JP6498053B2 - Manufacturing method of solar panel - Google Patents

Description

The present invention relates to a method for manufacturing a solar panel.

  Patent Document 1 discloses a conventional solar panel. This solar panel includes a panel body and an edge member. Although details of the structure of the panel main body are unknown in this document, generally, a protective cover having translucency from the front surface to the back surface, a plurality of solar cells, a sealing material, and a back surface of the sealing material And a back cover fixed to the head. The sealing material fixes each photovoltaic cell in a sealed state between the protective cover and the back cover.

  The edge member is composed of an adhesive sealing material and a frame made of metal or the like. In this solar panel, first, a sealing material is attached to the entire periphery of the end portion of the panel body, and then the edge member is assembled to the panel body by inserting the end portion of the panel body together with the sealing material into the frame. Thereby, the entire periphery of the end portion of the panel body is surrounded by the edge member, and the space between the protective cover and the back cover is sealed. Thus, in this solar panel, water or the like is prevented from entering through the gap between the protective cover and the back cover, and the power generation performance due to scattering of light due to peeling of the protective cover and the sealing material or submersion of the solar battery cells is reduced. The decline is prevented.

JP 2011-54444 A

  However, in the above-described conventional solar panel, the number of parts increases because the edge member is composed of the sealing material and the frame. Moreover, in this solar panel, when assembling the panel main body to the edge member, it is necessary to stick a sealing material to the end portion of the panel main body, and to insert the end portion of the panel main body together with the sealing material into the frame. For this reason, in this solar panel, manufacture becomes complicated and manufacturing cost increases.

  In particular, in recent years, solar panels can also be provided on automobile roofs and the like. In this case, the panel body can be formed in a curved shape according to the shape of the roof or the like. For this reason, in said solar panel, it becomes difficult to insert the edge part of the panel main body which stuck the sealing material in a flame | frame, and also the frame needs to be curved and formed. For these reasons, the manufacturing complexity becomes more prominent, and the manufacturing cost increases.

The present invention has been made in view of the above-described conventional situation, and provides a solar panel manufacturing method capable of realizing a reduction in manufacturing cost while sealing between a protective cover and a back cover. Is a problem to be solved.

The manufacturing method of the solar panel of the present invention includes a protective cover having translucency from the front surface to the back surface, a solar battery cell, a sealing material, and a back cover, and the sealing material includes the protective cover and the A panel main body in which the solar battery cell is fixed in a sealed state with a back cover,
A method of manufacturing a solar panel provided with at least a part of an end portion of the panel main body, and a resin edge member capable of sealing between the protective cover and the back cover,
An injection molding machine comprising: an insertion port through which the panel main body can be inserted; a molding die in which a forming surface capable of forming the edge member in communication with the insertion port is formed; and an injection machine connected to the molding die Preparing, inserting the end of the panel body into the insertion port, and forming a cavity in the mold by the forming surface and the end of the panel body;
By the injection machine, the molten resin constituting the edge member is injected into the cavity, and the molten resin injected into the cavity is solidified, so that at least a part of the end portion of the panel body is An injection molding process for forming an edge member,
In the injection molding step, the panel body is moved relative to the injection molding machine while injecting the molten resin into the cavity ,
The forming surface is continuous with the inner wall of the mold facing the surface of the protective cover at the insertion port so that the edge member is substantially flush with the surface of the protective cover.
The protective cover is formed with an entry portion that enters the mold rather than the surface .

  In the solar panel of the present invention, an edge member is provided on at least a part of the end of the panel body. For this reason, in the location where the edge member was provided, between the protective cover and the back cover is sealed by the edge member, and water or the like can be prevented from entering between the protective cover and the back cover.

And in this solar panel, an edge member consists of resin directly injection-molded with respect to the edge part of a panel main body. Thereby, not only can the number of parts be reduced, but also the formation of the edge member and the assembly of the edge member to the panel body can be performed simultaneously. For these reasons, the manufacturing method can facilitate the manufacture of solar panels. Further, in this manufacturing method , even if the panel body has a curved shape, the edge member can be formed by following the shape of the panel body.

Therefore, according to the solar panel manufacturing method of the present invention, it is possible to manufacture a solar panel capable of realizing a reduction in manufacturing cost while sealing between the protective cover and the back cover.

