CN109950344B

CN109950344B - Solar cell module

Info

Publication number: CN109950344B
Application number: CN201811554048.1A
Authority: CN
Inventors: 隅田健一郎; 内田真辅
Original assignee: Kyocera Corp
Current assignee: Kyocera Corp
Priority date: 2017-12-20
Filing date: 2018-12-18
Publication date: 2023-12-19
Anticipated expiration: 2038-12-18
Also published as: JP6957338B2; CN109950344A; JP2019110265A

Abstract

A solar cell module is provided with: a plate-like 1 st protective member, a 2 nd protective member, a solar cell element, a sealing material, a terminal box, an adhesive layer, and a 3 rd protective member. The 1 st protective member has light transmittance. The solar cell element is located between the 1 st and 2 nd protective members. The sealing material is located between the 1 st and 2 nd protective members in a state of sealing the solar cell element. The terminal box is located on the 1 st face of the 2 nd protection member. The adhesive layer is located on the 1 st surface. The 3 rd protective member is located on the 2 nd surface on the opposite side from the 1 st surface side among the adhesive layers. In the case of a top view perspective adhesive layer, 3 rd protective member, and terminal box, the adhesive layer and 3 rd protective member each have: a hole portion having an inner edge portion in a state of surrounding the terminal box; or a notched portion having an inner edge portion existing along a part of the periphery of the terminal box. Thus, the usable life of the solar cell module can be easily prolonged.

Description

Solar cell module

Technical Field

The present disclosure relates to a solar cell module and a method of manufacturing the solar cell module.

Background

In recent years, for the purpose of popularization of solar cell modules and the like, a system for buying renewable energy at a fixed price has been introduced in some countries. In this system, the purchase period (also referred to as the supply period) is set to be 10 years to 20 years. Therefore, it is expected that a large number of solar cell modules will be used after the supply period is completed in the future.

On the other hand, the durability of the solar cell module can be said to be about 20 years to 30 years. Therefore, a large number of solar cell modules capable of sufficiently generating power are included in the used solar cell modules. Therefore, for example, from the viewpoint of achieving reduction in the amount of waste of the solar cell module and efficient use of resources, it is considered to reuse the solar cell module.

However, for example, in the case of a solar cell module whose usable life is not long enough after reuse, the amount of power generated after the solar cell module is moved may not be enough to meet the expense required for the work of moving the solar cell module. Here, the usable period after reuse corresponds to, for example, a period from the end of the supply period to the elapse of the durable period.

Therefore, a technique for performing processing for prolonging the usable life of a solar cell module when reusing the solar cell module has been proposed (for example, refer to the disclosure of JP 2004-14791 a).

There is room for improvement in solar cell modules in that the usable life is easily prolonged.

Disclosure of Invention

Disclosed are a solar cell module and a method for manufacturing the solar cell module.

One embodiment of a solar cell module includes: a plate-like 1 st protective member, a 2 nd protective member, a solar cell element, a sealing material, a terminal box, an adhesive layer, and a 3 rd protective member. The 1 st protection member has light transmittance. The solar cell element is located between the 1 st protective member and the 2 nd protective member. The sealing material is located between the 1 st protective member and the 2 nd protective member in a state of sealing the solar cell element. The terminal box is located on a 1 st face on a side opposite to the 1 st protection member side among the 2 nd protection members. The adhesive layer is located on the 1 st face of the 2 nd protective member. The 3 rd protective member is located on a 2 nd face on a side opposite to the 1 st face side among the adhesive layers. In a plan view of the adhesive layer, the 3 rd protective member, and the terminal box, the adhesive layer and the 3 rd protective member each have: a hole portion having an inner edge portion in a state of surrounding the terminal box; or a notched portion having an inner edge portion existing along a part of the circumference of the terminal box.

One aspect of the method for manufacturing a solar cell module includes a 1 st step and a 2 nd step. In the step 1, a solar cell module before repair is prepared. The solar cell module before repair is provided with: a plate-like 1 st protective member, a 2 nd protective member, a solar cell element, a sealing material, and a terminal box. The plate-like 1 st protection member has light transmittance. The solar cell element is located between the 1 st protective member and the 2 nd protective member. The sealing material is located between the 1 st protective member and the 2 nd protective member in a state of sealing the solar cell element. The terminal box is located on a 1 st face on a side opposite to the 1 st protection member side among the 2 nd protection members. In the step 2, the 3 rd protective member is bonded to the 1 st surface through the adhesive layer in a state where the adhesive layer and the 3 rd protective member are laminated such that an inner edge portion of the hole or an inner edge portion of the notch in the 3 rd protective member is present along a periphery of the terminal box on the 1 st surface.

Effects of the invention

For example, the usable life of the solar cell module can be easily prolonged.

Drawings

Fig. 1 is a plan view showing an external appearance of a front surface side of an example of a solar cell module according to embodiment 1.

Fig. 2 is a plan view showing an external appearance of the back surface side of an example of the solar cell module according to embodiment 1.

Fig. 3 is a view showing an example of a virtual cut-away section of the solar cell module along the line III-III in fig. 2.

In fig. 4, (a) is a plan view showing an external appearance of the front surface side of the example of the solar cell element according to embodiment 1, and (b) is a plan view showing an external appearance of the back surface side of the example of the solar cell element according to embodiment 1.

In fig. 5, (a) is a flowchart showing an example of a flow of a process for manufacturing a solar cell module, and (b) is a flowchart showing an example of a flow of a process of step 2.

Fig. 6 is a perspective view showing an external appearance of an example of a solar cell module before repair prepared in step 1.

Fig. 7 is a view showing a virtual cross-sectional portion corresponding to the virtual cross-sectional portion of fig. 3 in an example of the solar cell module before repair prepared in step 1.

Fig. 8 is a perspective view showing an external appearance of an example of a solar cell module during repair in step 2.

In fig. 9, (a) and (b) are views showing virtual cross-sectional portions corresponding to the virtual cross-sectional portions of fig. 3, respectively, in an example of the solar cell module during repair in the 2A process.

In fig. 10, (a) and (B) are views showing virtual cross-sectional portions corresponding to the virtual cross-sectional portions of fig. 3, respectively, in an example of the solar cell module during repair in the 2B step.

Fig. 11 is a view showing a virtual cross-sectional portion of an example of a solar cell module and a laminator during repair of the lamination process performed in step 2C.

In fig. 12, (a) and (B) are views showing virtual cross-sectional portions corresponding to the virtual cross-sectional portions of fig. 3, respectively, in another example of the solar cell module during repair in the 2B step.

Fig. 13 is a cross-sectional view showing an example of the layer structure of the 3 rd protective member according to embodiment 2.

Fig. 14 is a plan view showing an external appearance of the back surface side of an example of a solar cell module according to embodiment 2.

Fig. 15 is a view showing an example of a virtual cut-away section of the solar cell module along the line XV-XV in fig. 14.

Fig. 16 is a view showing a virtual cross-sectional portion corresponding to the virtual cross-sectional portion of the solar cell module taken along the line III-III in fig. 2 in an example of the solar cell module according to embodiment 3.

Fig. 17 is a plan view showing an external appearance of the back surface side of an example of a solar cell module according to embodiment 4.

