JP2002319691A - Solar battery module and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve yield and man-hours of the manufacturing process of a solar battery module, by simplifying the wiring method of the cells and preventing crackings of solar battery cells in the manufacturing process. SOLUTION: The solar battery module has solar battery cell units 20, in each of which a plurality of mutually electrically connected solar battery cells 3 arranged in a matrix-like state is integrated by means of an integrating sheet 9, having a translucent resin sheet 7. The resin sheet 7 has electrode patterns 8a and 8b for light-receiving surface and rear surface, which are patterned so that the patterns 8a and 8b are connected respectively to the light receiving- surface electrodes and rear-surface electrodes of the cells 3, and a pattern 8c for serial connection which is patterned to connect adjacent two solar battery cells 3 to each other and is different from the patterns 8a and 8b.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module having a solar cell unit in which solar cells are sealed with a translucent resin, and a method for manufacturing the same.

[0002]

2. Description of the Related Art In solar power generation, attention is paid to the point that the environment is considered as clean energy, and many solar power generation systems are manufactured and sold for general household use. Current,
Many of the solar cell modules used in the solar power generation system adopt a structure called a super straight type, a substrate type, or a resin potting type.

FIG. 8 is a schematic perspective view showing an example of a conventional solar cell module in which components are disassembled in a manufacturing process. The solar cell module shown in FIG. 8 has a rectangular-shaped tempered glass 1 having a predetermined thickness that transmits sunlight on the light-receiving surface side of sunlight, and a transparent filling resin film 2 below the tempered glass 1. Solar cell unit 24
Are laminated. The solar cell unit 24 is configured such that a plurality of solar cells 3 arranged in a matrix are interconnected by an interconnector 4. The weather resistant film 5 is laminated on the solar cell unit 24 via the transparent filling resin film 2.

When manufacturing a solar cell module,
First, the solar cell unit 24 sandwiched between the pair of transparent filling resin films 2 between the tempered glass 1 and the weather resistant film 5 is set and heated by a laminator and an oven. Thereby, the weather-resistant film 5 and the plurality of solar cells 3 are adhered to the back surface of the tempered glass 1 by the transparent filling resin forming the transparent filling resin film 2 to form a plate-like laminated structure. The plate-shaped laminate structure is attached by inserting the side edges of the weather-resistant film 5 and the tempered glass 1 into a concave portion 6a formed on the inner surface of an outer frame 6 made of aluminum, reinforced plastic, wood, or the like. Can be This allows
It is a solar cell module.

FIGS. 9 (a) to 9 (d) show respective steps of a method for connecting the solar cell 3 and the interconnector which constitute the solar cell unit 24, respectively.

First, as shown in FIGS. 9 (a) and 9 (b), each end of a pair of interconnectors 4 having a copper wire coated with solder is parallel to the electrodes on the light receiving surface of the solar cell 3 respectively. Solder in proper condition.

Next, as shown in FIGS. 9 (c) and 9 (d), each of the solar cells 3 to which the interconnector 4 is soldered to the light receiving surface is turned upside down and linearly arranged. The end of each interconnector 4 extending from 3 is soldered to the back electrode of the adjacent solar cell 3. Thereby, a string in which the plurality of solar cells 3 are connected in series is formed. And
By arranging the strings of the formed plurality of solar cells 3 in parallel, predetermined solar cells 3 in each string are connected to each other by a pair of interconnectors 4 so that the solar cells 3 are connected in series. Connecting. Thus, a solar cell unit 24 in which a plurality of solar cells 3 arranged in a matrix are connected in series is obtained.

FIG. 10 is a plan view of a conventional super straight type solar cell module, and FIG.
It is sectional drawing in the -A 'line.

