Solar cell module and method of manufacturing the solar cell module

On a projected plane in parallel to the main surface of the solar cell module 100, an output interconnection 10 includes: a first output interconnection section 10a arranged along an conductive member 4 in a power non-generating field; and a second output interconnection section 10b leading to the first output interconnection section 10a in a power generating section X.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. P 2007-142467, filed on May 29, 2007; the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a solar cell module including a power generating field and output interconnections through which electric power is outputted from the power generating field, and to a method of manufacturing the solar cell module.

2. Description of the Related Art

A solar cell is expected to be an alternative energy source because the solar cell can directly convert sun light, which is an unlimited source of clean energy, into electricity.

Such a solar cell outputs electric power of only approximately several watts. For this reason, in a case where solar cells are intended to be used as an electric power source (or an energy source) for a house, a building or the like, a solar cell module in which multiple solar cells are arrayed is used instead.

Generally speaking, the solar cell module includes: a power generating field formed by arraying multiple solar cells; and paired positive and negative output interconnections, connected to the power generating field, through which electric power is outputted from the power generating field to the outside of the solar cell module.

In this respect, a publicly-known example of a conventional type of solar cell module includes the output interconnections, which are arranged along an outer periphery of the power generating field (see Japanese Patent Application Publication No. 2006-278904). Such a solar cell module has a terminal box, which is arranged on its back surface. The output interconnections extend along the outer periphery of the power generating field from the respective positions where the output interconnections are connected to the power generating field to the respective different positions which makes it easy for the output interconnections to be drawn out to the terminal box.

SUMMARY OF THE INVENTION

A first characteristic of the present invention is a solar cell module including a power generating field, a power non-generating field and at least one output interconnection. The power generating field includes: a light receiving surface for receiving light; and a back surface provided on the opposite side of the light receiving surface. The power generating field generates electric power by receiving light. The power non-generating field is formed outside the power generating field. The output interconnection outputs therethrough the electric power generated in the power generating field to the outside of the solar cell module. The first characteristic thereof has the following gist. The power generating field includes multiple solar cell groups each formed by arraying multiple solar cello in a first direction. The multiple solar cell groups are arranged one after another in a second direction almost orthogonal to the first direction. The output interconnection is electrically connected to an output solar cell group included in the multiple solar cell groups by use of a conductive member. The conductive member extends to the power non-generating field while connecting to the output solar cell group. The output interconnection is electrically connected to the conductive member in the power non-generating field, and extends to the back surface of the power generating field. On a projected plane in parallel to the main surface of the solar cell module, the output interconnection includes: a first output interconnection section provided along the conductive member in the power non-generating field; and a second output interconnection section led to the first output interconnection section in the power generating field.

As described above, the output interconnection extends to the back surface of the power generating field from a position where the output interconnection is connected to the conductive member in the power non-generating field. In other words, the output interconnection is not drawn outside the power generating field. This makes it possible to increase the ratio of the area of the power generating field to the area of the solar cell module. As a result, this makes it possible to increase the amount of power generation per unit area of the solar cell module.

In the first characteristic of the present invention, the solar cell module may include a solar cell group connecting member for electrically connecting a first and second solar cell groups to each other, included in the multiple solar cell groups, to each other; the solar cell group connecting member may be provided in the power non-generating field; the width of the output interconnection should be larger than the width of the solar cell group connecting members; and the thickness of the output interconnection may be smaller than the thickness of the solar cell group connecting member.

In the first characteristic of the present invention, the conductive member may include: a first conductive section extending to the power non-generating field while electrically connected to the output solar cell group; a second conductive section, being arranged alongside the first conductive section in the second direction, and extending to the power non-generating field while electrically connected to the output solar cell group; and a third conductive section for electrically connecting the first and the second conductive sections to each other in the power non-generating field. Concurrently, the output interconnection may be connected to the third conductive section; and on the projected plane in parallel to the main surface of the solar cell module, the output interconnection may not intersect the first or the second conductive section at the boundary between the power generating field and the power non-generating field.

In the first characteristic of the present invention, on the projected plane in parallel to the main surface of the solar cell module, the second output interconnection section may not intersect a boundary between the power generating field and the power non-generating field.

In the first characteristic of the present invention, a cushioning member may be arranged between the second output interconnection section and at least a part of the power generating field.

In the first characteristic of the present invention, an insulation treatment may be applied to at least a part of the second output interconnection section.

A second characteristic of the invention is the solar cell module according to the first characteristic of the present invention, and has the following gist. The solar cell module further includes: a first interconnection member for electrically connecting the first solar cell group and the solar cell group connecting member to each other; a second interconnection member for electrically connecting the second solar cell group and the solar cell group connecting member to each other; a bypass diode connecting interconnection electrically connected to the solar cell group connecting member. The bypass diode connecting interconnection extends to the back surface of the power generating field from a position where the bypass diode connecting interconnection is connected to the solar cell group connecting member. On the projected plane in parallel to the main surface of the solar cell module, the bypass diode connecting interconnection includes: a first bypass diode connecting interconnection section provided along the first and the second interconnection members in the power non-generating field; and a second bypass diode connecting interconnection section led to the first bypass diode connecting interconnection section in the power generating field.

