. Has the function of preventing mechanical contact. Moreover, the 3rd resin composition 17 has a function which prevents that the gap | interval which can become a path | route of a water | moisture content between the 2nd wiring materials 19 which overlap is generated, and can suppress that reliability falls.
　第３樹脂組成物１７は、重なり合う第２配線材１９ａと第２配線材１９ｂとの間、及び重なり合う第２配線材１９ｃと第２配線材１９ｄとの間から、それぞれ周囲にはみ出して設けられることが好適である。つまり、第３樹脂組成物１７は、第２配線材１９同士が重なり合う範囲よりも広範囲に設けられる。本実施形態では、第３樹脂組成物１７からなる層の幅（短手方向長さ）及び長さ（長手方向長さ）は、重なり部の幅及び長さよりも大きく、重なり部の全周囲からはみ出している（図１参照）。 The third resin composition 17 is provided so as to protrude from between the overlapping second wiring material 19a and the second wiring material 19b and between the overlapping second wiring material 19c and the second wiring material 19d. Is preferred. That is, the third resin composition 17 is provided in a wider range than the range where the second wiring members 19 overlap each other. In the present embodiment, the width (length in the short direction) and the length (length in the longitudinal direction) of the layer made of the third resin composition 17 are larger than the width and length of the overlapping portion, and from the entire periphery of the overlapping portion. It protrudes (see FIG. 1).
　図４及び図５に示すように、第３樹脂組成物１７からなる層の幅は、第２配線材１９の幅よりも広く、例えば、ストリングＳやフレーム２１に接触しない範囲で、第２配線材１９の幅に対して、１．１倍以上が好ましく、１．５倍以上がより好ましく、２．０倍以上である。 As shown in FIGS. 4 and 5, the width of the layer made of the third resin composition 17 is wider than the width of the second wiring member 19, for example, within a range not in contact with the string S and the frame 21. The width of the material 19 is preferably 1.1 times or more, more preferably 1.5 times or more, and more than 2.0 times.
　図４に例示する形態では、第３樹脂組成物１７からなる層が、モジュールの面方向に対して略平行に配置されている。この形態は、例えば、第３樹脂組成物１７の融点が、第１樹脂組成物１５及び第２樹脂組成物１６よりも高い場合に形成される。また、第２配線材１９ａ，１９ｂは、第３樹脂組成物１７にめり込んで互いに強く密着している。この形態は、例えば、重なり合う第２配線材１９ａと第２配線材１９ｂとの間に、その間隔よりも厚みのある第３樹脂組成物１７を押し込み、熱圧着工程で第３樹脂組成物１７が溶融することにより得られる。 4, the layer made of the third resin composition 17 is arranged substantially parallel to the surface direction of the module. This form is formed, for example, when the melting point of the third resin composition 17 is higher than that of the first resin composition 15 and the second resin composition 16. Further, the second wiring members 19a and 19b are embedded in the third resin composition 17 and are in close contact with each other. In this embodiment, for example, the third resin composition 17 having a thickness larger than the distance between the second wiring member 19a and the second wiring member 19b that is overlapped is pushed into the third resin composition 17 in the thermocompression bonding step. Obtained by melting.
　図５に例示する形態では、第３樹脂組成物１７からなる層の一部が、第１保護部材１２側に屈曲ないし湾曲している。より詳しくは、重なり部からはみ出た部分が、第１樹脂組成物１５からなる層側に偏在している。そして、重なり部からはみ出た部分と第１樹脂組成物１５との接触面積が、重なり部からはみ出た部分と第２樹脂組成物１６との接触面積よりも大きくなっている。この形態は、例えば、第１樹脂組成物１５を鉛直下方側に配置してラミネートすることで形成される。 5, a part of the layer made of the third resin composition 17 is bent or curved toward the first protective member 12 side. More specifically, the portion protruding from the overlapping portion is unevenly distributed on the layer side made of the first resin composition 15. The contact area between the portion protruding from the overlapping portion and the first resin composition 15 is larger than the contact area between the portion protruding from the overlapping portion and the second resin composition 16. This form is formed by arranging and laminating the first resin composition 15 on the vertically lower side, for example.
