CN100511722C - Method for manufacturing solar cell module - Google Patents

Method for manufacturing solar cell module Download PDF

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Publication number
CN100511722C
CN100511722C CNB2005800214480A CN200580021448A CN100511722C CN 100511722 C CN100511722 C CN 100511722C CN B2005800214480 A CNB2005800214480 A CN B2005800214480A CN 200580021448 A CN200580021448 A CN 200580021448A CN 100511722 C CN100511722 C CN 100511722C
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CN
China
Prior art keywords
sealing resin
solar battery
resin sheet
battery cell
solar
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Expired - Fee Related
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CNB2005800214480A
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Chinese (zh)
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CN1977390A (en
Inventor
勇木健
秋山胜
政田圭三
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NAKAJMA GLASS CO Inc
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NAKAJMA GLASS CO Inc
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Publication of CN1977390A publication Critical patent/CN1977390A/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/1077—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/02002—Arrangements for conducting electric current to or from the device in operations
    • H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
    • H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
    • H01L31/02013—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising output lead wires elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Photovoltaic Devices (AREA)

Abstract

A method is provided for manufacturing a solar cell module wherein a plurality of solar battery cells (4) are sealed with a resin between a light receiving side transparent board (2) and a rear board (3). The plurality of solar battery cells (4) are arranged at intervals of 5mm or less and are mutually connected with a conductive wire (8). A first sealing resin sheet (20) is arranged between the light receiving side transparent board (2) and the solar battery cells (4), a second sealing resin sheet (30) is arranged between the rear board (3) and the solar battery cells (4), and sealing resin sheet pieces (40, 41, 42, 43) having a total thickness more than that of the solar battery cell (4) are arranged on a margin part (10) on an external side of the solar battery cell (4). Then, the air between the light receiving side transparent board (2) and the rear board (3) is exhausted, heat is applied to melt the resin, and the resin is cooled to seal the cells. Thus, at the time of sealing the solar battery cells with the transparent resin, the solar battery cells are prevented from breaking.

Description

The manufacture method of solar module
Technical field
The present invention relates to the manufacture method of solar module.The manufacture method that particularly relates to the solar module that between sensitive surface side transparent panel and backplate, utilizes resin-sealed solar battery cell and constitute.
Background technology
In recent years, environmental consciousness improves, and it is more important that solar power generation seems.Utilize protective material to clip and utilize the transparent resin sealed solar can battery unit and make to become solar module, come in outdoor application.As the transparent resin that is used to seal, use ethylene-vinyl acetate copolymer (hereinafter to be referred as EVA) resin etc., it is clipped between protective material and the solar battery cell, seal by solidifying behind the heating and melting.For effectively configuration solar battery cell ground wiring, preferably a plurality of solar battery cells are sealed in the solar module.
The place that is provided with of solar cell also becomes diversified recently, and not only on the roof of building, the part of wall also can be used.When on wall, using, not only be installed on the exterior wall, also can utilize solar module to constitute wall itself.At this moment, big to the influence of facade, so the solar module that design does not have the rule of defective to dispose is very important.Simultaneously, require solar energy in large area battery module with intensity enough as the building construction body.
The practical new case of Japan is logined in No. 2500974 communique (patent documentation 1), put down in writing following duplexer, it is by constituting via 2 plate bodys of adhesive sheet joint solar cell is clamped in 2 modes between adhesive sheet, wherein, in the outside of solar cell is formed at gap between adhesive sheet, sandwich roughly part with the solar cell uniform thickness.By such formation, can make the circumference thickness of duplexer even, again, because moisture etc. is difficult to from the outside immerse above-mentioned gap, so can prevent to peel off.Put down in writing as adhesive sheet and can use EVA, but all used glass plate as the plate body two sides.
In TOHKEMY 2003-110127 communique (patent documentation 2), put down in writing following solar module, it is configured in a plurality of solar battery cells between front cover plate and the back cover plate and utilizes transparent packing material sealing such as EVA, wherein, between solar battery cell, dispose the distance piece (adjustment piece) of light transmission.Put down in writing as this distance piece, preferred use identical with transparent packing material material and with the parts of the same thickness of solar battery cell.This distance piece can not be out of shape under the situation that only is subjected to the lid deadweight, can guarantee the stream of air.Can make the inner not solar module of residual air thus.
In Japanese kokai publication sho 59-022978 communique (patent documentation 3), put down in writing following solar module with filling the adhesives sheet, it contains vinyl copolymer and organic peroxide, is processed with stamping on its two sides.This adhesives sheet has stamping, thereby can prevent the retardance (blocking) of sheet, and the degassing in the modular process is good, is difficult for producing bubble.In the embodiment of this communique, put down in writing following applying method: in vacuum laminator, keep being warmed up to 150 ℃ under the decompression state, continue decompression cooling after 1 hour down, stop decompression at 150 ℃.
In Japanese kokai publication hei 09-036405 communique (patent documentation 4), put down in writing following solar module, it makes duplexer via the stacked photovoltaic cell of sealing resin between front parts and back part, with this duplexer after keeping 5～40 minutes under the vacuum degree below the 5Torr, under the vacuum degree below the 5Torr, add thermo-compressed, after this adds thermo-compressed the cooling and fit.By under such condition, adding thermo-compressed, can provide surface elements be difficult for to take place peel off, be difficult for the residual module of gassing.Again, put down in writing, can improve the residual problem of bubble by between solar battery cell and sealing resin, inserting the air that nonwoven fabrics and the space in nonwoven fabrics discharge duplexer.
In Japanese kokai publication sho 61-069179 communique (patent documentation 5), put down in writing the manufacture method of following solar panel, it has bonding process, that is,, utilize the dual vacuum mode degassing to solar battery cell being layered in solar panel duplexer between cover glass and the backing material via packing material, pressurize after the heating, in the method, use EVA, dual vacuum chamber is kept the specific time in specific temperature range as packing material.By under specific temperature conditions, fitting, can not make EVA foaming, yellowing, can make it all crosslinked.According to the condition of putting down in writing among the embodiment, behind the 0.3Torr that reduces pressure (about 0.0004MPa), begin heating, carry out vacuum compressing after the substrate surface temperature of heater side reaches 140 ℃, after making it carry out cross-linking reaction under 148 ℃, be cooled to remove vacuum compressing then below 50 ℃.
But, link a plurality of unit and be clipped in and add thermo-compressed between 2 plates and when implementing to seal, be difficult to avoid the damage of solar battery cell.When particularly thereby the many module whole areas of cell block number were big, it is inhomogeneous that big load becomes easily, can not avoid bearing a part of unit breakage of excessive loads.Because a plurality of unit binding of connecting mutually in module, thus if a unit breakage, then a succession of unit of Xiang Lianing all could not play a role.When generating unit is damaged, not only can damage outward appearance, and power generation performance can reduce greatly also, so it is discarded as substandard products to have to.Therefore, wish to have the encapsulating method that is difficult for the generating unit breakage as far as possible.
Patent documentation 1: practical new case is logined communique No. 2500974;
Patent documentation 2: the spy opens the 2003-110127 communique;
Patent documentation 3: the spy opens clear 59-022978 communique;
Patent documentation 4: the spy opens flat 09-036405 communique;
Patent documentation 5: the spy opens clear 61-069179 communique.
Summary of the invention
The present invention makes in view of these problems, and its purpose is to provide a kind of manufacture method breakage, solar module that can prevent solar battery cell when utilizing resin-sealed solar battery cell.
The 1st invention is a kind of manufacture method of solar module, described solar module constitutes by with resin a plurality of solar battery cells being sealed between sensitive surface side transparent panel and the backplate, the method is characterized in that, a plurality of solar battery cells separate following being spaced of 5mm, utilize lead to connect mutually, between sensitive surface side transparent panel and solar battery cell, configuration covers whole the 1st sealing resin sheet of sensitive surface side transparent panel, overleaf between plate and the solar battery cell, configuration covers whole the 2nd sealing resin sheet of backplate, blank portion in the solar battery cell outside, dispose many sealing resin parts of aggregate thickness to be clamped in mode between the 1st sealing resin sheet and the 2nd sealing resin sheet greater than the thickness aggregate value of the thickness of solar battery cell and lead, on the mutual horizontal direction of sealing resin part, be separated with air-out at interval and from here, discharge the air between sensitive surface side transparent panel and the backplate then, heating makes cooling after the resin fusion and seals.
By blank portion's configuration aggregate thickness sealing resin part thicker than the thickness of solar battery cell in the solar battery cell outside, when stacked sensitive surface side transparent panel and backplate, can not act directly on the solar battery cell from double-edged load, but bear this load by above-mentioned part.And, although along with the rising resin of temperature is softening, the thickness that bears the part of load reduces, thereby unit or be connected the part of the lead on the unit and contact with up and down sealing resin sheet, but this moment, resin sheet was whole softening, so can not act on local load, unit or the lead that is connected on the unit can be close to softening sealing resin sheet in the mode of imbedding.Thus, can prevent that the unit in stacked operation or the decompression operation is cracked.Particularly at the mutual interval of solar battery cell when 5mm is following, be difficult to such sealing resin part is configured in solar battery cell each other, be very important so be configured in the blank portion in the solar battery cell outside.
