JPH0621501A - Solar cell module and method of manufacturing the same - Google Patents

Abstract

PURPOSE:To provide an inexpensive solar cell module with high conversion efficiency and resistance to bending and temperature fluctuation of the module, and hardly shortcircuited. CONSTITUTION:Within the solar cell module comprising multiple solar cell elements 120, 121 having a lower electrode layer 102, a semiconductor layer 103, an upper electrode layer 104 and a collector electrode 105 of the upper electrode 104 on a conductive substrate 101, the solar cell element 120 and the other solar cell element 121 adjacent to the former element 120 are to be connected by a connector 110 in laminated structure comprising a conductive member 112 and an insulating member 111.

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 plurality of solar cell elements connected in series and in parallel,
It is to provide a solar cell module having particularly high reliability and high conversion efficiency.

[0002]

Recently, it is expected to global warming by the greenhouse effect due to an increase in such CO ₂ occurs, clean energy requirements that do not emit CO ₂ and the like is increasing more and more.

Further, nuclear power generation which does not emit CO ₂ has not solved the problem of radioactive waste, and safer and cleaner energy is desired.

Among the clean energies expected in the future, solar cells are particularly expected because of their cleanliness, safety and easy handling.

Among various solar cells, particularly, amorphous silicon solar cells, polycrystalline silicon solar cells and the like can be manufactured in a large area and the manufacturing cost is low, and thus they are enthusiastically studied.

Since the above solar cell is required to have a voltage of several tens of volts or more for practical use, the upper electrode and the lower electrode of adjacent solar cell elements are connected in series and used.

When impact resistance and flexibility are required, a conductive base material such as stainless steel can be used as the substrate material.

FIGS. 10 and 11 are schematic views of a conventional solar cell module in which a plurality of solar cell elements are connected in series by using a wiring material.

In FIGS. 10 and 11, (200a),
(200b) is a conductive substrate, (201a), (201
b) is a lower electrode, (202a) and (202b) are semiconductor layers, (203a) and (203b) are upper electrodes, and (204)
a), (204b), (204c) are collector electrodes, (20)
5a) and (205b) are wiring materials, and (206) and (20
7) is a solar cell element. (208) is also a solar cell having the same configuration.

The solar cell element (206) is formed by sequentially forming a lower electrode (201a), a semiconductor layer (202a) and an upper electrode (203a) on a conductive substrate (200a), and then a solar cell. The electrically conductive substrate of the battery element (206) and the current collecting electrode (204b) of the adjacent solar cell element (207) are electrically connected using the wiring member (205a), and similarly the solar cell element (207). And the solar cell element (208) adjacent to are connected in series.

Since the connecting body used for the series connection is usually a metal body, even if the upper electrode (203a) comes into contact with the connecting body (205a), as shown in FIG.
Since the upper electrode can be separated as in 6, no short circuit occurs. In addition, even if it is not separated, in an a-Si solar cell, the resistance is large and a current does not easily flow in the lateral direction, so it may not be a problem, but since the lower electrode is a metal, it is connected to this connection body. The lower electrode (201b) of the solar cell element (207) whose body is connected to the collecting electrode (204b)
So that they do not come into contact with each other, and, for example, the lower electrodes (201) of adjacent solar cell elements (206) and (207)
a) and (201b) must not come into contact with each other, and inevitably the solar cell elements (206), (20)
Since the distance of 7) has to be increased, the ratio of the effective power generation area is reduced when viewed from the solar cell module.
There is a problem that the conversion efficiency is lowered.

Further, if the solar cell module is bent while the solar cell module is in use, stress is inevitably applied to the connecting body between the solar cell elements.
If the solar cell element and the series connection body and the solar cell element are short-circuited, the quality deteriorates, and the thickness of the connection body is thin, or if the connection body is connected to only a part of the solar cell, the solar cell module There is a problem that the connection body is broken by repeated bending of.

Further, in the connection body used for the series connection, the portion exposed on the surface of the solar cell module covers the light-receiving surface of the solar cell element and thus becomes a non-power generation region. The connecting body (2
It is also possible to connect in series by using a comb-shaped connecting body (210) as shown in FIG. 12 instead of 05a) and (205b). There is a problem that the strength becomes weak and the connection body for series connection is broken when the solar cell module in which the solar cell elements are connected in series using this connection body is repeatedly bent. Further, in order to prevent this, the thickness of the connecting body can be increased. However, since the connection body is a metal body such as copper, increasing the thickness increases the strength of the metal itself, and there is a problem that the metal edge of the connection body or the like damages the surface of the solar cell element.

Further, when the solar cells are connected in series and used, it is necessary to prevent the solar cells from being destroyed by the application of the reverse voltage. For example, when only the incident light of one solar cell element in a solar cell module in which four solar cell elements are connected in series is blocked to become a shadow, no electromotive force is generated in that solar cell element, and another solar cell There is a risk that the total output voltage of the device will be applied to this solar cell as a reverse voltage and the device will be destroyed.

In order to prevent such a reverse voltage application, as shown in FIG. 13, a reverse voltage application prevention bypass diode (230) must be installed in parallel with each solar cell element.

FIG. 13 is a schematic diagram in which three solar cell elements are connected in series and then a reverse voltage application preventing bypass diode is connected to the upper electrode and the lower electrode of each solar cell element. is there. Further, FIG. 14 shows X- in FIG.
It is a X'sectional view.

In FIGS. 13 and 14, (240),
(241) and (242) are conductive substrates (250)
This is a solar cell element in which a lower electrode (251), a semiconductor layer (252), and an upper electrode (253) are sequentially formed on top.

In these solar cell elements, next, after the comb-shaped electrode (214) which is the current collecting electrode of the upper electrode (253) is formed, the bus electrode which is the further current collecting electrode of the comb-shaped electrode (214) is formed. After the electrode (215) is placed on the comb-shaped electrode (214), the comb-shaped electrode (2) is formed with a conductive adhesive (216).
The lead-out terminal from the upper electrode is obtained by electrically connecting 14) and the bus-par electrode (215).

Next, electrical extraction from the lower electrode (251) exposes a part of the conductive substrate of the solar cell element (240) (220) and a conductor (21) such as copper.
9) is connected by a method such as spot welding.

Next, the bus bar electrode (215) of the solar cell element (240) and the conductor (219) from the conductive substrate of the adjacent solar cell element (241) are connected to form a series, and then each solar cell is connected. Bus bar electrode of battery element (21
A reverse voltage application preventing bypass diode is installed by soldering or the like between 5) and the conductor (219) from the conductive substrate.

However, in the method of connecting the bypass diode for preventing reverse voltage application to each solar cell element by the above method, the bypass diode for preventing reverse voltage application must be connected separately from each solar cell element, As a result, there is a problem that the ratio of the effective power generation region to the total area of the solar cell module is reduced.

Further, the normally used reverse voltage application preventing bypass diode is molded with resin and has a lead wire (foot) for soldering, so that there is a fear of disconnection and a relatively large shape. It becomes E, and in the subsequent process E
When encapsulating a solar cell element with a filler such as VA (ethylene-vinyl acetate copolymer), only the reverse voltage application bypass diode part rises from the surface, and the flatness of the solar cell module deteriorates. However, there is a problem that bubbles tend to remain in the vicinity of the reverse voltage application preventing bypass diode and the laminate material is gradually peeled from the solar cell element from the bubble portion when the solar cell module is used outdoors.

Further, in order to improve the flatness of the solar cell module, the amount of the filler used is inevitably large and the cost is high.

The manufacturing process of these solar cell modules is not simple, and there is a problem that automation is difficult.

[0025]

SUMMARY OF THE INVENTION It is an object of the present invention to provide an inexpensive solar cell module which has a small non-power generation area of the solar cell module, has high conversion efficiency, is durable and reliable, and can be easily manufactured. .

