JPH07147424A - Manufacture of thin film solar cell module - Google Patents
Manufacture of thin film solar cell moduleInfo
- Publication number
- JPH07147424A JPH07147424A JP5293727A JP29372793A JPH07147424A JP H07147424 A JPH07147424 A JP H07147424A JP 5293727 A JP5293727 A JP 5293727A JP 29372793 A JP29372793 A JP 29372793A JP H07147424 A JPH07147424 A JP H07147424A
- Authority
- JP
- Japan
- Prior art keywords
- solar cell
- film
- adhesive resin
- conductive
- cell module
- 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
Landscapes
- Photovoltaic Devices (AREA)
Abstract
Description
【発明の詳細な説明】Detailed Description of the Invention
【０００１】[0001]
【産業上の利用分野】本発明は、アモルファスシリコン
等を主成分とする半導体薄膜を用いた薄膜太陽電池サブ
モジュールの複数個を接続してなる薄膜太陽電池モジュ
ールの製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a thin film solar cell module in which a plurality of thin film solar cell submodules using a semiconductor thin film containing amorphous silicon as a main component are connected.
【０００２】[0002]
【従来の技術】原料ガスのグロー放電分解や光ＣＶＤに
より形成されるアモルファス半導体薄膜は、気相成長法
で形成できるために、大面積化が容易であること、ま
た、形成温度が低いために樹脂のような可とう性を有す
る基板に形成できるという特徴を有している。こうした
アモルファス薄膜を用いた太陽電池モジュールは、アモ
ルファス太陽電池のサブモジュールを直列または並列に
電気的に接続し、太陽電池を屋外において劣化せず且つ
湿気を通さないようなガラス等の耐候性材料よりなる保
護基板により挟み、この保護基板と太陽電池との間をエ
チレンビニルアセテート (ＥＶＡ) 等の接着樹脂にて封
止している。2. Description of the Related Art An amorphous semiconductor thin film formed by glow discharge decomposition of a raw material gas or photo-CVD can be formed by a vapor phase growth method, so that it is easy to increase the area and the formation temperature is low. It has a feature that it can be formed on a substrate having flexibility such as resin. A solar cell module using such an amorphous thin film is a sub-module of an amorphous solar cell that is electrically connected in series or in parallel, and is made of a weather resistant material such as glass that does not deteriorate the solar cell outdoors and does not allow moisture to pass. It is sandwiched between the protective substrates and the solar cell is sealed with an adhesive resin such as ethylene vinyl acetate (EVA).
【０００３】[0003]
【発明が解決しようとする課題】モジュールを作製する
ために太陽電池を直列または並列に接続する方法とし
て、導電性フィルムを用いることが従来行われている。
すなわち、はんだを太陽電池電極部に融着させ、さらに
その上に導電性フィルムを載せて、はんだと導電性フィ
ルムを熱融着させる。これにより、導電性フィルムと太
陽電池電極部とを電気的に接続していた。しかし、この
方法では、電極面積が小さく、有効面積の大きい薄膜太
陽電池や、融点の低い合成樹脂基板を用いた薄膜太陽電
池のモジュール化は困難であった。As a method of connecting solar cells in series or in parallel to manufacture a module, it is conventional to use a conductive film.
That is, the solder is fused to the solar cell electrode portion, a conductive film is further placed thereon, and the solder and the conductive film are thermally fused. Thereby, the conductive film and the solar cell electrode portion were electrically connected. However, with this method, it was difficult to modularize a thin film solar cell having a small electrode area and a large effective area, or a thin film solar cell using a synthetic resin substrate having a low melting point.
【０００４】本発明の目的は、上述の問題を解決し、電
極面積が小さく、有効面積の大きい薄膜太陽電池や、融
点の低い基板を用いた薄膜太陽電池を相互に接続して作
製することのできる薄膜太陽電池モジュールの製造方法
を提供することにある。An object of the present invention is to solve the above problems and to fabricate a thin film solar cell having a small electrode area and a large effective area, and a thin film solar cell using a substrate having a low melting point, which are connected to each other. An object of the present invention is to provide a method of manufacturing a thin film solar cell module that can be used.
