Abstract:
The present invention generally relates to a method for manufacturing an improved solar cell module, more particularly to a method for manufacturing the improved solar cell module that may not happen problems of power leakage and short circuit and save the cost to manufacturing.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to a method for manufacturing an improved solar cell module, more particularly to a method for manufacturing the improved solar cell module that may not happen problems of power leakage and short circuit. 
     2. Description of the Prior Art 
     Among the recent world spread consciousness of ecological and environmental protection issues, the deepest concern is directed to the warming of the earth by CO 2  production, and the development and stable supply of clean energy are urgently desired objectives. The solar cell is one of the most promising clean energy sources because of its safety and ease of handling. Solar cells have been prepared in various forms such as (a) monocrystalline silicon solar cells; (b) polycrystalline silicon solar cells; (c) amorphous silicon solar cells; (d) copper-indium selenide solar cells; and (e) compound semiconductor solar cells. Among these types of cells, the thin film crystalline silicon solar cells, compound semiconductor solar cells, and amorphous silicon solar cells are recent targets of active development as they are relatively inexpensive and can be formed into a large area. 
     Traditional manufacturing processes of solar cell modules have the steps of: (a) making a plurality of solar cell strings; (b) arranging the solar cell strings to be a solar cell matrix; (3) processing lamination process with a piece of glass as front sheet, first ethylene-vinyl acetate (EVA) as isolating cover, the solar cell matrix, second ethylene-vinyl acetate (EVA) as isolating cover, and back sheet in series; (4) wiring the laminated solar cell matrix with a junction box; and (5) assembling the laminated solar cell matrix with the junction box with an aluminum frame to form the traditional solar cell module. However, there are some problems that need to be improved. 
     Before the module is in the lamination process, the conductive wires are commonly connected with the junction box by passing through the first EVA, second EVA and back sheet. Some shortcomings follow. First, since the conductive wires go through the first EVA, the second EVA and the back sheet, the EVA, the second EVA and the back sheet need to be punched or cut before lamination process. In order to avoid the solar cell strings from shifting during ribbons, end points of the conductive wires, going through the holes, tapes are required to fix them together. However, the tapes may cause stability problem for the solar cell module in long term. 
     Secondly, power leakage and even short circuit still exist. When the solar module is under the manufacturing processes, non-insulated cables are commonly used to connect the conductive wires and the junction box. If the conductive wires are too close one another, the solar cell module will easily have power leakage or short circuit between the ribbons when generating electric power. Furthermore, it causes danger to human bodies and fire. 
     With references to  FIG. 12A  to  FIG. 12D , which illustrate schematic sequential views of forming an isolating member between conductive wires to prevent problems of power leakage and short circuit in prior arts. As shown in  FIG. 12A , a front sheet  203 ′ is a bottom layer, a first isolating cover  212   a ′ is beyond the front sheet  203 ′, and a plurality of conductive wire sets  2016 ′ are on the first isolating cover  212   a ′ and defined as another layer that is the same as a layer where the solar cell matrix is on, wherein each of the conductive wire sets  2016 ′ may have a pre-process that is to vertically bend the conductive wire sets  2016 ′, and the pre-process is applicable to electrically connect the conductive wire sets  2016 ′ with a junction box; as shown in  FIG. 12B , an isolating member  80 ′ is disposed between two conductive wire sets  2016 ′, each of the conductive wire sets  2016 ′ has one conductive wire  20161 ′ and one conductive wire  20162 ′, wherein the conductive wire  20162 ′ penetrates through a seam  212   a   5 ′ on the first isolating cover  212   a ′, then it can be seen that the arrangement lets the isolating member  80 ′ isolates the conductive wire  20161 ′ and the conductive wire  20162 ′; as shown in  FIG. 12C , a second isolating cover  212   b ′ is on the layer with the conductive wire sets  2016 ′, so that the isolating member  80 ′, the partial conductive wire  20161 ′ and the partial conductive wire  20162 ′ are shown by dot lines since they are covered by the second isolating cover  212   b ′, but other part of the conductive wire  20161 ′ and other part of the conductive wire  20162 ′ penetrate through a seam  212   b   5 ′ on the second isolating cover  212   b ′, so that the two parts of the conductive wire  20161 ′ and the conductive wire  20162 ′ are exposed on the second isolating cover  212   b ′; and as shown in  FIG. 12D , a back sheet  205 ′ is added on the second isolating cover  212   b , and the two parts of the conductive wire  20161 ′ and the conductive wire  20162 ′ penetrate through a seam  2055 ′ on the back sheet  205 ′ for exposing, so that the exposed parts of the conductive wire  20161 ′ and the conductive wire  20162 ′ are able to electrically connect with a junction box (not shown in figure), and then an adhesive  2054 ′ as silicone is coated on the seam  2055 ′ for seal. As it can be seen, there are three seams  212   a   5 ′,  212   b   5 ′ and  2055 ′ in the processes of forming the isolating member between conductive wires. Therefore, the seal may be considered while the solar cell module is assembled. Especially, solar cell module is always exposed under the Sun or stormy and rainy circumstances for quite a long time. Further, the pre-process to vertically bend the conductive wire sets  2016 ′ may increase the cost to manufacturing as well. 