Symbol description

1. 1 st solar cell module

1bs 1 st side

2. No. 2 solar cell module

2ms 2 nd side

Ad2 adhesive layer

Bx1 terminal box

Cl1 solar cell element

Cn 21 st central region

Cn3 2 nd central region

Ct1 st connecting part

Ct2 nd connecting part

Ep21 st outer edge portion

Ep22 2 nd peripheral portion

Fl1 frame

H21 1 st hole part

H21C 1 st notch portion

H22 2 nd hole part

H22C 2 nd notch portion

Ip21, ip21C 1 st inner edge portion

Ip22, ip22C 2 nd inner edge portion

Is0 inner space

Jg1 clamp

Ml1 metal layer

Oe1 st output extraction electrode

Oe2 nd output extraction electrode

Op0 peripheral portion

Op1 st outer peripheral portion

Op2 nd outer peripheral portion

Ot 21 st peripheral edge area

Ot3 No. 2 peripheral region

Pj1 st protrusion

Pj2 No. 2 protrusion

Pn1 st solar cell panel

Pn2 nd solar cell panel

Pr1 st protective member

Pr2 nd protective member

Pr3, pr3A 3 rd protective member

Ri3 insulating member

Rl1 st resin layer

Rl2 resin layer 2

Rc0 recess

Rp0 contact site

SK0 laminate

Sl1 sealing material

Sl1f 1 st seal material

Sl1b 2 nd sealing material

Tb1 st wiring member

Tb2 nd wiring member

Th0 through hole part

Detailed Description

From the standpoint of reducing the amount of waste and effectively utilizing resources, it is considered to reuse the used solar cell module.

The solar cell module generally has a structure in which a transparent substrate, a front-side sealing material, a plurality of solar cell elements, a rear-side sealing material, and a protective sheet are laminated in this order from the light-receiving surface side. In such a solar cell module, for example, moisture and the like are liable to be caused to penetrate into the solar cell element from the resin protective sheet in accordance with deterioration of the resin protective sheet and the like. This is one of the main causes, and deteriorates the solar cell module.

Therefore, for example, it is considered to improve durability of the back surface side of the solar cell module by replacing the protective sheet or the like of the solar cell module, thereby extending the usable life of the solar cell module.

However, if a complicated process is required for improving durability of the rear surface side of the solar cell module, there is a concern that the advantage of using the reuse product cannot be fully exerted as compared with a new product.

Therefore, there is room for improvement in terms of easy extension of the usable life of the solar cell module.

Accordingly, the inventors of the present invention have created a technique for easily extending the usable life of a solar cell module.

With respect to this, various embodiments are described below based on the drawings. In the drawings, the same components having the same structures and functions are denoted by the same reference numerals, and repetitive description thereof will be omitted in the following description. The figures are schematic. The XYZ coordinate system of the right-hand system is added to fig. 1 to 4 (b) and fig. 6 to 17. In the XYZ coordinate system, the long-side direction of the front surface 1fs of the 1 st solar cell module 1 before repair and the 2 nd solar cell module 2 after repair, which will be described later, is set to the +y direction, and the short-side direction of the front surface 1fs is set to the +x direction. In the XYZ coordinate system, a normal direction to the front surface 1fs orthogonal to both the +x direction and the +y direction is set as the +z direction.

<1. Embodiment 1 >

<1-1. Structure of solar cell Module >

A 2 nd solar cell module 2 according to embodiment 1 will be described with reference to fig. 1 to 4 (b).

The 2 nd solar cell module 2 is manufactured by repairing a portion on the back side of the 1 st solar cell module 1 (see fig. 6, 7, etc.) after use and before repair, for example. In embodiment 1, repair is performed on a portion of the solar cell panel (also referred to as a 1 st solar cell panel) Pn1 on the back side before repair among the 1 st solar cell modules 1. Therefore, the 2 nd solar cell module 2 is a repaired solar cell module. The 2 nd solar cell module 2 is manufactured by repairing the 1 st solar cell module 1, and thus contributes to reuse of the solar cell module.

As shown in fig. 1 to 3, the 2 nd solar cell module 2 includes, for example: a solar cell panel (also referred to as a 2 nd solar cell panel) Pn2, a terminal box Bx1, and a frame Fl1. The 2 nd solar cell panel Pn2 includes: the 1 st protective member Pr1, the sealing material Sl1, N (N is a natural number) solar cell elements Cl1, the 2 nd protective member Pr2, the adhesive layer Ad2, and the 3 rd protective member Pr3. The 2 nd solar cell panel Pn2 further includes: a plurality of 1 st wiring members Tb1, a plurality of 2 nd wiring members Tb2, and a plurality of 3 rd wiring members Wr1. Here, for example, the positions of the 1 st protection member Pr1 and the 2 nd protection member Pr2 are in a state of facing each other. For example, N solar cell elements Cl1, a sealing material Sl1, a plurality of 1 st wiring members Tb1, and a plurality of 2 nd wiring members Tb2 are located between the 1 st protective member Pr1 and the 2 nd protective member Pr 2. The sealing material Sl1 includes: a 1 st sealing material Sl1f located on the 1 st protective member Pr1 side; and a 2 nd sealing material Sl1b located on the 2 nd protective member Pr2 side. A part of the 3 rd wiring members Wr1 is led out to the outside through the through hole Hl1 provided in the 2 nd protective member Pr2 in advance, for example, and is connected to the terminals in the terminal box Bx 1.

In the examples of fig. 1 to 3, the 1 st protective member Pr1, the 1 st sealing material Sl1f, the N solar cell elements Cl1, the 2 nd sealing material Sl1b, the 2 nd protective member Pr2, the adhesive layer Ad2, and the 3 rd protective member Pr3 are stacked in this order. In the 2 nd solar cell panel Pn2, the surface in the +z direction of the 1 st protective member Pr1 is set to be a surface (also referred to as front surface) 1fs on which external light such as sunlight is mainly irradiated. In the 2 nd solar cell panel Pn2, the surface of the 3 rd protective member Pr3 on the-Z direction side is set to be a surface (also referred to as a back surface) 2bs that is not irradiated with external light such as sunlight from the front surface 1 fs.

The 1 st protective member Pr1 is a plate-like member having light transmittance. The 1 st protective member Pr1 has, for example, light transmittance for light of a specific range of wavelengths. As the specific range of wavelengths, for example, the wavelength of light having a high intensity, which is included in the light irradiated to the 2 nd solar cell module 2, and the wavelength of light which can be photoelectrically converted by the solar cell element Cl1 is used. For example, when a resin such as glass, acryl, or polycarbonate is used as the material of the 1 st protective member Pr1, the water blocking property of the 1 st protective member Pr1 and the light transmittance with respect to light having a wavelength in a specific range can be achieved. As the 1 st protection member Pr1, for example, a flat plate-like member having rectangular front and back surfaces and a thickness of about 1mm to 5mm is used. The 1 st protection member Pr1 having the above-described structure is in a state of protecting N solar cell elements Cl1 from the front surface 1fs side of the 2 nd solar cell panel Pn2 by rigidity and water blocking property, for example.

The 1 st sealing material Sl1f is located between the 1 st protective member Pr1 and the N solar cell elements Cl1 in a state where the N solar cell elements Cl1 are covered from the 1 st protective member Pr1 side, for example. In the example of fig. 3, the 1 st sealing material Sl1f is filled in the region between the 1 st protective member Pr1 and the N solar cell elements Cl 1. As a material of the 1 st sealing material Sl1f, for example, an ethylene/vinyl acetate copolymer (EVA), triacetyl cellulose (TAC), polyethylene naphthalate (PEN), or other polyester resin having excellent light transmittance to light of a specific range of wavelengths is used.

The N solar cell elements Cl1 are located between, for example, the 1 st protective member Pr1 and the 2 nd protective member Pr 2. Each solar cell element Cl1 can electrically convert incident sunlight, for example. As the solar cell Cl1, for example, a crystalline solar cell or a thin film solar cell can be used. In the example of fig. 1 to 4 (b), as the solar cell Cl1, a solar cell having a semiconductor substrate St1 of crystalline silicon is used. As shown in fig. 4 (a) and (b), the solar cell element Cl1 includes: the front surface 1fs side surface (also referred to as a 1 st element surface) Sfc1, the back surface 2bs side surface (also referred to as a 2 nd element surface) Sfc2, and the end surface (also referred to as a 3 rd element surface) Sfc3. The 3 rd element surface Sfc3 is present in a state where the 1 st element surface Sfc1 and the 2 nd element surface Sfc2 are connected. Here, for example, in the semiconductor substrate St1, the 1 St conductivity type (e.g., p-type) region is located at least on the 2 nd element surface Sfc2 side, and the 2 nd conductivity type (e.g., n-type) region is located at least on the 1 St element surface Sfc1 side. Therefore, the semiconductor substrate St1 has a pn junction, and can generate carriers by photoelectric conversion according to irradiation of light.

