JP6024529B2 - Solar cell module and method for manufacturing solar cell module - Google Patents

Description

  The present invention relates to a solar cell module provided with a plurality of granular solar cells.

  As a technique regarding manufacture of a solar cell module provided with a plurality of granular solar cells, for example, there are those described in Patent Documents 1 and 2.

  In Patent Document 1, a plurality of regular hexagonal through holes are formed in a resin-made printed wiring sheet (for example, punching process), a solar cell is poured into the through holes, and then resin is injected to seal the resin. Is forming.

  In Patent Document 2, a solar cell panel is formed by forming a plurality of spherical solar cell elements in a matrix using a conductive wire mixed woven glass cloth, and then coating with a transparent resin or the like. .

International Publication No. 2003/094248 Pamphlet International Publication No. 2005/041312 Pamphlet

  Here, when a solar cell module (solar cell panel) as described in Patent Documents 1 and 2 is applied to, for example, a vehicle roof, there are the following problems.

  In the technique described in Patent Document 1, printed wiring is used as means for electrically connecting small solar cells. When this is applied to a vehicle roof, there is a concern that the printed wiring is damaged (disconnected) due to thermal expansion and contraction.

  In the technique described in Patent Document 2, since a conductive wire is used as means for electrically connecting the spherical solar cell elements to each other, the reliability with respect to disconnection is higher than that of the printed wiring. However, when forming a solar cell panel, first, a plurality of spherical solar cell elements are formed in a matrix using a conductive wire mixed woven glass cloth. Thereby, although the reliability of fixation of the spherical solar cell element with respect to coating resin improves, this process is inferior to the productivity of a solar cell panel.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a solar cell module having high productivity and high reliability for fixing a granular solar cell.

  The present invention includes a plurality of granular solar cells connected by lead wires, a plurality of bottomed recesses into which the plurality of granular solar cells are respectively fitted, and a resin panel in which grooves into which the lead wires are fitted are formed, And a holding means for holding the granular solar cell in the recess. The lead wires are attached in advance to both sides of the granular solar cell so that the granular solar cell is sandwiched from the left and right in a state of being fitted in the resin panel, and the granular solar cell is With the lead wires attached in advance, the granular solar cell and the lead wires are fitted in the recesses and the grooves, respectively.

  According to the present invention, it is possible to provide a solar cell module that has higher productivity than conventional ones and also has high reliability for fixing granular solar cells.

It is a figure which shows a part of roof of a vehicle provided with the solar cell module of 1st Embodiment of this invention. It is a figure which shows the assembly method of the solar cell module shown in FIG. It is a partial cross section figure of the roof of a vehicle provided with the solar cell module of 2nd Embodiment of this invention. It is a partial cross section figure of the roof of a vehicle provided with the solar cell module of 3rd Embodiment of this invention. It is a partial cross section figure of the roof of a vehicle provided with the solar cell module of 4th Embodiment of this invention. It is a figure which shows the modification of the solar cell module shown in FIG.

  Embodiments of the present invention will be described below with reference to the drawings. In the embodiment shown below, the case where the solar cell module (solar cell panel) of this invention is applied to the roof of a vehicle is illustrated. The solar cell module of the present invention can also be applied to a window provided on a vehicle roof, a side window of the vehicle, a rear window, and the like.

(First embodiment)
Fig.1 (a) is a perspective view which shows a part of roof of a vehicle provided with the solar cell module 100 of 1st Embodiment of this invention. FIG. 1B and FIG. 1C are an AA sectional view and a BB sectional view of FIG. 1A, respectively.
FIG. 2A is a single product diagram (rear view) of the resin panel 3 constituting the solar cell module 100.

  As shown in FIG. 1, the solar cell module 100 includes a large number (plural) of spherical solar cells 1, a resin panel 3 in which these spherical solar cells 1 are fitted, and lead wires 2 that connect the spherical solar cells 1 to each other. And.

<Spherical solar cell>
The spherical solar cell 1 is an element that directly converts light energy into electric power, and is formed by forming an n-type semiconductor layer on the surface of a spherical p-type semiconductor. The diameter is, for example, 1.0 mm. Note that the shape of the solar cell is not limited to a spherical shape. It may be a polyhedron shape such as a columnar shape or a hexahedron (cube / cuboid) shape. The spherical, cylindrical, and polyhedral shapes are collectively referred to as “granular”, and a solar cell having such a shape is referred to as a granular solar cell.

