JP2001144312A - Method and device for manufacturing thin-film solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and a device for manufacturing a solar cell module where deformation of a solar cell is prevented, weight of module is reduced while the strength is raised, a module is manufactured substantially in one process, and a non-power-generating area is reduced. SOLUTION: A process where a surface protective film 101, surface-side sealing resin 102, solar cell element 103, rear-surface side sealing resin 105, and structure supporter 108 are provided, a process where thin-plate wiring materials 104 and 107, comprising the thin-plate wiring material for taking an electric output outside, are provided at the rear surface part of the solar cell element for electric connection, and a process where the resin is thermally cured, are provided. Here, the internal wiring 107 is embedded in advance on the surface part of the structure supporter 108 or the rear-surface side sealing resin 105, and if a process where a part of the module perimeter is bent to form a reinforcing rib is further included, the resin is thermally cured after bending.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art At present, research and development of clean energy are being promoted from the standpoint of environmental protection. Above all, solar cells are attracting attention because of their infinite resources (solar rays) and no pollution.

Thin-film solar cells are considered to be the mainstream of solar cells in the future because of their thinness, light weight, low production cost, and easy area enlargement. Demand is expanding for business use and general residential use, which are used for such purposes.

Conventional thin-film solar cells use a glass substrate, but research and development of a flexible solar cell using a plastic film and a metal film has been promoted in terms of weight reduction, workability, and mass productivity. Taking advantage of this flexibility, mass production has become possible by roll-to-roll or stepping roll manufacturing methods.

In the above-mentioned thin-film solar cell, a first electrode (hereinafter, also referred to as a lower electrode), a photoelectric conversion layer comprising a thin-film semiconductor layer, and a second electrode (hereinafter, also referred to as a transparent electrode) are formed on a flexible resin film substrate. A plurality of stacked photoelectric conversion elements (or cells) are formed. By repeatedly electrically connecting the first electrode of a certain photoelectric conversion element and the second electrode of the adjacent photoelectric conversion element, the first electrode of the first photoelectric conversion element and the second electrode of the last photoelectric conversion element Required voltage can be output. For example, it is converted to AC by an inverter and AC 100 V
In order to obtain the above, the output voltage of the thin-film solar cell is desirably 100 V or more, and actually several tens or more elements are connected in series.

[0006] Such a photoelectric conversion element and its serial connection are formed by forming an electrode layer and a photoelectric conversion layer, patterning each layer, and combining them. An example of the configuration and the manufacturing method of the solar cell is disclosed in, for example,
No. 0-233517 and Japanese Patent Application No. 11-19306.

In order to popularize such solar cells, it is necessary to install solar cell modules on roofs of many houses and the like. When installed on a roof or the like, it is desired that the solar cell module be lightweight. Naturally, the larger the effective power generation area per unit area, the better.

The structure of a conventional solar cell module using a glass plate on the surface and a method of manufacturing the same are described in, for example,
No. 8-116658 and the like. further,
For the purpose of weight reduction, a structure and a manufacturing method of a solar cell module using a metal plate on the back surface have been proposed in Japanese Patent Application Laid-Open No. 7-297440.

In order to increase the effective power generation area, thin wiring members are arranged on the back of a solar cell element comprising an a-Si solar cell on a plastic substrate, and protective films are formed on the front and rear sides of the solar cell, respectively. And sealing resin, etc.
2. Description of the Related Art A solar cell module having a configuration in which a resin is pressurized and heat-cured to be integrated has been developed. FIG. 6 shows a schematic sectional configuration of this module. Details will be described later in the following section and comparison with the configuration of the present invention.

Further, in order to laminate the protective film, the sealing resin, etc. as described above, and pressurize and heat cure the resin to integrate them, a vacuum laminator device is required as a solar cell module manufacturing device. is there. As this type of apparatus, an apparatus described in JP-A-61-69179 is known.