As shown in fig. 4 (a), the 1 St output extraction electrode Oe1 as the 1 St electrode and the 1 St collector electrodes Ce1 in a state intersecting the 1 St output extraction electrode Oe1 are located on the 1 St element surface Sfc1 side of the semiconductor substrate St 1. In other words, each solar cell element Cl1 has the 1 st output extraction electrode Oe1 on the 1 st protective member Pr1 side. The 1 St output extraction electrode Oe1 can collect carriers generated in accordance with photoelectric conversion in the semiconductor substrate St1 via the plurality of 1 St collector electrodes Ce1, and output electricity to the outside of the solar cell element Cl 1. In the example of fig. 4 (a), there are 2 1 st output extraction electrodes Oe1 each having a long side direction in the +y direction and 24 1 st collector electrodes Ce1 each having a long side direction in the +x direction.

As shown in fig. 4 (b), the 2 nd output extraction electrode Oe2 as the 2 nd electrode and the 2 nd collector electrode Ce2 in a state of being connected to the 2 nd output extraction electrode Oe2 are located on the 2 nd element surface Sfc2 side of the semiconductor substrate St 1. In other words, each solar cell element Cl1 has the 2 nd output extraction electrode Oe2 on the 2 nd protective member Pr2 side. The 2 nd output extraction electrode Oe2 can collect carriers generated in the semiconductor substrate St1 according to photoelectric conversion via the 2 nd collector electrode Ce2, and output electricity to the outside of the solar cell element Cl 1. In the example of fig. 4 (b), there are 2 nd output extraction electrodes Oe2 each having 4 island-like portions aligned in a row in the +y direction and a 2 nd collector electrode Ce2 located on substantially the entire surface of the 2 nd element surface Sfc2 side of the semiconductor substrate St 1. The 1 St output extraction electrode Oe1 and the 2 nd output extraction electrode Oe2 are, for example, in a state of sandwiching the semiconductor substrate St 1. For example, the 1 st output extraction electrode Oe1 may be 3 or more, and the 2 nd output extraction electrode Oe2 may be 3 or more.

Here, the 1 st wiring members Tb1 and the 2 nd wiring members Tb2 are located between adjacent solar cell elements Cl1 among the plurality of solar cell elements Cl1 in a state in which the 1 st output extraction electrode Oe1 and the 2 nd output extraction electrode Oe2 are electrically connected, respectively. Specifically, for example, among the N solar cell elements Cl1, 2 solar cell elements Cl1 existing in a state adjacent in the +y direction are in a state connected by the 1 st wiring member Tb1, with the 1 st output extraction electrode Oe1 and the 2 nd output extraction electrode Oe2. Here, for example, a member having a long and thin foil-like or wire-like structure made of a conductive material such as copper is applied to the 1 st wiring material Tb 1. The 1 st wiring material Tb1 is bonded to the 1 st output extraction electrode Oe1 and the 2 nd output extraction electrode Oe2 by soldering or the like, for example. Here, for example, in each solar cell element Cl1, the 1 st wiring material Tb1 exists in a state having a portion (also referred to as a 1 st connection portion) Ct1 and a portion (also referred to as a 2 nd connection portion) Ct2, the portion Ct1 is in a state of being connected to the 1 st output extraction electrode Oe1, and the portion Ct2 is in a state of being connected to the 2 nd output extraction electrode Oe2.

The N solar cell elements Cl1 are arranged on a plane along the XY plane. The N solar cell elements Cl1 are electrically connected in series by, for example, the 1 st wiring material Tb1 and the 2 nd wiring material Tb 2. In the example of fig. 1, 24 solar cell elements Cl1 are in a state of constituting 4 solar cell element groups St 1. In each solar cell element group St1, 6 solar cell elements Cl1 aligned in the +y direction are electrically connected in series by the wiring material Tb 1. The 4 solar cell element groups St1 are arranged in the +x direction and electrically connected in series by the 2 nd wiring material Tb 2. The same material and shape as those of the 1 st wiring member Tb1 can be applied to the material and shape of the 2 nd wiring member Tb2, for example. The 2 nd wiring member Tb2 is present in a state bonded to the 1 st wiring member Tb1 by soldering or the like, for example. For example, the 3 rd wiring material Wr1 is joined to the 1 st wiring material Tb1 by soldering or the like, and the 1 st wiring material Tb1 is connected to the solar cell element Cl1 at both ends of the 24 solar cell elements Cl1 connected in series. The same material and shape as those of the 1 st wiring material Tb1 may be applied to the material and shape of the 3 rd wiring material Wr 1.

The 2 nd sealing material Sl1b is located between the N solar cell elements Cl1 and the 2 nd protective member Pr2, for example, by covering the N solar cell elements Cl1 from the 2 nd protective member Pr2 side. In the example of fig. 3, the 2 nd sealing material Sl1b is filled in the region between the 2 nd protective member Pr2 and the N solar cell elements Cl 1. In other words, the sealing material Sl1 including the 1 st sealing material Sl1f and the 2 nd sealing material Sl1b is located between the 1 st protective member Pr1 and the 2 nd protective member Pr2 in a state of sealing the N solar cell elements Cl 1. As a material of the 2 nd seal material Sl1b, for example, a polyester resin such as EVA, TAC, or PEN can be used in the same manner as the 1 st seal material Sl1 f. Here, the 2 nd sealing material Sl1b may have light transmittance for light of a specific range wavelength, or may not have light transmittance for light of a specific range wavelength, for example.

The 2 nd protective member Pr2 is present in a state where N solar cell elements Cl1 are protected from the back surface 2bs side of the 2 nd solar cell panel Pn2, for example. For example, a plate-like member having a substantially rectangular shape and high rigidity or a flexible sheet-like member may be applied to the 2 nd protective member Pr 2. Here, the thickness of the plate-like member may be, for example, about 1mm to 5 mm. For example, when a resin such as polycarbonate is used as the material of the plate-like member, the 2 nd protective member Pr2 can realize water blocking property and light transmittance to light of a specific range of wavelengths. Further, for example, when 1 or 2 or more resins among polypropylene, polyolefin, and polyethylene terephthalate (PET) are used as the material of the sheet-like member, water resistance and water blocking property can be achieved in the 2 nd protective member Pr 2. The 2 nd protective member Pr2 may have light transmittance for light having a specific range of wavelengths, or may not have light transmittance for light having a specific range of wavelengths, for example. Here, the surface (also referred to as the 1 st surface) 1bs of the 2 nd protective member Pr2 on the opposite side to the 1 st protective member Pr1 side corresponds to a surface (also referred to as the back surface) on which the front surface 1fs is not irradiated with external light such as sunlight in the 1 st solar cell module 1 before repair.

The terminal box Bx1 is located on, for example, the 1 st surface 1bs of the 2 nd protection member Pr 2. The terminal box Bx1 is fixed to the 1 st surface 1bs by an adhesive Sc1 such as silicone resin, for example. The terminal box Bx1 can output electricity generated by the N solar cell elements Cl1 to the outside through the cable Cb1 or the like. The cable Cb1 includes, for example, a 1 st cable Cb1p for output of the positive electrode and a 2 nd cable Cb1n for output of the negative electrode.

The adhesive layer Ad2 is located on, for example, the 1 st surface 1bs of the 2 nd protective member Pr 2. The adhesive layer Ad2 has a function of adhering the 3 rd protective member Pr3 to the 1 st surface 1 bs. For example, a layer having a layered form along the 1 st surface 1bs may be applied to the adhesive layer Ad 2. As a material of the adhesive layer Ad2, for example, a polyester resin such as EVA, TAC, or PEN can be used as in the case of the sealing material Sl 1.