【０００５】[0005]
【課題を解決するための手段】上記の目的を達成するた
めに、本発明の薄膜太陽電池モジュールの製造方法の第
一は、絶縁性基板上に両端に帯状取出し電極を備えた太
陽電池構造を有するサブモジュールの複数個を取出し電
極の設けられない側で隣接させて一つの保護基板の上に
接着樹脂層を介して載せ、上面の両取出し電極の上に
は、その幅よりやや狭い幅を有する、両端面が露出する
金属片を分散して含む接着樹脂フィルムと、両端が端部
のサブモジュールの上より突出する導電性フィルムを、
取出し電極の上以外の部分には金属片を含まない接着樹
脂フィルムを積層し、さらにそれらの上に他の保護基板
を載せ、加熱圧着することにより、太陽電池サブモジュ
ールの両面を保護基板と接着すると共に、取出し電極を
導電性フィルムと電気的に接続するものとする。金属片
が銅よりなる柱状体であるか、金めっきした金属粉より
なることが良い。In order to achieve the above object, the first method of manufacturing a thin film solar cell module of the present invention is to provide a solar cell structure having strip-shaped extraction electrodes on both ends on an insulating substrate. Place a plurality of sub-modules that are adjacent to each other on the side where the extraction electrodes are not provided, and place them on a single protective substrate with an adhesive resin layer between them. Having an adhesive resin film containing dispersed metal pieces whose both end surfaces are exposed, and a conductive film having both ends protruding from above the end submodule,
Adhesive resin films that do not contain metal pieces are laminated on parts other than the extraction electrodes, and another protective substrate is placed on top of them, and the two sides of the solar cell submodule are bonded to the protective substrate by thermocompression bonding. In addition, the extraction electrode is electrically connected to the conductive film. The metal piece is preferably a columnar body made of copper or gold-plated metal powder.
【０００６】本発明の薄膜太陽電池モジュールの製造方
法の第二は、絶縁性基板上に両端に帯状取出し電極を備
えた太陽電池構造を有するサブモジュールの取出し電極
上に導電性の突起を形成し、そのサブモジュールの複数
個を取出し電極の設けられない側で隣接させて一つの保
護基板の上に接着樹脂層を介して載せ、各モジュールの
上を接着樹脂フィルムで覆い、両取出し電極上には両端
がサブモジュールの上により突出する導電性フィルムを
載せ、さらにその導電性フィルムおよび接着樹脂フィル
ムの露出面上に他の保護基板を載せ、加熱圧着すること
により太陽電池モジュールの両面を保護基板と接着する
と共に、取出し電極を接着樹脂フィルムを突き破った導
電性突起を介して導電性フィルムと電気的に接続するも
のとする。第三は、絶縁性基板上に両端に帯状取出し電
極を備えた太陽電池構造を有するサブモジュールの複数
個を取出し電極の設けられない側で隣接させて一つの保
護基板の上に接着樹脂層を介して載せ、各モジュールの
上を接着樹脂フィルムで覆い、両取出し電極の上には一
面に突起を形成した導電性フィルムを突起を取出し電極
に対向させて載せ、さらにその導電性フィルムおよび接
着樹脂フィルムの露出面上に他の保護基板を載せ、加熱
圧着することにより太陽電池モジュールの両面を保護基
板と接着すると共に、取出し電極を接着樹脂フィルムを
突き破った導電性突起を介して導電性フィルムと電気的
に接続するものとする。導電性突起が、はんだよりなる
ことが良い。いずれの方法でも、接着樹脂がエチレンビ
ニルアセテートであることが有効である。The second method of manufacturing the thin-film solar cell module of the present invention is to form a conductive protrusion on the extraction electrode of a submodule having a solar cell structure having strip-shaped extraction electrodes on both ends on an insulating substrate. , Multiple sub-modules are placed adjacent to each other on the side where the extraction electrodes are not provided, and placed on one protective substrate via an adhesive resin layer, and each module is covered with an adhesive resin film and placed on both extraction electrodes. Place a conductive film with both ends protruding above the sub-module, then place another protective substrate on the exposed surface of the conductive film and the adhesive resin film, and heat and pressure bond both sides of the solar cell module to the protective substrate. And the extraction electrode is electrically connected to the conductive film through the conductive protrusion that penetrates the adhesive resin film. Thirdly, a plurality of sub-modules having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate are taken out and adjacent to each other on the side where the extraction electrodes are not provided, and an adhesive resin layer is formed on one protective substrate. And then each module is covered with an adhesive resin film, and a conductive film with a protrusion formed on one surface is placed on both extraction electrodes facing the extraction electrode. Place another protective substrate on the exposed surface of the film, and bond both sides of the solar cell module to the protective substrate by heating and pressure bonding, and connect the extraction electrode to the conductive film through the conductive protrusion that pierces the adhesive resin film. It shall be electrically connected. The conductive protrusions are preferably made of solder. In either method, it is effective that the adhesive resin is ethylene vinyl acetate.