The above-mentioned vacuum laminator device includes a first vacuum tank having a diaphragm for pressurizing the solar cell module, and a second vacuum tank for heating and molding the solar cell module. This is an apparatus in which the first vacuum tank is returned to the atmospheric pressure while the tank is kept in a vacuum, so that the laminate of solar cell modules can be pressure-bonded in a vacuum through the diaphragm.

[0012]

However, the above-mentioned conventional thin-film solar cell module and its manufacturing method and apparatus have the following problems.

First, in a conventional thin-film solar cell module using a glass plate on the surface, a solar cell element having a glass plate on the surface and connected in series is sealed with an ethylene-vinyl acetate copolymer resin (EVA) resin or the like. As a backing material, aluminum foil having vinyl monofluoride adhered to both sides is used, a terminal portion is formed on the back surface, and four sides are fixed around the periphery by an aluminum frame. The module is fixed to a roof or the like using a dedicated stand or the like. The weight per m ^{2 of} this module is about 10 kg or more, and there is a problem that the weight is extremely heavy. In addition, there is a problem that the structure and the manufacturing procedure are complicated, for example, a frame for fixing the surface glass needs to be attached around the module.

Further, in a module using a metal plate on the back surface, a bending process is performed for the purpose of improving bending strength and mountability. In this case, a solar cell element cannot be arranged at a pressurized portion during the bending process. Therefore, there is a problem that the non-power generation area in the module increases. Furthermore, the weight per 1 m ² is about 5 kg, and the relatively heavy weight is also a problem.

Furthermore, in the case of a module as shown in FIG. 6 in which a thin plate-shaped wiring member is arranged on the back of a solar cell element comprising an a-Si solar cell on a plastic substrate for the purpose of expanding the effective power generation area, the following applies. There was a problem. The thickness of the thin wiring material, the adhesive and the insulating material formed as necessary, a-
As shown in FIG. 6, there is a problem that the solar cell element constituting the Si solar cell is deformed in a convex shape. As a result, cracks and the like are likely to occur in the deposited metal in portions where the solar cell element is largely deformed, and there is a possibility that the reliability may be reduced. In addition, as a material for the internal wiring of these modules, a material whose surface is coated with solder by a dip method or a plating method is usually used, but lead when discarded causes environmental pollution.

Furthermore, in the above-described conventional solar cell module manufacturing apparatus (vacuum laminator apparatus), reinforcing ribs are formed by bending the side surfaces of the solar cell module for the purpose of improving the strength and expanding the effective power generation area. When manufacturing a solar cell module having a well-known configuration, there is a problem that the side surface of the solar cell module cannot be pressurized.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to prevent deformation of a solar battery cell in a thin plate-like wiring member, to reduce a non-power generation area, and to provide a module. A method and apparatus for manufacturing a solar cell module that achieves light weight and high strength, substantially achieves module manufacturing including a module mounting portion in one process, reduces the amount of lead used, and facilitates processing of module reinforcing ribs. Is to provide.

[0018]

In order to solve the above-mentioned problems, the present invention provides at least a weather-resistant surface protective film, a front-side sealing resin, a solar cell element, a rear-side sealing resin, The step of arranging the support, and the auxiliary wiring (hereinafter also referred to as a thin-plate wiring material) and the internal wiring (hereinafter also referred to as a thin-plate wiring material) made of a thin-plate wiring material for extracting electric output to the outside are described above. In the method for manufacturing a thin-film solar cell module including a step of providing an electrical connection by arranging it on the back surface of the solar cell element and a step of thermally curing the resin, the internal wiring is previously formed on the back side sealing resin or It is embedded in the surface of the structural support (claim 1). In this case, it is preferable that the surface portion is buried so as to be substantially flush with the surface, and it is desirable that the internal wiring (thin plate-shaped wiring material) does not protrude from the surface by lightly pressing in advance.

As described above, since the thin plate-shaped wiring member is buried in the back side sealing resin or the structural support in advance, deformation of the plastic substrate a-Si solar cell element power generation section is prevented.