The 3 rd protective member Pr3 is located on a surface (also referred to as a 2 nd surface) 2ms on the opposite side of the 1 st surface 1bs side in the adhesive layer Ad2, for example. The 3 rd protective member Pr3 is a member constituting the back surface 2bs of the 2 nd solar cell panel Pn 2. Therefore, the 3 rd protective member Pr3 is present in a state where the 2 nd protective member Pr2 and the N solar cell elements Cl1 are protected from the back surface 2bs side, for example. For example, a plate-like member having a substantially rectangular shape on the front and back surfaces and having high rigidity or a flexible sheet-like member can be applied to the 3 rd protective member Pr3 in the same manner as the 2 nd protective member Pr 2. Here, for example, if the 3 rd protective member Pr3 is a plate-like member having water blocking properties, the durability of the 2 nd solar cell module 2 can be improved. For example, the shape, size, and material of the 3 rd protective member Pr3 can be similar to the shape, size, and material of the 2 nd protective member Pr 2. For example, a resin such as glass or propylene may be applied to the material of the 3 rd protective member Pr3 in the same manner as the 1 st protective member Pr 1. The 3 rd protective member Pr3 may have light transmittance for light of a specific range of wavelengths, or may not have light transmittance for light of a specific range of wavelengths, for example, like the 2 nd protective member Pr 2.

Here, for example, as shown in fig. 2 and 3, the adhesive layer Ad2 has a hole portion (also referred to as a 1 st hole portion) H21 penetrating the adhesive layer Ad2 in the thickness direction (here, ±z direction). As shown in fig. 2, for example, when the 3 rd protective member Pr3, the adhesive layer Ad2, and the terminal box Bx1 are seen in a plan view from the back surface 2bs side along the +z direction, the 1 st hole H21 has an inner edge portion (also referred to as a 1 st inner edge portion) Ip21 that surrounds the terminal box Bx1. Further, for example, as shown in fig. 2 and 3, the 3 rd protective member Pr3 has a hole portion (also referred to as a 2 nd hole portion) H22 penetrating the 3 rd protective member Pr3 in the thickness direction (here, ±z direction). As shown in fig. 2, the 2 nd hole H22 has an inner edge portion (also referred to as a 2 nd inner edge portion) Ip22 that surrounds the terminal box Bx1 when the 3 rd protective member Pr3 and the terminal box Bx1 are viewed in a +z direction from the back surface 2bs side, for example. In other words, the positions of the adhesive layer Ad2 and the 3 rd protective member Pr3 avoid the terminal box Bx1.

The 2 nd solar cell module 2 having the above-described structure can be manufactured by disposing the adhesive layer Ad2 and the 3 rd protective member Pr3 on the 1 st surface 1bs, which is the back surface of the 1 st solar cell module 1, without detaching the terminal box Bx1 from the 1 st solar cell module 1 after use. In other words, the repaired 2 nd solar cell module 2 has the following structure: the 1 st solar cell module 1 before repair; and an adhesive layer Ad2 and a 3 rd protective member Pr3 on the 1 st surface 1bs of the 1 st solar cell panel Pn 1. In this way, for example, the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs of the 1 st solar cell module 1 by the adhesive layer Ad2, and the usable life of the 1 st solar cell module 1 after use can be prolonged. Thus, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. Here, for example, the 2 nd protective member Pr2 whose moisture permeability is increased by degradation can be easily enhanced by the 3 rd protective member Pr3 whose moisture permeability is low. As a result, for example, the usable life (also referred to as lifetime) of the solar cell module 2 after repair can be easily prolonged.

Here, for example, as shown in fig. 2, it is assumed that the 3 rd protective member Pr3 and the terminal box Bx1 are viewed from the back surface 2bs side in the +z direction. In this case, for example, the 3 rd protective member Pr3 is provided in a state of being away from the terminal box Bx1. In this configuration, for example, when the 3 rd protective member Pr3 is disposed on the-Z direction side (also referred to as the upper side) of the 2 nd protective member Pr2 of the 1 st solar cell module 1 after use, the 3 rd protective member Pr3 hardly contacts the terminal box Bx1. Therefore, the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 of the used 1 st solar cell module 1. This can easily extend the usable life of the 2 nd solar cell module 2 after repair, for example. In the example of fig. 2, the distance separating the terminal box Bx1 and the 3 rd protective member Pr3 is the distance D1. Here, for example, it is assumed that the adhesive layer Ad2 and the terminal box Bx1 are seen in a plan view along the +z direction from the back surface 2bs side. In this case, for example, an edge portion (also referred to as an inner edge portion) Ip21 of the inner side of the adhesive layer Ad2 may exist in a state of being away from the terminal box Bx1.

The frame Fl1 is located along, for example, an outer peripheral portion (also referred to as 1 st outer peripheral portion) Op1 of the 1 st protection member Pr1 and an outer peripheral portion (also referred to as 2 nd outer peripheral portion) Op2 of the 2 nd protection member Pr 2. In other words, the frame Fl1 exists in a state of being attached along the outer peripheral portion Op0 in a state of connecting the front surface 1fs and the 1 st surface 1bs, for example. The 1 st outer peripheral portion Op1 and the 2 nd outer peripheral portion Op2 are included in the outer peripheral portion Op 0. Specifically, for example, the outer peripheral portion Op0 of the 2 nd solar cell panel Pn2 is fitted into the groove portion of the frame Fl 1. Here, the outer peripheral portion Op0 of the 2 nd solar cell panel Pn2 is positioned in the groove portion of the frame Fl1 in a state of being fixed to the frame Fl1 by an adhesive (also referred to as an outside adhesive) Sl2 such as butyl resin, for example.

Here, for example, as shown in fig. 2 and 3, it is assumed that the 3 rd protective member Pr3 and the frame Fl1 are viewed from the back surface 2bs side in the +z direction. In this case, for example, a structure is adopted in which an outer edge portion (also referred to as an outer edge portion) Ep22 of the 3 rd protective member Pr3 exists in a state of being apart from the frame Fl1. With such a configuration, when the 3 rd protective member Pr3 is disposed on the upper side of the 2 nd protective member Pr2 of the used 1 st solar cell module 1 having the frame Fl1, the 3 rd protective member Pr3 is hardly brought into contact with the frame Fl1. Therefore, the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 in the used 1 st solar cell module 1 having the frame Fl1. This can easily lengthen the usable life of the repaired 2 nd solar cell module 2, for example. In the example of fig. 2, the distance separating the 3 rd protective member Pr3 and the frame Fl1 is a distance D2. For example, it is assumed that the adhesive layer Ad2 and the frame Fl1 are seen in a planar view along the +z direction from the back surface 2bs side. In this case, for example, an outer edge portion (also referred to as an outer edge portion) Ep21 of the adhesive layer Ad2 may also exist in a state of being apart from the frame Fl1.

However, for example, in the 1 st solar cell module 1, if moisture is allowed to enter from the 1 st surface 1bs side, which is the back surface before repair, EVA constituting the sealing material Sl1 is hydrolyzed by the moisture, and acetic acid is generated. This acetic acid may deteriorate the 2 nd connection portion Ct2 between the 2 nd output extraction electrode Oe2 and the 1 st wiring material Tb1 due to corrosion, for example. For example, if the 2 nd connection portion Ct2 is degraded over the entire length of each solar cell element Cl1, the 1 st wiring material Tb1 may be peeled off from the 2 nd output extraction electrode Oe 2. As a result, in the 1 st solar cell module 1, there is a possibility that the resistance increases, and the output is greatly reduced.