In the second characteristic of the present invention, the width of the bypass diode connecting interconnection may be larger than the width of the solar cell group connecting member; and the thickness of the bypass diode connecting interconnection may be smaller than the thickness of the solar cell group connecting member.

In the second characteristic of the present invention, on the projected plane in parallel to the main surface of the solar cell module, the second output interconnection section and the second bypass diode connecting interconnection section may not intersect each other.

In the second characteristic of the present invention, on the projected plane in parallel to the main surface of the solar cell module, the second bypass diode connecting interconnection section may not intersect a boundary between the power generating field and the power non-generating field.

In the second characteristic of the present invention, a cushioning member may be arranged between the second bypass diode connecting interconnection section and at least a part of the power generating field.

In the second characteristic of the present invention, an insulation treatment may be applied to at least a part of the second bypass diode connecting interconnection section.

A third characteristic of the present invention is a method of manufacturing a solar cell module, and has the following gist. The method includes: the step A of: forming multiple solar cell groups, in each of which multiple solar cells are arrayed in a first direction; the step B of electrically connecting an conductive member extending to an output solar cell group included in the multiple solar cell groups, the conductive member extending to the outside of the output solar cell group; the step C of forming a power generating field by arranging the multiple solar cell groups one after another in a second direction almost orthogonal to the first direction, the power generating field including a light receiving surface for receiving light and a back surface provided on the opposite side of the light receiving surface, and the power generating field being that for generating electric power by receiving light; and the step D of electrically connecting an output interconnection to the conductive member outside the power generating field, the output interconnection being that through which the electric power generated in the power generating field is outputted to the outside of the solar cell module. In the step D, the output interconnection extends to the back surface of the power generating field; and on a projected plane in parallel to the main surface of the solar cell module, the output interconnection includes a first output interconnection section arranged along the conductive member outside the power generating field, and a second output interconnection section led to the first output interconnection section in the power generating field.

In the third characteristic of the present invention, in the step A, each of the plurality of solar cells may include a first principal surface and a second principal surface provided on the opposite side of the first principal surface, the second principal surface may have the opposite polarity from a polarity of the first principal surface, and the plurality of solar cells may be arranged in a way that the first principal surfaces of the plurality of solar cells face in the same direction. In the step B, a first interconnection member may be electrically connected to a first solar cell located at an end of the first solar cell group included in the plurality of solar cell groups, in a way that the first interconnection member may extend to an outside of a first solar cell group; and a second interconnection member may be electrically connected to a second solar cell located at an end of the second solar cell group included in the plurality of solar cell groups, in a way that the second interconnection member may extend to an outside of a second solar cell group, and a part of the first interconnection member may be folded along a side surface of the first solar cell in a thickness direction of the first solar cell. In the step C, outside the power generating field, a solar cell group connecting member for electrically connecting the first and the second cell groups to each other may be electrically connected to the first and the second interconnection members.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Descriptions will be subsequently provided for an embodiment of the present invention by use of the drawings. In any one of the drawings, components which are the same as or similar to those in any other of the drawings are denoted by the same or similar reference numerals. It should be noted that the drawings are schematic, and that dimensional ratios in the drawings are accordingly different from the actual ones. For this reason, concrete dimensions and the like should be estimated with the subsequent descriptions taken into consideration. Furthermore, it goes without saying that dimensional relationships and ratios are different from one drawing to another.

(Configuration of Solar Cell Module)

Descriptions will be provided hereinbelow for a configuration exemplifying a solar cell module100according to an embodiment of the present invention by referring toFIGS. 1 and 2.FIG. 1is a front view showing the configuration of the solar cell module100.FIG. 2is a back view showing the configuration of the solar cell module100.

The solar cell module100according to an embodiment includes: a power generating field X; a power non-generating field Y; output interconnections10and11through which electric power generated in the power generating field X is outputted to the outside of the solar cell module100; and bypass diode connecting interconnections20and21each connected to a bypass diode.

The power generating field X has 8 solar cell groups G1to G8each formed by arraying 5 solar cells C in a first direction. In other words, the power generating field X is formed by arranging solar cells C in an 8×5 matrix. Each solar cell C has a light receiving surface for receiving light and a back surface which is provided at the other side of the light receiving surface. Each solar cell C generates electric power by receiving light. As a result, the power generating field X formed by arranging the solar cells C in the 8×5 matrix similarly has a light receiving surface and a back surface, and generates electric power by receiving light. Note that the light receiving surface and the back surface of each solar cell C have opposite polarity, respectively. The light receiving surfaces of solar cells C have the same polarity. Though not illustrated, connecting electrodes are formed on the light receiving surface and the back surface of the solar cell C. A solar cell connecting member3described below is connected on each of the connecting electrodes.

The solar cell groups G1to G8are arrayed in a second direction almost orthogonal to the first direction in which the solar cells C are arrayed. Each of two neighboring solar cell groups G arrayed in the second direction is electrically connected to each other in series by use of a solar cell group connecting member1. The number of solar cell group connecting members1is seven. The seven solar cell group connecting members1are set in the power non-generating field Y. Each of solar cell group connecting members1is electrically connected to two neighboring solar cell groups by use of interconnection members2. A bypass diode connecting interconnection20is electrically connected to a corresponding one of the solar cell group connecting members1. Descriptions will be provided later for the interconnection configuration of a solar cell group connecting member1, an interconnection member2, and a bypass diode connecting interconnection20.

