JP2013172104A - Light condensing type photovoltaic power generation module and manufacturing method of the same - Google Patents

Abstract

An object of the present invention is to enable easy and accurate alignment of a condenser lens and a solar cell element during manufacture.
SOLUTION: A flexible substrate 10B on which a solar cell element 11 is mounted and arranged on a wiring pattern at a predetermined interval, a condenser lens 21 for condensing and irradiating sunlight on a light receiving region of the solar cell element, and a condenser lens And a lens array 20 that is integrally formed with a holding portion 22 that holds the distance and position between the solar cell element 21 and the solar cell element at predetermined intervals, and a positioning pin 23 is provided on the bottom surface of the holding portion 22. The flexible substrate 10B is provided with positioning holes 13 facing the positioning pins 23. By inserting the positioning holes 13 into the positioning pins 23, the flexible substrate 10B and the lens array 20 are aligned and assembled together. It is done.
[Selection] Figure 5B

Description

  The present invention relates to a concentrating solar power generation module and a method for manufacturing the same.

  A solar power generation device that converts solar energy into electric power has been put into practical use. As this solar power generation device, solar light collected by a condensing lens in order to achieve cost reduction and obtain higher power Is used to extract power by irradiating a solar cell element smaller than the light receiving area of the condenser lens.

  As an example of the concentrating solar power generation module used in this concentrating solar power generation device, there is one described in Patent Document 1.

  As shown in FIGS. 6 and 7, the concentrating solar power generation module 100 includes a solar cell 110 and an optical element 101 that is disposed on the surface 110 a side of the solar cell 110 and transmits sunlight. ing. The solar battery 110 includes a gantry 111 and solar cells 112 arranged in a matrix on the gantry 111. On the other hand, the optical element 101 is made of a material transparent to sunlight, and is a substrate 107 and a lens (hereinafter referred to as a condensing lens) disposed on one surface of the substrate 107 on the sunlight incident side indicated by an arrow A. 102) and the other surface of the substrate 107, and the refractive element 104 disposed on the solar cell 110 side.

  The condensing lens 102 is a convex lens having a refracting surface 120 facing the sunlight incident side, and the convex surface of the convex lens is arranged on the sunlight incident side. The refractive element 104 is a trapezoidal prism having a refracting surface 140 facing the solar cell 110, and the refracting surface of the trapezoidal prism is arranged on the solar cell 110 side.

  The attachment surface 141 of the refraction element 104 and the attachment surface 121 of the condenser lens 102 face each other with the same size, and the optical axis 122 of the condenser lens 102 and the optical axis 142 of the refraction element 104 coincide with each other.

  These condenser lenses 102 and refractive elements 104 are arranged in a matrix, and a plurality of condenser lenses 102 constitute a lens array 103, and a plurality of refractive elements 104 constitute a refractive element array 105. ing. Further, the optical element 101 includes a covering member 106 having a flat surface having a predetermined refractive index on the sunlight incident side of the condenser lens 102.

JP 2010-165959 A

  Such a configuration of the conventional concentrating solar power generation module 100 has a problem that it is difficult to align the condensing lenses 102 and the solar cells 112 arranged in a matrix.

  That is, when the lens array 103 and the refractive element array 105 are integrally formed, the arrangement position of each condenser lens 102 and the arrangement position of each solar battery cell 112 of the optical element 101 are caused by slight errors during manufacturing. Since there is a possibility that the lens array 103 and the entire optical element 101 are simply aligned, there is a possibility that the positions of the individual condenser lenses 102 and the solar battery cells 112 do not coincide with each other. There was a problem. In this case, since the lens array 103 or the optical element 101 is integrally formed, there is a problem that all of the lens array 103 or the optical element 101 is treated as a defective product.

  On the other hand, it is conceivable to individually arrange the solar cells mounted on the receiver substrate with respect to the lens array, but in this case, since the receiver substrate and the condenser lens are arranged apart from each other, Is difficult to align. Moreover, since it is necessary to manufacture a receiver board | substrate separately, position alignment is required for every receiver board | substrate, and there existed a problem that a manufacturing process became complicated.