[0026]

According to the present invention, a plurality of solar cells divided by a substrate, one electrode of the solar cell, and an electrode of a solar cell adjacent to the solar cell are electrically connected to each other. A solar cell module which is a strip-shaped connection body having a laminated structure of an insulating member and a conductive member, and the connection body on a transparent electrode which is one electrode of the solar cell. Is a solar cell module having an insulating member on the transparent electrode and a conductive member on the insulating member.

Furthermore, there is provided a solar cell module in which a collector electrode is provided on the transparent electrode, and the collector electrode and the conductive member of the connection body are electrically connected, and the solar cell is a thin film semiconductor. A certain solar cell module, wherein the insulating member has a light-transmitting property, and the conductive member has a comb-tooth shape, and the current collecting electrode and the comb-tooth portion of the conductive member having the comb-tooth shape And a solar cell module having a diode for preventing reverse voltage application in a part of the connection body, wherein the conductive member has a volume resistivity of 1 × 10 ⁻⁴ Ω. The solar cell module has a volume resistivity of 1 × 10 ¹⁰ Ω · cm or more.

Further, the solar cell module has a transmittance of the insulating member in the visible light region of 50% or more.

Further, in the solar cell module, the insulating member has a thickness of 20 to 200 microns.

The insulating member may be polyester, polyimide, polyethylene, nylon, polymethacrylate, polycarbonate, polyethylene terephthalate,
It is a solar cell module that is made of polyamide, polystyrene, or a fluororesin, and is a solar cell module that is one electrode of the solar cell, in which the substrate has conductivity.

The substrate is a solar cell module, which is stainless steel, aluminum, copper, or a carbon sheet, the substrate has a nickel-plated portion, and the nickel-plated portion and the conductive member are electrically connected. In the solar cell module is a solar cell module, which is a solar cell module having a thermosetting adhesive between the insulating member and the conductive member, the reverse voltage application preventing diode is a bare chip. is there.

Further, the solar cell module is such that the diode portion and the serial connection portion are separated by the notch portion of the connection body.

In addition, a step of electrically connecting a strip-shaped connector having a laminated structure of a conductive member and an insulating member to one electrode of the solar cell to temporarily assemble it, and adjoining the temporarily assembled connector of the solar cell, And a step of sequentially superimposing it on the other electrode of the solar cell.

According to the present invention, the non-power generation area of the solar cell module can be reduced, and as a result, the conversion efficiency of the solar cell module can be increased, and even if the solar cell module is repeatedly bent, the electrical connection can be improved. Since the connection body for disconnection does not break, long-term reliability can be improved, and even if the thickness of the conductive member of the connection body for electrical connection is increased, the solar cell element may be damaged. Since it does not exist, the manufacturing yield is increased, and as a result, an inexpensive solar cell module can be provided.

Further, the conductive member of the series connection body and the lower electrode of the solar cell element where the conductive member of the connection body is connected to the collecting electrode are not electrically short-circuited,
Further, since the lower electrode of the solar cell element and the conductive base members do not short-circuit, it is not necessary to separate the solar cell elements from each other more than necessary, and the non-power generation area of the solar cell module can be reduced. As a result, the conversion efficiency of the solar cell module can be increased.

Further, it is possible to prevent the solar cell module from being bent during the use of the solar cell module and to prevent the solar cell elements from short-circuiting due to expansion and contraction of the solar cell module due to temperature change. Long-term reliability can be improved.

By using a strip-shaped connecting member of an insulating member and a conductive member for the serially connected body, this connecting body also has a function of collecting the current from the collecting electrode, so that power loss due to current loss is caused. Can be reduced.

Further, since the connecting body is made of the transmissive insulating member and the comb-like conductive member, the strength of the connecting body itself can be increased and the light receiving portion of the semiconductor is increased. The reliability of the solar cell module can be improved, and the conversion efficiency and the like can be improved.

Further, the conductive member of the connection body and the lower electrode of the solar cell element in which the conductive member of the connection body is connected to the collector electrode are not electrically short-circuited. Moreover, since the conductive base members of the solar cell element do not short-circuit, automation is facilitated and an inexpensive solar cell module can be provided.

Further, it is not necessary to connect the reverse voltage application preventing bypass diode apart from each solar cell element, and as a result, the ratio of the effective power generation area to the entire solar cell module can be increased.

By using a chip-shaped reverse voltage application prevention bypass diode and a band-shaped connecting member of an insulating member and a conductive member as the reverse voltage application prevention bypass diode, the reverse voltage application prevention bypass diode is obtained. As a result, the solar cell module can be prevented from rising due to the above, and bubbles do not remain in the filling material in the vicinity of the reverse voltage application preventing bypass diode, so that the long-term reliability of the solar cell module can be improved. Further, since the connecting wiring for connecting the reverse voltage application bypass diode and each solar cell element is not required, there are few disconnections and the like, and the material cost and the steps for connection can be reduced with high reliability.

Further, by using a connecting body of an insulating member and a conductive member as the connecting body, the strength of the connecting body itself can be increased, and as a result, the solar cell can be subjected to changes in outside temperature and humidity (greenhouse cycle). The characteristics of the module can be exhibited stably.

Further, since the reverse voltage applying bypass diode, the connecting member of the insulating member and the conductive member can be sub-assembled in advance, the manufacturing process is simplified and the automation is facilitated. Can be provided.

(Embodiment 1) Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 and FIG. 2 show examples of schematic configuration diagrams of the solar cell module of the present invention.

FIG. 2 shows a lower electrode layer (102), a semiconductor layer (103), and an upper electrode layer (1) on a conductive substrate (101).
04), a plurality of solar cell elements on which the comb-shaped electrodes (105) that are the collector electrodes of the upper electrode layer (104) are formed are arranged in parallel, and each solar cell element is connected to an insulating member (111) and a conductive member ( It is a schematic diagram of the solar cell module connected in series using the connection body (110) of (112).

In FIG. 2, the solar cell element (120) and the solar cell element (121) are connected in series by a connector (110) of an insulating member and a conductive member, and the upper electrode (104) of the solar cell element (120). ) Collecting electrode (105)
And the connecting body (101) of the insulating member and the conductive member are electrically connected by a conductive adhesive (106) or the like, and the conductive base body (101) of the solar cell element (121) is connected to the insulating member and the conductive member. The conductor portion (112) of the body is a conductive adhesive (10).
7) etc. electrically connected.

The insulating member and the conductive member (112) of the connecting member of the conductive member used in the present invention may have a volume resistivity of the conductive member of 1 × 10 ⁻² Ω · cm or less, preferably. The metal is 1 × 10 ⁻⁴ Ω · cm or less. For example, a foil of copper, gold, silver, aluminum, tin, solder, or the like.

The insulating member used in the present invention and the insulating member (111) for connecting the conductive member have a volume resistivity of 1 × 10 ⁸ Ω · cm or more, preferably 1 ×. An insulating member having a resistance of 10 ¹⁰ Ω · cm or more is more preferable. For example, a flexible polymer resin such as polyester, polyimide, and modified epoxy, or an inorganic material such as glass nonwoven fabric can be used.

The thickness of the insulating member used in the present invention is, if it is repeatedly bent, not less than 20 μm and not more than 2 μm.
It is preferably less than 00 microns.

The current that can be taken out by the solar cell is usually
Weak current (several microamps ~
It is a large current (several hundred mA to several tens of A), unlike several mA.

Therefore, the conductive member of the connecting body used in the solar cell must be thick.

Therefore, the conductive member may be rigid, and burrs or the like may remain on the ends. Here, if the thickness of the insulating member is less than 20 μm, the burr at the end of the conductive member directly damages the surface of the solar cell element, and the upper electrode and the lower electrode of the solar cell element are short-circuited to lower the conversion efficiency. Will end up.

On the other hand, when the thickness of the insulating member is 200 μm or more, the connector itself becomes rigid and loses its flexibility. Here, when the solar cell is repeatedly bent, the connecting body may be peeled off from the surface of the solar cell element or the solar cell substrate due to its rigidity.