At this moment, preferably, the aggregate thickness of above-mentioned sealing resin part is greater than the aggregate value of the thickness of the thickness of solar battery cell and lead.Preferably, more than the thick 0.3mm of thickness of the aggregate thickness of above-mentioned sealing resin part than solar battery cell.In addition, preferably, the aggregate thickness of above-mentioned sealing resin part is 1～5mm.
In the 1st invention, preferably, above-mentioned sealing resin part is clamped between the 1st sealing resin sheet and the 2nd sealing resin sheet.At this moment, preferred embodiment be, along the complete cycle of above-mentioned blank portion continuously configuration the sealing resin part and overlap and be separated with mutually many sealing resin parts of compartment of terrain configuration, be clamped between the 1st sealing resin sheet and the 2nd sealing resin sheet.In addition, this moment, following execution mode was also preferred: in above-mentioned blank portion, be positioned at along complete cycle continuously the sealing resin part of configuration the inboard and be positioned on the position in the outside of solar battery cell the configuration width sealing resin part thinner than other sealing resin part.
In the 1st invention, preferably, the 1st sealing resin sheet or the 2nd sealing resin sheet constitute by stacked many sealing resin sheets.Preferred embodiment be this moment, and in above-mentioned blank portion, above-mentioned many sealing resin parts are separated with compartment of terrain configuration mutually, and be clamped in constitute the 1st sealing resin sheet or the 2nd sealing resin sheet many sealing resin sheets each other.
In the 1st invention, preferred embodiment be that sensitive surface side transparent panel and backplate are that glass plate more than the 20MPa constitutes by the surface compression stress with warpage, make the concave surface of their warpage carry out seal operation relative to one another.This moment, preferably the warpage of above-mentioned glass plate was that the value of standard test is the value in 0.05%～0.5% scope with JIS R3206.
The 2nd invention, it is a kind of manufacture method of solar module, described solar module constitutes by with resin a plurality of solar battery cells being sealed between sensitive surface side transparent panel and the backplate, the method is characterized in that, a plurality of solar battery cell devices spaced apart are arranged, utilize lead to connect mutually, between sensitive surface side transparent panel and solar battery cell, configuration covers whole the 1st sealing resin sheet of sensitive surface side transparent panel, overleaf between plate and the solar battery cell, configuration covers whole the 2nd sealing resin sheet of backplate, the 1st sealing resin sheet or the 2nd sealing resin sheet constitute by stacked many sealing resin sheets, the part of electric wiring is configured on the position that overlaps in discontiguous mode with solar battery cell, in the 1st sealing resin sheet or the 2nd sealing resin sheet, 1 sealing resin sheet of part configuration outside above-mentioned electric wiring, discharge the air between sensitive surface side transparent panel and the backplate then, heating makes cooling after the resin fusion and seals.
The aligning method that is sealed in the solar battery cell in the solar module is according to purpose or purposes and of all kinds.Usually, a plurality of adjacent solar battery cells are separated with the compartment of terrain each other and arrange, and utilize lead to connect mutually.And, in addition, connecting non-conterminous unit each other or be positioned at lead on the position spaced each other the time, or perforate and when electric wiring is drawn out to outside etc. on the plate overleaf, the part of electric wiring is configured in on discontiguous mode and the position that solar battery cell overlaps in vertical direction sometimes.Under such situation, by on the unit, overlapping electric wiring, when bearing, easily at the excessive load of superposed part effect and easily generating unit is cracked from up and down load.Relative therewith, dispose 1 sealing resin sheet in the 1st sealing resin sheet or the 2nd sealing resin sheet by the part outside electric wiring, can prevent that stop element is cracked.
In the 2nd invention, preferably,, fill up the thin sealing resin sheet of sealing resin sheet than configuration in the part of the above-mentioned electric wiring that does not dispose the sealing resin sheet.In addition, preferably, dispose dielectric film between above-mentioned electric wiring and solar battery cell, this dielectric film is respectively via at least 1 sealing resin sheet in the 1st sealing resin sheet that constitutes by stacked many sealing resin sheets or the 2nd sealing resin sheet and stacked with solar battery cell and above-mentioned electric wiring.
In the above-mentioned the 1st and the 2nd invention, preferably, when in sealed container, sealing, comprise the seal operation of following each operation: the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin (operation 1), the operation (operation 2) of the pressure below the 0.01MPa reduces pressure in sealed container under the temperature that is lower than the sealing resin fusing point, under the state that keeps decompression, be warmed up to more than the sealing resin fusing point, the operation of the temperature below 200 ℃ (operation 3), the operation (operation 4) that pressure in the above-mentioned sealed container is risen, and the operation of cooling off (operation 6).
The 3rd invention is a kind of manufacture method of solar module, described solar module constitutes by with resin solar battery cell being sealed between sensitive surface side transparent panel and the backplate, the method is characterized in that, between sensitive surface side transparent panel and solar battery cell, configuration covers whole basically the 1st sealing resin sheet of sensitive surface side transparent panel, overleaf between plate and the solar battery cell, configuration covers whole basically the 2nd sealing resin sheet of backplate, import to then in the sealed container, comprise the seal operation of following each operation: the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin (operation 1), the operation (operation 2) of the pressure below the 0.01MPa reduces pressure in sealed container under less than the temperature of sealing resin fusing point, under the state that keeps decompression, be warmed up to the operation (operation 3) of the temperature more than the sealing resin fusing point, the operation (operation 4) that pressure in the above-mentioned sealed container is risen, and the operation of cooling off (operation 6).
Begin decompression operation by heated sealant resin in advance after making its softnessization, hard resin can be prevented that stop element is cracked by from being pressed into up and down on the unit in the time of can preventing to reduce pressure.And the heating-up temperature during decompression operation is lower than the temperature of sealing resin fusion, so can guarantee the air duct that exists between sensitive surface side transparent panel and the backplate, can prevent that bubble is residual.
In the 3rd invention, preferably, in operation 1, the temperature in the sealed container is heated to 40～65 ℃, in this temperature range, keep more than 5 minutes.In addition, preferably, in operation 2, reduce pressure the temperature maintenance in the sealed container to below the 0.01MPa from 0.05MPa on 40～65 ℃ of limits in the limit.Preferably, in operation 2, with more than 5 minutes from the 0.05MPa 0.01MPa that reduces pressure.Preferably, in operation 4, the temperature when pressure is risen is below 120 ℃.Preferably, in operation 4, the limit is heated up the pressure rising edge in the above-mentioned sealed container simultaneously.In addition, preferably, in operation 4, the rate of pressure rise (MPa/ minute) is 0.001～0.1 (MPa/ ℃) with the ratio of programming rate (℃/minute).
In the 3rd invention, preferred embodiment be, above-mentioned sealing resin is crosslinkable thermoplastic resin, the operation (operation 3) that is warmed up to the temperature more than the sealing resin fusing point under the state that keeps decompression afterwards, through the operation (operation 4) that the pressure that makes in the above-mentioned sealed container rises, have and be warmed up to the temperature range of carrying out cross-linking reaction and carry out the operation (operation 5) of cross-linking reaction and the operation of cooling off (operation 6).In this case, preferably, pressure in the sealed container is risen after, temporarily be cooled to the following temperature of fusing point, in operation 5, be warmed up to the temperature range of carrying out cross-linking reaction afterwards.In addition, preferably, in operation 5, carry out cross-linking reaction below the pressure in the above-mentioned sealed container remained on the above atmospheric pressure of 0.05MPa.And then preferably, above-mentioned solar module is the solar module that constitutes with resin-sealed a plurality of solar battery cells, and a plurality of solar battery cells are separated with the compartment of terrain and arrange, and connect with lead mutually.
In above-mentioned the 1st, the 2nd and the 3rd invention, a kind of resin of selecting in the group that aforementioned sealing resin is made of ethylene-vinyl acetate copolymer, polyvinyl butyral resin and polyurethane constitutes.
According to the manufacture method of solar module of the present invention, at the arranged solar battery unit and utilize transparent resin when sealing, can prevent the breakage of solar battery cell.
Description of drawings
Fig. 1 is the generalized section of an example of the solar module after the seal operation.
Fig. 2 is the generalized section of an example of the duplexer before the seal operation.
Fig. 3 is another routine generalized section of the duplexer before the seal operation.
Fig. 4 is the profile of the solar module made among the embodiment of expression and the schematic diagram of the solar battery cell of arrangement wherein.
Fig. 5 is the figure (its 1) of manufacturing process of the duplexer of expression embodiment.
Fig. 6 is the figure (its 2) of manufacturing process of the duplexer of expression embodiment.
Fig. 7 is the figure (its 3) of manufacturing process of the duplexer of expression embodiment.
Fig. 8 is the figure (its 4) of manufacturing process of the duplexer of expression embodiment.
Fig. 9 is the figure (its 5) of manufacturing process of the duplexer of expression embodiment.
Figure 10 is the figure (its 6) of manufacturing process of the duplexer of expression embodiment.
Figure 11 is the synoptic diagram of encapsulation process device.
The figure of temperature and pressure when Figure 12 is the encapsulation process of expression embodiment.
Description of reference numerals
1 solar module
2 sensitive surface side transparent panels
3 backplates
4 solar battery cells
5 resins
8 leads
9 clearance portion
10 blank portions
20 the 1st sealing resin sheets
30 the 2nd sealing resin sheets
40～46 sealing resin parts
50～54 leads
55,56 dielectric films
60 duplexers
61 bags
66 hot-blast stoves
Embodiment
Below, describe the present invention in detail according to figure.Fig. 1 is the generalized section of an example of the solar module after the seal operation.Fig. 2 and Fig. 3 are the generalized sections of an example of the duplexer before the seal operation.
