JP3785263B2 - Solar cell module and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
In particular, the present invention relates to a solar cell module and a manufacturing method thereof for enabling mass production, that is, full automation.
[0002]
[Prior art]
Conventionally, the production of solar cell modules has mostly relied on handmade processes. FIG. 6 is a cross-sectional view showing the structure of the solar cell module 50 in one stage of the manufacturing process of the polycrystalline or single crystal type solar cell module. In FIG. 6, 51 is a solar battery in which solar cells are assembled and electrically connected in a matrix, and 52 and 53 are transparent laminated and bonded to the front surface side (lower side in the drawing) and back surface side of the solar cell 51. Filler made of flat resin such as EVA resin (ethylene / vinyl / acetate resin), 54 is a protective plate made of a transparent member such as a glass plate laminated and bonded to the front side filler 52, and 55 is a back side filler 53. It is a back material made of a weather-resistant film or the like laminated and bonded. The front-side filler 52 and the back-side filler 53 also cover the side edges of the solar cell 51, and the front-side filler 52 and the back-side filler 53 are integrated for the covering. That is, the solar cell 51 is sandwiched between the protective plate 54 and the back surface material 55 with the fillers 52 and 53 interposed therebetween, and is integrated by heating and pressing in this state, and the whole It is configured in a flat plate shape.
[0003]
Since the solar cell module is installed in a place exposed to sunlight and outside air, it receives rainwater. The front and back fillers 52 and 53 are intended to prevent rainwater from entering the solar cell 51 and hindering its function. Since rainwater is likely to enter from the end face, sufficient attention is paid to the end face treatment. Therefore, a sufficiently large amount of fillers 52 and 53 are filled until the filler peripheral portion 56 in which the front surface side filler 52 and the back surface side filler 53 are integrated at the end protrudes to the outside of the end portion of the protective plate 54. Like to do. Since a sufficiently large amount of the fillers 52 and 53 are filled before such a protruding portion 56a occurs, the filling amount of the filler peripheral portion 56 is sufficient, and the rainwater intrusion prevention function is enhanced. The reason for making such an extra protruding portion 56a is that the EVA resin constituting the fillers 52 and 53 contracts when the whole is integrated by heating, so that the extra portion is filled in anticipation of the contraction. There is also a reason. Therefore, in the process of manufacturing the solar cell module 50, the dimensions of both the fillers 52 and 53 and the dimension of the back material 55 are set in advance so as to be larger than the dimensions of the protective plate 54. However, as shown in FIG. 7, the protruding portion 56 a causes resin to adhere to other objects, becomes unsightly in shape, and interferes when the solar cell module 50 is attached to the frame. The entire periphery of the protruding portion 56a is cut and removed manually using a cutter 57, and a sealing tape 58 made of waterproof butyl rubber is manually wrapped around the cut end surface as shown in FIG. The reduction in waterproofness due to the removal of the protruding portion 56a is compensated. 58a is a release paper.
[0004]
[Problems to be solved by the invention]
The process of cutting and removing the excess protruding portion 56a of the filler peripheral portion 56 with the cutter 57 is performed manually, and the process of winding the sealing tape 58 around the cut end face after the cutting is also performed manually. It is very difficult to automate this process. In addition, the protruding portion 56a of the filler 52.53 made of EVA resin removed by cutting and the part of the back material 55 made of weathering film cannot be recycled and are discarded, so that the material is wasted. Has occurred. Due to these manual work and material destruction, the cost of the solar cell module is increased.
[0005]
The present invention proposes a structure suitable for automation suitable for mass production in view of increasing demand for solar cell modules in recent years, and aims to reduce costs.
[0006]
[Means for Solving the Problems]
The solar cell module according to claim 1 of the present invention has the following configuration. That is, a solar cell, a filler that is provided on each of the front and back surfaces of the solar cell and encapsulates the solar cell, and a protective plate that is provided on one side of the filler A solar cell module having a super straight structure in which a frame is bonded to the side surface of the peripheral portion of the entire member , and a back material is provided on the other surface side of the filler, and the protective plate The outer peripheral size is set larger than the outer peripheral size of the filler , and the protective plate peripheral plate surface portion and the back surface are in a state where the peripheral edge of the back material is in contact with the plate surface of the protective plate at a position inside the side edge of the protective plate. A step portion is formed between the sealing material and a sealing resin made of silicone resin that seals the periphery of the filler.