FIG. 28 shows a lower electrode on a stainless steel substrate,
A solar cell module in which an amorphous semiconductor, an upper electrode, and a solar cell element on which a collector electrode of the upper electrode is formed are connected in series by a connection body of an insulating member and a conductive member is prepared, and this solar cell module is repeated 50 times. It is the figure which plotted the change of the conversion efficiency of the solar cell module at the time of carrying out bending with respect to the thickness of an insulating member. Here, a polyimide film was used for the insulating member, and copper having a thickness of 100 μm was used for the conductive member. The conversion efficiency was based on the value before the insulating member was 100 μm thick and repeatedly bent.

The thickness of the insulating member is less than 20 μm,
It can be seen that the conversion efficiency of the solar cell greatly decreases when the thickness is 200 μm or more.

The connecting member of the insulating member and the conductive member used in the present invention can be prepared by bonding the insulating member and the conductive member with an adhesive such as an epoxy or acrylic adhesive by thermocompression bonding or the like.

There is no particular limitation on the conductive material for electrically connecting the conductive member (112) of the connecting body of the insulating member and the conductive member used in the present invention and the collector electrode (105) of the solar cell element. For example, a conductive adhesive such as silver paste or solder can be used.

There is no particular limitation on the conductive material for electrically connecting the conductive member of the connector used in the present invention to the conductive substrate of the solar cell element. For example, a conductive material such as silver paste can be used. An adhesive or solder can be used. When connecting with solder, it is more preferable to process not only the connecting body of the insulating member and the conductive member but also the surface of the conductive substrate to be connected in advance so that the solder can be easily connected. Specific treatment methods include plating with nickel, tin, solder, copper, etc., or etching or mechanically roughening the surface.

The conductive substrate of the solar cell element used in the present invention includes stainless steel, aluminum, copper, carbon sheet and the like. As the lower electrode provided on the substrate used in the present invention, Ti, Cr, Mo, W, Al,
Ag, Ni, or the like is used, and the forming method includes resistance heating vapor deposition, electron beam vapor deposition, and sputtering method, but is not particularly limited thereto.

For the photovoltaic layer of the solar cell element used in the present invention, known semiconductor materials generally used for solar cell elements can be used. Examples of the semiconductor layer of the solar cell element used in the present invention include a pin-junction amorphous silicon-based layer, a pn-junction polycrystalline silicon layer, and Cu.
A compound semiconductor layer such as InSe ₂ / CdS may be used.
As the method of forming the semiconductor layer, in the case of an amorphous silicon-based layer, it can be formed by plasma CVD or the like in which plasma discharge is generated in a raw material gas for forming a semiconductor thin film such as silane gas. The pn junction polycrystalline silicon layer is formed from, for example, molten silicon by a liquid layer growth method or a coating method. In addition, the above CuInS
The e ₂ / CdS is formed by a method such as an electron beam vapor deposition method, a sputtering method, an electrodeposition method (deposition by electrolysis of an electrolytic solution), or the like.

Materials used for the upper electrode of the solar cell element used in the present invention include In ₂ O ₃ , SnO ₂ , and In ₂ O.
_{3 -SnO 2, ZnO, TiO 2} , Cd 2 SnO 4, there is a crystalline semiconductor material such as doped with impurity at a high concentration, as a method for forming the resistance heating evaporation, electron beam evaporation, sputtering, spraying method, CVD Method, impurity diffusion method, etc., but not limited thereto.

For the electrode having a comb-teeth shape (comb-shaped electrode) used in the present invention, a material having a higher conductivity than that of the above electrode can be used. Examples include metal electrodes, conductive electrodes in which metal and polymer binder are dispersed,
Generally, a metal paste in which a metal powder and a polymer resin binder are in a paste form is used. These metal pastes are usually formed by a screen printing method on a transparent electrode which is an upper electrode. Of these metal pastes, silver paste, copper paste, gold paste, nickel paste, and aluminum paste are preferable in view of conductivity, but the metal paste is not limited thereto. Further, in order to reduce the resistance value, a multi-layer structure in which a metal such as solder or copper is formed by a plating method or the like on the comb-shaped electrode formed of the conductive paste may be used.

(Embodiment 2) FIG. 3, FIG. 4 and FIG. 5 show other schematic structural views of the solar cell module of the present invention.

4 and 5 show a lower electrode layer (102), a semiconductor layer (103), an upper electrode layer (104), and a collector electrode of the upper electrode layer (104) on a conductive substrate (101). A plurality of solar cell elements on which a certain comb-shaped electrode (105) is formed are arranged in parallel, and each of the solar cell elements has a translucent insulating member (131) and a comb-shaped conductive member (13).
It is a schematic diagram of the solar cell module connected in series using the connection body (130) of 2).

In FIG. 4, the solar cell element (120) and the solar cell element (121) are connected in series by a connecting body (130) of a translucent insulating member and a comb-shaped conductive member. The collector electrode (105) of the upper electrode (104) of the battery element (120) and the connection body (13)
0) is electrically connected with a conductive adhesive (106) or the like, and is a conductive base (101) of the solar cell element (121).
And the conductor portion (132) of the connection body (130) are electrically connected by a conductive adhesive (107) or the like.

The conductive member of the connector (130) of the translucent insulating member (131) and the comb-shaped conductive member (132) used in the present invention has a volume resistivity of 1 ×. The metal is 10 ⁻² Ω · cm or less, preferably 1 × 10 ⁻⁴ Ω · cm or less. For example, copper,
Examples include gold, silver, aluminum, tin, and solder foil. In addition, the pattern of the conductive member (132) having a comb tooth shape is patterned in a shape that matches the current collecting electrode (105). The patterning can be performed by a photolithography technique using an etching solution or a method such as a press punch.

Further, a connecting body (13) of the translucent insulating member and the comb-shaped conductive member used in the present invention.
The insulating member (131) of 0) may have an insulating member having a volume resistivity of 1 × 10 ⁸ Ω · cm or more, more preferably 1 × 10 ¹⁰ Ω · cm or more. It is a member and has a transmittance in the visible light region (400 to 700 nm) of 30% or more, preferably 50% or more.
For example, polyester, polyimide, polyethylene, nylon, polymethacrylate, polycarbonate, polyethylene terephthalate, polyamide, polystyrene,
A fluororesin or the like can be used, but is not limited to this.

The thickness of the insulating member used in the present invention is 2 μm or more, especially when it is repeatedly bent, of 20 μm or more.
It is preferably less than 00 microns.

The current that can be taken out by the solar cell is usually
Weak current (several microamps ~
It is a large current (several hundred mA to several tens of A), unlike several mA.

Therefore, the conductive member of the connecting body used in the solar cell must be thick.

Therefore, the conductive member becomes rigid, and burrs or the like may remain on the ends. Here, if the thickness of the insulating member is less than 20 μm, the burr at the end of the conductive member directly damages the surface of the solar cell element, and the upper electrode and the lower electrode of the solar cell element are short-circuited to lower the conversion efficiency. Will end up.

On the other hand, when the thickness of the insulating member is 200 μm or more, the connector itself becomes rigid and loses its flexibility. Here, when the solar cell is repeatedly bent, the connecting body may be peeled off from the surface of the solar cell element or the solar cell substrate due to its rigidity.

FIG. 28 shows a lower electrode on a stainless steel substrate,
A solar cell module in which an amorphous semiconductor, an upper electrode, and a solar cell element on which a collector electrode of the upper electrode is formed are connected in series by a connection body of an insulating member and a conductive member is prepared, and this solar cell module is repeated 50 times. It is the figure which plotted the change of the conversion efficiency of the solar cell module at the time of carrying out bending with respect to the thickness of an insulating member. Here, a polyimide film was used for the insulating member, and copper having a thickness of 100 μm was used for the conductive member. The conversion efficiency was based on the value before the insulating member was 100 μm thick and repeatedly bent.