Further, in the manufacturing method according to the first aspect, the structural support is made of a glass woven fabric impregnated with a thermosetting resin, and the impregnated resin is cured in a step of thermosetting the resin. (Claim 2). In this case, as in claim 3, the front-side sealing resin and the rear-side sealing resin are ethylene-vinyl acetate copolymer (EVA), and the solar cell element is an a-Si solar cell element having a resin substrate. It is preferable that the solar cell module is manufactured in substantially one step by superimposing and thermosetting simultaneously with an EVA bonded solar cell element having adhesiveness.

Further, in the manufacturing method according to any one of claims 1 to 3, the thin plate-shaped wiring member is a copper foil plated with an anticorrosive metal (claim 4).
The anticorrosive metal is tin, and the plating thickness is 0.5 to
By setting the thickness to 15 μm (claim 5), it is possible to provide a solar cell module that is less corrosive than copper foil alone and has a reduced amount of lead.

In the case of manufacturing a solar cell module having a well-known configuration in which a reinforcing rib is formed by bending a side surface of the solar cell module, at least the weather-resistant surface is formed from the light-receiving surface side. Arranging a protective film, a front-side sealing resin, a solar cell element, a rear-side sealing resin, a structural support, and an auxiliary wiring and an internal wiring made of a thin plate-shaped wiring material for extracting an electric output to the outside; A step of providing electrical connection by arranging it on the back surface of the solar cell element, a step of thermally curing the resin, and further bending at least two sides of a non-power generation area of the solar cell module at an outer peripheral portion of the module And forming a reinforcing rib on the thin-film solar cell module. It is assumed that. As a result, a non-power generation area can be reduced as described later.

An apparatus for carrying out the above method includes:
A first vacuum tank having a diaphragm for pressurizing the solar cell module, and a second vacuum tank for heating and shaping the solar cell module, wherein the second vacuum tank mounts the solar cell module A module structure support body installation plate having a portion to be bent and a pressure receiving surface portion for partially bending the non-power generation region, a pressurizing device for pressing the bent portion, and a heater for heating the module (Claim 7) is preferable.

[0024]

Embodiments of the present invention will be described below with reference to the drawings. A method for manufacturing a thin-film solar cell module will be described later for some embodiments, but common items will be described first. This will be described with reference to FIG. FIG.
(A) is a plan view of a thin-film solar cell module, conceptually showing only a solar cell element, a thin-plate wiring member, and the like. FIG.
(B) and FIG. 1 (c) correspond to A-
It is sectional drawing which follows A and BB.

The solar cell module according to the present invention has a surface protection film 101, a front side sealing resin 102, a reinforcing material 109, a solar cell element 103, a thin wiring member 104 for extracting electricity from the solar cell element from the light receiving surface side. , Reinforcement 109,
A rear-side sealing resin 105, a rear protective film 106, a thin plate-like wiring member 107, and a structural support 108 are provided.

As the surface protective film 101 used in the present invention, an ethylene-tetrafluoroethylene copolymer (hereinafter, referred to as ETFE), which is a highly weather-resistant film and one surface or both surfaces of which are surface-treated by a method such as corona discharge treatment, is used. ) And a hexafluoropropylene / tetrafluoroethylene copolymer (hereinafter referred to as FEP). Further, a film obtained by depositing an inorganic moisture-proof film such as SiOx on these films can be used.

As the sealing resins 102 and 105, ethylene-vinyl acetate copolymer resin (hereinafter referred to as EVA), ethylene-acrylate copolymer, silicone resin, tetrafluoroethylene
Hexafluoropropylene / vinylidene fluoride copolymer and the like can be used.

Front and back side sealing resin 1 of the present invention
02 and 105 may include a glass nonwoven fabric as a reinforcing material. As a binder for the glass nonwoven fabric, an acrylic resin-based material is preferable. By including the glass nonwoven fabric, the heat shrinkage of the sealing resin is reduced, and the stress acting on the bonding surface can be reduced.

