Flexible printed circuit, and concentrator photovoltaic module and concentrator photovoltaic panel using same

Abstract

Provided is a flexible printed circuit including: a film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; and an electric conductor layer formed on the insulating base material and forming a circuit pattern, wherein with respect to the insulating base material, a principal component thereof is a polyimide and a filler content thereof is 0%. Thus, a flexible printed circuit can be obtained that has an insulating base material which suppresses decrease in withstand voltage performance even in a high humidity environment.

Claims

1. A concentrator photovoltaic module comprising: a housing having a planar bottom surface; a reinforcement portion which is conductive and mounted to the planar bottom surface; a first adhesive layer forming a constant thickness layer on the reinforcement portion; a flexible printed circuit arranged in a plurality of rows on the bottom surface; a concentrating portion mounted to the housing and formed by a plurality of lens elements being arrayed, each lens element being configured to converge sun light; and cells mounted to the flexible printed circuit so as to correspond to light-concentrating positions of the respective lens elements, each cell being configured to receive the converged light to generate power, wherein the flexible printed circuit includes: a strip-film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; an electric conductor layer formed on the insulating base material and forming a circuit pattern; a lead frame of each of the cells mounted to the electric conductive layer, a second adhesive layer which covers both end faces of the electric conductive layer in a width direction perpendicular to a longitudinal direction of the electric conductive layer, and a cover layer which is provided on the second adhesive layer, and with respect to the insulating base material, a thickness thereof is in a range of 10 m to 50 m, a principal component thereof is a polyimide, and a filler is included, wherein the filler is any of calcium pyrophosphate, calcium phosphate, or calcium carbonate, an upper-limit content of the filler is 0.2% and excluding more than 0.2% to suppress hygroscopicity of the insulating base material even after having immersed the insulating base material in water, and external surfaces of the cover layer, the second adhesive layer, the insulating base material, and the first adhesive layer provide a path for a current leak from the lead frame to the reinforcement portion.

2. A concentrator photovoltaic panel formed by a plurality of the concentrator photovoltaic modules being arranged, according to claim 1.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a perspective view showing one example of a concentrator photovoltaic apparatus.

(2) FIG. 2 is a perspective view (partially cut out) showing an enlarged view of one example of a concentrator photovoltaic module.

(3) FIG. 3 is a cross-sectional view orthogonal to the longitudinal direction in the flexible printed circuit shown in FIG. 2, and is a cross-sectional view of the vicinity of a cell.

(4) FIG. 4 is a schematic diagram showing a configuration of a withstand voltage performance test.

(5) FIG. 5 is a bar graph indicating, with respect to four kinds of samples in three kinds of states, holding time [seconds] during which a certain withstand voltage performance can be maintained against an applied voltage of 3600 V.

(6) FIG. 6 is a bar graph indicating, with respect to the four kinds of samples in the three kinds of states, holding time [seconds] during which a certain withstand voltage performance is maintained when the applied voltage is raised to 4200 V.

(7) FIG. 7 is a schematic diagram showing how to conduct a slidability test.

(8) FIG. 8 is a bar graph showing a result of the slidability test.

DESCRIPTION OF EMBODIMENTS

Summary of Embodiment

(9) The summary of embodiment of the present invention includes at least the following.

(10) (1) This is a flexible printed circuit including: a film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; and an electric conductor layer formed on the insulating base material and forming a circuit pattern, wherein with respect to the insulating base material, a principal component thereof is a polyimide and a filler content thereof is 0%.

(11) In the flexible printed circuit configured as above, since the insulating base material does not contain any filler, the hygroscopicity can be suppressed at a low level. Thus, the withstand voltage performance can be maintained at a high level.

(12) (2) This is a flexible printed circuit including: a film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; and an electric conductor layer formed on the insulating base material and forming a circuit pattern, wherein with respect to the insulating base material, a thickness thereof is in a range of 10 m to 50 m, a principal component thereof is a polyimide, and a filler content thereof is not greater than 0.2%.

