Solar cell module and method for producing the same

A method for manufacturing a solar cell module comprising a plurality of spherical semiconductor elements arranged in a matrix form having a plurality of rows and a plurality of columns and having a function of photoelectric conversion respectively, in which spherical semiconductor elements in each row arranged to be a solar cell array so that their electrically conductive directions are aligned with the column direction of the matrix form and electrically connected in parallel via lead members, characterized by comprising:

• a first process of preparing in advance a plurality of spherical semiconductor elements, each having a p type or n type spherical semiconductor and a pn junction like partially spherical surface on an outer layer portion of the spherical semiconductor, and of also preparing in advance plural spherical bypass diodes of similar size to that of said spherical semiconductor elements;
• a second process of forming a plurality of openings in slit form in plural rows and plural columns in a thin metallic sheet, and forming band portions that are continuous along a column direction at both end portions in a row direction and between columns of said openings, and thereby forming a plurality of lead strings each having a width less than or equal to a radius of the spherical semiconductor element between said plural openings;
• a third process of applying a first conductive connection material in semi solid state on each of said plurality of lead strings in form of a plurality of spots in order to electrically connect the plurality of spherical semiconductor elements, and of also applying a second conductive connection material in semi solid state at sites on said band portions corresponding to said plurality of lead strings in form of plural spots in order to electrically connect said plural bypass diodes;
• a fourth process of connecting positive electrodes or negative electrodes of the plurality of spherical semiconductor elements to said plurality of spots of first conductive connection material, and also connecting cathodes or anodes of said plural bypass diodes to said plural spots of second conductive connection material;
• a fifth process of applying the first conductive connection material in form of spots to summit portions of said plurality of spherical semiconductor elements on said plurality of lead strings, and of also applying the second conductive connection material in form of spots to summit portions of said plural bypass diodes on said plural band portions;
• a sixth process of applying heat to said thin metallic sheet with said plurality of spherical semiconductor elements and said plural bypass diodes disposed thereon, and hardening said spots of first and second conductive connection material, thus forming first and second electrically conductive connection portions;
• a seventh process of, by making lead pieces by dividing said band portions of the thin metallic sheet into sections at positions corresponding to intermediate points between lead strings adjacent each other, manufacturing a plurality of solar cell sub arrays, each including a plurality of spherical semiconductor elements of each row, plural bypass diodes, and said single lead member;
• an eighth process of applying conductive adhesive material to first electrically conductive connection portions at summit portions of the plurality of spherical semiconductor elements, and to second electrically conductive connection portions at summit portions of the plural of bypass diodes, in said solar cell sub arrays;
• a ninth process of sequentially laminating together the plurality of solar cell sub arrays and thus assembling the plurality of spherical semiconductor elements and the plural bypass diodes into a cell assembly in matrix form having a plurality of rows and a plurality of columns, while guiding the pair of lead pieces at both ends of said solar cell sub array with a pair of guide members of a predetermined assembly jig;
• and
• a tenth process of hardening the conductive adhesive material by performing heating processing on said cell assembly in matrix form.