The thickness of the insulating member is less than 20 μm, and
It can be seen that the conversion efficiency of the solar cell greatly decreases when the thickness is 200 μm or more.

In the connected body of the translucent insulating member and the comb-shaped conductive member used in the present invention, the insulating member and the conductive member are bonded with a thermosetting adhesive such as epoxy or acrylic. It can be created by attaching.

A conductor (132) which is a connector of a light-transmitting insulator and a comb-shaped conductor used in the present invention.
The conductive material for electrically connecting the collector electrode (105) of the solar cell element is not particularly limited, and, for example, a conductive adhesive such as silver paste or solder can be used.

The conductive substrate, lower electrode, semiconductor layer and upper electrode, and comb-shaped electrode of the solar cell element used in the present invention are
It is formed in the same manner as in Embodiment 1.

(Embodiment 3) FIG. 6, FIG. 7, FIG. 8 and FIG.
Shows another schematic configuration diagram of the solar cell module of the present invention.

On the conductive substrate (101), the lower electrode layer (1
02), the semiconductor layer (103), the upper electrode layer (104),
A comb-shaped electrode (1) which is a collector electrode of the upper electrode layer (104)
05) is formed, a plurality of solar cell elements are arranged in parallel, and the respective solar cell elements are connected in series by using a connecting body (110) of an insulating member (111) and a conductive member (112) to form an insulating member (111). FIG. 3 is a schematic view of a solar cell module in which a reverse voltage application preventing bypass diode (140) is provided between a connection body of a conductive member (112) and a conductive substrate (101).

FIG. 6 shows a connector (11) of an insulator and a conductor.
It is a top view of 0). Reference numeral (140) denotes a reverse voltage application preventing bypass diode, which is placed on the connection body of the insulating member and the conductive member via the conductive joint body as shown in the figure.

FIG. 7 shows a solar cell element as an insulating member (11
1) and a conductive member (112) are connected in series using a connector (110), and an insulating member (111) and a conductive member (112) are connected.
FIG. 3 is a plan view of a solar cell module in which a reverse voltage application preventing bypass diode (140) is provided between the connection body (110) and the conductive substrate (101).

FIG. 8 and FIG. 9 are respectively ee ′,
It is a dd 'sectional view.

The solar cell element (120) and the solar cell element (121) are connected by a connecting member (110) of an insulating member and a conductive member, and a collector electrode of the upper electrode (104) of the solar cell element (120). (105) and the connection member (110) of the insulating member and the conductive member are electrically connected by a conductive adhesive (106) or the like, and the conductive substrate (101) of the solar cell element (121) and the insulating member and the conductive member are electrically connected. The conductor part (112) of the connection body of the members is electrically connected by a conductive adhesive (107) or the like.

In addition, the connecting member (11) of the insulating member and the conductive member is
0) and the conductive substrate (101), a reverse voltage application preventing bypass diode (140) is provided as shown in part A of FIG. 7 and FIG. In FIG. 9, the reverse voltage application prevention bypass diode (140) is electrically connected to the solar cell element (120), and the reverse voltage application prevention bypass diode (140) is electrically connected to the connection body (110). Adhesives (141) and (142).

Here, in the connection body of the insulating member and the conductive member, the portion connected to the comb-shaped electrode (105) of the solar cell element is on the upper side of the solar cell element, and the reverse diode for preventing reverse voltage application. The portion connected to is provided below the solar cell element.

Here, the solar cell element used in the present invention, the connecting member of the insulating member and the conductive member, and the conductive material for connecting the solar cell element and the connecting member are the same as those in the first and second embodiments. Is formed.

The performance and shape of the reverse voltage application bypass diode used in the present invention are not limited, and are determined by the size and electromotive force of the solar cell element, current used, connection form, etc. In order to eliminate the unevenness, it is preferable that the thickness is as thin as possible and the shape is small, and the chip diode is particularly preferable.
Here, the chip diode may be a bare chip that is not covered with a protective member, or may be a molded product molded with resin.

As the conductive adhesive for electrically connecting the connecting member of the insulating member and the conductive member and the reverse voltage applying bypass diode used in the present invention, solder, conductive paste or the like can be used. Is not limited to.

As the conductive adhesive for electrically connecting the conductive substrate and the reverse voltage applying bypass diode used in the present invention, solder, conductive paste, or the like can be used, but is not limited thereto. is not.

[0091]

The present invention will be described in detail below with reference to examples, but the present invention is not limited to these examples.

Example 1 In this example, a case of an amorphous silicon solar cell using a stainless steel substrate as a conductive substrate will be specifically described. FIG. 15 is a plan view of the solar cell element of the present embodiment, and FIG. 16 is a sectional view taken along the line ff ′ of FIG. (301) is a conductive substrate, (302) is a lower electrode,
(303) is an amorphous silicon semiconductor layer, (30
4) is an upper electrode layer, (305) is a comb-shaped collector electrode, (3)
06) is a portion where the upper electrode is removed. First, a 0.1 mm-thick stainless steel foil with a cleaned surface was prepared as a conductive substrate for a solar cell element.

Next, on a stainless steel foil, a 5000 Å aluminum film and a 700 Å Z film were formed as the lower electrodes.
An nO film was formed by a sputtering method at a substrate temperature of 350 ° C.

Then, 150 Å n-type a was deposited on the ZnO film.
-Si layer, 4000 Å i-type a-Si layer, 100 Å
Of the p-type a-Si layer of SiH ₄ gas / PH ₃ gas / H ₂ gas, SiH ₄ gas / H ₂ gas, SiH ₄ gas / B, respectively.
Using F ₃ gas / H ₂ gas, the substrate temperature is maintained at 250 ° C., and continuous formation is performed by the plasma CVD method.
A photoelectric conversion layer was formed as the n-junction semiconductor layer.

Then, a transparent electrode, which is an upper electrode, is formed on the semiconductor layer, which is the photoelectric conversion layer, with 700 Å In ₂ O ₃ −.
SnO ₂ film (ITO film) at 200 ℃ under oxygen atmosphere,
It was formed by resistance heating vapor deposition of In and Sn.

Next, the rolled stainless steel substrate thus formed was cut into a pattern as shown in FIG. 15 to obtain three solar cell elements (300).

Next, the ITO etching material (FeC
(1 ₃ , HCl) -containing paste was screen-printed on the pattern (306) and then heated and washed to remove the ITO layer on the paste-printed portion to ensure electrical separation between the upper electrode and the lower electrode. .

Next, a 0.3 mm width current-collecting comb-shaped electrode (305) was formed on the ITO by screen printing with a silver paste, as shown in FIG. 17A is a perspective view of a connection body of an insulating member and a conductive member used in this embodiment, and FIG. 17B is a configuration diagram of a connection body of the insulating member and the conductive member. In FIG. 17 (B),
(111) is a 25 micron thick polyimide film,
(112) is a 35-micron thick copper foil, and (113) is an acrylic adhesive material, which was prepared by heat-pressing a polyimide film with an acrylic adhesive material and a copper foil. The connecting body of the insulating member and the conductive member prepared here has flexibility, and therefore the solar cell module itself can also have flexibility. Next, the three solar cell elements are arranged, and the adjacent solar cell elements (30
0), the connection body shown in FIG. 17 (A) is sandwiched as shown in FIG. 18, the connection body is joined to the collector electrode of the solar cell element, and the solar cell adjacent to the connection body is connected. The element was joined to the conductive substrate by applying a silver paste with a dispenser. Next, the plus side lead terminal (501) was taken out by soldering on the upper part of the connection body of the insulating member and the conductive member connected to the collector electrode of the rightmost solar cell element shown in FIG. . The upper end of the leftmost solar cell element was taken out from the negative side of the conductive base by spot welding the lead wire (502) to the conductive base.

These solar cell modules were placed on a PET film having a thickness of 0.3 mm and resin-sealed with a fluororesin and EVA (ethylene-vinyl acetate copolymer) to prepare a solar cell module.

