WO2024262344A1 - Module de batterie solaire et son procédé de production - Google Patents
Module de batterie solaire et son procédé de production Download PDFInfo
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- WO2024262344A1 WO2024262344A1 PCT/JP2024/020866 JP2024020866W WO2024262344A1 WO 2024262344 A1 WO2024262344 A1 WO 2024262344A1 JP 2024020866 W JP2024020866 W JP 2024020866W WO 2024262344 A1 WO2024262344 A1 WO 2024262344A1
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- solar cell
- cell module
- solar cells
- arrangement direction
- sealing material
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- 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
Definitions
- the present invention relates to a solar cell module and a method for manufacturing the same.
- Patent Document 1 discloses a sheet-like solar cell that includes a large number of solar cells arranged in a required positional relationship, a flexible conductive member that electrically connects the electrodes of the large number of solar cells, and a sheet-like transparent film member that covers the large number of solar cells and the flexible conductive member. Patent Document 1 states that this configuration makes it possible to provide a sheet-like solar cell that is flexible overall, resistant to repeated bending, and easy to transport and store.
- Patent Document 2 discloses a solar cell module in which each photovoltaic element is electrically connected, the module being made up of individual units sealed with a moisture-proof film, and the terminals on the collector electrodes, which connect the collector electrodes and terminals to electrically connect each unit, are positioned on the end face of the conductive substrate via an insulating layer, and each electrode of the photovoltaic element is connected to the terminals by a connection lead.
- Patent Document 2 states that this configuration makes it easy to bend at the bends by providing a relay point between both electrodes of each unit, and prevents stress concentration due to bending at the lead connection parts, particularly the lead connection parts of the collector electrodes on the light-receiving side.
- the conductive members flexible conductive members, power extraction leads
- the pair of films were prone to peeling from those portions, and durability was insufficient.
- the objective of the present invention is to provide a solar cell module that is both flexible and durable, and a method for manufacturing the same.
- a solar cell module includes a plurality of solar cells arranged in a line at intervals in a direction parallel to the light receiving surfaces, with the light receiving surfaces facing the same direction; a tab wire electrically connecting adjacent solar cells to each other; A pair of cover films sandwiching the solar cell from a light receiving surface and a back surface thereof; a sealing material filled between the pair of cover films and interposed between the pair of cover films and the solar cell and the tab wire, Between adjacent solar cells, one or both of the faces are recessed in the thickness direction, and a groove-shaped link portion is formed in which the recess extends in a direction substantially perpendicular to the arrangement direction of the solar cells, The thickness of the sealing material at the link portion is smaller than the thickness of the sealing material at the portion other than the link portion.
- the area in the arrangement direction of the solar cells where the thickness of the sealing material in the link portion is 0.05 to 0.6 mm may be 1 mm or more.
- the solar cells may be electrically connected to each other by the tab wire in parallel.
- a solar cell module includes a plurality of solar cells arranged in a grid pattern at intervals in a direction parallel to the light receiving surfaces, the solar cells having light receiving surfaces facing the same direction; a first tab wire electrically connecting some or all of the solar cells adjacent to each other in one arrangement direction; a second tab wire electrically connecting the solar cell adjacent to each other in another arrangement direction that is substantially perpendicular to the one arrangement direction; A pair of cover films sandwiching the solar cell from a light receiving surface and a back surface thereof; a sealing material filled between the pair of cover films and interposed between the pair of cover films and the solar cell, the first tab wire, and the second tab wire; Between the solar cells adjacent to each other in the one arrangement direction, one or both of the surfaces are recessed in a thickness direction, and a groove-shaped link portion is formed in which the recess extends in the other arrangement direction, The thickness of the sealing material at the link portion is smaller than the thickness of the sealing material at the portion other than the link portion.
- a region in the link portion where the thickness of the sealing material is 0.05 to 0.6 mm in the one arrangement direction may be 1 mm or more.
- the electrical connection between the solar cell units by the first tab wire is a parallel connection, The solar cells may be electrically connected to each other in series by the second tab wire.
- a groove-shaped second link portion is formed between the solar cells adjacent to each other in the other arrangement direction, with one or both surfaces of the second link portion being recessed in the thickness direction and the recess extending in the one arrangement direction,
- the thickness of the sealing material in the second link portion may be smaller than the thickness of the sealing material in a portion other than the link portion and the second link portion.
- a region in the other arrangement direction where the thickness of the sealing material in the second link portion is 0.05 to 0.6 mm may be 1 mm or more.
- a method for manufacturing a solar cell module includes sandwiching a plurality of solar cells arranged in a row with their light-receiving surfaces facing the same direction and spaced apart in a direction parallel to the light-receiving surfaces, and tab wires electrically connecting adjacent solar cells, between a pair of resin films from both sides of the solar cells via an encapsulant material;
- a jig consisting of a rod-shaped part extending in a direction approximately perpendicular to the arrangement direction of the solar cells, or a jig including a rod-shaped portion, is placed on either or both sides between adjacent solar cells, and the solar cells are heated and pressed in the thickness direction using a laminator.
- a method for manufacturing a solar cell module includes sandwiching a plurality of solar cells arranged in a grid pattern with their light-receiving surfaces facing the same direction and spaced apart in a direction parallel to the light-receiving surfaces, and tab wires electrically connecting some or all of the adjacent solar cells, between a pair of resin films from both sides of the solar cells via an encapsulant material;
- a lattice-shaped jig including rod-shaped portions extending in one arrangement direction of the solar cells and rod-shaped portions extending in a direction approximately perpendicular to the one arrangement direction is placed on either or both surfaces between adjacent solar cells, and the solar cells are heated and pressed from the thickness direction using a laminator.
- the solar cell module of the present invention can provide a solar cell module that is both flexible and durable. Furthermore, the manufacturing method of the solar cell module of the present invention can easily manufacture a solar cell module that is both flexible and durable.
- FIG. 1 is a plan view of a solar cell module according to a first embodiment which is an exemplary aspect of the present invention.
- 2 is a partially enlarged cross-sectional view of a solar cell module according to a first embodiment which is an illustrative aspect of the present invention, showing only a part of the AA cross section in FIG. 1 in an enlarged manner.
- FIG. 4 is an explanatory diagram for explaining the dimensions of the link portion, and shows the outline of the sealing material by extracting only the region in which the sealing material exists in the link portion and its surrounding area in FIGS. 2 and 3 .
- FIG. 1 is a schematic cross-sectional view showing a state in which a solar cell module according to a first embodiment, which is an exemplary aspect of the present invention, is attached to a curved surface of a structure.
- 13 is a schematic diagram showing a modified example of the link portion, illustrating the outline of the link portion and the sealing material in its surrounding area.
- FIG. 13 is a schematic diagram showing another modified example of the link portion, illustrating the outline of the link portion and the sealing material in its surrounding area.
- FIG. 13 is a schematic diagram showing yet another modified example of the link portion, illustrating the outline of the link portion and the sealing material in its surrounding area.
- FIG. 13 is a schematic diagram showing still another modified example of the link portion, illustrating the outline of the link portion and the sealing material in its surrounding area.
- FIG. 4 is a plan view of a solar cell module according to a second embodiment which is an exemplary aspect of the present invention.
- 10 is a partially enlarged cross-sectional view of a solar cell module according to a second embodiment of the present invention, showing only a part of the cross section taken along line BB in FIG. 9 in an enlarged manner.
- 1 is a schematic cross-sectional view showing a state in which a solar cell module according to a first embodiment, which is an exemplary aspect of the present invention, is attached to the outer peripheral surface of a cylindrical body.
- 12 is a schematic cross-sectional view showing a state in which the light irradiation direction is tilted from the state shown in FIG. 11 .
- FIG. 11 is a schematic cross-sectional view showing a state in which the light irradiation direction is tilted from the state shown in FIG. 11 .
- FIG. 11 is a plan view of a solar cell module according to a third embodiment which is an exemplary aspect of the present invention.
- 14 is a partially enlarged cross-sectional view of a solar cell module according to a third embodiment which is an exemplary aspect of the present invention, showing only a part of the CC cross section in FIG. 13 in an enlarged manner.
- 14 is a partially enlarged cross-sectional view of a solar cell module according to a third embodiment which is an exemplary aspect of the present invention, showing only a part of the cross section DD in FIG. 13 in an enlarged manner.
- FIG. 11 is a schematic cross-sectional view showing a state in which a solar cell module according to a third embodiment, which is an exemplary aspect of the present invention, is attached to the outer peripheral surface of a cylindrical body.
- FIG. 13 is a plan view of a solar cell module according to a fourth embodiment which is an exemplary aspect of the present invention.
- 18 is a partially enlarged cross-sectional view of a solar cell module according to a fourth embodiment which is an exemplary aspect of the present invention, showing only a part of the E-E cross section in FIG. 17 in an enlarged manner.
- 18 is a partially enlarged cross-sectional view of a solar cell module according to a fourth embodiment which is an exemplary aspect of the present invention, showing only a part of the FF cross section in FIG.
- FIG. 1 is a plan view showing a state immediately before being subjected to a lamination process during production in a first production method for a solar cell module according to an embodiment that is an exemplary aspect of the present invention.
- FIG. 21 is a partially enlarged cross-sectional view taken along line GG in FIG. 20, showing only a portion of the cross-section in an enlarged manner.
- 22 is a partially enlarged cross-sectional view showing a state after lamination processing during manufacturing in a first manufacturing method of a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and is a cross-sectional view of the same location as FIG. 21.
- FIG. 1 is a plan view showing an example of an integrated jig that can be used in a first manufacturing method for a solar cell module according to an embodiment that is an exemplary aspect of the present invention.
- FIG. 1 is a plan view showing a state immediately before being subjected to a lamination process during production in a second production method for a solar cell module according to an embodiment that is an exemplary aspect of the present invention.
- FIG. 25 is a partially enlarged cross-sectional view taken along line HH in FIG. 24, showing only a portion of the cross-section in an enlarged manner. 25 is a partially enlarged cross-sectional view taken along line II of FIG. 24, showing only a portion of the cross-section in an enlarged manner.
- FIG. 26 is a partially enlarged cross-sectional view showing a state after lamination processing during production in a second manufacturing method for a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and is a cross-sectional view of the same location as FIG. 25.
- 27 is a partially enlarged cross-sectional view showing a state after lamination processing during production in a second manufacturing method for a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and is a cross-sectional view of the same location as FIG. 26.
- FIG. 13 is a plan view of a solar cell module according to a fifth embodiment which is an exemplary aspect of the present invention.
- FIG. 30 is a partially enlarged cross-sectional view of a solar cell module according to a fifth embodiment which is an illustrative aspect of the present invention, showing only a portion of the K-K cross section in FIG. 29 in an enlarged manner.
- 30 is a partially enlarged cross-sectional view of a solar cell module according to a fifth embodiment which is an illustrative aspect of the present invention, showing only a part of the MM cross section in FIG. 29 in an enlarged manner.
- FIG. 13 is a plan view of a solar cell module according to a sixth embodiment which is an exemplary aspect of the present invention.
- FIG. 33 is a partially enlarged cross-sectional view of a solar cell module according to a sixth embodiment which is an exemplary aspect of the present invention, showing only a portion of the LL cross section in FIG. 32 in an enlarged manner.
- FIG. 13 is a plan view of a solar cell module according to a seventh embodiment which is an exemplary aspect of the present invention.
- FIG. 13 is a plan view of a solar cell module according to an eighth embodiment which is an exemplary aspect of the present invention.
- FIG. 2 is a plan view of a solar cell module produced in an example.
- 37 is a cross-sectional view of a solar cell module produced in an example, taken along the line JJ in FIG. 36.
- FIG. 2 is a schematic diagram for explaining an outline of a bending property test in the examples.
- FIG. 1 is a plan view of a solar cell module 10 according to a first embodiment
- Fig. 2 is a partially enlarged cross-sectional view of the A-A section in Fig. 1.
- Fig. 2 shows only a part of the A-A section in Fig. 1 (areas with numbers in parentheses (3) to (6) attached to solar cell 11).
- the solar cell module 10 according to this embodiment has flexibility and can be stored or used in a folded, bent or curved state, but hereinafter, the solar cell module 10 will be described mainly in an unfolded, substantially flat state, which is regarded as a stationary state. This is the same for the plan views of the second to eighth embodiments and the manufacturing method of the solar cell module.
