JP4304855B2 - Manufacturing method and manufacturing apparatus for composite metal tape - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention provides a method for producing a composite metal tape comprising at least a second metal tape adhered to a conductive adhesive tape of a composite tape laminated in the order of a first metal tape, a conductive adhesive tape, and a separate tape, and It relates to a manufacturing apparatus.
[0002]
[Prior art]
Currently, research and development of clean energy sources is underway from the standpoint of environmental protection. Among them, solar cells are attracting attention because their resources (sunlight) are infinite and pollution-free. A typical example of a solar cell (photoelectric conversion device) in which a plurality of photoelectric conversion elements formed on the same substrate are connected in series and parallel is a thin film solar cell.
[0003]
Thin-film solar cells are expected to become the mainstream of solar cells in the future because they are thin and light, low in manufacturing cost, and easy to increase in area. Demand is expanding as a power source for business use and general housing that is attached to windows.
Conventional thin-film solar cells use glass substrates, but research and development of flexible solar cells using plastic films as substrates, which are superior in terms of weight reduction, workability, and mass productivity, are underway. The roll-to-roll manufacturing method that makes use of this flexibility enables mass production.
[0004]
FIG. 8 shows an example of a solar cell module, where (a) is a plan view and (b) is a cross-sectional view taken along line XX in (a). The solar battery cell 1 is composed of a flexible film substrate having electrical insulation and a plurality of photoelectric conversion elements formed thereon and connected in series / parallel. An internal lead wire 2 of a flat foil copper wire is arranged in parallel along both sides of the solar battery cell 1, and both poles of the output of the solar battery cell 1 are internal lead wires by an auxiliary wiring 3 of a metal tape with a conductive adhesive tape. 2 respectively. Thus, one or more solar cells 1 are connected in parallel. Both surfaces of the solar battery cell 1 and the wiring are covered and sealed with a moisture-proof film 4 through ethylene vinyl acetate (hereinafter abbreviated as EVA), and then cut and individualized so as to include appropriate solar battery cells. It is referred to as module M.
[0005]
The moisture-proof film 4 is made of a fluorine resin film having high weather resistance, for example, ethylene / tetrafluoroethylene copolymer (hereinafter referred to as ETFE).
As the internal lead 2, a laminated tape made of a metal foil (metal tape) such as nickel, aluminum or copper and polyethylene terephthalate (hereinafter referred to as PET) is used.
[0006]
As the auxiliary wiring 3, a metal tape in which a conductive adhesive material is attached to a metal foil such as copper or a copper alloy is used. The conductive adhesive material is, for example, a Ni powder-containing acrylic adhesive material.
Such a connection process of the internal wiring of the solar battery cell 1, a coating sealing process of the moisture-proof film 4, and a cutting process are called modularization.
[0007]
Thus, when a metal tape with a conductive adhesive is used as the auxiliary wiring 3, the metal produced by the difference in thermal expansion and contraction between the metal tape with a conductive adhesive and the moisture-proof film 4 in a heat cycle test after modularization. In the worst case, the metal tape with the conductive adhesive material was disconnected, resulting in poor electrical connection.
[0008]
As a countermeasure, a method of increasing the thickness of the metal tape with the conductive adhesive material to the metal and the conductive adhesive material can be considered. In this case, in order to ensure the mechanical strength to withstand the heat cycle test, Since the film thickness of the tape must be several hundred μm or more, air bubbles remain around the auxiliary wiring during modularization, and the portion of the moisture-proof film that covers the metal tape becomes thin when modularized, resulting in mechanical strength. In some cases, the cutting phenomenon occurred in the heat cycle test. Also, there is a risk of damage when the module is installed on the roof.
[0009]
In order to solve such a problem, the auxiliary wiring was improved to the following composite metal tape. FIG. 9 shows an improved composite metal tape, where (a) is a plan view and (b) is a cross-sectional view taken along line XX in (a).
A flat foil copper tape Ba (second film) is formed by keeping the film thickness of the first metal tape Aa and the conventional metal tape A1 with the conductive adhesive material made of the conductive adhesive material as it is, and further soldering or tin-coating Bb to the metal tape. When the composite metal tape C to which the metal tape B) is adhered is used as the auxiliary wiring, the conventional problem does not occur even if the total film thickness is reduced as compared with the case where the metal tape having the increased thickness is used. lost. In addition, the cutting phenomenon was not observed in the mechanical strength test and the heat cycle test.
[0010]
Actually, it was appropriate that the width of the metal tape with conductive adhesive was 6 to 10 mm, the thickness was 50 to 100 μm, and the thickness of the conductive adhesive was 25 to 50 μm. The width of the solder or tin-coated flat foil copper tape was 2-3 mm, and the thickness was suitably 0.75-1.0 mm.