Each of the solar cell groups G1to G8includes 5 solar cells C that are arrayed in the first direction and solar cell connecting members3that electrically connects the 5 solar cells C one to another in series.

As shown inFIGS. 1 and 2, paired positive and negative interconnections10and11are electrically connected to the solar cell groups G1and G8located at the both ends of the power generating field X in the second direction through conductive members4, respectively. In the case of the present embodiment, the solar cell groups G1and G8are referred to as output solar cell groups G1and G8.

The output solar cell group G1includes solar cells C11to C15, and the output solar cell group G8includes solar cells C81to C85. Similarly, another solar cell group G2includes solar cells C21to C25; yet another solar cell group G3, solar cells C31to C35; . . . ; and the other solar cell groups G7, solar cells C71to C75.

First of all, descriptions will be provided for the output solar cell group G1. The 5 solar cells C11to C15included in the output solar cell group G1are arranged one after another in the first direction. Each of the solar cells C11to C15are electrically connected one to another in series, by the solar cell connecting members3. Specifically, the 2 solar cell connecting members3are electrically connected to the connecting electrode provided on the light receiving surface of the solar cell C11and the connecting electrode provided on the back surface of the solar cell C12. The same holds for the solar cells C12to C15. The number of solar cell connecting members3included in the output solar cell group G1is 2×4.

The output interconnection10is electrically connected to the output solar cell group G1through the conductive member4. The conductive member4is connected to the output solar cell group G1, and extends to the power non-generating field Y. The conductive member4is connected to the connecting electrode provided on the light receiving surface of the solar cell C11located at one end of the output solar cell group G1in the first direction. Descriptions will be provided for the interconnection configuration of the conductive member4and the output interconnection10later. It should be noted that a corresponding one of the solar cell group connecting members1is electrically connected to the solar cell C15located at the other end of the output solar cell group G1in the first direction through the interconnection members2.

The output solar cell group G8includes 5 solar cells C81to G85and 4 solar cell connecting members3, and has the same configuration as the output solar cell group G1. The output interconnection11is electrically connected to the output solar cell group G8through an conductive member4. The conductive member4is connected to the connecting electrode provided on the back surface of the solar cell C81.

Each of the solar cell groups G2to G7includes 5 solar cells C and 4 solar cell connecting members3, and has the same configuration as the output solar cell groups G1and G2, except that a corresponding one of the solar cell group connecting member1is electrically connected to each of the solar cells C located at the both ends of each of the solar cell group G2to G7in the first direction through the interconnection members2.

FIG. 3shows a side view of the solar cell module100having the foregoing configuration. As shown inFIG. 3, the solar cell module100includes: the multiple solar cells C (only the solar cells C11to C15are illustrated) arranged in the 8×5 matrix; a sealing member101; a light receiving surface-side protecting member102; the back surface-side protecting members103; and a terminal box104.

The multiple solar cells C arranged in the 8×5 matrix, or the 8 solar cell groups G1to G8constituting the power generating field X, are sealed by the sealing member101. A translucent resin such as an EVA, EEA, PVB, silicon, urethane, acrylic, epoxy resin or the like can be used for the sealing member101.

The light receiving surface-side protecting member102is arranged on the sealing member101at the side of the light receiving surface. A translucent and water-impermeable glass, a translucent plastic or the like can be used for the light receiving surface-side protecting member102.

The back surface-side protecting member103is arranged on the sealing member101at the side of the back surface. A resin film made of a resin such as a PET (polyethylene terephthalate) resin, or a laminated film obtained by sandwiching an Al foil with resin films can be used for the back surface-side protecting member103.

A terminal box104is arranged on the back surface of the solar cell module100. The paired positive and negative output interconnections10and11as well as the bypass diode connecting interconnections20and21are guided to a bypass diode (not illustrated) housed in the terminal box104. In the case of the present embodiment, the terminal box104is arranged in a position which causes the terminal box104to overlap the solar cells C41and C51on the projected plane in parallel to the main surface of the solar cell module100. The position of the terminal box104can be changed whenever deemed necessary depending on the shapes respectively of the solar cell module100, the power generating field X and the like.

An Al frame can be attached to the periphery of the solar cell module100having the foregoing configuration.

Descriptions will be subsequently provided for an interconnection configuration of the conductive member4and the output interconnection10by referring toFIG. 4.FIG. 4is a magnified view of the solar cells C11, C21, C31and C41as well as their vicinity shown inFIG. 2.

As shown inFIG. 4, the conductive member4includes a first conductive section4a, a second conductive section4band a third conductive section4c. The first and second conductive section4aand4bare electrically connected to the light receiving surface of the solar cell C11, and extend to the power non-generating field Y. The third conductive section4celectrically connects the first and the second conductive sections4aand4bto each other in the power non-generating field Y.

