JP2001036118A - Solar cell module and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] [Problem] To integrate a conventional solar cell module, use an EV
Although the lamination method using the A sheet as a filler, many steps such as evacuation and heating are performed, and the batch method requires a long time for production. SOLUTION: A solar cell group 15 is made of an ultraviolet curable resin 1.
2, the solar cell module 100 sandwiched between the front surface material 11 and the back surface material 13 is integrated at a high speed by ultraviolet irradiation.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in the structure of a solar cell module and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, as a filler for a solar cell module, an ethylene vinyl acetate resin (hereinafter referred to as E) has been mainly used.
VA resin). This EVA resin is a sheet-like thermoplastic resin.

A conventional method for manufacturing a solar cell module using this EVA resin will be described. First, a glass plate is used as a surface material, a film is used as a back material, and a row of solar cells is interposed between them using an EVA resin as a filler. In this state, heating is performed at a temperature of about 150 ° C. The entire solar cell module can be integrated by a laminating step in which a vacuum is applied after a vacuum of 0.7 to 1.0 Torr. Regarding the laminating process and the laminating apparatus, see, for example, JP-A-9-141.
No. 743 discloses an example of a laminating apparatus.

Japanese Patent Application Laid-Open No. Hei 5-299686 discloses a method of manufacturing a solar cell module including a technique of sealing the peripheral portion of the solar cell module with an ultraviolet curable resin. According to this method, an ultraviolet curable resin is applied to a peripheral portion of a box-shaped back cover case, a glass substrate on which a solar cell is formed is disposed thereon, and a continuous belt type ultraviolet irradiation is used to irradiate an edge of the solar cell module. Only seal. There is an atmosphere in the back cover case, and a desiccant for moisture prevention is arranged.

[0005]

However, in the method using the conventional EVA resin, there are many steps related to integration of the solar cell module such as heating, evacuation, and pressurization.
In addition, because of the batch method, it takes time to manufacture the solar cell module, which hinders continuous automation. In addition, since a change in stress is applied to the solar cell by the pressurization after evacuation, the solar cell may be broken, which makes it difficult to reduce the thickness of the solar cell. In addition, since the EVA resin softens and integrates the sheet-like material once by heating, it takes time to remove air interposed between the front surface material, the solar cell, and the back surface material, which hinders shortening of the process. are doing.

[0006] In the method of sealing only the peripheral portion of the solar cell module using an ultraviolet curable resin, the solar cell directly comes into contact with air remaining in the back cover case. is there. When a desiccant is arranged to improve this, the thickness of the solar cell module increases, which makes manufacture and installation difficult. In order to solve these problems, it is necessary to bury the solar cell in resin, but if an ultraviolet curing resin is applied here, since the solar cell and wiring do not transmit ultraviolet light, the shadowed part The problem remains that it cannot be cured.

An object of the present invention is to provide a solar cell sandwiched between a surface material and a back surface material using an ultraviolet curing resin or the like, or to arrange a solar cell on a back reinforcing substrate and apply an ultraviolet curing resin or the like. To provide a structure and a manufacturing method of a solar cell module that can shorten the time required for the process by integrating the components at high speed by ultraviolet light and infrared irradiation so that there is no uncured portion such as an ultraviolet curable resin. is there.

[0008]

According to a first aspect of the present invention, there is provided a solar cell module in which a row of solar cells is sandwiched between a front surface material and a back surface material by using a filler. , A transparent material is used for the back material, and the solar cell module is integrated by irradiating ultraviolet rays from both the front and back surfaces of the solar cell module.

A solar cell module according to a second aspect of the present invention comprises:
In a solar cell module in which a row of solar cells is sandwiched between a front material and a back material using a filler, an ultraviolet curable resin is used for a filler on a light receiving surface side, and a thermoplastic resin or a thermosetting resin is used for a filler on a back surface side. It is characterized in that the solar cell module is integrated by irradiating ultraviolet rays from the light receiving surface of the solar cell module and infrared rays from the back surface thereof, using an ionic liquid resin.