In this solar cell module, a plurality of solar cells 3 connected in series by an interconnector 4 are arranged in a matrix on a rectangular weather-resistant film 5 (see FIG. 11). On the light receiving surface of the solar cell 3, a rectangular tempered glass 1 (see FIG. 11) that transmits sunlight is provided, and the side edges of the weather-resistant film 5 and the tempered glass 1 are
It is inserted and attached to a concave portion 6a (see FIG. 11) formed on the inner surface of a rectangular outer frame 6 made of aluminum.

As shown in FIG. 11, a concave portion 6a is formed in the upper portion of a hollow rectangular parallelepiped outer frame 6 made of aluminum, and in the concave portion 6a, the tempered glass 1 sandwiching the solar cell unit 24 is formed. The side edges of the weather-resistant film 5 are inserted and fixed by the adhesive 22. The solar cell unit 24 is fixed between the weather-resistant film 5 and the tempered glass 1 by a transparent filling resin 2a.

[0011]

In such a solar cell module, the solar cell unit 24 is constituted by connecting a plurality of solar cells 3 by an interconnector 4, respectively. Since the connection on the electrode side on the light receiving surface and the connection on the electrode side on the back surface of the solar cell 3 need to be performed in separate steps, the number of steps in the manufacturing process is increased and the cost may be increased. In addition, since operations such as turning over the solar cell 3 are required in the manufacturing process, there is a possibility that the solar cell 3 is cracked, and the yield may be reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to simplify a wiring method of a solar cell and to prevent a solar cell from cracking in a manufacturing process, thereby improving yield and reducing man-hours. And to provide a low-cost solar cell module and a method for manufacturing the same.

[0013]

According to the present invention, there is provided a solar cell module comprising an integrated sheet having a plurality of electrically connected solar cells arranged in a matrix and having a light-transmitting resin sheet. An integrated solar cell unit is provided, and the sheet made of the translucent resin is patterned to be connected to the light receiving surface electrode and the back surface electrode of each solar cell, respectively. The second wiring pattern and the first wiring pattern connected to one of the adjacent solar cells are connected to the second wiring pattern connected to the other solar cell. A third pattern different from the first and second wiring patterns
And a wiring pattern of

Each of the first to third wiring patterns is formed of an anisotropic conductive material.

Each of the first to third wiring patterns is formed of a conductive adhesive.

Each of the first to third wiring patterns is formed by a conductive wire coated with solder.

The translucent resin of the integrated sheet is a thermosetting resin.

The translucent resin of the integrated sheet is an ultraviolet curable resin.

The solar cell unit is provided with three or more integrated sheets in which solar cells arranged linearly are integrated.

The surface of the sheet made of a transparent resin of the integrated sheet is processed into an uneven state.

The surface of the light-transmitting resin sheet has areas with irregularities of different heights.

The method for manufacturing a solar cell module according to the present invention is characterized in that the first and second wiring patterns patterned so as to be connected to the light receiving surface electrode and the back surface electrode of a plurality of solar cells, respectively. Different from the first and second wiring patterns so that the first wiring pattern connected to one solar cell of the battery cell is connected to the second wiring pattern connected to the other solar cell. A step of preparing an integrated sheet in which a patterned third wiring pattern is provided on a sheet made of a light-transmitting resin, and arranging a plurality of solar cells on the integrated sheet; Connecting the light receiving surface electrode and the back surface electrode of the cell to the first and second wiring patterns on the integrated sheet to electrically connect the solar cells to each other; each A step of integrating positive cells,
It is characterized by including.

The connection between the light receiving surface electrode and the back surface electrode of the solar cell and the first and second wiring patterns on the integrated sheet is performed by thermocompression bonding.

[0024]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is an exploded perspective view showing a solar cell module according to an embodiment of the present invention into components in a manufacturing process, and FIG. 2 is a plan view of the solar cell module according to an embodiment of the present invention. .

