JP3418064B2 - Method of manufacturing solar cell module - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module having an improved wiring connection structure, a method of manufacturing the solar cell module and a mounting structure, and a roof with the solar cell module.

[0002]

2. Description of the Related Art In recent years, a solar cell power generation system for a home has been promoted by installing a panel-shaped solar cell module on the roof of a house or the like and directly extracting electric power from solar energy to supply the house. ing. At present, solar energy is attracting attention because, unlike fossil fuels, there is no fear of exhaustion, and since electric power can be taken out without undergoing a combustion process, there is no problem of global environmental destruction. By the way, when installing this kind of solar cell module on the roof, first install a plurality of exclusive mounts parallel to each other on the roof surface, and then install a plurality of solar battery modules by straddling these mounts. It has been common practice to fix them side by side. At this time, the solar cell modules are connected to each other in series by electrical wiring, fixed on a pedestal, and the terminal electrical wiring derived from the solar cell module at the end of the connection direction is guided to the inverter installed indoors. I am trying. In this way, the electric power generated by all the solar cell modules is collected, converted from direct current to alternating current by the inverter, and supplied to the indoor wiring.

However, conventionally, there has been a disadvantage that these electric wirings are complicated on the roof and hinder the subsequent work, or the electric wirings are exposed to the outside to make the appearance unsightly. . Therefore, as means for eliminating such inconvenience, Japanese Patent Laid-Open No. 7-153
The inter-module wiring structure described in Japanese Patent Publication No. 985 is proposed. In the wiring structure described in this publication,
An opening is formed in the side wall of the frame made of channel steel, and at the installation site on the roof, through the opening formed in the frame,
The solar cell modules are connected to each other by wiring. According to such a wiring structure, the wiring between the solar cell modules is performed through the openings formed in the gantry, so that there is no need for detour wiring, and the electric wiring is arranged in an orderly manner on the roof surface under the solar cell module. can do.

[0004]

However, in the wiring structure described in the above publication, since the wiring work for inserting the electric wiring into the opening formed in the pedestal must be performed on the roof of the site, the solar cell is required. There is a drawback that the installation work of the module becomes very complicated. In addition, when manufacturing a gantry using channel steel, there is a problem that the manufacturing cost of the gantry becomes high because a new step of punching is required.

The present invention has been made in view of the above circumstances, and can reduce the on-site construction load of electrical wiring, avoid the high cost of the pedestal, and thus contribute to the reduction of the overall cost. An object of the present invention is to provide a manufacturing method and a mounting structure, and a roof with a solar cell module.

[0006]

[0007]

[0008]

[0009]

In order to solve the above-mentioned problems, according to the first aspect of the present invention, a solar battery cell is formed by disposing a solar battery cell on the back surface of a transparent plate and further covering with a back cover material. After that, the peripheral end of the solar cell panel is sealed with a frame-shaped end sealing member, and the side wall of the end sealing member crawls under the solar cell panel to form the solar cell. A solar cell module manufacturing method for completing a solar cell module by forming a wiring notch or a wiring opening for passing an electrical wiring that takes out electric power from a cell, and substantially conforms to the outer surface shape of the front side of the solar cell module. In a mold for injection molding, which comprises a pair of a front mold having an inner surface shape and a back mold having an inner surface shape substantially matching the outer surface shape on the back side of the solar cell module, the peripheral edge portion of the mating mold. Leaving the cavity in In the state, after housing the solar cell panel, by injecting the polymer raw material of the end sealing member into the cavity defined by the mold and the solar cell panel and shaping and solidifying The end sealing member is molded in a frame shape, and the peripheral end of the solar cell panel is sealed by the molded end sealing member.

The invention according to claim 2 relates to the method for manufacturing a solar cell module according to claim 1, wherein the side wall portion of the end sealing member is formed on the peripheral portion of the back mold. An annular groove is provided, and a shallow bottom portion for forming the wiring notch is provided in the annular groove.