The output interconnection10is connected to the third conductive section4cby use of an conductive adhesive such as solder. In this manner, the output interconnection10is electrically connected to the solar cell C11(or the output solar cell group G1) through the conductive member4.

The output interconnection10extends toward the back surface of the solar cell C11, or toward the back surface of the power generating field X, from the position in the power non-generating field Y where the output interconnection10is connected to the third conductive section4cby use of solder. As a result, as shown inFIG. 4, on the projected plane in parallel to the main surface of the solar cell module100, the output interconnection10includes: a first output interconnection section10aprovided along the conductive member4in the power non-generating field Y; and a second output interconnection section10bprovided in the power generating field X to connects to the first output interconnection section10a. A cushioning member (not illustrated) for releasing stress produced in the module process is arranged between the second output interconnection section10band the power generating field X. An EVA resin or the like can be used for the cushioning member. In addition, an insulation treatment is applied to the surface of the second output interconnection section10b.

In this respect, the output interconnection10does not intersect the first conductive section4aor the second conductive sections4bat the boundary between the power generating field X and the power non-generating field Y on the projected plane in parallel to the main surface of the solar cell module100. Specifically, the output interconnection10is placed away from the first and the second conductive sections4aand4bat the end of the solar cell C11in the first direction. The end of the solar cell C11constitutes the boundary between the power generating field X and the power non-generating field Y.

The second output interconnection section10bis arranged on the center of the back surface of each of the solar cells C11, C21, C31and C41. The second output interconnection section10bis placed away from the end of the solar cells C11, C21, C31and C41in the first direction. The end of the solar cells C11, C21, C31and C41constitute the boundary between the power generating field X and the power non-generating field Y. As a result, the second output interconnection10bis placed the power generating field X

The side line constitutes the boundary between the power generating field X and the power non-generating field Y. In addition, the output interconnection10is located near the center on the projected plane in parallel to the main surface of the solar cell module100.

(Interconnection Configuration of Solar Cell Group Connecting Members1, Interconnection Members2and Bypass Diode Connecting Interconnection20)

Descriptions will be subsequently provided for an interconnecting configuration of a solar cell group connecting member1, interconnection members2and a bypass diode connecting interconnection20by referring toFIG. 4.

As shown inFIG. 4, two interconnection members2are connected to the solar cell group G2, and extend to the power non-generating field Y in the first direction. Specifically, the two interconnection members2are connected to the respective connecting electrodes provided on the back surface of the solar cell C21. Similarly, another two interconnection members2are connected to the solar cell group G3, and extends to the power non-generating field Y in the first direction. Specifically, the two interconnection members2are connected to the respective correcting electrodes provided on the light receiving surface of the solar cell C31. The solar cell group connecting member1is electrically connected to these four interconnection members2by use of an conductive adhesive such as solder in the power non-generating field Y.

In addition, the two interconnection members2connected to the solar cell C31are arranged alongside in the second direction. In the power non-generating field Y, the bypass diode connecting interconnection20is arranged between the two interconnection members2, and is electrically connected to the solar cell group connecting member1by use of an conductive adhesive such as solder.

The bypass diode connecting interconnection20extends toward the back surface of the solar cell C31, that is, the back surface of the power generating field X, from the position where the bypass diode connecting interconnection20is connected to the solar cell group connecting member1in the power non-generating field Y. As a result, as shown inFIG. 4, the bypass diode connecting interconnection20has a first bypass diode connecting interconnection section20aand a second bypass diode connecting interconnection section20bon a projected plane in parallel to the main surface of the solar cell module100. The first bypass diode connecting interconnection section20ais provided along the interconnection members2in the power non-generating field Y. The second bypass diode connecting interconnection section20bis provided to connect to the first bypass diode connecting interconnection section20ain the power generating field X. A cushioning member (not illustrated) for releasing stress produced in the module process is arranged between the second bypass diode connecting interconnection section20band the power generating field X. An EVA resin or the like can be used for the cushioning member. In addition, an insulation treatment is applied to the surface of the second bypass diode connecting interconnection section20b.

In this respect, the bypass diode connecting interconnection20does not intersects the interconnection members2at the boundary between the power generating field X and the power non-generating field Y on the projected plane in parallel to the main surface of the solar cell module100. As a result, the bypass diode connecting interconnection20is placed away from the interconnection members2at the end of the solar cell C31in the first direction. The end of the solar cell C31constitutes the boundary between the power generating field X and the power non-generating field Y.

Furthermore, the second bypass diode connecting interconnection section20bis placed away from the end of the solar cells C11, C21, C31and C41in the first direction, on the projected plane in parallel to the main surface of the solar cell module100. The end of the solar cells C11, C21, C31and C41constitutes the boundary between the power generating field X and the power non-generating field Y. The second bypass diode connecting interconnection section20bis placed in the power generating field X on the projected plane in parallel to the main surface of the solar cell module100.

In addition, the second output interconnection section10band the second bypass diode connecting interconnection section20bdo not intersect each other on the projected plane in parallel to the main surface of the solar cell module100. The both sections10band20bare arranged in parallel in the second direction.