- the solar cell module 10 is a rectangular flat plate, and is mainly composed of a plurality of solar cells 11 (12 in this embodiment), tab wires 12, a pair of transparent cover films 13F, 13B, and a sealing material 14.
- the solar cells 11 are arranged in a row with the light receiving surfaces 11F facing in the same direction (arrow Z direction) and spaced apart in a direction parallel to the light receiving surfaces 11F (arrow X direction).
- the subnumber after the hyphen when describing solar cells in general or when referring to all solar cells, the subnumber after the hyphen is omitted and it is written as "solar cell 11".
- the subnumber after the hyphen when describing a specific solar cell or an individual solar cell, the subnumber after the hyphen is added and it is written as "solar cell 11-(1)", “solar cell 11-(12)", etc. (the same applies to the second and third embodiments).
- the subnumber after the hyphen corresponds to the number in parentheses added to each solar cell 11 (reference number 31 in the third embodiment) in Figure 1 ( Figure 9 in the second embodiment, Figure 13 in the third embodiment).
- the arrow X direction and its opposite direction are the direction in which the solar cells 11 are lined up (hereinafter referred to as "line-up direction X"); the arrow Y direction and its opposite direction are the direction perpendicular to the line-up direction of the solar cells 11 (hereinafter referred to as “vertical direction Y”); and the arrow Z direction and its opposite direction are the thickness direction of the solar cell module 10 (hereinafter referred to as "thickness direction Z").
- the solar cells 11 and tab wires 12 are members located below the cover film 13F and sealing material 14, but since the cover film 13F and sealing material 14 are transparent members and visible, they are drawn with solid lines.
- the solar cell 11 is an electric element that generates an electromotive force when light strikes its light-receiving surface. It is broadly divided into silicon-based, compound-based, and organic-based cells, and any of these can be used in this embodiment. Silicon-based cells are divided into crystalline silicon-based and amorphous silicon-based cells, and crystalline silicon-based cells are further divided into single-crystal silicon-based and polycrystalline silicon-based cells. Compound-based cells are divided into single-crystal compound-based and thin-film polycrystalline-based cells. In this embodiment, crystalline silicon-based and single-crystal compound-based cells can be particularly suitably used.
- a flexible solar cell module by applying it to solar cells that have no flexibility, a flexible solar cell module can be manufactured.
- solar cells such as monocrystalline silicon type, polycrystalline silicon type, heterojunction (HIT) type, III-V multijunction (GaAs, etc.) type, CIS type on glass substrate, CdTe type on glass substrate, perovskite/crystalline silicon tandem type, etc. can be suitably used.
- the thickness of the solar cell 11 there are no particular limitations on the thickness of the solar cell 11, but from a cost perspective it is preferable that it is not too thick, and it is preferably about 0.5 mm or less, more preferably 0.3 mm or less, and even more preferably 0.2 mm or less. There is no preferred lower limit to the thickness, as it is best to obtain thin, high-performance cells, but if it is too thin it will easily become brittle and the amount of light absorbed will decrease, making it difficult to ensure performance.
- the length of the arrangement direction X of the solar cell 11 the shorter it is and the more solar cell cells 11 are used, the smaller the radius of curvature of the solar cell module 10 as a whole can be. However, this tends to reduce the area ratio of the light receiving surface 11F in the solar cell module 10, and manufacturing becomes more complicated, leading to increased costs. Therefore, the length should be determined from a comprehensive perspective of the purpose, desired performance, and cost. Specifically, it should be selected from the range of about 10 mm to 250 mm, with the range of about 15 mm to 150 mm being preferable.
- the length of the solar cell 11 in the vertical direction Y there is no particular limit to the length of the solar cell 11 in the vertical direction Y, and it can be determined by comprehensively considering the above-mentioned points as well as the installation location of the solar cell module 10, ease of handling, etc. Specifically, it can be selected from the range of about 20 mm to 300 mm, and the range of about 30 mm to 210 mm is preferable.
- the tab wire 12 is a conductive wire that electrically connects adjacent solar cells 11. As shown in Figs. 1 and 2, each tab wire 12 is between adjacent solar cells 11, and one end (the end opposite the direction of the arrow X on the drawing) is connected to a first electrode terminal (not shown) provided on the light-receiving surface 11F of the solar cell 11, and the other end (the end on the direction of the arrow X on the drawing) is connected to a second electrode terminal (not shown) provided on the surface on the back side of the light-receiving surface 11F (hereinafter referred to as "back surface 11B").
- the electrode terminals provided on the light-receiving surface 11F and back surface 11B have opposite polarities, so that the electromotive force generated by light can be taken out from between the two electrode terminals.
- the tab wires 12 are connected in the same way between all the solar cells 11 arranged in the arrangement direction X, and the tab wires 12' at both ends in the arrangement direction X have one end electrically connected to the solar cell 11 and the other end free to function as an output terminal connected to the outside.
- the solar cells 11 are electrically connected in series by the tab wires 12 between the tab wires 12' at both ends in the arrangement direction X. Therefore, the total voltage of the electromotive forces generated in all the solar cells 11 is generated between the tab wires 12' at both ends in the arrangement direction X.
- bypass diodes may be provided in parallel with each solar cell 11, or with multiple solar cells 11 connected in series.
- leads or films made of metals e.g., copper, aluminum, silver, etc.
- metals e.g., copper, aluminum, silver, etc.
- solder such as tin
- the tab wire 12 passes through link portions 15F, 15B between adjacent solar cell 11, which will be described later, and is bent at these portions, so it is preferable that the tab wire 12 has excellent durability.
- the thickness of the tab wire 12 is preferably about 1 mm or less, more preferably 0.5 mm or less, and even more preferably 0.2 mm or less. There is no preferable lower limit for the thickness, since it is best to obtain a thin, high-performance tab wire, but if it is made too thin, it will easily become brittle and it will be difficult to pass a current corresponding to the cell output.
- the cover films 13F, 13B are a pair of transparent resin films that sandwich the solar cell 11 from the light-receiving surface 11F and the back surface 11B. Note that when only one surface (light-receiving surface 11F) is used as the light-receiving surface as in this embodiment, the cover film 13B on the other surface (back surface 11B) does not have to be transparent.
- the material of the cover films 13F, 13B is not particularly limited, and may be, for example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), ethylene-tetrafluoroethylene copolymer (ETFE), polyvinyl butyrate (PVB), polyvinyl fluoride (PVF), low density polyethylene (LDPE), polypropylene (PP), nylon, and laminates thereof, depending on the usage environment.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- ETFE ethylene-tetrafluoroethylene copolymer
- PVB polyvinyl butyrate
- PVF polyvinyl fluoride
- LDPE low density polyethylene
- PP polypropylene
- nylon and laminates thereof, depending on the usage environment.
- Different materials may be used for the cover film 13F on the light receiving surface 11F side and the cover film 13B on the back surface 11B side.
- the thickness of the cover films 13F and 13B is preferably about 1 mm or less, more preferably 500 ⁇ m or less, and even more preferably 200 ⁇ m or less.
- the thickness of the cover film 13F on the light receiving surface 11F side and the cover film 13B on the back surface 11B side may differ.
- the sealing material 14 is filled between the pair of cover films 13F, 13B, and is interposed between the cover films 13F, 13B and the solar cell 11, and between the cover films 13F, 13B and the tab wire 12.
- the sealing material 14 is a transparent material that has flexibility, adhesiveness, and environmental resistance according to the usage conditions, and examples of the material include ethylene-vinyl acetate copolymer resin (EVA), ionomer resin, polyvinyl butyral (PVB), polyolefin resin, silicone resin, and acrylic copolymer resin.
- EVA ethylene-vinyl acetate copolymer resin
- PVB polyvinyl butyral
- acrylic copolymer resin acrylic copolymer resin
- the surfaces on the light receiving surface 11F side and the back surface 11B side are both recessed in the thickness direction between adjacent solar cells 11, forming groove-shaped link portions 15F, 15B in which the recesses extend in the vertical direction Y (see Figure 2.
- the link portion 15F is diagrammatically represented by a two-dot chain line).
- the thickness T1 of the sealing material 14 at the link portions 15F, 15B is smaller than the thickness (T2 + T3 + T4) of the sealing material 14 at the portions other than the link portions 15F, 15B.
- the solar cell module 10 can be bent at the link portions 15F, 15B.
- the sealing material 14 is present even in the link portions 15F, 15B, which are the thin portions, and is interposed between the cover films 13F, 13B and the tab wires 12. Therefore, even if the link portions 15F, 15B are folded, or even if they are folded repeatedly, the adhesion between the cover films 13F, 13B and the sealing material 14 is strong and does not easily peel off.
- the tab wires 12 are surrounded by the sealing material 14 even in the link portions 15F, 15B, and are protected by the sealing material 14 even when folded, so they have excellent durability against bending.
- the length of a region in the arrangement direction X of the solar cells 11 where the thickness T1 of the sealing material 14 is 0.05 to 0.6 mm (hereinafter referred to as "region 0.05-0.6 ”) is 1 mm or more.
- the maximum thickness Ta in the region indicated by the double arrow a is 0.6 mm and the minimum thickness Tb is within the range of 0.05 to 0.6 mm, the region indicated by the double arrow a corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment of the double arrow a is 1 mm or more. Also, in Figure 3, if the minimum thickness Tb is 0.6 mm, the region indicated by the double arrow b with the minimum thickness Tb corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment of the double arrow b is 1 mm or more.
- the lower limit of the thickness of the sealing material 14 in the link portions 15F, 15B, 0.05 mm, is a sufficient thickness to ensure adhesion between the sealing material 14 and the cover films 13F, 13B when bent at the link portions 15F, 15B, and to ensure the protective function of the tab wire 12.
- the upper limit of the thickness of the sealing material 14 in the link portions 15F, 15B, 0.6 mm is a sufficient thickness to ensure bendability at the link portions 15F, 15B.
- the length of the region 0.05-0.6 in the link portions 15F, 15B 1 mm or more, it is possible to provide the solar cell module 10 with excellent flexibility in the link portions 15F, 15B. From the viewpoint of flexibility, it is more preferable that the length of the region 0.05-0.6 in the link portions 15F, 15B be 1.5 mm or more.
- the length of the region 0.05-0.6 in the link portions 15F, 15B there is no particular upper limit on the length of the region 0.05-0.6 in the link portions 15F, 15B from the viewpoint of providing flexibility to the solar cell module 10.
- the length of the region 0.05-0.6 becomes larger, the distance between the solar cells 11 will inevitably become larger, which in turn will reduce the area proportion of the light receiving surface 11F in the solar cell module 10, thereby reducing the power generation efficiency of the solar cell module 10 as a whole.
- the length of the region 0.05-0.6 to a range that ensures a certain or greater area of the light receiving surface 11F per unit area in the solar cell module 10.
- the area ratio of the light receiving surface 11F in the solar cell module 10 may be appropriately designed depending on the purpose and application, but specifically, for example, it is preferably 50% or more, more preferably 70% or more, and even more preferably 90% or more.
- the area ratio of the light receiving surface 11F in the solar cell module 10 referred to here is the ratio of the total area of the light receiving surface 11F to the total area of the solar cells 11 arranged in the arrangement direction X (total area of the light receiving surface 11F and the total area of the area between adjacent solar cells 11).
- the area ratio SR (%) of the light receiving surface 11F in the solar cell module 10 can be expressed by the following formula.
- the area of the frame-like portion (see FIG. 1) that corresponds to the area outside the area in which the solar cells 11 are arranged in the arrangement direction X is not taken into consideration when calculating the area ratio SR (%) of the light receiving surface 11F of the solar cell module 10.
- the length of a region in the arrangement direction X of the solar cell 11 where the thickness T1 of the sealing material 14 is 0.05 to 0.4 mm (hereinafter referred to as the "region 0.05-0.4 ") is 1 mm or more, and it is even more preferable that the length of a region in which the thickness T1 of the sealing material 14 is 0.05 to 0.3 mm (hereinafter referred to as the "region 0.05-0.3 ”) is 1 mm or more.
- the thickness (T2+T3+T4) of the sealing material 14 in areas other than the link portions 15F and 15B there are no particular limitations on the thickness (T2+T3+T4) of the sealing material 14 in areas other than the link portions 15F and 15B, but the lower limit is approximately 0.7 mm or more, and preferably 1.0 mm or more. By setting the thickness (T2+T3+T4) to an appropriate value, it is possible to protect the sealed solar cell while maintaining its performance.