【０００７】[0007]
【作用】薄膜太陽電池サブモジュールを両面の保護基板
と接着樹脂で接着する際に、サブモジュール相互間の接
続および外部への発電電力の取出しに用いる導電性フィ
ルムとサブモジュールと端部電極との間を、接着樹脂に
含ませた金属片もしくは端部電極上あるいは導電性フィ
ルム上に形成され接着樹脂フィルムを突き破る導電性突
起により電気的に接続する。これによりはんだ付けによ
る導電性フィルムとの接続が回避される。When the thin-film solar cell submodule is bonded to the protective substrates on both sides with the adhesive resin, the conductive film, the submodule, and the end electrodes are used to connect the submodules to each other and take out the generated power to the outside. The spaces are electrically connected to each other by conductive projections formed on the metal pieces or the end electrodes included in the adhesive resin or on the conductive film and penetrating the adhesive resin film. This avoids soldering to the conductive film.
【０００８】[0008]
【実施例】次に、本発明の実施例を図面に基づいて説明
する。図１(a) 、(b) に示す実施例では、薄膜太陽電池
と耐候性基板間の接着樹脂に金属片を含有させている。
太陽電池の基板１に可とう性を有する膜厚50μｍのポリ
エチレンナフタレートフィルムを用いた。この基板の表
面上にスパッタ法によりＩＴＯ膜を1000Åの厚さに形成
し、このＩＴＯ膜をレーザスクライブ法により短冊状に
分離した。その後に、プラズマＣＶＤ法によりアモルフ
ァスシリコン (以下ａ−Siと記す) 膜を形成し、これを
再びレーザスクライブ法により短冊状に分離した。さら
にこの上に、スパッタ法により銀を2000Åの厚さに形成
し、レーザスクライブ法により短冊状に分離することに
より、ａ−Si太陽電池サブモジュール２を作製した。そ
して、透明な耐候性保護基板であるガラス板31の上に接
着樹脂であるＥＶＡ４のフィルムを介してａ−Si太陽電
池サブモジュール２を実装した基板１を乗せた。そし
て、各サブモジュールの電極部の上には、金属片５とし
て銅片を含有したＥＶＡ４のフィルム、例えば日立化成
(株) 商品名異方導電フィルムアニソルムおよび透明電
極部と同じ幅の銅箔の片面に導電性接着剤を塗布した導
電性フィルム６、それ以外の部分にはＥＶＡ４のみのフ
ィルムを載せ、その上にさらにガラス板32を載せ熱圧着
した。熱圧着した時の熱により、接着樹脂であるＥＶＡ
４が溶け、ａ−Si太陽電池サブモジュール２とガラス板
31、32が接着する。同時に、銅片５を介して、ａ−Si太
陽電池サブモジュール２の取出し電極と導電性フィルム
６が電気的に接続され、ａ−Si太陽電池サブモジュール
２相互間の接続が行われ、また端部61から外部への発電
電力の取出しを行うことができる。このように、ａ−Si
太陽電池サブモジュール２の出力は、各サブモジュール
の取出し電極をＥＶＡ４の中に分散した銅片５を介し
て、導電性フィルム６と接続することにより外部に取り
出されている。この各サブモジュールの接続は、必要電
圧に応じて直列および並列に行う。ＥＶＡ４の中に分散
した銅片５は、ここでは、直径50μｍ、高さ100 μｍの
円柱状で50μｍ程度のピッチでランダムに分散している
が、銅片の形状が球状やリベット状の物も同様の効果が
ある。銅片５により、ａ−Si太陽電池セル間を短絡させ
ないために、銅片５を含有するＥＶＡフィルム６の幅
は、サブモジュール２の裏面電極である銀電極のパター
ニング幅よりもやや狭いことが重要である。ＥＶＡ４の
中に分散させる金属片５の材料としては、銅に限定され
ず、太陽電池サブモジュール２の取出し電極および導電
性フィルム６との接続を良好にするものであればよく、
例えば金属粉の表面に金をコーティングしたものも有効
である。また、金属粉を含有するＥＶＡ４のフィルムの
膜厚は、金属粉がＥＶＡフィルムから露出し、太陽電池
サブモジュール２の取出し電極および導電性フィルム６
と十分に接触するように薄くする必要がある。このこと
から今回の試作では、ＥＶＡ４のフィルムの膜厚を100
μｍとした。またこの実施例では、片側に導電性接着剤
を塗布した導電性フィルム６を用いたが、これは、導電
性フィルム６を導電性接着剤により、ＥＶＡ４のフィル
ムまたはガラス板32に固定することにより、熱圧着時の
導電性フィルム６の位置ずれを防ぐためである。本構造
にすることにより、太陽電池サブモジュール２の取出し
電極にはんだ付けすることなく、簡単に、太陽電池サブ
モジュール２相互間の直列または並列接続および外部へ
の電力の取出しが行える。また、導電性フィルム６の幅
を太陽電池サブモジュール２の裏面電極幅より小さくす
ることによって、精密な位置合わせが必要なくなるの
で、取出し電極面積が小さく面積効率の高いａ−Si太陽
電池モジュールが作製できるということがある。Embodiments of the present invention will now be described with reference to the drawings. In the embodiment shown in FIGS. 1 (a) and 1 (b), a metal piece is contained in the adhesive resin between the thin film solar cell and the weather resistant substrate.