In contrast, in the repaired 2 nd solar cell module 2, for example, the 1 st surface 1bs side is in a state of being covered with the 3 rd protective member Pr 3. Specifically, for example, consider a case where the 3 rd protective member Pr3, the solar cell element Cl1, and the 1 st wiring material Tb1 are seen in a plan view along the +z direction from the back surface 2bs side. In this case, for example, as shown in fig. 1 and 2, a structure is considered in which the 3 rd protective member Pr3 overlaps at least a part of the 2 nd connection portion Ct2 in each of the N solar cell elements Cl 1. With such a configuration, for example, the penetration of moisture from the 1 st surface 1bs side, which is the back surface before repair, toward the 2 nd connection portion Ct2 can be reduced. Thus, for example, in each solar cell element Cl1, the problem that the 2 nd connection portion Ct2 is degraded over the entire length is hardly caused. Therefore, for example, it is difficult to reduce the output of the 2 nd solar cell module 2 after repair. As a result, for example, the usable life of the repaired 2 nd solar cell module 2 can be easily prolonged.

Here, for example, as shown in fig. 2, it is assumed that the adhesive layer Ad2 is seen in a plan view along the +z direction from the back surface 2bs side. In this case, as shown in fig. 2, the adhesive layer Ad2 has a 1 st central area Cn2 and a 1 st peripheral area Ot2. The 1 st peripheral region Ot2 includes, for example, a portion located along the outer edge portion (also referred to as 1 st outer edge portion) Ep21 of the adhesive layer Ad2 and a portion located along the 1 st inner edge portion Ip21 of the adhesive layer Ad2 around the 1 st central region Cn 2. In the example of fig. 2, in the adhesive layer Ad2, the 1 st central region Cn2 is located between the 1 st outer edge portion Ep21 and the 1 st inner edge portion Ip 21. As shown in fig. 3, for example, the 1 st peripheral region Ot2 may have a smaller thickness than the 1 st central region Cn 2. At this time, the 3 rd protective member Pr3 is positioned in a region (also referred to as a peripheral region) Ot3 that is in contact with the 1 st peripheral region Ot2 in a state where it is closer to the 2 nd protective member Pr2 than the region (also referred to as a 2 nd central region) Cn3 that is in contact with the 1 st central region Cn 2. In such a configuration, for example, in a portion where the 3 rd protective member Pr3 and the 2 nd protective member Pr2 are close to each other along the 2 nd inner edge portion Ip22 and the outer edge portion (also referred to as a 2 nd outer edge portion) Ep22 of the 3 rd protective member Pr3, the area where the adhesive layer Ad2 is exposed to the outside can be reduced. Thus, for example, the penetration of moisture into the sealing material Sl1 through the 1 st peripheral region Ot2 and the 2 nd protective member Pr2 of the adhesive layer Ad2 in the order of the 1 st peripheral region Ot2 and the 2 nd protective member Pr2 of the adhesive layer Ad2 can be reduced. As a result, for example, the usable life of the solar cell module 2 after repair can be easily prolonged.

<1-2 > method for manufacturing solar cell module

An example of a method of manufacturing the 2 nd solar cell module 2 after repair from the 1 st solar cell module 1 before repair will be described with reference to fig. 5 (a) to 11. Here, the 1 st solar cell module 1 can be repaired and the 2 nd solar cell module 2 can be manufactured by performing the 1 st step Sp1 and the 2 nd step Sp2 in the order shown in fig. 5 (a).

First, in the 1 st step Sp1, for example, the 1 st solar cell module 1 before repair is prepared. Here, the 1 st solar cell module 1 includes, for example, as shown in fig. 6 and 7: the 1 st protective member Pr1, the 2 nd protective member Pr2, the N solar cell elements Cl1, the sealing material Sl1, and the terminal box Bx1, and includes the 1 st solar cell panel Pn1. Here, the 1 st protective member Pr1 is a plate-like member having light transmittance. The N solar cell elements Cl1 are located between the 1 st protective member Pr1 and the 2 nd protective member Pr 2. The sealing material Sl1 is located between the 1 st and 2 nd protective members Pr1 and Pr2 in a state of sealing the N solar cell elements Cl 1. The terminal box Bx1 is located on the 1 st surface 1bs on the opposite side to the 1 st protection member Pr1 side among the 2 nd protection members Pr 2. In other words, the adhesive layer Ad2 and the 3 rd protective member Pr3 in the 2 nd solar cell module 2 after repair are not present in the 1 st solar cell module 1 before repair.

Next, in the 2 nd step Sp2, for example, the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs through the adhesive layer Ad2 in a state that the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs which is the back surface of the 1 st solar cell module 1. Specifically, in the 2 nd step Sp2, for example, the 2 nd a step Sp2A, the 2 nd B step Sp2B, and the 2 nd C step Sp2C shown in fig. 5 (B) are performed in this order.

In the 2A-th step Sp2A, for example, as shown in fig. 8, fig. 9 (a) and (b), the adhesive layer Ad2 and the 3-th protective member Pr3 are laminated on the 1 st surface 1bs of the 1 st solar cell module 1. Thus, the laminated body SK0 is formed in which the 1 st solar cell module 1, the adhesive layer Ad2, and the 3 rd protective member Pr3 are laminated in this order. At this time, for example, the adhesive layer Ad2 is laminated on the 1 st surface 1bs with the 1 st inner edge portion Ip21 of the 1 st hole H21 in the adhesive layer Ad2 positioned along the periphery of the terminal box Bx 1. Further, for example, the 3 rd protective member Pr3 is laminated on the 2 nd surface 2ms of the adhesive layer Ad2 with the position of the 2 nd inner edge portion Ip22 of the 2 nd hole portion H22 in the 3 rd protective member Pr3 along the periphery of the terminal box Bx 1.

Next, in step 2B, as shown in fig. 10 (a) and (B), for example, the jig Jg1 is placed on the 3 rd protective member Pr3 in a state in which the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs of the 1 st solar cell module 1. In other words, the jig Jg1 is disposed on the 3 rd protective member Pr3 of the laminated body SK0. In embodiment 1, for example, at the time point when the 2A step Sp2A is performed, as shown in fig. 9 b, the frame Fl1 is in a state of protruding in the-Z direction from the surface (back surface) 2bs of the 3 rd protective member Pr3 opposite to the adhesive layer Ad 2. In this state, in the lamination process in the 2C step Sp2C described later, it is not easy to press the rear surface 2bs of the 3 rd protective member Pr3. Therefore, as shown in fig. 10 (b), the jig Jg1 has a thickness such that a surface (also referred to as an upper surface) Su0 of the jig Jg1 on the opposite side (-Z direction side) from the 3 rd protective member Pr3 is higher than a surface Sf0 on the-Z direction side of the frame Fl1 in a state of being disposed on the 3 rd protective member Pr3. Here, the thickness of the jig Jg1 is the thickness in the ±z directions. The jig Jg1 has a shape capable of pressing the entire surface (back surface) 2bs of the 3 rd protective member Pr3 on the-Z direction side in the lamination process in the 2 nd C step Sp2C described later, for example. For example, as the shape of the jig Jg1, a rectangular parallelepiped shape can be used.

Next, in the 2C step Sp2C, for example, as shown in fig. 11, the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs by the adhesive layer Ad2 in a state in which the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs by the laminating apparatus 200. Specifically, for example, the 1 st solar cell panel Pn1, the adhesive layer Ad2, and the 3 rd protective member Pr3 in the laminated body SK0 are integrated. Here, first, for example, the laminate SK0 is mounted on the hot plate Hp0 in the chamber Cm1 of the laminating apparatus 200. Then, a voltage is applied to the hot plate Hp0 by the power supply Es2, and the hot plate Hp0 is resistance heated. At this time, for example, the laminated body SK0 is heated by a hot plate Hp 0. At this time, for example, by opening the valves Vv1 and Vv2 and sucking the pump Pm2, the air pressure of the space Ls0 below (also referred to as a lower space) where the laminated body SK0 is located is made lower than the air pressure of the space Us0 above (also referred to as an upper space) inside the laminating apparatus 200. The flexible sheet-like diaphragm Df1 is deformed by the air pressure difference between the lower space Ls0 and the upper space Us0, and a pressing force is applied to the jig Jg 1. Thus, in a state where the laminate SK0 is heated, the 3 rd protective member Pr3 is pressed against the 2 nd protective member Pr2 via the jig Jg1, and the lamination process for integrating the 1 st solar cell module 1, the adhesive layer Ad2, and the 3 rd protective member Pr3 before repair is performed.