As the solar cell element 103, an a-Si solar cell formed on a plastic substrate is preferable.
There is no particular limitation. The solar cell element 103 is
Normally, EVA is pasted on the front surface side in advance, and in FIG. 1, the display of the EVA part number is omitted. The same applies to FIG. 1 and subsequent figures.

The required property of the backside protective film 107 is to prevent the low molecular weight component of the thermosetting resin as the backing material from diffusing into EVA. Good adhesion to both the sealing resin and the thermosetting resin. Low heat shrinkage during the manufacturing process. As a material having sufficient weather resistance and satisfying these required characteristics, a material obtained by corona-treating both surfaces of a fluorine-based film such as ETFE or FEP is preferable.

As the structural support 108 on the back surface, a thermosetting resin containing a glass woven fabric is used. As the thermosetting resin to be used, epoxy resin, unsaturated polyester, thermosetting acrylic resin, urethane resin, diallyl phthalate resin, silicone resin, and phenol resin can be used. Resins are preferred.

The manufacturing process of the solar cell module is as follows. Glass woven cloth impregnated thermosetting resin sheet 108 in which thin wiring member 107 is embedded in advance by a heating roll on a movable flat plate, back protective film 106, reinforcing material 1
09, a glass nonwoven fabric, a sheet-shaped rear-side sealing resin, and a solar cell element 103 in which the thin plate-like wiring member 104 is electrically connected in advance with a conductive adhesive tape 110 or the like, and then the thin plate-like wiring member 104 and the thin plate Wiring material 107
Are electrically connected by soldering or the like. In addition, glass non-woven fabric on the thin wiring material of the part to make electrical connection,
The sheet EVA is cut in advance.

After the connection is completed, a glass nonwoven fabric, a front-side sealing resin 102, and a surface protective film 101 are sequentially laminated on the EVA attached to the solar cell element 103 as a reinforcing material 109. In addition, on the surface of the thin plate-shaped wiring member, a thermosetting resin sheet impregnated with a glass woven cloth was used for adhesion to the back protective film.
The resin used for 8 is applied beforehand.

The thickness of the thin wiring material is 50 μm or more.
A range of 100 μm is good. The width is preferably in the range of 5 to 50 mm. If the thickness of the thin wiring material exceeds 100 μm, there is a problem that unevenness may occur when the thin wiring material is embedded with a heating roll. Also,
If the thickness is too small, the strength is weak and there is a possibility that the film may be broken by stress such as a heat cycle.

After completion of the superposition, the flat module is placed in a known module manufacturing apparatus, vacuum-laminated at a temperature of 150 ° C., and cured by heating. In the case of a module whose end is bent, the module is manufactured by a module manufacturing apparatus provided with a device capable of pressing a side surface of the module described later.

The length from the cell end to the module end of the module according to the present invention (A in FIG. 1A) is preferably about 20 mm. If it is 20 mm or more, there is a problem that module power generation efficiency is reduced. A minimum of 5 mm is empirically possible. At dimensions below this, there is moisture ingress from the end via the EVA.

The surface of the module obtained by the present invention is
It is flat except for the part where the thin wiring material is installed. Since the thin-film wiring member installation portion slightly deforms the solar cell element, it is preferably provided in a non-power generation region of the solar cell element.

Example 1 As described above, FIG. 1 shows the configuration of a thin-film solar cell module according to Example 1. The solar cell module according to the first embodiment includes an ETFE in which an adhesive surface is corona-treated as a surface protective film 101, a sheet-shaped EVA as a sealing resin 102, an aramid substrate a-Si solar cell element as a solar cell element 103, and a solar cell. A thin plate-like wiring member 104 for extracting electricity from the element is a tin-plated copper foil having a width of 3 mm and a thickness of 50 μm, a sheet-like EVA as a backside sealing resin 105, and a 25 μm-thick corona-treated both sides as a backside protective film 106. ETFE, tin-plated copper foil having a width of 10 mm, a thickness of 100 μm, and a plating thickness of 1 to 2 μm as a thin plate-shaped wiring member 107, and a 1.5 m-thick structure support 108 made of a thermosetting resin containing a glass woven fabric
m woven fabric impregnated with an epoxy resin.
Each part according to this embodiment will be described in detail below.