(13) When the filler content exceeds 0.2%, the higher the required withstand voltage value is, the more significant the decrease in the withstand voltage performance becomes due to moisture absorption. However, with the flexible printed circuit configured as above, the hygroscopicity can be suppressed at a low level by making the filler content not greater than 0.2%. Thus, the withstand voltage performance can be maintained at a high level.

(14) (3) This is a concentrator photovoltaic module including: a housing having a planar bottom surface; a flexible printed circuit arranged in a plurality of rows on the bottom surface; a concentrating portion mounted to the housing and formed by a plurality of lens elements being arrayed, each lens element being configured to converge sun light; and cells mounted to the flexible printed circuit so as to correspond to light-concentrating positions of the respective lens elements, each cell being configured to receive the converged light to generate power, wherein the flexible printed circuit includes: a strip-film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; and an electric conductor layer formed on the insulating base material and forming a circuit pattern, and with respect to the insulating base material, a principal component thereof is a polyimide and a filler content thereof is 0%.

(15) With respect to the flexible printed circuit in the concentrator photovoltaic module configured as above, since the insulating base material does not contain any filler, the hygroscopicity can be suppressed at a low level. Therefore, even when the state inside the concentrator photovoltaic module becomes a high humidity state due to dewing or the like, the withstand voltage performance of the flexible printed circuit can be maintained at a high level.

(16) (4) This is a concentrator photovoltaic module including: a housing having a planar bottom surface; a flexible printed circuit arranged in a plurality of rows on the bottom surface; a concentrating portion mounted to the housing and formed by a plurality of lens elements being arrayed, each lens element being configured to converge sun light; and cells mounted to the flexible printed circuit so as to correspond to light-concentrating positions of the respective lens elements, each cell being configured to receive the converged light to generate power, wherein the flexible printed circuit includes: a strip-film-shaped insulating base material having flexibility and having a withstand voltage value of at least 2000 V; and an electric conductor layer formed on the insulating base material and forming a circuit pattern, and with respect to the insulating base material, a thickness thereof is in a range of 10 m to 50 m, a principal component thereof is a polyimide, and a filler content thereof is not greater than 0.2%.

(17) When the filler content exceeds 0.2%, the higher the required withstand voltage value is, the more significant the decrease in the withstand voltage performance becomes due to moisture absorption. However, with the flexible printed circuit in the concentrator photovoltaic module configured as above, the hygroscopicity can be suppressed at a low level by making the filler content not greater than 0.2%. Therefore, even when the state inside the concentrator photovoltaic module becomes a high humidity state due to dewing or the like, the withstand voltage performance of the flexible printed circuit can be maintained at a high level.

(18) (5) Moreover, a concentrator photovoltaic panel can be formed by a plurality of the concentrator photovoltaic modules being arranged, according to (3) or (4) above.

(19) With this concentrator photovoltaic panel, even when the state inside each concentrator photovoltaic module becomes a high humidity state due to dewing or the like, the withstand voltage performance of the flexible printed circuit can be maintained at a high level.

Details of Embodiment

Concentrator Photovoltaic Panel and Concentrator Photovoltaic Apparatus

(20) First, a configuration of a concentrator photovoltaic apparatus will be described.

(21) FIG. 1 is a perspective view showing one example of a concentrator photovoltaic apparatus. In FIG. 1, a concentrator photovoltaic apparatus 100 includes: a concentrator photovoltaic panel 1; and a pedestal 3 which includes a post 3a and a base 3b therefor, the post 3a supporting the concentrator photovoltaic panel 1 on the rear surface side thereof. The concentrator photovoltaic panel 1 is formed by assembling a large number of concentrator photovoltaic modules 1M vertically and horizontally. In this example, 62 (7 in length9 in breadth1) concentrator photovoltaic modules 1M except the center portion are assembled vertically and horizontally. When one concentrator photovoltaic module 1M has a rated output of about 100 W, for example, the entirety of the concentrator photovoltaic panel 1 has a rated output of about 6 kW.