Forming surface, the edge member, such a substantially flush with the surface of the protective cover Suyo, it is preferable that the continuous and the mold inner wall that faces the surface of the protective cover at the insertion opening. The surface of the protective cover constitutes the design surface of the panel body. For this reason, by making the edge member and the surface of the protective cover substantially flush with each other, that is, making the edge member substantially flush with the design surface of the panel body, the edge member becomes inconspicuous and the appearance of the solar panel is increased. Can do. Further, when the edge member is injection-molded on the panel body, the surface of the protective cover can be made difficult to be damaged by the injection molding machine. Note that “substantially flush” includes the case where the edge member and the surface of the protective cover are completely flush with each other and the case where a slight step inevitably occurs between the edge member and the surface of the protective cover during manufacturing. It is a concept.

  It is preferable that at least one of the protective cover and the back cover is formed with a wall portion capable of enclosing the sealing material. In this case, by forming a wall portion on the protective cover or the back cover, water or the like can be suitably prevented from entering between the protective cover and the back cover. Further, by enclosing the sealing material with the wall portion, in this solar panel, it is possible to prevent the protective cover and the sealing material from shifting due to expansion or contraction due to temperature change.

  The wall can be formed in a protective cover. The wall portion preferably extends toward the back cover while being in contact with the edge member, and is in contact with the surface of the back cover. In this case, even if the back cover is thermally expanded at the time of molding the panel body, the wall portion can be brought into contact with the surface of the back cover, so that the design of the protective cover and the back cover is facilitated.

  Further, the wall portion can be formed on the protective cover. The wall portion preferably extends toward the back cover while being in contact with the edge member, and is in contact with the side surface of the back cover. In this case, not only the sealing material but also the back cover can be surrounded by the wall portion. For this reason, it becomes possible to more suitably prevent water or the like from entering between the protective cover and the back cover.

  It is preferable that the edge member is provided in the outer region of the sealing material. In this case, it can prevent that a sealing material foams with the heat | fever at the time of injection-molding an edge member to a panel main body. For this reason, the performance fall of the solar panel by the sealing capability of a sealing material falling can be prevented.

According to the method for manufacturing a solar panel of the present invention, it is possible to manufacture a solar panel capable of realizing a reduction in manufacturing cost while sealing between the protective cover and the back cover.

1 is a top view showing a solar panel of Example 1. FIG. FIG. 2 is an enlarged cross-sectional view showing the AA cross section in FIG. 1 according to the solar panel of the first embodiment. FIG. 3 relates to the solar panel of Example 1, and is a cross-sectional view illustrating a preparation process in the manufacturing process of the panel body. FIG. 4 relates to the solar panel of Example 1, and is a cross-sectional view showing a sealing process in the manufacturing process of the panel body. FIG. 5 is a cross-sectional view illustrating the laminating process in the manufacturing process of the panel body according to the solar panel of the first embodiment. FIG. 6 is a cross-sectional view illustrating the preparation process in the manufacturing process of the edge member according to the solar panel of the first embodiment. FIG. 7 is a cross-sectional view illustrating the injection molding process in the manufacturing process of the edge member according to the solar panel of the first embodiment. FIG. 8 relates to the solar panel of the first embodiment and is an enlarged cross-sectional view of a main part showing a region X in FIG. FIG. 9 is an enlarged cross-sectional view of a main part showing a cross section in the same direction as the AA cross section in FIG. 1 according to the solar panel of the second embodiment. Figure 10 relates to a solar panel of Example 1, an enlarged fragmentary cross-sectional view showing the A-A cross section in the same direction of the cross section of FIG. FIG. 11 is an enlarged cross-sectional view of a main part showing a cross section in the same direction as the AA cross section in FIG. 1 according to the solar panel of Example 3 . 12 relates to the solar panel of Reference Example 2 , and is an essential part enlarged cross-sectional view showing a cross section in the same direction as the AA cross section in FIG.

Hereinafter, the present invention will be described with reference to Examples 1 to 3 and Reference Examples 1 and 2, which embody the present invention.