In the above solar cell module, by using the connecting body of the insulating member and the conductive member for the connecting body for connecting the adjacent solar cell elements in series, the solar cell element and the series connecting body may be short-circuited. Since there is no possibility of short circuit between adjacent solar cell elements,
The distance between adjacent solar cell elements, which had to be separated by at least 1 mm or more, can be suppressed to 0.2 mm.

In addition, as shown in FIG.
Using a band-shaped insulating member and a conductive member, an electrical connection from a collector electrode of a solar cell element to a connecting member of the insulating member and the conductive member, and an adjacent solar cell from the connecting member of the insulating member and the conductive member By connecting the element to the conductive substrate at multiple points instead of at one point, the flowing current can be dispersed, resulting in power loss due to resistance loss caused by collecting the current at one point. The conversion efficiency can be increased by 1% because it has been eliminated. Further, by using the connecting body of the insulating member and the conductive member for the series connection body, the manufacturing process is simplified and automation is facilitated.

(Example 2) As a conductive substrate for a solar cell element, a 0.1 mm stainless steel foil having a cleaned surface was prepared, and only the back surface of the stainless substrate was plated with nickel to prepare an insulating member and a conductive member. A solar cell module in the same manner as in Example 1 except that the connection between the connection body of 1) and the nickel-plated stainless steel substrate of the adjacent solar cell element was soldered using solder containing tin 62% -lead 38%. It was created.

Nickel plating of the stainless steel substrate was performed as follows. First, the surface of the stainless steel substrate was covered with a polypropylene cover sheet, and only the back surface was nickel-plated. Next, cathodic electrolytic degreasing is performed at 10 A / d.
m ² , 5 min, anodic electrolytic degreasing was 10 A / dm ² , 2 mi
After that, the substrate was washed with hydrochloric acid to perform pretreatment for plating. Next, in a nickel strike bath, 3 A / dm ² , 30
After nucleating sec nickel, nickel plating was performed in a nickel plating bath at 3 A / dm ² for 4 min.
This plated 2 microns of nickel.

In addition to the effects of the first embodiment, the above-mentioned solar cell module has a nickel-plated stainless steel substrate in a portion to be connected to the connection body, which enables soldering, so that the connection strength between the connection body and the stainless steel base body is improved. Compared with the case where the silver paste is used as the connecting material, it can be increased five times or more, and as a result, the quality of the solar cell module can be improved.

Example 3 In this example, the case of an amorphous silicon solar cell using a stainless steel substrate as a conductive substrate will be specifically described. The solar cell element is formed in the same manner as in Example 1. Next, FIG. 19A is a perspective view of a connected body of a light-transmitting insulating member and a comb-shaped conductive member used in this embodiment, and FIG. 19B is light-transmitting. It is a block diagram of a connection body of an insulating member and a conductive member having a comb tooth shape. (131) is a 25 micron thick polyimide film with a visible light transmittance of 50%, (132) is a 35 micron thick comb-teeth-shaped copper foil, and (133) is an acrylic thermosetting adhesive material, It was prepared by thermocompression bonding a polyimide film with an acrylic adhesive and a copper foil. The comb-teeth shape of the copper foil was formed by using photolithography technology. The connected body of the translucent insulating member and the comb-shaped conductive member created here has flexibility, and therefore the solar cell module itself can also have flexibility.

Next, three solar cell elements shown in FIG. 3 are arranged, and between the adjacent solar cell elements (300), the translucent insulating member and the comb-like conductive member shown in FIG. 17A are formed. The connection body (130) is sandwiched as shown in FIG. 20, the connection body and the collector electrode of the solar cell element are joined, and the connection body and the conductive base body of the solar cell element adjacent to the connection body are connected. Were joined by using a silver paste adhesive.

Next, the lead-out terminal (501) on the plus side was soldered out to the upper portion of the connection body connected to the collector electrode of the rightmost solar cell element shown in FIG. The upper end of the leftmost solar cell element was taken out from the negative side of the conductive base by spot welding the lead wire (502) to the conductive base.

After placing this solar cell module on a PET film having a thickness of 0.3 mm, fluororesin and EV
A solar cell module was prepared by resin-sealing with A (ethylene-vinyl acetate copolymer).

In the above solar cell module, since the connecting body for electrically connecting the adjacent solar cell elements to each other is the connecting body of the insulating member having a light-transmitting property and the conductive member having a comb-teeth shape, Since the light receiving part of the solar cell element located below the connection body of the insulating member having the optical property and the conductive member having the comb-teeth shape can be used as the power generation region, the copper foil is used for the series connection body of the solar cell elements. The conversion efficiency could be increased by about 5% as compared with the case where it was present.

Further, there is no possibility of short circuit between the solar cell element and the series connection body, and since the adjacent solar cell elements also sandwich the conductor member between the insulating members, there is no possibility of short circuit, so that the adjacent solar cells are not connected. The distance between the battery elements could be kept to the minimum necessary, and the reliability could be further increased.

(Example 4) The same as Example 3 except that a polyester resin having a thickness of 25 μm and a visible light transmittance of 90% was used as the insulator of the connector of the insulating member and the conductive member. A solar cell module was created by the method. By using the polyester resin for the insulator of the connection body of the insulating member and the conductive member, the conversion efficiency could be increased by about 10% as compared with the case where the copper foil was used for the series connection body of the solar cell elements.

Further, the flexibility of the connecting body of the insulating member and the conductive member can be enhanced, and the material cost of the connecting body of the insulating member and the conductive member can be further reduced.

(Embodiment 5) As shown in FIG. 21, a transparent adhesive is applied to the transparent insulating member of the connecting body of the transparent insulating member and the comb-shaped conductive member used in the fourth embodiment. Tape (1004) was applied. In FIG. 21, (100
1) is the polyester resin used in Example 4, (1
002) is the copper foil used in Example 4, (1003)
Is an acrylic adhesive material, and (1004) is a transparent acrylic adhesive tape having a thickness of 30 μm. Adhesive tape
The solar cell element is attached to a translucent insulator of a connecting body of a translucent insulating member and a comb-shaped conductive member located on the front surface side, and the translucent insulating member and the comb tooth shape are attached. The connected body of the conductive member and the solar cell element were fixed.

A solar cell module was prepared in the same manner as in Example 3 except for the above.

This facilitates the step of connecting the connection body of the translucent insulating member and the comb-shaped conductive member and the collector electrode with the silver paste adhesive, and also increases the reliability of the connection. I was able to.

(Embodiment 6) In this embodiment, the case of an amorphous silicon solar cell using a stainless steel substrate as a conductive substrate will be specifically described. The solar cell element is formed in the same manner as in Example 1. FIG. 22 shows a vertical length of 2.5 mm and a horizontal length of 2.5 mm at the end portion on the connection body of the insulating member and the conductive member used in this example.
FIG. 26 is a diagram in which a bare-chip silicon diode having a thickness of 0.2 mm is soldered, and FIG. 25 is a configuration diagram of a connection body of an insulating member and a conductive member. FIG. 22C is a cross-sectional view of the silicon diode. In FIG. 22, (1110) is a diode element and (1111) is a gold electrode.

In FIG. 22 (A), a connecting body of an insulating member and a conductive member is soldered to a portion (1101) connected to a comb-shaped electrode of a solar cell element and a silicon diode (140) to form a solar cell element. The portion (1103) connected to the conductive substrate and the portion (1103) can be divided into notches (1102) for connecting the lower side of the conductive substrate. In FIG. 22, (111) is 2
5 micron thick polyimide film, (112) is 35
Micron-thick copper foil, (113) is an acrylic thermosetting adhesive material, and was prepared by thermocompression bonding a polyimide film with an acrylic adhesive material and a copper foil. The connecting body of the insulating member and the conductive member prepared here has flexibility, and therefore the solar cell module itself can also have flexibility. Next, as shown in FIG.
22 is sandwiched between the adjacent solar cell elements (300) as shown in FIG. 23 to bond the connection body to the collector electrode of the solar cell element, and to connect the connection body with the connection body. Bonding of the adjacent solar cell elements to the conductive substrate was performed by using a silver paste adhesive.