- the solar cell module 10 according to this embodiment can be folded at the link portions 15F, 15B because the link portions 15F, 15B are durable against bending. Therefore, by folding the link portions 15F, 15B in the same direction, the solar cell module 10 as a whole can be wound up in the arrangement direction X into a roll.
- the solar cell module 10 according to this embodiment can be folded into an accordion shape by alternately folding in peaks and valleys at adjacent link portions 15F, 15B, for example, by making the length of the region 0.05-0.6 in link portions 15F, 15B sufficiently large to increase the flexibility.
- the area when folded (when wound into a roll or folded into an accordion shape) can be significantly reduced compared to before folding, making it easy to transport and store when not in use.
- the durability of the link parts 15F and 15B against bending is also high, making it advantageous for repeated transportation and storage.
- the solar cell module 10 according to this embodiment can be attached to a curved surface by bending the solar cell module 10 as a whole in the arrangement direction X by bending the link portions 15F and 15B in the same direction. Therefore, the solar cell module 10 according to this embodiment can be attached to a curved surface that is not flat and used as a solar cell.
- FIG. 4 shows an example of one embodiment in which the solar cell module 10 according to the present embodiment is attached to a curved surface.
- FIG. 4 is a schematic cross-sectional view showing the state in which the solar cell module 10 according to the present embodiment is attached to the curved surface of a structure 16 having a curved surface.
- the cross-section in FIG. 4 is a cross-section in the direction in which the curved surface of the structure 16 is drawn as a curve.
- Examples of curved surfaces in the structure 16 include the outer wall surfaces of cylindrical buildings and lighthouses, and dome-shaped buildings.
- the cover films 13F, 13B, etc. of the solar cell module 10 are omitted, and only the solar cell cells 11-(1) to 11-(12) are drawn so that the relationship between the solar cell cells 11-(1) to 11-(12) and the curved surface of the structure 16 can be seen.
- the solar cell module 10 is attached to the curved surface of the structure 16, so that the 12 solar cells 11-(1) to 11-(12) are lined up in the circumferential direction R1 and attached to the structure 16.
- the solar cells 11 are attached with their light receiving surfaces 11F facing outward in the radial direction, lined up at angles of 5° each in an area of the curved surface of the structure 16 that corresponds to an arc with a central angle of approximately 60°.
- the solar cell module 10 can be attached, for example, along the curved surface of the structure 16 and can be used as a solar cell as is.
- the light receiving surfaces 11F of the individual solar cells 11 face radially outward, so that the solar cell module 10 can efficiently receive light and generate electricity even if the position of the light source, such as the sun, changes slightly.
- the current will be limited to that of the solar cell with the lowest power generation, lowering the overall power generation efficiency.
- the total current value will be limited by those solar cells, resulting in a significant reduction in power generation.
- the angle of incidence of light L is 60° even for the solar cell 11-(1) that is the furthest from the solar cell 11-(7), and the difference in power generation is approximately 14%. Therefore, there is little concern that the power generation efficiency will decrease significantly even in the solar cell module 10 of this embodiment in which the solar cells 11-(1) to 11-(12) are connected in series by the tab wires 12.
- the effects of the solar cell module 10 according to this embodiment are not limited to this.
- the link portions 15F, 15B by having the link portions 15F, 15B, even if some external force is applied, the link portions 15F, 15B bend, dissipating the action of the external force and making it difficult for the solar cell cells 11 surrounded by the sealing material 14 to be affected. Therefore, even if an external force is applied to the solar cell module 10, damage to the solar cell 11 and the effects of the external force can be suppressed.
- the solar cell module 10 of this embodiment allows external forces to escape via the link portions 15F, 15B and is surrounded and protected by the sealing material 14, so the solar cell 11 can be kept away from damage and the effects of external forces.
- Solar cells generally have the property of being easily damaged, although to varying degrees. For this reason, the solar cell is usually protected by covering at least the light-receiving surface with a hard glass plate and covering the other surface with a hard or soft layer, sandwiching the solar cell in between.
- the glass plate and hard layer used are inevitably somewhat heavy, as they are intended to protect the solar cell from damage and the effects of external forces.
- conventional solar cell modules become heavy as their area increases, requiring a great deal of effort to transport, move, and install.
- the locations and objects in which solar cell modules, which are heavy objects, can be installed are quite limited, as they must be able to stably support the weight.
- the solar cell module 10 of this embodiment does not require a glass plate or hard layer to protect the solar cell 11, and protects the solar cell 11 with the sealing material 14 and cover films 13F, 13B, which can be made of a lightweight plastic material, making it possible to achieve a reduction in weight overall. Therefore, with the solar cell module 10 of this embodiment, it is possible to achieve a reduction in weight overall, making it easy to transport, move, and install, and also alleviating restrictions on where and what it can be installed.
- the link portions 15F and 15B have a groove (depression) in a cross section in the arrangement direction X that has a trapezoidal shape with the bottom of the groove being the short side, but is not limited to this.
- a groove (depression) in a cross section in the arrangement direction X that has a trapezoidal shape with the bottom of the groove being the short side, but is not limited to this.
- the shape of the link portion There are no particular limitations on the shape of the link portion as long as it is a groove (depression).
- Modified examples of the shape of the link portion are shown below.
- Figures 5 to 7 are schematic diagrams showing modified examples of the link portion, respectively, and show the outline of the sealing material of the link portion and its surrounding area.
- the thickness Tb of the sealant 14 is minimum over the entire area of the grooved link portions 15Fa, 15Ba in the arrangement direction X. Therefore, if the thickness Tb is within the range of 0.05 to 0.6 mm, the entire area of the link portions 15Fa, 15Ba indicated by the double-headed arrow a corresponds to the area 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment of the double-headed arrow a is 1 mm or more.
- the bottom shape of the groove (depression) in the cross section in the arrangement direction X in the link parts 15Fb and 15Bb is semicircular.
- the wall surface of the groove is steep in the thickness direction Z in the cross section in the arrangement direction X, and the bottom of the groove is semicircular.
- the region indicated by the double arrow c corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment of the double arrow c is 1 mm or more.
- the region indicated by the double arrow a corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment of the double arrow a is 1 mm or more.
- the link portions 15Fc and 15Bc show an example of a groove (depression) shape in a cross section in the arrangement direction X in the link portions 15Fc and 15Bc, which is gentle from the start of the groove depression to the bottom.
- the maximum thickness Ta in the region indicated by the double arrow a is 0.6 mm and the minimum thickness Tb is within the range of 0.05 to 0.6 mm, the region indicated by the double arrow a corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment indicated by the double arrow a is 1 mm or more.
- FIG. 8 is a schematic diagram showing a modified example in which the link portion 15Fd is formed only on the light receiving surface, showing the outline of the link portion 15Fd and the sealing material 14 around it.
- the modified link portion 15Fd shown in FIG. 8 has a groove (depression) in a cross section in the arrangement direction X that is trapezoidal in shape with the bottom of the groove as the short side. Even when the link portion 15Fd is formed on only one side as in this modified example, it is the same as the link portions 15F and 15B in the first embodiment.
- the length of the line segment indicated by the double arrow a is 1 mm or more.
- the minimum thickness Tb is 0.6 mm
- the region indicated by the double arrow b with the minimum thickness Tb corresponds to the region 0.05-0.6 . Therefore, in this case, it is preferable that the length of the line segment indicated by the double arrow b is 1 mm or more.
- a pair of tab wires 12 is connected to each solar cell 11, but multiple pairs of tab wires may be connected depending on the magnitude of the current.
- electrode terminals are provided on both the light-receiving surface 11F and the back surface 11B of the solar cell 11, but for example, a back-electrode type solar cell having two electrode terminals only on the back surface of the light-receiving surface may be used, in which case a pair of tab wires or flexible wiring is connected only to the back surface of the solar cell.
- a single-sided light-receiving solar cell is used in which only one side of the solar cell 11 is the light-receiving surface 11F, but a double-sided light-receiving solar cell that receives light on both the front and back may be used.
- Fig. 9 is a plan view of the solar cell module 20 according to the second embodiment
- Fig. 10 is a partially enlarged cross-sectional view of the cross section B-B in Fig. 9.
- Fig. 10 shows only a part of the cross section B-B in Fig. 9 (areas with numbers (3) to (6) in parentheses attached to the solar cell 11).
- members having the same configurations and functions as those in Figs. 1 and 2 are denoted by the same reference numerals, and description thereof will be omitted.
- two tab wires 22a, 22b extending over almost the entire area in the arrangement direction X are arranged near both ends of the solar cell 11 in the vertical direction Y.
- the tab wires 22a, 22b are members that electrically connect adjacent solar cells 11 to each other, similar to the tab wire 12 in the first embodiment, and are conductive wires.
- Each solar cell 11 has a first electrode terminal (not shown) near the end on the light-receiving surface 11F side in the direction of the arrow Y, and a second electrode terminal (not shown) near the end on the back surface 11B side opposite the end on the side in the direction of the arrow Y.
- the first electrode terminal on the light-receiving surface 11F and the second electrode terminal on the back surface 11B have opposite polarities, so that the electromotive force generated by light can be extracted between the two electrode terminals.
- the tab wire 22a extends to the range of all the solar cells 11 in the arrangement direction X on the side of the solar cell 11 in the direction of the arrow Y.
- a branch wire member 22a' branches off from the tab wire 22a and extends in the opposite direction to the direction of the arrow Y, and the branch wire member 22a' is connected to a first electrode terminal (not shown) of each solar cell 11.
- the tab wire 22a extends further in the direction of the arrow X and protrudes from the edge of the cover film 13F, with the protruding end serving as an output terminal 22at that connects to the outside.
- the tab wire 22b extends across all of the solar cells 11 in the arrangement direction X, on the opposite side of the solar cell 11 in the direction of the arrow Y.
- a branch wire member 22b' extends in the direction of the arrow Y and is connected to a second electrode terminal (not shown) of each solar cell 11.
- the tab wire 22b extends further in the direction of the arrow X and protrudes from the edges of the cover films 13F, 13B, with the protruding end serving as an output terminal 22bt that connects to the outside.
- the solar cells 11 are electrically connected in parallel by the tab wires 22a and 22b. Therefore, the total current of the electromotive forces generated in all the solar cells 11 is generated between the output terminals 22at and 22bt.
- the surfaces on the light receiving surface 11F side and the back surface 11B side are both recessed in the thickness direction between adjacent solar cells 11, forming groove-shaped link portions 15F, 15B in which the recesses extend in the arrangement direction X of the solar cells 11 (see Figure 10.
- the link portion 15F is diagrammatically represented by a two-dot chain line).
- the solar cell module 20 of this embodiment has a configuration similar to that of the solar cell module 10 of the first embodiment, except that the solar cells 11 are electrically connected in parallel. Therefore, the solar cell module 20 of this embodiment has the same flexibility and durability as the solar cell module 10 of the first embodiment, and is easy to transport and store when not in use. It can also be attached to a curved surface and used as a solar cell.
- FIG. 11 shows an example of a solar cell module 20 according to this embodiment attached to a curved surface.
- FIG. 11 is a schematic cross-sectional view showing a solar cell module 20 according to this embodiment attached to the outer peripheral surface of a cylindrical body 26.
- the cross-section in FIG. 11 is a cross-section perpendicular to the axial direction of the cylindrical body 26. Examples of the cylindrical body 26 include a telegraph pole, a chimney, and a street light support.
- the cover films 13F, 13B, etc. of the solar cell module 20 are omitted and only the solar cell cells 11-(1) to 11-(12) are drawn so that the relationship between the solar cell cells 11-(1) to 11-(12) and the outer peripheral surface of the cylindrical body 26 can be seen.
- the sub-numbers in parentheses following the hyphens in the solar cell 11 correspond to the numbers in parentheses given to each solar cell 11 in FIG. 9.
- the solar cell module 20 is attached to the curved outer peripheral surface of the cylinder 26, so that the 12 solar cells 11-(1) to 11-(12) are lined up in the circumferential direction R2 and attached to the cylinder 26.
- the solar cells 11 are attached in a row with the light receiving surface 11F facing outward (towards the direction of arrow O) in the radial direction (directions of arrows I and O), at angles of 15° each in an area of the outer peripheral surface of the cylinder 26 that corresponds to an arc with a central angle of approximately 180°.