The invention according to claim 3 relates to the method for manufacturing a solar cell module according to claim 1, wherein the side wall portion of the end sealing member is formed on the peripheral portion of the back mold. An annular groove is provided, and in the annular groove, a pin member for molding the wiring opening is projected from one groove wall of the annular groove and enters the other groove wall, It is characterized by being pierced freely.

The invention according to claim 4 relates to the method for manufacturing a solar cell module according to claim 1, 2 or 3, wherein a plurality of polymer compounds which are hardened when mixed with each other are contained in the metal mold. By being kneaded and injected and shaped and solidified,
It is characterized in that the end sealing member is formed in a frame shape, and a peripheral end of the solar cell panel is sealed.

[0013]

[0014]

[0015]

[0016]

(Operation) In order to manufacture the solar battery module according to the method of the present invention, first, the solar battery cells are arranged on the back surface of the transparent plate and further covered with a back surface cover material to form a solar battery panel. To do. Next, the solar cell panel is housed in a molding die for injection molding with a cavity left in the peripheral portion of the molding die, and then the solar cell panel is defined by the molding die and the solar cell panel. A polymer compound as a raw material is injected into the cavity and solidified to solidify the end sealing member into a frame shape to seal the peripheral end of the solar cell panel (the invention according to claim 1). At this time, if an annular groove is provided in the peripheral portion of the back die that constitutes the mating die, and a shallow bottom portion is provided in this annular groove, when the end sealing member is formed, the side wall portion is electrically insulated. A wiring notch for passing the wiring is also formed at the same time (the invention according to claim 2). Further, instead of the shallow bottom portion, if the pin member is detachably provided in such a manner that it projects from one groove wall of the annular groove and projects into the other groove wall, the end portion sealing member is formed. At the same time, a wiring opening for passing an electric wiring is simultaneously formed in the side wall portion (the invention according to claim 3).

[0018] In the prior art (the technique described in the above publication), it was difficult to carry out the wiring work of the solar cell module only after climbing onto the roof. However, since the notch for wiring or the opening for wiring is provided in the end sealing member, the wiring work can be completed (for example, in a factory) before the solar cell module is lifted on the roof. Therefore, it is possible to reduce the on-site work of electrical wiring work when installing a large number of solar cell modules in an array on the roof. (If you use appropriate auxiliary tools, you can also pass electrical wiring through the wiring notches. Is).
Further, conventionally, it is necessary to perform a punching process for passing the electric wiring through the gantry, which causes an increase in the cost of the gantry. On the other hand, according to the configuration of the present invention, since the wiring opening or the wiring notch is formed at the same time when the end sealing member is formed, the productivity is improved and the cost is not increased.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. The description will be specifically made using the embodiments. First Embodiment Solar Cell Module Configuration FIG. 1 is a diagram showing the configuration of the solar cell module according to the first embodiment of the present invention. FIG. 1 (a) is a perspective view showing the front side of the solar cell module. 2B is a perspective view showing the back side of the solar cell module, FIG. 2 is a cross-sectional view taken along the line AA of FIG. 1A, and FIG. 3 is a line BB of FIG. 1A. FIG. 4 is a cross-sectional view schematically showing the configuration of the solar cell panel that is the main body of the solar cell module. As shown in FIGS. 1 to 4, the solar cell module 1A of this example has a plurality of crystalline silicon solar cells 21, 21 electrically connected to each other through internal lead wires.
..., with horizontal dimensions of approximately 900 to 1,200 mm and vertical dimensions of approximately 90
After the solar cell panel 2 is formed by arranging the transparent glass substrate 22 of 0 mm vertically and horizontally on the back surface, adhering it with the filling adhesive 23, and covering with the back surface cover material 24 to form the solar cell panel 2, the peripheral end portion of the solar cell panel 2 is frame-shaped. And the terminal box 25 is adhered to the central portion of the back surface of the solar cell panel 2, and the side wall 3 of the end sealing member 3 is formed.
1, 31 are provided with lead wire insertion holes 31 a, 31 a for passing the external lead wires 4 extending from the terminal box 25. The transparent glass substrate 22 is a white plate tempered glass having a thickness of about 3.2 mm, which is excellent in light transmittance and impact resistance, and the filling adhesive 23 is excellent in moisture resistance.
VA (ethylene vinyl acetate) film,
As the back cover material 24, for example, a resin-coated metal sheet having a thickness of about 0.1 mm in which both surfaces of an aluminum sheet are coated with PVF (vinyl fluoride resin) having excellent insulation properties is preferably used.