  The present invention was devised to solve such problems, and an object of the present invention is to provide a concentrating solar cell module that can be simply and accurately aligned during manufacturing and a method for manufacturing the same. .

  In order to solve the above problems, a concentrating solar cell module according to the present invention collects sunlight in a flexible substrate in which solar cell elements are mounted and arranged on a wiring pattern at a predetermined interval, and a light receiving region of the solar cell element. A condensing lens that irradiates with light, and a lens array in which holding portions that hold the condensing lens and the solar cell element together with a distance and a position are arranged at a predetermined interval and are integrally formed. In the concentrating solar power generation module, a positioning pin is provided on a bottom surface of the holding portion facing the solar cell element, and a positioning hole is provided on the flexible substrate so as to face the positioning pin. The flexible substrate and the lens array are integrally assembled by inserting the positioning hole into the positioning pin.

  According to the said structure, positioning of a condensing lens and a solar cell element can be easily performed only by inserting a positioning pin in a positioning hole. Moreover, even if it is a case where the space | interval of a lens array and the space | interval of a solar cell element have shifted | deviated by using a flexible substrate, the shift | offset | difference can be absorbed by the bending of a flexible substrate.

  In the concentrating solar cell module of the present invention, a pair of the positioning pins are formed on the bottom surface of the holding portion, and the positioning holes facing the positioning pins are near both sides of the solar cell element. It is the structure provided in.

  According to this configuration, the positioning holes are provided in the vicinity of both sides of the solar cell element, so that the solar cell element and the collector that may be generated due to the difference in the extension amount of the flexible substrate and the condensing lens caused by the temperature increase during actual use are collected. The shift of the optical lens can be minimized. That is, the difference in elongation between the flexible substrate and the condenser lens is absorbed by the flexure of the flexible substrate, and the solar cell element (cell) in the vicinity of the positioning pin is hardly affected by the elongation. The difference in the amount of elongation is caused by the difference in thermal expansion coefficient between the flexible substrate and the condenser lens.

  In the concentrating solar cell module of the present invention, the width of the wiring pattern is equal to or greater than the width of the solar cell element. Thus, by increasing the width of the wiring pattern, the heat dissipation effect can be enhanced even when a flexible substrate is used.

  In the concentrating solar cell module of the present invention, the predetermined interval between the solar cell elements is longer than the predetermined interval between the condensing lenses. Thus, by extending the wiring pattern, even when the flexible substrate expands and contracts due to heat from sunlight, the stress can be relieved and the heat dissipation effect can be enhanced. In other words, it is not necessary to separately provide a mechanism for stress relaxation. Even when the flexible substrate expands and contracts, the positioning holes are provided close to both sides of the solar cell element, so the positions of the condenser lens and the solar cell element are fixed by the positioning holes and the positioning pins on the lens side. Therefore, the positions of the condensing lens and the solar cell element do not shift.

  The method for manufacturing a concentrating solar cell module according to the present invention condenses sunlight on a flexible substrate in which solar cell elements are mounted and arranged on a wiring pattern at a predetermined interval, and a light receiving region of the solar cell element. A lens array that is integrally formed with a condensing lens that irradiates and a holding portion that holds the condensing lens and the solar cell element in alignment with each other and is arranged in an array at predetermined intervals; A step of forming positioning pins at the predetermined interval on the bottom surface of the holding portion facing the solar cell element when the lens array is molded, and Forming a positioning hole at a position facing the positioning pin of the flexible substrate; forming a wiring pattern on the flexible substrate; and A step of mounting arrangement the solar cell element in, by inserting the positioning hole with the positioning pin, is characterized in that it comprises the steps of assembling together with said lens array and the flexible substrate.