　図５に例示する形態では、第３樹脂組成物１７と第１樹脂組成物１５との接触面積が大きくなるため、両組成物の溶解性パラメータ（ＳＰ値）は近いことが好適であり、少なくとも主成分が同一であることが好ましい。換言すれば、第３樹脂組成物１７の重なり部からはみ出す部分は、第１樹脂組成物１５及び第２樹脂組成物１６のうち、ＳＰ値が近い樹脂組成物側に偏在することが好適である。 In the form illustrated in FIG. 5, since the contact area between the third resin composition 17 and the first resin composition 15 is large, it is preferable that the solubility parameter (SP value) of both compositions is close, at least It is preferable that the main components are the same. In other words, it is preferable that the portion of the third resin composition 17 that protrudes from the overlapping portion is unevenly distributed on the resin composition side where the SP value is close to the first resin composition 15 and the second resin composition 16. .
　充填材１４を構成する各樹脂組成物は、例えば、太陽光が照射される環境下で溶融することなく、太陽電池１１、第１配線材１８、及び第２配線材１９に対する密着性が高い樹脂を主成分とすることが好適である。また、主成分となる樹脂は、含水し難いことが好ましい。ここで、「主成分」とは、樹脂組成物に占める重量の割合（重量％）が最も多い成分を意味する。 Each resin composition constituting the filler 14 is, for example, a resin having high adhesion to the solar cell 11, the first wiring member 18, and the second wiring member 19 without melting in an environment irradiated with sunlight. It is preferable to use as a main component. Moreover, it is preferable that the resin as the main component is difficult to contain water. Here, the “main component” means a component having the largest weight ratio (% by weight) in the resin composition.
　各樹脂組成物は、複数の樹脂から構成される組成物であってもよいが、生産性の観点等から、主成分となる樹脂（以下、単に「主成分」とも称する）が全体の５０重量％以上である組成物が好ましい。更に、組成物のＳＰ値が近いことが好適であるため、樹脂組成物に占める主成分の割合は、７０重量％以上がより好ましく、９０重量％以上が特に好ましい。 Each resin composition may be a composition composed of a plurality of resins, but from the viewpoint of productivity, etc., the resin as the main component (hereinafter also simply referred to as “main component”) is 50% by weight. % Or more of the composition is preferred. Furthermore, since it is suitable that the SP value of the composition is close, the proportion of the main component in the resin composition is more preferably 70% by weight or more, and particularly preferably 90% by weight or more.
　各樹脂組成物は、各種添加剤を含有することができる。添加剤としては、酸化防止剤、紫外線吸収剤、耐候性付与剤、シランカップリング剤、架橋剤、架橋助剤（触媒）、粘着性付与剤、酸化チタン（ＴｉＯ2）等の白色顔料などが例示できる。裏面側からの受光を想定しない場合には、例えば、第２樹脂組成物１６に酸化チタン（ＴｉＯ2）を添加することで、太陽電池１１の裏面側における光の反射率を高めて太陽電池１１の受光効率を向上させることができる。 Each resin composition can contain various additives. Additives include antioxidants, ultraviolet absorbers, weather resistance imparting agents, silane coupling agents, crosslinking agents, crosslinking aids (catalysts), tackifiers, white pigments such as titanium oxide (TiO 2 ), and the like. It can be illustrated. When light reception from the back surface side is not assumed, for example, by adding titanium oxide (TiO 2 ) to the second resin composition 16, the reflectance of light on the back surface side of the solar cell 11 is increased and the solar cell 11. The light receiving efficiency can be improved.
　各樹脂組成物は、含水率及び太陽電池１１等に対する密着性の観点から、ＳＰ値が７．０～１１．０であることが好ましく、７．３～１０．０であることがより好ましく、７．５～９．０であることが特に好ましい。そして、各樹脂組成物の互いのＳＰ値の差異は、１．５未満であることが好ましく、１未満がより好ましく、０．５未満が特に好ましい。ＳＰ値の差異がこの範囲内であれば、各樹脂組成物同士の密着性がより向上するため、層界面の剥離等に起因して隙間が発生することを高度に抑制できる。 Each resin composition preferably has an SP value of 7.0 to 11.0, more preferably 7.3 to 10.0, from the viewpoint of moisture content and adhesion to the solar cell 11 and the like. It is particularly preferably 7.5 to 9.0. And the difference of each SP value of each resin composition is preferably less than 1.5, more preferably less than 1, and particularly preferably less than 0.5. If the difference in the SP value is within this range, the adhesiveness between the resin compositions is further improved, so that generation of a gap due to peeling of the layer interface or the like can be highly suppressed.