In this way, for example, the positions of the adhesive layer Ad2 and the 3 rd protective member Pr3 can be kept away from the terminal box Bx1. Therefore, the adhesive layer Ad2 and the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 in the used 1 st solar cell module 1 without removing the terminal box Bx1 from the used 1 st solar cell module 1. In other words, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. Thus, for example, the 2 nd protective member Pr2 whose moisture permeability is increased by degradation can be easily enhanced by the 3 rd protective member Pr3 whose moisture permeability is low. As a result, for example, the usable life of the 2 nd solar cell module 2 after repair can be easily prolonged.

However, for example, in the 2 nd step Sp2, it is assumed that the 2 nd protective member Pr2, the 3 rd protective member Pr3, and the terminal box Bx1 are seen in a plan view along the +z direction. In this case, it is considered that the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs by the adhesive layer Ad2 in a state where the 2 nd inner edge portion Ip22 of the 3 rd protective member Pr3 is away from the terminal box Bx1. Thus, when the 3 rd protective member Pr3 is disposed on the upper side of the 2 nd protective member Pr2 of the used 1 st solar cell module 1, the 3 rd protective member Pr3 is hardly brought into contact with the terminal box Bx1. Therefore, the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 of the used 1 st solar cell module 1. This can easily extend the usable life of the 2 nd solar cell module 2 after repair, for example.

For example, the 1 st solar cell module 1 before repair includes a plurality of 1 st wiring members Tb1 and N solar cell elements Cl1, similarly to the 2 nd solar cell module 2 (fig. 1 to 4 (b)) after repair described above. Here, in the examples of fig. 1, 4 (a) and (b), the plurality of 1 st wiring members Tb1 are each in a state of electrically connecting the 1 st output extraction electrode Oe1 and the 2 nd output extraction electrode Oe2 of the adjacent solar cell elements Cl1 among the N solar cell elements Cl1. Specifically, in each solar cell element Cl1, the 1 st wiring material Tb1 is present in a state having the 1 st connection portion Ct1 in a state of being connected to the 1 st output extraction electrode Oe1 and the 2 nd connection portion Ct2 in a state of being connected to the 2 nd output extraction electrode Oe 2. At this time, for example, when the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs through the adhesive layer Ad2 in the 2 nd step Sp2, the 3 rd protective member Pr3 and the 2 nd connecting portion Ct2 are seen in a plan view along the +z direction. In this case, for example, the 3 rd protective member Pr3 is overlapped with at least a part of the 2 nd connecting portion Ct2 in each solar cell element Cl1. In this structure, for example, a part of the 2 nd connection portion Ct2 may be covered with the 3 rd protective member Pr3 from the upper side of the 2 nd protective member Pr2 for all the solar cell elements Cl1. Therefore, for example, the penetration of moisture from the back surface 2bs side to the 2 nd connection portion Ct2 can be reduced. Thus, for example, in each solar cell element Cl1, the problem that the 2 nd connection portion Ct2 is degraded over the entire length is hardly caused. Therefore, for example, it is difficult to reduce the output of the 2 nd solar cell module 2 after repair. As a result, for example, the usable life of the 2 nd solar cell module 2 after repair can be easily prolonged.

In embodiment 1, for example, the 1 st solar cell module 1 before repair includes a frame Fl1 in the same manner as the 2 nd solar cell module 2 (fig. 1 to 4 (b)) after repair described above. Here, in the example of fig. 1 to 3, the frame Fl1 is positioned along, for example, the peripheral edge portion (1 st peripheral edge portion) Op1 of the 1 st protection member Pr1 and the peripheral edge portion (2 nd peripheral edge portion) Op2 of the 2 nd protection member Pr2. At this time, for example, in the 2 nd step Sp2, it is assumed that the 2 nd protective member Pr2, the 3 rd protective member Pr3, and the frame Fl1 are seen in a plan view along the +z direction. In this case, for example, when the 3 rd protective member Pr3 is adhered to the 1 st surface 1bs by the adhesive layer Ad2 in a state where the 2 nd outer edge portion Ep22 of the 3 rd protective member Pr3 is away from the frame, the 3 rd protective member Pr3 is hardly brought into contact with the terminal box Bx1. Therefore, the 3 rd protective member Pr3 can be easily bonded from the upper side of the 2 nd protective member Pr2 of the 1 st solar cell module 1 after use. This can easily extend the usable life of the 2 nd solar cell module 2 after repair, for example.

Further, here, for example, the above-described jig Jg1 may have a structure for avoiding contact with the terminal box Bx1. For example, as shown in fig. 10 (a), when the jig Jg1 is arranged on the 3 rd protective member Pr3, a concave portion Rc0 for avoiding contact with the terminal box Bx1 may be present on a surface (also referred to as a lower surface) Sb0 on the 3 rd protective member Pr3 side among the jigs Jg 1. In other words, the jig Jg1 may have the concave portion Rc0 in a state of being concave in the-Z direction. In this case, for example, as shown in fig. 10B, in the 2B step Sp2B, the jig Jg1 having the concave portion Rc0 Is disposed in a space (also referred to as an internal space) Is0 in which the terminal box Bx1 Is located in the concave portion Rc0 on the 3 rd protective member Pr3. Thus, for example, the 3 rd protective member Pr3 and the adhesive layer Ad2 can be easily pressed against the 2 nd protective member Pr2 via the jig Jg1 while avoiding the terminal box Bx1 by the diaphragm Df1 of the laminating apparatus 200. As a result, for example, the 1 st solar cell module 1, the 3 rd protective member Pr3, and the adhesive layer Ad2 before repair can be easily integrated.

Here, for example, the jig Jg1 has the 1 st protruding portion Pj1 protruding in the +z direction in order to press the 2 nd peripheral edge portion Ot3 along the 2 nd inner edge portion Ip22 out of the 3 rd protective member Pr3 on the lower surface Sb 0. For example, the jig Jg1 has a 2 nd protrusion Pj2 protruding in the +z direction so as to press down the 2 nd peripheral edge portion Ot3 along the 2 nd peripheral edge portion Ep22 in the 3 rd protective member Pr3 on the lower surface Sb 0. Specifically, for example, when the bottom surface Sb0 is viewed in the-Z direction, the 1 st protrusion Pj1 is present in a ring shape along the recess Rc0 in the bottom surface Sb 0. For example, when the lower surface Sb0 is viewed in the-Z direction, the 2 nd protrusion Pj2 is present in a ring shape along the outer peripheral portion of the lower surface Sb 0. If the 1 st projection Pj1 and the 2 nd projection Pj2 are present, for example, the 2 nd peripheral region Ot3 can be pushed down in the +z direction more than the 2 nd central region Cn3 in the 3 rd protective member Pr3 when the lamination process is performed. Thus, for example, as shown in fig. 3, in the adhesive layer Ad2, the 1 st peripheral region Ot2 has a smaller thickness than the 1 st central region Cn2, and the 2 nd peripheral region Ot3 of the 3 rd protective member Pr3 may be in a state closer to the 2 nd protective member Pr2 than the 2 nd central region Cn 3.