  According to the manufacturing method of the present invention, the focusing lens and the solar cell element can be easily positioned by simply inserting the positioning pin into the positioning hole. Moreover, even if it is a case where the space | interval of a lens array and the space | interval of a solar cell element have shifted | deviated by using a flexible substrate, the shift | offset | difference can be absorbed by the bending of a flexible substrate.

  Since the present invention is configured as described above, the focusing lens and the solar cell element can be easily positioned by simply inserting a positioning pin into the positioning hole. Moreover, even if it is a case where the space | interval of a lens array and the space | interval of a solar cell element have shifted | deviated by using a flexible substrate, the shift | offset | difference can be absorbed by the bending of a flexible substrate.

It is a perspective view of the concentrating solar cell module which concerns on embodiment of this invention. It is a top view of the concentrating solar cell module which concerns on embodiment of this invention. It is a bottom view of the concentrating solar cell module which concerns on embodiment of this invention. 1 is a side view of a concentrating solar cell module according to an embodiment of the present invention. It is a bottom view of a lens array. It is one side view of a lens array. It is a top view of a flexible substrate. It is a graph which shows the change of the raise temperature of a solar cell element with respect to various lens sizes of a condensing lens. It is one side view of a concentrating solar cell module using the flexible substrate of another structural example. It is one side view of a concentrating solar cell module using the flexible substrate of another structural example. It is a perspective view which shows the structural example of the conventional concentrating solar power generation module. It is a partial block diagram of the conventional concentrating solar power generation module.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1A is a perspective view of a concentrating solar cell module 1 according to an embodiment of the present invention, FIG. 1B is a top view, FIG. 1C is a bottom view, and FIG. 1D is a side view. 2A is a bottom view of the lens array, and FIG. 2B is a side view of the lens array. FIG. 3 is a top view of the flexible substrate.

  In the concentrating solar cell module 1 of the present embodiment, as shown in FIG. 3, a wiring pattern 12 is formed on the surface of a film-like insulator (hereinafter also referred to as a receiver base) 14 with copper foil, aluminum foil, or the like. The long flexible substrate 10A in which the solar cell elements 11 are mounted and arranged in rows at a predetermined interval P1 on the wiring pattern 12, and the light reception of the solar cell element 11 as shown in FIGS. 1A and 1B. The condensing lens 21 that collects and irradiates sunlight on the region, and the holding portions 22 that hold the condensing lens 21 and the distance and position between the condensing lens 21 and the solar cell element 11 are arranged in a matrix at a predetermined interval P1. And a lens array 20 having a square shape in plan view that is integrally formed.

  In the present embodiment, the lens array 20 includes 36 condensing lenses 21 arranged in a matrix in 6 rows and 6 columns in a matrix, and is formed integrally with each holding portion 22 facing each condensing lens 21. As shown in FIGS. 1C and 2A, a pair of positioning pins 23 and 23 are provided on the bottom surface 22a with a predetermined interval W1 in the vertical direction (hereinafter also referred to as Y direction). The pair of positioning pins 23 and 23 are arranged with a predetermined interval P1 in the lateral direction (hereinafter also referred to as X direction).

  In addition, as a material of such a lens array 20, glass materials such as borosilicate glass can be used. In addition, various resin materials such as acrylic, silicon, and epoxy are used. Is also possible.

  On the other hand, as shown in FIG. 3, the flexible substrate 10 </ b> A is provided with a pair of positioning holes 13, 13 facing the positioning pins 23 of the holding portion 22 with a predetermined interval W <b> 1 in the Y direction. In addition, as a material of the receiver base | substrate 14 which is an insulator, a polyimide-type resin material, PET (polyethylene terephthalate), etc. can be used. In addition, the type of the solar cell is not particularly limited, for example, a silicon solar cell such as a monocrystalline silicon solar cell, a polycrystalline silicon solar cell, a thin film silicon solar cell, a compound solar cell, An organic solar cell etc. can be mentioned.