FIG. 5is a cross-sectional view of the solar cell C31and its vicinity taken along the C-C line ofFIG. 4. As shown inFIGS. 4 and 5, the width α1of the output interconnection10(the first output interconnection section10a) is larger than the width β1of the solar cell group connecting member1. The thickness α2of the output interconnection10is smaller than the thickness α2of the solar cell group connecting member1. In addition, the width γ1of the bypass diode connecting interconnection20is larger than the β1of the solar cell group connecting member1. The thickness γ2of the bypass diode connecting interconnection20is smaller than the thickness β2of the solar cell group connecting member1.

The foregoing descriptions have been provided for the interconnection configuration of the output interconnection10and the bypass diode connecting interconnection20. The output interconnection11electrically connected to the solar cell C81has the same interconnection configuration as the output interconnection10. In addition, the bypass diode connecting interconnection21electrically connected to the solar cell C61has the same interconnection configuration as the bypass diode connecting interconnection20.

(Method of Manufacturing Solar Cell Module)

First of all, multiple solar cells C are prepared. General solar cells each having a semiconductor junction such as a semiconductor p-n junction or a semiconductor pin junction as its basic structure can be used for the solar cells C. It should be noted that the light receiving surface and the back surface of each solar cell C have opposite polarity, respectively. The light receiving surfaces of solar cells C have the same polarity. The connecting electrodes are formed on the light receiving surface and the back surface of the solar cell C.

Subsequently, the 5 solar cells C11to C15are sequentially arrayed in the array direction. The solar cell connecting members3are electrically connected to each of the 5 solar cells C11to C15by use of an conductive adhesive such as solder. At this time, the conductive member4is connected to the solar cell C11, and the interconnection members2are connected to the solar cell C15. In this manner, the output solar cell group G1is formed. Similarly, the output solar cell group G8is formed.

In addition, the 5 solar cells C21to C25are arrayed in the array direction. The solar cell connecting members3are electrically connected to each of the 5 solar cells C21to C25by use of the conductive adhesive such as solder. At this time, interconnection members2are connected to each of the solar cells C21and C25. In this respect, the interconnection members2connected to the solar cell C21are formed in the shape of a straight line as shown inFIG. 6A. In this manner, the solar cell group G2is formed. Similarly, the solar cells groups G4and G6are formed.

In addition, the 5 solar cells C31to C35are arrayed in the array direction. The solar cell connecting members3are electrically connected to each of the 5 solar cells C31to C35by use of the conductive adhesive such as solder. At this time, interconnection members2are connected to each of the solar cells C31and C35. In this respect, a part of the interconnection members2connected to the solar cell C31is folded to the back surface side, as shown inFIG. 6B. In other way, the positions of the interconnection members2connected to the solar cell C31in the thickness direction corresponds to the positions of the interconnection members2connected to the solar cell C21in the thickness direction. In this manner, the solar cell group G3is formed. Similarly, the solar cell groups G5and G7are formed.

Subsequently, each solar cell group connecting member1is electrically connected to its corresponding interconnection members2by use of the conductive adhesive such as solder.FIG. 7Ashows how a solar cell group connecting member1is connected to the interconnection members2connected to the solar cell C21.FIG. 7Bshows how another solar cell group connecting member1is connected to another interconnection member2connected to the solar cell C31. With these connections, the 8 solar cell groups G1to G8are electrically connected one to another in series, and the power generating field X is accordingly formed.

Subsequently, the output interconnections10and11are connected to conductive members4by use of solder, respectively. Concurrently, the bypass diode connecting interconnections20and21are electrically connected to their corresponding solar cell group connecting members1by use of the conductive adhesive such as solder, respectively. The output interconnections10and11extend to the back surface of the power generating field X from the positions where the output interconnections10and11are connected to the conductive members4, respectively. The bypass diode connecting interconnections20and21extend to the back surface of the power generating field X from the positions where the bypass diode connecting interconnections20and21are connected to the solar cell group connecting members1, respectively.

A laminated body is formed by sequentially laminating, following sheets onto a glass substrate (serving as the light receiving surface-side protecting member102); an EVA resin sheet (serving as a part of the sealing member101); the 8 solar cell groups G1to G8, an EVA resin sheet (serving as the other part of the sealing member1); and a PET/aluminum/PET laminated sheet (serving as the back surface-side protecting member103). At this time, parts of the output interconnections10and11as well as parts of the bypass diode connecting interconnections20and21are drawn outside the laminated body through notches formed on the sealing member1and the back surface-side protecting members103.

Subsequently, the components constituting the laminated body are bonded by compression while heated in a vacuum atmosphere. Thereby, the 8 solar cell groups G1to G8are sealed between the glass substrate and the PET/aluminum/PET sheet.

The external parts of the output interconnections10and11as well as the external parts of the bypass diode connecting interconnections20and21are housed in the terminal box104.

In the foregoing manner, the solar cell module100is produced. It should be noted that an Al frame can be attached to the solar cell module100.