[0010] A solar cell module according to a third aspect of the present invention comprises:
In a solar cell module in which rows of solar cells are arranged on a back reinforcing substrate and integrated using a filler, a solar cell module using a translucent substrate as a back reinforcing substrate and an ultraviolet curable resin as a filler The solar cell module is integrated by irradiating ultraviolet rays from both sides.

[0011] A solar cell module according to a fourth aspect of the present invention comprises:
In a solar cell module in which rows of solar cells are arranged on a back reinforcing substrate and integrated using a filler, an ultraviolet curable resin is used for a filler on a light receiving surface side and a thermoplastic resin is used for a filler on a back side. Alternatively, using a thermosetting liquid resin, the solar cell module is integrated by irradiating ultraviolet rays from the light receiving surface of the solar cell module and infrared rays from the back surface.

[0012] A solar cell module according to a fifth aspect of the present invention comprises:
In a solar cell module in which a row of solar cells is arranged on a back reinforcing substrate and integrated using a filler, the row of solar cells is fixed to the back reinforcing substrate in advance with an adhesive,
An ultraviolet curable resin is applied as a filler, and ultraviolet rays are irradiated from the light receiving surface of the solar cell module to integrate the solar cell module.

[0013] A solar cell module according to a sixth aspect of the present invention comprises:
In a solar cell module in which a row of solar cells is arranged on a back reinforcing substrate and integrated using a filler, a wiring pattern is formed on the back reinforcing substrate in advance, and the row of solar cells is predetermined with a conductive adhesive. It is characterized in that it is fixed at a position, wired, applied with an ultraviolet curing resin as a filler, and irradiated with ultraviolet rays from the light receiving surface of the solar cell module to integrate the solar cell module.

[0014] A solar cell module according to a seventh aspect of the present invention comprises:
In any one of the third to sixth aspects of the invention, the light-receiving surface side of the ultraviolet curable resin as a filler is covered with a weather-resistant, flame-retardant resin light-transmitting film.

According to an eighth aspect of the present invention, there is provided a method for manufacturing a solar cell module according to any one of the first to seventh aspects, wherein the carrier is installed in a chamber irradiated with ultraviolet rays or infrared rays. In this case, the solar cell module is automatically sent in and the solar cell modules are continuously integrated.

A method for manufacturing a solar cell module according to a ninth aspect is the solar cell module according to the eighth aspect, wherein ultraviolet rays or infrared rays are irradiated from both upper and lower surfaces of the solar cell module using a translucent belt for the transporter. It is characterized by integrating the modules.

[0017]

FIG. 1 is a sectional view showing a structure of a solar cell module according to a first embodiment of the present invention.

Referring to FIG. 1, in this solar cell module 100, an ultraviolet curable resin 12 is applied on a white sheet glass 11 as a surface material, and two solar cells 5 are placed thereon so as to prevent air bubbles from entering. A group of solar cells 15 arranged in series is arranged. Further, an ultraviolet curable resin 12 is applied from above, and a translucent back film 13 is placed from above so as to prevent air bubbles from entering.

At this time, two lead outlets 23 are opened in the back film 13, and the back film 13 is set while the output leads 14 are taken out from the lead outlet 23.

FIG. 2 is a sectional view showing an example of the structure of an ultraviolet irradiation device used in the method for manufacturing a solar cell module according to the present invention.

Referring to FIG. 2, this ultraviolet irradiation apparatus comprises:
Ultraviolet lamps 50 a and 50 b and a translucent transport belt 53 are provided in a chamber in which the exhaust duct 52 is formed.

The laminate obtained as described above is placed on the translucent transport belt 53 of this ultraviolet irradiation device, and is moved as shown by the arrow A while the ultraviolet lamps 50a, 50b
Irradiates ultraviolet rays from both sides of the solar cell module 100 to integrate the solar cell module 100. At this time, the time required for integration by ultraviolet irradiation is 6
It takes about 0 seconds and is integrated in a short time.

FIG. 3 is a sectional view showing a structure of a solar cell module according to a second embodiment of the present invention.