     However, only new materials used for lamination process can not permanently solve the problems mentioned above. The most important reason is no more care of wired cables in the solar cell structure. Although solar cells can be well protected, protection of wired cables is not considered. The cables will have power leakage or even cause circuit shortage after long time use. Therefore, a method for overcoming the above problems in manufacturing a solar cell module is still desired. 
     SUMMARY OF THE INVENTION 
     The main object of the present invention is to provide a method for manufacturing an improved solar cell module, and the solar cell module may figure out the shortcomings of power leakage and short circuit in prior arts and increase the seal level of the improved solar cell module. 
     The second object of the present invention is to provide the method for manufacturing the improved solar cell module in order to save the cost to manufacturing. 
     A method for manufacturing an improved solar cell module comprising the steps of: (1) concatenating a plurality of solar cells with a plurality of conductive wires to form a plurality of solar cell strings, arranging the solar cell strings to form a solar cell matrix, and extending each conductive wire to form an extended outer-connection section, then converging the plurality of extended outer-connection sections to a plurality of integrated extended outer-connection sections, wherein the number of the integrated extended outer-connection sections is less than the number of the extended outer-connection sections; (2) forming an isolating cover on a first surface of the solar cell matrix and another isolating cover on a second surface of the solar cell matrix; (3) forming a front sheet on a first surface of the isolating cover and a back sheet on a second surface of the another isolating cover in order to assemble the solar cell module; (4) pressing the front sheet, the isolating cover, the solar cell matrix, the another isolating cover, and the back sheet by way of using lamination technologies and the chemical characteristics of the isolating cover and the another isolating cover; (5) aiming at an end point of each of the integrated extended outer-connection sections, drilling holes from the back sheet and the another isolating cover to the end point on the second surface of the solar cell matrix, so as to form a plurality of holes on the back sheet and a plurality of holes on the another isolating cover, wherein each of the end points is not drilled through and therefore a plurality of end point indentations are formed on the second surface of the solar cell matrix; (6) soldering each of the end point indentations and an insulated cable; (7) coating an adhesive on the soldering location of the end point indentation and the insulated cable; and (8) connecting each of the insulated cables with an junction box. 
     Other and further features, advantages, and benefits of the invention will become apparent in the following description taken in conjunction with the following drawings. It is to be understood that the foregoing general description and following detailed description are exemplary and explanatory but are not to be restrictive of the invention. The accompanying drawings are incorporated in and constitute a part of this application and, together with the description, serve to explain the principles of the invention in general terms. Like numerals refer to like parts throughout the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The objects, spirits, and advantages of the preferred embodiments of the present invention will be readily understood by the accompanying drawings and detailed descriptions, wherein: 
         FIG. 1  to  FIG. 10  illustrate schematic structural views of the steps of the method for manufacturing an improved solar cell module of the present invention; 
         FIG. 11  illustrates a flow chart of the method for manufacturing the improved solar cell module of the present invention; and 
         FIG. 12A  to  FIG. 12D  illustrate schematic sequential views of forming an isolating member between conductive wires to prevent problems of power leakage and short circuit in prior arts. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Following preferred embodiments and figures will be described in detail so as to achieve aforesaid objects. 