A flexible polyethylene naphthalate film having a thickness of 50 μm was used as the substrate 1 of the solar cell. An ITO film having a thickness of 1000 Å was formed on the surface of this substrate by a sputtering method, and this ITO film was separated into strips by a laser scribing method. After that, an amorphous silicon (hereinafter referred to as a-Si) film was formed by the plasma CVD method, and this was again separated into strips by the laser scribing method. Further, silver was formed thereon to a thickness of 2000 Å by a sputtering method and separated into strips by a laser scribing method, whereby an a-Si solar cell submodule 2 was produced. Then, the substrate 1 on which the a-Si solar cell sub-module 2 was mounted was placed on the glass plate 31 which was a transparent weather-resistant protective substrate via the EVA4 film which was an adhesive resin. Then, on the electrode portion of each sub-module, a film of EVA4 containing a copper piece as the metal piece 5, for example, Hitachi Chemical
(Trade name) Anisotropic conductive film Anisolm and conductive film 6 with conductive adhesive applied to one side of the copper foil of the same width as the transparent electrode part, and the other part is a film of EVA4 only. A glass plate 32 was further placed on the above and thermocompression bonded. EVA that is an adhesive resin due to the heat of thermocompression bonding
4 melted, a-Si solar cell sub-module 2 and glass plate
31 and 32 adhere. At the same time, the extraction electrode of the a-Si solar cell sub-module 2 and the conductive film 6 are electrically connected via the copper piece 5, and the a-Si solar cell sub-modules 2 are connected to each other, and the ends are also connected. It is possible to take out the generated power from the unit 61 to the outside. Thus, a-Si
The output of the solar cell sub-module 2 is taken out to the outside by connecting the take-out electrode of each sub-module to the conductive film 6 via the copper piece 5 dispersed in the EVA 4. The submodules are connected in series and in parallel according to the required voltage. Here, the copper pieces 5 dispersed in the EVA 4 are columnar with a diameter of 50 μm and a height of 100 μm and are randomly dispersed at a pitch of about 50 μm. However, copper pieces having a spherical shape or a rivet shape are also available. It has the same effect. In order to prevent short circuit between the a-Si solar cells by the copper piece 5, the width of the EVA film 6 containing the copper piece 5 may be slightly narrower than the patterning width of the silver electrode which is the back surface electrode of the submodule 2. is important. The material of the metal piece 5 to be dispersed in the EVA 4 is not limited to copper, and may be any material as long as it makes good connection with the extraction electrode of the solar cell submodule 2 and the conductive film 6.
For example, a metal powder whose surface is coated with gold is also effective. In addition, the film thickness of the EVA4 film containing the metal powder is such that the metal powder is exposed from the EVA film and the extraction electrode of the solar cell sub-module 2 and the conductive film 6 are formed.