Referring to FIG. 3, in this solar cell module 200, an ultraviolet curable resin 12 is applied on a white sheet glass 11 as a surface material, and two solar cells 5 are placed thereon so as to prevent air bubbles from entering. A group of photovoltaic cells 15 arranged in series is arranged, a thermosetting liquid resin 16 is applied from above, and a weather-resistant back film 13 is placed from above so as to prevent air bubbles from entering. At this time, two lead outlets 23 are opened in the back film 13, and the back film 13 is set while the output leads 14 are taken out from the lead outlet 23.

The thus obtained laminate is placed on a conveyor belt of an ultraviolet irradiation device shown in FIG. 2, irradiated with ultraviolet light while moving, and then the back surface is heated using an infrared irradiation device. The solar cell module 200
Is integrated. In this case, the irradiation time is 3 minutes for both ultraviolet rays and infrared rays. However, by simultaneously irradiating from both the front and back surfaces, integration is possible in about 1.5 minutes.

FIG. 4 is a sectional view showing a structure of a solar cell module according to a third embodiment of the present invention.

Referring to FIG. 4, in this solar cell module 300, an ultraviolet curable resin 12 is applied on white sheet glass 17 as a back surface reinforcing material, and two solar cells 5 are serially wired thereon. The cell group 15 is arranged, and the ultraviolet curable resin 12 is further applied thereon, and the surface is smoothed with a squeegee. The output lead 14 is taken out from the side. Similarly to the solar cell module 100, this laminate is transferred to the light-transmitting transport belt 53 of the ultraviolet irradiation device shown in FIG.
And irradiate ultraviolet rays from both sides of the solar cell module 300 to integrate the solar cell module 300. Like the solar cell module 100, the time required for integration by ultraviolet irradiation is about 60 seconds.

In this example, the back reinforcing member 17 is used.
Even when a thermosetting liquid resin is applied on the top, the arrangement of the solar cell groups 15 and the application of the ultraviolet curing resin 12 are performed,
By irradiating ultraviolet rays and infrared rays simultaneously from the front and back surfaces of the solar cell module 300, integration can be performed in about 1.5 minutes. In this case, the back surface reinforcing member 17 is an insulating material having high heat resistance, and desirably has a color close to black, which easily absorbs infrared rays. Further, a film having light-transmitting weather resistance, heat resistance, flame retardancy, or the like may be disposed on the surface so that air bubbles do not enter.

FIG. 5 is a sectional view showing a structure of a solar cell module according to a fourth embodiment of the present invention.

Referring to FIG. 5, in this solar cell module 400, solar cell 5
Are bonded in series using a quick-drying adhesive (not shown). From above,
An ultraviolet curable resin 12 is applied, and the surface is smoothed with a squeegee. The output lead 14 is taken out from the side.

The laminate thus obtained is placed on a translucent transport belt 53 of an ultraviolet irradiation device shown in FIG.
Ultraviolet rays are irradiated from the light receiving surface of the solar cell module 400 to integrate the solar cell module 400. Like the solar cell module 100, the time required for integration by ultraviolet irradiation is about 60 seconds. In this case, a film having light-transmitting weather resistance, heat resistance, flame retardancy, or the like may be provided on the surface so that air bubbles do not enter.

FIG. 6 is a plan view showing a structure of a solar cell module according to a fifth embodiment of the present invention.

Referring to FIG. 6, in this solar cell module 500, as shown in FIG. 7, a solar cell 5 is formed of silver on an insulating reinforcing substrate 30 having a conductive wiring pattern 31 such as a copper film. Adhesion is performed using a conductive adhesive such as a paste. In addition, the grid 19 of the solar cell 5 is bonded to the conductive wiring pattern 31 to which the adjacent solar cell 5 is attached by using a conductive adhesive such as a silver paste. Further, an ultraviolet curable resin is applied from above, and the surface is smoothed with a squeegee. The output lead is taken out from the side.

The thus obtained laminate is placed on a translucent transport belt 53 of an ultraviolet irradiation device shown in FIG.
Ultraviolet rays are irradiated from the light receiving surface side of the solar cell module 500 to integrate the solar cell module 500. Like the solar cell module 100, the time required for integration by ultraviolet irradiation is about 60 seconds.