(22) A drive device (not shown) is provided on the rear surface side of the concentrator photovoltaic panel 1. By causing this drive device to operate, it is possible to drive the concentrator photovoltaic panel 1 in two axes of azimuth and elevation. Accordingly, the concentrator photovoltaic panel 1 is driven so as to always face the direction of the sun both in azimuth and elevation. At a place in the concentrator photovoltaic panel 1 (at the center portion in this example) or in a vicinity of the panel 1, a tracking sensor 4 and a pyrheliometer 5 are provided. The operation of tracking the sun is performed on the basis of the tracking sensor 4, and the position of the sun calculated from the time and the latitude and the longitude of the installation place.

Concentrator Photovoltaic Module

(23) FIG. 2 is a perspective view (partially cut out) showing an enlarged view of one example of a concentrator photovoltaic module (hereinafter, also simply referred to as module) 1M (however, a shielding plate described later is not shown). In FIG. 2, the module 1M includes, as main components: a housing 11 formed in a vat shape and having a flat bottom surface 11a; a flexible printed circuit 12 disposed so as to be in contact with the bottom surface 11a and in a plurality of rows; and a concentrating portion 13 mounted, like a cover, to a flange portion 11b of the housing 11. The housing 11 is made of a metal.

(24) The flexible printed circuit 12 is obtained by providing an electric conductor layer forming a circuit pattern on a strip-film-shaped insulating base material. On top of this, cells 21 and other electronic components are mounted. As each cell 21, a solar battery having heat resistance and a high power generation efficiency is used.

(25) The concentrating portion 13 is a Fresnel lens array and is formed by arranging, in a matrix shape, a plurality of Fresnel lenses 13f (for example, 16 in length12 in breadth, 192 in total) which concentrate sun light. Such a concentrating portion 13 can be obtained by, for example, forming a silicone resin film on a back surface (inside) of a glass plate used as a base material. Each Fresnel lens 13f is formed on this resin film. The total number and the arrangement of the Fresnel lenses 13f are the same as the total number and the arrangement of the cells 21, and the Fresnel lenses 13f and the cells 21 are in one-to-one correspondence with each other so that their optical axes are aligned with each other. A connector 14 for taking out the output of the module 1M is provided on the external surface of the housing 11.

Configuration of Flexible Printed Circuit

(26) FIG. 3 is a cross-sectional view orthogonal to the longitudinal direction in the flexible printed circuit 12 shown in FIG. 2, and is a cross-sectional view of the vicinity of the cell 21. It should be noted that the shown thickness dimensions are merely examples. Also, this figure is for schematic representation of the cross sectional structure, and is not necessarily proportional to the actual size.

(27) In FIG. 3, the flexible printed circuit 12 includes: an insulating base material 121 (thickness 25 m) made of a polyimide; an electric conductor layer 122 (thickness 35 m) provided on top of the insulating base material 121, made of copper, and forming a circuit pattern; a solder portion 123 which connects a cell 21 packaged together with a lead frame 18 to the electric conductor layer 122 via the lead frame 18; an adhesive layer 124 (maximum thickness 60 m); and a cover layer 125 (thickness 25 m) made of a polyimide. The insulating base material 121 has flexibility and has a strip-film shape (ribbon shape extending in the longitudinal direction). The flexible printed circuit 12, also as a whole, has a thickness of about 110 m, has a strip-film-shape, and has flexibility.

(28) A reinforcement portion 16 (thickness 800 m) made of an aluminium alloy is mounted to the lower surface of the insulating base material 121, via an adhesive layer 15 (thickness 25 m). The reinforcement portion 16 allows the flexible printed circuit 12 to have a certain rigidity, thereby facilitating handling during mounting of the flexible printed circuit 12. In addition, the reinforcement portion 16 also contributes to dissipation of heat from the flexible printed circuit 12 to the bottom surface 11a of the housing 11. The reinforcement portion 16 is fixed to the bottom surface 11a (thickness 1000 m=1 mm) with a double-sided tape 17 (thickness 35 m) which has electric conductivity (which also has good thermal conductivity).