In the case of the solar cell module100according to the present embodiment, on the projected plane in parallel to the main surface of the solar cell module100, the output interconnection10includes: the first output interconnection section10aprovided along the conductive member4in the power non-generating field Y; and the second output interconnection section10bprovided to connects to the first output interconnection section10ain the power generating field X. In addition, the bypass diode connecting interconnection20includes: the first bypass diode connecting interconnection section20aprovided along its corresponding interconnection members2in the power non-generating field Y; and the second bypass diode connecting interconnection section20bprovided to connects to the first bypass diode connecting interconnection section20ain the power generating field X.

In this manner, the output interconnection10and the bypass diode connecting interconnection20are not drawn outside the power generating field X. This design makes it possible to increase the ratio of the area of the power generating field X to the area of the solar cell module100, and as a result, it makes it possible to increase the amount of power generation per unit area of the solar cell module100.

In addition, in the case of the solar cell module100according to the present embodiment, the width of the output interconnection10is larger than the width of each solar cell group connecting member1. The thickness of the output interconnection10is smaller than the thickness of each solar cell group connecting member1. In addition, the width of the bypass diode connecting interconnection20is larger than the width of each solar cell group connecting member1. The thickness of the bypass diode connecting interconnection20is smaller than the thickness of each solar cell group connecting member1.

In this manner, the thicknesses respectively of the output interconnection10and the bypass diode connecting interconnection20are smaller than the thickness of each solar cell group connecting member1. This makes it possible to check stress from concentrating on a certain part of the solar cells C arranged in the way that the solar cells C overlap the output interconnection10, while the components of the solar cell module100are being bonded into the laminated body by compression. As a result, this makes it possible to check the solar cells C from cracking or chipping during the module process. Additionally, the widths respectively of the output interconnection10and the bypass diode connecting interconnection20are made larger than the width of each solar cell group connecting member1. This design prevents increase in the resistance values of the respective interconnections10and the bypass diode connecting interconnection20. Moreover, each solar cell group connecting member1is formed thicker and narrower in the power non-generating field Y. This design makes it possible to decrease the area of the power non-generating field Y while preventing increase in the resistance values of the solar cell group connecting member1. As a result, this makes it possible to further increase the amount of power generation per unit area of the solar cell module100.

Moreover, in the case of the solar cell module100according to the present embodiment, the second output interconnection section10band the second bypass diode connecting interconnection20bdo not intersect each other. This design makes it possible to prevent stress concentration in a certain part of the solar cells C. As a result, this makes it possible to check the solar cells C from cracking or chipping during the module process.

In this respect, the concentration of stress on a certain part of the solar cells C tends to cause the solar cells C to crack or chip at their ends. For this reason, it is desirable that the components should not overlap the ends of the solar cells C.

In the case of the solar cell module100according to the present embodiment, the output interconnection10does not intersect the first and the second conductive sections4aand4bat the boundary between the power generating field X and the power non-generating field Y, that is, at the ends of the solar cells C. This design makes it possible to check the solar cells C from cracking or chipping at their ends.

Furthermore, in the case of the solar cell module100according to the present embodiment, the second output interconnection section10band the second bypass diode connecting interconnection section20bdo not intersect at the boundary between the power generating field X and the power non-generating field Y, that is, at the ends of the solar cells C11, C21, C31and C41. This design makes it possible to check the solar cells C from cracking or chipping at their ends.

Additionally, in the case of the solar cell module100according to the present embodiment, the cushioning member (made of an EVA resin or the like) is arranged between the second output interconnection section10band the power generating field X, and between the second bypass diode connecting intersection section20band the power generating field X. These arrangements make it possible to release stress which is applied to the solar cell module100during the module process.

In addition, in the case of the solar cell module100according to the present embodiment, the insulation treatment is applied to the second output interconnection section10band the second bypass diode connecting interconnection section20b. This application makes it possible to sufficiently secure insulation between the second output interconnection section10band each of the solar cells C included in the power generating field X, as well as insulation between the second bypass diode connecting interconnection section20band each of the solar cells C included therein.

Furthermore, in the case of the production method of the solar cell module100according to the present embodiment, the part of the interconnection member2connected to the solar cell C31is folded along the side surface of the solar cell C31to the thickness direction. In other words, in the power non-generating field Y, the positions of the interconnection members2connected to the solar cell C31in the thickness direction corresponds to the positions of the interconnection members2connected to the solar cell C21in the thickness direction.

This positional correspondence makes it unnecessary that the interconnection members2connected to the solar cell C31is folded by pressing the solar cell group connecting member1against the interconnection members2, when the solar cell group connecting member1is connected to the interconnection members2. This makes it possible to prevent the concentration of stress at the end of the solar cell C31. As a result, this makes it possible to check the solar cell from cracking or chipping.

Modification of Embodiment

The foregoing descriptions have been provided according to the embodiment of the present invention, in a case where the solar cell module100is constituted of 8 solar cell groups G1to G8electrically connected one to another in series. However, the present invention is not limited to this embodiment. The present invention is applicable to a solar cell module in a case where some solar cell groups are connected to each other in parallel, as well.

Descriptions will be provided for the solar cell module100according to this modification by referring toFIG. 8. FIG.8is a back view of a configuration of the solar cell module100according to this modification.