Here, the portion (1103) where the silicon diode is soldered to the end portion on the connection body is located under the stainless steel substrate of the solar cell element (300), and the electrical connection between the silicon diode (140) and the stainless steel substrate is made. The physical connection was made by using a silver paste adhesive. next,
The lead terminal (501) on the positive side was taken out by soldering on the upper part of the connection body of the insulating member and the conductive member connected to the collector electrode of the rightmost solar cell element shown in FIG. In addition, the lead wire (50) is used to take out the upper end of the leftmost solar cell element from the negative side of the conductive substrate.
2) was taken out by spot welding to a conductive substrate.

After placing this solar cell module on a PET film having a thickness of 0.3 mm, fluororesin and E
A solar cell module was prepared by resin sealing with VA (ethylene-vinyl acetate copolymer).

In the above solar cell module, a bypass diode for preventing reverse voltage application is provided between the connecting body of the insulating member and the conductive member and the conductive substrate, whereby the bypass diode for preventing reverse voltage application is provided for each solar cell element. Therefore, there is no need to make a connection, and there is no risk of short-circuiting between the solar cell elements or between the solar cell elements and the connection body, and as a result, the proportion of the effective power generation area in the entire solar cell module can be increased.

Further, by using the chip-shaped reverse voltage application prevention bypass diode 140 as the reverse voltage application prevention bypass diode, the thickness of the solar cell element in the reverse voltage application bypass diode mounting portion is 1 mm or less at the maximum. Therefore, it is possible to prevent the solar cell module from being swollen by the reverse voltage application preventing bypass diode, and it is possible to prevent bubbles from remaining in the filling material in the vicinity of the reverse voltage applying prevention bypass diode. The long-term reliability of the module can be improved and the wiring for connecting the reverse voltage application bypass diode and each solar cell element is not required, which reduces the material cost and the process for connection. did it. Further, by using a connecting body of an insulating member and a conductive member as a connecting body for electrically connecting adjacent solar cell elements to each other, there is no possibility that the solar cell element and the series connecting body are short-circuited, and they are also adjacent to each other. Since there is no possibility of short-circuiting between the solar cell elements, the distance between adjacent solar cell elements could be kept to the minimum necessary.

Further, as shown in FIG. 23, in the series connection body,
Using a band-shaped insulating member and a connecting member of a conductive member, the electrical connection from the collector electrode of the solar cell element to the connecting member of the insulating member and the conductive member, and from the connecting member of the insulating member and the conductive member of the solar cell element By making electrical connection to the conductive substrate at multiple points instead of at one point, the flowing current can be dispersed, and as a result, power loss due to current loss caused by collecting the current at one point can be eliminated. I was able to.
Further, by using the above-mentioned connecting body, the manufacturing process is simplified and automation is facilitated.

(Example 7) In Example 6, the chip diode was connected to the back surface side of the stainless steel substrate, but in this example, the same chip diode was connected to the front surface side of the stainless substrate. FIG. 24 is a plan view of the solar cell element of this embodiment, FIG. 25 is a cross-sectional view of a connection body of an insulating member and a conductive member used in this embodiment, and FIG. FIG. 27 is a diagram in which the chip diodes are connected in series by a body and a chip diode is connected between the front surface side of the solar cell element and the conductive member of the connection body, and FIG. 27 is a sectional view taken along line ii ′.

In FIG. 24, (1400) is the sixth embodiment.
It is a solar cell element created in the same manner as (1401)
Is a silver paste, and (1402) is a portion where the ITO layer is removed. Further, (1403) is a portion where the stainless steel substrate is exposed by the grinder.

In FIG. 25, (1411) is a 25 micron thick polyimide film, and (1412) is a 35 micron thick copper foil, which were adhered by an acrylic thermosetting adhesive.

Here, as shown in FIG. 25, the ends of the connector of this embodiment are folded back.

Next, the solar cell element (1400) shown in FIG.
25 were sandwiched between the adjacent solar cell elements (700) as shown in FIG. 26 to expose the stainless substrate of the solar cell element (700) used in this example. Using the silver paste adhesive (1440), the chip diode (140) used in Example 6 was provided between the part (1403) and the folded end (1414) of the connector (1410) of the insulating member and the conductive member. Connections were made as shown in FIG. 27 (where FIG. 27 is a sectional view taken along line i = i ′ in FIG. 26).

In addition, the folded back end (141
The connection between 4) and the comb-shaped electrode and the electrical connection between the stainless steel substrate of the adjacent solar cell element and the connection body (1410) were performed by applying a silver paste adhesive with a dispenser.

Then, the lead wire was taken out in the same manner as in Example 6 and then sealed with resin to prepare a solar cell module. In addition to the effect of the sixth embodiment, the solar cell module of the present embodiment can connect the reverse voltage application bypass diode on the front surface side of the solar cell element, and thus the manufacturing process is further simplified.

(Embodiment 8) In this embodiment, the case of an amorphous silicon solar cell using a stainless steel substrate as a conductive substrate will be specifically described. FIG. 15 is a plan view of the solar cell element of the present embodiment, and FIG. 16 is a sectional view taken along the line ff ′ of FIG. (301) is a conductive substrate, (302) is a lower electrode,
(303) is an amorphous silicon semiconductor layer, (30
4) is an upper electrode layer, (305) is a comb-shaped collector electrode, (3)
06) is a portion where the upper electrode is removed. First, a 0.1 mm-thick stainless steel foil with a cleaned surface was prepared as a conductive substrate for a solar cell element.

Next, on a stainless steel foil, an aluminum film of 5000 Å and a Z film of 700 Å were used as a lower electrode.
An nO film was formed by a sputtering method at a substrate temperature of 350 ° C.

Then, 150 Å n-type a was formed on the ZnO film.
-Si layer, 4000 Å i-type a-Si layer, 100 Å
Of the p-type a-Si layer of SiH ₄ gas / PH ₃ gas / H ₂ gas, SiH ₄ gas / H ₂ gas, SiH ₄ gas / B, respectively.
Using F ₃ gas / H ₂ gas, the substrate temperature is maintained at 250 ° C., and continuous formation is performed by the plasma CVD method.
Three photoelectric conversion layers were formed as the n-junction semiconductor layer.

Then, a transparent electrode, which is an upper electrode, is formed on the semiconductor layer, which is the photoelectric conversion layer, with 700 Å In ₂ O ₃ −.
SnO ₂ film (ITO film) at 200 ℃ under oxygen atmosphere,
It was formed by resistance heating vapor deposition of In and Sn.

Next, the rolled stainless steel substrate thus formed was cut into a pattern as shown in FIG. 15 to obtain three solar cell elements (300).

Next, an ITO etching material (FeC
(1 ₃ , HCl) -containing paste was screen-printed on the pattern (306) and then heated and washed to remove the ITO layer on the paste-printed portion to ensure electrical separation between the upper electrode and the lower electrode. .

Next, a 0.3 mm width current-collecting comb-shaped electrode (305) was formed on the ITO by screen printing with a silver paste, as shown in FIG. Also, 1
7A is a perspective view of a connection body of an insulating member and a conductive member used in this embodiment, and FIG. 17B is a configuration diagram of a connection body of the insulating member and the conductive member. In FIG. 17B, (1
11) is a 25 micron thick polyimide film, (11
2) is a 35-micron-thick copper foil, and (113) is an acrylic adhesive material, which was prepared by thermocompression bonding a polyimide film with an acrylic adhesive material and a copper foil.
The connecting body of the insulating member and the conductive member prepared here has flexibility, and therefore the solar cell module itself can also have flexibility.