- the solar cell module 10 can be attached along a curved surface, such as the outer periphery of a cylinder 26, and can be used as a solar cell as is.
- the light receiving surfaces 11F of the solar cell cells 11 of the solar cell module 10 face radially outward, so that even if the position of the light source, such as the sun, changes, one or more of the solar cell cells 11 can efficiently receive light and generate electricity.
- light L is shown being irradiated perpendicularly (at an incident angle of 90°) to the light receiving surface 11F of solar cell 11-(7) among the solar cells 11 attached to the outer periphery of the cylindrical body 26.
- solar cell 11-(7) generates the most electricity, followed by the solar cell 11-(6) and 11-(8) on either side of it, which are irradiated with light L at an incident angle of 75°.
- the incidence angle becomes smaller by 15° in succession for solar cell 11-(5), 11-(9), solar cell 11-(4), 11-(10), solar cell 11-(3), 11-(11), solar cell 11-(2), 11-(12), and the amount of power generation decreases successively.
- solar cell 11-(1) which is the farthest from solar cell 11-(7)
- the light receiving surface 11F is parallel to the irradiation direction of light L
- the incidence angle is 0°, and almost no power is generated.
- the solar cells 11 are connected in parallel, so the power generated by each of the solar cells 11-(1) to 11-(12) is all added together and there is no waste. Therefore, in this example using the solar cell module 20 of this embodiment, although the voltage obtained is smaller than when the solar cells 11 are connected in series, the decrease in the amount of power generated can be suppressed.
- FIG. 12 shows a state in which the direction of the light source, such as sunlight, is tilted by 15° from the state in FIG. 11, and light L is irradiated perpendicularly (at an incident angle of 90°) to the light receiving surface 11F of the solar cell 11-(6).
- the solar cell 11-(6) generates the most electricity, equivalent to the solar cell 11-(7) in the state in FIG. 11.
- the solar cell 11-(5) and 11-(7) on either side of it, which are irradiated with light L at an incident angle of 75° generate the most electricity, equivalent to the solar cell 11-(6) and 11-(8) in the state in FIG. 11.
- the use of the solar cell module 20 in the example shown in Figure 11 can generate power with high power generation efficiency, for example, over a long period from sunrise to sunset.
- the overall weight can be reduced, making it easier to transport, move, and install, and reducing restrictions on where and what it can be installed.
- Fig. 13 is a plan view of a solar cell module 30 according to a third embodiment
- Fig. 14 is a partially enlarged cross-sectional view taken along the line CC in Fig. 13
- Fig. 15 is a partially enlarged cross-sectional view taken along the line D-D in Fig. 13.
- Fig. 14 shows only a portion of the CC cross section in Fig. 13 (areas with numbers in parentheses (31), (41), (51), and (61) attached to the solar cell 31).
- Fig. 15 shows only a portion of the D-D cross section in Fig. 13 (areas with numbers in parentheses (72) to (74) attached to the solar cell 31).
- the solar cell module 30 is a rectangular flat plate and mainly comprises a plurality of solar cells 31 (72 in this embodiment), first tab wires 32a, 32b, a second tab wire 37, a pair of transparent cover films 33F, 33B, and a sealing material 44.
- the solar cell 31 is arranged in a checkerboard pattern with the light receiving surface 31F facing in the same direction (arrow Z direction) and spaced apart in a direction parallel to the light receiving surface 11F (arrow XY direction).
- the solar cell 31, the first tab wires 32a, 32b, and the second tab wire 37 are members located under the cover film 33F and the sealing material 34, but because the cover film 33F and the sealing material 34 are transparent members and visible, they are drawn with solid lines (the same applies to the fourth to eighth embodiments described below).
- the solar cell 31 is the solar cell 11 in the first embodiment
- the first tab wires 32a, 32b and the second tab wire 37 are the tab wire 12 in the first embodiment
- the pair of cover films 33F, 33B are the pair of cover films 13F, 13B in the first embodiment
- the sealing material 34 is the sealing material 14 in the first embodiment.
- the solar battery cells 31 are arranged in a grid pattern with 12 cells in one arrangement direction X and 6 cells in the other arrangement direction Y, for a total of 72 cells.
- Each solar cell 31 is provided with a first electrode terminal (not shown) on the light-receiving surface 31F side near the end in the direction of the arrow Y, and a second electrode terminal (not shown) on the back surface 31B side near the end on the opposite side to the direction of the arrow Y.
- the first electrode terminal provided on the light-receiving surface 31F and the second electrode terminal provided on the back surface 31B have opposite polarities, so that an electromotive force generated by light can be taken out between both electrode terminals.
- the first tab wire 32b extends over the entire range of the 12 solar cells 31-(16) to 31-(U6) arranged in one arrangement direction X on the side furthest away from the arrow Y direction.
- the first tab wire 32b includes a long portion 32bs extending in one arrangement direction X, a branch portion 32b' branching off from the long portion 32bs in the arrow Y direction, and an output terminal 32bt extending in the arrow X direction of the long portion 32bs and connecting to the outside at its tip protruding from the edge of the cover films 33F, 33B.
- the branch portion branch member 32b' is connected to the second electrode terminal (not shown) of each solar cell 31.
- the second tab wires 37 electrically connect adjacent solar cells 31 in the other arrangement direction Y. More specifically, each second tab wire 37 is located between adjacent solar cells 31, and one end (the end on the side in the direction of the arrow Y on the drawing) is connected to a second electrode terminal (not shown) provided on the back surface 31B, and the other end (the end on the side opposite the direction of the arrow Y on the drawing) is connected to a first electrode terminal (not shown) provided on the light receiving surface 11F side.
- the second tab wires 37 are connected in the same way between all solar cells 11 arranged in the other arrangement direction Y.
- the solar cells 31 are electrically connected to each other in series by the second tab wire 37.
- the solar cells 31 are electrically connected to each other in parallel by the first tab wires 32a, 32b.
- groups of six solar cell cells 31 (hereinafter sometimes referred to as "series-connected groups") arranged in series in the other arrangement direction Y are arranged in 12 rows in one arrangement direction X, and all of these 12 rows of series-connected groups are connected in parallel.
- a total current of the 12 rows of series-connected groups is output from the output terminals 32at, 32bt in the form of a total voltage of electromotive forces generated by the six solar cell cells 31.
- Each series-connection group may further be provided with a backflow prevention diode in series, and each solar cell 31 may be provided with a bypass diode in parallel.
- the surfaces on the light receiving surface 31F side and the back surface 31B side are both recessed in the thickness direction, forming groove-shaped link portions 35F, 35B in which the recesses extend in the other arrangement direction Y (see Figure 14.
- the link portion 35F is diagrammatically represented by a two-dot chain line).
- the thickness T11 of the sealing material 34 at the link portions 35F, 35B is smaller than the thickness (T12+T13+T14) of the sealing material 34 at portions other than the link portions 35F, 35B.
- the link portions 35F, 35B which are groove-shaped thin portions extending in the other arrangement direction Y, it is possible to bend at the link portions 35F, 35B.
- the sealing material 34 is present even in the link portions 35F, 35B, which are the thin portions, and is interposed between the cover films 33F, 33B and the first tab wires 32a, 32b. Therefore, even if the link portions 35F, 35B are folded, or even if the folding is repeated, the adhesion between the cover films 33F, 33B and the sealing material 34 is strong and is not easily peeled off.
- the first tab wires 32a, 32b are surrounded by the sealing material 34 even in the link portions 35F, 35B, and are protected by the sealing material 34 even when folded, so that they have excellent durability against folding.
- the region where the thickness of the sealing material 34 is 0.05 to 0.6 mm in one arrangement direction X of the solar cell 31 is 1 mm or more.
- the definition, concept, and preferred range of the region 0.05-0.6 are the same as those in the first embodiment, so please refer to the explanation of the link portions 15F, 15B in the first embodiment. The same applies to the regions 0.05-0.4 and 0.05-0.3 .
- the link sections 35F and 35B in this embodiment have the same configuration and function as the link sections 15F and 15B in the first embodiment.
- the same also applies to modified examples. Therefore, for these details, please refer to the explanation of the link sections 15F and 15B in the first embodiment.
- the solar cell module 30 according to this embodiment can be folded at the link portions 35F, 35B because the link portions 35F, 35B are durable against bending. Therefore, by folding the link portions 35F, 35B in the same direction, the solar cell module 30 as a whole can be wound up in one arrangement direction X into a roll.
- the solar cell module 30 according to this embodiment can be folded into an accordion shape by alternately bending the adjacent link portions 35F, 35B in mountain and valley folds, for example, by making the length of the region 0.05-0.6 in the link portions 35F, 35B sufficiently large to increase its flexibility.
- the solar cell module 30 of this embodiment can be folded up to a significantly smaller area than when it is unfolded (before folding), making it easy to transport and store when not in use.
- the link sections 35F and 35B are highly durable against bending, making it advantageous for repeated transport and storage.
- the solar cell module 30 according to this embodiment can be bent in the same direction at the link portions 35F, 35B to curve the solar cell module 30 as a whole in one arrangement direction X, and attached to a curved surface. Therefore, the solar cell module 30 according to this embodiment can be attached to a curved surface that is not flat, and used as a solar cell.
- FIG. 16 is a schematic cross-sectional view showing the solar cell module 30 of this embodiment attached to the outer peripheral surface of a cylinder 36 similar to the cylinder 26 shown in FIG. 11.
- the cross-section in FIG. 16 is a cross-section perpendicular to the axial direction of the cylinder 36.
- the cover films 33F, 33B, etc. of the solar cell module 30 are omitted and only the solar cell 31 is drawn so that the relationship between the solar cell 31 and the outer peripheral surface of the cylindrical body 36 can be seen.
- the sub-numbers following the hyphens in the solar cell 31 correspond to the numbers in parentheses given to each solar cell 31 in FIG. 13.
- each of the solar cells 31-(11) to 31-(U1) has five solar cells 31 connected in series behind it, forming each series-connected group.
- the symbol of the solar cell 31 closest to the front shown in FIG. 16 will be used to refer to the series-connected group 31-(11) to 31-(U1).
- the solar cell module 30 is attached to the curved outer periphery of the cylinder 36, so that the 72 solar cells 31 are attached to the cylinder 36 in series connection groups arranged in the circumferential direction R2.
- the solar cells 31 are attached in a row at angles of 15° each in an area of the outer periphery of the cylinder 36 that corresponds to an arc with a central angle of approximately 180°, with the light receiving surface 31F facing outward (towards the direction of arrow O) in the radial direction (directions of arrows I and O).
- the solar cell module 30 can be attached along a curved surface, such as the outer periphery of the cylinder 36, and can be used as a solar cell as is.
- the light receiving surfaces 31F of the individual solar cell 31 face radially outward, so that even if the position of the light source, such as the sun, changes, the solar cell 31 belonging to any one or more of the series-connected groups can efficiently receive light and generate electricity.
- light L is shown being irradiated perpendicularly (at an incident angle of 90°) to the light receiving surface 31F of the solar cell 31 belonging to the series connection group 31-(71) among the solar cell 31 attached to the outer circumferential surface of the cylindrical body 36.
- the solar cell 31 belonging to the series connection group 31-(71) generates the most electricity, followed by the solar cell 31 on either side of it belonging to the series connection group 31-(61) where light L is irradiated at an incident angle of 75°, and the solar cell 31 belonging to the series connection group 31-(81).
- the incident angle of the solar cell 31 in each of the series-connected groups 31-(51), 31-(91), 31-(41), 31-(S1), 31-(31), 31-(T1), 31-(21), 31-(U1) becomes smaller by 15°, and the amount of power generation decreases.
- the solar cell 31-(1) furthest from the solar cell 31-(71) has a light receiving surface 31F parallel to the direction of the light L, and the incident angle is 0°, so that almost no power is generated.
- the incident angle of light in the solar cell 31 differs for each series-connected group, resulting in a difference in the amount of power generation.
- the overall weight can be reduced, making it easier to transport, move, and install, and reducing restrictions on where and what it can be installed.
- Fig. 17 is a plan view of the solar cell module 40 according to the fourth embodiment
- Fig. 18 is a partially enlarged cross-sectional view of the E-E section in Fig. 17
- Fig. 19 is a partially enlarged cross-sectional view of the F-F section in Fig. 17.