<Lead wire>
The lead wire 2 is a conductive wire that transmits electric power obtained by the spherical solar cell 1 and is made of a thin metal wire.

<Resin panel>
The resin panel 3 is a transparent or translucent panel (insulating panel) made of, for example, polycarbonate. As shown in FIG. 1C and FIG. 2B, the cross-sectional shape is curved to match the desired roof shape of the vehicle. On one surface of the resin panel 3, a plurality of bottomed concave portions 11 into which the spherical solar cells 1 are fitted, and grooves 12 into which the lead wires 2 are fitted are formed.

  The plurality of recesses 11 are formed in a matrix on the surface of the resin panel 3 with a plurality of vertical and horizontal rows at predetermined intervals. The shape of the bottom of the recess 11 is a sphere in which half of the spherical solar cell 1 is in surface contact, and the side surface of the recess 11 is cylindrical. Here, as shown in FIG. 1C, the opening diameter D <b> 2 of the recess 11 before the spherical solar cell 1 is fitted is slightly smaller than the outer diameter D <b> 1 of the spherical solar cell 1.

  The grooves 12 into which the lead wires 2 are fitted are formed on both sides of the plurality of recesses 11 arranged in a row so as to partially overlap the ends of the recesses 11. With respect to the thickness direction of the resin panel 3, the groove 12 has a depth in which the lead wire 2 is positioned directly beside the spherical solar cell 1 (see FIG. 1B).

  These recesses 11 and grooves 12 are simultaneously molded when the resin panel 3 is manufactured by, for example, injection molding.

<Assembly method of solar cell module>
A method for assembling the solar cell module 100 will be described with reference to FIG. In addition, the cross section of the resin panel 3 shown in FIG.2 (b) is CC cross section of the resin panel 3 of Fig.2 (a). First, before fitting the spherical solar cells 1 into the recesses 11 of the resin panel 3, the lead wires 2 are attached to both sides of the plurality of spherical solar cells 1 to produce a connection form such as a rosary (for example, FIG. (See the lower figure in 2 (b)). Note that one of the two lead wires 2 is attached to the p-type semiconductor portion of the plurality of spherical solar cells 1, and the other lead wire 2 is attached to the n-type semiconductor portion.

  Next, with the lead wires 2 attached in advance on both sides of the spherical solar cell 1, the spherical solar cell 1 and the lead wire 2 are fitted into the recess 11 and the groove 12 of the resin panel 3, respectively. In the present embodiment, since the outer diameter D1 of the spherical solar cell 1 is larger than the opening diameter D2 of the concave portion 11, the spherical solar cell 1 is fitted into the concave portion 11 of the resin panel 3 by press fitting. The recess 11 is elastically deformed, and the spherical solar cell 1 is held in the recess 11 of the resin panel 3 by this elastic force. That is, the outer diameter D1 of the spherical solar cell 1> the opening diameter D2 of the recess 11 is a holding means for holding the spherical solar cell 1 in the recess 11 in the solar cell module 100 of the present embodiment.

  Note that the outer diameter D1 of the spherical solar cell 1 ≦ the opening diameter D2 of the concave portion 11, and the spherical solar cell 1 may be held in the concave portion 11 of the resin panel 3 by a method such as welding. In press-fitting and welding, press-fitting is a simpler method, that is, press-fitting has higher productivity of the solar cell module 100.

<Action / Effect>
The main means in the present embodiment for arranging and fixing the plurality of spherical solar cells 1 to the resin panel 3 in a matrix is a plurality of bottomed recesses 11 formed in the resin panel 3. These recesses 11 can be formed simultaneously with the resin panel 3 by, for example, injection molding of the resin panel 3. On the other hand, in the technique described in Patent Document 2, a plurality of spherical solar cell elements are formed in a matrix using a conductive wire mixed woven glass cloth. Obviously, the productivity of the solar cell module 100 is higher in the present embodiment.

  In the present embodiment, the spherical solar cell 1 is fitted into the plurality of bottomed recesses 11 formed in the resin panel 3 and the lead wires attached to both sides thereof so as to sandwich the spherical solar cell 1 from the left and right. 2 is fitted in a groove 12 formed in the resin panel 3. According to this configuration, since the lead wires 2 attached to both sides of the spherical solar cell 1 are both held by the inner wall of the groove 12 portion of the resin panel 3, the spherical solar cell 1 is fixed in the concave portion 11 of the resin panel 3. The lead wire 2 is reinforced.