Here, for example, in the case where the 3 rd protective member Pr3 is a sheet-like member having flexibility, a portion (also referred to as a contact portion) Rp0 of the jig Jg1 in the 2 nd step Sp2B, which is in contact with the 3 rd protective member Pr3, may be made of an elastomer made of a resin. In other words, for example, in the case of using a protective member including a sheet-like member having flexibility as the 3 rd protective member Pr3, as the jig Jg1, a jig in which a portion in contact with the 3 rd protective member Pr3 in the 2 nd step Sp2 is in a state of being made of a resin-made elastic body may be used. In this case, for example, even if the 1 st surface 1bs of the 2 nd protective member Pr2 of the 1 st solar cell module 1 before repair has irregularities corresponding to the presence of the solar cell element Cl1, the 1 st wiring material Tb1, the 2 nd wiring material Tb2, and the like, the surface of the jig Jg1 may be deformed corresponding to the irregularities. Thus, for example, the adhesive layer Ad2 and the 3 rd protective member Pr3 can be pressed and deformed along the irregularities of the 1 st surface 1bs of the 2 nd protective member Pr 2. As a result, for example, in the lamination process, voids such as bubbles are hardly generated between the 2 nd and 3 rd protective members Pr2 and Pr3, and the adhesion of the adhesive layer Ad2 and the 3 rd protective member Pr3 to the 2 nd protective member Pr2 can be improved. Therefore, for example, the usable life of the 2 nd solar cell module 2 after repair can be easily prolonged. Here, for example, a form in which the entire jig Jg1 or the contact portion Rp0 of the jig Jg1 along the lower surface Sb0 is made of a resin elastomer may be considered. For example, a sponge including a terpolymer of ethylene, propylene, and a small amount of diene (EPDM) may be used as the resin elastomer.

Here, for example, as shown in fig. 12 (a), in order to avoid contact with the terminal box Bx1, the jig Jg1 may have a hole portion (also referred to as a through hole portion) Th0 penetrating the jig Jg1 instead of the concave portion Rc 0. In the example of fig. 12 (a), the through hole Th0 penetrates the jig Jg1 in the ±z directions. In this case, for example, as shown in fig. 12B, in the step 2B, the jig Jg1 having the through hole Th0 Is disposed on the 3 rd protective member Pr3 so that the terminal box Bx1 Is located in the space (internal space) Is0 within the through hole Th0.

< 1-3. Summary of embodiment 1 >

As described above, the repaired 2 nd solar cell module 2 according to embodiment 1 includes, for example: the 1 st solar cell module 1 before repair; and an adhesive layer Ad2 and a 3 rd protective member Pr3 on the 1 st surface 1bs, which is the back surface of the 1 st solar cell module 1. Therefore, for example, by adhering the 3 rd protective member Pr3 to the 1 st surface 1bs of the 1 st solar cell module 1 before repair by the adhesive layer Ad2, the usable life of the 1 st solar cell module 1 after use can be prolonged. Thus, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. As a result, for example, the usable life (also referred to as lifetime) of the solar cell module 2 after repair can be easily prolonged. Therefore, the 2 nd solar cell module 2 according to embodiment 1 can be said to have a structure suitable for reuse in addition to repairing the used 1 st solar cell module 1 for reuse.

In the method for manufacturing the 2 nd solar cell module 2 according to embodiment 1, for example, the 3 rd protective member Pr3 is bonded to the 1 st surface 1bs by the adhesive layer Ad2 in a state in which the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs of the 1 st solar cell module 1. At this time, for example, the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs such that the 1 st inner edge portion Ip21 of the 1 st hole portion H21 and the 2 nd inner edge portion Ip22 of the 2 nd hole portion H22 are positioned along the periphery of the terminal box Bx1, respectively. In this way, when the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs of the 1 st solar cell module 1, for example, the positions of the adhesive layer Ad2 and the 3 rd protective member Pr3 are kept away from the terminal box Bx1. Therefore, for example, the adhesive layer Ad2 and the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 in the 1 st solar cell module 1 after use without removing the terminal box Bx1 from the 1 st solar cell module 1 after use. Thus, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. As a result, for example, the usable life of the repaired 2 nd solar cell module 2 can be easily prolonged.

<2 > other embodiments

The present disclosure is not limited to embodiment 1 described above, and various changes, modifications, and the like can be made without departing from the gist of the present disclosure.

<2-1. Embodiment 2 >

In embodiment 1 described above, for example, as shown in fig. 13, the 3 rd protective member Pr3 may be replaced with a 3 rd protective member Pr3A, and the 3 rd protective member Pr3A has a metal layer Ml1 and 1 st resin layer Rl1 and 2 nd resin layer Rl2 that exist in a state of sandwiching the metal layer Ml 1. In this case, as shown in fig. 14 and 15, for example, there may be an insulating member Ri3 positioned in a state of covering the 2 nd outer edge portion Ep22 of the 3 rd protective member Pr 3A. Here, for example, since the 3 rd protective member Pr3 has the metal layer Ml1, the moisture permeability of the 3 rd protective member Pr3 may be reduced. Thus, for example, the penetration of moisture into the sealing material Sl1 through the adhesive layer Ad2 and the 2 nd protective member Pr2 can be reduced. As a result, for example, the usable life (also referred to as lifetime) of the solar cell module 2 after repair can be easily prolonged. Further, for example, when the 2 nd outer edge portion Ep22 of the 3 rd protective member Pr3A having the metal layer Ml1 is covered with the insulating member Ri3, the insulation resistance between the frame Fl1 and the metal layer Ml1 can be improved in the 2 nd solar cell module 2 regardless of the influence of rain water or the like. Thus, for example, it is difficult to reduce the output of the 2 nd solar cell module 2 after repair.

Here, for example, zinc-plated iron foil obtained by zinc-plating aluminum foil or iron foil, tin-plated iron foil obtained by tin-plating iron foil, stainless steel foil, and the like can be applied to the metal layer Ml 1. The insulating member Ri3 is located, for example, in a ring-shaped region along the 2 nd outer edge portion Ep22 of the 3 rd protective member Pr 3A. As a material of the insulating member Ri3, various insulating materials such as crosslinked polyethylene, epoxy resin, vinyl chloride, and synthetic rubber can be used. For example, a solid insulating material may be used for the insulating material. The solid insulating material includes, for example, an organic fibrous material or an inorganic solid insulating material. The organic fibrous material includes, for example, synthetic fibers such as paper, cotton, polyester, nylon, or natural fibers. The paper may be reduced in moisture permeability by being immersed in an insulating oil. The inorganic solid insulating material includes, for example, mica, ceramic, glass, or asbestos. The insulation resistance and the method for measuring the insulation resistance are, for example, according to Japanese Industrial Standard (JIS) C8951: 2011.

<2-2. Embodiment 3 >

In each of the above embodiments, for example, as shown in fig. 16, the 1 st solar cell module 1 and the 2 nd solar cell module 2 may not include the frame Fl1. In this case, for example, the 1 st solar cell module 1 may be equal to the 1 st solar cell panel Pn1, and the 2 nd solar cell module 2 may be equal to the 2 nd solar cell panel Pn 2.