Example 1
As shown in FIG. 1, the solar panel of Example 1 includes a panel body 1 and an edge molding 3. The panel body 1 includes a protective plate 5, a plurality of solar cells 7, a plurality of tab wires 9a and 9b, a plurality of interconnectors 11a and 11b, a sealing material 13, and a back panel 15 shown in FIG. have. The protective plate 5 corresponds to the protective cover in the present invention, and the edge molding 3 corresponds to the edge member in the present invention. The back panel 15 corresponds to the back cover in the present invention. For ease of explanation, in FIG. 1, a part of the protective plate 5 is not shown by a broken line. For convenience of explanation, in FIG. 1, the front-rear direction and the left-right direction of the solar panel are defined by the arrow directions shown in the figure. And in FIG. 2 etc., each direction of a solar panel is prescribed | regulated corresponding to FIG. However, these directions are not related to the directions when the solar panel is used.

  As shown in FIG. 2, the protective plate 5 is formed of a resin whose main component is polycarbonate having translucency from the front surface 5a to the back surface 5b. The surface 5a of the protection plate 5 constitutes the surface of the panel body 1, that is, the design surface. The front surface 5a is formed flat and horizontally, and the back surface 5b is also formed parallel and flat with the front surface 5a. Thereby, as shown in FIG. 1, the protection plate 5 is formed in a substantially rectangular flat plate shape. The protective plate 5 may be formed of other resin, inorganic glass, or the like. Moreover, the thickness of the protective plate 5 can be designed suitably.

  Further, as shown in FIG. 2, a wall portion 5 c that extends toward the back panel 15 while being curved is formed on the outer peripheral edge of the protection plate 5. The wall 5c can surround the sealing material 13 over the entire circumference.

  Further, as shown in FIG. 1, a concealing portion 50 is formed on the protective plate 5. The concealing portion 50 includes a main body portion 50a capable of concealing each tab wire 9a, 9b from the surface 5a side of the protective plate 5, and a plurality of connecting portions 50b capable of concealing each interconnector 11a, 11b from the surface 5a side. Has been.

  The main body portion 50a and each connecting portion 50b are used to paint a predetermined position on the back surface 5b of the protective plate 5 with an opaque color such as black, or to print an opaque color such as black at a predetermined position on the back surface 5b. It is formed by. Specifically, the main body portion 50 a is formed at a position that is an outer region of each solar battery cell 7 in the protective plate 5, and has a frame shape surrounding each solar battery cell 7. Each connecting portion 50b is located inside the main body portion 50a, extends in the vertical direction of the protection plate 5, and is continuous with the upper end side and the lower end side of the main body portion 50a. Here, the number of the connecting portions 50b is defined according to the number of intervals between the solar cells 7 adjacent in the left-right direction. Moreover, the magnitude | size of the space | interval of each connection part 50b is prescribed | regulated corresponding to the magnitude | size of the space | interval of each photovoltaic cell 7 adjacent in the left-right direction. For ease of explanation, the main body portion 50a of the concealing portion 50 is not shown in FIGS.

  As shown in FIG. 1, crystalline silicon is adopted for each solar battery cell 7. Each of these solar cells 7 is arranged in a lattice shape in the vertical direction and the horizontal direction of the panel body 1. The size and number of solar cells 7 can be appropriately changed depending on the size of the panel body 1 and the like.

  The tab lines 9a and 9b are formed of a thin metal plate. The tab lines 9a and 9b are arranged on the right end side or the left end side of the panel main body 1. Further, the tab lines 9a and 9b are arranged at a predetermined interval. The tab wires 9a and 9b are connected to electrodes (not shown) of the solar cells 7 located in different rows, thereby connecting the solar cells 7 to each other so as to be energized.

  The interconnectors 11a and 11b are also formed of a thin metal plate. The interconnectors 11a and 11b are connected to electrodes (not shown) of the solar cells 7 adjacent in the left-right direction, so that the solar cells 7 are connected to each other so as to be energized. In addition to the shape and number of the tab wires 9a and 9b and the interconnectors 11a and 11b, the connection positions with the solar cells 7 can be changed as appropriate.

  As the sealing material 13 shown in FIG. 2, an ethylene vinyl acetate copolymer (EVA) is employed. As will be described later, the sealing material 13 includes sheet-shaped sealing materials 13a and 13b. The sealing material 13 is formed between the protection plate 5 and the back panel 15, and more specifically, between each of the solar cells 7 and each tab line 9 a between the back surface 5 b of the protection plate 5 and the surface 15 a of the back panel 15. 9b and each interconnector 11a, 11b are fixed in a sealed state. Thereby, the sealing material 13 is integrated with the protective plate 5 and the back panel 15, and also protects the solar cells 7 and the like fixed in a sealed state from deterioration due to moisture and oxygen. As the sealing material 13, for example, a silicon resin, a polyolefin, or the like can be employed in addition to the ionomer resin.