The terminal box 25 has a solder joint portion for connecting an internal lead wire in the solar cell panel 2 and two external lead wires 4, 4 that crawl under the solar cell panel 2, and a backflow prevention member. The diode is housed and sealed with a filling adhesive such as silicone resin. The external lead wires 4 and 4 are waterproof-coated, and male or female waterproof connectors 41 and 42 are attached to the respective tips. The end sealing member 3 is injection-molded as a resin frame having side walls 31, 31, ... On the lower four sides in order to play a role as a mounting site of the solar cell panel 2, and the side walls 31, 31, ... The locking recessed steps 31b, 3 along the longitudinal direction on the outer side of the lower portion.
Are provided, and a pair of opposed locking concave steps 31b, 31b, ... Are placed in a locked state on the upper edge portion of the mounting base described later. Further, the lead wire insertion holes 31a, 31a are provided in the waterproof connector 41,
42 has a hole diameter (for example, 10 mm) through which 42 can pass, and as shown in FIGS. Parts 31b, 3
It is provided above 1b.

Method for Manufacturing Solar Cell Module FIG. 5 is a perspective view schematically showing the structure of a mold for molding an end sealing member used in the method for manufacturing a solar cell module.
Is a diagram showing the structure of the mold, and FIG. 5 (a) is C- of FIG.
5 is a cross-sectional view taken along line C, FIG. 7B is a cross-sectional view taken along line D-D in FIG. 5, and FIG. 7 is a view showing a state in which the solar cell panel is housed in the same mold. 6A is a cross-sectional view corresponding to FIG. 6A, FIG. 6B is a cross-sectional view corresponding to FIG. 6B, and
FIG. 8: is sectional drawing which shows the state which injected the liquid resin raw material of an edge part sealing member into the same metal mold | die which accommodated the same solar cell panel. As shown in FIGS. 5 and 6, the end sealing member forming mold 5 (hereinafter referred to as a combined mold) used in the manufacturing method of this example includes a front mold 5a of the solar cell module 1A and a back mold. A panel having a paired structure with 5b, and a non-peripheral part (entire space region excluding the peripheral part) for accommodating and holding the solar cell panel 2 between the front mold 5a and the back mold 5b in the mold. In the storage portion 51, a peripheral edge portion is a square annular cavity portion (casting portion) 52 into which the liquid resin raw material of the end portion sealing member 3 is injected.
Has become. Back mold 5 occupying most of the cavity 52
At the peripheral portion of b, the side walls 31, 31, ...
5 and 6 (b) are provided on the outer peripheral side groove wall portion and the inner peripheral side groove wall portion at a predetermined position of the annular groove 53. As shown in
Lead wire insertion hole 31a, pin member 54 for molding 31a,
A pin fitting hole 53a for removably fitting 54,
53a are bored in a state where their axes are common to each other. In this example, as shown in FIGS. 5 to 8, pairs of pin fitting holes 53a, 53a are provided in the groove walls on the "two sides" of the annular groove 53 forming four sides, which face each other. The bottom of the annular groove 53 is a step bottom having a deep inner periphery and a shallow outer periphery in order to form the above-mentioned locking concave step portion 31b in the lower portion of the end sealing member 3. Also, the back mold 5b and the front mold 5
A gate portion 56 for pouring the liquid resin raw material (two-component curable urethane resin raw material in this example) kneaded by the mixing head 55 into the mold is provided at the joint with a.