- Fig. 18 shows only a part of the E-E section in Fig. 17 (areas where the numbers in parentheses attached to the solar cell 41 are (31), (41), (51), and (61)).
- Fig. 19 shows only a part of the F-F section in Fig. 17 (areas where the numbers in parentheses attached to the solar cell 31 are (72) to (74)).
- members having the same configurations and functions as those of the solar cell module 30 according to the third embodiment are given the same reference numerals as those in Figs. 13 to 15, and their description will be omitted.
- first link portions 45F, 45B are formed, with the recesses extending in the other arrangement direction Y (see Figure 18.
- first link portion 45F is diagrammatically represented by a two-dot chain line).
- the thickness T21 of the sealing material 44 at the first link portions 45F, 45B is smaller than the thickness (T22+T23+T24) of the sealing material 44 at portions other than the first link portions 45F, 45B.
- the first link portions 45F, 45B which are groove-shaped thin portions extending in the other arrangement direction Y, it is possible to bend at the first link portions 45F, 45B.
- the sealing material 44 is present even in the first link portions 45F, 45B, which are the thin portions, and is interposed between the cover films 43F, 43B and the first tab wires 42a, 42b. Therefore, even if the link portions 45F, 45B are folded, or even if they are folded repeatedly, the adhesion between the cover films 43F, 43B and the sealing material 44 is strong and does not easily peel off.
- the first tab wires 42a, 42b are surrounded by the sealing material 44 even in the first link portions 45F, 45B, and are protected by the sealing material 44 even when folded, so they have excellent durability against bending.
- the region where the thickness of the sealing material 44 is 0.05 to 0.6 mm in one arrangement direction X of the solar cell 41 is 1 mm or more.
- the definition, concept, and preferred range of the region 0.05-0.6 are the same as those in the first embodiment, so please refer to the explanation of the link portions 15F, 15B in the first embodiment. The same applies to the regions 0.05-0.4 and 0.05-0.3 .
- first link parts 45F, 45B in this embodiment have the same configuration and function as the link parts 15F, 15B in the first embodiment.
- the same also applies to modified examples. Therefore, for these details, please refer to the explanation of the link parts 15F, 15B in the first embodiment.
- the surfaces on the light receiving surface 41F side and the back surface 41B side are both recessed in the thickness direction, forming groove-shaped second link portions 48F, 48B with the recesses extending in one arrangement direction X (see Figure 19.
- the second link portion 48F is diagrammatically represented by a two-dot chain line).
- the thickness T21 of the sealing material 44 at the second link portions 48F, 48B is smaller than the thickness (T32+T33+T34) of the sealing material 44 at portions other than the second link portions 48F, 48B.
- the second link portions 48F, 48B which are groove-shaped thin portions extending in one of the arrangement directions X, it is possible to bend at the second link portions 48F, 48B.
- the sealing material 44 is also present in the second link portions 48F, 48B, which are the thin portions, and is interposed between the cover films 43F, 43B and the second tab wire 37. Therefore, even if the second link portions 48F, 48B are folded, or even if the folding is repeated, the adhesion between the cover films 43F, 43B and the sealing material 44 is strong and is not easily peeled off.
- the second tab wire 37 is also surrounded by the sealing material 44 in the second link portions 48F, 48B, and is protected by the sealing material 44 even when folded, so it has excellent durability against folding.
- the region where the thickness of the sealing material 44 is 0.05 to 0.6 mm in the other arrangement direction Y of the solar cell 41 is 1 mm or more.
- the definition, concept, and preferred range of the region 0.05-0.6 are the same as those in the first embodiment, so please refer to the explanation of the link portions 15F, 15B in the first embodiment. The same applies to the regions 0.05-0.4 and 0.05-0.3 .
- the second link parts 48F, 48B in this embodiment have the same configuration and function as the link parts 15F, 15B in the first embodiment.
- the same also applies to modified examples. Therefore, for these details, please refer to the explanation of the link parts 15F, 15B in the first embodiment.
- first link sections 45F, 45B and second link sections 48F, 48B that intersect at approximately right angles (approximately perpendicular) are provided between the solar cell cells 41 arranged in a grid pattern. Therefore, the solar cell module 40 according to this embodiment can be folded in both the arrangement direction X and the other arrangement direction Y.
- the solar cell can be folded at the first link portions 45F, 45B, which provides excellent portability and storability when not in use, and can be attached to a curved surface for use as a solar cell.
- the second link portions 48F, 48B formed between adjacent solar cells 31 in the other arrangement direction Y can also be folded. Therefore, for example, the folding direction when stored and the curved direction when installed can be set independently. For example, even if a solar cell module (not shown) in which the Y direction is longer than the X direction is folded in one arrangement direction X and attached to a curved surface for use, when not in use, it can be folded in the other arrangement direction Y to make the solar cell module more compact in the longitudinal direction. Therefore, there is an even greater degree of freedom in shape both when not in use and when used as a solar cell, and it is easy to handle and has excellent freedom in design.
- the solar cell module 40 of this embodiment has first link portions 45F, 45B and second link portions 48F, 48B perpendicular thereto, and is adapted to bend in these two directions. That is, even when some external force acts on the solar cell module 40 of this embodiment, the first link portions 45F, 45B and second link portions 48F, 48B bend, and the action of the external force is efficiently dissipated. Therefore, even though the solar cell module 40 of this embodiment has a large area, it is unlikely to affect the solar cell cells 31 surrounded by the sealing material 34. Therefore, even if an external force acts on the solar cell module 40, damage to the solar cell cells 31 and the effects of the external force can be suppressed.
- the solar cell module 40 of this embodiment does not require a glass plate or hard layer to protect the solar cell 31, and protects the solar cell 31 with the sealing material 34 and cover films 33F, 33B, which can be made of a lightweight plastic material, so that the overall weight can be reduced. Therefore, with the solar cell module 40 of this embodiment, the overall weight can be reduced, making it easy to transport, move, and install, and reducing restrictions on where and what it can be installed.
- first link sections 45F, 45B and second link sections 48F, 48B are provided between the solar cells 41 arranged in a grid pattern, and cross at approximately right angles (approximately perpendicular), but the scope of the present invention also includes a configuration in which only one of these is provided.
- the configuration in which only the first link portions 45F, 45B are formed between adjacent solar cell cells 31 in one arrangement direction X is the same as the solar cell module 30 according to the third embodiment in which the link portions 35F, 35B are formed in similar locations, and is therefore as described above.
- the present invention also includes a configuration in which only the second link portions 48F, 48B are provided between solar cell cells 31 adjacent in the direction of the arrow Y.
- the direction of the arrow Y corresponds to the "one arrangement direction” in the present invention (claim 4)
- the direction of the arrow X corresponds to the "other arrangement direction” in the present invention (claim 4)
- the second link portions indicated by the symbols 48F, 48B correspond to the "link portion" in the present invention (claim 4).
- the first manufacturing method a method for manufacturing a solar cell module similar to the solar cell module 10 according to the first embodiment will be mainly described.
- the reference symbols in Fig. 1 and Fig. 2 will be used, but the solar cell module manufactured has a different shape from the solar cell module 10 according to the first embodiment in the strict sense.
- Preparation process (process up to wiring) First, prepare the required number of solar cell cells 11, the required number of tab wires 12, a pair of resin films (reference number 13' described below) made of, for example, polyethylene terephthalate (PET) that will become cover films 13F, 13B when completed, and two sheets (reference number 14' described below) of a sealing material, for example, a sheet-like ethylene-vinyl acetate copolymer that will become sealing material 14 when completed.
- a sealing material for example, a sheet-like ethylene-vinyl acetate copolymer that will become sealing material 14 when completed.
- One end of the tab wire 12 is soldered to the wiring portion (first electrode terminal portion not shown in the first embodiment) on the light-receiving surface 11F side of each of the prepared solar cell 11.
- the solar cells 11 are arranged in a row on a flat table with the light receiving surfaces 11F all facing downwards, with some space between them, and one end of the tab wire 12, the other end of which is soldered to the first electrode terminal portion, is soldered to the wiring portion on the back surface 11B side of the adjacent solar cell 11 (the second electrode terminal portion, not shown in the first embodiment), thereby electrically connecting the adjacent solar cells 11.
- Figure 20 is a plan view showing a state during manufacturing in a method for manufacturing a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and more specifically, shows a state immediately before the lamination process is performed after the next lamination preparation step is completed (hereinafter, this state is referred to as a "pre-lamination stack").
- Figure 21 is a partially enlarged cross-sectional view of the G-G cross section in Figure 20. Arrows X to Z in Figures 20 and 21 are the same as the arrows shown in the drawings of the first embodiment of the solar cell module.
- a resin film 13' was placed on a flat table, a sheet 14' of sealing material was placed on top of it, and solar cell 11 with wiring by tab wire 12 was placed side by side on top of it. Another sheet 14' of sealing material was placed on top of it, and another resin film 13' was placed on top of that. In this way, solar cell 11 with wiring by tab wire 12 was sandwiched between a pair of resin films 13' on both sides (11F and 11B) of solar cell 11 with sealing material (sheet 14') between them.
- the laminate for which the operation of the stacking arrangement step (2) was completed was placed on top of the piano wire 91B placed on the silicone sheet 99B. At this time, fine adjustments were made as necessary so that the piano wire 91B extended in the direction of the arrow Y in the center between adjacent solar cell 11. In this state, it is preferable to fix the piano wire 91B and the laminate by some method (for example, adhesive tape) so that the position does not move.
- some method for example, adhesive tape
- the same number of piano wires 91F were arranged on the upper resin film 13' of the laminate in positions that coincide in plan view with the piano wires 91B arranged on the silicone sheet 99B. In this state, it is preferable to fix the piano wires 91F and the laminate in the same manner as above so that the positions do not move. Furthermore, a silicone sheet 99F was placed on top of the piano wires 91F arranged on the upper resin film 13' to obtain a pre-lamination laminate.
- the pre-lamination laminate shown in Fig. 20 and Fig. 21 was subjected to a lamination process by heating and pressing from the thickness direction Z using a vacuum laminator.
- the conditions for the heating and pressing may be appropriately set depending on the sealing material and the resin film material used, but in this embodiment, the lamination process was performed using a vacuum laminator under the conditions of atmospheric pressure after evacuation for 3 minutes and at 150°C for 15 minutes.
- the sheet 14' of the sealing material melts and embeds the piano wires 91F and 91B together with the resin film 13'.
- the sheet 14' melted by heating becomes liquid and is crushed, wrapping around and filling the gap between the pair of resin films 13' (for example, around the solar cell 11 and the tab wire 12).
- Figure 22 is a partially enlarged cross-sectional view showing the state after lamination during manufacturing in a method for manufacturing a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and is a cross-sectional view of the same location as Figure 21.
- Figure 22 the positions of silicone sheets 99F, 99B and piano wires 91F, 91B before lamination are drawn with dotted lines.
- the pre-lamination laminate becomes thinner overall, and the space between the pair of resin films 13' is filled with the sealing material that was previously sheet 14', eliminating any gaps, and the piano wires 91F, 91B become embedded together with the resin film 13', so that the resin film 13' becomes cover films 13F, 13B, and the sheet 14' becomes sealing material 14. Also, the grooves formed by the piano wires 91F, 91B in the surfaces of the cover films 13F, 13B become link sections 15F', 15B'.
- the resulting solar cell module 10 has link sections 15F', 15B' to which the cross-sectional shapes of the piano wires 91F, 91B (in the description of this manufacturing method, "cross-sectional shape” refers to the shape at a cross section in the arrangement direction X) are transferred.
- the cross-sectional shape of the sealing material 14 at the link sections 15F', 15B' has the shape of the link sections 15Fb, 15Bb shown in FIG. 6.
- jigs piano wires 91F, 91B
- the resin film 13' on both the top and bottom of the laminate and the silicone sheets 99F, 99B.
- the jigs only on either the top or bottom, it is possible to create a solar cell module in which the link portion is formed only on either the light receiving surface 11F side or the back surface 11B side.
- FIG. 23 is a plan view showing an example of a one-piece jig 93 that can be used in the first manufacturing method.
- the jig 93 is a ladder-like structure in which rod-shaped sections 92, each with a cross-sectional shape that corresponds to the cross-sectional shape of the groove of the link section to be formed, are arranged in the same number as the number of links to be formed (12 in this embodiment), with both ends of each section connected by connecting sections 94.
