JP2003282922A - Method of manufacturing solar cell module - Google Patents
Method of manufacturing solar cell moduleInfo
- Publication number
- JP2003282922A JP2003282922A JP2002082925A JP2002082925A JP2003282922A JP 2003282922 A JP2003282922 A JP 2003282922A JP 2002082925 A JP2002082925 A JP 2002082925A JP 2002082925 A JP2002082925 A JP 2002082925A JP 2003282922 A JP2003282922 A JP 2003282922A
- Authority
- JP
- Japan
- Prior art keywords
- solar cell
- manufacturing
- long sheet
- cell module
- unit
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- 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
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、フレシキブルな長
尺シートを基板として、この基板上に太陽電池を形成し
たフィルム基板形薄膜太陽電池をモジュール化した太陽
電池モジュールの製造方法に関し、さらに詳しくは、太
陽電池モジュールを封止保護する封止材の処理方法、お
よび単位太陽電池に取付けた電力取出し用外部接続用端
子の接続方法に係わる。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a solar cell module in which a flexible thin film sheet is used as a substrate, and a solar cell is formed on the substrate to form a film substrate type thin film solar cell into a module. The present invention relates to a method for treating a sealing material that seals and protects a solar cell module, and a method for connecting an external connection terminal for extracting power, which is attached to a unit solar cell.
【０００２】[0002]
【従来の技術】頭記した薄膜太陽電池として、在来のガ
ラス基板に代わるフレシキブルなプラスチックシートを
基板として、この基板上にアモルファスシリコン形の薄
膜半導体層からなる光電変換素子，透明電極，および接
続電極をパターンニングして複数ユニットセルの集積形
直列接続構造になる単位太陽電池を形成したフィルム基
板形の薄膜太陽電池の研究開発が進められており、その
一例として本発明の出願人よりいわゆるＳＣＡＦ（Seri
es Connection through Apertures on Film） と名付け
た集積形直列接続構造の薄膜太陽電池が特開平１０−２
３３５１７号，特開２０００−２２３７２７号などで提
案されており、その単位太陽電池の構造（モジュール化
する以前の段階）を図７に示す。2. Description of the Related Art As the above-mentioned thin-film solar cell, a flexible plastic sheet, which replaces a conventional glass substrate, is used as a substrate, and a photoelectric conversion element composed of an amorphous silicon-type thin-film semiconductor layer, a transparent electrode, and a connection are formed on the substrate. Research and development of a film substrate type thin film solar cell in which a unit solar cell having an integrated series connection structure of a plurality of unit cells is formed by patterning electrodes is being conducted, and as an example, a so-called SCAF by the applicant of the present invention. (Seri
es Connection through Apertures on Film) is a thin film solar cell with an integrated series connection structure.
FIG. 7 shows the structure of the unit solar cell (stage before modularization), which has been proposed in JP-A-33517, JP 2000-223727 A, and the like.
【０００３】図において、１はプラスチック基板、２は
光電変換層（アモルファスシリコン層）、３は透明電
極、４は裏面電極、５は背面電極、６は基板１を貫通し
て透明電極３と背面電極５との間を接続する集電ホー
ル、７は背面電極５と裏面電極４との間を接続する直列
ホールであり、基板１の光入射側に形成した透明電極
３，光電変換層２，および裏面電極４はセル分割溝（レ
ーザースクライブ）８により複数のユニットセル領域に
分離され、このセル分割に対応して基板１の背面電極５
もセル分割溝９で分離されている。In the figure, 1 is a plastic substrate, 2 is a photoelectric conversion layer (amorphous silicon layer), 3 is a transparent electrode, 4 is a back electrode, 5 is a back electrode, 6 is a transparent electrode 3 penetrating the substrate 1 and a back surface. A current collecting hole that connects the electrode 5 and a series hole 7 that connects the back electrode 5 and the back electrode 4 to each other. The transparent electrode 3, the photoelectric conversion layer 2, and the transparent electrode 3 formed on the light incident side of the substrate 1. And the back surface electrode 4 is divided into a plurality of unit cell regions by a cell dividing groove (laser scribe) 8, and the back surface electrode 5 of the substrate 1 is corresponding to this cell division.
Are also separated by the cell dividing groove 9.
【０００４】かかる構成で、各ユニットセルの光電変換
層２で発電した電流は透明電極３に集められ、ここから
集電ホール６→背面電極５→直列ホール７を経て隣接す
るユニットセルの裏面電極４に接続されており、これに
より複数ユニットセルの直列接続構造を形成している。With this structure, the electric current generated in the photoelectric conversion layer 2 of each unit cell is collected in the transparent electrode 3, and from there, through the collector hole 6 → back electrode 5 → serial hole 7 and the back electrode of the adjacent unit cell. 4 are connected to form a series connection structure of a plurality of unit cells.
【０００５】このフィルム基板形薄膜太陽電池は電池製
造のための材料入手の制約が少なく、かつ量産性に優れ
ていること、さらに軽量で屋根等への敷設も容易である
ことなどから、将来の太陽電池の主流として大きな期待
が寄せられており、特にプラスチック等のフレキシブル
な材料を基板とした前記構造では、その柔軟性を活かし
た用途への適用も考えられ、今後さらに普及化が進むも
のと予想される。This film substrate type thin film solar cell has less restrictions on material acquisition for cell manufacturing, is excellent in mass productivity, is lightweight, and can be easily laid on a roof or the like. There are great expectations as the mainstream of solar cells, and in particular, the structure using a flexible material such as plastic as a substrate is considered to be applicable to applications that take advantage of its flexibility, and it is expected that it will become more popular in the future. is expected.
【０００６】ところで、上記の太陽電池をモジュール化
した製品として普及させるには、太陽電池の性能向上に
加え、低価格のモジュールを高い生産性で製造できるよ
うにした量産技術の開発が重要となる。In order to popularize the above solar cell as a modularized product, it is important to improve the performance of the solar cell and to develop a mass production technology that enables low-cost modules to be manufactured with high productivity. .