1. Structural support As the epoxy resin-impregnated glass woven fabric, a prepreg made for a printed wiring board was used. These prepregs are supplied in a state of being wound around a core in the form of a sheet having a release sheet attached to both sides. The release sheet on one side is peeled off, the thin wiring material is buried in a predetermined position by a roll, the back protective film 106 is integrated at the same time, and then cut into a certain size.

2. Solar Cell Element The plastic substrate a-Si solar cell element is produced by a known method described in the section of the prior art. The used solar cell element has a positive electrode and a negative electrode on the side opposite to the power generation surface.

3. Thin Wiring Material As shown in FIG. 1C, the thin wiring material 104 is fixed to a solar cell with a tape 110 having a conductive adhesive. As shown in FIG. 1B, the electrical connection between the thin wiring member and the thin wiring member is performed by cutting off a part of the EVA sheet and the back protective film and soldering the vicinity of the solar cell element.

4. Sealing resin In the sealing resin sheet, as a reinforcing material 109 in advance,
Glass nonwoven fabric is laminated.

5. Module Manufacturing Apparatus A known vacuum laminator apparatus described in the section of the prior art can be used.

6. Module end shape and terminal box.

The module of this embodiment is a flat module without bending. In the case of this embodiment, a known terminal box (not shown) is attached to the power generation surface side of the module.

Example 2 FIG. 2 is a sectional view showing the structure of a thin-film solar cell module according to Example 2. 0.3mm
Example 1 Example 1 was repeated except that a thin wiring member 207 pre-integrated with a thick adhesive EVA was embedded in a back-side sealing resin 205 using a heating roll, and no back-side reinforcing material was used. Created in the same way as Description of each part number is omitted.

(Comparative Example 1) The configuration of Comparative Example 1 is shown in FIG. 0.3mm thick adhesive EVA
It was formed in the same manner as in Example 2 except that the thin plate-shaped wiring member 607 obtained by integrating the sheet 610 and the insulating film 609 was sandwiched between the back sealing resin 605 and the solar cell element 603 as it was. Description of each part number is omitted.

(Embodiment 3) FIG. 4 is a sectional view showing the configuration of a thin-film solar cell module according to Embodiment 3, wherein reinforcing ribs are formed by bending the side surfaces of the solar cell module in order to improve strength and expand an effective power generation area. The following is an example of the configuration. This module was manufactured by using a module manufacturing apparatus shown in FIG. 3 described later, using a prepreg obtained by impregnating a 1.0-mm-thick glass woven fabric with an epoxy resin as a structural support 408, and bending the end to 90 °. Except for the above, it was prepared in the same manner as in Example 1.

On the side surface of the module shown in FIG.
01, a front side sealing resin 402, a back surface protective film 406, and a reinforcing material 409. Therefore, even if the solar cell element is arranged close to the end of the module, the influence of the entry of moisture is small. The length from the module end to the solar cell element of this module is about 5 mm, and the non-power generation area can be reduced by shortening the length of the module periphery.

Next, a manufacturing apparatus (vacuum laminator apparatus) according to claim 7 of the present invention will be described. As shown in FIG. 3, this apparatus includes a first vacuum chamber 301 having a diaphragm 302 made of a rubber sheet for pressurizing a solar cell module, and a second vacuum chamber 301 for heating and molding the solar cell module. The second vacuum chamber 303 includes a module structure support installation plate 305 having a portion on which the solar cell module 400 is mounted and a pressure-receiving surface portion for partially bending the non-power generation region, and the bent portion. Pressing device 304a (spring type) or 30 for pressurizing
4b (pneumatic type) and a heater 306 for module heating
And

Each vacuum chamber is provided with a vacuum exhaust pipe 30.
7 is provided. FIG. 3 shows a state where the first vacuum tank 301 and the second vacuum tank 303 are separated from each other. However, at the time of manufacturing, the first vacuum tank 301 is lowered and the second vacuum tank 303 is lowered. , And presses the vacuum holding gasket 308 to form a seal for the second vacuum chamber 303.