  The back panel 15 is formed of a metal plate such as an aluminum alloy. The back panel 15 is formed in a substantially rectangular flat plate shape, and includes a front surface 15a facing the back surface 5b and the sealing material 13 of the protective plate 5, a back surface 15b opposite to the front surface 15a, a front surface 15a, and a back surface. And a side surface 15c connected to 15b. The back panel 15 is provided on the back surface side of the sealing material 13, and together with the sealing material 13, protects each solar cell 7, each tab wire 9a, 9b, and each interconnector 11a, 11b from deterioration due to moisture or oxygen. . Further, the rear panel 15 ensures the rigidity of the panel body 1 when the protection plate 5 is not sufficiently rigid. The back panel 15 may be formed of a resin such as carbon fiber reinforced resin (CFRP). When the protective plate 5 is rigid enough to ensure the rigidity of the panel body 1, a thin film film made of, for example, polyetherketone (PEK) is used instead of the back panel 15. It may be adopted as a cover.

  The panel body 1 in this solar panel is manufactured as follows. First, as a preparation step, as shown in FIG. 3, a heatable vacuum forming jig 17 is prepared. Then, the protection plate 5 formed in advance is placed on the vacuum forming jig 17. At this time, the protection plate 5 is placed on the vacuum forming jig 17 with the surface 5 a facing the vacuum forming jig 17.

  Next, as shown in FIG. 4, as a sealing process, on the back surface 5 b side of the protective plate 5, the sheet-shaped sealing material 13 a, each solar cell 7, the sheet-shaped sealing material 13 b, and the back panel 15 are arranged. Arrange in order. At this time, the solar cells 7 are connected to each other so as to be energized by the tab wires 9a and 9b and the interconnectors 13a and 13b. Further, the back panel 15 is arranged with the front surface 15 a facing the back surface 5 b of the protection plate 5.

  After arranging each of these solar cells 7 and the like, a laminating process is performed. Specifically, as shown in FIG. 5, while pressing the diaphragm 19 toward the vacuum forming jig 17, each of the above components constituting the panel body 1, that is, between the vacuum forming jig 17 and the diaphragm 19. A vacuum is created between the members. Further, by heating the vacuum forming jig 17 simultaneously with the pressing of the diaphragm 19, the sealing materials 13a and 13b are softened and the members are brought into close contact with each other. Thereby, between the back surface 5b of the protection board 5, and the surface 15a of the back panel 15, each photovoltaic cell 7, each interconnector 11a, 11b, etc. are fixed in the sealing state. Thus, the panel body 1 is completed.

  Here, as described above, the wall portion 5 c extending toward the back panel 15 is formed on the outer peripheral edge of the protection plate 5. For this reason, in the panel main body 1 formed as described above, the sealing material 13 is surrounded by the wall portion 5c from the outer peripheral side as shown in FIG. Then, the protection plate 5 and the back panel 15 are joined in a state where the wall portion 5 c is in contact with the surface 15 a of the back panel 15 in the outer region of the sealing material 13.

  As shown in FIG. 2, the edge molding 3 is integrated with the panel body 1 by being joined to the end 1 a of the panel body 1. More specifically, the edge molding 3 is joined to the wall 5c of the protective plate 5 and a part of the side surface 15c to the back surface 15b of the back panel 15. Thus, as shown in FIG. 1, the edge molding 3 is provided over the entire circumference of the end portion 1 a of the panel body 1 and surrounds the entire panel body 1. The edge molding 3 is made of vinyl chloride resin (PVC). Further, as shown in FIG. 2, the edge molding 3 has a substantially rectangular cross section in a direction perpendicular to the vertical direction of the solar panel. The edge molding 3 may be formed of a resin such as ethylene propylene rubber (EPDM).