In order to manufacture the solar battery module 1A of this example, first, a plurality of crystalline silicon solar battery cells 21, 21, ... Which are electrically connected to each other through internal lead wires.
Are aligned vertically and horizontally on the back surface of a transparent glass substrate 22 such as white plate tempered glass and attached with a filling adhesive 23 such as EVA, and covered with a back cover material 24 such as a resin-coated metal sheet to cover the solar cell panel 2 (see FIG. 4). ) Is formed. Next, as shown in FIG. 7, the solar cell panel 2 is housed and held in the panel housing part 51 in the mating die 5. When the solar cell panel 2 is housed and held in the panel housing portion 51, the cavity 52 in the mating mold 5 includes the solar cell panel 2, the front mold 5a, and the back mold 5b.
And is defined as a mold space for molding the end sealing member 3. It should be noted that, as shown in FIG.
4, 54 are fitted and mounted in the pin fitting holes 53a, 53a, ... Of the back mold 5b and pierced through the annular groove 53.

After this, injection molding of the two-component curing type urethane resin raw material is performed. The two-component curable urethane resin raw material is composed of an isocyanate compound (main agent) and a polyol (curing agent), and becomes a liquid kneading resin composition immediately before being injected into the mold and is injected into the mold. It Here, suitable isocyanate compounds include MDI (diphenylmethane-4,4′-diisocyanate) and TDI (tolylene diisocyanate), and suitable polyols include polyester and polyether. You can More specifically, at the time of injection molding, an isocyanate compound (main agent) and a polyol (curing agent) are respectively injection-fed from two liquid agent pressure-feeding units (not shown) toward the mold 5. Both of them are kneaded by the mixing head 55 to form a liquid kneaded resin composition M in the middle of the route. The liquid kneading resin composition M is introduced into the gate portion 56 of the mating die 5 while being kneaded by the mixing head 55, and the gate portion 5
While being further kneaded in 6, the square cavity 52
It is injected and shaped into a solid state where it undergoes a chemical reaction to solidify.

The liquid kneaded resin composition M contains the cavity 52.
When completely solidified in the inside, the lid (the front mold 5a) is opened, the pin members 54, 54 are pulled out from the pin fitting holes 53a, 53a ,. When the mold is removed, the molded product of the end sealing member 3 is obtained in a state of being integrated with the solar cell panel 2, that is, in a state where the peripheral end of the solar cell panel 2 is sealed in a frame shape from the beginning. . Moreover, in this end portion sealing member 3,
Since the liquid kneaded resin composition M is shaped by the pin members 54, 54, the lead wire insertion holes 31a, 31a are punched. After that, the internal lead wires in the solar cell panel 2 and the two external lead wires 4 and 4 with the male or female waterproof connectors 41 and 42 are connected with solder, and a diode for preventing backflow is further provided. Then, these solder joints and diodes are placed in the terminal box 25. Then, the terminal box 25 accommodating these is bonded to the central portion of the back surface of the solar cell panel 2 to complete the solar cell module 1A.

Mounting Structure of Solar Cell Module FIG. 9 is a view showing a roof mounting structure of the solar cell modules arranged in two rows on both sides, and FIG. 9 (a) is a sectional view showing no lead wire insertion hole. FIG. 10B is a sectional view showing a lead wire insertion hole, FIG. 10 is a sectional view showing a roof mounting structure of the solar cell modules arranged in one row on one side, and FIG. 11 is FIG. 9 and FIG. 10 is an exploded perspective view showing the same mounting structure of FIG. 10, and FIG. 12 is a perspective view showing a roof with a solar cell module adopting the same mounting structure. In this embodiment, the solar cell module 1 having the above configuration is used.
As a mounting member for mounting and fixing A on the roof, as shown in FIG.
As shown in FIG. 11, a long lower frame 61, which is a dedicated mount for the solar cell module 1A, and a long upper frame 62, which is a pressing member, are used. The lower frame 61 has a two-stage structure in which the widthwise central portion is the upper portion and the widthwise peripheral portion is the lower portion, and the upper frame fixing portion 611 provided in the upper central portion and the upper corner portions on both sides of the upper frame fixing portion 611. It is a long product consisting of a pair of module mounting parts 612 and 612 extending to the outside and a pair of roof fixing parts 613 and 613 extending to the lower stage outside each module mounting part 612, and is extruded integrally from a metal such as aluminum as a raw material. Obtained by molding. Female screw holes N, N, ... For fixing the upper frame 62 are screwed to the upper frame fixing portion 611 at a plurality of positions along the longitudinal direction. Each module mounting part 6
On side 12, the side wall 31 of the end sealing member 3 constituting one side of the solar cell module 1A is placed with the locking recessed stepped portions 31b in contact with the corners. Roof fixing part 6
In order to fix the lower frame 61 itself to the roof with the screws B1, B1, ..., Screw holes are provided at a plurality of positions in the 13 along the longitudinal direction.