The solar cell module of the present invention shown in FIG. 1 has a strengthened glass 1 having a rectangular thickness and a predetermined thickness through which sunlight is transmitted, on the light receiving surface side of sunlight. A solar cell unit 20 in which a large number of solar cells are integrated is laminated by an integrated sheet 9 provided with a wiring pattern 8 formed of a conductive material on a translucent resin sheet 7. In the solar cell unit 20, a plurality of solar cells 3 arranged in a matrix are connected in series by a wiring pattern 8 provided on a translucent resin sheet 7. Below the solar cell unit 20, the weather-resistant film 5 is laminated.

Such a solar cell module of the present invention is heated by a laminator and an oven with the solar cell unit 20 set between the tempered glass 1 and the weather-resistant film 5. As a result, the weather-resistant film 5 and the plurality of solar cells 3 are attached to the back surface of the tempered glass 1 by the translucent resin sheet 7 to form a plate-shaped laminated structure. The plate-shaped laminate structure is formed in a concave portion 6a formed on the inner surface of an outer frame 6 made of aluminum, reinforced plastic, wood, or the like.
The solar cell module of the present invention is obtained by inserting and attaching the side edges of the weather-resistant film 5 and the tempered glass 1.

The solar cell module of the present invention shown in FIG. 2 has an integrated sheet 9 on a rectangular weather-resistant film 5.
A plurality of solar cells 3 connected in series with each other are arranged in a matrix, and on the light receiving surface of the solar cells 3 arranged in a matrix, a tempered glass 1 that transmits rectangular sunlight is provided. The side edges of the weather-resistant film 5 and the tempered glass 1 are provided on the inner surface of an outer frame 6 made of aluminum.
a is inserted and attached.

FIGS. 3A and 3B respectively show a pattern electrode 8a made of a conductive material on a light-transmitting resin sheet 7. FIG.
FIG. 4 is a development view of the integrated sheet 9 on which the sheets 8 and 8b are formed.
(A) and (b) are the top views in the state where the solar cell 3 was mounted on the integrated sheet 9, respectively.

The solar cell unit 20 is shown in FIG.
A plurality of solar cells 3 arranged linearly are integrated by the respective integrated sheets 9 shown in (b) and (b), respectively, while being connected in series. The integrated sheet 9 has a sheet-shaped translucent resin sheet 7 patterned into a predetermined shape. The translucent resin sheet 7 has a band-shaped solar cell mounting area 7a of a predetermined size so that the solar cells 3 each having a substantially square plate shape are placed in a straight line in a state of being in close contact with each other. Have. The solar cell mounting area 7a is provided with an area 7b where one solar cell 3 is not mounted at one end, and is electrically connected to the solar cell mounting area 7a excluding the area 7b where the solar cell 3 is not mounted. Back electrode patterns 8b each made of a conductive material are provided. The back electrode pattern 8b is formed by a pair of linear patterns parallel to each other. 3 (a) and 3 (b)
Each of the integrated sheets 9 has the same configuration except that the position where the region 7b where the solar cell 3 is not mounted is provided is different.

In each area of the solar cell mounting area 7a where the solar cells 3 are mounted, a cover area 7c that is bent so as to cover each mounted solar cell 3 projects to one side. It is provided in.
Each of the cover regions 7c is provided so as to protrude in the left and right opposite directions in the mutually adjacent regions where the solar cells 3 are mounted.

Each of the cover regions 7c is connected to the light receiving surface electrode of each of the covered solar cells 3 when it is bent so as to cover each of the solar cells 3 mounted on the solar cell mounting region 7a. The light receiving surface electrode pattern 8a is formed of a conductive material. Light receiving surface electrode pattern 8
a is formed by a pair of linear patterns parallel to each other, and each light-receiving surface electrode pattern 8a
Solar cell 3 to which light-receiving surface electrode pattern 8a is connected
Are connected by a back electrode pattern 8b connected to the solar cell 3 adjacent in the same direction, respectively, and a series connection pattern 8c. The series connection pattern 8c is formed by a pair of linear patterns parallel to each other, and is orthogonal to the light receiving surface electrode pattern 8a and the back surface electrode pattern 8b.