[0011]
[Problems to be solved by the invention]
As described above, the composite metal tape was satisfactory in terms of structure and characteristics, but there is still no method for producing such a composite metal tape. It had to be cut, both sides were fixed on a desk with tape, and the adhesive part of the metal tape with conductive adhesive had to be applied. As a result, the solder or tin-coated flat is too close to one side or meanders, so when pasted in this state, only the metal tape was cut in the heat cycle test and the electrical connection was unstable. . Moreover, there was a problem that there was no meandering and it took a very long time to apply it uniformly.
[0012]
The present invention has been made to solve the above problems, and the object of the present invention is to prevent the second metal tape from meandering uniformly at a predetermined position of the first metal tape with the conductive adhesive tape. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus for a bonded composite metal tape.
[0013]
[Means for Solving the Problems]
In order to achieve the above object, at least a second metal at a predetermined position in the tape width direction of the surface of the conductive adhesive tape of the composite tape laminated in the order of the first metal tape, the conductive adhesive tape, and the separate tape. A method for producing a composite metal tape formed by adhering a tape, wherein the composite tape immediately after being positioned by passing the first guide after peeling the separate tape and positioned by passing the second guide It is assumed that the second metal tape immediately after is adhered by a pressing means.
[0014]
The pressurizing means may be a plurality of pressure rolls arranged with the composite tape and the second metal tape interposed therebetween.
The separate tape peeled off before the adhesion is preferably adhered again to the conductive adhesive tape of the composite metal tape and used as a separate tape of the composite metal tape.
In the composite metal tape manufacturing apparatus that implements the above-described method for manufacturing a composite metal tape, a roll for unwinding the composite tape, a roll for unwinding the second metal tape, a release roll for separating the separate tape, the first The guide and the second guide, and the pressurizing means may be provided.
[0015]
The cross section of the first guide and the second guide in a plane perpendicular to the tape running direction has a substantially concave shape, and both inner side surfaces of the concave shape have an arbitrary distance corresponding to the tape width. It should be adjustable.
A cutter for cutting the composite metal tape into a predetermined length may be provided after the pressurizing means.
[0016]
According to the present invention, before and after the adhesion of the second metal tape to the conductive adhesive tape of the composite tape, that is, before the pressurizing means, a guide is used so that both tapes coincide with a predetermined position. No wobbling in the width direction of each tape occurs, and the position of the second metal tape is always at a predetermined position (center) with respect to the composite tape and does not meander. Therefore, the solar cell module using this composite metal tape is expected to have high reliability without causing any defects in the outer shape.
[0017]
In addition, since the separate tape used for the composite tape is reused for the composite metal tape, the composite metal tape does not adhere to dust or damage during winding or subsequent processes. The defective solar cell module does not occur, and high reliability can be expected. Moreover, it can contribute to cost reduction.
In addition, the manufacturing apparatus for carrying out such a manufacturing method is composed of simple parts such as the above-described unwinding roll, peeling roll, and guide, so that operation and maintenance are easy, and reliability is high. Stable production with few defects can be done in a short time.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view along a tape running direction showing a method for producing a composite metal tape according to the present invention. The composite metal tape A unwound from the roll R1 is positioned at a position perpendicular to the traveling direction (indicated by an arrow) by the first guide G1. The position of the second metal tape B unwound from the roll R1 in the direction perpendicular to the traveling direction is determined by the guide G2. Both tapes are sandwiched and adhered between at least two pressure rolls Rp. The center lines of the tapes of the guides G1 and G2 are set so as to be within the same plane or at a predetermined off-center. The guides G1 and G2 may have a variable width so as to correspond to the width of the tape to be handled. Thus, since the position of each tape is determined immediately before adhesion, each tape does not shake, and the second metal tape B is adhered without meandering to the center of the composite metal tape A.
[0019]
FIG. 2 is a side view along the tape running direction showing the main part of another method for producing a composite metal tape according to the present invention.
In this manufacturing method, the separated separate tape Ac is adhered to the adhesive material film surface of the composite tape D by the roll Rq. The separate tape protects the metal surface and the adhesive film surface of the composite tape from dust and damage in subsequent processes.
[0020]
Next, the manufacturing apparatus of the composite metal tape which implements said manufacturing method is demonstrated.
FIG. 3 is a side view of the composite metal tape manufacturing apparatus according to the present invention along the tape running direction.
The following rolls, guides, and the like are attached to the plate base P by means of mounting shafts (rotating shafts) and jigs perpendicular to the base surface.