Also in this example, a film having light-transmitting weather resistance, heat resistance, flame retardancy, etc. may be arranged on the side surface so as to prevent air bubbles from entering. Further, in order to strengthen the adhesive force of the conductive adhesive and shorten the bonding time, infrared rays may be irradiated from the back surface. In this case, the back reinforcing substrate 30 is desirably of a color close to black, which easily absorbs infrared rays.

[0036]

EXAMPLES The solar cell modules 100, 200, 300, 400 and 500 according to the first to fifth embodiments described above were actually manufactured. For comparison, a solar cell module using a conventional EVA resin sheet was produced as follows.

FIG. 12 is a sectional view showing the structure of a conventional superstrate type solar cell module.

Referring to FIG. 12, in this solar cell module 900, an EVA resin sheet 18, a solar cell group 15 in which two solar cells 5 are wired in series on a white sheet glass 11, an EVA resin sheet 18, a weatherproof sheet. Back sheet 13 was sequentially laminated. At this time, two lead outlets 23 and 28 were opened in the back sheet 13 and the back side EVA resin sheet 18, respectively, and the output lead 14 was taken out from these lead outlets 23 and 28.

FIG. 13 is a sectional view showing the structure of an example of a laminating apparatus used in a conventional method for manufacturing a solar cell module.

Referring to FIG. 13, this laminating apparatus comprises an upper chamber inlet / outlet port 62 and a lower chamber inlet / outlet port 6.
A heater plate 64 and a diaphragm 65 are provided in a chamber 60 in which the first and second chambers 3 are formed.

The laminate obtained as described above is inserted into the chamber 60 of the laminating apparatus, and the upper chamber and the lower chamber are simultaneously evacuated to 1 Torr to raise the heater plate 64 and contact the solar cell module 900. And heated. Then, atmospheric pressure is introduced into the upper chamber, and the solar cell module 90 is heated by the heater plate 64 and the diaphragm 65.
By narrowing the pressure to 0, the solar cell module 900 was integrated. The time required for lamination was 10 minutes.

With respect to the solar cell modules according to the first to fifth embodiments and the conventional solar cell module thus obtained, the reflectance was measured immediately after integration in order to examine the optical characteristics. Was. Furthermore, in order to examine the weather resistance of the solar cell module, the following weather resistance test was performed, the appearance was inspected after the test, the reflectance was measured again, and the deterioration of the optical characteristics during long-term use was examined. .

First, a JIS C8917 A-2 temperature / humidity cycle test was performed. This is because the solar cell module is kept at a temperature of 85 ° C. and a relative humidity of 85% for 2 hours.
This test aims at examining deterioration in a short period of time when the solar cell module is used in a state where it is subjected to a temperature change at a high humidity by repeating the holding at 40 ° C. for 1 hour for 10 cycles.

Next, a JIS C8917 A-5 light irradiation test was performed. This is intended to examine the weather resistance when the solar cell module is exposed to sunlight by irradiating for 500 hours under the specified conditions using a sunshine carbon arc lamp type weather resistance tester specified in JIS B7753. This is a test.

The solar cell modules 100, 200, 300, 400, and 500 according to the first to fifth embodiments
In addition, with respect to the conventional solar cell module 900, in the appearance inspection after the weather resistance test, it is considered that no peeling, change of air bubbles and the like are observed in the laminate, and the sealing property does not deteriorate.

FIG. 8 shows the reflectance of the solar cell module 100 according to the first embodiment of the present invention.

As shown in FIG. 8, the reflectance immediately after integration is about 5% in a range of 1050 nm or less, and it has been confirmed that the reflectance has substantially the same characteristics as a conventional solar cell module 900 described later. Furthermore, there was no change in the reflectance even after the weather resistance test, and no deterioration was observed even after long-term use.

FIG. 9 shows the reflectance of the solar cell module 200 according to the second embodiment of the present invention.

As shown in FIG. 9, the solar cell module 1
Similar to 00, the reflectance immediately after integration was about 5% in a range of 1050 nm or less. Furthermore, there was no change in the reflectance even after the weather resistance test, and no deterioration was observed even after long-term use.