- the spacing between the rod-shaped sections 92 is the same as the spacing between the links to be formed.
- this jig 93 is used instead of the piano wires 91F and 91B to perform the operation of the lamination preparation process (3), the labor required to arrange the piano wires 91F and 91B at a predetermined interval can be eliminated, and the jig 93 can be removed in one go after the lamination process (4), resulting in excellent work efficiency.
- piano wire is used as the material for these jigs, but of course this is not limited to this, and any material can be used, such as metal, various resins, various rubbers, wood, ceramics, etc., as long as it has heat resistance to the heat applied during lamination and rigidity to pressure. It is preferable to use a material for the jigs that does not easily adhere to the sealing material, or that is easy to peel off even if it does adhere. Considering all factors, the jig materials that are preferable are iron, stainless steel, brass, silicone rubber, or fluororesin.
- Preparation process (process up to wiring) First, prepare the required number (72) of solar cell cells 31, the required number of two types of tab wires 32a, 32b, 37, a pair of resin films (reference numeral 33' described below) which will become cover films 33F, 33B when completed, and two sheets of encapsulant material (reference numeral 34' described below) which will become encapsulant 34 when completed. Specific examples of the resin films and encapsulant material are the same as those explained in the section on the first manufacturing method.
- first tab wires 32a, 32b have been described as being one tab wire each consisting of the branch wire portions 32a', 32b', the long portions 32as, 32bs, and the output terminals 32at, 32bt.
- the branch wire portions 32a', 32b' and the other portions are separate members. Therefore, hereinafter, the members that become the branch wire portions 32a', 32b' will be referred to as branch wire members 32a', 32b' using the same reference numerals, and the other portions will be referred to as long wire members 32as, 32bs, omitting the reference numerals 32at, 32bt.
- branch wire member 32a' is soldered to the wiring portion on the light receiving surface 31F side (first electrode terminal portion, not shown in the fourth embodiment).
- branch wire member 32b' is soldered to the wiring portion on the back surface 31B side (second electrode terminal portion, not shown in the fourth embodiment).
- the solar cell 31 with the branch wire member 32a' soldered is placed at the top (the side closest to the direction of the arrow Y), and the second tab wire 37 and branch wire member 32b' are placed at the bottom (the side closest to the direction of the arrow Y).
- the four solar cells 31 between the top and bottom have only the second tab wire 37 soldered.
- the other end of the second tab wire 37 one end of which is soldered to the first electrode terminal portion, is soldered to the wiring portion (the second electrode terminal portion, not shown in the fourth embodiment) on the back surface 31B side of the adjacent solar cell 31 in the other arrangement direction Y, thereby electrically connecting the solar cell cells 31 adjacent to each other in the other arrangement direction Y.
- the remaining 66 solar cells 11 are similarly connected in groups of six to create a total of 12 series-connected groups. By arranging these series-connected groups in 12 rows at equal intervals in one of the arrangement directions X, a total of 72 cells are arranged in a grid pattern.
- Long wire members 32as extending in one arrangement direction X are arranged so as to come into contact with the 12 branch wire members 32a' soldered to the solar cell 11 located at the top (furthest from the arrow Y direction) of the solar cell 11 arranged in a grid pattern, and each is soldered.
- long wire members 32bs extending in one arrangement direction X are arranged so as to come into contact with the 12 branch wire members 32b' soldered to the solar cell 11 located at the bottom (furthest from the arrow Y direction), and each is soldered.
- the solar cell 31 and the tab wires 32a, 32b, 37 are wired as shown in Figure 17.
- Figure 24 is a plan view showing a state during manufacturing in the second manufacturing method of a solar cell module according to an embodiment that is an exemplary aspect of the present invention, and more specifically, shows a state immediately before the lamination process is performed after the next lamination preparation step is completed (referred to as a "pre-lamination stack" as in the above ⁇ First Manufacturing Method>).
- Figure 25 is a partially enlarged cross-sectional view of the H-H cross section in Figure 24
- Figure 26 is a partially enlarged cross-sectional view of the I-I cross section in Figure 24.
- Fig. 24 the uppermost silicone sheet (reference numeral 99F), which will be described later, is omitted from the illustration.
- Fig. 25 only a portion of the H-H cross section in Fig. 24 (the region in which the numbers in parentheses attached to the solar cell 31 are (31) to (61)) is shown.
- Fig. 26 only a portion of the I-I cross section in Fig. 24 (the region in which the numbers in parentheses attached to the solar cell 31 are (71) to (73)) is shown.
- the arrows X to Z in Figs. 24 to 26 are the same as the arrows shown in the respective drawings of the solar cell module according to the fourth embodiment.
- a resin film 33' was placed on a flat table, a sheet 34' of sealing material was placed on top of it, and solar cell 31 with wiring by tab wires 32a, 32b, 37 was placed side by side on top of it. Another sheet 34' of sealing material was placed on top of it, and another resin film 33' was placed on top of that. In this way, solar cell 31 with wiring by tab wires 32a, 32b, 37 was sandwiched between a pair of resin films 33' on both sides (reference numerals 31F and 31B) of solar cell 31 with sealing material (sheet 34') in between.
- the jigs 95 are arranged in pairs, one on the upper side (the Z direction side) and one on the lower side (the opposite side of the Z direction) of the laminated body after the operation of the (2) laminate arrangement process is completed.
- the portion arranged on the upper side is indicated with an F at the end of the reference numeral, as “rod-shaped portions 96F and 97F”
- the portion arranged on the lower side is indicated with a B at the end of the reference numeral, as "rod-shaped portions 96B and 97B.”
- the rod-shaped portions 96 and 97 are integrated at the points where they intersect, and the jig 95 as a whole has a lattice shape. All ends of the rod-shaped portions 96 and 97 are fixed to a frame 98. This frame 98 is not essential. As explained in the section on the first manufacturing method, there are no particular limitations on the material of the jig 95, so long as it has heat resistance and rigidity.
- the laminate after the operation of the stacking arrangement step (2) was placed on top of the jig 95 placed on the silicone sheet 99B.
- the jig 95 was adjusted so that the rod-shaped portion 96B extended in the direction of the arrow Y at the center between adjacent solar cells 31 in one arrangement direction X, and the rod-shaped portion 97B extended in the direction of the arrow X at the center between adjacent solar cells 31 in the other arrangement direction Y.
- jig 95 was placed on the upper resin film 33' of the laminate at a position that coincides in plan view with the jig 95 arranged on the silicone sheet 99B. In this state, it is preferable to fix the jig 95 and the laminate in the same manner as above so that the position does not move. Furthermore, a silicone sheet 99F was placed on top of the jig 95 placed on the upper resin film 33' to obtain a pre-lamination laminate.
- the pre-lamination laminate was subjected to heat and pressure bonding from the thickness direction Z by a vacuum laminator to perform lamination.
- the conditions for heat and pressure bonding may be appropriately set depending on the sealing material and the resin film material used, but in this embodiment, the laminate was performed using a vacuum laminator under the conditions of atmospheric pressure after evacuation for 3 minutes and at 150° C. for 15 minutes.
- the sheet 34' of the sealing material melts and embeds the rod-shaped portions 96, 97 together with the resin film 33'.
- the sheet 34' melted by heating becomes liquid and is crushed, wrapping around and filling the gaps between the pair of resin films 33' (for example, around the solar cell 31 and the tab wires 32a, 32b, 37).
- Figures 27 and 28 are partially enlarged cross-sectional views showing the state after lamination during manufacturing in the second manufacturing method of a solar cell module according to an embodiment that is an exemplary aspect of the present invention, with Figure 27 being a cross-sectional view of the same location as Figure 25, and Figure 28 being a cross-sectional view of the same location as Figure 26.
- Figures 27 and 28 the positions of silicone sheets 99F, 99B and rod-shaped portions 96F, 96B, 97F, 97B before lamination are drawn with dotted lines.
- the pre-lamination laminate becomes thinner overall, and the space between the pair of resin films 33' is filled with the sealant material that was the sheet 34', eliminating any gaps, and the rod-shaped portions 96F, 96B, 97F, and 97B are embedded together with the resin film 33', so that the resin film 33' becomes the cover films 33F and 33B, and the sheet 34' becomes the sealant 34.
- the grooves in the surfaces of the cover films 33F and 33B depressed by the rod-shaped portions 96F and 96B become the first link portions 45F' and 45B'.
- the grooves in the surfaces of the cover films 33F and 33B depressed by the rod-shaped portions 97F and 97B become the second link portions 48F' and 48B'.
- the solar cell module 40 thus obtained has first link portions 45F', 45B' to which the cross-sectional shapes of the rod-shaped portions 96F, 96B (in the description of this manufacturing method, the "cross-sectional shape" of the rod-shaped portions 96F, 96B refers to the shape in a cross section in one of the arrangement directions X) are transferred.
- the solar cell module 40 also has second link portions 48F', 48B' to which the rod-shaped portions 97F, 97B (in the description of this manufacturing method, the "cross-sectional shape" of the rod-shaped portions 97F, 97B refers to the shape in a cross section in the other arrangement direction Y) are transferred.
- the cross-sectional shapes of the sealing material 44 in the first link parts 45F', 45B' and the second link parts 48F', 48B' are both the same as the shapes of the link parts 15Fb, 15Bb shown in FIG. 6.
- the cross-sectional shapes of the first link portion and the second link portion that are formed can be controlled by forming the rod-shaped portions 96 and 97 of the jig 95 into different shapes. This is the same as in the case of the piano wire used as the jig described in the first manufacturing method section.
- the jig 95 is placed between the resin film 13' on both the top and bottom of the laminate and the silicone sheets 99F, 99B, but by placing the jig only on either the top or bottom, it is possible to create a solar cell module in which the first link portion and the second link portion are formed only on either the light receiving surface 11F side or the back surface 11B side. This is also the same as in the case of the piano wire used as a jig described in the first manufacturing method section.
- the above-described embodiments of the solar cell module and the embodiments of the manufacturing method of the solar cell module merely show typical forms of the present invention, and the present invention is not limited to these embodiments.
- the above-described embodiments show an example in which the maximum number of solar cells in the bending direction is 12, but there is no particular limit to this number, and by increasing the number of solar cells in the bending direction and increasing the number of link sections, it is possible to create a solar cell module that is easier to bend overall (smaller radius of curvature) and/or has a large area and high output.
- FIG. 29 is a plan view of the solar cell module 50 according to the fifth embodiment
- FIG. 30 is a partially enlarged cross-sectional view of the K-K cross section in FIG. 29
- FIG. 31 is a partially enlarged cross-sectional view of the M-M cross section in FIG. 29.
- FIG. 30 only the area surrounded by a rectangular dashed line in the K-K cross section in FIG. 29 (areas in which the numbers in parentheses given to the solar cell 51 are (1-2), (1-3), (1-4), and (1-5)) is shown.
- FIG. 31 only a part of the M-M cross section in FIG. 29 (areas in which the numbers in parentheses given to the solar cell 51 are (1-11) and (1-12)) is shown.
- members having the same configuration and function as the solar cell module 30 according to the third embodiment are given reference numerals obtained by changing the reference numerals in the 30s in FIG. 13 to FIG. 15 to the 50s, and their description will be omitted.
- the surfaces on the light receiving surface 51F side and the back surface 51B side are both recessed in the thickness direction, and groove-shaped link portions 55F, 55B are formed with the recesses extending in one arrangement direction X. Note that the link portion 55F is not shown in FIG. 29.
- the surfaces on the light receiving surface 51F side and the back surface 51B side are both recessed in the thickness direction, and groove-shaped link portions 58F, 58B are also formed, with the recesses extending in the other arrangement direction Y. Since the link portions 58F, 58B correspond to the "second link portions 58F, 58B" in the fourth embodiment, they are also referred to as the “second link portions” in this embodiment, and the link portions 55F, 55B are also referred to as the "first link portions 55F, 55B.”
- the solar cell 51 is an elongated rectangle, and is arranged in a checkerboard pattern with spaces between each other, with 4 cells (4 rows) in one arrangement direction X and 20 cells (20 columns) in the other arrangement direction Y, for a total of 80 cells.
- the space between adjacent solar cell cells 51 in one arrangement direction X is, for example, 5 mm
- the space between adjacent solar cell cells 51 in the other arrangement direction Y is, for example, 6 mm.