　各樹脂組成物は、さらに、使用環境下で溶融しない程度の耐熱性、生産性等の観点から、軟化温度が６０℃～１５０℃であることが好ましく、６５℃～１３０℃であることが特に好ましい。そして、各樹脂組成物の軟化温度は、互いに略同一であることが好ましい。ここで、「軟化温度」とは、試験サンプルに一定の荷重を加えたときに、所定の変形を生じる温度と定義する。また、軟化温度が「略同一」とは、同一又は実質的に同一とみなせることを意味し、具体的には、軟化温度の差異が１０％程度の範囲内であることを意味する。融点が存在する場合には、各樹脂組成物の融点は、互いに略同一（融点の差異が１０％程度の範囲内）であることが好ましい。 Each resin composition further preferably has a softening temperature of 60 ° C. to 150 ° C., particularly 65 ° C. to 130 ° C., from the viewpoints of heat resistance and productivity that do not melt in the use environment. preferable. And it is preferable that the softening temperature of each resin composition is mutually substantially the same. Here, the “softening temperature” is defined as a temperature at which a predetermined deformation occurs when a certain load is applied to the test sample. In addition, the “substantially the same” softening temperature means that they can be regarded as the same or substantially the same, and specifically means that the difference in softening temperature is within a range of about 10%. When there is a melting point, the melting points of the resin compositions are preferably substantially the same (the difference in melting point is within a range of about 10%).
　第３樹脂組成物１７の主成分は、第１樹脂組成物１５の主成分及び第２樹脂組成物１６の主成分の少なくともいずれか一方と略同一とすることが好適である。例えば、第１樹脂組成物１５の主成分と第３樹脂組成物１７の主成分とが略同一であり、第２樹脂組成物１６の主成分と第３樹脂組成物１７の主成分とが異なる場合、又は各樹脂組成物の主成分が互いに略同一である場合が挙げられる。生産性の観点から、各樹脂組成物の主成分は、互いに略同一であることが好ましい。 The main component of the third resin composition 17 is preferably substantially the same as at least one of the main component of the first resin composition 15 and the main component of the second resin composition 16. For example, the main component of the first resin composition 15 and the main component of the third resin composition 17 are substantially the same, and the main component of the second resin composition 16 and the main component of the third resin composition 17 are different. Or the main components of each resin composition are substantially the same. From the viewpoint of productivity, it is preferable that the main components of each resin composition are substantially the same.
　また、第３樹脂組成物１７は、第１樹脂組成物１５及び第２樹脂組成物１６の少なくともいずれか一方と略同一、即ち添加物を含む組成物全体を略同一とすることができる。例えば、第１樹脂組成物１５と第３樹脂組成物１７とが略同一であり、第２樹脂組成物１６と第３樹脂組成物１７とが異なる場合、又は各樹脂組成物が互いに略同一である場合が挙げられる。後者の場合、充填材１４は、単一の樹脂組成物から構成されることを意味し、例えば、単層構造を呈する。充填材１４が単一の樹脂組成物から構成される場合であっても、後述するように、３つの部材をラミネートして充填材１４を形成すれば、各部材の界面が残り同種積層構造を呈する場合がある。 Further, the third resin composition 17 can be substantially the same as at least one of the first resin composition 15 and the second resin composition 16, that is, the entire composition including the additive can be made substantially the same. For example, when the 1st resin composition 15 and the 3rd resin composition 17 are substantially the same, and the 2nd resin composition 16 and the 3rd resin composition 17 differ, or each resin composition is mutually substantially the same. There are some cases. In the latter case, it means that the filler 14 is composed of a single resin composition, and exhibits, for example, a single layer structure. Even when the filler 14 is composed of a single resin composition, as will be described later, if the filler 14 is formed by laminating three members, the interface of each member remains and the same kind of laminated structure is formed. May present.
　ここで、樹脂組成物又はその主成分が「略同一」とは、上記と同様に、同一又は実質的に同一とみなせることを意味する。具体的に、主成分が実質的に同一とみなせる場合とは、主成分を構成するモノマーの共重合比の差異が５％程度の範囲内であること、分子量（例えば、重量平均分子量）の差異が５％程度の範囲内であること等が例示できる。樹脂組成物が実質的に同一とみなせる場合とは、各構成成分の重量の割合の差異が５％程度の範囲内であること等が例示できる。 Here, the phrase “substantially the same” for the resin composition or its main component means that it can be regarded as the same or substantially the same as described above. Specifically, when the main components can be regarded as substantially the same, the difference in the copolymerization ratio of monomers constituting the main component is within a range of about 5%, and the difference in molecular weight (for example, weight average molecular weight). Is within the range of about 5%. The case where the resin compositions can be regarded as substantially the same can be exemplified by the fact that the difference in the proportion of the weight of each constituent component is within the range of about 5%.