(29) The cell 21 is packaged together with the lead frame 18 for taking out an output. The lead frame 18 is electrically and mechanically connected to the electric conductor layer 122 via the solder portion 123. The top and the periphery of the cell 21 and the periphery of the lead frame 18 are covered with a transparent silicone resin layer 19.

(30) The potential of the bottom surface 11a of the housing 11 is maintained at the ground potential. Therefore, the potential of the reinforcement portion 16 mounted to the bottom surface 11a via the electrically conductive double-sided tape 17 also is the ground potential. A direct-current voltage generated through solar photovoltaic power generation is applied to the electric conductor layer 122. Accordingly, a current I.sub.dc caused to flow due to a potential difference V.sub.dc between the electric conductor layer 122 and the reinforcement portion 16 needs to be suppressed to less than a predetermined value I.sub.L of an allowable level (I.sub.dc<I.sub.L) by means of the insulating base material 121 and the adhesive layer 15. As indicated by arrows in FIG. 3, for example, the current leak includes a current leak L1 which penetrates the insulating base material 121 and the adhesive layer 15, a current leak L2 caused by a void (not shown) in the adhesive layer 15 locally reducing the withstand voltage value, and a current leak L3 which flows from the lead frame 18 on the external surface against insulation.

Relationship Between Filler for Insulating Base Material, and Withstand Voltage Performance and Slidability

(31) The present inventors examined what change appears in withstand voltage performance and slidability by changing the content of a filler contained in the insulating base material 121 whose principal component is a polyimide. Hereinafter, the examination result will be described in detail. As the filler, calcium pyrophosphate was used.

(32) As the filler, calcium phosphate, calcium carbonate, and silica are also appropriate, other than calcium pyrophosphate. However, here, as a representative, a case where the filler was calcium pyrophosphate was examined.

(33) The kinds of the insulating base material 121 used in the examination are shown in table 1. Here, with respect to the thickness of the insulating base material 121, the nominal value is 25 m, and the measured value is also approximately 25 m.

(34) TABLE-US-00001 TABLE 1 Article Article Conventional containing containing Non- article filler by 0.2% filler by 0.1% filler Nominal 25 25 25 25 thickness [m] Measured 24.9 24.8 25.0 24.8 thickness [m]

(35) It is preferable that the thickness of the insulating base material 121 is in the range of 10 m to 50 m (not less than 10 m and not greater than 50 m). When the thickness is less than 10 m, it becomes difficult to ensure a necessary withstand voltage value. When the thickness exceeds 50 m, it becomes difficult to ensure a necessary thermal conductivity (heat dissipation performance). The thickness 10 m to 50 m for the insulating base material 121 is a preferable range for realizing both the necessary withstand voltage value and the necessary thermal conductivity.

(36) The concept regarding the withstand voltage is as follows according to the IEC standard (62108, 62688).

(37) The withstand voltage performance in the case of grade A is being able to withstand (system voltage4)+2000 V for two minutes.

(38) The withstand voltage performance in the case of grade B is being able to withstand (system voltage2)+1000 V for two minutes.

(39) The system voltage is 500 to 1000 V in general, and a target therefor can be 500 V, 600 V, or 1000 V, for example.

(40) When the system voltage is 1000 V, the withstand voltage value for grade A is 6000 V, and the withstand voltage value for grade B is 3000 V.

(41) When the system voltage is 600 V, the withstand voltage value for grade A is 4400 V and the withstand voltage value for grade B is 2200 V.

(42) When the system voltage is 500 V, the withstand voltage value for grade A is 4000 V, and the withstand voltage value for grade B is 2000 V.