Adopt the generalized section of an example of the solar module 1 that manufacture method of the present invention obtains to be shown in Fig. 1.Solar module 1 is a module of utilizing resin 5 sealed solars energy battery unit 4 to form between sensitive surface side transparent panel 2 and backplate 3.Be sealed in the quantity of the solar battery cell 4 in the solar module 1,, preferably seal a plurality of solar battery cells 4 though also can be one.Usually, the sensitive surface 6 of adjacent solar battery cell 4 is connected via lead 8 with the back side 7.
The solar battery cell 4 that uses among the present invention can use the unit of various solar cells such as monocrystaline silicon solar cell, polysilicon solar cell, non-crystal silicon solar cell, compound semiconductor solar cell.These solar battery cells 4 generally are that 1mm is following, the thin plate of the following thickness of the more common 0.5mm of being, mostly are the above quadrangle of 1 limit 5cm.The material of its substrate can be used semiconductor substrate, glass substrate, metal substrate of silicon or germanium etc. etc., but under the situation of silicon substrate, wish thin plateization for the requirement of cost aspect, on the other hand owing to be hard and crisp material, so especially easily split during sealing, thereby adopt manufacture method meaning of the present invention big.
Be sealing into the piece number of 1 solar battery cell 4 in the solar module 1, be not particularly limited, also can have only 1.At this moment, lead to outside distribution as long as connect from solar battery cell 4.But the number that is sealing into 1 solar battery cell 4 in the solar module 1 is many more, and the defect rate that the breakage of solar battery cell 4 causes is high more, so adopt the actual benefit of manufacture method of the present invention big more.Therefore, preferred more than 10, more preferably more than 30, further preferred solar battery cell 4 more than 100 is configured in the solar module 1.
The width of the clearance portion 9 that adjacent solar battery cell is 4 is not particularly limited, but normally more than the 0.5mm, solar battery cell 4 adjacent when 0.5mm is following contacts with each other, and may make the unit breakage when sealing.If daylighting is preferential, then preferably enlarge clearance portion 9, if the utilization ratio of light is preferential, then preferably reduce clearance portion 9.Requirement according to purposes or design aspect can suitably be adjusted.
Enclose under the situation of a plurality of solar battery cells 4, a plurality of solar battery cells 4 preferably separate set width and arrange and utilize mutually lead 8 connections.At this moment, adjacent solar battery cell 4 utilizes lead 8 to connect each other between the sensitive surface 6 and the back side 7, connects a plurality of solar battery cells 4 with series system.The sensitive surface 6 or the back side 7 are connected with lead 8, and conductive adhesives such as use soft solder carry out.Again,, also preferably on sensitive surface 6, utilize conduction solder flux etc. to form the current collection figure, and make itself and lead 8 conductings in order effectively to collect the electric current that produces.And then, also connect sometimes non-conterminous unit each other or be positioned on the position spaced lead 8 each other, or perforate and lead 8 is drawn out to the outside on the plate 3 overleaf.
Lead 8 also is called intermediate connector, and its material is not particularly limited, and can use copper cash etc.Owing to sandwich configuration between sensitive surface side transparent panel 2 and backplate 3, so the preferred ribbon conductor 8 that approaches that uses, its thickness is usually below 0.5mm, preferably below 0.3mm.Again, common is more than the 0.05mm.On lead 8, apply conductive adhesives such as soft solder in advance, can make attended operation become easily, thus preferred.Under the state that has connected lead 8, from the surface of solar battery cell 4 to the height of high part of lead 8, exist according to the difference in place discrete, according to the difference of attended operation, sometimes about the thick 0.5mm of thickness than lead 8.
The material of sensitive surface side transparent panel 2 gets final product with respect to sunlight is transparent, also can use polycarbonate resin or acrylic resin etc. except that glass.But, consider factors such as durability, hardness, flame retardancy, preferably use glass.Because it is also more to constitute the situation of large-area structure spare, so from the glass plate of intensity aspect consideration preferred surface compression stress more than 20MPa.When area is big, also easily produce hot tearing, so, preferably use the glass plate of surface compression stress more than 20MPa from this point along with the intensification that causes at sunshine etc. again.But the glass plate with big surface compression stress normally heats, chilling kickboard glass is made, so can not avoid taking place certain strain.Because the glass warpage that produces easily acts on excessive load on a part of solar battery cell 4 during sealing like this, employing can prevent that the actual benefit of the manufacture method of the present invention that stop element is cracked is big.
At this, the surface compression stress of glass sheet is to be the value of standard test with JIS R3222.As the glass plate of surface compression stress more than 20MPa, specifically can exemplify out double strength glass, tempered glass, super-strengthening glass etc.Double strength glass, surface compression stress is usually at 20～60MPa; Tempered glass, surface compression stress is usually at 90～130MPa; Super-strengthening glass, surface compression stress is usually at 180～250MPa.Surface compression stress is big more, and intensity is high more, but warpage is increased manufacturing cost is increased.Double strength glass owing to be easy to make the less product of warpage, can not become fragment when damaged and fall, so preferred.Glass plate can be selected according to purposes or purpose.
Backplate 3 needs not to be transparent, if but consider daylighting, then backplate 3 also be relative sunlight transparent for well.For the reason same with sensitive surface side transparent panel 2, and preferred glass, the particularly glass plate of surface compression stress more than 20MPa.
The material of glass is not particularly limited, and preferably uses soda-lime glass, wherein, and the sensitive surface side transparent panel 2 preferred high light transmittance ratio glass (so-called blank glass) that use.High light transmittance ratio glass is the few soda-lime glass of iron-holder, the light penetration height.For the glass of backplate 3, except that using the more soda-lime glass (so-called backboard glass) of aforementioned high light transmittance ratio glass, iron-holder, also can preferably use infrared reflection glass, infrared absorbing glass etc. according to purposes again.Also can use figured plate glass of being formed with stamping on the surface etc. again.The thickness of glass plate is not particularly limited, if but use as the structure part, more than the then preferred 3mm, more preferably more than the 5mm.When using thick like this glass plate, the influence of deadweight is big, and the unit may be damaged during overlapping glass plate on the unit before fitting, so adopt manufacture method actual benefit of the present invention big.The thickness of glass plate is normally below the 20mm.Again, the area of glass can be according to the purposes adjustment, but 1m 2Adopt manufacture method actual benefit of the present invention big when above.
As long as the material of resin 5 transparent and have cementability, flexibility, is not particularly limited, but a kind of resin of selecting in the group of preferably use ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral resin and polyurethane formation.At this moment, consider preferred crosslinked resin from intensity and durability aspect.Therefore, the raw material of resin 5, preferred crosslinkable thermoplastic resin, the preferred especially resin that utilizes heating to carry out cross-linking reaction.The form of such resin with sheet is clipped between sensitive surface side transparent panel 2 and the backplate 3, behind the heating and melting, makes it carry out cross-linking reaction as required, make its cooling curing afterwards and sealed solar energy battery unit 4.Crosslinked material can make durability and cementability good by heating in use.As crosslinkable thermoplastic resin, so long as the time carrying out the resin of cross-linking reaction, heating get final product, be not particularly limited, but a kind of resin of selecting in the group of preferably use ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral resin and polyurethane formation.For example if EVA, then by cooperating the crosslinking agent heating can make it crosslinked, if polyurethane, then by making NCO and carboxyl reaction can make it crosslinked.
Under the situation of polyurethane, owing to be under lower temperature, to carry out cross-linking reaction, so preferred under the low situations such as resin plate of at least one use thermal endurance of sensitive surface side transparent panel and backplate.Again, the polyurethane flexibility might as well, so even when being used for sensitive surface side transparent panel and backplate, also be difficult for peeling off at combination thermal coefficient of expansion differs greatly as glass and plastics material, thereby preferably.And the perforation intensity of polyurethane might as well.
Even in crosslinkable thermoplastic resin, the also preferred thermoplastic resin that contains crosslinking agent that uses.The thermoplastic resin of this moment then is not particularly limited so long as carry out cross-linking reaction when heating with crosslinking agent, but most preferably use the transparency, good ethylene-vinyl acetate copolymers (EVA) such as flexibility, durability.
The sealing resin sheet is clipped between sensitive surface side transparent panel 2 and the backplate 3, makes its cooling curing behind the heating and melting and sealed solar energy battery unit 4.The sealing resin sheet preferably contains the resin sheet of crosslinking agent in the EVA resin, in this case, make it carry out cross-linking reaction behind the heating and melting, can utilize crosslinked EVA to seal by cooling afterwards.EVA in the sealing resin sheet if the fusing point that utilizes the DSC method to measure is 50～80 ℃, then considers preferably from the viewpoint of the balance of the transparency and form retentivity.
The sealing resin sheet then can prevent retardance (blocking) if having suitable stamping at its single or double, and it is residual also to suppress bubble easily, so preferred.Preferred depth of indentation is 10～100 μ m, if cross deeply then on the contrary may residual bubble.Preferred 0.2～the 2mm of sheet thickness, more preferably 0.3～1mm can use one or overlapping many to regulate the thickness use.
Seal operation method in the manufacture method of the present invention below is described.In the explanation herein, with sensitive surface side transparent panel 2 place the below after carry out overlap operation, but also can earlier backplate 3 be placed the below, overlapping with opposite order again.