【０００７】ここで先記したフィルム基板形薄膜太陽電
池をモジュール化する製造工程について考えると、第１
に太陽電池本体の電力取出し用電極と外部接続用端子と
の接続方法があり、これを如何に信頼性を維持したまま
で簡略化できるかが大きな課題となる。Considering the manufacturing process for modularizing the film substrate type thin film solar cell described above,
There is a method of connecting the electrode for taking out the electric power of the solar cell main body and the terminal for external connection, and how to simplify this while maintaining the reliability is a major issue.
【０００８】かかる点、従来ではフレキシブルな長尺シ
ートの基板上に連続してパターン形成した薄膜太陽電池
について、まず長尺シートから所定寸法の単位太陽電池
を裁断し、続くモジュール組立工程では裁断した単位太
陽電池について、その電力取出し用電極に銅などの導電
材で作られた箔状の端子板をはんだ付けなどで接合した
上で、電池の耐候性を確保するために単位太陽電池に透
光性の封止材を被覆して封止するように処理している。
すなわち、長尺シートから裁断した所定サイズの単位太
陽電池に対し、その電力取出し用電極に外部接続用端子
を取付けた上で、その電池本体のサイズよりも一回り大
きい寸法に裁断して用意したフィルム状の封止材，耐候
性保護材で太陽電池のシート全体を被覆し、ラミネータ
などを使って一体化する。次に、太陽電池モジュールの
所定外形寸法に合わせて前記封止材を再度裁断し、さら
に前記端子板を覆っている封止材の一部を剥がし、ここ
に端子リード線を接続した上で充填材などにより剥がし
た部分を修復するようにしている。With respect to this point, in the conventional thin film solar cells formed by patterning continuously on a flexible long sheet substrate, first, a unit solar cell having a predetermined size is cut from the long sheet, and then cut in a subsequent module assembly process. Regarding the unit solar cell, after connecting a foil-shaped terminal plate made of a conductive material such as copper to the power extraction electrode by soldering etc., the unit solar cell is translucent to ensure the weather resistance of the cell. Processing is performed so as to cover and seal the conductive sealing material.
That is, for a unit solar cell of a predetermined size cut from a long sheet, an external connection terminal was attached to the power extraction electrode, and then cut to a size slightly larger than the size of the battery main body. The entire solar cell sheet is covered with a film-shaped encapsulant and weather-resistant protective material, and integrated using a laminator. Next, the encapsulant is cut again according to the predetermined external dimensions of the solar cell module, a part of the encapsulant covering the terminal plate is peeled off, and a terminal lead wire is connected to the encapsulant and then filled. I try to repair the part that was peeled off with a material.
【０００９】[0009]
【発明が解決しようとする課題】ところで、前記した従
来の太陽電池モジュールの製造方法では次記のよう問題
点がある。However, the above-mentioned conventional method for manufacturing a solar cell module has the following problems.
【００１０】(1) 単位太陽電池への外部接続用端子の取
付けについて、従来方法では前記のように長尺シートか
ら単位太陽電池を裁断した上で、各単位太陽電池ごとに
端子板をはんだ付けし、この端子板を含めて電池全体に
封止材，耐候性の保護フィルムを被覆した後に、端子板
を被覆している封止材の一部を剥がし、ここに端子リー
ド線を接続した上で充填材などで剥がした部分の修復を
行うようにしている。この製造方法では、長尺シートか
ら裁断した単位太陽電池ごとに枚葉処理するためにその
作業には多くの時間と手間を必要としてコスト高とな
る。(1) Regarding the attachment of the external connection terminal to the unit solar cell, the conventional method is to cut the unit solar cell from the long sheet as described above, and then solder the terminal plate for each unit solar cell. Then, after covering the entire battery including this terminal board with a sealing material and a weather-resistant protective film, part of the sealing material covering the terminal board is peeled off, and the terminal lead wire is connected here. The part that has been peeled off with a filler is repaired. In this manufacturing method, a lot of time and labor are required for the operation because a single-wafer treatment is performed for each unit solar cell cut from a long sheet, resulting in high cost.
【００１１】また、太陽電池の電極と端子板とをはんだ
接合すると、はんだ付けの際の加熱により太陽電池の素
子が熱的に損傷を受けるおそれがある。さらに、端子板
の板面にリード線をはんだ付けする構造では、はんだ付
け部が盛り上がるためこの部分に貼り合わせた封止材が
周域から浮き上がり、このために十分な封止性能が確保
されずに外部からリード線と封止材との間に残る隙間を
通して湿気が侵入するなどの問題もある。その他、端子
リード線との接続についても、端子板を被覆した封止材
の一部を剥がし、リード線を接続した後に封止材の剥が
れた部分を充填材などで改めて被覆処理する必要があ
り、この工程においても多くの工数が発生するという問
題がある。Further, when the electrode of the solar cell and the terminal plate are joined by soldering, the element of the solar cell may be thermally damaged by heating during soldering. Furthermore, in the structure in which the lead wire is soldered to the plate surface of the terminal board, the soldering part rises, so the sealing material attached to this part floats from the peripheral area, and as a result, sufficient sealing performance cannot be ensured. In addition, there is also a problem that moisture invades from the outside through a gap left between the lead wire and the sealing material. In addition, regarding the connection with the terminal lead wire, it is necessary to peel off a part of the encapsulant that covers the terminal board, and then cover the separated part of the encapsulant with a filler after connecting the lead wire. However, there is a problem that a lot of man-hours are generated also in this process.
【００１２】(2) また、太陽電池モジュールの封止方法
についても、従来では前述のように所定の寸法に裁断さ
れたシート状の単位太陽電池に対して、その表裏両面に
フィルム状の封止材や耐候性樹脂を貼り合わせて電池の
周域を封止する方法が採られているが、これらの薄いフ
ィルム状の材料を複数枚重ねてラミネートする作業は想
像以上の工数と作業時間が必要となるなど、従来のモジ
ュール製造技術では製品がコスト高となる。(2) As for the method of sealing the solar cell module, conventionally, a sheet-shaped unit solar cell cut into a predetermined size as described above is provided with film-shaped sealing on both front and back surfaces thereof. Although the method of sealing the battery area by bonding materials and weather resistant resin is adopted, the work of stacking multiple thin film-like materials and laminating them requires more man-hours and work time than expected. As a result, the cost of the product increases with the conventional module manufacturing technology.