Should be thin enough to make good contact with. Therefore, in this trial production, the film thickness of EVA4 film was 100
μm. In addition, in this embodiment, the conductive film 6 coated with a conductive adhesive on one side is used. This is achieved by fixing the conductive film 6 to the EVA 4 film or the glass plate 32 with the conductive adhesive. This is to prevent the conductive film 6 from being displaced during thermocompression bonding. With this structure, it is possible to easily connect the solar cell submodules 2 in series or in parallel with each other and take out the electric power to the outside without soldering to the extraction electrodes of the solar cell submodules 2. Also, by making the width of the conductive film 6 smaller than the back electrode width of the solar cell sub-module 2, it is not necessary to perform precise alignment, so that an a-Si solar cell module having a small extraction electrode area and high area efficiency is produced. There are things you can do.
【０００９】同じ効果を有する構造として、本発明の別
の実施例による図２(a) 、(b) の構造がある。本実施例
では、基板１に可とう性を有する膜厚50μｍのポリレチ
レンナフタレートフィルムを用いた。この基板にスパッ
タ法によりＩＴＯ膜を1000Åの厚さに形成し、このＩＴ
Ｏ膜をレーザスクライブ法により短冊状に分離した。そ
の後に、プラズマＣＶＤ法により、ａ−Si膜を形成し、
これを再びレーザスクライブ法により短冊状に分離し
た。さらにこの上に、スパッタ法により銀を2000Åの厚
さに形成し、レーザスクライブ法により短冊状に分離す
ることにより裏面電極とし、ａ−Si太陽電池サブモジュ
ール２を形成した。ここで、裏面電極である銀電極の電
極取出し部へ、超音波はんだ付けにより、導電性突起７
を形成した。この導電性突起は、導電性ペーストをスク
リーン印刷する方法やディスペンダにてはんだや導電性
ペーストを滴下する方法でも同様に行える。そして、こ
のような加工を施した太陽電池サブモジュール２を透明
な耐候性保護基板であるガラス板31の上に、接着樹脂で
あるＥＶＡ４を介して載せた。その上にＥＶＡ４のフィ
ルム、銅箔の片面に導電性接着剤を塗布した導電性フィ
ルム６、ガラス板32を載せ熱圧着した。熱圧着した時の
熱により、接着樹脂であるＥＶＡ４が溶け、太陽電池サ
ブモジュール２とガラス板31、32が接着する。この時、
太陽電池サブモジュール２の銀電極部に形成された導電
性突起７が、上に乗ったＥＶＡ４のフィルムを突き破
り、その上の導電性フィルム６と電気的に接続するの
で、太陽電池サブモジュール２相互間の接続を行い、外
部への発電電力の取出しに用いられる。この構造で重要
なことは、導電性突起７の先端を尖らせ、ＥＶＡ４のフ
ィルムを突き破れるようにすることである。この実施例
では、はんだが円錐状になるようにはんだ付けを行っ
た。また、導電性突起52および導電性フィルム６に低融
点はんだを塗布することにより、熱圧着時に低融点はん
だが溶け、導電性突起７と導電性フィルム６をはんだ付
けする方法も有効である。As a structure having the same effect, there is a structure shown in FIGS. 2 (a) and 2 (b) according to another embodiment of the present invention. In this example, a flexible polyretylene naphthalate film having a film thickness of 50 μm was used as the substrate 1. An ITO film is formed on this substrate by a sputtering method to a thickness of 1000 Å, and this IT
The O film was separated into strips by the laser scribing method. After that, an a-Si film is formed by the plasma CVD method,
This was again separated into strips by the laser scribing method. Further, silver was formed thereon to a thickness of 2000 Å by a sputtering method and separated into strips by a laser scribing method to form a back electrode, thereby forming an a-Si solar cell submodule 2. Here, the conductive protrusion 7 is formed by ultrasonic soldering on the electrode extraction portion of the silver electrode which is the back surface electrode.
Was formed. This conductive protrusion can be similarly formed by a method of screen-printing a conductive paste or a method of dropping solder or a conductive paste with a dispenser. Then, the solar cell sub-module 2 thus processed was placed on the glass plate 31 which is a transparent weatherproof protective substrate via the EVA 4 which is an adhesive resin. A film of EVA 4, a conductive film 6 in which a conductive adhesive was applied to one surface of a copper foil, and a glass plate 32 were placed thereon and thermocompression bonded. EVA 4 which is an adhesive resin is melted by the heat generated by thermocompression bonding, and the solar cell submodule 2 and the glass plates 31 and 32 are adhered to each other. This time,
Since the conductive protrusion 7 formed on the silver electrode portion of the solar cell sub-module 2 breaks through the EVA 4 film on it and is electrically connected to the conductive film 6 thereon, the solar cell sub-module 2 It is used to take out the generated power to the outside by connecting between. What is important in this structure is to sharpen the tips of the conductive protrusions 7 so that the EVA 4 film can be pierced. In this example, soldering was performed so that the solder had a conical shape. Further, by applying the low melting point solder to the conductive protrusions 52 and the conductive film 6, the low melting point solder is melted during thermocompression bonding, and the conductive protrusions 7 and the conductive film 6 are soldered.