FIG. 10 shows the reflectance of the solar cell module 300 according to the third embodiment of the present invention.

As shown in FIG. 10, similarly to the solar cell module 100, the reflectance immediately after integration was about 5% in a range of 1050 nm or less. Furthermore, there was no change in the reflectance after the weather resistance test, and no deterioration was observed even after long-term use.

FIG. 11 shows a conventional solar cell module 90.
0 reflectance. As shown in FIG. 11, the reflectance after the integration is slightly large on the short wavelength side, but is approximately 1050%.
It was about 5% in the range of nm or less. Furthermore, there was no change in the reflectance even after the weather resistance test, and no deterioration was observed even after long-term use.

From these results, it can be seen that the solar cell module integrated by using the ultraviolet curable resin and the thermosetting liquid resin according to the present invention has the same characteristics and weather resistance as the conventional solar cell module formed by lamination using EVA. It is possible to perform high-speed integration while maintaining the performance.

Further, in a solar cell module integrated by using an ultraviolet curable resin, by performing ultraviolet irradiation only from the light receiving surface, it is not necessary to use an infrared irradiation device, and integration can be performed at high speed. It is. on the other hand,
When using a method for manufacturing a solar cell module that irradiates ultraviolet rays and infrared rays using an ultraviolet curable resin and a thermosetting liquid resin and integrates the same, it is equivalent to a solar cell module integrated by lamination using conventional EVA. While maintaining the characteristics described above, it is possible to greatly reduce the time required for integration.

[0055]

According to the solar cell module of the present invention,
While maintaining the same optical characteristics and weather resistance as a conventional solar cell module by lamination using EVA, it integrates by irradiating ultraviolet rays and infrared rays. There is an effect that it can be shortened.

In particular, in the solar cell module according to the first to fourth aspects of the present invention, the filler can be cross-linked by irradiating ultraviolet rays or infrared rays from the front and back surfaces to integrate the solar cell module. Yes, and manufacturing energy can be reduced.

Further, even when the wiring of the solar cell group is previously installed on the back reinforcing substrate as in the solar cell modules according to the fifth and sixth inventions, the filler is cross-linked and integrated by ultraviolet irradiation. Therefore, the speed is higher than in the conventional laminating process. Further, since no filler is interposed between the solar cell and the back reinforcing substrate, the solar cell module can be integrated by irradiating ultraviolet rays only from the light receiving surface.

In the solar cell module according to the third to sixth aspects, the surface can be covered with a resin film in order to improve the weather resistance and the flame retardancy as in the seventh aspect.

In the method for manufacturing a solar cell module according to the eighth aspect of the present invention, the solar cell modules can be continuously integrated by putting the laminate into a carrier such as a belt conveyor as needed. is there.

Further, as in the ninth aspect, by irradiating ultraviolet rays or infrared rays from both sides of the solar cell module, the filler can be crosslinked in a shorter time. Further, since steps such as evacuation and pressurization are not required, it is possible to reduce the time required for the steps and prevent cell cracking due to pressurization.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a structure of a solar cell module according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view showing the structure of an example of an ultraviolet irradiation device used in the method for manufacturing a solar cell module according to the present invention.

FIG. 3 is a sectional view showing a structure of a solar cell module according to a second embodiment of the present invention.

FIG. 4 is a sectional view showing a structure of a solar cell module according to a third embodiment of the present invention.

FIG. 5 is a sectional view showing a structure of a solar cell module according to a fourth embodiment of the present invention.

FIG. 6 is a plan view showing a structure of a solar cell module according to a fifth embodiment of the present invention.

FIG. 7 is a plan view of a back reinforcing substrate having a wiring pattern used for a solar cell module according to a fifth embodiment of the present invention.

FIG. 8 is a diagram showing a reflectance of the solar cell module 100 according to the first embodiment of the present invention.

FIG. 9 is a diagram showing a reflectance of a solar cell module 200 according to a second embodiment of the present invention.

FIG. 10 is a diagram showing a reflectance of a solar cell module 300 according to a third embodiment of the present invention.