[0007]
In order to prevent rainwater from entering solar cells, it is not sufficient to use only the front and back surface fillers. In particular, the periphery of the filler material is required to have strong waterproof properties. In the present invention, however, the stepped portion is coated with a sealing resin. As a result, waterproofness is strong. In addition, there is no excess protrusion around the filler as in the conventional case. Naturally, the protrusion is cut manually with a cutter and the sealing tape is manually wound around the cut surface. The structure is made unnecessary. Moreover, it has a structure in which waste associated with discarding the cut off protruding portion does not occur. Furthermore, it is a structure which can coat sealing resin to a level | step difference part, moving the dispenser of sealing resin by using a level | step difference part as a guide. That is, it has a structure suitable for automation suitable for mass production accompanying the recent increase in demand for solar cell modules. And the solar cell module manufactured by automation in this way is advantageous in reducing the cost.
[0008]
The filler is composed of EVA resin (ethylene vinyl acetate resin). The filler made of EVA resin exhibits a very high waterproof property, but is relatively expensive. However, unnecessary cutting and discarding of unnecessary items as described above is unnecessary, and unnecessary cost increase can be avoided.
[0009]
The sealing resin is a silicone resin. Higher waterproof performance than when sealing with butylene rubber.
[0010]
The method for manufacturing a solar cell module according to claim 2 of the present invention includes the following steps. That is, the present invention provides a protective plate having an outer peripheral size larger than the outer peripheral size of the filler composed of EVA resin (ethylene vinyl acetate resin) provided on the front and rear surfaces of the solar cell . On the surface, after laminating the front side filler, solar cell, back side filler in this order and encapsulating the solar cell between the front and back side fillers, laminating the back side material on the upper surface of these fillers , By setting the peripheral edge of the back material in contact with the plate surface of the protective plate at a position where the side edge of the protective plate is inside, a step portion is formed between the protective plate peripheral surface portion and the back material , The whole is heated and pressurized to integrate the whole, and then the stepped portion is coated with a sealing resin made of a silicone resin for sealing the periphery of the filler, and after the sealing resin is cured, the frame body Are joined. The present invention is an automatic manufacturing method of a solar cell module using the structure of the solar cell module of claim 1. In addition, the step portion can be used as a guide, and the step portion can be filled with sealing resin. Therefore, the number of man-hours can be reduced as much as possible as a whole, and each process can be carried out efficiently. Therefore, it is suitable for mass production, stabilization of quality, improvement of reliability, and reduction of product cost can be achieved.
[0011]
According to a third aspect of the present invention, there is provided a method for manufacturing a solar cell module according to the second aspect , wherein the discharge port of the dispenser containing the sealing resin is moved from the discharge port while moving the discharge port along the stepped portion. The step resin is coated on the stepped portion. A sealing resin can be supplied very efficiently and stably over the stepped portion.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of a solar cell module according to the present invention will be described in detail with reference to the drawings.
[0014]
1 is a perspective view of a disassembled state of a solar cell module according to an embodiment, FIG. 2 is an enlarged cross-sectional view showing an end surface treatment state in one stage of a manufacturing process, and FIG. 3 shows a state of coating with a sealing resin. It is a schematic perspective view. 2 and FIG. 3 have the vertical (front and back) positional relationship opposite to that in FIG.