(43) Therefore, an insulating base material for a flexible printed circuit to be used in a concentrator photovoltaic module is required to have insulation performance capable of withstanding at least 2000 V, preferably 3000 V or greater. When the system voltage is 1000 V, the withstand voltage for grade B is 3000 V.

(44) FIG. 4 is a schematic diagram showing a configuration of a withstand voltage performance test. The test condition was as follows. An insulating base material 121s serving as a sample (hereinafter, simply referred to as sample) was interposed between disc electrodes P and N each having a diameter of 20 mm, and then, direct-current voltage was applied. The applied voltage was 3600 V, and the step-up condition was 500 V/sec. The time period during which 3600 V was applied was 300 seconds at maximum. The sample was prepared in three states in which:

(45) (a) the sample in an ordinary state (not immersed in water);

(46) (b) the sample immediately after being taken out of pure water where the sample has been immersed at 23 C. for 10 hours; and

(47) (c) the sample immediately after being taken out of pure water where the sample has been immersed at 23 C. for 24 hours.

(48) The sample itself was prepared in four kinds:

(49) (1) conventional article (filler content 2%);

(50) (2) article having filler content of 0.2%;

(51) (3) article having filler content of 0.1%; and

(52) (4) non-filler article that does not contain any filler (filler content 0%)

(53) It should be noted the contents above are expressed in mass %.

(54) FIG. 5 is a bar graph indicating, with respect to the four kinds of samples in the three kinds of states (a), (b), and (c) defined above, a time period until a current leak I.sub.dc, (?I.sub.L) not less than a predetermined value I.sub.L is detected under the applied voltage of 3600 V, i.e., holding time [seconds] during which a certain withstand voltage performance can be maintained. In FIG. 5, in the case of (a) ordinary state i.e., non-immersion in water, all samples attain 300 seconds. However, in the case of (b) 10 hours, with respect to the conventional article sample (1), the holding time is considerably decreased and is far from the specification value (120 seconds). With respect to other samples (2) and (3), the holding time is slightly decreased but satisfies the specification value. With respect to non-filler sample (4), the holding time is not decreased.

(55) Further, in the case of (c) 24 hours, with respect to the conventional article sample (1), the holding time is further decreased, and is far from the specification value (about 120 seconds). Also with respect to other samples (2) and (3), the holding time is further decreased, but still satisfies the specification value. With respect to the non-filler sample (4), decrease in the holding time is not observed.

(56) When summarizing the result shown in FIG. 5, with respect to (1) conventional article, it is seen that after the immersion in water, the withstand voltage performance against the applied voltage 3600 V is considerably decreased and does not satisfy the specification value. With respect to (2) filler 0.2% and (3) filler 0.1%, the withstand voltage performance is decreased in accordance with the time period of the immersion in water, but satisfies the specification value. With respect to (4) non-filler, even after the immersion in water, the withstand voltage performance is not decreased.

(57) That is, in terms of the withstand voltage performance in the case of the immersion in water performed, non-filler is best, followed by filler 0.1% and then by filler 0.2%, in this order, and conventional article is not appropriate.

(58) FIG. 6 is a bar graph indicating, with respect to the same four kinds of samples as in FIG. 5 in the same three kinds of states (a), (b), and (c) defined above, the holding time [seconds] during which a certain withstand voltage performance is maintained when the applied voltage is raised to 4200 V. This can be said as an examination for confirming how change in the holding time appears when an intentionally-raised voltage is applied.

(59) Here, with respect to all the samples, the holding time after the immersion in water shows decrease when compared with that in (a) ordinary state. However, with the extent of the decrease focused, when the holding time after the immersion for 24 hours relative to the holding time in the ordinary state is expressed in the rate [%], (1) conventional article exhibits 13%, (2) filler 0.2% exhibits 56%, (3) filler 0.1% exhibits 65%, and (4) non-filler exhibits 89%.