【００１３】本発明は上記の点に鑑みなされたものであ
り、その目的はシート状の単位太陽電池に取付ける電力
取出し用の外部接続用端子の構造，取り付け方法、およ
び封止材の処理方法を工夫することで、信頼性を損なう
ことなく低コストで量産性に優れた太陽電池モジュール
の製造方法を提供することにある。The present invention has been made in view of the above points, and an object thereof is to provide a structure, a mounting method, and a sealing material processing method of an external connection terminal for extracting electric power, which is mounted on a sheet-shaped unit solar cell. By devising the invention, it is to provide a method for manufacturing a solar cell module that is low in cost and excellent in mass productivity without impairing reliability.
【００１４】[0014]
【課題を解決するための手段】上記目的を達成するため
に、本発明によれば、ロール状に巻取り可能なフレシキ
ブル性のある長尺シートを基板として、該基板上に光電
変換素子，透明電極および接続電極の各層をパターニン
グして複数ユニットセルの集積形直列接続構造を形成し
た各単位太陽電池に対し、その電力取出し用電極に外部
接続用端子を取付け、さらに電池本体に封止材を被覆し
て封止した構成になる太陽電池モジュールの製造方法に
おいて、前記の外部接続用端子を、単位太陽電池を長尺
シートから裁断する以前段階でその電極に取付けた上
で、長尺シートの表裏両面の全域に貼り合わせた封止材
と、長尺シートから単位太陽電池を裁断した後にその裁
断面に被着した封止材とで個々の単位太陽電池を封止す
る（請求項１）こととし、具体的には次記のような態様
で製造する。In order to achieve the above object, according to the present invention, a flexible long sheet that can be wound into a roll is used as a substrate, and a photoelectric conversion element, a transparent element, and a transparent element are provided on the substrate. For each unit solar cell in which each layer of the electrode and connection electrode is patterned to form an integrated series connection structure of multiple unit cells, an external connection terminal is attached to the power extraction electrode, and a sealing material is attached to the battery body. In the method for manufacturing a solar cell module having a covered and sealed configuration, the external connection terminal is attached to the electrode before the unit solar cell is cut from the long sheet, and then the long sheet is attached. The individual unit solar cells are sealed with the sealing material bonded to the entire front and back surfaces and the sealing material adhered to the cut surface after cutting the unit solar cells from the long sheet (claim 1). thing And, specifically, prepared in the manner as follows follow.
【００１５】(1) フレシキブル基板は、太陽電池の製造
工程および実運転条件の下で、物理的，化学的に安定し
た性質のプラスチックを使用する（請求項２）。(1) As the flexible substrate, a plastic having a physically and chemically stable property is used under the manufacturing process and actual operating conditions of the solar cell (claim 2).
【００１６】(2) 基板上に形成した光電変換素子を、ア
モルファスシリコン形の素子で構成する（請求項３）。(2) The photoelectric conversion element formed on the substrate is composed of an amorphous silicon type element (claim 3).
【００１７】(3) 封止材として、封止樹脂と耐候性のあ
る樹脂フィルムを貼り合わせたラミネートフィルムを用
いる（請求項４）。(3) As the sealing material, a laminated film obtained by laminating a sealing resin and a weather resistant resin film is used (claim 4).
【００１８】(4) また、外部接続用端子は、銅箔もしく
はアルミ箔の端子板に銅線もしくはアルミ線のリード線
を接続した構造とし、前記リード線の先端接続部を単位
太陽電池のシート側縁から突き出すようにして端子板を
単位太陽電池の電力取出し用電極面に電気的に接合する
（請求項５）。(4) Further, the external connection terminal has a structure in which a lead wire of a copper wire or an aluminum wire is connected to a terminal plate of a copper foil or an aluminum foil, and the tip connection portion of the lead wire is a sheet of a unit solar cell. The terminal plate is electrically joined to the power extraction electrode surface of the unit solar cell so as to project from the side edge (claim 5).
【００１９】(5) 前記請求項５において、外部接続用端
子は、先端接続部を除くリード線の周面に絶縁処理を施
した構造とする（請求項６）。(5) In the above-mentioned claim 5, the external connection terminal has a structure in which the peripheral surface of the lead wire excluding the tip connection portion is subjected to an insulation treatment (claim 6).
【００２０】(6) 前記請求項５において、端子板の片面
に導電性接着剤を塗布した上で、該端子板を単位太陽電
池の電力取出し用電極面に貼り付けて電気的に接続する
（請求項７）。(6) In the above-mentioned claim 5, after applying a conductive adhesive to one surface of the terminal plate, the terminal plate is attached to an electric power extraction electrode surface of the unit solar cell for electrical connection ( Claim 7).
【００２１】(7) 前記請求項５において、リード線の先
端接続部をピン端子として、相手側の配線コネクタに差
込んで接続できるようにする（請求項８）。(7) In the above-mentioned claim 5, the tip connecting portion of the lead wire is used as a pin terminal so that the lead wire can be inserted into the mating wiring connector for connection (claim 8).
【００２２】さらに、前記請求項１の太陽電池モジュー
ルの製造方法として、本発明によれば、フレシキブルな
基板に単位太陽電池をパターン形成した長尺シートをロ
ールから繰り出し、そのシート搬送経路上で、まず各単
位太陽電池ごとに外部接続用端子を取付け、次に長尺シ
ートの表裏両面に封止材を貼り合わせてラミネートした
上で、長尺シートから単位太陽電池を裁断し、さらに裁
断した単位太陽電池についてその裁断面に封止材を被着
して封止して太陽電池モジュールを製造する（請求項
９）。Further, according to the present invention as a method for manufacturing a solar cell module according to claim 1, a long sheet having unit solar cells pattern-formed on a flexible substrate is fed out from a roll, and on the sheet conveying path, First, attach the external connection terminal to each unit solar cell, then laminate the sealing material on both sides of the long sheet, then cut the unit solar cell from the long sheet, and further cut the unit. The solar cell module is manufactured by applying a sealing material to the cut surface of the solar cell and sealing it.