[0021]
The composite tape A composed of the first metal tape Aa, the conductive adhesive film Ab, and the separate tape Ac is fed from the roll R1, and first the separate tape Ac is peeled off and reversed in the running direction by the roll Rs and wound around the roll R4. Taken. The tape A1 from which the separate tape Ac has been peeled is positioned by the guide G1.
[0022]
On the other hand, the second metal tape B made of solder or tin-coated flat foil copper tape B is fed from the roll R2, and is first positioned by the guide G2 so that the centers of the tape A1 and each other coincide. The two tapes are sandwiched between a plurality of pressure rolls Rp, pressed and fixed to each other, integrated into a composite metal tape C, and then wound on a roll R4.
[0023]
Thus, by winding up to roll R4, it can draw out from a roll suitably at the time of use.
FIG. 4 is a side view along the tape running direction showing another apparatus for producing a composite metal tape according to the present invention.
In this manufacturing apparatus, once the separated tape Ac is peeled off, the direction is changed by the roll Ro1, removed from the running area of the tape, returned to the original running area by the roll Ro2, and again adhered to the composite metal tape by the roll Rq. Protect the adhesive surface as a tape. The extra length of the separate tape Ac can be reduced by removing the separate tape Ac from the traveling region.
[0024]
The widths and relative positions of the guides G1 and G2 are preferably variable so as to correspond to the width of the tape to be handled and the necessary relative positions of the two tapes.
FIG. 5 is a side view along the tape running direction showing another apparatus for producing a composite metal tape according to the present invention.
In this composite metal tape manufacturing apparatus, a sensor Ks and a cutter Kk interlocking with the signal are provided instead of the take-up roll. After the tip of the composite metal tape C reaches the sensor Ks after being formed into the composite metal tape C by the pressure roll Rp, the cutter Kk operates according to a signal from the sensor Ks, and has a predetermined length, that is, the auxiliary wiring 3 (FIG. 8). ).
[0025]
6A and 6B show a roll-type guide according to the present invention, in which FIG. 6A is a side view and FIG. 6B is a sectional view taken along line XX in FIG. The cross section of the guide G is substantially H-shaped so that the tape can be easily set at the start of manufacture. The inner side surfaces of the both side surface members Gs define the position in the width direction of the tape, and the cylindrical surface of the main member Gm is the bottom surface inside the substantially concave shape, and determines the position in the thickness direction of the tape. The side member Gs is moved along the screw surface Gc so that the tape can have an arbitrary width, and the distance between the inner surfaces can be variably adjusted (in the direction of the arrow) so that it can be fixed by the rear set screw Gf. . Gc is a rotation shaft hole.
[0026]
The guide may be a stationary type in which the tape is rubbed without rotating. FIG. 7 shows an example of a stationary guide according to the present invention, and (a) and (b) are XX cross-sectional views in (a). The cross section is substantially concave. The measuring guide Gb is slidably fitted on the rail R of the base Ga, and both the left and right screws Gc are fitted through the screw holes of the side guide Gb. By turning the screw Gc, the side guides Gb move along the rail R, and the distance between them can be changed so as to match the width of the tape.
[0027]
Example 1
By using the above-described manufacturing apparatus of the pressure roll and the separation tape reusing system, the conductive tape is a composite tape made of a metal tape having a thickness of 35 μm, a width of 8 mm, and a thickness of 50 μm, and a width of 2 to 3 mm. A composite metal tape was produced using a tin-coated flat foil copper tape with a thickness of 0.8 mm as the second metal tape, and when the appearance was confirmed, the second metal tape had a conductive adhesive. Located in the center of the metal tape, no meandering was observed. The time required for producing 100 100 mm long composite metal tapes was 10 minutes.
[0028]
Using this composite metal tape for auxiliary wiring, a solar cell module (shown in FIG. 8) was produced, and after 50 cycles of a heat cycle test (−40 ° C. to + 100 ° C.), there was no abnormality in the auxiliary wiring 3. I couldn't.
Comparative Example 1
The same two types of tapes as in Example 1 were used, and the second metal tape cut to a predetermined length was fixed on a flat plate with a tape on both sides, and a metal tape with a conductive adhesive was used. The adhesive part was manually affixed on the 2nd metal tape, and the composite metal tape was produced. It took 10 minutes to produce 10 composite metal tapes with a length of 100 mm.
[0029]
When the external appearance was confirmed, the second metal tape was meandering from the center on the metal tape with the conductive adhesive and leaning toward one side.