　各樹脂組成物の主成分に適用できる樹脂としては、炭素数２～２０のαオレフィンから選らばれる少なくとも１種を重合して得られるポリオレフィン樹脂（例えば、ポリエチレン（ＰＥ）、ポリプロピレン（ＰＰ）、エチレンとその他のαオレフィンとのランダム又はブロック共重合体など）、ポリエステル樹脂（例えば、ポリオールとポリカルボン酸又はその酸無水物・低級アルキルエステルとの重縮合物など）、ポリウレタン樹脂（例えば、ポリイソシアネートと活性水素基含有化合物（ジオール、ポリオールリオール、ジカルボン酸、ポリカルボン酸、ポリアミン、ポリチオール等）との重付加物など）、エポキシ樹脂（例えば、ポリエポキシドの開環重合物、ポリエポキシドと上記活性水素基含有化合物との重付加物など）、アクリル樹脂、αオレフィンとカルボン酸ビニル、アクリル酸エステル、又はその他ビニルモノマーとの共重合体（例えば、ＥＶＡやアイオノマー）が例示できる。例えば、ＥＶＡを用いる場合には、有機化酸化物を架橋剤として用いることが好ましい。 As a resin applicable to the main component of each resin composition, a polyolefin resin obtained by polymerizing at least one selected from α-olefins having 2 to 20 carbon atoms (for example, polyethylene (PE), polypropylene (PP), ethylene, etc.) And other α-olefin random or block copolymers), polyester resins (eg, polycondensates of polyols with polycarboxylic acids or their acid anhydrides / lower alkyl esters), polyurethane resins (eg, polyisocyanates) And active hydrogen group-containing compounds (such as polyaddition products of diols, polyol riols, dicarboxylic acids, polycarboxylic acids, polyamines, polythiols, etc.), epoxy resins (for example, polyepoxide ring-opening polymers, polyepoxides and active hydrogen groups) Polyaddition product with compound) And a copolymer (e.g., EVA or ionomer) of a vinyl resin, an α-olefin and a vinyl carboxylate, an acrylate ester, or other vinyl monomers. For example, when EVA is used, an organic oxide is preferably used as a crosslinking agent.
　上記例示した樹脂のうち、主成分として好適なものは、ポリオレフィン樹脂、αオレフィンとカルボン酸ビニル、アクリル酸エステル、又はその他ビニルモノマーとの共重合体（例えば、ＥＶＡやアイオノマー）であり、特にポリオレフィン樹脂が好適である。ポリオレフィン樹脂の中でも、ポリエチレン（エチレンとその他のαオレフィンとの共重合体を含む）が特に好ましい。 Among the resins exemplified above, those suitable as the main component are polyolefin resins, copolymers of alpha olefins with vinyl carboxylates, acrylate esters, or other vinyl monomers (for example, EVA and ionomers), especially polyolefins. Resins are preferred. Of the polyolefin resins, polyethylene (including copolymers of ethylene and other α-olefins) is particularly preferable.
　各樹脂組成物の好適な組合せとしては、例えば、いずれもポリオレフィン樹脂を主成分とする構成、いずれもポリオレフィン樹脂を主成分とし、第２樹脂組成物１６のみが酸化チタン（ＴｉＯ2）を含有する構成、又は第２樹脂組成物１６と第３樹脂組成物１７が酸化チタン（ＴｉＯ2）を含有する構成、第１樹脂組成物１５及び第２樹脂組成物１６をポリオレフィン樹脂とし、第３樹脂組成物１７をＥＶＡ等の架橋性樹脂とする構成などが例示できる。 As a suitable combination of each resin composition, for example, all are composed mainly of polyolefin resin, all are composed mainly of polyolefin resin, and only second resin composition 16 contains titanium oxide (TiO 2 ). Configuration, or configuration in which second resin composition 16 and third resin composition 17 contain titanium oxide (TiO 2 ), first resin composition 15 and second resin composition 16 are polyolefin resins, and third resin composition The structure etc. which make the thing 17 crosslinkable resin, such as EVA, can be illustrated.
　次に、図６を参照して、太陽電池モジュール１０の製造方法を詳説する。
　図６は、太陽電池モジュール１０を構成する各部材を示す断面図である。図６では、重なり合う第２配線材１９の間に第３樹脂組成物１７を挿入し、ラミネートする様子を示している。 Next, with reference to FIG. 6, the manufacturing method of the solar cell module 10 is explained in detail.
FIG. 6 is a cross-sectional view showing each member constituting the solar cell module 10. FIG. 6 shows a state in which the third resin composition 17 is inserted and laminated between the overlapping second wiring members 19.