FIG. 11 is a diagram showing the reflectance of a conventional solar cell module 900.

FIG. 12 is a cross-sectional view showing a structure of a conventional super straight type solar cell module.

FIG. 13 is a cross-sectional view illustrating a structure of an example of a laminating apparatus used in a conventional method for manufacturing a solar cell module.

[Explanation of symbols]

Reference Signs List 5 solar cell 11 surface material 12 ultraviolet curable resin 13 transparent back film 14 output lead 15 solar cell group 16 thermosetting liquid resin 17 back reinforcing material 18 EVA resin sheet 19 grid 23, 28 lead outlet 30 insulation reinforcement Substrate 31 Conductive wiring pattern 50a, b UV lamp 52 Exhaust duct 53 Translucent transport belt 60 Chamber 62 Upper chamber intake / exhaust port 63 Lower chamber intake / exhaust port 64 Heater plate 65 Diaphragm 100, 200, 300, 400, 500, 900 Solar cell module

 ────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Toru Fui 22-22-22 Nagaikecho, Abeno-ku, Osaka-shi, Osaka F-term (reference) 5F051 BA14 BA18 EA18 EA20 JA04 JA05

Claims (9)

[Claims] 1. A solar cell module in which a row of solar cells is sandwiched between a front surface material and a back surface material by using a filler material, wherein an ultraviolet curable resin is used for the filler material, and a translucent material is used for the back surface material. It is characterized in that the solar cell module is integrated by irradiating ultraviolet rays from both sides of the solar cell module,
Solar cell module. 2. A solar cell module in which a row of solar cells is sandwiched between a front surface material and a back surface material by using a filler, wherein an ultraviolet curable resin is used for the filler on the light receiving surface side, and the filler material on the back surface side is used. A solar cell module using a thermoplastic resin or a thermosetting liquid resin, and irradiating ultraviolet rays from a light receiving surface of the solar cell module and infrared rays from a back surface thereof to integrate the solar cell module. 3. A solar cell module in which rows of solar cells are arranged on a back-side reinforcing substrate and integrated using a filler, wherein a translucent substrate is used for the back-side reinforcing substrate, and ultraviolet curing is used for the filler. Using a resin, irradiating ultraviolet rays from both sides of the solar cell module to integrate the solar cell module,
Solar cell module. 4. A solar cell module in which a row of solar cells is arranged on a back reinforcing substrate and integrated using a filler, wherein an ultraviolet curable resin is used for the filler on the light receiving surface side, Using a thermoplastic resin or a thermosetting liquid resin as the filler, irradiating ultraviolet rays from the light receiving surface of the solar cell module and irradiating infrared rays from the back surface to integrate the solar cell module, . 5. A solar cell module in which rows of solar cells are arranged on a back reinforcing substrate and integrated using a filler, wherein the rows of solar cells are fixed to the back reinforcing substrate in advance with an adhesive. An ultraviolet curable resin is applied as the filler, and the solar cell module is integrated by irradiating ultraviolet rays from a light receiving surface of the solar cell module. 6. A solar cell module in which a row of solar cells is arranged on a back reinforcing substrate and integrated using a filler, a wiring pattern is formed on the back reinforcing substrate in advance, and the row of solar cells is formed. Is fixed at a predetermined position with a conductive adhesive, wired, an ultraviolet curable resin is applied as the filler, and ultraviolet rays are irradiated from the light receiving surface of the solar cell module to integrate the solar cell module. , Solar cell module. 7. The method according to claim 3, wherein the light-receiving surface side of the ultraviolet curable resin as the filler is coated with a weather-resistant, flame-retardant resin light-transmitting film. Solar cell module. 8. The method for manufacturing a solar cell module according to claim 1, wherein the solar cell module is automatically sent by a carrier into a chamber irradiated with ultraviolet rays or infrared rays. A method for manufacturing a solar cell module, comprising continuously integrating solar cell modules. 9. The solar cell according to claim 8, wherein a ultraviolet ray or an infrared ray is radiated from both upper and lower surfaces of the solar cell module by using a translucent belt for the carrier, and the solar cell module is integrated. Module manufacturing method.