<2-3. Embodiment 4 >

In each of the above embodiments, for example, as shown in fig. 17, the 1 st hole H21 of the adhesive layer Ad2 may be replaced with a 1 st notch H21C having a 1 st inner edge portion Ip21C at the end of the adhesive layer Ad 2. For example, as shown in fig. 17, when the adhesive layer Ad2 is seen in a plan view from the back surface 2bs side in the +z direction, the 1 st notch H21C is a portion having a shape in which the outer peripheral portion of the adhesive layer Ad2 is cut away and recessed. In the example of fig. 17, when the adhesive layer Ad2 is seen in a plan view from the back surface 2bs side in the +z direction, the 1 st notch H21C is a portion having a shape recessed with respect to a rectangular region in the outer peripheral portion of the adhesive layer Ad 2. In the example of fig. 17, the 1 st inner edge portion Ip21C is a U-shaped portion. At this time, the 2 nd hole H22 of the 3 rd protection member Pr3 may be replaced with a 2 nd notch H22C having a 2 nd inner edge portion Ip22C at the end of the 3 rd protection member Pr 3. For example, as shown in fig. 17, when the 3 rd protective member Pr3 is viewed in a +z direction from the back surface 2bs side, the 2 nd notch H22C is a portion having a shape in which the outer peripheral portion of the 3 rd protective member Pr3 is cut away and recessed. In the example of fig. 17, when the 3 rd protective member Pr3 is viewed in the +z direction from the rear surface 2bs side, the 2 nd notch H22C is a portion having a shape recessed with respect to the rectangular region in the outer peripheral portion of the 3 rd protective member Pr 3. In the example of fig. 17, the 2 nd inner edge portion Ip22C is a U-shaped portion. Here, for example, as shown in fig. 17, a case is assumed in which the 3 rd protective member Pr3, the adhesive layer Ad2, and the terminal box Bx1 are seen in a plan view from the back surface 2bs side along the +z direction. In this case, for example, the 1 st notch H21C of the adhesive layer Ad2 has a 1 st inner edge portion Ip21C existing in a state of being recessed along a part of the periphery of the terminal box Bx1 (for example, a part of 3 sides out of 4 sides). Further, for example, the 2 nd notch portion H22C of the 3 rd protective member Pr3 has a 2 nd inner edge portion Ip22C existing in a state of being recessed along a part of the periphery of the terminal box Bx1 (for example, a part of 3 sides out of 4 sides). Even with such a configuration, for example, the 3 rd protective member Pr3 can be bonded to the 1 st surface 1bs, which is the back surface of the 1 st solar cell module 1 before repair, by the adhesive layer Ad2, whereby the usable life of the 1 st solar cell module 1 after use can be prolonged. Thus, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. As a result, for example, the usable life (also referred to as lifetime) of the repaired 2 nd solar cell module 2 can be easily prolonged.

In the case of the above-described configuration, for example, in the 2 nd step Sp2, the 1 st inner edge portion Ip21C of the 1 st notch portion H21C of the adhesive layer Ad2 is positioned along the periphery of the terminal box Bx1 on the 1 st surface 1bs of the 2 nd protective member Pr 2. Further, the 2 nd inner edge portion Ip22C of the 2 nd notch portion H22C of the 3 rd protection member Pr3 is positioned along the periphery of the terminal box Bx1. Therefore, the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs such that the 1 st inner edge portion Ip21C of the 1 st notch portion H21C of the adhesive layer Ad2 and the 2 nd inner edge portion Ip22C of the 2 nd notch portion H22C of the 3 rd protective member Pr3 are positioned along the periphery of the terminal box Bx1. In this state, the 3 rd protective member Pr3 can be bonded to the 1 st surface 1bs by a lamination process or the like using the adhesive layer Ad 2. Even with such a configuration, for example, when the adhesive layer Ad2 and the 3 rd protective member Pr3 are laminated on the 1 st surface 1bs of the 1 st solar cell module 1, the positions of the adhesive layer Ad2 and the 3 rd protective member Pr3 can be kept away from the terminal box Bx1. Therefore, the adhesive layer Ad2 and the 3 rd protective member Pr3 can be easily disposed on the upper side of the 2 nd protective member Pr2 in the used 1 st solar cell module 1 without removing the terminal box Bx1 from the used 1 st solar cell module 1. Thus, for example, the number of man-hours required for repairing the 2 nd protective member Pr2 side in the used 1 st solar cell module 1 can be reduced. Therefore, for example, the usable life of the repaired 2 nd solar cell module 2 can be easily prolonged.

<3. Other >

In each of the above embodiments, for example, the 3 rd protective member Pr3 may be bonded to the 1 st surface 1bs of the 2 nd protective member Pr2 by the adhesive layer Ad2 in a state of being bonded to the 3 rd protective member Pr3 in advance. In this case, for example, the 3 rd protective member Pr3 may be attached to the 1 st surface 1bs of the 2 nd protective member Pr2 in the form of an adhesive seal.

In each of the above embodiments, for example, a part of the adhesive layer Ad2 and the 3 rd protective member Pr3 may be in contact with a part of the terminal box Bx1 and the frame Fl 1.

All or part of the above embodiments and various modifications may be appropriately combined within a range where no contradiction exists.

Claims

1. A solar cell module is provided with:

a plate-like 1 st protective member having light transmittance;

a 2 nd protective member;

a solar cell element located between the 1 st protective member and the 2 nd protective member;

a sealing material located between the 1 st protective member and the 2 nd protective member in a state of sealing the solar cell element;

a terminal box on the 1 st face on the opposite side to the 1 st protection member side among the 2 nd protection members;

An adhesive layer on the 1 st face of the 2 nd protective member; and

a 3 rd protective member on a 2 nd surface on a side opposite to the 1 st surface side among the adhesive layers,

when the adhesive layer, the 3 rd protective member, and the terminal box are seen in plan view, the adhesive layer has: a 1 st hole portion having a 1 st inner edge portion existing in a state surrounding the terminal box, and the 3 rd protection member has: a 2 nd hole portion having a 2 nd inner edge portion in a state of surrounding the terminal box,

the adhesive layer has a 1 st central region and a 1 st peripheral region having a smaller thickness than the 1 st central region when the 2 nd surface is seen in plan view,

the 1 st peripheral edge region includes, when the 2 nd surface is seen in plan view, around the 1 st central region: a portion existing along the 1 st outer edge portion of the adhesive layer, and a portion existing along the 1 st inner edge portion,

the 3 rd protective member has: a 2 nd peripheral edge region contiguous with the 1 st peripheral edge region, and a 2 nd central region contiguous with the 1 st central region,

the 2 nd peripheral edge region includes, when the 2 nd surface is seen in plan view: a portion existing along the 2 nd outer edge portion of the 3 rd protective member and a portion existing along the 2 nd inner edge portion,

The 3 rd protective member is provided in a state of being closer to the 2 nd protective member than the 2 nd central region along the 2 nd inner edge portion and the 2 nd outer edge portion in the 2 nd peripheral region.

2. The solar cell module of claim 1 wherein,

when the 3 rd protective member and the terminal box are viewed from above, the 3 rd protective member is present in a state of being away from the terminal box.

3. The solar cell module according to claim 1 or 2, wherein,

the solar cell module further comprises a frame that is provided along the 1 st peripheral edge portion of the 1 st protective member and the 2 nd peripheral edge portion of the 2 nd protective member,

in a case where the 3 rd protective member and the frame are viewed from above, the 2 nd outer edge portion of the 3 rd protective member exists in a state of being apart from the frame,

the 2 nd outer edge portion of the 3 rd protection member is provided in a state of being separated from the 2 nd peripheral edge portion of the 2 nd protection member,

the 3 rd protective member is provided in a state of being closely contacted with the 2 nd protective member in the 2 nd outer edge portion.

4. The solar cell module according to claim 1 or 2, wherein,

The solar cell module is provided with:

a plurality of wiring members; and

a plurality of the solar cell elements described above,

each of the solar cell elements has a 1 st electrode on the 1 st protective member side and a 2 nd electrode on the 2 nd protective member side,

the plurality of wiring members are located between adjacent solar cell elements among the plurality of solar cell elements in a state in which the 1 st electrode and the 2 nd electrode are electrically connected respectively,

in each of the solar cell elements, the wiring member is present in a state having a connection portion in a state of being connected to the 2 nd electrode,

when the 3 rd protective member and the connection portion are seen in plan view, the 3 rd protective member is positioned so as to overlap at least a part of the connection portion in each of the solar cell elements.

5. The solar cell module of claim 1 wherein,

the solar cell module further comprises an insulating member which is provided in a state of covering the 2 nd outer edge portion of the 3 rd protective member,

the 3 rd protective member has: a metal layer; and a 1 st resin layer and a 2 nd resin layer which are present in a state of sandwiching the metal layer.