(60) That is, in the viewpoint of suppressing decrease in withstand voltage performance after immersion in water, non-filler is best, followed by filler 0.1% and then filler 0.2%, in this order, and conventional article is inferior.

(61) From the result above, the following conclusion can be derived.

(62) First, the target is an insulating base material for a flexible printed circuit, the insulating base material having a withstand voltage value of at least 2000 V. As such an insulating base material, if an insulating base material whose principal component is a polyimide and whose filler content is 0% (non-filler) is used, it is possible to suppress the hygroscopicity at a very low level because the insulating base material does not contain a filler. Thus, the withstand voltage performance can be maintained at a high level. In addition, even when the state inside the concentrator photovoltaic module becomes a high humidity state due to dewing or the like, the withstand voltage performance of the flexible printed circuit can be maintained at a high level.

(63) Also, even when the insulating base material is not a non-filler, if an insulating base material is used whose thickness is in the range of 10 m to 50 m, whose principal component is a polyimide, and whose filler content is not greater than 0.2%, the hygroscopicity can be suppressed at a low level. Thus, the withstand voltage performance can be maintained at a high level. In addition, even when the state inside the concentrator photovoltaic module becomes a high humidity state due to dewing or the like, the withstand voltage performance of the flexible printed circuit can be maintained at a high level. It should be noted that, if the filler content exceeds 0.2%, as shown by the (2) filler 0.2% sample in FIG. 6, decrease in the withstand voltage performance becomes significant due to moisture absorption. The (2) filler 0.2% sample satisfies the necessary withstand voltage performance in FIG. 5, but does not satisfy the withstand voltage performance when the voltage is increased to 4200 V, and thus, can be considered as the upper limit line for preferable content. That is, it can be considered that 0.2% is the upper limit for the filler.

(64) Next, FIG. 7 is a schematic diagram showing how to conduct a slidability test. The sample is obtained by forming a copper foil on an insulating base material made of a polyimide (P1). In FIG. 7, the respective materials are represented by hatchings having different directions. From a stationary state where the two samples, i.e., the polyimide insulating base materials, are in contact with each other under a load (weight 200 g on 64 cm.sup.2=80 mm80 mm), a force F for moving the upper sample in the arrow direction is applied. This force F is proportional to the friction force at surface contact between the insulating base materials. The larger the value of F is, the worse the slidability is, and the smaller the value of F is, the better the slidability is.

(65) FIG. 8 is a bar graph showing a result of the slidability test. The value 1.8 of F in the vertical axis is the value of a general polyimide film. From this graph, it is seen that conventional article, filler 0.2%, and filler 0.1% have slidability equivalent to or greater than or equal to the slidability of the general polyimide film, but non-filler does not have good slidability.

(66) When the slidability is not good, the insulating base materials easily adhere to each other, which poses a defect of difficult handling thereof. However, if the insulating base material is attached to the reinforcement portion 16 (FIG. 3), this defect is not so troublesome. Therefore, for usage that requires a withstand voltage performance not less than 2000 V, even if slidability is sacrificed to some extent, it is overwhelmingly meaningful to ensure a withstand voltage performance obtained by employing a non-filler insulating base material or by suppressing the filler content to not greater than 0.2%.

(67) It should be noted that the embodiment herein is to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

REFERENCE SIGNS LIST

(68) 1 concentrator photovoltaic panel 1M concentrator photovoltaic module 3 pedestal 3a post 3b base 4 tracking sensor 5 pyrheliometer 11 housing 11a bottom surface 11b flange portion 12 flexible printed circuit 13 concentrating portion 13f Fresnel lens 14 connector 15 adhesive layer 16 reinforcement portion 17 double-sided tape 18 lead frame 19 silicone resin layer 21 cell 100 concentrator photovoltaic apparatus 121, 121s insulating base material 122 electric conductor layer 123 solder portion 124 adhesive layer 125 cover layer