The upper frames 62a and 62b are long members made of a metal such as aluminum which is paired with the lower frame 61. The upper frames 62a and 62b are for fixing the solar cell modules 1A and 1A in two rows on one side and the one for one side.
There are two types, one for fixing the solar cell modules in a row.
As shown in FIG. 9, the upper frame 62a is for fixing the two rows of solar cell modules 1A, 1A on both sides, and is provided on both sides of the lower frame fixing portion 621 and the lower frame fixing portion 621 in the widthwise central portion. It is composed of a pair of extending module pressing portions 622 and 622, and is obtained by extrusion integral molding. In the lower frame fixing portion 621, screws that can be screwed into the female screw holes N, N, ... Are inserted at positions corresponding to the screwing positions of the female screw holes N, N ,. A hole is provided. Each module pressing portion 622 is connected to the end sealing member 3 of the solar cell module 1A by the fastening force of the screws B2, B2, ....
Is firmly pressed against the module mounting portion 612 of the lower frame 61 to be fixed, and the lower surface is a flat surface. Also,
As shown in FIG. 10, the upper frame 62b is for fixing one row of solar cell modules 1A on one side, and includes a lower frame fixing part 621 and a single module holding part extending to one side of the lower frame fixing part 621. 622 and the lower frame 61 are covered,
It is composed of a cover type indicator 623 that supports one half of itself and is obtained by extrusion integral molding.

In order to mount and fix a plurality of solar cell modules 1A on the roof 7 using the lower frame 61 and the upper frame 62 having the above-described structure, first, as shown in FIG. The required number of frames 61, 61, ... Is fried. In this example, the roof 7 has a waterproof / fireproof structure by laying a waterproof sheet 72 such as asphalt roofing on a base plate 71 such as structural plywood and further covering it with a vinyl chloride steel plate (polyvinyl chloride coated steel plate) 73. It is said that. On the roof 7 having such a structure, a plurality of lower frames 61, 61, ... Are arranged in parallel with each other at a predetermined interval and aligned with the rafter 74, and screwed from the screw holes of the roof fixing portion 613. B1, B1, ...
Is screwed in and fixed to the rafter 74.

Next, on the ground, a wire passing operation is performed in which only one of the external lead wires 4 is inserted into the lead wire insertion hole 31a of the solar cell module 1A, 1A, .... Figure 9
In (b), an example is shown in which only the external lead wire 4 on the male waterproof connector 41 side is inserted into the lead wire insertion hole 31a. The work of inserting the external lead wires 4 may be performed on the roof 7, or may be performed in advance at the time of manufacturing the solar cell modules 1A, 1A, ... In the factory. In this example, after completing the wiring work on the ground, the solar cell module 1
A, 1A, ... Are fried on the roof and placed so as to straddle between the long lower frames 61, 61 arranged in parallel with each other.
Specifically, of the four side edges of the solar cell modules 1A, 1A, ..., the side with the lead wire insertion holes 31a, 31a is directed to the lower frame 61 side, and the lead wire insertion holes 31a, 31a.
Locking recessed steps 31b, 31b of the end sealing member 3 on the side with
The end sealing member 3 is placed on the lower frame 61 by abuttingly locking the module mounting portion (upper corner portion) 612 of the lower frame 61. As shown in FIG. 9B, for example, after mounting the solar cell modules 1A, 1A, ... In the left column on the lower frame 61, the solar cell modules 1A, 1A ,. At this time, the male waterproof connector 41 and the female waterproof connector 42 are connected and placed.