【００１０】図３は、本発明の別の実施例により製造さ
れた、薄膜太陽電池サブモジュールを直列または並列に
接続する導電性フィルム６に導電性突起を形成した薄膜
太陽電池モジュールを示している。この場合は、太陽電
池の基板１に可とう性を有する膜厚50μｍのポリエチレ
ンナフタレートフィルムを用いた。この基板にスパッタ
法によりＩＴＯ膜を1000Åの厚さに形成し、このＩＴＯ
膜をレーザスクライブ法により短冊状に分離した。その
後に、プラズマＣＶＤ法により、ａ−Si膜を形成し、こ
れを再びレーザスクライブ法により短冊状に分離した。
さらにこの上に、スパッタ法により銀を2000Åの厚さに
形成し、レーザスクライブ法により短冊状に分離するこ
とにより、ａ−Si太陽電池サブモジュール２を作製し
た。そして、この太陽電池サブモジュール２を透明な耐
候性保護基板であるガラス板31、接着樹脂であるＥＶＡ
４の上に載せた。その上に、ＥＶＡ４のフィルム、導電
性突起７のついた導電性フィルム６を突起７を下側にし
て載せ、さらにガラス板32を載せ、熱圧着した。導電性
フィルム６に導電性突起７を付ける方法としては、図２
に示した実施例と同様に超音波はんだ付けによる方法
や、導電性ペーストをスクリーン印刷する方法あるいは
ディスペンダにてはんだや導電性ペーストを滴下する方
法により行える。熱圧着した時の熱により、接着樹脂で
あるＥＶＡ４が溶け、太陽電池サブモジュール２とガラ
ス板31、32が接着する。この時、導電性フィルム６の下
面に形成された導電性突起７が下地のＥＶＡ４のフィル
ムを突き破り、太陽電池サブモジュール２の取出し電極
と電気的に接続するのでａ−Si太陽電池モジュール２相
互間の接続を行い、また外部への発電電力の取出しに用
いられる。この構造で重要なことは、導電性突起７の先
端を尖らせ、ＥＶＡ４のフィルムを突き破れるようにす
ることである。本実施例では、はんだが円錐状になるよ
うにはんだ付けを行った。また、導電性突起に低融点は
んだを塗布することにより、熱圧着時に低融点はんだが
溶け、導電性突起７と導電性フィルム６をはんだ付けす
る方法も有効である。FIG. 3 shows a thin film solar cell module manufactured according to another embodiment of the present invention, in which conductive protrusions are formed on a conductive film 6 for connecting thin film solar cell submodules in series or in parallel. . In this case, a flexible polyethylene naphthalate film having a thickness of 50 μm was used for the substrate 1 of the solar cell. An ITO film is formed on this substrate by a sputtering method to a thickness of 1000 Å.
The film was separated into strips by the laser scribing method. After that, an a-Si film was formed by the plasma CVD method, and this was again separated into strips by the laser scribing method.
Further, silver was formed thereon to a thickness of 2000 Å by a sputtering method and separated into strips by a laser scribing method, whereby an a-Si solar cell submodule 2 was produced. Then, the solar cell sub-module 2 is provided with a glass plate 31 which is a transparent weatherproof protective substrate and an EVA which is an adhesive resin.
Placed on top of 4. A film of EVA 4 and a conductive film 6 having conductive projections 7 were placed thereon, with the projections 7 on the lower side, and a glass plate 32 was further placed thereon, followed by thermocompression bonding. As a method for attaching the conductive protrusions 7 to the conductive film 6, a method shown in FIG.