  This edge molding 3 is formed as follows. First, as shown in FIG. 6, as a preparation process, an injection molding machine 21 is prepared, and the panel body 1 is assembled to the injection molding machine 21. The injection molding machine 21 has a molding die 210 and an injection machine 211. The molding die 210 is formed with an insertion port 210a into which the panel body 1 can be inserted, a forming surface 210b in which the edge molding 3 can be formed, and an injection hole 210c opening in the forming surface 210b. The forming surface 210b communicates with the insertion port 210a. Here, in this mold 210, when the edge molding 3 is formed on the end 1a of the panel body 1, the surface 5a of the protection plate 5 and the edge molding 3 are substantially flush with each other, and the edge molding 3 is The formation surface 210b is formed so as to be thicker than the panel body 1. Specifically, the forming surface 210b is continuous with the inner wall of the mold 210 facing the surface 5a of the protection plate 5 at the insertion port 210a without a step, while the back surface 15b of the back panel 15 is at the insertion port 210a. And the inner wall of the mold 210 facing each other are formed in a continuous shape with a step in the thickness direction of the edge molding 3. The injection machine 211 is connected to the injection hole 210c and attached to the mold 210. Note that the formation surface 210b may be formed in another shape.

  In assembling the panel main body 1 to the injection molding machine 21, the end 1 a of the panel main body 1 is inserted into the insertion port 210 a of the mold 210. Thereby, the wall portion 5 c of the protection plate 5 and the side surface 15 c to a part of the back surface 15 b of the back panel 15 are arranged in the mold 210. At this time, the amount of insertion of the panel body 1 into the mold 210 is adjusted so that the sealing material 13 is not disposed in the mold 210. In this way, the panel main body 1 is assembled to the injection molding machine 21, and a cavity is formed in the mold 210 by the forming surface 210b, the wall portion 5c of the protective plate 5, and the side surface 15c to a part of the back surface 15b of the back panel 15. C1 is formed.

  Next, as shown in FIG. 7, as an injection molding process, the injection machine 211 moves the panel body 1 relative to the injection molding machine 21 while injecting the molten resin P1 constituting the edge molding 3 into the cavity C1. Let Specifically, with the end 1a inserted into the insertion port 210a, the panel main body 1 is moved to the front side or the back side of the paper surface with respect to the injection molding machine 21, and the panel main body is moved to the injection molding machine 21. Make 1 round. And the edge molding is joined to the edge part 1a of the panel main body 1 because the molten resin P1 inject | emitted in the cavity C1 solidifies. Thus, the edge molding 3 is continuously formed along the end 1a of the panel body 1. In addition, an edge molding 3 that is separately formed short is joined between the start point portion and the end point portion of the edge molding 3 formed at the end 1 a of the panel body 1. In this way, as shown in FIG. 1, the edge molding 3 is provided over the entire periphery of the end 1a of the panel body 1 so as to surround the panel body 1, and the solar panel is completed.

  The edge molding 3 formed in this way is substantially flush with the surface 5a of the protective plate 5, as shown in FIG. That is, in this solar panel, the design surface of the panel body 1 and the edge molding 3 are substantially flush. Further, the edge molding 3 protrudes in the thickness direction from the back surface 15 b of the back panel 15.

  Here, as described above, in this solar panel, when the edge molding 3 is formed, the insertion amount of the panel body 1 with respect to the molding die 210 is adjusted so that the sealing material 13 is not disposed in the molding die 210. ing. Thereby, in this solar panel, the edge molding 3 is provided in the outer region of the sealing material 13. More specifically, the edge molding 3 is provided in the end 1a of the panel body 1 at a position that is spaced from the sealing material 13 toward the outer side by a distance S1.

Thus, in the solar panel of Example 1 manufactured with the manufacturing method of this invention , the edge molding 3 is provided in the perimeter of the edge part 1a of the panel main body 1. FIG. For this reason, in this solar panel, between the protective plate 5 and the back panel 15 is sealed by the edge molding 3 between the protective plate 5 and the back panel 15 over the entire circumference of the panel body 1. Specifically, water or the like can be prevented from entering between the wall 5c of the protection plate 5 and the surface 15a of the back panel 15.

And in this solar panel, the edge molding 3 consists of vinyl chloride resin, and this edge molding 3 is provided in the edge part 1a of the panel main body 1 by being directly injection-molded with respect to the edge part 1a of the panel main body 1. FIG. ing. Thereby, in this manufacturing method , not only the number of parts can be reduced, but also the formation of the edge molding 3 and the assembly of the edge molding 3 to the panel body 1 can be performed simultaneously. For these reasons, according to this production method, the production of the solar panel can be facilitated.