[0015]
As shown in FIGS. 1 and 2, the solar cell module 10 includes a solar cell 11, a front surface side filler 12, a back surface side filler 13, a protective plate 14, a back surface material 15, and a sealing resin 16 for end surface treatment. As a component. The solar cell 11 has a rectangular plate-like super straight structure in which polycrystalline or single crystal solar cells 11a are arranged in a matrix and electrically connected in series or in parallel by an interconnector or the like. The front and back surface fillers 12 and 13 are made of a transparent resin such as EVA resin (ethylene vinyl acetate resin) into a rectangular flat plate shape, and prevent rainwater from entering the solar cell 11. It has a function. The protection plate 14 is formed in a rectangular flat plate shape from a transparent and high strength plate material such as a glass plate or a transparent film. The protective plate 14 becomes a surface on which sunlight is incident when the solar cell module is used. The back material 15 is formed in a rectangular flat plate shape from a weather resistant film made of resin, glass or metal. As the sealing resin 16, for example, a synthetic resin adhesive such as silicone resin or a synthetic rubber adhesive such as silicone rubber is used.
[0016]
Describe the preparatory work. This will be described with reference to FIG. The front surface side filler 12 and the back surface side filler 13 are cut so as to be slightly larger than the size of the solar cell 11 and smaller than the size of the protective plate 14. Since the peripheral edge of the solar cell 11 is covered, the filler peripheral portion 17 integrated in the peripheral portion is in a state of slightly bulging outward from the peripheral edge of the solar cell 11 in the planar direction. The bulging filler peripheral portion 17 has a cross-sectional shape and does not have a right-angled corner portion but is curved. The protective plate 14 is cut so that the size is slightly larger than the size of the filler peripheral portion 17. The back material 15 is cut as follows. The peripheral edge 15a of the back material 15 covers the surface of the filler peripheral portion 17 in a state along the curved shape, but the edge 15b of the peripheral edge 15a of the back material 15 is located inside the side edge 14a of the protective plate 14. The back surface material 15 is cut into a size that comes into contact with the plate surface of the protective plate 14 at the entered position.
[0017]
Next, the process of manufacturing the solar cell module 10 by integrating the elements will be described with reference to FIG. Although FIG. 2 is a cross-sectional view, hatching is omitted for easy understanding. In this description, when referring to FIG. This is because the up-and-down (front and back) relationship is reversed between use and manufacture.
[0018]
As shown in FIG. 2A, the solar cell 11 is laminated on the protective plate 14 with the surface-side filler 12 turned upside down, and the back-side filler 13 is laminated on the solar cell 11. In this lamination, the peripheral portions of the front and back fillers 12 and 13 are in a state of slightly protruding outward from the side edges of the solar cell 11. This protruding state extends over the entire circumference. As shown in FIG. 2 (b), the fillers 12 and 13 on the front surface and the back surface that protrude from the side edge of the solar cell 11 hang down under their own weight to be integrated into a filler peripheral portion 17. As described above, the filler peripheral portion 17 bulges from the side edge of the solar cell 11 and is curved. This filler peripheral portion 17 also extends over the entire circumference.
[0019]
Next, as shown in FIG. 2C, the back surface material 15 is laminated on the back surface side filler 13. In this lamination, the peripheral edge 15a of the back material 15 is coated on the filler peripheral portion 17 along the curved shape. Such a coating extends over the entire circumference. It is natural to prevent rainwater from entering the solar cell 11. At this time, the lamination is performed in a state where the peripheral portion 17 of the filler material 17 and the peripheral edge 15a of the back material 15 are located on the inner side of the side edge 14a of the protective plate 14. Although it repeats, it is set as the state which touches the board surface of the protection board 14 in the position where the edge 15b of the peripheral edge 15a of the back surface material 15 entered inside the side edge 14a of the protection board 14. With such a lamination, in the peripheral portion of the protective plate 14, the step portion 18 is provided between the plate surface of the protective plate 14, that is, the protective plate peripheral plate surface portion 14 b, the filler peripheral portion 17, and the peripheral edge 15 a of the back material 15. Make a. The step portion 18 also extends over the entire circumference. The step portion 18 is a location where the sealing resin 16 is coated in a later process.
[0020]
Next, an integrated process is performed on the product manufactured in the state of FIG. That is, the whole structure having the structure shown in FIG. 2C is integrated by passing through a laminating process in which a vacuum is applied after heating at a temperature of about 150 ° C.