【００２３】また、前記の製造方法において、外部接続
用端子の取付け工程でその端子のリード線に小片の封止
材を重ね合わせ、該封止材を続く工程で長尺シートの表
裏両面に張り合わせた封止材と一緒にラミネートしてリ
ード線の周域を隙間なくシールするようにする（請求項
１０）。Further, in the above-described manufacturing method, a small piece of sealing material is superposed on the lead wire of the terminal in the step of attaching the external connection terminal, and the sealing material is attached to both front and back surfaces of the long sheet in the subsequent step. It is laminated together with the sealing material so that the peripheral area of the lead wire is sealed without any gap (claim 10).
【００２４】上記のモジュールの製造方法によれば、長
尺シートから単位太陽電池を裁断した上で、単位太陽電
池の各枚葉ごとに外部接続用端子の取付け、封止材の処
理を施すようにした従来の製造法と比べて、製造工数を
大幅に節減して太陽電池モジュールの低コスト化，製造
プロセスの高スループット化が達成できる。According to the above-described method for manufacturing a module, the unit solar cell is cut from the long sheet, and then the external connection terminal is attached and the sealing material is treated for each individual sheet of the unit solar cell. Compared with the conventional manufacturing method described above, the manufacturing man-hours can be significantly reduced, and the cost of the solar cell module and the throughput of the manufacturing process can be increased.
【００２５】[0025]
【発明の実施の形態】以下本発明の実施の形態を図示実
施例に基づいて説明する。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below based on illustrated examples.
【００２６】〔実施例１〕まず、この実施例に関わる太
陽電池モジュールについて、その背面から見た模式図を
図２に示す。図において、１０はフレシキブルなプラス
チックの長尺シートを基板として、基板上に構成した複
数ユニットセルの集積形直列接続構造になる単位太陽電
池（図７参照）、１１は単位太陽電池１０の電力取出し
用電極５ａ（正極），５ｂ（負極）に取付けた外部接続
用端子、１２（破線で表す）は単位太陽電池１０の全体
に被覆した封止材の輪郭を表し、その他の符号は図７に
対応している。なお、図中の矢印Ｐは長尺シートの長手
方向、矢印Ｘは長尺シートから裁断した単位太陽電池１
０の裁断位置を表している。Example 1 First, FIG. 2 shows a schematic view of the solar cell module according to this example as seen from the back surface thereof. In the figure, 10 is a unit solar cell (see FIG. 7) having an integrated series connection structure of a plurality of unit cells formed on a substrate using a flexible long plastic sheet as a substrate, and 11 is power extraction from the unit solar cell 10. External connection terminals attached to the electrodes 5a (positive electrode) and 5b (negative electrode), 12 (represented by a broken line) represents the contour of the sealing material covering the entire unit solar cell 10, and other symbols are shown in FIG. It corresponds. In the figure, an arrow P indicates a longitudinal direction of the long sheet, and an arrow X indicates a unit solar cell 1 cut from the long sheet.
The cutting position of 0 is shown.
【００２７】次に、前記した外部接続用端子１１の詳細
構造を図４に示す。すなわち、外部接続用端子１１は、
端子板１１ａと、該端子板１１ａから側方に引出したリ
ード線１１ｂからなり、リード線１１ｂはその先端接続
部を除く周面を絶縁材１１ｃで覆い、端子板１１ａの片
面には導電接着剤１１ｄが塗布されている。ここで、端
子板１１ａは厚さ３００μｍ程度の銅箔もしくはアルミ
箔で、ここに長径３mm, 短径１．５mm程度の楕円形の断
面を持つ銅線もしくはアルミ線のリード線１１ｂが接続
されており、リード線１１ｂはその先端接続部をピン端
子として接続相手の配線コネクタへ差込み接続するよう
にしている。なお、この実施例では絶縁材１１ｃにはＰ
ＥＴ（ポリエチレンテレフタレート）を使用している。Next, the detailed structure of the external connection terminal 11 is shown in FIG. That is, the external connection terminal 11 is
It consists of a terminal plate 11a and a lead wire 11b that is pulled out laterally from the terminal plate 11a. The lead wire 11b covers the peripheral surface except the tip connecting portion with an insulating material 11c, and one surface of the terminal board 11a is provided with a conductive adhesive. 11d is applied. Here, the terminal board 11a is a copper foil or an aluminum foil having a thickness of about 300 μm, to which the lead wire 11b of a copper wire or an aluminum wire having a long diameter of 3 mm and a short diameter of about 1.5 mm and having an elliptical shape is connected. The lead wire 11b is adapted to be inserted and connected to a wiring connector of a connection partner by using the tip connection portion as a pin terminal. In this embodiment, the insulating material 11c has P
ET (polyethylene terephthalate) is used.
【００２８】一方、図１で単位太陽電池１０のシート全
体を包囲する封止材１２は、図３のモジュール断面図で
表すように、単位太陽電池１０の両面に貼り合わせた封
止材１２ａ，１２ｂと、単位太陽電池１０の裁断面（図
２の矢印Ｘに対応）に被着して前記封止材１２ａ，１２
ｂと一体化した封止材１２ｃとの組合せからなる。ここ
で、前記の封止材１２ａ〜１２ｃは、封止樹脂フィルム
１３と耐候性樹脂フィルム１４を貼り合わせて一体化し
たラミネートフィルムを用い、封止樹脂としてはブリヂ
ストン社製ＥＶＡ（エチレンビニルアセテート：商品名
EVASAFE1425厚さ０．４mm）を、また耐候性樹脂として
旭硝子社製ＥＴＦＥ（アフレックス25NlO30D・CS 厚さ
２５μｍ）を用いた。On the other hand, the encapsulant 12 surrounding the entire sheet of the unit solar cell 10 in FIG. 1 is the encapsulant 12a attached to both sides of the unit solar cell 10 as shown in the module cross section of FIG. 12b and the cut surface of the unit solar cell 10 (corresponding to the arrow X in FIG. 2), and the sealing materials 12a, 12
It is composed of a combination of b and an encapsulating material 12c. Here, the encapsulating materials 12a to 12c are laminated films in which the encapsulating resin film 13 and the weather resistant resin film 14 are bonded and integrated, and the encapsulating resin is EVA (ethylene vinyl acetate: manufactured by Bridgestone Corporation). Product name
EVASAFE1425 thickness 0.4 mm) and Asahi Glass ETFE (Aflex 25NlO30D.CS thickness 25 μm) were used as weather resistant resin.