At first, the structure of inventing according to figure explanation the 1st.The 1st invention is characterised in that, separate the following narrow compartment of terrain of 5mm and arrange a plurality of solar battery cells 4, the blank portion 10 configuration aggregate thickness sealing resin part 40,41,42,43 thicker in solar battery cell 4 outsides than the thickness of solar battery cell 4, sealing afterwards.Fig. 2 is the generalized section of an example of the duplexer 60 before the seal operation, and expression is parallel to the section that direction that a plurality of solar battery cells 4 are connected in series is cut off.
At first, on sensitive surface side transparent panel 2, cover overlapping the 1st sealing resin sheet 20 in its whole ground basically.At this moment, sensitive surface side transparent panel 2 is glass plate preferably, particularly has the glass plate of surface compression stress more than 20MPa of warpage.And, preferably to sensitive surface side transparent panel 2, with the inboard of warpage be concave side in last mode, overlapping thereon the 1st sealing resin sheet 20.The warpage of the sensitive surface side transparent panel 2 of this moment preferred (is the value of standard test with JIS R3206) is 0.05～0.5%.When warpage is excessive, may be after the sealing in the remaining power peeled off of causing of inside modules, more preferably below 0.4%, and then preferably below 0.3%.On the other hand, when warpage is too small, in seal operation, may near the central authorities of module, on solar battery cell 4, act on the load of backplate 3 and generating unit is cracked, more preferably more than 0.1%, and then be preferably more than 0.15%.
The thickness of the 1st sealing resin sheet 20 is preferably more than the 0.5mm, more preferably more than the 1mm.Again, normally below the 5mm, below the preferred 3mm.By being designed to the thickness more than the set degree, can effectively protect solar battery cell 4 thereby can effectively absorb to impact.The 1st sealing resin sheet 20 preferably constitutes by stacked many sealing resin sheets.This is because easy like this and purposes or performance requirement are correspondingly adjusted the thickness of the 1st sealing resin sheet 20.In the example of Fig. 2, overlapping 3 sealing resin sheets 21,22,23 and constitute the 1st sealing resin sheet 20.The 1st sealing resin sheet 20 covers whole basically of sensitive surface side transparent panels 2 and get final product, also can local disappearance the 1st sealing resin sheet 20 for the configuration of carrying out lead etc., and also many sealing resin sheets that can be disposed by the form with the limit center edge constitute.
Mounting solar battery cell 4 on the 1st sealing resin sheet 20.At this moment, preferred mounting is arranged as required in length and breadth alignedly according to the interconnective a plurality of solar battery cells 4 of aforementioned main points.In this case, but the solar battery cell 4 that mounting connects in advance also can on the 1st sealing resin sheet 20, connect, but also connect remaining part behind the unit that connects of a mounting part.
In the 1st invention, the width of the clearance portion 9 between the adjacent solar battery cell 4 is below 5mm, preferably below 4mm, more preferably below 3mm.Again, the width of clearance portion 9 is usually more than 0.5mm, preferably more than 1mm.By with the narrow like this solar battery cell 4 that is spaced, can improve the utilization ratio of light.But when clearance portion 9 is narrow, be difficult to the sealing resin part is configured in the gap of adjacent solar battery cell 4 in case stop element is cracked, so must be in the blank portion 10 in solar battery cell 4 outsides, the configuration aggregate thickness is greater than the sealing resin part 40,41,42,43 of the thickness of solar battery cell 4.
Dispose the sealing resin part 40,41,42,43 of aggregate thickness by blank portion 10 greater than the thickness of solar battery cell 4 in solar battery cell 4 outsides, to inner pressure relief the time, can not act directly on the solar battery cell 4 from the load that double-edged atmospheric pressure caused, but bear this load by sealing resin part 40,41,42,43.Therefore, the load of backplate 3 is not acted directly on the solar battery cell 4 of configuration in the module.And, rising along with temperature, resin is softening, the thickness that bears the sealing resin part 40,41,42,43 of load reduces, unit or be connected the part of the lead 8 on the unit and contact with up and down sealing resin sheet, but this moment are because resin sheet is whole softening, so can not act on local load, unit or the lead 8 that is connected on the unit can be close to softening sealing resin sheet in the mode of imbedding.Thereby the unit in the operation that can prevent to reduce pressure is cracked.The number that particularly is sealing into 1 solar battery cell 4 in the solar module 1 is many more, and then the defect rate that causes of the breakage of solar battery cell 4 is high more, so the actual benefit of configuration sealing resin part 40,41,42,43 is big more.
For the thickness of the sealing resin part in the blank portion 10 that is configured in solar battery cell 4 outsides 40,41,42,43, need make the thickness of its aggregate thickness greater than solar battery cell 4.At this, so-called aggregate thickness refers to the thickness that they added up to when overlapping many sealing resin parts 40,41,42,43 used.For example, not only comprise the sealing resin part only is configured in situation between the 1st sealing resin sheet 20 and the 2nd sealing resin sheet 30, also comprise to be clamped in the situation that many sealing resin sheets mode each other that constitutes the 1st sealing resin sheet 20 or the 2nd sealing resin sheet 30 disposes.In the example of Fig. 2, be meant the thickness that is configured in 2 the sealing resin parts 40,41 between the 1st sealing resin sheet 20 and the 2nd sealing resin sheet 30 and is configured in the total (4) of 4 sealing resin sheets 31,32,33,34,2 the sealing resin parts 42,43 each other that constitute the 2nd sealing resin sheet 30.
The aggregate thickness of sealing resin part 40,41,42,43 preferably is thicker than the aggregate value of the thickness of the thickness of solar battery cell 4 and lead 8, more preferably than more than the thick 0.2mm of this aggregate value.Again, the aggregate thickness of sealing resin part 40,41,42,43 is preferably more than the thick 0.3mm of thickness than solar battery cell 4, more than the more preferably thick 0.6mm.Specifically, the aggregate thickness of sealing resin part 40,41,42,43 is preferably 1～5mm.The aggregate thickness of sealing resin part 40,41,42,43 is more preferably more than the 1.5mm, and then is preferably more than the 2mm.More preferably below the 4mm, and then be preferably below the 3mm again.
Preferably be separated with compartment of terrain configuration sealing resin part 40,41,42,43 in the horizontal direction mutually, make and to discharge inner air at interval from this.By guaranteeing actively to discharge the passage of inner air, it is residual to suppress bubble, can make the good solar module of outward appearance 1.At this moment, if sealing resin part direct overlapping structure each other, then as long as therein at least 1 go up in resin part along continuous straight runs devices spaced apart each other, get final product and can discharge inner air at interval from this.
In the example of Fig. 2, blank portion 10 in solar battery cell 4 outsides, on the 1st sealing resin sheet 20, configuration is along the complete cycle of the blank portion 10 sealing resin part 40 of configuration and overlapping and be spaced from each other the sealing resin part 41 of compartment of terrain configuration, overlapping the 2nd sealing resin sheet 30 thereon with sealing resin part 40 continuously basically.By disposing sealing resin part 40 continuously at upper edge, position complete cycle with solar battery cell 4 same height, can realize the even filling of molten resin, can prevent the generation of bubble.Sealing resin part 40 preferably has the width more than 50% of blank portion 10, more preferably has the width more than 70%.Sealing resin part 40 also can be made of many parts of configured in parallel.Preferably dispose sealing resin part 41, thereby can discharge inner air smoothly in the mode that overlaps on the sealing resin part 40 and be separated with mutually at interval.
Mounting solar battery cell 4 on the 1st sealing resin sheet 20, blank portion 10 mounting sealing resin parts 40 in solar battery cell 4 outsides, mounting sealing resin part 41 backs utilize the sealing resin sheet 31 that constitutes the 2nd sealing resin sheet 30 to cover whole on sealing resin part 40.Next, at blank portion 10 interrupted mounting sealing resin parts 42, it is whole to utilize 2 sealing resin sheets 32,33 to cover, and again at blank portion 10 interrupted mounting sealing resin parts 43, it is whole to utilize sealing resin sheet 34 to cover.Thus, utilize 4 sealing resin sheets 31,32,33,34 to constitute the 2nd sealing resin sheet 30.The preferred thickness of the 2nd sealing resin sheet 30 is the same with the situation of the 1st sealing resin sheet 20 that had illustrated.Add 2 the sealing resin parts 42,43 that exist with by the form of 4 sealing resin sheet 31,32,33,34 clampings, add up to 4 sealing resin parts 40,41,42,43 overlapping and be positioned at blank portion 10.At this, the 2nd sealing resin sheet 30 covers whole basically of backplates 3 and get final product, also can be and local disappearance for the configuration of carrying out lead etc., and also many sealing resin sheets that can be disposed by the form with the limit center edge constitute.
At last, mounting backplate 3 on the 2nd sealing resin sheet 30.At this moment, backplate 3 is preferably glass plate, particularly has the glass plate of surface compression stress more than 20MPa of warpage.And, for backplate 3, the preferred so that inboard of warpage be concave side under mode be positioned on the 2nd sealing resin sheet 30.This moment, the warpage preferred (is the value of standard test with JIS R3206) of backplate 3 was 0.05～0.5%.When warpage is excessive, may be after the sealing in the remaining power peeled off of causing of inside modules, more preferably below 0.4%, and then preferably below 0.3%.On the other hand, when warpage is too small, in seal operation, may near the central authorities of module, on solar battery cell 4, act on the load of backplate 3 and generating unit is cracked, more preferably more than 0.1%, and then be preferably more than 0.15%.