　太陽電池モジュール１０は、各構成部材を積層して熱圧着するラミネート工程により製造されることが好適である。例えば、第１樹脂組成物１５及び第２樹脂組成物１６は、厚みが０．１ｍｍ～１．０ｍｍ程度のフィルムの形態（以下、それぞれ第１の樹脂フィルム１５ｐ、第２の樹脂フィルム１６ｐとする）で供給され、第３樹脂組成物１７は、重なり部よりも大きな樹脂の小片の形態（以下、樹脂部材１７ｐとする）で供給される。 The solar cell module 10 is preferably manufactured by a laminating process in which the constituent members are laminated and thermocompression bonded. For example, the first resin composition 15 and the second resin composition 16 are in the form of a film having a thickness of about 0.1 mm to 1.0 mm (hereinafter referred to as a first resin film 15p and a second resin film 16p, respectively). The third resin composition 17 is supplied in the form of a small resin piece (hereinafter referred to as a resin member 17p) larger than the overlapping portion.
　太陽電池モジュール１０の製造過程では、まず、太陽電池１１が公知の方法により製造される（太陽電池１１の製造過程について詳しい説明は省略）。太陽電池１１が準備されると、太陽電池１１の受光面電極３１及び裏面電極３２に第１配線材１８を取り付けて、隣接して配置される複数の太陽電池１１を電気的に接続する。こうして、複数のストリングＳが得られる。 In the manufacturing process of the solar cell module 10, first, the solar cell 11 is manufactured by a known method (a detailed description of the manufacturing process of the solar cell 11 is omitted). When the solar cell 11 is prepared, the 1st wiring material 18 is attached to the light-receiving surface electrode 31 and the back surface electrode 32 of the solar cell 11, and the several solar cell 11 arrange | positioned adjacently is electrically connected. Thus, a plurality of strings S are obtained.
　続いて、ストリングＳの端部から延びた第１配線材１８に第２配線材１９を取り付けて、ストリングＳ同士を電気的に接続する。また、第２配線材１９により、一部のストリングＳと端子部２０の端子台とを電気的に接続する。この工程では、第２配線材１９ａの一部と第２配線材１９ｂの一部、及び第２配線材１９ｃの一部と第２配線材１９ｄの一部が、モジュールの厚み方向に重なり合うように配置される。こうして、第２配線材１９の一部同士が重なって配置された構造が得られる。 Subsequently, the second wiring member 19 is attached to the first wiring member 18 extending from the end of the string S, and the strings S are electrically connected. In addition, a part of the strings S and the terminal block of the terminal portion 20 are electrically connected by the second wiring member 19. In this step, a part of the second wiring member 19a and a part of the second wiring member 19b, and a part of the second wiring member 19c and a part of the second wiring member 19d are overlapped in the thickness direction of the module. Be placed. In this way, a structure is obtained in which a part of the second wiring material 19 is arranged to overlap each other.
　続いて、重なり合う第２配線材１９ａと第２配線材１９ｂとの間、及び重なり合う第２配線材１９ｃと第２配線材１９ｄとの間に樹脂部材１７ｐを挿入する。樹脂部材１７ｐとしては、重なり部よりも大きなものを用いて、その一部が、重なり合う第２配線材１９の間の周囲からはみ出すように挿入する。このように挿入すれば、ラミネート工程等で、樹脂部材１７ｐ又は第２配線材１９の位置ズレが発生した場合であっても、重なり合う第２配線材１９の間に隙間なく第３樹脂組成物１７を充填できる。 Subsequently, the resin member 17p is inserted between the overlapping second wiring material 19a and the second wiring material 19b and between the overlapping second wiring material 19c and the second wiring material 19d. As the resin member 17p, a member larger than the overlapping portion is used, and a part thereof is inserted so as to protrude from the periphery between the overlapping second wiring members 19. If inserted in this way, even if the resin member 17p or the second wiring member 19 is misaligned in the laminating process or the like, the third resin composition 17 has no gap between the overlapping second wiring members 19. Can be filled.