Further, in the present embodiment, the spherical solar cell 1 and the lead wire 2 are respectively inserted into the concave portion 11 and the groove 12 of the resin panel 3 in a state where the lead wires 2 are attached in advance to both sides of the plurality of spherical solar cells 1. Fit. According to this configuration, the production of the resin panel 3 having the recesses 11 and the grooves 12 and the production of the state in which the lead wires 2 are attached to both sides of the plurality of spherical solar cells 1 can be performed in parallel.
On the other hand, in the technique described in Patent Document 1, for example, printed wiring is applied to a resin sheet, and thereafter a plurality of through holes are formed in the printed wiring sheet, and then a plurality of solar cells are put into the through holes. Thereafter, resin is injected into the through hole and sealed with resin.
Obviously, the productivity of the solar cell module 100 is higher in the present embodiment.

  From these, according to the present invention, it is possible to provide a solar cell module that has higher productivity than conventional ones and also has high reliability for fixing granular solar cells.

(Second Embodiment)
A second embodiment of the present invention will be described with reference to FIG. In the following description, only differences from the first embodiment will be described. That is, fitting the spherical solar cell 1 and the lead wire 2 into the concave portion 11 and the groove 12 of the resin panel 3 with the lead wires 2 attached in advance on both sides of the plurality of spherical solar cells 1, The same applies to the present embodiment (the same applies to other embodiments and modifications described later).

  FIG. 3 is a cross-sectional view corresponding to FIG. 1C of the first embodiment. As shown in FIG. 3, in this embodiment, the claw 23a (locking part) is provided in the opening edge part by which the spherical solar cell 1 is engage | inserted among the recessed parts 11 of the resin panel 23. FIG. The claw 23a is for preventing the spherical solar cell 1 from falling off, and is formed simultaneously with the resin panel 3 by, for example, injection molding.

  The cross-sectional shape of the claw 23a is, for example, a triangle as shown in FIG. The claw 23a may be continuously formed in a ring shape around the inner side of the opening end of the concave portion 11, or may be formed discontinuously at a predetermined interval. Furthermore, only one place may be formed in a part of the inner periphery of the opening end of the recess 11. The nail | claw 23a is an example of the holding means of the spherical solar cell 1 provided in the side by which the spherical solar cell 1 of the resin panel 23 is engage | inserted.

  When the spherical solar cell 1 is fitted into the recess 11 of the resin panel 23, the claw 23a is elastically deformed. When the spherical solar cell 1 is completely fitted in the recess 11, the elastic deformation of the claw 23a is recovered and the claw 23a returns to its original shape. The claw 23 a is prevented from falling off, and the spherical solar cell 1 is held in the recess 11 of the resin panel 23.

  According to the present embodiment, a device is required for forming the claw 23a, but the reliability of fixing the spherical solar cell 1 can be further improved.

  In the present embodiment, the spherical solar cell 1 is not fitted into the recess 11 of the resin panel 23 by press fitting. Note that the holding of the spherical solar cell 1 by press-fitting shown in the first embodiment may be applied to this embodiment. In other words, the spherical solar cell 1 may be further fitted into the recess 11 of the resin panel 23 by press fitting (the same applies to other embodiments described later).

(Third embodiment)
A third embodiment of the present invention will be described with reference to FIG. FIG. 4 is a cross-sectional view corresponding to FIG. 1C of the first embodiment. As shown in FIG. 4, in this embodiment, the spherical solar cell 1 and the lead wire 2 that are respectively fitted in the recess 11 and the groove 12 of the resin panel 3 are embedded in the resin 4. Examples of the resin 4 to be used include thermoplastic resins such as polycarbonate / ethylene vinyl acetate (EVA) and thermosetting resins such as epoxy / urethane / silicon.

  The resin 4 is an example of a holding means for the spherical solar cell 1 provided on the side of the resin panel 3 on which the spherical solar cell 1 is fitted. According to this embodiment, the reliability of fixing the spherical solar cell 1 can be further increased.