【００２９】次に、前記した太陽電池モジュールの製造
方法を図１に示した製造工程で説明する。なお図中で、
１５はシート上に図２に示した集積形直列接続構造にな
る単位太陽電池１０が連続してパターン形成されている
長尺シート１６を巻き取ったロール、１７はロール１６
から繰り出した長尺シート１６の搬送経路上に設置した
端子取付装置、１８，１９は図３で述べた封止材１２
ａ，１２ｂを巻き取ったロール、２０，２１はロール１
８，１９から繰り出した封止材１２ａ，１２ｂを長尺シ
ート１６の表，裏面に貼り合わせるロール、２２は連続
ラミネータ、２３は裁断装置である。なお、前記のロー
ル１５には図７に示した単位太陽電池１０の透明電極３
が外側に向くように長尺シート１６が巻き取られてい
る。また、ロール１８，１９には図３における封止材１
２ａ，１２ｂの貼り付け方向に合わせて封止樹脂フィル
ム１３が外側，耐候性樹脂フィルム１４が内側に向くよ
うに巻かれており、封止材１２ａ，１２ｂの幅は長尺シ
ート１６の幅よりも一回り大きい寸法に設定されてい
る。Next, a method for manufacturing the above-mentioned solar cell module will be described with reference to the manufacturing process shown in FIG. In the figure,
Reference numeral 15 is a roll formed by winding a long sheet 16 on which the unit solar cells 10 having the integrated series connection structure shown in FIG.
3, the terminal mounting devices 18 and 19 installed on the conveying path of the long sheet 16 fed out from the sealing sheet 12 described in FIG.
Rolls a and 12b are wound, rolls 20 and 21 are rolls 1
A roll for bonding the sealing materials 12a and 12b fed out from Nos. 8 and 19 to the front and back surfaces of the long sheet 16, 22 is a continuous laminator, and 23 is a cutting device. The roll 15 has the transparent electrode 3 of the unit solar cell 10 shown in FIG.
The long sheet 16 is wound so that the sheet is directed outward. In addition, the rolls 18 and 19 have the sealing material 1 in FIG.
The sealing resin film 13 is wound so that the sealing resin film 13 faces the outside and the weather resistant resin film 14 faces the inside according to the attaching direction of the 2a and 12b, and the width of the sealing materials 12a and 12b is larger than the width of the long sheet 16. Is also one size larger.
【００３０】そして、前記の薄膜太陽電池をモジュール
化する製造工程で、ロール１５から送り出された長尺シ
ート１６はその搬送経路で最初に端子取付装置１７を通
過する。この端子取付装置１７には、あらかじめ図４に
示した外部接続用端子１１と、図５で示すように端子１
１のリード線１１ｂの周域を封止するために用意した短
冊状の封止材２４がセットされており、長尺シート１６
に形成した集積形直列接続構造の単位太陽電池１０の領
域が端子取付装置１７を通過する際に、単位太陽電池１
０の両端に並ぶ電力取出用の電極５ａ，５ｂに外部接続
用端子１１および封止材２４を自動で取り付けるように
している。なお、外部接続用端子１１の取付位置は、図
２で示すようにリード線１１ｂの先端接続部が封止材１
２の輪郭から側方に突き出すように位置決めし、端子板
１１ａが導電接着剤１１ｄを介して単位太陽電池１０の
電極面に接合され、この際に前記した封止材２４が図５
のようにリード線１１ｂを挟んで上下にセットされる。
なお、この封止材２４としては、ブリジストン社製のＥ
ＶＡ（エチレンビニルアセテート：商品名EVASAFE162
5：厚さ０．６mm) を縦, 横２０mmの短冊形に裁断した
ものを採用した。Then, in the manufacturing process for modularizing the thin film solar cell, the long sheet 16 sent out from the roll 15 first passes through the terminal mounting device 17 in its transport path. The terminal mounting device 17 includes an external connection terminal 11 shown in FIG. 4 and a terminal 1 shown in FIG.
The strip-shaped sealing material 24 prepared for sealing the peripheral area of the first lead wire 11b is set, and the long sheet 16 is provided.
When the area of the unit solar cell 10 having the integrated series connection structure formed in FIG.
The external connection terminals 11 and the sealing material 24 are automatically attached to the power extraction electrodes 5a and 5b arranged at both ends of 0. At the mounting position of the external connection terminal 11, as shown in FIG.
The terminal plate 11a is bonded to the electrode surface of the unit solar cell 10 via the conductive adhesive 11d while being positioned so as to project laterally from the contour of FIG.
As shown in FIG.
As the sealing material 24, E manufactured by Bridgestone Corporation is used.
VA (Ethylene vinyl acetate: trade name EVASAFE162
5: thickness 0.6 mm) was cut into a rectangular shape with a length of 20 mm and a width of 20 mm.