The glass plate that has certain warpage by such use is as sensitive surface side transparent panel 2 and backplate 3, and makes its concave surface carry out seal operation relative to one another, can prevent 4 breakages of sealed solar battery cell.In the 1st invention, the width of the clearance portion 9 that adjacent solar battery cell is 4 is below the 5mm, is difficult to the sealing resin part is configured in clearance portion 9.Therefore, in order to prevent the breakage of sealed a plurality of solar battery cells 4, only the blank portion 10 in solar battery cell 4 outsides disposes sealing resin parts 40,41,42,43.And when only utilizing periphery to support large-sized glass sheet, can not ignore the deflection that the deadweight of glass sheet causes.For example in embodiment 1 described later, reach 51kg as the weight of the glass sheet of the 2810mm * 1795mm * 12mm of backplate 3.Therefore, the sensitive surface side transparent panel 2 and the concave surface of backplate 3 are sealed relative to one another, even so that because deadweight, the central part deflection of backplate 3 and drop to the below also can not make the load of backplate 3 act directly on the solar battery cell 4.Usually, make inner what when all not have the laminated glass of sealing, make mostly 2 glass plates warpage towards consistent and fit, employing in the present invention is different from this method.
Below, according to the structure of figure explanation the 2nd invention.The 2nd invention is characterised in that, the part of electric wiring is configured on the position that overlaps in discontiguous mode with solar battery cell 4, in the 1st sealing resin sheet 20 or the 2nd sealing resin sheet 30, dispose 1 sealing resin sheet 33 in mode, then sealing in the excalation of this electric wiring.Fig. 3 is the generalized section of an example of the duplexer 60 before the seal operation, the vertical section that cuts off of direction that expression is connected in series with respect to a plurality of solar battery cells 4.
Overlapping the 1st sealing resin sheet 20 on sensitive surface side transparent panel 2, the mounting solar battery cell 4 thereon, and is all the same with the 1st invention up to this step.In the 1st invention, the width of the clearance portion 9 that adjacent solar battery cell is 4 is below the 5mm, but in the 2nd invention, can further enlarge the width of clearance portion 9.When the width of clearance portion 9 surpasses 5mm, can also in clearance portion 9, dispose the sealing resin part, in this case, needn't only use periphery support plate glass, even thereby have in use under the situation of glass plate as sensitive surface side transparent panel 2 and backplate 3 of certain warpage, make its concave surface necessity respect to one another also lower.
In the example of Fig. 3, except that connecting adjacent solar battery cell 4 lead 8 each other, also with position that solar battery cell 4 overlaps in discontiguous mode on dispose lead 50.This lead 50, the direction that is connected in series with respect to a plurality of solar battery cells 4 disposes abreast, its section of expression in Fig. 3.The lead 8 that this lead 50 is used for being positioned at an end of the one group of solar battery cell 4 that is connected in series is electrically connected to the lead 8 that is positioned at the other end, forms bypass circuit.Lead 50 is configured on the position that overlaps up and down with solar battery cell 4, so when bearing from up and down load, can act on too much load and easily generating unit is cracked in superposed part.In the example of Fig. 3, between lead 50 and solar battery cell 4,2 sealing resin sheets that far are thicker than lead 50 are arranged, but according to inventor's experience, even it is cracked also to be difficult to anti-fully stop element under such situation.Except that such example, rearward draw from the hole that backplate 3 is offered etc. under the situation will being connected to outside electric wiring, also sometimes electric wiring is configured on the position that overlaps in discontiguous mode with solar battery cell 4 from solar module 1.According to the purposes of solar module 1 etc., can consider various methods for designing, there is electric wiring to overlap the various situations of configuration with solar battery cell 4.
Mounting solar battery cell 4 on the 1st sealing resin sheet 20, blank portion 10 mounting sealing resin parts 40 in solar battery cell 4 outsides, mounting sealing resin part 41 on sealing resin part 40 utilizes the sealing resin sheet 31 that constitutes the 2nd sealing resin sheet 30 to cover whole then.This operation is the same with the example of Fig. 2.Configuration dielectric film 55 on sealing resin sheet 31.Dielectric film 55 is the insulating properties that are used to guarantee between lead 50 and the solar battery cell 4, and banded dielectric film 55 disposes with lead 50 with overlapping.Simultaneously, on sealing resin sheet 31, at blank portion 10 interrupted mounting sealing resin parts 42.Then, it is whole to utilize sealing resin sheet 32 to cover, thereby dielectric film 55 is respectively via sealing resin sheet 31 and sealing resin sheet 32 and stacked with solar battery cell 4 and lead 50.At this moment, in order to connect lead 50 and lead 8, also can suitably on sealing resin sheet 31,32, hole or otch be set.Also many sealing resin sheets that can be disposed by the form with the limit center edge constitute sealing resin sheet 31,32, draw lead 50 from its gap.
Configuration lead 50 on sealing resin sheet 32.As lead 50, can use the lead the same with lead 8.Then, dispose sealing resin sheet 33 in mode in the excalation of lead 50.At this, do not cover the mode of the part of lead 50 with sealing resin sheet 33, separate the sealing resin sheet 33 that configuration with gap is divided into many, cover whole of duplexer.By disposing 1 the sealing resin sheet 33 that constitutes the 2nd sealing resin sheet 30 in mode like this in the excalation of lead 50, in seal operation, can on solar battery cell 4, act on the load of part in the part of lead 50, can prevent that stop element is cracked.Sealing resin sheet 33 gets final product at the width of the excalation of lead 50 width greater than lead 50.
At this moment, preferably in the part of disappearance sealing resin sheet 33, to dispose the sealing resin part 44 thinner than sealing resin sheet 33 with the overlapping mode of lead 50.Thus, can prevent that gassing is residual near lead 50.The thickness of sealing resin part 44 is preferably than more than the sealing resin sheet 33 thin 0.1mm.Again, the width of the width of sealing resin part 44 and above-mentioned disappearance part is the same or than its narrow getting final product, but does not overlap on the sealing resin sheet 33.If it is both are overlapping, then cracked at this part possibility generating unit.Prevent the balance of effect if consider operation and bubble, then preferably about the narrow 0.5～10mm of width than above-mentioned disappearance part.
Behind configuration sealing resin sheet 33 and the sealing resin part 44, at blank portion 10 mounting sealing resin part 43 intermittently.Then, it is whole to utilize sealing resin sheet 34 to cover, again mounting backplate 3 thereon.
The stepped construction of the 1st invention and the 2nd invention more than has been described.Next discharge the air between sensitive surface side transparent panel 2 and the backplate 3, heating makes cooling after the resin fusion and seals.At this moment, preferred heating makes the resin fusion, and makes it carry out cooling after the cross-linking reaction and seal.Seal employed device,, be not particularly limited as long as can carry out the discharging operation and the heating operation of air.The preferred use has the sealed container of taking in duplexer 60 in inside, and can carry out the discharging operation of air and the device of heating operation.At this moment, part or all of preferred sealing container handling constitutes with the soft film of non-gas permeability.Can adopt the outside of the sealed container that the soft film by non-gas permeability constitutes to keep atmospheric so-called substance vacuum mode, also can adopt so-called double-layer vacuum mode, that is the mode that can adjust the vacuum degree of the both sides of two Room in the next door that constitutes across soft film, by non-gas permeability.The substance vacuum mode is preferred because equipment is simple.If adopt manufacture method of the present invention, even then before the sealing resin fusion from the substance vacuum mode of the service load up and down of duplexer 60, can prevent that also stop element is cracked.The material of above-mentioned film, as long as be the soft film of non-gas permeability, if to a certain degree above flexibility and intensity are arranged, external pressure acted on duplexer on the whole equably when the inside of film became vacuum, then be not particularly limited, can use the sheet or the film of rubber or resin.
The sealed container of substance vacuum mode, also with the incorporate container of heater, the container that constitutes by the soft film of non-gas permeability of a part only also, but the preferred bag 61 that uses whole soft film to constitute by non-gas permeability.In this case, because sealed container is simple bag 61, thus can tackle flexibly when making the solar module of different shape or size, in the purposes of the product that requires to make multiple size such as building materials, desirable especially.Duplexer 60 was imported bag at 61 o'clock, and the preferred complete cycle that utilizes the disappointing part 62 that is made of the material with gas permeability to cover the end face of duplexer 60 prevents that the molten resin of duplexer 60 inside from flowing out, and guarantees from the passing away of duplexer 60 inner air-outs.As the material that the part 62 that loses heart uses, can be cloth and silks such as yarn fabric, knitted fabric, nonwoven fabrics.
In the bag that uses whole like this soft film to constitute 61 o'clock, a plurality of bags 61 that imported duplexer 60 can be configured in the heater by non-gas permeability.But the pipe 63 that connects exhaust on each bag 61 connects vacuum pump 65 by pressure-regulating valve 64.Utilize such method, can utilize easy device to concentrate and carry out a plurality of applying operations.