29 and 30, the connection method in which the above solar cell elements are connected by a connecting member of an insulating member and a conductive member will be described in detail. First, a heat-resistant double-sided tape (2940) was attached to one side surface of the insulating member of the connector (2910). Next, this connection body (2910) is connected to the solar cell element (290
It was attached to one side of 1). Next, a silver paste (2920) was applied with a dispenser to bond the connection body and the collector electrode of the solar cell element (2901) and dried in an oven at 250 ° C. for 1 hour.
It was carried out by curing. Next, a silver paste (2930) was applied onto one side surface of the copper foil of the connection body joined to the solar cell element by a dispenser to prepare a temporary assembly (2990) of the solar cell element. Next, as shown in FIG. 30, after the above temporary assemblies were sequentially stacked, the silver paste (29
30) was dried and cured to connect three solar cell elements (2900, 2901, 2902) in series.

Specifically, the solar cell element of (2901) is placed on the connection body connected to the solar cell element of (2902), and further the connection body connected to the solar cell element of (2901). The solar cell of (2900) was placed on (2910) and connected in series to manufacture the solar cell module of FIG. 18.

Next, solder the lead terminal (501) on the positive side to the upper part of the connection body of the insulating member and the conductive member connected to the collector electrode of the rightmost solar cell element shown in FIG. It was taken out by. The upper end of the leftmost solar cell element was taken out from the negative side of the conductive base by spot welding the lead wire (502) to the conductive base.

Next, these solar cell modules were assembled in the form of 0.
After being placed on a PET film having a thickness of 3 mm, it was resin-sealed with a fluororesin and EVA (ethylene-vinyl acetate copolymer) to prepare a solar cell module.

In the above solar cell module, by using a connecting body of an insulating member and a conductive member as a connecting body for electrically connecting adjacent solar cell elements to each other, the solar cell element and the connecting body may be short-circuited. And there is no possibility of short circuit between adjacent solar cell elements,
The distance between adjacent solar cell elements, which had to be separated by at least 1 mm or more, can be suppressed to 0.2 mm.

As shown in FIG. 18, a band-shaped connecting member of an insulating member and a conductive member is used as the connecting member to electrically connect the collector electrode of the solar cell element to the connecting member of the insulating member and the conductive member. And, the electrical connection from the connection member of the insulating member and the conductive member to the conductive substrate of the adjacent solar cell element is performed at a plurality of points, rather than at a single point, it is possible to disperse the flowing current, As a result, the power loss due to the resistance loss generated by collecting the current at one point could be eliminated, so that the conversion efficiency could be increased by 1%. Further, by using a connecting body of an insulating member and a conductive member as the connecting body, the manufacturing process is simplified and automation is facilitated.

(Example 9) A solar cell module of Example 8 except that the solar cell element and the connection body of the polyimide and the copper foil are different in the method of producing the solar cell module of Example 8 from each other. Created in the same way.

The solar cell module of this example was prepared as follows. First, after a solar cell element (3100) similar to that of Example 8 was created, as shown in FIG. 31, a heat-resistant double-sided tape (3140) was attached to one side of polyimide to connect a copper foil and the polyimide. Body, solar cell element (3100)
Silver paste (3130) on one side of the stainless steel substrate
Temporary assembly of solar cell element and connector by joining with (3190)
It was created. The silver paste (3130) was cured by drying in an oven at 150 ° for 1 hour. Next, the above-mentioned solar cell element and the temporary assembly of the connection body were sequentially stacked, so that the solar cell element was stacked as shown in FIG.

Specifically, the temporary assembly (3190) of the solar cell element and the connection body was placed on the solar cell element. Here, the upper electrode of the solar cell element (3102) and the temporary assembly (31
91) is fixed with double-sided tape.

Next, the solar cell element (3101) of the temporary assembly (3191) is mounted and fixed with the connection body portion of another temporary assembly (3190), and the three solar cell elements are fixed. (3100, 3101 and 3102) were connected in series.

Next, the extraction electrode from the collector electrode (3150) of the solar cell element of (3100) was performed by using a connection body (3110) of polyimide and copper foil. Here, the electrical connection between the collector electrode and the bonded body was performed with a silver paste.

[0148]

According to the present invention, by using a connecting body having a laminated structure of an insulating member and a conductive member as a connecting body for connecting a solar cell element and a solar cell element adjacent to the solar cell element, The conductive member of the connection body and the lower electrode of the solar cell element where the conductive member of the connection body is connected to the collector electrode are prevented from electrically short-circuiting, and the conductive substrate of the solar cell element is also provided. Since they do not become short-circuited, it is not necessary to separate the solar cell elements from each other more than necessary, and the non-power generation area of the solar cell module can be reduced, and as a result, the conversion efficiency of the solar cell module can be improved. Became possible.

Further, it is possible to prevent the solar cell module from being bent during the use of the solar cell module, the expansion and contraction of the solar cell module due to temperature change, and the short circuit between the solar cell elements due to temperature and humidity cycles. Therefore, the long-term reliability of the solar cell module could be improved.

Further, since the connection body of the insulating member and the conductive member is used as the series connection body, the strength of the connection body itself can be increased, and as a result, the quality of the solar cell module can be improved.

Further, by using a strip-shaped insulating member and a conductive member connecting member in the series connection member, since this connecting member also has a function of collecting current from a plurality of current collecting electrodes,
The power loss due to the current loss could be reduced.

Further, since the automation is facilitated, an inexpensive solar cell module can be provided. Furthermore, in the case of using a connecting body having a laminated structure of a translucent insulating member and a comb-shaped conductive member for a connecting body for serially connecting a solar cell element and a solar cell element adjacent to the solar cell element The non-power generation area decreases because the light receiving area of the solar cell module increases, and as a result, the conversion efficiency of the solar cell module can be increased, and even if the solar cell module is repeatedly bent, connection for series connection is possible. Since the body does not break, long-term reliability can be improved, and even if the thickness of the connection body for series connection is increased, the solar cell element will not be damaged by the edge of the connection body. , The manufacturing yield is increased, and as a result,
It was possible to provide an inexpensive solar cell module.

Further, since the connecting body of the insulating member having a light transmitting property and the conductive member having a comb shape is used for the series connection body,
The strength of the connection body itself can be increased, and as a result, the quality of the solar cell module and the conversion efficiency can be improved. Furthermore, a connecting body having a laminated structure of an insulating member and a conductive member is used as a connecting body for serially connecting a solar cell element and a solar cell element adjacent to the solar cell element, and the connecting body of the insulating member and the conductive member is electrically connected to the connecting body. By providing the reverse voltage application prevention bypass diode between the bases, it is not necessary to connect the reverse voltage application prevention bypass diode apart from each solar cell element, and as a result, it is effective in the entire solar cell module. We were able to increase the proportion of power generation areas.

By using a chip-shaped reverse voltage application prevention bypass diode and a strip-shaped connecting member of an insulating member and a conductive member as the reverse voltage application prevention bypass diode, the reverse voltage application prevention bypass diode is obtained. It is possible to prevent the solar cell module from rising due to, and because bubbles do not remain in the filling material in the vicinity of the reverse voltage application preventing bypass diode, it is possible to improve the long-term reliability of the solar cell module. ,
Since the wiring for connecting the reverse voltage application bypass diode and each solar cell element is not required, there is little disconnection, etc., and it is highly reliable, and the material cost and the process for connection can be reduced. And the lower electrode of the solar cell element where the conductor part of the connection body is connected to the collector electrode are not electrically short-circuited, and the conductive base members of the solar cell element are not short-circuited. Because,
It is not necessary to separate the solar cell elements from each other more than necessary, the non-power generation area of the solar cell module can be reduced, and the solar cell module can be easily manufactured.

Further, since the chip-shaped reverse voltage applying bypass diode, the connecting member of the insulating member and the conductive member can be sub-assembled, the manufacturing process is simplified,
Automation became easy, and an inexpensive solar cell module could be provided.