【００３１】また、前記の端子取付工程に続く封止工程
では、外部接続用端子１１，および端子リードの封止材
２４の取付けが完了した長尺シート１６に対し、ロール
１８から送り出された封止材１２ａ、およびロール１９
から送り出された封止材１２ｂがそれぞれロール２０，
２１により長尺シート１６の表裏両面に連続的に貼り合
わされ、次の連続ラミネータ２２での加熱，加圧処理に
より長尺シート１６，封止材１２ａ，１２ｂ，および２
４がラミネートされて単位太陽電池１０の周域が封止さ
れる。また、このラミネート操作により単位太陽電池１
０から側方に突き出た端子のリード線１１ｂの周面には
熱可塑性樹脂である封止材２４が軟化，密着して隙間を
残さずに封止される。In the encapsulating step following the above-mentioned terminal attaching step, the long sheet 16 on which the external connection terminals 11 and the terminal lead encapsulating material 24 have been attached is delivered from the roll 18. Stopping material 12a and roll 19
The sealing material 12b sent out from the roll 20 is
21 is continuously bonded to both the front and back surfaces of the long sheet 16, and the long sheet 16 and the sealing materials 12a, 12b, and 2 are heated and pressed by the continuous laminator 22.
4 is laminated and the peripheral region of the unit solar cell 10 is sealed. In addition, the unit solar cell 1
A sealing material 24, which is a thermoplastic resin, is softened and closely adhered to the peripheral surface of the lead wire 11b of the terminal protruding laterally from 0 to leave no gap.
【００３２】続くシートの裁断工程では、裁断装置２３
のカッタ操作で長尺シート１６から所定寸法の単位太陽
電池１０が切り離される。なお、単位太陽電池１０の裁
断位置（図２の矢印Ｘ）はあらかじめ長尺シート上に設
定して自動的に裁断するものとする。In the subsequent sheet cutting process, the cutting device 23
The unit solar cell 10 having a predetermined size is separated from the long sheet 16 by the cutter operation. The cutting position (arrow X in FIG. 2) of the unit solar cell 10 is set on the long sheet in advance and automatically cut.
【００３３】また、前記のプロセスを経て長尺シート１
６から裁断された単位太陽電池１０は、その裁断面にプ
ラスチック基板および基板上に製膜された光電変換素
子、電極などの端面が露呈している。そこで、この発明
ではモジュール製造プロセスの最終工程として単位太陽
電池１０の裁断面に、図３に示した封止材１２ｃを被着
して封止する。なお、この封止材１２ｃは先記のように
封止樹脂フィルム１３と耐候性樹脂フィルム１４の張り
合わせたラミネートフィルムで、あらかじめ封止材１２
ａ，１２ｂの幅に合わせて短冊状に裁断しておき、図１
の製造ラインとは別なラインで治具を用いて図３で表す
ようにラミネートする。そして、以上の工程を経て太陽
電池モジュールが完成する。Also, through the above process, the long sheet 1
The unit solar cell 10 cut from 6 has its cut surface exposed at the end faces of the plastic substrate and the photoelectric conversion elements, electrodes and the like formed on the substrate. Therefore, in the present invention, as the final step of the module manufacturing process, the cut surface of the unit solar cell 10 is coated with the sealing material 12c shown in FIG. The sealing material 12c is a laminated film obtained by laminating the sealing resin film 13 and the weather resistant resin film 14 as described above.
It is cut into strips according to the widths of a and 12b.
Laminate as shown in FIG. 3 using a jig on a line different from the manufacturing line. Then, the solar cell module is completed through the above steps.
【００３４】〔実施例２〕図６は長尺シートに形成した
セルパターンを変えた別な実施例を示すものである。こ
の実施例における太陽電池の基本構造は先記実施例１
（図２参照）と同様であるが、そのユニットセルの配列
については次のようにパターンニングしている。すなわ
ち、実施例１では太陽電池の各ユニットセルが長尺シー
トの長手方向Ｐに対して垂直方向に構成されているが、
この実施例では、ユニットセルを長尺シートの長手方向
Ｐに沿って平行に並ぶように構成した上で、その両サイ
ドに並ぶ電力取出し用電極５ａ，５ｂのうち、一方の電
極５ａをシートの右端縁に沿って他方の電極５ｂと並ぶ
位置まで延在するようにパターンニングしておき、図２
と同様に単位太陽電池１０の左右両端に外部接続用端子
１１を取り付けて外部に電力を取り出すようにしてい
る。[Embodiment 2] FIG. 6 shows another embodiment in which the cell pattern formed on the long sheet is changed. The basic structure of the solar cell in this embodiment is the same as in the first embodiment.
(See FIG. 2), but the unit cell array is patterned as follows. That is, in Example 1, each unit cell of the solar cell is configured in a direction perpendicular to the longitudinal direction P of the long sheet,
In this embodiment, the unit cells are arranged in parallel along the longitudinal direction P of the long sheet, and one of the power extraction electrodes 5a and 5b arranged on both sides of the unit cell is the electrode 5a of the sheet. Patterning is performed so as to extend along the right edge to a position aligned with the other electrode 5b.
Similarly, the external connection terminals 11 are attached to the left and right ends of the unit solar cell 10 to take out electric power to the outside.
【００３５】なお、外部接続用端子１１は、正極端子，
負極端子を長尺シートの長手方向Ｐに対して両サイド側
に振り分けて取付けるようにすることも可能である。The external connection terminal 11 is a positive electrode terminal,
It is also possible to distribute and attach the negative electrode terminals to both sides in the longitudinal direction P of the long sheet.
【００３６】[0036]
【発明の効果】以上述べたように、本発明によれば、フ
レシキブルなプラスチックの長尺シートを基板としてこ
の基板上に形成した単位太陽電池に対して、長尺シート
の状態で各単位太陽電池に外部接続用端子を取付け、さ
らに長尺シートの表裏両面の封止，耐候処理を行った後
に長尺シートから単位太陽電池を裁断し、その裁断部分
を封止，耐候処理を行うようにしたことにより、従来の
ように、長尺シートから単位太陽電池を裁断した上で外
部接続用端子の端子板を取付け、そのモジュールサイズ
に合わせて別に裁断して用意した封止材料を単位太陽電
池に貼り合わせ後、その封止材を部分的に剥がして端子
板にリード線を接続してその接続部分を再度封止してモ
ジュール化するようにした枚葉処理方式と比べて、製造
プロセスの工数を大幅に削減することができ、これによ
り太陽電池モジュールの大幅な低コスト化，高スループ
ット化を達成して製品を低価格で供給することができ
る。As described above, according to the present invention, a unitary solar cell formed on a flexible plastic long sheet as a substrate is used as a unit solar cell in the state of a long sheet. External connection terminals were attached to the front and back surfaces of the long sheet, and after weathering treatment, the unit solar cells were cut from the long sheet, and the cut portion was sealed and weathered. Therefore, as in the past, after cutting the unit solar cell from the long sheet, attach the terminal plate of the external connection terminal, and cut the sealing material separately prepared according to the module size to prepare the unit solar cell. After bonding, the encapsulating material is partially peeled off, the lead wire is connected to the terminal board, and the connecting part is resealed to make a module, so that the manufacturing process is more man-hours. To Can be reduced to the width, thereby significantly lower the cost of solar cell modules, the product to achieve high throughput can be supplied at low cost.