Above-mentioned be configured like that after, discharge the air between sensitive surface side transparent panel 2 and the backplate 3, heating makes cools off after the resin fusion and seals.The temperature conditions of this moment has no particular limits, as long as rise to the fusible temperature of resin, the fusing point of this resin is above to get final product if crystalline resin then is heated to.Again, sealing resin is if crosslinkable thermoplastic resin then makes it be warmed up to crosslinkable temperature, and the crosslinkable temperature of maintenance given time.As long as pressure also is can reduce pressure can discharge the air in the duplexer 60 and can reduce the residual pressure of bubble, this pressure is not particularly limited.
Wherein, when in sealed container, sealing, preferably comprise the seal operation of following each operation: the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin (operation 1), the operation (operation 2) of the pressure below the 0.01MPa, the operation (operation 3) that is warmed up to the temperature more than the sealing resin fusing point under the state that keeps decompression, the operation (operation 4) that makes the pressure rising above-mentioned sealed container in and the operation of cooling off (operation 6) reduce pressure in sealed container under less than the temperature of sealing resin fusing point.Though preferably use this method to seal, be not limited thereto to duplexer with above-mentioned the 1st invention or the 2nd structure of inventing.
Aforementioned operation 1 is that the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin.By the pressure in the sealed container is remained on more than the 0.05MPa, can prevent that above-below direction from duplexer 60 is at the big load of unit effect.More preferably, this pressure is more than the 0.06MPa.Also atmospheric pressure (0.1MPa) of the pressure of this moment in the sealed container, but, can check the leakage of sealed container by for example reducing pressure below the 0.09MPa.In operation 1, sealing resin does not also have fusion, so when sealed container has leakage, can repair in this stage.When particularly using soft bag as sealed container, because the bag cracky, so preferably decompression so a little.When reducing pressure set pressure more than the 0.05MPa, preferably the decompression operation required time was located at more than 10 minutes from atmospheric pressure.This is because though do not bear big load, also may cause that because of the decompression operation of fierceness the unit is cracked.
By heated sealant resin under the state that the pressure in sealed container is high as described above, make sealing resin softening in advance.The temperature that heating reached of this moment is the temperature of not fusion of sealing resin, and is the temperature that spring rate descends.At this, the temperature of not fusion of so-called sealing resin normally than the low temperature of fusing point (Tm), is preferably below (Tm-5) ℃, more preferably below (Tm-10) ℃.When sealing resin did not have fusing point, said here fusing point can be thought of as vitrification point or softening point.The preferred temperature of most sealing resins is below 65 ℃, and preferred temperature is below 60 ℃.When this temperature was too high, resin just began to flow before the pressure in operation 2 in the sealed container dropped to below the 0.01MPa, thereby the passage that is used to discharge the air of duplexer 60 inside can be blocked, and possible gassing is residual.Again, the temperature that aforementioned heating reached is preferably more than (Tm-30) ℃, more preferably more than (Tm-20) ℃.The preferred temperature of most sealing resins is more than 40 ℃, more preferably more than 45 ℃.This temperature is crossed when hanging down, and the decline of the spring rate of sealing resin is not enough, and the possibility generating unit is cracked when reducing the pressure in the sealed container in operation 2.Begin the decompression operation of operation 2 after preferably in such temperature range, keeping more than 5 minutes.
Operation 2 is the operations of the pressure below the 0.01MPa of reducing pressure in sealed container under less than the temperature of the fusing point of sealing resin, is then operation 1 operation of carrying out.By under temperature, reducing pressure, guarantee to discharge the passage of the air of duplexer 60 inside less than the sealing resin fusing point.At this moment, the pressure in the sealed container preferably drops to below the 0.005MPa.By abundant decompression, the bubble after can effectively suppressing to seal is residual.In operation 2, from reduce pressure temperature during the 0.01MPa of 0.05MPa, preferably maintain with operation 1 in the same temperature range of the temperature of utilizing aforementioned heating to reach of explanation.Again, in order to prevent to cause that because of the decompression operation of fierceness the unit is cracked, from 0.05MPa to 0.01MPa, preferably through slowly decompression more than 5 minutes.
Operation 3 is the operations that are warmed up to the temperature more than the sealing resin fusing point under the state that keeps decompression, is to follow the operation that operation 2 is carried out.When sealing resin heated up, spring rate descended greatly near fusing point, becomes full-bodied liquid, and operation 3 is to keep decompression state until the operation that reaches such temperature.Boost if reduce the decompression degree during spring rate is higher, then air may flow into the inside of duplexer 60, residual bubble in sealing resin.At this, the lower limit of the temperature that warming temperature reached of operation 3 is preferably more than (Tm+10) ℃, more preferably more than (Tm+20) ℃.The preferred lower limit of most sealing resins is more than 80 ℃, more preferably more than 85 ℃.Again, higher limit is normally below 200 ℃.
The speed that heats up in the operation 3 preferably relatively slowly, rises to the said temperature required time from room temperature and is preferably more than 15 minutes, more preferably more than 30 minutes, and then is preferably more than 1 hour.By slow intensification, load can sharply not act on, and can prevent that effectively stop element is cracked.At this moment, also can change programming rate midway, also can stop to heat up and implement to eliminate the balancing run of duplexer 60 temperature inside gradients.Consider that from productivity ratio the heating-up time is usually below 20 hours.
Operation 4 is operations that the pressure in the sealed container is risen, and operation 6 is operations of cooling off, all is to follow the operation that operation 3 is carried out.Operation 4 and operation 6, carry out earlier any one can, but also two-step carries out simultaneously.In the refrigerating work procedure of operation 6, though near the common cool to room temperature, glass may be cracked if cooling rate is too fast, so preferably cool off more than 10 minutes, more preferably cools off more than 30 minutes.
In operation 4, preferably slowly boost, be preferably pressure rising time more than 5 minutes, more preferably more than 10 minutes, and then be preferably more than 20 minutes.Consider that from productivity ratio pressure rising time is usually below 5 hours, preferably below 2 hours.Pressure after boosting is preferably more than the 0.05MPa, more preferably more than the 0.07MPa, also can boost to the pressure the same with atmospheric pressure (0.1MPa).At this moment, also can stage boost.In operation 4, if the temperature when pressure is risen is too high, then molten resin can unnecessarily flow, possible generating unit mobile.Usually below 120 ℃, preferably below 100 ℃.
Again, in operation 4, while preferably have the process that makes the interior pressure of aforementioned sealed container rise and heat up simultaneously.Like this,, can remove the pressure that acts on the duplexer 60 gradually, suppress the generation of residual bubble effectively, suppress unnecessary molten resin simultaneously and flow increasing in the mobile process gradually.At this moment, the temperature in when beginning of boosting is made as (Tm-10) ℃～(Tm+20) ℃, more preferably is made as (Tm-5) ℃～(Tm+15) ℃, and wish heating up from this temperature during 3～30 ℃, more preferably boost during 5～20 ℃ heating up.The rate of pressure rise (MPa/ minute) is preferably 0.001～0.1 (MPa/ ℃) with the ratio of programming rate (℃/minute), more preferably 0.002～0.05 (MPa/ ℃).
When using crosslinkable thermoplastic resin as sealing resin, preferably after near the operation (operation 3) more than being warmed up to the sealing resin fusing point under the state that keeps decompression, the operation (operation 4) that rises through the pressure that makes in the above-mentioned sealed container, and have and be warmed up to the temperature range of carrying out cross-linking reaction and carry out the operation (operation 5) of cross-linking reaction and the operation of cooling off (operation 6).
In this case, after the also preferred pressure rising that in operation 4, makes in the sealed container, temporarily be cooled to the following temperature of fusing point, in operation 5, be warmed up to the temperature range of carrying out cross-linking reaction afterwards.Although also can after pressure is risen, under this state, be warmed up to the temperature range of carrying out cross-linking reaction, but by temporary transient cooling, can guarantee the time that residual stress relaxes, that can more effectively suppress molten resin overflows, shrinks the mobile of (in the part of terminal deficiency resin), unit.At this moment, preferably be cooled to the degree that resin fully loses flowability, preferably be cooled to below (Tm-10) ℃, more preferably be cooled to below (Tm-20) ℃.
After making the pressure rising in the sealed container as described above, be warmed up to the temperature range of carrying out cross-linking reaction and carry out cross-linking reaction in operation 5.Usually be heated to more than 100 ℃, preferred more than 120 ℃, more preferably more than 130 ℃, so that preferred more than 140 ℃, carry out cross-linking reaction.In order to prevent the deterioration of resin, adopt the crosslinking temperature below 200 ℃ usually.Remain on the time in the temperature range of carrying out cross-linking reaction, according to the target degree of cross linking etc. and different, but, be preferably 10 minutes usually at 5 minutes～2 hours～1 hour.
Pressure in the sealed container when carrying out cross-linking reaction in operation 5 is preferably more than 0.05MPa, more preferably more than 0.06MPa.By the pressure in the sealed container is risen, can reduce the pressure that acts on from up and down.Because cross-linking reaction is at high temperature carried out, so the melt viscosity of the sealing resin of this moment is than much lower near the fusing point.So do not suppress overflowing of the moving of unit, resin this moment, be very important from acting on unnecessary pressure up and down.But, when boosting to, because the reasons in structure of duplexer produces sometimes and shrinks, so at this moment be preferably set to pressure below atmospheric pressure with the same pressure of atmospheric pressure.Again, when boosting to the same pressure of atmospheric pressure, thereby disappointing part be difficult to push duplexer around also have resin to overflow situation, so at this moment also preferably set in pressure below atmospheric pressure.The pressure of this moment preferably forces down pressure more than the 0.001MPa than atmosphere, the pressure (be below the 0.09MPa this moment) that more preferably low 0.01MPa is above.In addition, said atmosphere end finger does not actively pressurize or the state of decompression operation among the present invention, for example becomes and is higher than atmospheric situation a little owing to utilizing fan to force to be blown into hot blast in hot-blast stove, and is also the same with atmospheric pressure basically.