The solar cell module100according to this modification includes: a power generating field X; a power non-generating field Y; solar cell group connecting members5; conductive members6; output interconnections10and11through which electric power generated in the power generating field X is outputted to the outside of the solar cell module100; and a bypass diode connecting interconnection20.

The power generating field X includes 12 solar cell groups G01to G12, that is a first to 12th solar cell groups, each formed by arraying certain number n of solar cells C in the first direction. The 12 solar cell groups G01to G12are arranged alongside in the second direction. Therefore, in the present modification of embodiment, the power generating field X is formed by arraying the solar cells C in a 12×n matrix.

It should be noted that the light receiving surface and the back surface of each solar cell C have opposite polarity, respectively. The light receiving surfaces of solar cells C have the opposite polarity one-by-one, in the first direction. The light receiving surfaces of solar cells C have the same polarity three-by-three, in the first direction.

The solar cell module100according to this modification includes three solar cell group connecting members5. The first solar cell group connecting member5is electrically connected to the back surfaces of each of the solar cells C01nto C06n. The second solar cell group connecting member5is electrically connected to the back surfaces of each of the solar cells C041to C091. The third solar cell group connecting member5is electrically connected to the back surface of each of the solar cells C07nto C12n. In this manner, this solar cell group connecting member5electrically connects each three neighboring solar cell groups G in parallel, and electrically connects a cluster consisting of the three neighboring solar cell groups to the other cluster of the other three neighboring solar cell groups in series. The three solar cell group connecting members5are arranged in the power non-generating field Y. The bypass diode connecting interconnection20is electrically connected to a solar cell connecting group member5to which the fourth to 9th solar cell groups G04to G09are connected.

The paired positive and negative output interconnections10and11are electrically connected to the third and 10th solar cell groups G03and G10through the conductive members6, respectively. For this reason, in the case of this modification, the solar cell groups G03and G10are referred to as output solar cell groups.

The output interconnection10is electrically connected to the output solar cell group G03through the conductive member6. This conductive member6is connected to the output solar cell group G3, and extends to the power non-generating field Y. Specifically, the conductive member6is connected to the solar cell C031located at one end of the output solar cell group G03in the first direction, and extends to the power non-generating field Y in the first direction.

The output solar cell group G10includes a certain number n of solar cells C101to C10n, and has the same configuration as the output solar cell group G03. As a result, the output interconnection11is electrically connected to the output solar cell group G10through the conductive member6.

Descriptions will be subsequently provided for an interconnection configuration of the conductive member6and the output interconnection10. The interconnection configuration of the conductive member6and the output interconnection10is the same as the interconnection configuration of the conductive member4and the output interconnection10according to the foregoing embodiment. For the following descriptions, refer toFIG. 4whenever deemed necessary.

The conductive member6is connected to the output solar cell group G03, and extends to the power non-generating field Y in the first direction. In the power non-generating field Y, the output interconnection10is connected to a third conductive section6cby use of solder. In this manner, the output interconnection10is electrically connected to the solar cell C031(or the output solar cell group G03) through the conductive member6.

The output interconnection10extends along a first and second conductive section6aand6bto the back surface of the solar cell C031, that is, to the back surface of the power generating field X, from the position where the output interconnection10is connected to the third conductive section6cin the power non-generating field Y. As a result, the output interconnection10includes a first output interconnection section10aand a second output interconnection section10bon the projected plane in parallel to the main surface of the solar cell module100. The first output interconnection section10ais provided along the first and the second conductive sections6aand6bin the power non-generating field Y. The second output interconnection section10bis provided to be connected to the first output interconnection section10ain the power generating field X. A cushioning member for releasing stress produced during the module process is arranged between the second output interconnection section10band a part of the power generating field X. An EVA resin or the like can be used for the cushioning member. In addition, an insulation treatment is applied to a part of the outer periphery of the second output interconnection section10b.

In this respect, the output interconnection10does not intersect the first conductive section6aand the second conductive section6bat the boundary between the power generating field X and the power non-generating field Y on the projected plane in parallel to the main surface of the solar cell module100. Furthermore, the second output interconnection section10bdoes not intersect at the boundary between the power generating field X and the power non-generating field Y on the projected plane in parallel to the main surface of the solar cell module100.

(Interconnection Configuration of Solar Cell Group Connecting Member5and Bypass Diode Connecting Interconnection20)

The interconnection configuration of the solar cell group connecting member5and the bypass diode connecting interconnection20is the same as the interconnection configuration of the solar cell group connecting member1and the bypass diode connecting interconnection20according to the foregoing embodiment. For this reason, for the following descriptions, refer to theFIG. 4whenever deemed necessary.

Two interconnection members2are connected to the solar cell group G07, and extend to the power non-generating field Y in the first direction. Specifically, the two interconnection members2are connected to a connecting electrode provided on the back surface of the solar cell C071. The solar cell group connecting member5is connected to these interconnection members2by use of solder in the power non-generating field Y.

In addition, the two interconnection members2connected to the solar cell C071are arranged alongside in the second direction. The bypass diode connecting interconnection20is arranged in parallel to these two interconnection members2, and is connected to the solar cell group connecting member5in the power non-generating field Y.