Here, in this solar panel, the panel body 1 has a flat plate shape by forming the protective plate 5 and the back panel 15 in a flat plate shape. However, the present invention is not limited to this, and the panel main body 1 can be formed in a curved shape by forming the protective plate 5 and the back panel 15 in a curved shape. And even if the panel body 1 has a curved shape in this way , in this manufacturing method , the edge molding 3 is formed on the end 1a of the panel body 1 by injection molding the edge molding 3 on the panel body 1. It can be formed following the shape.

Therefore, according to the method for manufacturing a solar panel of the present invention, it is possible to manufacture the solar panel of Example 1 that can realize a reduction in manufacturing cost while sealing between the protective plate 5 and the back panel 15. it can.

In particular, in this manufacturing method , when the edge molding 3 is injection-molded in the panel body 1, the insertion amount of the panel body 1 with respect to the molding die 210 is adjusted so that the sealing material 13 is not disposed in the molding die 210. . For this reason, in this solar panel, the edge molding 3 is provided in the edge part 1a of the panel main body 1 in the position which separated the space | interval S1 from the sealing material 13 to the outer region side. Thus, by providing the edge molding 3 in the outer region of the sealing material 13, in this manufacturing method , the sealing material 13 is foamed by the heat of the molten resin P1 when the edge molding 3 is injection-molded on the panel body 1. Can be prevented. For this reason, in the solar panel manufactured with this manufacturing method, the performance fall by the sealing capability of the sealing material 13 falling can be prevented.

  Further, in this solar panel, the edge molding 3 is substantially flush with the surface 5a of the protective plate 5. Thereby, in this solar panel, by making the edge molding 3 substantially flush with the design surface of the panel body 1, the edge molding 3 becomes inconspicuous, and the beauty of the solar panel is enhanced. Further, in forming such an edge molding 3, the forming surface 210b of the forming die 210 has a continuous shape without a step with the inner wall of the forming die 210 facing the surface 5a of the protective plate 5 at the insertion port 210a. It is said. Thereby, when the edge molding 3 is injection-molded on the panel body 1, the surface 5 a of the protection plate 5 is hardly damaged by the molding die 210.

  Here, the protective plate 5 is formed with a wall portion 5 c that comes into contact with the surface 15 a of the back panel 15. Thereby, the sealing material 13 can be enclosed by the wall part 5c. For this reason, in this solar panel, it is not necessary to cut off the sealing material 13 protruding from the protective plate 5 and the back panel 15 after the laminating process, and the panel body 1 can be easily formed. Moreover, by enclosing the sealing material 13 by the wall part 5c, in this solar panel, it can prevent that the sealing material 13 and the protective plate 5 slip | deviate by expansion | swelling and shrinkage | contraction by a temperature change.

  Further, in this solar panel, when the edge molding 3 is provided at the end 1a of the panel body 1, the edge molding 3 includes the wall portion 5c of the protective plate 5, and part of the side surface 15c to the back surface 15b of the back panel 15. Therefore, a large contact area between the panel body 1 and the edge molding 3 can be secured. For this reason, it is possible to suitably seal between the protective plate 5 and the back panel 15 by the edge molding 3, and it is difficult for the end 1a of the panel body 1 and the edge molding 3 to peel off. .

  Furthermore, since the wall 5c contacts the surface 15a of the back panel 15, even if the back panel 15 is thermally expanded when the panel body 1 is formed, the wall 5c is brought into contact with the surface 15a of the back panel 15. Can do. For this reason, in this solar panel, the protection plate 5 and the back panel 15 can be easily designed.

  In this solar panel, a concealing part 50 is formed on the protective plate 5. For this reason, even when the solar panel is viewed from the surface 5a side of the protective plate 5, the tab wires 9a, 9b and the interconnectors 11a, 11b are not visible. In this respect as well, this solar panel has high aesthetics.

(Example 2)
As shown in FIG. 9, in the solar panel of Example 2, in the panel main body 1, the sealing material 13 and the back panel 15 are surrounded by the wall portion 5 c of the protection plate 5. The wall portion 5 c is in contact with the side surface 15 c of the back panel 15. Further, in this solar panel, the edge molding 3 is injection-molded on the end 1a of the panel body 1, so that the edge molding 3 is formed by the wall portion 5c of the protection plate 5 and a part of the back surface 15b of the back panel 15. To be joined. Here, in this solar panel, a part of the edge molding 3 is provided so as to overlap the sealing material 13. Other configurations of the solar panel are the same as those of the solar panel of the first embodiment, and the same reference numerals are given to the same configurations, and detailed descriptions of the configurations are omitted.