- each solar cell 51 is given a number in parentheses consisting of the row number from the top in one arrangement direction X and the column number from the left in the other arrangement direction Y, connected with a hyphen (-).
- the solar cell 51 used in this embodiment is a quarter of the size of a solar cell that is approximately 160 mm square, that is, approximately 160 mm x 40 mm. These are arranged in a grid pattern to create a solar cell module 50 with a large area of approximately 700 mm x 1000 mm.
- Each solar cell 51 has a first electrode terminal (not shown) on the light-receiving surface 31F and a second electrode terminal (not shown) on the back surface 31B.
- the first electrode terminal on the light-receiving surface 31F and the second electrode terminal on the back surface 31B have opposite polarities, so that the electromotive force generated by light can be extracted between the two electrode terminals.
- the first tab wires 52a, 52b electrically connect adjacent solar cells 51 in one arrangement direction X.
- the first tab wire 52a extends between the top two solar cells (1-1) and (2-1) arranged in one arrangement direction X on the side furthest away from the arrow Y direction, and between the bottom two solar cells (3-1) and (4-1).
- the first tab wire 52b extends between the middle two solar cells (2-20) and (3-20) arranged in one arrangement direction X on the side furthest in the arrow Y direction.
- the first tab wires 52a, 52b have long portions 52as, 52bs extending in one arrangement direction X, and branch wire portions 52a', 52b' branching off from the long portions 52as, 52bs in the direction of the arrow Y or in the opposite direction.
- the branch wire portions 52a', 52b' are connected to the first electrode terminal (not shown) or the second electrode terminal (not shown) of each solar cell 51.
- each second tab wire 57 electrically connect adjacent solar cells 51 in the other arrangement direction Y. More specifically, each second tab wire 57 is located between adjacent solar cells 51 and is connected to a second electrode terminal (not shown) provided on the back surface 51B, and the other end (the end on the opposite side to the arrow Y direction in the drawing) is connected to a first electrode terminal (not shown) provided on the light receiving surface 51F.
- the second tab wires 57 are connected in the same manner between all solar cells 11 arranged in the other arrangement direction Y.
- a total of three second tab wires 57 are arranged in parallel between adjacent solar cell cells 51 in the other arrangement direction Y. These three second tab wires 57 have the same shape and material, are routed in the same manner, and are connected to the solar cell cells 51 in the same manner.
- Each second tab wire 57 is a very thin conductor, and by making them thin, they do not interfere with the light incident on the light receiving surface 51F and are flexible, while by increasing the number of wires, large electrical capacity and connection strength are ensured.
- the widths of the first tab wires 52a, 52b and the second tab wire 57 are all, for example, 1.8 mm.
- the second tab wire 57 is connected, as shown in FIG. 30, on the arrow Y direction side (right side in FIG. 30) to a second electrode terminal (not shown) provided on the back surface 51B, and on the opposite side to the arrow Y direction (left side in FIG. 30) to a first electrode terminal (not shown) provided on the light receiving surface 51F.
- the connection between the second tab wire 57 and the electrode terminal is similar between the solar cells (3-1) to (3-20) in the third row in one arrangement direction X.
- the second tab wire 57 is connected on the side opposite to the arrow Y direction (left side in FIG. 30) to a second electrode terminal (not shown) provided on the back surface 51B, and on the side in the arrow Y direction (right side in FIG. 30) to a first electrode terminal (not shown) provided on the light receiving surface 51F.
- the connection between the second tab wire 57 and the electrode terminal is similar between the solar cells (4-1) to (4-20) in the bottom row in one arrangement direction X. In other words, the connection relationship between the second tab wire 57 and the electrode terminal is reversed between the top and third rows and the second and bottom rows in one arrangement direction X.
- Three branch wires 52a', 52b' extend outward from each of the solar cells (1-1) to (4-1), (1-20) to (4-20) at both ends of the other arrangement direction Y, and are joined together by the long portions 52as, 52bs.
- the long portions 52as, 52bs then extend appropriately in one arrangement direction X, electrically connecting the solar cells 51 adjacent in one arrangement direction X.
- a second electrode terminal (not shown) provided on the back surface 51B of the top solar cell (1-1) in one arrangement direction X and a first electrode terminal (not shown) provided on the light receiving surface 51F of the second solar cell (2-1) are electrically connected by a first tab wire 52a
- a second electrode terminal (not shown) provided on the back surface 51B of the third solar cell (3-1) and a first electrode terminal (not shown) provided on the light receiving surface 51F of the bottom solar cell (4-1) are electrically connected by a first tab wire 52a.
- a second electrode terminal (not shown) provided on the back surface 51B of the second row of solar cell (2-20) in one arrangement direction X and a first electrode terminal (not shown) provided on the light receiving surface 51F side of the third row of solar cell (3-20) are electrically connected by a first tab wire 52b.
- the solar cells 51 are individually labeled with the following symbols: (1-20) to (1-1), (2-1) to (2-20), (3-20) to (3-1), and (4-1) to (4-20).
- Three branch wires 52bt' extend from each of the solar cell (1-20), (4-20) located at both ends of this series connection in the direction of the arrow Y, and are combined into one by a pair of output wirings 52bt.
- the branch wire 52bt' extending from the solar cell (1-20) is electrically connected to a first electrode terminal (not shown) provided on the light receiving surface 51F side, and the branch wire 52bt' extending from the solar cell (4-20) is electrically connected to a second electrode terminal (not shown) provided on the back surface 51B.
- the solar cell module 50 has a wiring outlet 58 in which a cut is made in the cover film 53F on the light receiving surface 11F side, approximately in the center in one arrangement direction X.
- the pair of output wirings 52bt are connected to a pair of external output cables 59 at the wiring outlet 58, and power is output from the pair of external output cables 59.
- the solar cell module 50 of this embodiment has a large area and high output, but because the individual solar cell cells 51 are small, it can be significantly reduced in size by folding it at the first link parts 55F, 55B and rolling it up in the other arrangement direction Y as a whole or folding it into an accordion shape, making it easy to transport and store when not in use. In addition, it can be used as a solar cell by folding it at the first link parts 55F, 55B and attaching it to a curved surface that curves in the other arrangement direction Y.
- the solar cell module 50 of this embodiment can be folded not only at the first link portions 55F, 55B but also at the second link portions 58F, 58B, so that it can be folded at the second link portions 58F, 58B to reduce the length in one arrangement direction X when not in use, or to attach to a curved surface that curves in one arrangement direction X. Furthermore, the solar cell module 50 of this embodiment can be made lightweight overall while being large in area and high in output, making it easy to transport, move, and install, and easing restrictions on where and what it can be installed.
- FIG. 32 is a plan view of a solar cell module 60 according to the sixth embodiment
- Fig. 33 is a partially enlarged cross-sectional view of the L-L cross section in Fig. 32.
- Fig. 33 shows only the region enclosed by a rectangular dashed dotted line in the L-L cross section in Fig. 30 (the regions with numbers in parentheses attached to the solar cell 61 as (1-2), (1-3), and (1-4)).
- members having the same configurations and functions as those of the solar cell module 50 according to the fifth embodiment are designated by reference numbers obtained by changing the reference numbers in the 50s in Figs. 29 to 31 to the 60s, and description thereof will be omitted.
- the surfaces on the light receiving surface 61F side and the back surface 61B side are both recessed in the thickness direction, and groove-shaped link portions 65F, 65B are formed in which the recesses extend in the other arrangement direction Y. Note that the link portion 65F is not shown in Figure 32.
- the solar cell 61 is a square with chamfered corners, and is arranged in a checkerboard pattern with gaps between each other, with five cells (five columns) in one arrangement direction X and four cells (four rows) in the other arrangement direction Y, for a total of 20 cells.
- the gap between adjacent solar cell cells 61 in one arrangement direction X is, for example, 5 mm
- the gap between adjacent solar cell cells 61 in the other arrangement direction Y is, for example, 5 mm.
- each solar cell 61 is given a number in parentheses, which is the column number from the left in one arrangement direction X and the row number from the top in the other arrangement direction Y, connected in row-column order with a hyphen (-).
- the solar cell 61 used in this embodiment is approximately 160 mm square. These are arranged in a grid pattern to form a solar cell module 60 with a large area of approximately 700 mm x 900 mm.
- the electrical connections between the first tab wires 62a, 62b and the second tab wire 67 and the solar cell 61 are similar to the electrical connections between the first tab wires 52a, 52b and the second tab wire 57 and the solar cell 51 in the fifth embodiment.
- a total of three second tab wires 67 are arranged in parallel between adjacent solar cell 61 in one arrangement direction X ("the other arrangement direction Y" in FIG. 29 of the fifth embodiment) like the second tab wire 57 in the fifth embodiment.
- the solar cells 61 are individually labeled with the following 20 solar cells 61 connected in series in the following order: (1-5) to (1-1), (2-1) to (2-5), (3-5) to (3-1), and (4-1) to (4-5).
- the solar cells (1-5), (4-5) located at both ends of this series connection are connected to a pair of external output cables 69 via three branch lines 62bt' extending in the direction of the arrow Y, a pair of output wiring 62bt, and wiring outlets 68, and are wired to output power, similar to the solar cell module 50 according to the fifth embodiment.
- the solar cell module 60 has a large area and high output, but because the solar cell 61 is divided into multiple parts, it can be significantly reduced in size by folding it at the link parts 65F, 65B and rolling it up in one arrangement direction X as a whole or folding it into an accordion-like shape, making it easy to transport and store when not in use. In addition, it can be used as a solar cell by folding it at the link parts 65F, 65B and attaching it to a curved surface that curves in one arrangement direction X.
- the solar cell module 60 of this embodiment has a large surface area and high output, yet is lightweight overall, making it easy to transport, move, and install, and mitigating restrictions on where and what it can be installed.
- Seventh embodiment 34 is a plan view of the solar cell module 70 according to the seventh embodiment.
- the electrical connections between the first tab wires 72a, 72b and the second tab wire 77 and the solar cell 71, the series connection of the solar cell 71, and the wiring from the solar cell cells (1-5) and (4-5) located at both ends to the pair of external output cables 79 are the same as those of the solar cell module 60 according to the sixth embodiment. Therefore, the description thereof and the publication of a cross-sectional view are omitted.
- the light receiving surface 71F side and the back surface (not shown) side are both recessed in the thickness direction, and a groove-shaped link portion (not shown) is formed in which the recess extends in the other arrangement direction Y.
- the solar cell 71 used in this embodiment is a square of approximately 180 mm on each side with the four corners chamfered, and is arranged in a grid pattern with four cells (four rows) in one arrangement direction X and five cells (five columns) in the other arrangement direction Y, for a total of 20 cells, spaced apart.
- the spacing between adjacent solar cell cells 71 in one arrangement direction X is, for example, 5 mm
- the spacing between adjacent solar cell cells 71 in the other arrangement direction Y is, for example, 6 mm.
- a total of 16 second tab wires 77 are arranged in parallel between adjacent solar cell cells 71 in the other arrangement direction Y. These 16 second tab wires 77 have the same shape and material, are routed in the same manner, and are connected to the solar cell cells 71 in the same manner.
- Each second tab wire 77 is a very thin conductor with a circular cross section, and by making them thin, they do not interfere with the light incident on the light receiving surface 71F and are flexible, while by increasing the number of wires, large electrical capacity and connection strength are ensured.
- the diameters of the first tab wires 72a, 72b and the second tab wire 77 are all, for example, 0.2 mm.
- the solar cell module 70 has a large area and high output, but because the solar cell 71 is divided into multiple parts, it can be folded at the link parts extending in the other arrangement direction Y and rolled up or folded bellows-like as a whole in one arrangement direction X, thereby making it easy to transport and store when not in use. In addition, it can be used as a solar cell by folding it at the link parts and attaching it to a curved surface that curves in one arrangement direction X.
- the solar cell module 70 of this embodiment has a large surface area and high output, yet is lightweight overall, making it easy to transport, move, and install, and mitigating restrictions on where and what it can be installed.
- Eighth embodiment 35 is a plan view of a solar cell module 80 according to the eighth embodiment.
- the electrical connections between the first tab wires 82a, 82b and the second tab wire 87 and the solar cell 81, the series connection of the solar cell 81, and the wiring from the solar cell cells (1-5) and (4-5) located at both ends to the pair of external output cables 89 are similar to those of the solar cell module 60 according to the sixth embodiment. Therefore, the description thereof and the publication of a cross-sectional view are omitted.