Next, the manufacturing process of the module shown in FIG. 4 will be described below.

The module is formed as a structural support 408 made of a thermosetting resin containing glass woven cloth on a PTFE sheet containing glass woven cloth for peeling in advance and having a thickness of 0.8 mm.
Sheet prepreg impregnated with epoxy resin in woven fabric of
25 μm with corona treatment on both sides as back protective film 406
A sheet in which ETFE having a thickness, a sheet-like EVA serving as a back-side sealing resin 405 and a tin-plated copper foil having a width of 10 mm, a thickness of 0.1 mm, and a plating thickness of 1 to 2 μm serving as a thin wiring material 407 are integrated by a roll. Then, an aramid substrate a-Si solar cell element as the solar cell element 403 and a thin plate-shaped wiring member 404 for taking out electricity from the solar cell element are laminated with a tin-plated copper foil having a width of 3 mm. At this stage, the thin plate-shaped wiring member and the thin plate-shaped wiring member are electrically connected by soldering or the like. Further, as the front side sealing resin 402, a sheet-like EVA, the surface protective film 101
After the ETFE having the adhesive surface corona-treated is superposed in order and integrated with a heating roll, the ETFE is set on the structural support mounting plate 305 in the module manufacturing apparatus shown in FIG.

The structural support mounting plate 305 is previously heated to 120 ° C. by a heater. Immediately after setting, the first vacuum chamber 301 and the second vacuum chamber 303 are integrated by an opening / closing mechanism (not shown). The vacuum chamber is simultaneously evacuated and maintained for 5 minutes, and after removing air in the module, the first vacuum chamber 301 is brought to normal pressure. At the same time, the pressing device 304a on the side surface (in this case, 304a provided on both side surfaces) is operated to press the module side surface. After that, the structural support mounting plate is raised to 150 ° C. and held for 20 minutes.
A, and the thermosetting resin is cured. Next, after the heating plate is cooled to 120 ° C. by air cooling or the like, the module is taken out together with the PTFE sheet 309 containing the glass woven fabric for peeling.

Fourth Embodiment FIG. 4 shows a module having a reinforcing rib 510 different from that of the third embodiment. Except that the end was bent into a circle and integrated with the aluminum pipe 511, it was produced in the same manner as in Example 2. In this case, a conventional vacuum laminator device was used.

(Comparative Example 2) FIG. 7 is a plan view of a module of Comparative Example 2. Structural support 108 of Example 1 (FIG. 1)
A 0.4 mm painted zinc steel plate is used, a thin plate-like wiring member is arranged outside the solar cell element, and as shown in FIG.
Except for being sandwiched between the two samples, it was prepared in the same manner as in Example 1. FIG.
The end of the module was bent at 90 ° at the portions A and A.

Table 1 shows the results of comparing the weight of the module, the area ratio with the solar cell element, the surface irregularities, the results of the reliability test, and the like for each of the examples and comparative examples.

[0058]

[Table 1] The above-mentioned module was a square having a side of 1 m, and the measurement of the unevenness of the surface of the thin wiring member installation portion was measured at the center of the module where the thin wiring member was installed. The measurement is 0.0
Using a dial gauge capable of measuring up to 1 mm, the difference between the thickness at the center of the installation portion of the thin wiring member and the thickness of the portion other than the installation portion of the thin wiring member was made uneven.

In Comparative Example 1, irregularities of 0.35 mm were generated. The reason is that the thickness of the thin wiring material is 0.1 mm, the thickness of the insulating film is 0.05 mm, and the thickness of the adhesive is 0.3 mm. Because there is almost no reflection,
It is estimated that irregularities of 0.35 mm were generated.

In the reliability test results of Comparative Example 1,
The meaning of the asterisk indicates that 3.5% of the characteristics of one of the tested modules 5 was deteriorated in the heat cycle test. No abnormalities were observed visually, and the cause of the decrease is unknown. In other modules,
No clear characteristic deterioration has occurred.