  In this solar panel, not only the sealing material 13 but also the back panel 15 can be surrounded by the wall portion 5 c of the protection plate 5. For this reason, water or the like is less likely to enter from between the protective plate 5 and the back panel 15. Here, in this solar panel, although a part of the edge molding 3 is provided so as to overlap the sealing material 13, the overlapping part is made as small as possible. Thereby, in this solar panel, it suppresses that the sealing material 13 foams with the heat | fever of the molten resin P1 at the time of carrying out the injection molding of the edge molding 3 to the panel main body 1. FIG. Other functions of this solar panel are the same as those of the solar panel of the first embodiment.

( Reference Example 1 )
As shown in FIG. 10, in the solar panel of the reference example 1 , the protective plate 5 is not formed with the wall 5c, and the protective plate 5 has a side surface 5d continuous with the front surface 5a and the back surface 5b. Yes. Thereby, the sealing material 13 is exposed at the end 1 a of the panel body 1. In this solar panel, the edge molding 3 is injection-molded on the end 1 a of the panel body 1, so that the edge molding 3 includes a part of the surface 5 a to the side surface 5 d of the protective plate 5, the sealing material 13, The back panel 15 is bonded to the side surface 15c to a part of the back surface 15b. The edge molding 3 is formed in a shape that protrudes in the thickness direction from the front surface 5a of the protection plate 5 and the back surface 15b of the back panel 15. Also in this solar panel, a part of the edge molding 3 is provided so as to overlap the sealing material 13. Other configurations of the solar panel are the same as those of the solar panel of the first embodiment.

In this solar panel, since it is not necessary to form the wall part 5c in the protective plate 5, the protective plate 5 can be easily formed also with inorganic glass or the like. Further, since the edge molding 3 is joined to a part or the side surface 5d of the front surface 5a of the protective plate 5, the sealing material 13, and a part of the side surface 15c or the back surface 15b of the back panel 15, A larger contact area with the molding 3 can be ensured. For this reason, in this solar panel, it is possible to more suitably seal between the protective plate 5 and the back panel 15 by the edge molding 3. Other functions of this solar panel are the same as those of the solar panel of the first embodiment.

(Example 3 )
As shown in FIG. 11, in the solar panel of Example 3, a wall portion 5e extending substantially perpendicular to the rear panel 15 is formed on the outer peripheral edge of the protective plate 5, and the panel is further formed from the wall portion 5e. An extending portion 5f extending toward the outer region of the main body 1 is formed. In the panel body 1, the extending portion 5 f and the surface 15 a of the back panel 15 are in contact with each other. Further, in this solar panel, the edge molding 3 is injection-molded on the end 1 a of the panel body 1, so that the edge molding 3 includes the wall 5 e to the extension 5 f of the protection plate 5 and the side surface of the back panel 15. 15c to a part of the back surface 15b. Furthermore, the edge molding 3 is formed so as to be substantially flush with the surface 15 a of the protective plate 5, and is provided in an outer region than the sealing material 13. Other configurations of the solar panel are the same as those of the solar panel of the first embodiment.

In this solar panel, the sealing material 13 can be surrounded by the wall 5e. In addition, the contact area when the protective plate 5 and the back panel 15 are joined can be increased by the extension portion 5f coming into contact with the surface 15a of the back panel 15. Furthermore, since the edge molding 3 is joined to the wall portion 5e to the extension portion 5f of the protective plate 5 and a part of the side surface 15c to the back surface 15b of the back panel 15, the edge molding 3 is placed outside the sealing material 13. A large contact area between the end 1a of the panel body 1 and the edge molding 3 can be secured while being provided. For this reason, this solar panel can also more suitably seal between the protective plate 5 and the back panel 15 by the edge molding 3, and the edge 1 a of the panel body 1 and the edge molding 3. It is difficult to peel off. Other functions of this solar panel are the same as those of the solar panel of the first embodiment.