  According to the configuration of the flexible substrate 10A and the lens array 20 as described above, as shown in FIGS. 1C and 1D, the condensing lens 21 and the solar cell element 11 are simply inserted by inserting the positioning pins 23 into the positioning holes 13. Positioning can be performed easily.

  Here, the flexible substrate 10 </ b> A is formed in a strip shape long in the Y direction, and has a shape that fits each column of the lens array 20 in the X direction. That is, in the present embodiment, six flexible substrates 10 </ b> A are attached to each row for one lens array 20. Thereby, in the concentrating solar power generation module 1 of this embodiment, the positional relationship at the time of assembling each condensing lens 21 of the lens array 20 and each solar cell element 11 corresponding thereto is considered only in the X direction. There is no need to consider the Y direction. In addition, the stress due to the expansion and contraction of the flexible substrate 10A after assembling only needs to consider the X direction and does not need to consider the Y direction. That is, even when the interval P1 between the condensing lenses 21 and the interval P1 between the solar cell elements 11 are shifted (specifically, when the interval between the solar cell elements 11 is longer than the interval between the condensing lenses 21). The deviation can be absorbed by the bending of the flexible substrate 10A.

  In the present embodiment, the positioning holes 13 are provided near both sides of the solar cell element 11. The closer the position of the positioning hole 13 to the solar cell element 11, the better. By providing the positioning holes 13 in the vicinity of both sides of the solar cell element 11, the solar cell element 10 </ b> A that may be generated due to the difference in elongation between the flexible substrate 10 </ b> A and the condensing lens 21 caused by the temperature increase during actual use and the light collecting The displacement of the lens 21 can be minimized. That is, the difference in elongation between the flexible substrate 10A and the condensing lens 21 is absorbed by the flexure of the flexible substrate 10A, and the solar cell element (cell) 11 near the positioning pin 23 is hardly affected by the elongation. The difference in the amount of elongation is caused by the difference in thermal expansion coefficient between the flexible substrate 10A and the condenser lens 21.

  In this embodiment, the width (width in the Y direction) W11 of the wiring pattern 12 may be the same as the width (width in the Y direction) W12 of the solar cell element 11, but more preferably the width of the solar cell element 11. It is good to set it as W12 or more. Thus, by increasing the width W11 of the wiring pattern 12, even when the flexible substrate 10A is used, the heat dissipation effect can be enhanced.

  Here, the heat dissipation effect will be described with specific examples of each dimension.

  In this embodiment, when the diameter of the condensing lens 21 is about 10 mm and the condensing magnification is about 200 times, the solar cell element 11 is a quadrangle having a side of about 0.7 mm (= W12).

  In this case, if the width W11 of the wiring pattern (here, copper foil) 12 is about 0.7 mm, which is the same as the width (one side) of the solar cell element 11, and the thickness of the wiring pattern 12 is 35 μm, The rising temperature ΔT of the solar cell element 11 due to heat conduction from the heated wiring pattern 12 is as shown in the graph of FIG.

In the graph shown in FIG. 4, the horizontal axis represents various lens sizes (lens area) (mm ² ) of the condenser lens, and the vertical axis represents the wiring pattern 12 and the solar cell element 11 having dimensions corresponding to the various lens sizes under the above conditions. The rising temperature (° C.) of the solar cell element 11 is shown.

In FIG. 4, the rising temperature of the solar cell element 11 when the lens size (lens area) is 100 mm ² is about 50 ° C. Therefore, when the upper limit value of the rising temperature of the solar cell element 11 is set to, for example, 50 ° C., the width W11 of the wiring pattern 12 needs to be at least the same as the width W12 of the solar cell element 11, and wider than that. By forming, the inclination angle of the graph shown in FIG. 4 becomes a gentler inclination angle, and the temperature rise of the solar cell element 11 is also suppressed. That is, the heat dissipation effect can be enhanced.

  From the above results, it is preferable that the width W11 of the wiring pattern 12 is, for example, about 1 to 1.5 mm, which is wider than the width W12 (≈0.7 mm) of the solar cell element 11.