The light-receiving surface electrode pattern 8a, the back surface electrode pattern 8b, and the series connection pattern 8c formed of a conductive material protrude from the front and back surfaces of the light-transmitting resin sheet 7, respectively. The linear pattern of the light-receiving surface electrode pattern 8a located on the side of the back-surface electrode pattern 8b is such that the light-receiving surface electrode pattern 8a and the back-surface electrode pattern 8b face each other with the solar cell 3 interposed therebetween. Each straight line is aligned with the straight line pattern of the back electrode pattern 8b.

The translucent resin sheet 7 used as the integrated sheet 9 is made of a thermosetting resin (EVA resin or the like) or an ultraviolet curable resin. 8b, pattern 8 for series connection
As the conductive material for forming c, an anisotropic conductive material, a conductive adhesive, a solder-coated conductive wire, or the like is used.

FIGS. 4 (a) and 4 (b) show a state where the solar cells 3 are mounted on the respective integrated sheets 9 shown in FIGS. 3 (a) and 3 (b). In FIGS. 4A and 4B, a plurality of solar cells are provided in the solar cell mounting area 7 a of the translucent resin sheet 7, except for an area 7 b at each end where the solar cell 3 is not mounted. 3 are mounted in close contact with each other. Each solar battery cell 3 is mounted on the solar battery cell mounting area 7a such that each back electrode is connected to the back electrode pattern 8b provided in the solar battery cell mounting area 7a.

As shown in FIGS. 4A and 4B, when each solar cell 3 is mounted on the integrated sheet 9, the cover area provided on the side of the area 7b where the solar cell 3 is not mounted is provided. Except for 7c, the cover area 7c on which the light receiving surface electrode pattern 8a is formed is folded in the direction of the arrow so as to cover the light receiving surface side of the solar cell 3 respectively. Thereafter, the area 7b where the solar cell 3 is not mounted and the cover area 7c on the side thereof are integrally folded in the direction of the arrow. As a result, FIG.
As shown in (a) and (b), the cover region 7c protruded laterally at one end of the solar cell mounting region 7a, and the surface of the solar cell 3 was exposed at the other end. In this state, the plurality of solar cells 3 are integrated by the integrated sheet 9.

As shown in FIGS. 5A and 5B, when the plurality of solar cells 3 are integrated with the integrated sheet 9, respectively, the state shown in FIGS. 5A and 5B is obtained. 6 are arranged so as to be adjacent to each other as shown in FIG. 6, and as shown by the arrow, the exposed solar cell 3 is disposed at the end of one of the integrated sheets 9.
Cover area 7c at the end of the other integrated sheet 9
Layer. Thus, a solar cell unit 20 in which a large number of solar cells 3 arranged in a matrix are connected in series is obtained. The connector terminals 23 are provided on the light receiving surface electrodes of the solar cells 3 that are not connected by the light receiving surface electrode patterns 8a in the cover area 7c of the integrated sheet 9 disposed on each side edge of the solar cell unit 20. Connected.

Next, a method for manufacturing a solar cell module according to an embodiment of the present invention will be described.

For example, an EVA resin which is a thermosetting resin is used as the translucent resin sheet 7 and an anisotropic conductive material is used as the conductive material to form an integrated sheet 9 as described above. The solar cell unit 20 is formed. The formed solar cell unit 20 is set between the tempered glass 1 and the weather-resistant film 5 shown in FIG. 1 and temporarily bonded by lamination.

Next, in order to connect the light receiving surface electrode pattern 8a and the back surface electrode pattern 8b made of an anisotropic conductive material to the light receiving surface electrode and the back surface electrode of the solar cell 3, respectively, a thermocompression bonding machine is used. Perform crimping. In this case, since the light receiving surface electrode pattern 8a and the back surface electrode pattern 8b disposed with the solar cell 3 interposed therebetween face each other, the connection of the light receiving surface electrode of the solar cell 3 is performed. The pressurization of the part and the pressurization of the connection part of the back electrode coincide with each other, and there is no possibility that a shear force acts on the solar cell 3, and the solar cell 3 is prevented from cracking.