( Reference Example 2 )
As shown in FIG. 12, in the solar panel of Reference Example 2 , the wall 5 c is not formed on the protection plate 5, while the wall 15 d is formed on the back panel 15. The wall 15d extends from the outer peripheral edge of the back panel 15 toward the protective plate 5 while being curved. The wall portion 15d is in contact with the back surface 5b of the protective plate 5 while enclosing the sealing material 13 over the entire circumference. Note that the wall portion 15 d may be formed so as to extend substantially at right angles toward the protection plate 5.

In this solar panel, the edge molding 3 is injection-molded on the end 1 a of the panel body 1, so that the edge molding 3 includes a part of the surface 5 a to the side surface 5 d of the protective plate 5 and the wall 15 d of the back panel 15. And a part of the back surface 15 b of the back panel 15. The edge molding 3 is formed so as to protrude in the thickness direction from the front surface 5a of the protective plate 5 and the back surface 15b of the back panel 15. Also in this solar panel, a part of the edge molding 3 is provided so as to overlap the sealing material 13. Other configurations of the solar panel are the same as those of the solar panel of the first embodiment.

  In this solar panel, even if it is difficult to form the wall portion 5c on the protection plate 5 due to the material, thickness, etc. of the protection plate 5, the wall portion 15d is formed on the back panel 15 to be sealed by the wall portion 15d. The stopper 13 can be enclosed. For this reason, also in this solar panel, it can prevent that the sealing material 13 and the protection board 5 shift | deviate by the expansion | swelling and shrinkage | contraction by a temperature change. Other functions of this solar panel are the same as those of the solar panel of the first embodiment.

In the above, the present invention has been described with reference to the first to third embodiments. However, the present invention is not limited to the first to third embodiments, and can be appropriately modified and applied without departing from the spirit of the present invention. Needless to say.

For example, you may comprise a solar panel by combining Example 1-3 suitably.

Moreover, it is good also as a structure which encloses the sealing material 13 by both wall part 5c, 15d by forming the wall part 5c in the protective plate 5, and forming the wall part 15d in the back panel 15. FIG.

  INDUSTRIAL APPLICABILITY The present invention can be used for solar panels used for various types of solar power generation equipment, in addition to solar panels provided on the roof of a vehicle.

DESCRIPTION OF SYMBOLS 1 ... Panel main body 1a ... End part 3 ... Edge molding (edge member)
5 ... Protective plate (protective cover)
5a ... front surface 5b ... back surface 5c, 5e ... wall 7 ... solar cell 13 ... sealing material 15 ... back panel (back cover)
15a ... Surface 15c ... Side 15d ... Wall

Claims (3)

A protective cover having translucency from the front surface to the back surface, a solar battery cell, a sealing material, and a back cover, and the solar battery cell between the protective cover and the back cover. A panel body fixed in a sealed state,
A method of manufacturing a solar panel provided with at least a part of an end portion of the panel main body, and a resin edge member capable of sealing between the protective cover and the back cover,
An injection molding machine comprising: an insertion port through which the panel main body can be inserted; a molding die in which a forming surface capable of forming the edge member in communication with the insertion port is formed; and an injection machine connected to the molding die Preparing, inserting the end of the panel body into the insertion port, and forming a cavity in the mold by the forming surface and the end of the panel body;
By the injection machine, the molten resin constituting the edge member is injected into the cavity, and the molten resin injected into the cavity is solidified, so that at least a part of the end portion of the panel body is An injection molding process for forming an edge member,
In the injection molding step, the panel body is moved relative to the injection molding machine while injecting the molten resin into the cavity ,
The forming surface is continuous with the inner wall of the mold facing the surface of the protective cover at the insertion port so that the edge member is substantially flush with the surface of the protective cover.
The method for manufacturing a solar panel, wherein the protective cover is formed with an entry portion that enters the mold rather than the surface . Wherein in the preparation step, wherein such sealing material is positioned on the insertion port side of the said mold, a manufacturing method of a solar panel according to claim 1, wherein inserting the end portion of the panel body to the insertion port . In the injection molding step, the edge member is continuously formed from the start point portion to the end point portion along the end portion of the panel body by making the panel main body make a round with respect to the injection molding machine,
The method for manufacturing a solar panel according to claim 1 or 2, wherein the edge member formed separately from the injection molding step is joined between the start point portion and the end point portion.

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