Metal foil pattern layered body, metal foil layered body, metal foil multi-layer substrate, solar cell module, and method of manufacturing metal foil pattern layered body

Patent metadata

Field	Value
Publication number	US-10056517-B2
Application number	US-201314098020-A
Country	US
Kind code	B2
Filing date	Dec 5, 2013
Priority date	Jun 6, 2011
Publication date	Aug 21, 2018
Grant date	Aug 21, 2018

Abstract

A metal foil pattern layered body of the invention includes: a base member; a metal foil including a metal foil pattern formed by an opening and a metal portion; and a protuberance provided at the metal foil and at a boundary between the opening and the metal portion.

First claim

What is claimed is:

1. A back sheet for a solar cell module, the back sheet comprising a metal foil pattern layered body comprised of:
a base member having a top surface;
an adhesive layer disposed above the top surface of the base member; and
a metal foil, wherein the metal foil comprises:
a metal foil pattern having a metal portion and an opening formed in the metal portion, the metal portion of the metal foil pattern having a top face, a back face and a side portion and being stacked on the base member with the adhesive layer interposed between the back face of the metal foil portion and the top surface of the base member, and
(ii) a protuberance protruding from the side portion of the metal foil into the adhesive layer, the protuberance being made of the same material as that of the metal foil and being provided at a boundary between the opening and the metal portion, wherein
the protuberance includes a first inclined surface extending from the top face of the metal portion toward the top surface of the base member, and a second inclined surface extending from the bottom face of the metal portion toward the base member in contact with the adhesive layer, the first and second inclined surfaces terminating at an edge of a front-end portion which is positioned at a boundary surface between the adhesive layer and the base member, and wherein
the adhesive layer includes an adhesive-layer inclined surface which is spaced from and oppositely faces the first inclined surface of the protuberance so as to define a substantially V-shaped cross-sectional space between the adhesive-layer inclined surface and the first inclined surface of the protuberance thereby providing a cut portion of the adhesive layer.

2. The back sheet according to claim 1 , wherein the protuberance is bent in a direction toward the base member and formed in the adhesive layer.

3. The back sheet according to claim 2 , wherein the adhesive layer is disposed on the top surface of the base member.

4. The back sheet according to claim 2 , further comprising
a buffer layer disposed between the base member and the adhesive layer, wherein the adhesive layer is disposed on the buffer layer, and
the metal foil pattern is stacked on the base member with the adhesive layer interposed therebetween, the adhesive layer being disposed on the buffer layer.

5. The back sheet according to claim 1 , wherein the cut portion is continuously formed at the adhesive layer and the base member.

6. The back sheet claim 4 , wherein the buffer layer is a PET film.

7. A solar cell module comprising:
a plurality of solar cells;
a seal layer sealing the solar cells and having a back face side; and
the back sheet according to claim 1 disposed at the back face side of the seal layer, the back sheet electrically connecting the solar cells to each other.

8. The back sheet according to claim 1 , wherein the metal foil pattern layered body further comprises an insulating layer coating the metal foil, wherein
the adhesive layer is provided on one face of the base member,
the metal foil pattern is an electroconductive pattern provided on the base member with the adhesive layer interposed therebetween,
the metal foil has an inclined edge face having an inverse tapered shape, and
the protuberance is provided at the edge face and projects to the insulating layer.

9. The back sheet according to claim 8 , wherein
a cross-sectional shape of the protuberance is substantially triangular, and
the protuberance protrudes from the edge face on an extension of the edge face of the metal foil.

10. The back sheet according to claim 8 , wherein an inclination angle of the edge face of the metal foil with respect to the base member is in the range of 55° to 85°.

11. A solar cell module comprising:
the back sheet metal foil pattern layered body according to claim 8 , wherein the metal foil includes a circuit pattern;
a solar cell sealed inside the insulating layer; and
a light-transmissive front plate stacked on a face on the opposite side of the face of the insulating layer on which the metal foil is provided.

12. The back sheet according to claim 1 , wherein the adhesive-layer inclined surface and the first inclined surface of the protuberance intersect one another at the top surface of the base member.

Assignees

• Dsm Ip Assets Bv

Inventors

• Kumai Koichi
• Ueda Ryuji
• Tomono Takao
• Tsukamoto Takehito

Classifications

• H05K2201/10143

  Solar cell · CPC title

• H05K3/3431

  Leadless components · CPC title

• H05K3/041

  by using a die for cutting the conductive material · CPC title

• Y10T29/301

  Method · CPC title

• H05K2201/0195

  Dielectric or adhesive layers comprising a plurality of layers, e.g. in a multilayer structure · CPC title