(Fourth embodiment)
A fourth embodiment of the present invention will be described with reference to FIG. FIG. 5 is a cross-sectional view corresponding to FIG. 1C of the first embodiment. As shown in FIG. 5, in the present embodiment, the film 5 covers the spherical solar cell 1 and the lead wire 2 on the surface of the resin panel 3 on the side where the spherical solar cell 1 and the lead wire 2 are fitted. Is pasted. Examples of the material of the film 5 to be used include ethylene vinyl acetate (EVA).

  Several examples of the method for attaching the film 5 will be described. After the resin panel 3 and the film 5 are overlapped, the resin panel 3 and the film 5 are pressure-bonded by heating and vacuuming. As another method, the film 5 is sandwiched between the resin panel 3 and another resin panel (not shown), and then the panel is clamped. The film 5 is pressure-bonded between the resin panel 3 and another resin panel (not shown) by a clamping force by clamping.

  According to this embodiment, the reliability of fixing the spherical solar cell 1 can be further increased. Moreover, the design property of a solar cell module can be improved by decorating to the film 5. FIG.

(Modification)
A modification of the first embodiment will be described with reference to FIG. FIG. 6A is a perspective view showing a part of a vehicle roof provided with the solar cell module 101 of the present modification. FIG. 6B is a DD cross-sectional view of FIG.

  In the first embodiment, two lead wires 2 are attached beside the spherical solar cell 1 (see FIG. 1B). On the other hand, as in this modification, the lead wires 2 may be attached to both sides of the spherical solar cell 1 at a position slightly deviated from the side of the spherical solar cell 1 with the spherical solar cell 1 sandwiched from the left and right ( (Refer FIG.6 (b)). In this case, the two lead wires 2 are attached at positions shifted to the side opposite to the side of the spherical solar cell 1 that receives sunlight (the side facing the light source). By doing so, the light receiving area of the spherical solar cell 1 can be increased.

  In this modification, the groove 32 into which the lead wire 2 provided on the resin panel 33 is fitted is a groove into which the two lead wires are fitted together. This is because the distance between the lead wires 2 is narrow (the diameter of the spherical solar cell 1 is, for example, 1.0 mm as described above). Note that, depending on the interval between the lead wires 2, as in the first embodiment, the two lead wires may be grooves that are individually fitted.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments and examples, and various design changes can be made as long as they are described in the claims. is there.

1: Spherical solar cell (granular solar cell)
2: Lead wire 3: Resin panel 4: Resin 5: Film 11: Bottomed recess 12: Groove 100: Solar cell module

Claims (5)

A plurality of granular solar cells connected by lead wires;
A plurality of bottomed recesses into which the plurality of granular solar cells are respectively fitted, and a resin panel formed with grooves into which the lead wires are fitted;
Holding means for holding the granular solar cell in the recess;
With
The manner in a state fitted to the resin panel becomes form such as to sandwich the particulate solar cell from the left and right, the and lead is Ri attached taken on both sides of the granular solar battery,
The groove is formed so that the granular solar cell and the lead wire are inserted into the concave portion and the groove, respectively , and the lead wire sandwiches the granular solar cell from the left and right . , Solar cell module. The solar cell module according to claim 1, wherein
The solar cell module in which the holding means is provided on the side on which the granular solar cell of the resin panel is fitted. In the solar cell module according to claim 2,
The holding means is resin,
The solar cell module, wherein the granular solar cell fitted in the recess and the lead wire fitted in the groove are embedded in the resin. In the solar cell module according to claim 2,
The holding means is a film,
The solar cell module by which the film is affixed so that the said granular solar cell and the said lead wire may be covered on the surface by which the said granular solar cell of the said resin panel was engage | inserted. A plurality of granular solar cells connected by lead wires;
A plurality of bottomed recesses into which the plurality of granular solar cells are respectively fitted, and a resin panel formed with grooves into which the lead wires are fitted;
Holding means for holding the granular solar cell in the recess;
A manufacturing method of a solar cell module Ru provided with,
Wherein as in a state fitted to the resin panel becomes form such as to sandwich the particulate solar cell from the left and right, Installing the leads on both sides of the granular solar battery,
Wherein in a state in which the lead wire is attached in advance on either side of the granular solar battery, the granular solar battery and the lead wire, write fitted to each of the recess and the groove-free method of manufacturing a solar cell module.

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