Thus, all solar cell modules 1
When the placement of A, 1A, ... Is completed, the upper frames 62, 62 ,.
Are fried on the roof 7, and the solar cell module 1 is mounted on the lower frames 61, 61, ...
The upper frames 62a, 62b, ... Are stacked in such a manner that the end sealing members 3, 3 ,. Then, pass the screws B2, B2, ... through the insertion holes of the lower frame fixing portion 621,
The lower frame 61 is screwed into the female screw holes N, N, .... Due to the generation of the fastening force of the screws B2, B2, ... Accompanying this, the end portion sealing member 3 of each solar cell module 1A moves to the upper frames 62a, 6
The module holding portion 622 of 2b strongly presses and fixes the module mounting portion 612 of the lower frame 61. As shown in the figure, the upper frame 62a is used at a connecting portion between the solar cell modules 1A, 1A, ... In the left column and the solar cell modules 1A, 1A ,.
As shown in FIG. 10, 2b is used at the outermost portion of the solar cell array (non-connection portion of solar cell modules 1A, 1A, ...). In this way, as shown in FIG. 12, a solar cell array composed of a large number of solar cell modules 1A, 1A, ... Connected to each other by external lead wires 4, 4 is completed on the roof 7.

As described above, according to the configuration of this example, the lead wire insertion holes 31a and 31a are provided not in the lower frame 61 (dedicated mounting frame) but in the end sealing member 3, so that the solar cell module is provided. Before the 1A, 1A, ... Are fried on the roof 7, the wiring work can be completed (for example, at the factory). Therefore, it is possible to reduce the on-site work burden of electric wiring work when installing a large number of solar cell modules in an array on the roof. Further, since the lead wire insertion holes 31a, 31a are formed at the same time as the molding of the end portion sealing member 3 and the productivity is improved, even if the lead wire insertion holes 31a, 31a are provided,
As a whole, there is no increase in cost.

Second Embodiment FIG. 13 is a view showing the arrangement of a solar cell module according to the second embodiment of the present invention. FIG. 13 (a) is a perspective view showing the front side of the solar cell module. FIG. 2B is a perspective view showing the back side of the solar cell module. The solar cell module 1B of this example is greatly different from the solar cell module 1A of the first embodiment described above in that instead of the lead wire insertion hole 31a, a rectangular notch 8 for passing the external lead wire 4 is provided. It is a point. Along with this, the mating die (not shown) used in this example is greatly different from the mating die 5 of the first embodiment in that the pin fitting holes 53a, 53 are provided.
.. and the pin members 54, 54 are eliminated, and instead, a shallow bottom portion for forming the notch 8 for wire passage is provided in the annular groove. According to the configuration of the second embodiment, it is possible to obtain substantially the same effect as that described in the first embodiment. For example, if an adhesive or an auxiliary tool such as a fastener is used, it is possible to previously pass the external lead wire 4 through the cutout 8 for the wire. In addition, since it is possible to omit the work of mounting and withdrawing the pin member on the mating die, the operation at the time of molding becomes simple.

The embodiment of the present invention has been described in detail above with reference to the drawings. However, the specific structure is not limited to this embodiment, and there are design changes and the like within the scope not departing from the gist of the present invention. Also included in the present invention. For example, the number of lead wire insertion holes (wiring openings) can be increased or decreased as appropriate, the shape is arbitrary, and the placement location can be changed as appropriate.