[0021]
Next, as shown in FIG. 2 (d), the stepped portion 18 formed between the protective plate peripheral plate surface portion 14 b of the protective plate 14 and the peripheral edge 15 a of the back material 15 is sealed with silicone resin or the like. The resin 16 is coated, and the sealing resin 16 coated by heating is dried and cured. In the coating of the sealing resin 16, as shown in FIG. 3, a dispenser 19 filled with the sealing resin in advance is used. The dispenser 19 is moved by an XY traverser through a holder (not shown) in an arbitrary direction on an XY two-dimensional plane by an arbitrary distance. Therefore, by inputting the shape and dimensions of the solar cell module 10 to the XY traverser in advance, the piston of the syringe of the dispenser 19 is driven while the discharge port of the dispenser 19 is moved along the stepped portion 18. Thus, the sealing resin 16 can be discharged and filled in the stepped portion 18. The filling of the sealing resin 16 extends over the entire circumference. The sealing resin 16 filled in the stepped portion 18 is coated over the protective plate peripheral plate surface portion 14 b of the protective plate 14 and the peripheral edge 15 a of the back surface material 15 to ensure waterproofness to the solar cell 11. If a fast-curing resin is used as the sealing resin 16, the heating step for drying and curing after coating can be omitted or simplified.
[0022]
All the above processes are performed automatically by the manufacturing apparatus. Thereby, the rectangular flat solar cell module 10 is produced.
[0023]
As is apparent from a comparison between the state of FIG. 6 where the conventional protruding portion 56a is formed and FIG. 2 (c) where the stepped portion 18 of the present embodiment is formed, in this embodiment, the extra portion as in the conventional case is used. Manual cutting with the cutter 57 of the protruding portion 56a is not necessary. Further, when filling the stepped portion 18 with the sealing resin 16, the dispenser 19 can be moved with the stepped portion 18 as a reference for the traverse, so the filling of the stepped portion 18 with the sealing resin 16 can be automated, There is no need to manually wind the sealing tape 58 around the cut end face as in the conventional case. There is no need to waste the material without discarding the cut portion (the protruding portion 56a of the filler material made of EVA resin and part of the back surface material made of the weather resistant film attached thereto) as in the past. .
[0024]
In the above embodiment, the fillers 12 and 13 on the front and back surfaces in the solid state are laminated on the solar cell 11, but instead of this, the filler material having fluidity by increasing the temperature is used for the solar cell. You may make it apply | coat automatically with respect to 11 front and back both surfaces.
[0025]
FIG. 4 shows a solar cell panel 30 with a frame made using the polycrystalline or single crystal solar cell module 10 manufactured as described above. (A) of a figure is a top view, (b) is a front view. A metal or synthetic resin frame 31 is joined to the solar cell 11 with electrical and thermal insulation properties on the four side surfaces of the peripheral portion of the solar cell module 10. The surface of the solar cell panel 30 is a protective plate 14 such as a glass plate.
[0026]
FIG. 5 shows a frameless solar cell panel 40 made using the polycrystalline or single crystal solar cell module 10 manufactured as described above. (A) of a figure is a top view, (b) is a front view. Although not shown in FIG. 4, a terminal box 41 is attached to the back surface, and an output cable 42 extending from the terminal box 41 is wired.
[0027]
【The invention's effect】
According to the solar cell module of the first aspect of the present invention, the operation of cutting the excess protruding portion around the filler as in the conventional case with a cutter by hand and sealing the cut surface manually. It has a structure that eliminates the need to wind the tape, and there is no waste associated with discarding the cut-out protruding part. Also, while moving the sealing resin dispenser using the stepped part as a guide, the sealing resin It is relatively easy to automate its manufacture and is suitable for mass production, so it is inexpensive while ensuring stable quality and reliability. Solar cell module.
[0028]
In addition, since highly waterproof EVA resin (ethylene / vinyl / acetate resin) is used as the filler, it is not necessary to cut off and discard unnecessary items, thereby avoiding unnecessary cost increase.
[0029]
Further, by making the sealing resin and silicone resin, it exhibits high waterproofness than are butyl rubber.