Using this composite metal tape as an auxiliary wiring, a solar cell module (shown in FIG. 8) was prepared and subjected to 50 cycles of a heat cycle test (−40 ° C. to + 100 ° C.). Cracks occurred. That is, the stress applied to the meandering second metal tape and the metal tape with the conductive adhesive becomes non-uniform due to the repeated stress of contraction and expansion in the heat cycle test. It can be presumed that cracks occurred in the metal tape with the adhesive.
[0030]
【The invention's effect】
According to the present invention, the composite metal tape is manufactured by adhering the second metal tape to the conductive adhesive tape of the composite tape laminated in the order of the first metal tape, the conductive adhesive tape, and the separate tape by the pressing means. In the method, since a guide is used so that both tapes coincide with a predetermined position before the pressurizing means, there is no fluctuation in the width direction of each tape before and after adhesion, and the second metal tape with respect to the composite tape The position of is always at a predetermined position (center) and does not meander. Therefore, the solar cell module using this composite metal tape does not cause any defects in the outer shape and is highly reliable.
[0031]
In addition, since the separate tape used for the composite tape is reused for the composite metal tape, the composite metal tape does not adhere to dust or damage during winding or subsequent processes. The defective solar cell module does not occur, has high reliability, and can contribute to cost reduction.
In addition, the manufacturing apparatus for carrying out such a manufacturing method is composed of simple parts such as the above-described unwinding roll, peeling roll, and guide, so that operation and maintenance are easy, and reliability is high. Stable production with few defects can be done in a short time.
[Brief description of the drawings]
FIG. 1 is a side view along a tape running direction illustrating a method for producing a composite metal tape according to the present invention.
FIG. 2 is a side view along the tape running direction showing another method for producing a composite metal tape according to the present invention.
FIG. 3 is a side view of the composite metal tape manufacturing apparatus according to the present invention along the tape running direction.
FIG. 4 is a side view of another composite metal tape manufacturing apparatus according to the present invention along the tape running direction.
FIG. 5 is a side view of another composite metal tape manufacturing apparatus according to the present invention along the tape running direction.
6A and 6B show a roll-type guide according to the present invention, in which FIG. 6A is a side view, and FIG. 6B is a sectional view taken along line XX in FIG.
7A and 7B show examples of a stationary guide according to the present invention, and FIGS. 7A and 7B are cross-sectional views taken along line XX in FIG.
FIGS. 8A and 8B show an example of a solar cell module, where FIG. 8A is a plan view and FIG. 8B is a sectional view taken along line XX in FIG.
9A and 9B show an improved composite metal tape, wherein FIG. 9A is a plan view and FIG. 9B is a sectional view taken along line XX in FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Solar cell 2 Internal lead wire 3 Auxiliary wiring 4 Moisture-proof film M Solar cell module A Composite tape Aa 1st metal tape Ab Conductive adhesive tape Ac Separate tape B 2nd metal tape Ba Flat foil copper wire Bb Solder Or tin coat C Composite metal tape R1 Unwinding roll R2 Unwinding roll R3 Winding roll Ro Direction change roll Rp Pressure roll Rs Peeling roll Rq Adhesive roll G1 First guide G2 Second guide Gm Main member Gs Member Kk Tape Cutter Ks sensor

Claims (5)

A composite metal tape obtained by adhering a second metal tape to at least a predetermined position in the tape width direction of a conductive adhesive tape surface of a composite tape laminated in the order of a first metal tape, a conductive adhesive tape, and a separate tape. The composite tape immediately after being positioned by passing the first guide after the separation tape is peeled off and the second metal tape immediately after being positioned by passing the second guide A method for producing a composite metal tape that adheres by means of pressure,
A method for producing a composite metal tape, wherein the separate tape peeled before the adhesion is adhered again to the conductive adhesive tape of the composite metal tape and used as a separate tape of the composite metal tape. 2. The method for producing a composite metal tape according to claim 1, wherein the pressurizing means is a plurality of pressure rolls arranged with the composite tape and the second metal tape interposed therebetween. A roll for unwinding the composite tape, a roll for unwinding the second metal tape, a peeling roll for peeling the separate tape, the first guide and the second guide, and the pressure roll. An apparatus for producing a composite metal tape, which implements the method for producing a composite metal tape according to claim 1 or 2 . The cross section of the first guide and the second guide in the tape running portion of the tape running section in a plane perpendicular to the tape running direction is a substantially concave character shape, and both inner side surfaces of the concave character shape correspond to the tape width. The apparatus for producing a composite metal tape according to claim 3 , wherein the apparatus can be adjusted to an arbitrary distance. The apparatus for producing a composite metal tape according to claim 3 or 4 , wherein a cutter for cutting the composite metal tape into a predetermined length is provided after the pressing means.

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