After in operation 5, carrying out cross-linking reaction, supply to the refrigerating work procedure of operation 6.About refrigerating work procedure 6, as previously mentioned.
The module that the solar module of Huo Deing like this is a plurality of solar battery cells can not damaged formal rule to arrange.Because can be with resin-sealed a plurality of solar battery cells, so the large-sized solar batteries module can be provided under not damaged situation.And bubble is residual to be suppressed, and resin is suppressed from overflowing also of end, marshalling, and outward appearance is beautiful, so that exterior wall, roof, window of being used in various buildings etc. are located is all very desirable.
Embodiment
Utilize embodiment to illustrate in greater detail the present invention below.
Embodiment
Fig. 4 represents the profile of solar module 1 and the solar battery cell of wherein arranging 4.As solar battery cell 4, used the square monocrystaline silicon solar cell unit of 416 100mm * 100mm * 0.3mm.Four jiaos of chamferings are counted the degree of mm.As lead 8, the dipping soft solder copper strips shape electric wire that has used Hitachi Cable Ltd. to make.The width of this strap wire is that 1.5mm, thickness are 0.15mm.In the sensitive surface 6 of solar battery cell 4 and the back side 7, on the part of bonding lead 8, print soft solder in advance.Overlapping and solder is in the soft solder Printing Department of the sensitive surface 6 of solar battery cell 4 with an end of lead 8, and overlapping and solder is in the soft solder Printing Department at the back side 7 of adjacent solar battery unit 4 with the other end.Utilize 2 leads 8 to connect between the adjacent unit, make it be spaced apart 2mm.That is, the width of clearance portion 9 is 2mm.
As sensitive surface side transparent panel 2, use the kickboard tempered glass (blank glass) of 2810mm * 1795mm * 12mm.The surface compression stress of this tempered glass is 100MPa, and the warpage that with JISR3206 is standard test is 0.25%.As the sealing resin sheet, only otherwise forbid especially, the resin sheet that is about to the thickness 0.6mm of " ソ-ラ-エ バ SC36 " that Ha イ シ-ト Industrial Co., Ltd makes cuts off and is used.The sealing resin sheet is the resin sheet that has cooperated crosslinking agent, organosilan coupling agent, stabilizer etc. in ethylene-vinyl acetate copolymer (EVA), and the fusing point of measuring with the DSC method of crosslinked preceding resin is 71 ℃.Single face at the sealing resin sheet forms shallow stamping (pears surface), and its degree of depth is about 45 μ m.The concave surface of warpage that makes sensitive surface side transparent panel 2 is last, the sealing resin sheet 21,22,23 of the size of overlapping thereon 3 2810mm * 1795mm.These 3 sealing resin sheets 21,22,23 constitute the 1st sealing resin sheet 20 of thickness 1.8mm.
Fig. 5～Figure 10 is the figure that amplifies presentation graphs 4 upper left and upper right portion (part that the single-point line is surrounded).As shown in Figure 5, the group that is connected in series with 26 solar battery cells 4 is in the longitudinal direction arranged 16 groups with the 2mm spaced and parallel, will add up to 416 module units to be configured on the 1st sealing resin sheet 20.The width of the clearance portion 9 that adjacent solar battery cell is 4 all is made as 2mm in length and breadth.In the end of the solar battery cell 4 of configured in series, the lead 8 that connects on the solar battery cell 4 connects with the locational lead 51 at a distance of 5mm each other.From the end of solar battery cell 4 to the distance of the end of sensitive surface side transparent panel 2, the width of promptly blank portion 10, end is made as 80mm about on Fig. 4, upper and lower side is made as 82.5mm.Zuo Ce blank portion 10 utilizes lead 52 to connect lead 51 each other in the drawings.As lead 51,52, use the dipping soft solder copper strips shape electric wire of wide 4.0mm, thick 0.25mm.
Next, as shown in Figure 6, configuration sealing resin part 40 in blank portion 10.Sealing resin part 40 is in the end configuration along sensitive surface side transparent panel 2 of the complete cycle of blank portion 10.About blank portion 10 (width is 80mm), the width of sealing resin part 40 is 49mm; In blank portion 10 (width is 82.5mm) up and down, the width of sealing resin part 40 is 51.5mm.In the inboard of sealing resin part 40, separate about 8mm and dispose sealing resin part 45 abreast with sealing resin part 40 at interval.Sealing resin part 45 is about 8mm with the distance of the end of solar battery cell 4.At this moment, the blank portion 10 in the left side, sealing resin part 45 is than skew ground configuration a little laterally in other blank portions 10, so that do not overlap on the lead 52.By at the inboard configuration sealing resin part 45 narrower, can prevent that sealing resin part 40 from flowing into unevenly to the direction of solar battery cell 4 when melted by heating than sealing resin part 40 width.Can prevent the generation of the mobile or bubble of solar battery cell 4 thus.Afterwards, intermittently dispose the sealing resin part 41 of long 100mm, wide 10mm along the end of sensitive surface side transparent panel 2.Like this, can between next stacked sealing resin sheet 31 and sealing resin part 40, the gap be set, can discharge the air in the space that forms between sealing resin sheet 23 and the sealing resin sheet 31 smoothly.
Then, as shown in Figure 7, exist the part that has lead 52 in the blank portion 10 in the part of lead 51 and left side to vacate the gap 36 of wide 5mm respectively in the blank portion 10 on right side, the sealing resin sheet 31 that utilizes 3 sheets to constitute covers roughly whole.Can see through gap 36 is connected lead 50 on lead 51 and 52.Then, intermittently dispose the sealing resin part 42 of long 100mm, wide 10mm along the end of sensitive surface side transparent panel 2.After coinciding with, dispose the dielectric film 55 of wide 10mm, thick 0.1mm on the position of lead 50 downsides of configuration again.After coinciding with, on the position of the downside of the lead 53,54 of configuration, also dispose the dielectric film 56 of wide 30mm, long 100mm, thick 0.1mm.
Then, as shown in Figure 8, exist the part that has lead 52 in the blank portion 10 in the part of lead 51 and left side to vacate the gap 36 of wide 5mm respectively in the blank portion 10 on right side, the sealing resin sheet 32 that utilizes 3 sheets to constitute covers roughly whole.Then, the lead 52 that the lead 51 that utilizes lead 50 to connect to exist from the blank portion 10 on figure right side exists in the blank portion 10 in left side, and lead 50 is configured on the sealing resin sheet 32.As lead 50, use the dipping soft solder copper strips shape electric wire of wide 6mm, thick 0.1mm.On the electric wiring in the blank portion 10 that is present in the left side (figure does not show), connect 2 leads 53,54 of drawing to terminal board again. Lead 53,54 is the same with lead 50.Also can be on electric wiring in the blank portion 10 that is present in the left side (figure does not show) or lead 52, corresponding to the elements such as assembling diode such as specification of module.
Then, as shown in Figure 9, sealing resin sheet 33 with excalation 40 * 130mm size range of the width of the about 20mm of excalation of lead 50, lead 53,54 covers, on the lead 50 of above-mentioned disappearance part, configuration is by the wide sealing resin part 44 of 15mm of the resin sheet formation of the thickness 0.4mm of " ソ-ラ-エ バ SC36 " of Ha イ シ-ト Industrial Co., Ltd manufacturing.Again, on the lead 53,54 of above-mentioned disappearance part, to cover the whole basically mode of range of loss, the thick sealing resin part 46 of configuration 0.4mm.Then, intermittently dispose the sealing resin part 43 of long 100mm, wide 10mm along the end of sensitive surface side transparent panel 2.
Next, utilize sealing resin sheet 34 to cover whole.As shown in figure 10, on sealing resin sheet 34, cut out the otch 37 of long 300mm, draw 2 leads 53,54 of drawing from this otch to terminal board.Afterwards, overlapping backplate 3.As backplate 3, use the kickboard tempered glass (backboard glass) of 2810mm * 1795mm * 12mm.The surface compression stress of this tempered glass is 100MPa, is that the warpage of standard test is 0.25% with JIS R3206.Again, plate 3 is provided with the circular open portion of the 20mm diameter that is used to pass 2 leads 53,54 of drawing to terminal board overleaf.The concave surface that makes backplate 3 is down, and the opening that is provided with from backplate 3 is drawn 2 leads 53,54 and overlapping.
Obtain to offer the duplexer 60 of seal operation as described above.At this, the 1st sealing resin sheet 20 is made of 3 sealing resin sheets, and aggregate thickness is 1.8mm.Again, the 2nd sealing resin sheet 30 is made of 4 sealing resin sheets, aggregate thickness 2.4mm.Again, the aggregate thickness that is configured in the sealing resin part 40,41,42,43 of blank portion 10 is 2.4mm.
The part 62 that utilize to lose heart covers the complete cycle of the end face of the duplexer 60 that obtains like this, puts in the bag 61 as the rubber system of sealed container closing bag 61.Why the utilization part 62 that loses heart covers the end face of duplexers 60, is in order to prevent that the molten resins in the duplexer 60 from flowing out, and guarantees the passing away from duplexer 60 air-outs.