  When the diameter of the positioning hole 13 is about 0.5 to 1.0 mm, the distance between the centers of the pair of positioning holes 13 and 13 is about 2.5 to 3.0 mm. However, the distance between the centers of the positioning holes 13, 13 may be further reduced. In this case, the positioning hole 13 may overlap with the wiring pattern 12 protruding from the solar cell element 11. In this case, the positioning hole 13 may be formed by cutting out the overlapping portion of the wiring pattern 12.

  In addition, the wiring pattern 12 is extended in planar view L shape from the edge part by the side of the solar cell element 11, and the bypass diode 15 for protecting the solar cell element 11 is mounted and arrange | positioned at the extended front-end | tip part 12a. ing. Then, one electrode of the solar cell element 11 and one electrode of the bypass diode 15 are connected to the other electrode of the adjacent wiring pattern 12 by, for example, a wire bond, so that the solar cell element 11 and the bypass diode 15 are connected. And are connected in parallel. However, the wiring structure of the bypass diode 15 is not limited to such a shape and structure, and may be any shape and structure as long as the connection is ensured.

(Description of other configuration examples of flexible substrate)
5A and 5B are side views showing a configuration example of the concentrating solar cell module 1 using the flexible substrate 10B of another configuration example.

  In other words, in the flexible substrate 10B of another configuration example, the interval P1 ′ in the X direction of the solar cell elements 11 is formed longer than the interval P1 in the X direction of the condenser lens 21 (P1 ′> P1). Specifically, with respect to the interval P1 in the X direction of the condenser lens 21 = 10 mm, the interval P1 ′ in the X direction of the solar cell element 11 is set to 11 mm, for example. That is, the wiring pattern 12 between the adjacent solar cell elements 11 is correspondingly longer.

  In this way, the distance P1 ′ between the solar cell elements 11 is formed longer than the distance P1 between the condenser lenses 21 (that is, the distance between the positioning pins 13 adjacent in the Y direction) P1, so that the pair on the condenser lens 21 side. When the positioning holes 13 on both sides of the solar cell element 11 facing the positioning pins 23 are fitted together, as shown in FIG. 5B, the flexible substrate 10B between the adjacent solar cells 11 is bent in a U shape. Become. Thereby, even when the flexible substrate 10B expands and contracts due to heat from sunlight, the stress can be absorbed by the bent portion, and the heat radiation effect can be enhanced by the length of the wiring pattern 12. In other words, it is not necessary to separately provide a mechanism for stress relaxation. Even when the flexible substrate 10B expands and contracts, since the positioning holes 13 are provided close to both sides of the solar cell element 11, the condensing lens 21 and the sun are formed by the positioning holes 13 and the positioning pins 23 on the lens side. Since the position with respect to the battery element 11 is fixed, the positions of the condenser lens 21 and the solar cell element 11 do not shift.

  Next, the manufacturing method of the concentrating solar cell module 1 having the above configuration will be described.

  First, when the lens array 20 is molded, the positioning pins 13 are formed at a predetermined interval P1 in the Y direction on the bottom surface 22a of the holding portion 22 facing the solar cell element 11. That is, a total of 36 condensing lenses 21 and holding portions 22 in six rows and six rows are formed, and a pair of positioning pins 13 are formed on the bottom surface 22 a of each holding portion 22.

  On the other hand, on the wiring pattern 12 of the film-like receiver substrate 14 in which the wiring pattern 12 and the positioning hole 23 are formed in advance, the solar cell elements 11 are arranged in a row at a predetermined interval P1 or P1 ′ (in this example, six pieces are arranged). The long flexible substrates 10 </ b> A and 10 </ b> B are manufactured by mounting and arranging in rows, and by disposing the bypass diodes 15 in the vicinity of the solar cell elements 11 and connecting them by wire bonding or the like.