Next, the translucent resin sheet 7 made of EVA resin is cured by a curing furnace,
The weather resistant film 5 and the plurality of solar cells 3 are EVA
It is attached to the back surface of the tempered glass 1 via a resin. Thereby, a plate-like laminate structure is obtained. Then, the side edges of the weather-resistant film 5 and the tempered glass 1 of the plate-like laminated structure are inserted and attached to the concave portions 6a formed on the inner surface of the outer frame 6 which is an aluminum frame, so that the solar cell A module is formed.

The solar cell module is not limited to such a manufacturing method. For example, an ultraviolet curable resin is used as the light-transmitting resin sheet 7 in the solar cell unit 20 and an anisotropic conductive material is used. A conductive material may be used. In this case, after the solar cell unit 20 is formed, the solar cell unit 20
Is set between the tempered glass 1 and the weather-resistant film 5 shown in FIG. 1 and irradiated with ultraviolet rays while applying pressure and deaeration to perform temporary bonding. Then, the pattern 8a for the light receiving surface electrode and the pattern 8b for the back surface electrode are formed by thermocompression bonding.
Then, after connecting the light receiving surface electrode and the back surface electrode of the solar battery cell 3 respectively, the ultraviolet ray is irradiated, so that the ultraviolet ray curable resin as the translucent resin sheet 7 can be completely cured.

Further, as shown in FIG.
The surface 7d of the translucent resin sheet 7 may be embossed to make the surface 7d uneven. In this way, by forming the surface 7d of the translucent resin sheet 7 in an uneven shape, when the solar cell 3 is mounted and crimped on the surface 7d, cracking of the solar cell 3 is more reliably prevented. can do. In this case, as shown in FIG. 7, the height of the convex portion of the surface 7d of the translucent resin sheet 7 is set to h2 at the set position of the solar cell 3, and except for the position where the solar cell 3 is crimped, The height h1 of the protrusion is h2
By making the height higher (h1> h2), the workability of positioning the solar cell 3 is facilitated, and the displacement of the solar cell 3 can be prevented.

[0044]

According to the solar cell module of the present invention, a plurality of solar cells electrically connected to each other are arranged in a matrix and integrated by an integrated sheet having a sheet made of a light-transmitting resin. First and second wiring patterns each having a solar cell unit and having a light-transmitting resin sheet patterned to be connected to a light-receiving surface electrode and a back surface electrode of each solar cell, respectively. And a third wiring pattern different from the first and second wiring patterns for connecting one of the adjacent solar cells and the other solar cell. Thereby, the yield can be improved by preventing the solar cell from cracking in the manufacturing process.

Further, the method for manufacturing a solar cell module according to the present invention is characterized in that the first and second wiring patterns patterned so as to be connected to the light receiving surface electrode and the back surface electrode of a plurality of solar cells, respectively, A third wiring pattern, which is different from the first and second wiring patterns for connecting one of the solar cells to the other solar cell, and a sheet made of a translucent resin. A step of preparing an integrated sheet provided in, and arranging a plurality of solar cells on the integrated sheet, the light-receiving surface electrode and the back electrode of each solar cell, the first and the second on the integrated sheet By including a step of electrically connecting the respective solar cells to each other by connecting to the second wiring pattern, and a step of integrating the integrated sheet and the respective solar cells, Can simplify the wiring method of Le, strive to reducing man-hours in the manufacturing process, it is possible to lower cost.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a configuration of a solar cell module according to an embodiment of the present invention.

FIG. 2 is a plan view of a solar cell module according to an embodiment of the present invention.

FIGS. 3A and 3B are configuration diagrams of an integrated sheet used in the solar cell module of the present invention.