Bag group more than 61 of above-mentioned rubber system is configured on the shelf 67 that is provided with in the hot-blast stove 66 side by side.But the pipe 63 that connects exhaust on the bag 61 of each rubber system, pipe 63 connects vacuum pump 65 through pressure-regulating valve 64.The simplified schematic illustration of encapsulation process device is in Figure 11.
After below being provided with like that, carry out the encapsulation process operation of following operation 1～6.The temperature and pressure of this moment is as table 1 and control as shown in Figure 12.This moment, temperature was the temperature in the hot-blast stove 66, and pressure is the pressure that utilizes pressure-regulating valve 64 to set.
Operation 1: " pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin ".
Intensification in the beginning hot-blast stove 66, and the decompression in the beginning sealed container.Make pressure slowly drop to 0.07MPa from atmospheric pressure (0.1MPa) with 45 minutes, its chien shih temperature slowly rises to 50 ℃ from room temperature (30 ℃).
Operation 2: " operation of the pressure below the 0.01MPa that under less than the temperature of sealing resin fusing point, reduces pressure in sealed container ".
With the temperature maintenance in the hot-blast stove 66 50 ℃ 30 minutes, the pressure in its chien shih sealed container slowly drops to less than 0.005MPa from 0.07MPa.
Operation 3: " under the state that keeps decompression, being warmed up to the operation of the temperature more than the sealing resin fusing point ".
Temperature in the hot-blast stove 66 was warmed up to 60 ℃ with 120 minutes from 50 ℃, was warmed up to 71 ℃ (fusing points of sealing resin) from 60 ℃, after keeping 10 minutes under 71 ℃, be warmed up to 78 ℃ from 71 ℃ with 45 minutes with 150 minutes.Therebetween, the pressure in the sealed container is maintained less than 0.005MPa.
Operation 4: " operation that the pressure in the above-mentioned sealed container is risen ".
In above-mentioned operation 3, the temperature in the hot-blast stove 66 begin to boost after arriving 78 ℃, make in the sealed container pressure from less than 0.005Mpa with slowly boosting to 0.07MPa in 70 minutes.Therebetween, temperature slowly rose to 90 ℃ with 75 minutes from 78 ℃.The rate of pressure rise (MPa/ minute) of this moment is 0.0063 (MPa/ ℃) with the ratio of programming rate (℃/minute).Afterwards, under 90 ℃, kept 30 minutes, be cooled to 30 ℃ with 30 minutes, under 30 ℃, kept 5 minutes, keep the pressure of 0.07MPa therebetween.
Operation 5: " being warmed up to the temperature range of carrying out cross-linking reaction and the operation of carrying out cross-linking reaction ".
Next, be warmed up to 155 ℃ from 30 ℃, under 155 ℃, kept 36 minutes and carry out cross-linking reaction with 90 minutes.Keep the pressure of 0.07MPa therebetween.
Operation 6: " operation of cooling off ".
Then, keeping the pressure of 0.07MPa, be cooled to 30 ℃ from 155 ℃, after reaching 30 ℃, making the pressure in the sealed container boost to 0.1MPa (atmospheric pressure) with about 1 minute, taking out from hot-blast stove 66 with 60 minutes.
Table 1
Figure C200580021448D00301
The solar module that obtains, the unit is cracked, damaged, the conductor cord disconnection problem does not all have, and it is residual also not observe bubble, does not also observe sealing resin overflowing or shrinking at periphery.And solar battery cell is arranged sealing regularly.

Claims (15)

1, a kind of manufacture method of solar module, described solar module constitutes by with resin a plurality of solar battery cells being sealed between sensitive surface side transparent panel and the backplate, the method is characterized in that,
A plurality of solar battery cells separate following being spaced of 5mm, utilize lead to connect mutually, between sensitive surface side transparent panel and solar battery cell, configuration covers whole the 1st sealing resin sheet of sensitive surface side transparent panel, overleaf between plate and the solar battery cell, configuration covers whole the 2nd sealing resin sheet of backplate, blank portion in the solar battery cell outside, dispose many sealing resin parts of aggregate thickness to be clamped in mode between the 1st sealing resin sheet and the 2nd sealing resin sheet greater than the thickness aggregate value of the thickness of solar battery cell and lead, on the mutual horizontal direction of sealing resin part, be separated with air-out at interval and from here, discharge the air between sensitive surface side transparent panel and the backplate then, heating makes cooling after the resin fusion and seals.
2, the manufacture method of solar module as claimed in claim 1 is characterized in that, the aggregate thickness of above-mentioned sealing resin part is 1～5mm.
3, the manufacture method of solar module as claimed in claim 1 or 2, it is characterized in that, along the complete cycle of above-mentioned blank portion continuously configuration the sealing resin part and overlap and be separated with mutually many sealing resin parts of compartment of terrain configuration, be clamped between the 1st sealing resin sheet and the 2nd sealing resin sheet.
4, the manufacture method of solar module as claimed in claim 3, it is characterized in that, in above-mentioned blank portion, be positioned at along complete cycle continuously the sealing resin part of configuration the inboard and be positioned on the position in the outside of solar battery cell the configuration width sealing resin part thinner than other sealing resin part.
5, the manufacture method of solar module as claimed in claim 1 or 2 is characterized in that, the 1st sealing resin sheet or the 2nd sealing resin sheet constitute by stacked many sealing resin sheets.
6, the manufacture method of solar module as claimed in claim 5, it is characterized in that, in above-mentioned blank portion, above-mentioned many sealing resin parts are separated with compartment of terrain configuration mutually, and be clamped in constitute the 1st sealing resin sheet or the 2nd sealing resin sheet many sealing resin sheets each other.
7, the manufacture method of solar module as claimed in claim 1 or 2, it is characterized in that, sensitive surface side transparent panel and backplate are that glass plate more than the 20MPa constitutes by the surface compression stress with warpage, make the concave surface of their warpage carry out seal operation relative to one another.
8, the manufacture method of solar module as claimed in claim 7 is characterized in that, the warpage of above-mentioned glass plate is that the value of standard test is the value in 0.05%～0.5% scope with JIS R3206.
9. the manufacture method of solar module as claimed in claim 1 or 2, it is characterized in that, when in sealed container, sealing, the seal operation that comprises following each operation: operation 1: the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin, operation 2: the operation of the pressure below the 0.01MPa that under the temperature that is lower than the sealing resin fusing point, reduces pressure in sealed container, operation 3: under the state that keeps decompression, be warmed up to more than the sealing resin fusing point, the operation of the temperature below 200 ℃, operation 4: the operation that the pressure in the above-mentioned sealed container is risen, and operation 6: the operation of cooling off.
10. the manufacture method of solar module as claimed in claim 1 or 2 is characterized in that, a kind of resin of selecting in the group that aforementioned sealing resin is made of ethylene-vinyl acetate copolymer, polyvinyl butyral resin and polyurethane constitutes.
11, a kind of manufacture method of solar module, described solar module constitutes by with resin a plurality of solar battery cells being sealed between sensitive surface side transparent panel and the backplate, the method is characterized in that,
A plurality of solar battery cell devices spaced apart are arranged, utilize lead to connect mutually, between sensitive surface side transparent panel and solar battery cell, configuration covers whole the 1st sealing resin sheet of sensitive surface side transparent panel, overleaf between plate and the solar battery cell, configuration covers whole the 2nd sealing resin sheet of backplate, the 1st sealing resin sheet or the 2nd sealing resin sheet constitute by stacked many sealing resin sheets, the part of electric wiring is configured on the position that overlaps in discontiguous mode with solar battery cell, in the 1st sealing resin sheet or the 2nd sealing resin sheet, part outside above-mentioned electric wiring disposes 1 in above-mentioned many sealing resin sheets, discharge the air between sensitive surface side transparent panel and the backplate then, heating makes cooling after the resin fusion and seals.
12, the manufacture method of solar module as claimed in claim 11 is characterized in that, in the part of the above-mentioned electric wiring that does not dispose sealing resin, fills up the thin sealing resin sheet of sealing resin sheet than configuration.
13, as the manufacture method of claim 11 or 12 described solar modules, it is characterized in that, dispose dielectric film between above-mentioned electric wiring and solar battery cell, this dielectric film is respectively via at least 1 sealing resin sheet in the 1st sealing resin sheet that constitutes by stacked many sealing resin sheets or the 2nd sealing resin sheet and stacked with solar battery cell and above-mentioned electric wiring.
14, manufacture method as claim 11 or 12 described solar modules, it is characterized in that, when in sealed container, sealing, the seal operation that comprises following each operation: operation 1: the pressure in the sealed container is remained on more than the 0.05MPa and the operation of heated sealant resin, operation 2: the operation of the pressure below the 0.01MPa that under the temperature that is lower than the sealing resin fusing point, reduces pressure in sealed container, operation 3: under the state that keeps decompression, be warmed up to more than the sealing resin fusing point, the operation of the temperature below 200 ℃, operation 4: the operation that the pressure in the above-mentioned sealed container is risen, and operation 6: the operation of cooling off.
As the manufacture method of claim 11 or 12 described solar modules, it is characterized in that 15, a kind of resin of selecting in the group that aforementioned sealing resin is made of ethylene-vinyl acetate copolymer, polyvinyl butyral resin and polyurethane constitutes.
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