  Next, an adhesive is applied to the peripheral portion including the solar cell element 11, and in this state, the flexible substrates 10 </ b> A and 10 </ b> B are attached to the pair of positioning pins 13 formed on the bottom surface 22 a of each holding portion 22 of the lens array 20. The positioning holes 23 formed on both sides of the corresponding solar cell element 11 are inserted, and the solar cell element 11 is bonded and fixed to the bottom surface 22a of the holding portion 22 so that the flexible substrates 10A and 10B and the lens array 20 are integrated. Assemble to. At this time, as described above, some or all of the flexible substrates 10A and 10B between the adjacent solar cell elements 11 and 11 are in a free state (flexible state) that is not bonded to the lens array 20.

  According to the manufacturing method of the present embodiment, the positioning of the condenser lens 21 and the solar cell element 11 can be easily performed only by inserting the positioning pins 13 into the positioning holes 23 and fixing them. Further, when the flexible substrates 10A and 10B are used, the interval between the condenser lenses 21 of the lens array 20 and the interval between the solar cell elements 11 on the flexible substrates 10A and 10B are shifted (however, the flexible substrate 10B is conscious). However, the lens array 20 and the flexible substrates 10A and 10B are not wasted because the deviation can be absorbed by the bending of the flexible substrates 10A and 10B.

  In addition, embodiment disclosed this time is an illustration in all the points, Comprising: It does not become the basis of limited interpretation. Therefore, the technical scope of the present invention is not interpreted only by the above-described embodiments, but is defined based on the description of the scope of claims. Moreover, all the changes within the meaning and range equivalent to a claim are included.

DESCRIPTION OF SYMBOLS 1 Concentration type photovoltaic power generation module 10A, 10B Flexible substrate 11 Solar cell element 12 Wiring pattern 13 Positioning hole 14 Insulator (receiver base)
15 Bypass diode 20 Lens array 21 Condensing lens 22 Holding part 22a Bottom surface 23 Positioning pin

Claims (5)

A flexible substrate on which a solar cell element is mounted and arranged on a wiring pattern at a predetermined interval, a condensing lens that collects and irradiates sunlight on a light receiving region of the solar cell element, the condensing lens, and the solar cell element A concentrating solar power generation module comprising: a lens array in which holding portions that hold the distance and position between the two and the lens array are integrally formed at predetermined intervals;
A positioning pin is provided on the bottom surface of the holding portion facing the solar cell element, a positioning hole is provided on the flexible substrate to face the positioning pin, and the positioning hole is inserted into the positioning pin, The concentrating solar power generation module, wherein the flexible substrate and the lens array are integrally assembled. The concentrating solar power generation module according to claim 1,
A pair of the positioning pins are formed on the bottom surface of the holding portion,
The concentrating solar power generation module, wherein the positioning holes facing the positioning pins are provided in the vicinity of both sides of the solar cell element. The concentrating solar power generation module according to claim 1 or 2,
The concentrating solar power generation module, wherein a width of the wiring pattern is equal to or greater than a width of the solar cell element. The concentrating solar power generation unit according to any one of claims 1 to 3,
The concentrating solar power generation unit, wherein the predetermined interval of the solar cell elements is longer than the predetermined interval of the condensing lens. A flexible substrate on which a solar cell element is mounted and arranged on a wiring pattern at a predetermined interval, a condensing lens that collects and irradiates sunlight on a light receiving region of the solar cell element, the condensing lens, and the solar cell element And a lens array in which holding portions that hold the distance and position together are arranged at a predetermined interval and are integrally formed, and a manufacturing method of a concentrating solar power generation module comprising:
Forming positioning pins at the predetermined interval on the bottom surface of the holding portion facing the solar cell element at the time of molding the lens array;
Forming a positioning hole at a position facing the positioning pin of the flexible substrate;
Forming a wiring pattern on the flexible substrate, and mounting and arranging the solar cell elements at the predetermined intervals on the wiring pattern;
And a step of integrally assembling the flexible substrate and the lens array by inserting the positioning holes into the positioning pins.

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