- this embodiment is similar to the seventh embodiment in that a total of 16 second tab wires 77 are arranged in parallel between adjacent solar cell cells 81 in the other arrangement direction Y.
- the configuration and significance of the 16 second tab wires 87 are similar to the second tab wires 77 in the seventh embodiment.
- a groove-shaped link portion (not shown) is formed between adjacent solar cells 81 in one arrangement direction X, with the depression extending in the other arrangement direction Y, but there is no depression between adjacent solar cells 81 in the other arrangement direction Y, i.e., no link portion is formed, which is the same as in the seventh embodiment.
- the solar cell 81 used in this embodiment is roughly half the size of the solar cell 71 in the seventh embodiment, which is approximately 180 mm square, i.e., approximately 180 mm x 90 mm, and is arranged in a grid pattern with gaps between each other, with four cells (four rows) in one arrangement direction X and ten cells (ten columns) in the other arrangement direction Y, for a total of 40 cells.
- the spacing between adjacent solar cell cells 81 in one arrangement direction X is, for example, 5 mm
- the spacing between adjacent solar cell cells 81 in the other arrangement direction Y is, for example, 6 mm.
- the solar cell module 80 of this embodiment has a large area and high output, but because the individual solar cell cells 81 are small, it can be significantly reduced in size by folding it at the link parts extending in the other arrangement direction Y and rolling it up in one arrangement direction X as a whole or folding it into an accordion-like shape, making it easy to transport and store when not in use. In addition, it can be used as a solar cell by folding it at the link parts and attaching it to a curved surface that curves in the other arrangement direction Y.
- the solar cell module 80 of this embodiment has a large surface area and high output, yet is lightweight overall, making it easy to transport, move, and install, and mitigating restrictions on where and what it can be installed.
- FIG. 36 A plan view of the solar cell module 100 produced in the example is shown in Fig. 36, and a cross-sectional view taken along the line J-J in Fig. 36 is shown in Fig. 37.
- the comparative example is similar with some exceptions. Note that the arrows X to Z in Fig. 36 and Fig. 37 are the same as the arrows shown in the drawings of the solar cell module according to the first embodiment.
- the solar cell module 100 produced in the example is composed of two solar cells 111, a tab wire 112, a pair of transparent cover films 113F, 113B, and a sealing material 114.
- the solar cell module 100 produced in the example is a module with a basic structure of only two solar cells 111.
- the solar cell module 100 has a different number of solar cells 111 from the solar cell module 10 according to the first embodiment shown in Figures 1 to 3, and accordingly the number of tab wires 112 and other configurations are different, but the basic structure is the same.
- the solar cell 111 was a single crystal silicon cell measuring 26 mm in length in the arrangement direction X, 78 mm in length in the vertical direction Y, and 0.2 mm in thickness.
- the solar cell 111 was spaced apart at a distance equal to the width of the link (depressed) parts 115F, 115B plus 4 mm.
- the tab wire 112 was made of solder-plated copper foil measuring 1.2 mm in width and 100 ⁇ m in thickness.
- the resin film used to form cover films 113F and 113B was a heat-resistant polyethylene terephthalate (PET) film with a length of 70 mm in the alignment direction X, a length of 90 mm in the vertical direction Y, and a thickness of 0.1 mm.
- the sheet of sealing material used to form sealing material 14 was an ethylene-vinyl acetate copolymer resin (EVA) sheet with the same length in the alignment direction X and vertical direction Y as the resin film and a thickness of 0.45 mm.
- EVA ethylene-vinyl acetate copolymer resin
- the solar cell module 100 shown in Figures 36 and 37 was manufactured in accordance with the method described in the first manufacturing method section. Specifically, first, the tab wires 112 were soldered to the prepared solar cell 111 to electrically connect and wire it. After that, the light receiving surface 111F and back surface 111B of the solar cell 111 were sandwiched between a sheet of sealing material, a PET film, and a silicone sheet.
- the vacuum lamination process was carried out under conditions of 150°C and atmospheric pressure application for 15 minutes after 3 minutes of vacuuming. After that, it was cooled to room temperature, and the silicone sheet and jig were removed to obtain solar cell modules of each example and comparative example with different shapes of link parts 115F, 115B. At this time, the thickness (T2+T3+T4) of the sealant 114 in the areas other than the link parts 115F, 115B was 1.1 mm. Furthermore, the sealant material (EVA) protruding from the cover films 113F, 113B was removed with scissors.
- EVA sealant material
- Each solar cell module of the Examples was produced by controlling the shape of the jig so that the shape of the link parts 115F, 115B would be the "sealant thickness T1" and the "length of the region 0.05-0.6 " shown in Table 1 below, which will be shown together with the results.
- a laminate was produced without placing a jig in the center of the arrangement direction X, and a lamination process was performed.
- a laminate was produced without placing a sheet of the sealant material in the areas corresponding to the link parts 115F, 115B, and a lamination process was performed.
- each solar cell module 100 was irradiated with 1000 lux white LED light, and the open circuit current and short circuit voltage were measured. The measurements were performed by placing the modules flat on a flat plate. For each solar cell module, the short circuit current was 2.1 mA ⁇ 0.2 mA, and the voltage was measured within the range of 1.0 V ⁇ 0.1 V.
- each solar cell module 100 after the bending endurance test described below was also placed flat on a flat plate and a power generation confirmation test was performed. As a result, the change in photocurrent before and after the bending endurance test was within 5% in all cases except for Comparative Examples 1 and 2.
- Fig. 38 is a schematic diagram showing a state in which the bending property test is being carried out on the solar cell module 100, as viewed from the side.
- the solar cell module 100 was held so that the arrangement direction X was vertical, and one of the ends in the arrangement direction X was placed on the weighing platform 171 of the platform scale 170. In this state, a load P was applied in the direction of gravity to the other end of the solar cell module 100 in the arrangement direction X. As shown in FIG. 38, when a load was applied, the link parts 115F, 115B were bent in one direction.
- the load P was increased until the measurement value of the platform scale 170 (i.e., the load P) reached a maximum of 500 gf or until the bending angle ⁇ of the bent link portions 115F, 115B reached a maximum of 90 degrees. If the bending angle ⁇ reached 90 degrees before the measurement value of the platform scale 170 reached a maximum of 500 gf, the result of the bendability test was recorded as 90 degrees, and if the load P was increased until the measurement value of the platform scale 170 reached a maximum of 500 gf, the value of the bending angle ⁇ at the point when the load P reached 500 gf was recorded as the result of the bendability test.
- Table 1 summarized in Table 1 below.
- a solar cell module 100 having only two solar cells 111 was produced, but in a solar cell module with a larger number of solar cells arranged, the value of this bending angle ⁇ contributes greatly to compactness. If the bending angle ⁇ is 90 degrees, for example, when the solar cell module is rolled up, it can be rolled up with a curvature radius of about 0.7 times the length in the arrangement direction X of the solar cells, which makes it easy to transport and store when not in use.
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- Photovoltaic Devices (AREA)
Abstract
L'invention concerne un module de batterie solaire qui est à la fois flexible et durable, et son procédé de production. Ce module de batterie solaire 10 comprend : une pluralité de cellules de batterie solaire 11 qui sont alignées en une seule rangée avec des espaces entre elles ; des fils de connexion 12 qui connectent électriquement les cellules de batterie solaire 11 adjacentes ; une paire de films de protection 13F, 13B qui prennent en sandwich les cellules de batterie solaire 11 depuis un côté de réception de lumière 11F et un côté arrière 11B ; et un matériau d'étanchéité 14 qui est interposé entre la paire de films de protection 13F, 13B et les cellules de batterie solaire 11 et les fils de connexion 12, et qui remplit l'espace entre la paire de films de protection 13F, 13B. Des parties de liaison en forme de rainure 15F, 15B qui sont en retrait dans la direction d'épaisseur Z sur un ou deux côtés sont formées entre les cellules de batterie solaire 11 adjacentes de telle sorte que les retraits sont sensiblement orthogonaux à la direction d'alignement X des cellules de batterie solaire 11. L'épaisseur du matériau d'étanchéité 14 au niveau des parties de liaison 15F, 15B est inférieure à l'épaisseur du matériau d'étanchéité 14 dans les autres parties.
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| JP2024566690A JP7740777B2 (ja) | 2023-06-22 | 2024-06-07 | 太陽電池モジュール及びその製造方法 |
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| JP2023102456 | 2023-06-22 | ||
| JP2023-102456 | 2023-06-22 |
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| WO2024262344A1 true WO2024262344A1 (fr) | 2024-12-26 |
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| PCT/JP2024/020866 Pending WO2024262344A1 (fr) | 2023-06-22 | 2024-06-07 | Module de batterie solaire et son procédé de production |
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| WO (1) | WO2024262344A1 (fr) |
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| JPS62173768A (ja) * | 1986-01-27 | 1987-07-30 | Sharp Corp | 太陽電池モジユ−ル |
| JPS62279682A (ja) * | 1986-05-28 | 1987-12-04 | Sharp Corp | 太陽電池モジユ−ルの製造方法 |
| JPH07235686A (ja) * | 1994-02-25 | 1995-09-05 | Sanyo Electric Co Ltd | 太陽電池 |
| JPH0951118A (ja) * | 1995-08-09 | 1997-02-18 | Shiroki Corp | シート状太陽電池 |
| JPH11135813A (ja) * | 1997-10-30 | 1999-05-21 | Fuji Electric Co Ltd | 太陽電池モジュールおよびその製造方法、設置方法およびその外部リード接続方法 |
| CN102315293A (zh) * | 2010-06-30 | 2012-01-11 | 财团法人工业技术研究院 | 太阳光电模块封装叠层结构及其制造方法 |
| JP2015507814A (ja) * | 2011-12-29 | 2015-03-12 | アップル インコーポレイテッド | 可撓性を有するバッテリーパック |
| US20150083191A1 (en) * | 2011-06-07 | 2015-03-26 | At & S Austria Technologie & Systemtechnik Aktiengesellschaft | Photovoltaic module and use thereof |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014003064A (ja) | 2012-06-15 | 2014-01-09 | Nisshinbo Holdings Inc | 太陽電池モジュールの製造方法、太陽電池モジュールの製造装置および太陽電池モジュール製造用被覆材 |
| JP2015170640A (ja) | 2014-03-05 | 2015-09-28 | シーアイ化成株式会社 | 太陽電池モジュール用封止材及び太陽電池モジュール |
| JP6794750B2 (ja) | 2016-09-30 | 2020-12-02 | 大日本印刷株式会社 | 太陽電池モジュール用の封止材シート、それを用いた太陽電池モジュール、及び太陽電池モジュールの製造方法 |
-
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- 2024-06-07 JP JP2024566690A patent/JP7740777B2/ja active Active
- 2024-06-07 WO PCT/JP2024/020866 patent/WO2024262344A1/fr active Pending
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62173768A (ja) * | 1986-01-27 | 1987-07-30 | Sharp Corp | 太陽電池モジユ−ル |
| JPS62279682A (ja) * | 1986-05-28 | 1987-12-04 | Sharp Corp | 太陽電池モジユ−ルの製造方法 |
| JPH07235686A (ja) * | 1994-02-25 | 1995-09-05 | Sanyo Electric Co Ltd | 太陽電池 |
| JPH0951118A (ja) * | 1995-08-09 | 1997-02-18 | Shiroki Corp | シート状太陽電池 |
| JPH11135813A (ja) * | 1997-10-30 | 1999-05-21 | Fuji Electric Co Ltd | 太陽電池モジュールおよびその製造方法、設置方法およびその外部リード接続方法 |
| CN102315293A (zh) * | 2010-06-30 | 2012-01-11 | 财团法人工业技术研究院 | 太阳光电模块封装叠层结构及其制造方法 |
| US20150083191A1 (en) * | 2011-06-07 | 2015-03-26 | At & S Austria Technologie & Systemtechnik Aktiengesellschaft | Photovoltaic module and use thereof |
| JP2015507814A (ja) * | 2011-12-29 | 2015-03-12 | アップル インコーポレイテッド | 可撓性を有するバッテリーパック |
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| JPWO2024262344A1 (fr) | 2024-12-26 |
| JP7740777B2 (ja) | 2025-09-17 |
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