[Brief description of drawings]

FIG. 1 is a schematic view of a solar cell module according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view of a solar cell module according to an embodiment of the present invention.

FIG. 3 is a schematic view of a solar cell module according to another embodiment of the present invention.

FIG. 4 is a schematic cross-sectional view of a solar cell module according to an embodiment of the present invention.

5A and 5B are a schematic view and a cross-sectional view of a connection body according to an embodiment of the present invention.

FIG. 6 is a schematic view of a connection body according to another embodiment of the present invention.

FIG. 7 is a schematic view of a solar cell module according to an embodiment of the present invention.

FIG. 8 is a schematic cross-sectional view of a solar cell module according to an embodiment of the present invention.

FIG. 9 is a schematic cross-sectional view of a solar cell module according to an embodiment of the present invention.

FIG. 10 shows a solar cell module 1 for comparison with the present invention.
It is a schematic diagram.

11 is a schematic cross-sectional view of the solar cell module of FIG.

FIG. 12 is a schematic view of a connection body for comparison with the present invention.

FIG. 13 is a schematic view of a conventional solar cell module.

FIG. 14 is a schematic cross-sectional view of a conventional solar cell module.

FIG. 15 is a plan view of a solar cell element according to an example of the present invention.

FIG. 16 is a schematic cross-sectional view of a solar cell element according to an example of the present invention.

FIG. 17 is a schematic diagram of a connection body for electrically connecting the solar cell elements according to the examples of the present invention.

FIG. 18 is a schematic view of a solar cell module according to an example of the present invention.

FIG. 19 is a schematic view of another connection body for electrically connecting the solar cell elements according to the examples of the present invention.

FIG. 20 is a schematic view of a solar cell module according to another embodiment of the present invention.

FIG. 21 is a schematic diagram of a connection body for electrically connecting the solar cell elements according to the examples of the present invention.

FIG. 22 is a schematic view of another connection body for electrically connecting the solar cell elements according to the examples of the present invention.

FIG. 23 is a schematic view of a solar cell module according to still another embodiment of the present invention.

FIG. 24 is a plan view of another solar cell element of the present invention.

FIG. 25 is a schematic view of another connection body of the present invention.

FIG. 26 is a schematic view of still another solar cell module of the present invention.

FIG. 27 is a schematic cross-sectional view of a solar cell module of the present invention.

FIG. 28 is a diagram showing the relationship between the change in conversion efficiency and the thickness of the insulating member when the solar cell module is repeatedly bent.

FIG. 29 is a schematic diagram in which the connection body of the present invention and a solar cell are temporarily assembled.

FIG. 30 is a diagram showing a method for manufacturing a solar cell module according to the present invention.

FIG. 31 is a schematic view showing a temporary assembly of another connection body of the present invention and a solar cell.

FIG. 32 is a diagram showing another method for manufacturing a solar cell module according to the present invention.

[Explanation of symbols]

Reference Signs List 101 conductive substrate 102 lower electrode layer 103 semiconductor layer 104 upper electrode layer 105 current collecting electrode 106 conductive adhesive 107, 141, 142 conductive adhesive 110, 130, 150, 2910 connection member 111 of insulating member and conductive member 111, 131 Insulating member 112, 132 Conductive member 113, 133 Adhesive material 120, 121 Solar cell element 140 Chip diode 200a, 200b Conductive substrate 201a, 201b Lower electrode layer 202a, 202b Semiconductor layer 203a, 203b Upper electrode layer 204a, 204b, 204c Current collecting electrode 200a, 200b Connection body 205a, 205b Connection body 206, 207, 208 Solar cell element 210 Connection body 214 Comb type electrode 215 Bus bar electrode 216 Conductive adhesive 219 Conductor 220 Exposed conductive substrate 230 Reversed Directional voltage application bypass diode 240, 241, 242 Solar cell element 250 Conductive substrate 251 Lower electrode layer 252 Semiconductor layer 253 Upper electrode layer 300 Solar cell element 301 Conductive substrate 302 Lower electrode layer 303 Semiconductor layer 304 Upper electrode layer 305, 3150 Current collecting electrode 306 Element separation part 501 Positive electrode side extraction 502 Negative electrode side extraction 700 Solar cell element 740, 2920, 2930, 3130 Silver paste adhesive 1001 Insulating member 1002 Conductive member 1003 Adhesive 1004 Adhesive tape 1101 Conductive substrate of solar cell Part to be connected 1102 Cutout part 1103 Part to be connected to comb-shaped electrode of solar cell 1110 Diode element 1111 Metal electrode 1400 Solar cell element 1401 Comb-shaped electrode 1402 ITO removal part 1403 Tenres base exposed portion 1410, 3110 Connecting body of insulating member and conductive member 1411 Insulating member 1412 Conductive member 1414 Folded end portion of connecting body 2900, 2901, 2902, 3100, 3101
3102 Solar cell element 2940, 3140 Heat-resistant double-sided tape 2990, 3190 Temporary assembly of solar cell

Claims (20)

[Claims] 1. A plurality of solar cells divided by a substrate, one electrode of the solar cell, and a connecting body electrically connecting the electrode of the solar cell adjacent to the solar cell. The solar cell module, wherein the connector is a strip-shaped connector having a laminated structure of an insulating member and a conductive member. 2. The solar cell module according to claim 1, wherein the electrical connection is a series connection. 3. The connection body on a transparent electrode, which is one electrode of the solar cell, has an insulating member on the transparent electrode and a conductive member on the insulating member.
The solar cell module described. 4. The solar cell module according to claim 3, further comprising a collector electrode on the transparent electrode, wherein the collector electrode and the conductive member of the connector are electrically connected. 5. The solar cell module according to claim 1, wherein the solar cell is a thin film semiconductor. 6. The insulating member has a light-transmitting property, and the conductive member has a comb tooth shape.
The solar cell module described. 7. The solar cell module according to claim 6, wherein the collector electrode and the comb-tooth portion of the comb-shaped conductive member are electrically connected. 8. The solar cell module according to claim 1, further comprising a diode for preventing reverse voltage application in a part of the connection body. 9. The volume resistivity of the conductive member is 1 × 10 ^−4.
9. The solar cell module according to claim 1, wherein the solar cell module has an Ω · cm or less. 10. The volume resistivity of the insulating member is 1 × 10.
The solar cell module according to claim 1, which has a resistance of ¹⁰ Ω · cm or more. 11. The transmittance of the insulating member in the visible light region is 50% or more, as claimed in any one of claims 1 to 1.
The solar cell module according to 0. 12. The insulating member has a thickness of 20 μm or more and 200 μm or less.
~ 11. The solar cell module according to item 11. 13. The insulating member is polyester, polyimide, polyethylene, nylon, polymethacrylate, polycarbonate, polyethylene terephthalate,
Polyamide, polystyrene, and fluororesin, The solar cell module of Claim 1-12 characterized by the above-mentioned. 14. The substrate according to claim 1, wherein the substrate has conductivity and is one of the electrodes of the solar cell.
The solar cell module described. 15. The solar cell module according to claim 1, wherein the substrate is stainless steel, aluminum, copper, or a carbon sheet. 16. The substrate has a nickel-plated portion,
The solar cell module according to claim 1, wherein the nickel-plated portion and the conductive member are electrically connected. 17. A thermosetting adhesive is provided between the insulating member and the conductive member.
6. The solar cell module according to 6. 18. The solar cell module according to claim 8, wherein the diode for preventing reverse voltage application is a bare chip. 19. The solar cell module according to claim 18, wherein the diode portion and the serial connection portion are separated by the notch portion of the connection body. 20. A step of electrically connecting and temporarily assembling a strip-shaped connector having a laminated structure of a conductive member and an insulating member to one electrode of a solar cell; and a step of adjoining the temporarily assembled connector of the solar cell. And a step of sequentially superimposing it on the other electrode of the solar cell.