[0030]
Since the manufacturing method of the solar cell module according to claim 2 of the present invention is an automatic manufacturing method using the structure of the solar cell module according to claim 1, the peripheral portion of the filler as in the conventional case is used. The cutting process of the extra protrusion part is made unnecessary, and the operation | work which winds a sealing tape around a cut surface is made unnecessary. In addition, the step portion can be used as a guide, and the step portion can be filled with sealing resin. Therefore, the number of man-hours can be reduced as much as possible as a whole, and each process can be carried out efficiently. Therefore, it is suitable for mass production, stabilization of quality, improvement of reliability, and reduction of product cost can be achieved.
[0031]
According to the method for manufacturing a solar cell module of claim 3 according to the present invention, the sealing resin is discharged from the discharge port while moving the discharge port of the dispenser storing the sealing resin along the stepped portion. Since the step portion is coated, the sealing resin can be supplied very efficiently and stably.
[Brief description of the drawings]
FIG. 1 is a perspective view of a disassembled state of a solar cell module according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view showing an end face processing state at one stage of the manufacturing process in the embodiment.
FIG. 3 is a schematic perspective view showing a state of coating with a sealing resin in the embodiment.
FIGS. 4A and 4B are a plan view and a front view showing a solar cell panel with a frame made using a solar cell module. FIGS.
FIGS. 5A and 5B are a plan view and a front view showing a frameless solar cell panel made using a solar cell module. FIGS.
FIG. 6 is a cross-sectional view of a conventional solar cell module manufacturing process in one stage.
FIG. 7 is a perspective view showing a cutting operation of a protruding portion around a filler in the case of a conventional technique.
FIG. 8 is a perspective view showing a sealing tape winding operation in the case of a conventional technique.
[Explanation of symbols]
10 ... Solar cell module 11 ... Solar cell 11a ... Solar cell 12 ... Surface side filler (EVA resin)
13 …… Back side filler (EVA resin)
14 ... Protective plate (glass plate)
14a ... side edge 14b of protective plate ... protective plate peripheral plate surface 15 ... back material (weather-resistant film)
15a ... Rear edge 15b ... Rear edge 16 ... Sealing resin (silicone resin)
17 …… Filler peripheral part 18 …… Step part 19 …… Dispenser

Claims (3)

A solar cell, a filler made of EVA resin (ethylene / vinyl / acetate resin) provided on each of the front and back surfaces of the solar cell and enclosing the solar cell, and a protective plate provided on one side of the filler A solar cell module having a super straight structure in which a frame is joined to the side surface of the peripheral portion of the entire member ,
A position where the back surface material is provided on the other surface side of the filler, the outer peripheral size of the protective plate is set larger than the outer peripheral size of the filler , and the peripheral edge of the back material enters the inner side edge of the protective plate A stepped portion is formed between the protective plate peripheral plate surface portion and the back surface material in a state of being in contact with the plate surface of the protective plate, and a sealing resin made of silicone resin for sealing the periphery of the filler is formed on the stepped portion. A solar cell module characterized by being arranged. A protective plate having an outer peripheral size larger than the outer peripheral size of the filler composed of EVA resin (ethylene / vinyl / acetate resin) provided on each of the front and rear surfaces of the solar cell is prepared. After laminating the filler, the solar cell, and the back side filler in this order and encapsulating the solar cell between the front and back side fillers, laminating the back side material on the upper surface of these fillers , the peripheral edge of the back side material By setting the edge in contact with the plate surface of the protective plate at the position inside the side edge of the protective plate, a step portion is formed between the peripheral surface portion of the protective plate and the back material, and the whole is heated and pressurized. The entire step is then integrated, and then the stepped portion is coated with a sealing resin made of silicone resin for sealing the periphery of the filler, and after the sealing resin is cured, the frame body is joined. Super straight structure Method of manufacturing a solar cell module. A method for producing a solar cell module according to claim 2 ,
A method for manufacturing a solar cell module, comprising: coating the stepped portion with the sealing resin from the discharge port while moving a discharge port of a dispenser containing the sealing resin along the stepped portion.

Images