The bypass diode connecting interconnection20extends to the back surface of the solar cell C071, that is to the back surface of the power generating field X, from the position where the bypass diode connecting interconnection20is connected to the solar cell group connecting member5in the power non-generating field Y. As a result, the bypass diode connecting interconnection20includes a first bypass diode connecting interconnection section20aand a second bypass connecting interconnection section20bon the projected plane in parallel to the main surface of the solar cell module100. The first bypass diode connecting interconnection section20ais provided along the interconnection members2in the power non-generating field Y. The second bypass diode connecting interconnection section20bis provided to connect to the first bypass diode connecting interconnection section20ain the power generating field X. A cushioning member for releasing stress produced during the module process is arranged between the second bypass diode connecting interconnection section20band the power generating field X. An EVA resin or the like can be used for the cushioning member. In addition, an insulating process is applied to the surface of the second bypass diode connecting interconnection section20b.

In this respect, the bypass diode connecting interconnection20does not intersect the two interconnection members2at the boundary between the power generating field X and the power non-generating field Y on the projected surface in parallel to the principal surface of the solar cell module100. Furthermore, the second bypass diode connecting interconnection section20bdoes not intersect at the boundary between the power generating field X and the power non-generating field Y on the projected plane in parallel to the principal surface of the solar cell module100.

Furthermore, the second output interconnection section10band the second bypass diode connecting interconnection section20bdo not intersect each other on the projected plane in parallel to the main surface of the solar cell module100. It should be noted that the position where the second output interconnection section10bis located and the position where the second bypass diode connecting interconnection section20bis located can be changed whenever deemed necessary.

In this respect, the width of the output interconnection10is larger than the width of the solar cell group connecting member5, and the thickness of the output interconnection10is smaller than the thickness of the solar cell group connecting member5. Moreover, the width of the bypass diode connecting interconnection20is larger than the width of the solar cell group connecting member5, and thickness of the bypass diode connecting interconnection20is smaller than the thickness of the solar cell group connecting member5,

(Method of Manufacturing Solar Cell Module)

A method of manufacturing a solar cell module100according to the present modification is as same as the method of manufacturing a solar cell module100according to the foregoing embodiment. For this reason, descriptions will be provided for what makes the method according to the present modification different from the method according to the embodiment.

In the case of the foregoing embodiment, the light receiving surfaces of all of the solar cells C have the same polarity. As a result, each solar cell group connecting member1is connected to corresponding interconnection members2connected to a light receiving surface and also to another corresponding interconnection members2connected to a back surface. By use of this connecting scheme, the solar cells C are electrically connected one to another in series. With this taken into consideration, one of the two interconnection members2is partly so folded in advance before connected to the solar cell group connecting member1to prevent the stress concentration.

On the other hand, in the case of the modification, solar cells C having the back surface with the same polarity are electrically connected to one anther in parallel. In addition, solar cells C having the back surface with the opposite polarity are electrically connected to each other in series. In the case of this modification, all of the interconnection members2are connected to the back surfaces of the corresponding solar cells C, respectively. In addition, each of the solar cell group connecting members5is connected to all of its corresponding interconnection members2from the light receiving surface side in the power non-generating field Y. As a result, all of the interconnection members2used in the solar cell module according to the modification are formed in the shape of a straight line.

The solar cell module100according to the present modification brings about the same working-effect as the solar cell module100according to the foregoing embodiment. Specifically, because, as described above, the output interconnections10and11as well as the bypass diode connecting interconnection20are not drawn outside the power generating field X, it is possible to increase the amount of power generation per unit area of the solar cell module100.

In addition, solar cells C, among which the connecting electrodes with the first polarity are arranged to face in the same direction, are electrically connected to one another in parallel. Another group consisting of solar cells C, among which the connecting electrodes with the second polarity are arranged to face in the same direction, are electrically connected to each other in series. These connection schemes make it possible to use all of the formed interconnection members2in the shape of a straight line.

Other Embodiments

The present invention has been described using the foregoing embodiment and its modification. It should not be understood, however, that the descriptions and drawings constituting this disclosure limits the scope of the present invention. To those skilled in the art, various alternative embodiments, examples and operational technologies will be clear from this disclosure.

For example, the number of solar cells C included in each solar cell group G and the number of solar cell groups G can be changed whenever deemed necessary, although, in the case of the foregoing embodiment, all of the solar cells are arrayed in a matrix.

In addition, the arrangement of the second output interconnection section10band the second bypass diode connecting interconnection section20bcan be changed as long as the two sections do not intersect each other, although, in the case of the foregoing embodiment, the two sections are arranged almost in parallel to each other.

Furthermore, bypass diode connecting interconnections may be respectively connected to the solar cell groups G2and G7, although, in the case of the foregoing embodiment, the solar cell groups G3and G6are respectively connected to the bypass diode connecting interconnections20and21. Moreover, the solar cell module100may not include the bypass diode connecting interconnections20and21.

Additionally, as shown inFIG. 9, the first output interconnection section10amay be connected to an extended portion of the third conductive section4c, although in the case of the foregoing embodiment, the first output interconnection section10ais connected to the third conductive section4cat the portion between a first conductive section4aand a second conductive section4b.