Further, in the above-mentioned embodiment, the case where the two-component curing type urethane resin raw material is used as the material of the end sealing member is described, but the present invention is not limited to this, and the two-component mixing curing type epoxy resin is used. Is also good. Further, not limited to the two-component mixed curable resin, for example, polyethylene, polypropylene, polycarbonate, polyamide, polyacetal, polyethylene terephthalate, chlorinated polyethylene, polystyrene, polyester amide, polyphenylene sulfide,
Polyether ester, soft polyvinyl chloride, polymethacrylic acid ester, polyacrylic acid ester, polymethylmethacrylate, fluororesin, sulfone resin, ethylene-vinyl acetate copolymer, vinyl chloride-vinylidene chloride copolymer, polyvinyl butyral, Polyvinylidene fluoride,
Thermoplastic resins such as styrene-acrylic copolymers, silicone resins, urea resins, melia resins, thermosetting resins such as melamine / phenol resins, metal-containing plastics, reinforced resins compounded with glass fibers, EPDM (ethylene-
Synthetic rubbers such as propylene-diene-terpolymer) can be preferably used depending on the required performance such as moisture resistance, fire resistance, elasticity, and weather resistance.

Not only single crystal silicon solar cells, but also polycrystalline silicon solar cells, amorphous silicon solar cells, compound semiconductor solar cells, and organic semiconductor solar cells may be selectively enclosed if necessary. good.
The solar cell module described above is not limited to being mounted on an existing roof, but may be mounted and fixed in advance on a roof panel, a roof unit, or a roofed building unit at a factory.

[0035]

As described above, according to the configuration of the present invention, the notch for wiring or the opening for wiring is provided in the end sealing member, not in the mounting base, so that the solar cell module is mounted on the roof. Prior to frying, line work can be completed (eg at the factory). Therefore, it is possible to reduce the on-site work burden of electric wiring work when installing a large number of solar cell modules in an array on the roof. Further, since the wiring notch or the wiring opening is also molded at the same time when the end sealing member is molded, the productivity is improved. Therefore, even if the wiring notch or the wiring opening is provided, the overall cost does not increase. .

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a solar cell module according to a first embodiment of the present invention, in which FIG. 1 (a) is a perspective view in which the front side of the solar cell module can be seen, and FIG. It is a perspective view which can see the back side of a battery module.

FIG. 2 is a sectional view taken along the line AA of FIG.

FIG. 3 is a sectional view taken along the line BB of FIG.

FIG. 4 is a cross-sectional view schematically showing a configuration of a solar cell panel that is a main body portion of the solar cell module.

FIG. 5 is a perspective view schematically showing a configuration of an end sealing member molding die used in the method for manufacturing the solar cell module.

6 is a diagram showing the structure of the mold, FIG. 6 (a) is a sectional view taken along line CC of FIG. 5, and FIG. 6 (b) is a sectional view taken along line DD of FIG. is there.

FIG. 7 is a view showing a state where the solar cell panel is housed in the mold, FIG. 7A is a sectional view corresponding to FIG. 6A, and FIG. 7B is corresponding to FIG. 6B. FIG.

FIG. 8 is a cross-sectional view showing a state in which the liquid resin raw material of the end sealing member is injected into the same mold that houses the solar cell panel.

FIG. 9 is a view showing a roof mounting structure of the solar cell modules arranged in two rows on both sides, FIG. 9 (a) is a cross-sectional view in which a lead wire insertion hole does not appear, and FIG. 9 (b) is a lead. It is sectional drawing in which a wire insertion hole appears.

FIG. 10 is a cross-sectional view showing a roof mounting structure of the solar cell modules arranged in one row on one side.

FIG. 11 is an exploded perspective view showing the mounting structure of FIGS. 9 and 10 in an exploded manner.

FIG. 12 is a perspective view showing a roof with a solar cell module in which the mounting structure of FIGS. 9 and 10 is adopted.

FIG. 13 is a diagram showing a configuration of a solar cell module according to a second embodiment of the present invention, in which FIG. 13 (a) is a perspective view showing the front side of the solar cell module, and FIG. It is a perspective view which can see the back side of a battery module.