Similar to the embodiment shown in the above, the method can be performed by ultrasonic soldering, a method of screen-printing a conductive paste, or a method of dropping solder or a conductive paste with a dispenser. EVA 4 which is an adhesive resin is melted by the heat generated by thermocompression bonding, and the solar cell submodule 2 and the glass plates 31 and 32 are adhered to each other. At this time, the conductive protrusions 7 formed on the lower surface of the conductive film 6 pierce the EVA 4 film as the base and electrically connect to the extraction electrodes of the solar cell sub-module 2, so that the a-Si solar cell modules 2 are connected to each other. It is also used for connecting the power supply and taking out the generated power to the outside. What is important in this structure is to make the tips of the conductive protrusions 7 sharp so that they can break through the EVA 4 film. In this example, the soldering was performed so that the solder had a conical shape. Further, a method of applying the low melting point solder to the conductive protrusions to melt the low melting point solder during thermocompression bonding and soldering the conductive protrusions 7 and the conductive film 6 is also effective.
【００１１】[0011]
【発明の効果】本発明によれば、接着樹脂フィルムに含
まれる金属片もしくは太陽電池サブモジュールの端部電
極あるいは導電性フィルム上に形成した導電性突起の圧
接により導電性フィルムと端部電極を電気的に接続する
ことにより、はんだ付け工程を必要とせず、電極面積が
小さいものや合成樹脂基板を用いた薄膜太陽電池の接続
が行えるという利点を有している。この方法を用いるこ
とにより、薄膜太陽電池モジュールの単位面積当たりの
発電電力を容易に増加させることができる。また、複雑
な配線プロセスを必要としないため薄膜太陽電池モジュ
ールの製造コストを低減できる。According to the present invention, the conductive film and the end electrode are attached by pressure welding of the metal piece contained in the adhesive resin film or the end electrode of the solar cell sub-module or the conductive protrusion formed on the conductive film. By electrically connecting, there is an advantage that a soldering process is not required and a thin electrode solar cell using a small electrode area or a synthetic resin substrate can be connected. By using this method, the generated power per unit area of the thin film solar cell module can be easily increased. Moreover, since a complicated wiring process is not required, the manufacturing cost of the thin film solar cell module can be reduced.
【図１】第一の本発明の一実施例による薄膜太陽電池モ
ジュールを示し、(a) が断面図、(b) が平面図FIG. 1 shows a thin-film solar cell module according to an embodiment of the present invention, (a) is a sectional view and (b) is a plan view.
【図２】第二の本発明の一実施例による薄膜太陽電池モ
ジュールを示し、(a) が断面図、(b) が平面図FIG. 2 shows a thin-film solar cell module according to an embodiment of the second invention, (a) is a sectional view and (b) is a plan view.
【図３】第三の本発明の一実施例による薄膜太陽電池モ
ジュールを示し、(a) が断面図、(b) が平面図FIG. 3 shows a thin-film solar cell module according to an embodiment of the third invention, (a) is a cross-sectional view and (b) is a plan view.
１ 太陽電池基板 ２ 太陽電池サブモジュール 31、32 ガラス板 ４ ＥＶＡ ５ 銅片 ６ 導電性フィルム ７ 導電性突起 1 solar cell substrate 2 solar cell sub-modules 31, 32 glass plate 4 EVA 5 copper piece 6 conductive film 7 conductive protrusion
Claims (7)
えた太陽電池構造を有するサブモジュールの複数個を取
出し電極の設けられない側で隣接させて一つの保護基板
の上に接着樹脂層を介して載せ、上面の両取出し電極の
上には、その幅よりやや狭い幅を有する、両端面が露出
する金属片を分散して含む接着樹脂フィルムと、両端が
端部のサブモジュールの上より突出する導電性フィルム
を、取出し電極の上以外の部分には金属片を含まない接
着樹脂フィルムを積層し、さらにそれらの上に他の保護
基板を載せ、加熱圧着することにより、太陽電池サブモ
ジュールの両面を保護基板と接着すると共に、取出し電
極を導電性フィルムと電気的に接続することを特徴とす
る薄膜太陽電池モジュールの製造方法。1. An adhesive resin layer on a protective substrate, wherein a plurality of sub-modules having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate are adjacent to each other on the side where the extraction electrodes are not provided. On top of both extraction electrodes on the top surface, and an adhesive resin film that has a width that is slightly narrower than that width and that contains metal pieces with exposed end surfaces, and a sub-module whose both ends are ends. The conductive film that protrudes further is laminated on an adhesive resin film that does not contain metal pieces on the part other than the extraction electrode, and then another protective substrate is placed on them, and by thermocompression bonding, the solar cell sub A method for manufacturing a thin-film solar cell module, characterized in that both sides of the module are adhered to a protective substrate and the extraction electrode is electrically connected to a conductive film.