FIGS. 4A and 4B are diagrams in which solar cells are mounted on the integrated sheet of FIG.

5 (a) and (b) are schematic views of a solar cell module assembled by mounting solar cells on the integrated sheet of FIG. 3;

FIG. 6 is a configuration diagram of a solar cell module of the present invention.

FIG. 7 is a cross-sectional view of the integrated sheet used in the solar cell module of the present invention, showing a state in which the integrated sheet has been embossed.

FIG. 8 is an exploded schematic perspective view showing an example of a conventional solar cell module.

FIGS. 9A to 9C are process diagrams illustrating respective steps of a method of connecting a solar cell and an interconnector that constitute a solar cell unit in a conventional solar cell module.

FIG. 10 is a plan view of a conventional solar cell module.

11 is a cross-sectional view taken along line A-A 'of FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Tempered glass 2 Transparent filling resin film 2a Transparent filling resin 3 Solar cell 4 Interconnector 5 Weatherproof film 6 Outer frame 6a Concave 7 Translucent plastic resin 7a Solar cell mounting area 7b Area where solar cell is not mounted 7c Cover Area 7d Surface of translucent plastic resin 8 Wiring pattern 8a Pattern for light-receiving surface electrode 8b Pattern for back electrode 8c Pattern for series connection 9 Integrated sheet (translucent plastic resin + conductive material) 20 Solar cell unit 23 Connector Terminal 24 solar cell unit

Claims (11)

[Claims] 1. A solar cell unit in which a plurality of solar cells electrically connected to each other are arranged in a matrix and integrated by an integrated sheet having a sheet made of a light-transmitting resin. The sheet made of a translucent resin includes first and second wiring patterns patterned so as to be respectively connected to a light receiving surface electrode and a back surface electrode of each solar cell, and an adjacent solar cell. The first wiring pattern connected to one of the photovoltaic cells is connected to the second wiring pattern connected to the other photovoltaic cell by a different pattern from the first and second wiring patterns. A solar cell module comprising: a third wiring pattern. 2. The solar cell module according to claim 1, wherein each of the first to third wiring patterns is formed of an anisotropic conductive material. 3. The solar cell module according to claim 1, wherein each of the first to third wiring patterns is formed of a conductive adhesive. 4. The solar cell module according to claim 1, wherein each of the first to third wiring patterns is formed by a conductive wire coated with solder. 5. The solar cell module according to claim 1, wherein the translucent resin of the integrated sheet is a thermosetting resin. 6. The solar cell module according to claim 1, wherein the translucent resin of the integrated sheet is an ultraviolet curable resin. 7. The solar cell module according to claim 1, wherein the solar cell unit is provided with three or more integrated sheets in which solar cells arranged linearly are integrated. 8. The solar cell module according to claim 1, wherein the surface of the sheet made of a transparent resin of the integrated sheet is processed into an uneven state. 9. The solar cell module according to claim 8, wherein the surface of the light-transmitting resin sheet has regions having irregularities having different heights. 10. A first and second wiring pattern patterned so as to be connected to a light receiving surface electrode and a back surface electrode of a plurality of solar cells, respectively, and to one of the adjacent solar cells. A third wiring pattern different from the first and second wiring patterns so that the connected first wiring pattern is connected to the second wiring pattern connected to the other solar cell. And a step of preparing an integrated sheet provided on a sheet made of a translucent resin, arranging a plurality of solar cells on the integrated sheet, and a light receiving surface electrode and a back electrode of each solar cell Connecting each of the solar cells to the first and second wiring patterns on the integrated sheet to electrically connect the solar cells to each other, and integrating the solar cell and the integrated sheet. And A method for manufacturing a solar cell module, comprising: 11. The connection between the light receiving surface electrode and the back surface electrode of the solar battery cell and the first and second wiring patterns on the integrated sheet is performed by thermocompression bonding.
0. A method for manufacturing a solar cell module according to item 0.