【図１】本発明の実施例による太陽電池モジュールの製
造工程図FIG. 1 is a manufacturing process diagram of a solar cell module according to an embodiment of the present invention.
【図２】本発明の実施例１に対応する単位太陽電池の背
面図FIG. 2 is a rear view of a unit solar cell corresponding to Example 1 of the present invention.
【図３】図２の矢視Ａ−Ａ断面に対応した太陽電池モジ
ュールの封止構造図FIG. 3 is a sealing structure diagram of a solar cell module corresponding to a cross section taken along the line AA in FIG.
【図４】図２における外部接続用端子の構造図4 is a structural diagram of an external connection terminal in FIG.
【図５】図２における外部接続用端子のリード線引出し
部に対応した封止材配置の模式図5 is a schematic diagram of the arrangement of the sealing material corresponding to the lead wire lead-out portion of the external connection terminal in FIG.
【図６】本発明の実施例２に対応する単位太陽電池の背
面図FIG. 6 is a rear view of a unit solar cell corresponding to Example 2 of the present invention.
【図７】本発明の太陽電池モジュールに適用するフィル
ム基板薄膜太陽電池の模式構造図FIG. 7 is a schematic structural diagram of a film substrate thin film solar cell applied to the solar cell module of the present invention.
１ フレシキブルなプラスチック基板 ２ 光電変換層 ３ 透明電極 ４ 裏面電極 ５ 背面電極 １０ 単位太陽電池 １１ 外部接続用端子 １１ａ 端子板 １１ｂ リード線 １１ｃ 絶縁材 １１ｄ 導電接着剤 １２，１２ａ〜１２ｃ 封止材 １３ 封止樹脂フィルム １４ 耐候性樹脂フィルム １５ 長尺シートのロール １６ 単位太陽電池を形成した長尺シート １７ 端子取付装置 ２２ 連続ラミネータ ２３ 裁断装置 1 Flexible plastic substrate 2 Photoelectric conversion layer 3 transparent electrodes 4 Back electrode 5 Back electrode 10 unit solar cell 11 External connection terminal 11a terminal board 11b lead wire 11c insulation 11d conductive adhesive 12, 12a-12c Sealing material 13 Sealing resin film 14 Weatherproof resin film 15 Roll of long sheet Long sheet with 16 unit solar cells 17 terminal mounting device 22 continuous laminator 23 Cutting device
Claims (10)
ある長尺シートを基板として、該基板上に光電変換素
子，透明電極および接続電極の各層をパターニングして
複数ユニットセルの集積形直列接続構造を形成した単位
太陽電池に対し、その電力取出し用電極に外部接続用端
子を取付けた上で、単位太陽電池のシート全体に封止材
を被覆して封止する太陽電池モジュールの製造方法にお
いて、 前記の単位太陽電池に対し、前記の外部接続用端子を長
尺シートの状態で取付けた上で、長尺シートの表裏両面
に貼り合わせた封止材と、長尺シートから単位太陽電池
を裁断した後にその裁断面に被着した封止材とで個々の
単位太陽電池を封止することを特徴とする太陽電池モジ
ュールの製造方法。1. A flexible long sheet that can be wound into a roll is used as a substrate, and each layer of a photoelectric conversion element, a transparent electrode and a connection electrode is patterned on the substrate to form an integrated series connection of a plurality of unit cells. In a method for manufacturing a solar cell module, in which a unit solar cell having a structure is mounted with an external connection terminal on its power extraction electrode, and then a sealing material is applied to the entire sheet of the unit solar cell for sealing. For the unit solar cell, after mounting the external connection terminal in the state of a long sheet, the sealing material pasted on both front and back surfaces of the long sheet, the unit solar cell from the long sheet A method for manufacturing a solar cell module, which comprises cutting each unit solar cell with a sealing material adhered to the cut surface after cutting.
キブル基板がプラスチックであることを特徴とする太陽
電池モジュールの製造方法。2. The method of manufacturing a solar cell module according to claim 1, wherein the flexible substrate is plastic.
に形成した光電変換素子がアモルファスシリコン形素子
であることを特徴とする太陽電池モジュールの製造方
法。3. The method of manufacturing a solar cell module according to claim 1, wherein the photoelectric conversion element formed on the substrate is an amorphous silicon type element.
が、封止樹脂と耐候性のある樹脂フィルムを貼り合わせ
たラミネートフィルムであることを特徴とする太陽電池
モジュールの製造方法。4. The method for manufacturing a solar cell module according to claim 1, wherein the encapsulating material is a laminate film obtained by laminating a sealing resin and a resin film having weather resistance.
続用端子が、銅箔もしくはアルミ箔の端子板に銅線もし
くはアルミ線のリード線を接続した構造であり、前記リ
ード線の先端接続部を単位太陽電池のシート側縁から側
方に突き出すようにして端子板を単位太陽電池の電力取
出し用電極面に電気的に接合することを特徴とする太陽
電池モジュールの製造方法。5. The manufacturing method according to claim 1, wherein the external connection terminal has a structure in which a lead wire made of a copper wire or an aluminum wire is connected to a terminal plate made of a copper foil or an aluminum foil, and the tip of the lead wire is connected. A method for manufacturing a solar cell module, wherein the terminal plate is electrically joined to the power extraction electrode surface of the unit solar cell such that the portion protrudes laterally from the side edge of the sheet of the unit solar cell.