[Explanation of symbols]

1A solar cell module 2 solar panel 21 Silicon solar cells (solar cells) 22 Transparent glass substrate (transparent plate) 24 Back cover material 25 terminal box 3 Edge sealing member 31 Side wall (side wall part) 31a Lead wire insertion hole (opening for wiring) 4 External lead wire (electrical wiring) 41 Male Waterproof Connector 42 female waterproof connector 5 Mold for molding the end sealing member (matching mold) 5a Table type 5b back type 51 panel storage 52 Cavity part (cavity) 53 annular groove 53a Pin fitting hole 54 pin member 55 mixing head 56 Gate M Liquid kneading resin composition (polymer raw material) 61 Lower frame (long frame) 612 Module mounting part 613 Roof fixing part 62a, 62b Upper frame (long pressing member) 622 Module retainer B1, B2 screw (fixture) 7 roof 8 cutouts for wiring (cutouts for wiring)

─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Atsushi Hasegawa 32 Wadai, Tsukuba, Ibaraki Prefecture Sekisui Chemical Co., Ltd. (72) Inventor, Souta Morohuchi 22-22 Nagaike, Abeno-ku, Osaka (72) Inventor Cycle Sugita 22-22 Nagaikecho, Abeno-ku, Osaka-shi, Osaka Prefecture Sharp Corporation (72) Inventor Satoshi Fujii 22-22 Nagaike-cho, Abeno-ku, Osaka City, Osaka Prefecture (72) Inventor Tanaka Satoshi, 22-22 Nagaike-cho, Abeno-ku, Osaka City, Osaka Prefecture (56) References JP-A-4-343481 (JP, A) JP-A-57-162473 (JP, A) JP-A-8-139353 ( JP, A) JP-A-7-153985 (JP, A) JP-A-8-167730 (JP, A) JP-A-9-219532 (JP, A) Actually developed 63-108652 (JP, U) (58) )investigated Field (Int.Cl. ^7, DB name) H01L 31/04 - 31/078

Claims (4)

(57) [Claims] 1. A solar cell is provided on the back surface of a transparent plate,
Further, after forming a solar cell panel by covering with a back cover material, the peripheral end of the solar cell panel is sealed with a frame-shaped end sealing member, and the side wall of the end sealing member is formed. A method for manufacturing a solar cell module, which crawls under the solar cell panel to form a wiring notch or a wiring opening for passing an electric wiring for extracting electric power from the solar cell, thereby completing the solar cell module. An injection molding consisting of a pair of a front mold having an inner surface shape substantially conforming to the outer surface shape of the solar cell module and a back mold having an inner surface shape substantially conforming to the outer surface shape of the back side of the solar cell module. After the solar cell panel is housed in the alignment mold with a cavity left in the peripheral edge of the alignment mold, the cavity is defined by the alignment mold and the solar cell panel. The polymer material for the end sealing member is injected, shaped and solidified to mold the end sealing member into a frame shape, and the solar cell panel is formed by the molded end sealing member. A method for manufacturing a solar cell module, which comprises sealing the peripheral edge portion of the. 2. An annular groove for molding a side wall portion of the end portion sealing member is provided in a peripheral portion of the back mold,
The method for manufacturing a solar cell module according to claim 1, wherein the annular groove is provided with a shallow bottom portion for forming the wiring notch. 3. An annular groove for molding a side wall portion of the end portion sealing member is provided in a peripheral portion of the back mold,
In addition, a pin member for forming the wiring opening is detachably inserted into the annular groove in such a manner as to protrude from one groove wall of the annular groove and enter the other groove wall. The method for manufacturing a solar cell module according to claim 1, wherein. 4. The end mold sealing member is molded into a frame mold by kneading and injecting a plurality of polymer compounds that are hardened when mixed with each other into the molding die and shape-solidified. The method of manufacturing a solar cell module according to claim 1, 2, or 3, wherein a peripheral end portion of the solar cell panel is sealed.