　続いて、第１保護部材１２上に第１の樹脂フィルム１５ｐを積層し、第１の樹脂フィルム１５ｐ上に太陽電池１１を積層する。太陽電池１１上に第２の樹脂フィルム１６ｐを積層し、第２の樹脂フィルム１６ｐ上に第２保護部材１３を積層する。そして、第１の樹脂フィルム１５ｐ、第２の樹脂フィルム１６ｐ、及び樹脂部材１７ｐが溶融する温度で加熱しながら、第２保護部材１３側から圧力を加えてラミネートする。このとき、第１の樹脂フィルム１５ｐ、第２の樹脂フィルム１６ｐ、及び樹脂部材１７ｐは、互いに隙間なく密着すると共に、太陽電池１１、第１保護部材１２、第２保護部材１３、第１配線材１８、及び第２配線材１９に対しても隙間なく密着する。こうして、太陽電池１１等が充填材１４で封止された構造が得られる。 Subsequently, the first resin film 15p is laminated on the first protective member 12, and the solar cell 11 is laminated on the first resin film 15p. The second resin film 16p is laminated on the solar cell 11, and the second protective member 13 is laminated on the second resin film 16p. And it laminates by applying a pressure from the 2nd protective member 13 side, heating at the temperature which the 1st resin film 15p, the 2nd resin film 16p, and the resin member 17p fuse | melt. At this time, the first resin film 15p, the second resin film 16p, and the resin member 17p are in close contact with each other without gaps, and the solar cell 11, the first protection member 12, the second protection member 13, and the first wiring member. 18 and the second wiring member 19 are also in close contact with each other without a gap. Thus, a structure in which the solar cell 11 and the like are sealed with the filler 14 is obtained.
　つまり、ラミネート工程では、第１保護部材１２／第１の樹脂フィルム１５ｐ／太陽電池１１／第２の樹脂フィルム１６ｐ／第２保護部材１３の順に重ね合わせて積層体とし、例えば、真空状態において、該積層体を熱圧着して一体化する。積層体を圧縮する熱板の温度は、各樹脂組成物の溶融温度以上（例えば、１５０℃程度）に設定される。そして、第２配線材１９ａと第２配線材１９ｂとの間、及び第２配線材１９ｃと第２配線材１９ｄとの間には、樹脂部材１７ｐが挿入されているため、重なり部にも隙間なく充填材１４が設けられる。 That is, in the laminating step, the first protective member 12 / first resin film 15p / solar cell 11 / second resin film 16p / second protective member 13 are stacked in this order to form a laminate, for example, in a vacuum state, The laminate is integrated by thermocompression bonding. The temperature of the hot plate for compressing the laminate is set to be equal to or higher than the melting temperature of each resin composition (for example, about 150 ° C.). Since the resin member 17p is inserted between the second wiring member 19a and the second wiring member 19b and between the second wiring member 19c and the second wiring member 19d, there is a gap between the overlapping portions. A filler 14 is provided.
　最後に、フレーム２１や端子ボックスを取り付けて、太陽電池モジュール１０を得る。 Finally, the frame 21 and the terminal box are attached to obtain the solar cell module 10.
　以上のように、太陽電池モジュール１０は、第２配線材１９の一部同士をモジュールの厚み方向に重ねて配置している。これにより、単位面積当たりの発電量を高めてモジュール効率を向上させることができる。そして、重なり合う第２配線材１９の間に、第２配線材１９に密着して隙間なく充填材１４が挿入されている。これにより、重なり合う第２配線材１９同士の絶縁性を確保できると共に、水分等の不純物の混入等を高度に抑制できる。つまり、太陽電池モジュール１０によれば、単位面積当たりの発電量を高めるために第２配線材１９同士を重ね合わせて配置した構造において、モジュール内に水分等の不純物の通り道となり得る隙間が発生することを防止でき、信頼性の低下を抑制できる。 As described above, in the solar cell module 10, a part of the second wiring material 19 is arranged so as to overlap in the thickness direction of the module. Thereby, the power generation amount per unit area can be increased and the module efficiency can be improved. The filler 14 is inserted between the overlapping second wiring members 19 in close contact with the second wiring members 19 without any gaps. Thereby, while being able to ensure the insulation of the 2nd wiring materials 19 which overlap, mixing of impurities, such as a water | moisture content, can be suppressed highly. That is, according to the solar cell module 10, in the structure in which the second wiring members 19 are arranged so as to overlap each other in order to increase the amount of power generation per unit area, a gap that can be a passage for impurities such as moisture is generated in the module. Can be prevented, and a decrease in reliability can be suppressed.
　なお、本実施形態は、発明の目的を損なわない範囲で適宜設計変更することができる。 It should be noted that the design of this embodiment can be changed as appropriate without departing from the object of the invention.