続用端子は、先端接続部を除くリード線の周面に絶縁処
理を施した構造とすることを特徴とする太陽電池モジュ
ールの製造方法。6. The method of manufacturing a solar cell module according to claim 5, wherein the external connection terminal has a structure in which the peripheral surface of the lead wire excluding the tip connection portion is subjected to an insulation treatment. .
の片面に導電性接着剤を塗布した上で、該端子板を単位
太陽電池の電力取出し用電極面に貼り付けて電気的に接
続することを特徴とする太陽電池モジュールの製造方
法。7. The manufacturing method according to claim 5, wherein a conductive adhesive is applied to one surface of the terminal plate, and then the terminal plate is attached to the power extraction electrode surface of the unit solar cell for electrical connection. A method for manufacturing a solar cell module, comprising:
線の先端接続部は、接続相手側の配線コネクタに差込ん
で接続するピン端子とすることを特徴とする太陽電池モ
ジュール。8. The solar cell module according to claim 5, wherein the tip connecting portion of the lead wire is a pin terminal which is inserted into and connected to a wiring connector of a connection partner.
方法であって、基板上に単位太陽電池を連続的にパター
ン形成した長尺シートをロールから繰り出し、そのシー
ト搬送経路上で、 (1) 各単位太陽電池に外部接続用端子を取付ける、 (2) 長尺シートの表裏両面に封止材を貼り合わせてラミ
ネートする、 (3) 長尺シートから単位太陽電池を裁断する、さらに、
裁断済みの単位太陽電池に対し、その裁断面に封止材を
被着する工程からなることを特徴とする太陽電池モジュ
ールの製造方法。9. The method for manufacturing a solar cell module according to claim 1, wherein a long sheet having a pattern of unit solar cells continuously formed on a substrate is fed out from a roll, and (1) ) Attach terminals for external connection to each unit solar cell, (2) stick and seal the sealing material on the front and back surfaces of the long sheet, (3) cut the unit solar cell from the long sheet, and
A method of manufacturing a solar cell module, comprising a step of applying a sealing material to a cut surface of a cut unit solar cell.
接続用端子の取付け工程で端子のリード線に小片の封止
材を重ね合わせ、続く封止工程で前記封止材を長尺シー
トの表裏両面に張り合わせた封止材と一緒にラミネート
することを特徴とする太陽電池モジュールの製造方法。10. The manufacturing method according to claim 9, wherein a small piece of sealing material is superposed on the lead wire of the terminal in the step of attaching the external connection terminal, and the sealing material is formed into a long sheet in the subsequent sealing step. A method for manufacturing a solar cell module, which comprises laminating together with encapsulating materials stuck to both front and back surfaces.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002082925A JP4085304B2 (en) | 2002-03-25 | 2002-03-25 | Manufacturing method of solar cell module |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002082925A JP4085304B2 (en) | 2002-03-25 | 2002-03-25 | Manufacturing method of solar cell module |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003282922A true JP2003282922A (en) | 2003-10-03 |
| JP4085304B2 JP4085304B2 (en) | 2008-05-14 |
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ID=29230926
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|---|---|---|---|
| JP2002082925A Expired - Lifetime JP4085304B2 (en) | 2002-03-25 | 2002-03-25 | Manufacturing method of solar cell module |
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| Country | Link |
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Cited By (7)
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|---|---|---|---|---|
| JP2004186549A (en) * | 2002-12-05 | 2004-07-02 | Fuji Electric Holdings Co Ltd | Method for manufacturing solar battery module |
| KR100903950B1 (en) | 2008-11-22 | 2009-06-25 | 이차석 | Solar battery module manufacturing apparatus and process for producing the same |
| KR100942435B1 (en) | 2008-06-23 | 2010-02-17 | (주)텔리오솔라코리아 | Auto laminator and solarcell module laminating method using thereof |
| KR101036839B1 (en) | 2008-12-10 | 2011-05-25 | 주식회사 에스에프에이 | Over head jig and apparatus for manufacturing of solar cell string |
| KR101086779B1 (en) | 2008-11-27 | 2011-11-25 | (주)리드 | feeder unit and protection sheet feeding system for manufacturing solar cell module having the same |
| KR101105638B1 (en) | 2008-11-27 | 2012-01-18 | (주)리드 | protection sheet feeding system for manufacturing solar cell module |
| US9448711B2 (en) | 2005-05-23 | 2016-09-20 | Nokia Technologies Oy | Mobile communication terminal and associated methods |
-
2002
- 2002-03-25 JP JP2002082925A patent/JP4085304B2/en not_active Expired - Lifetime
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004186549A (en) * | 2002-12-05 | 2004-07-02 | Fuji Electric Holdings Co Ltd | Method for manufacturing solar battery module |
| US9448711B2 (en) | 2005-05-23 | 2016-09-20 | Nokia Technologies Oy | Mobile communication terminal and associated methods |
| US9785329B2 (en) | 2005-05-23 | 2017-10-10 | Nokia Technologies Oy | Pocket computer and associated methods |
| KR100942435B1 (en) | 2008-06-23 | 2010-02-17 | (주)텔리오솔라코리아 | Auto laminator and solarcell module laminating method using thereof |
| KR100903950B1 (en) | 2008-11-22 | 2009-06-25 | 이차석 | Solar battery module manufacturing apparatus and process for producing the same |
| KR101086779B1 (en) | 2008-11-27 | 2011-11-25 | (주)리드 | feeder unit and protection sheet feeding system for manufacturing solar cell module having the same |
| KR101105638B1 (en) | 2008-11-27 | 2012-01-18 | (주)리드 | protection sheet feeding system for manufacturing solar cell module |
| KR101036839B1 (en) | 2008-12-10 | 2011-05-25 | 주식회사 에스에프에이 | Over head jig and apparatus for manufacturing of solar cell string |
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| Publication number | Publication date |
|---|---|
| JP4085304B2 (en) | 2008-05-14 |
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