記載の薄膜太陽電池モジュールの製造方法。2. The metal piece is a columnar body made of copper.
A method for manufacturing the thin film solar cell module described.
項１記載の薄膜太陽電池モジュールの製造方法。3. The method of manufacturing a thin film solar cell module according to claim 1, wherein the metal piece is made of gold-plated metal powder.
えた太陽電池構造を有するサブモジュールの取出し電極
上に導電性の突起を形成し、そのサブモジュールの複数
個を取出し電極の設けられない側で隣接させて一つの保
護基板の上に接着樹脂層を介して載せ、各モジュールの
上を接着樹脂フィルムで覆い、両取出し電極上には両端
がサブモジュールの上により突出する導電性フィルムを
載せ、さらにその導電性フィルムおよび接着樹脂フィル
ムの露出面上に他の保護基板を載せ、加熱圧着すること
により太陽電池モジュールの両面を保護基板と接着する
と共に、取出し電極を接着樹脂フィルムを突き破った導
電性突起を介して導電性フィルムと電気的に接続するこ
とを特徴とする薄膜太陽電池モジュールの製造方法。4. An electrically conductive protrusion is formed on an extraction electrode of a submodule having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate, and a plurality of extraction electrodes of the submodule are provided. Adjacent to the other side, it is placed on one protective substrate via an adhesive resin layer, each module is covered with an adhesive resin film, and both ends of both extraction electrodes project above the submodule. On the exposed surface of the conductive film and the adhesive resin film, and by thermocompression bonding, both sides of the solar cell module are bonded to the protective substrate, and the extraction electrode pierces the adhesive resin film. A method for manufacturing a thin-film solar cell module, which comprises electrically connecting to a conductive film via a conductive protrusion.
えた太陽電池構造を有するサブモジュールの複数個を取
出し電極の設けられない側で隣接させて一つの保護基板
の上に接着樹脂層を介して載せ、各モジュールの上を接
着樹脂フィルムで覆い、両取出し電極の上には一面に突
起を形成した導電性フィルムを突起を取出し電極に対向
させて載せ、さらにその導電性フィルムおよび接着樹脂
フィルムの露出面上に他の保護基板を載せ、加熱圧着す
ることにより太陽電池モジュールの両面を保護基板と接
着すると共に、取出し電極を接着樹脂フィルムを突き破
った導電性突起を介して導電性フィルムと電気的に接続
することを特徴とする薄膜太陽電池モジュールの製造方
法。5. An adhesive resin layer on one protective substrate, wherein a plurality of sub-modules having a solar cell structure having strip-shaped extraction electrodes at both ends on an insulating substrate are adjacent to each other on the side where the extraction electrodes are not provided. The module, cover each module with an adhesive resin film, and place a conductive film with a protrusion on one side of both extraction electrodes facing the extraction electrode. Put another protective substrate on the exposed surface of the resin film, and bond both sides of the solar cell module to the protective substrate by heating and pressure bonding, and at the same time, take out the electrode from the conductive resin through the conductive protrusion that penetrates the adhesive resin film. And a method for manufacturing a thin-film solar cell module, which is characterized in that the thin-film solar cell module is electrically connected to.
いは５記載の薄膜太陽電池モジュールの製造方法。6. The method for manufacturing a thin-film solar cell module according to claim 4, wherein the conductive protrusion is made of solder.
る請求項１ないし６のいずれかに記載の薄膜太陽電池モ
ジュールの製造方法。7. The method for manufacturing a thin-film solar cell module according to claim 1, wherein the adhesive resin is ethylene vinyl acetate.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP29372793A JP3448924B2 (en) | 1993-11-25 | 1993-11-25 | Method for manufacturing thin-film solar cell module |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP29372793A JP3448924B2 (en) | 1993-11-25 | 1993-11-25 | Method for manufacturing thin-film solar cell module |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH07147424A true JPH07147424A (en) | 1995-06-06 |
| JP3448924B2 JP3448924B2 (en) | 2003-09-22 |
Family
ID=17798466
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP29372793A Expired - Fee Related JP3448924B2 (en) | 1993-11-25 | 1993-11-25 | Method for manufacturing thin-film solar cell module |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3448924B2 (en) |
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