　例えば、太陽電池１１は、受光面電極３１を有さず、光電変換部３０の裏面上のみに電極が形成された所謂裏面接合型構造であってもよい。この場合も、太陽電池１１の出力を外部に導くための複数の第２配線材１９が用いられる。そして、第２配線材１９の一部同士をモジュールの厚み方向に重ねて配置し、重なり合う第２配線材１９の間に隙間なく充填材１４が挿入された構造を形成できる。 For example, the solar cell 11 may have a so-called back junction structure in which the light receiving surface electrode 31 is not provided and an electrode is formed only on the back surface of the photoelectric conversion unit 30. Also in this case, a plurality of second wiring members 19 for guiding the output of the solar cell 11 to the outside are used. Then, a part of the second wiring material 19 is arranged so as to overlap each other in the thickness direction of the module, and a structure in which the filler 14 is inserted between the overlapping second wiring materials 19 without a gap can be formed.
　また、上記実施形態では、第３樹脂組成物１７が重なり部の全周囲からはみ出しているものとして説明したが、重なり部の周囲の一部において、第３樹脂組成物１７がはみ出して設けられた形態であってもよい。 In the above embodiment, the third resin composition 17 is described as protruding from the entire periphery of the overlapping portion. However, the third resin composition 17 is provided so as to protrude from a part of the periphery of the overlapping portion. Form may be sufficient.
　１０　太陽電池モジュール、１１　太陽電池、１２　第１保護部材、１３　第２保護部材、１４　充填材、１５　第１樹脂組成物、１５ｐ　第１の樹脂フィルム、１６　第２樹脂組成物、１６ｐ　第２の樹脂フィルム、１７　第３樹脂組成物、１７ｐ　樹脂部材、１８　第１配線材、１９（１９ａ～１９ｇ）　第２配線材、２０　端子部、２１　フレーム、２２　絶縁部材、３０　光電変換部、３１　受光面電極、３２　裏面電極、３３，３５　フィンガー電極、３４，３６　バスバー電極、Ｓ（Ｓ１～Ｓ６）　ストリング。 10 solar cell module, 11 solar cell, 12 first protective member, 13 second protective member, 14 filler, 15 first resin composition, 15p first resin film, 16 second resin composition, 16p second Resin film, 17 3rd resin composition, 17p resin member, 18 1st wiring material, 19 (19a-19g) 2nd wiring material, 20 terminal part, 21 frame, 22 insulation member, 30 photoelectric conversion part, 31 light receiving surface Electrode, 32 back electrode, 33, 35 finger electrode, 34, 36 bus bar electrode, S (S1 to S6) string.

Claims (8)

  1. 　複数の太陽電池と、
    　前記太陽電池同士を接続する複数の第１配線材と、
    　前記第１配線材に接続され、前記太陽電池の出力を外部に導くための複数の第２配線材と、
    　前記太陽電池、前記第１配線材、及び前記第２配線材を封止する充填材と、
    　を備え、
    　前記第２配線材は、その一部同士が重なり合って配置され、
    　前記充填材は、重なり合う前記第２配線材の間に隙間なく設けられた太陽電池モジュール。     A plurality of solar cells;
    A plurality of first wiring members for connecting the solar cells;
    A plurality of second wiring members connected to the first wiring member for guiding the output of the solar cell to the outside;
    A filler for sealing the solar cell, the first wiring material, and the second wiring material;
    With
    The second wiring material is disposed so that a part thereof overlaps,
    The solar cell module in which the filler is provided without a gap between the overlapping second wiring members.
  2. 　請求項１に記載の太陽電池モジュールであって、
    　前記充填材は、
    　前記太陽電池の受光面側を覆う第１樹脂組成物と、
    　前記太陽電池の裏面側を覆う第２樹脂組成物と、
    　重なり合う前記第２配線材の間に隙間なく挿入される第３樹脂組成物と、
    　を含み、
    　前記各樹脂組成物は、互いのＳＰ値の差異が１．５未満である太陽電池モジュール。     The solar cell module according to claim 1,
    The filler is
    A first resin composition covering the light-receiving surface side of the solar cell;
    A second resin composition covering the back side of the solar cell;
    A third resin composition inserted between the overlapping second wiring members without gaps;
    Including
    Each said resin composition is a solar cell module whose difference of mutual SP value is less than 1.5.
  3. 　請求項２に記載の太陽電池モジュールであって、
    　前記各樹脂組成物は、軟化温度が互いに略同一である太陽電池モジュール。     The solar cell module according to claim 2, wherein
    Each said resin composition is a solar cell module whose softening temperature is substantially the same.