     With references to  FIG. 1  to  FIG. 10  and  FIG. 11 , which illustrate schematic structural views of the steps of the method for manufacturing an improved solar cell module of the present invention and a flow chart of the method for manufacturing the improved solar cell module of the present invention. As shown in figures, the method includes the steps of:
     (1) as shown in  FIG. 1 , concatenating the plurality of solar cells  2014  with at least one conductive wire  2016  to form the solar cell string  2011  via a concatenating machine, not shown in figure, and then repeating to form more solar cell strings  2011 ;   (2) as shown in  FIG. 2 , arranging the solar cell strings  2011  to form the solar cell matrix  201  via a jig, the solar cell matrix  201  having a first surface  201 A, not shown in figure, and a second surface  201 B, extending each conductive wire  2016  to form the extended outer-connection section  11 X, then converging the plurality of extended outer-connection sections  11 X to the plurality of integrated extended outer-connection sections  11 XT, wherein the number of the integrated extended outer-connection sections  11 XT is less than the number of the extended outer-connection sections  11 X, the integrated extended outer-connection sections  11 XT being on the one side of the second surface  201 B of the solar cell matrix  201 ;   (3) as shown in  FIG. 3 , forming the isolating cover  212   a  on the first surface  201 A of the solar cell matrix  201  and the another isolating cover  212   b  on the second surface  201 B of the solar cell matrix  201 , wherein the isolating cover  212   a  has a first surface  212   a   1  and a second surface  212   a   2  and the another isolating cover  212   b  has a first surface  212   b   1  and a second surface  212   b   2 , thus the second surface  212   a   2  of the isolating cover  212   a  compounds into the first surface  201 A of the solar cell matrix  201 , and the first surface  212   b   1  of the another isolating cover  212   b  compounds into the second surface  201 B of the solar cell matrix  201 ;   (4) as shown in  FIG. 4 , forming the front sheet  203  on the first surface  212   a   1  of the isolating cover  212   a  and the back sheet  205  on the second surface  212   b   2  of the another isolating cover  212   b  in order to assemble the solar cell module  20 , wherein the front sheet  203  has a first surface  2031  and a second surface  2032 , and the back sheet  205  has a first surface  2051  and a second surface  2052 ′, thus the second surface  2032  of the front sheet  203  compounds into the first surface  212   a   1  of the isolating cover  212   a , and the first surface  2051  of the back sheet  205  compounds into the second surface  212   b   2  of the another isolating cover  212   b;      (5) pressing the front sheet  203 , the isolating cover  212   a , the solar cell matrix  201 , the another isolating cover  212   b , and the back sheet  205  in a vacuum chamber, not shown in figure, by way of using lamination technologies and the chemical characteristics of the isolating cover  212   a  and the another isolating cover  212   b , wherein the isolating cover  212   a  and the another isolating cover  212   b  are made of EVA (ethylene-vinyl acetate) for the preferred embodiment;   (6) as shown in  FIG. 5  and  FIG. 6 , aiming at the end point  11 XTP of each of the integrated extended outer-connection sections  11 XT, drilling holes from the second surface  2052 ′ and the first surface  2051  of the back sheet  205  and a second surface  212   b   2  and a first surface  212   b   1  of the another isolating cover  212   b  to the end point  11 XTP on the second surface  201 B of the solar cell matrix  201 , so as to form the plurality of holes  2052  on the back sheet  205  and the plurality of holes  2042  on the another isolating cover  212   b , wherein each of the end points  11 XTP is not drilled through so as to leave a copper layer, not shown in figure, exposed in the end point indentation  11 XTPH and therefore the plurality of end point indentations  11 XTPH are formed on the second surface  201 B of the solar cell matrix  201 ;   (7) as shown in  FIG. 6 , using high-pressure air and cleaning solution, not shown in figure, to clean up a location where the end point indentations  11 XTPH are on the second surface  2052 ′ of the back sheet  205 ;   (8) as shown in  FIG. 7 , forming a soldering ball S on the copper layer, not shown in figure, of each of the end point indentations  11 XTPH;   (9) as shown in  FIG. 8 , soldering the soldering ball S and a core  2062  of the insulated cable  206 ;   (10) as shown in  FIG. 9 , coating an adhesive  2054  as silicone on the soldering location of the end point indentation  11 XTPH and the insulated cable  206 ; and   (11) as shown in  FIG. 10 , connecting each of the insulated cables  206  with an junction box E;
 
wherein the isolating cover  212   a  and the another isolating cover  212   b  are made by one of ethylene-vinyl acetate (EVA), polytetrafluoroethylene (PTFE) and casting resin, and the front sheet  203  and the back sheet  205  are made by one of polymethyl methacrylate (PMMA), polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), glass, and plastic.
   

     Compared to prior arts, the present invention does solve the shortcomings and those advantages are listed below:
     1. There are no punches for through holes in the method provided by the present invention, and therefore the sealing after lamination process shall approach a standard. And once the lamination process is finished, following steps will be always the processes of sealing.   2. In order to avoid the solar cell strings from shifting during ribbons, end points of the conductive wires, going through the holes, the lamination process is done right after the solar cell matrix is finished. Hence, the sequences of the method may also prevent power leakage and short circuit.   3. In prior arts, a pre-process to vertically bend conductive wires is convenient to electrically connect with a junction box, and it takes time to manufacturing, hence the cost to manufacturing is being raised. The method of the present invention omits the process.   

     Although the invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments that will be apparent to persons skilled in the art. This invention is, therefore, to be limited only as indicated by the scope of the appended claims