  4. 　請求項３に記載の太陽電池モジュールであって、
    　前記第３樹脂組成物の主成分は、前記第１樹脂組成物の主成分又は前記第２樹脂組成物の主成分と略同一である太陽電池モジュール。     The solar cell module according to claim 3, wherein
    The main component of the third resin composition is substantially the same as the main component of the first resin composition or the main component of the second resin composition.
  5. 　請求項３に記載の太陽電池モジュールであって、
    　前記第３樹脂組成物は、前記第１樹脂組成物又は前記第２樹脂組成物と略同一である太陽電池モジュール。     The solar cell module according to claim 3, wherein
    The third resin composition is a solar cell module that is substantially the same as the first resin composition or the second resin composition.
  6. 　請求項２～５のいずれか１項に記載の太陽電池モジュールであって、
    　前記第３樹脂組成物は、重なり合う前記第２配線材の周囲の少なくとも一部において、はみ出して設けられた太陽電池モジュール。     The solar cell module according to any one of claims 2 to 5,
    The third resin composition is a solar cell module provided so as to protrude from at least a part of the periphery of the overlapping second wiring member.
  7. 　複数の太陽電池と、
    　前記太陽電池同士を接続する複数の第１配線材と、
    　前記第１配線材と接続され、前記太陽電池の出力を外部に導くための複数の第２配線材と、
    　前記太陽電池、前記第１配線材、及び前記第２配線材を封止する充填材と、
    　を備える太陽電池モジュールの製造方法であって、
    　前記第２配線材の一部同士が重なり合うように、前記第２配線材を配置する工程と、
    　重なり合う前記第２配線材の間に、前記充填材の一部を構成する樹脂部材を挿入する工程と、
    　前記太陽電池の受光面上に前記充填材の一部を構成する第１の樹脂フィルムを、前記太陽電池の裏面上に前記充填材の一部を構成する第２の樹脂フィルムを、それぞれ積層する工程と、
    　前記樹脂部材、前記第１樹脂フィルム、及び前記第２樹脂フィルムを互いに熱圧着して、前記太陽電池、前記第１配線材、及び前記第２配線材を封止する工程と、
    　を含む太陽電池モジュールの製造方法。     A plurality of solar cells;
    A plurality of first wiring members for connecting the solar cells;
    A plurality of second wiring members connected to the first wiring member for guiding the output of the solar cell to the outside;
    A filler for sealing the solar cell, the first wiring material, and the second wiring material;
    A solar cell module manufacturing method comprising:
    Arranging the second wiring material such that a part of the second wiring material overlaps;
    Inserting a resin member constituting a part of the filler between the overlapping second wiring members;
    A first resin film constituting a part of the filler is laminated on the light receiving surface of the solar cell, and a second resin film constituting a part of the filler is laminated on the back surface of the solar cell. Process,
    Sealing the solar cell, the first wiring material, and the second wiring material by thermocompression bonding the resin member, the first resin film, and the second resin film to each other;
    The manufacturing method of the solar cell module containing this.
  8. 　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、
    　前記樹脂部材を挿入する工程では、前記樹脂部材の一部が、重なり合う前記第２配線材の周囲の少なくとも一部からはみ出すように前記樹脂部材を挿入する太陽電池モジュールの製造方法。     It is a manufacturing method of the solar cell module according to claim 7,
    In the step of inserting the resin member, a method for manufacturing a solar cell module, wherein the resin member is inserted so that a part of the resin member protrudes from at least a part of the periphery of the overlapping second wiring member.
PCT/JP2011/066669 2011-07-22 2011-07-22 Solar cell module and method for producing same WO2013014723A1 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015029069A (en) * 2013-06-27 2015-02-12 京セラ株式会社 Solar cell module
CN110892540A (en) * 2017-09-29 2020-03-17 积水化学工业株式会社 Solar cell module and method for manufacturing solar cell module

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006278905A (en) * 2005-03-30 2006-10-12 Sanyo Electric Co Ltd Solar cell module and solar cell device with it
JP2011109129A (en) * 2011-01-26 2011-06-02 Sanyo Electric Co Ltd Method of manufacturing solar cell module and method of manufacturing solar cell device

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006278905A (en) * 2005-03-30 2006-10-12 Sanyo Electric Co Ltd Solar cell module and solar cell device with it
JP2011109129A (en) * 2011-01-26 2011-06-02 Sanyo Electric Co Ltd Method of manufacturing solar cell module and method of manufacturing solar cell device

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015029069A (en) * 2013-06-27 2015-02-12 京セラ株式会社 Solar cell module
CN110892540A (en) * 2017-09-29 2020-03-17 积水化学工业株式会社 Solar cell module and method for manufacturing solar cell module

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