The reliability test was performed as follows. Among the reliability tests described in JIS C 8938, a high-temperature and high-humidity storage test (85 ° C., 85% RH, 1000 h), a heat cycle test (−20 ° C., 90 ° C., 200 cycles), a temperature / humidity cycle test (−40 ° C., 85 ℃ 85% R
H, 20 cycles), a salt spray test and a weathering test were carried out, and a change in characteristics and a change in appearance were examined. In the judgment, those having a characteristic variation of 5% or less and having no appearance abnormality such as corrosion were accepted.

[0062]

According to the present invention, as described above, at least the weather-resistant surface protective film, the front-side sealing resin, the solar cell element, the rear-side sealing resin, and the structural support are provided from the light-receiving surface side. A step of arranging an auxiliary wiring and an internal wiring made of a thin plate-like wiring material for taking out an electric output to the outside on the back surface of the solar cell element to make an electrical connection, and a step of thermally curing the resin In the method for manufacturing a thin-film solar cell module including the above, the internal wiring is embedded in advance in the surface of the back-side sealing resin or the surface of the structural support, and a part of the non-power generation region of the solar cell module is bent. In a method for manufacturing a thin-film solar cell module further comprising a step of forming reinforcing ribs on at least two opposite sides of the module outer peripheral portion, a part of the non-power generation region is bent in advance. Later, by performing thermosetting of the resin, it is possible to prevent the deformation of the solar cell of the thin wiring member in the thin film solar cell module, reduce the non-power generation area, and increase the weight and strength of the module. it can. In addition, the module can be manufactured in substantially one step including the module mounting portion, and further, the amount of lead used can be reduced, and the module reinforcing rib processing can be facilitated.

[Brief description of the drawings]

FIG. 1 is a diagram showing a schematic configuration of a thin-film solar cell module according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a thin-film solar cell module according to an embodiment different from FIG.

FIG. 3 is a diagram showing a schematic configuration of a thin-film solar cell module manufacturing apparatus according to the present invention.

FIG. 4 is a partial cross-sectional view of a thin-film solar cell module with a reinforcing rib according to an embodiment of the present invention.

FIG. 5 is a partial cross-sectional view of a thin-film solar cell module with a reinforcing rib different from FIG.

FIG. 6 is a cross-sectional view of the thin-film solar cell module of Comparative Example 1.

FIG. 7 is a schematic plan view of a thin-film solar cell module of Comparative Example 2.

[Explanation of symbols]

101, 201, 401, 501: surface protective film, 10
2, 202, 402, 502: front-side sealing resin, 10
3, 203, 403, 503: solar cell element, 104,
204, 404, 504: thin wiring material, 105, 20
5,405,505: Back side sealing resin, 106, 20
6,406,506: Back protective film, 107,207,4
07,507: thin wiring material, 108,208,40
8,508: structural support, 109,209,409,5
09: reinforcing material, 301: first vacuum tank, 302: diaphragm for module pressurization, 303: second vacuum tank, 30
4a, 304b: pressurizing device, 305: structural support mounting plate, 306: heater, 410, 510: reinforcing rib.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hiroshi Fujii 1-1, Tanabe Nitta, Kawasaki-ku, Kawasaki, Kanagawa Prefecture Inside Fuji Electric Co., Ltd. (72) Inventor Yujiro Watanuki 1, Tanabe Nitta, Kawasaki-ku, Kawasaki-ku, Kanagawa No. 1 Fuji Electric Co., Ltd. F-term (reference) 5F051 AA05 BA03 BA18 CB30 EA02 EA18 FA16 FA30 JA04 JA09

Claims (7)

[Claims] 1. A step of arranging at least a weather-resistant surface protective film, a surface-side sealing resin, a solar cell element, a rear-side sealing resin, and a structural support from a light-receiving surface side, and for taking out an electric output. A method for manufacturing a thin-film solar cell module, comprising the steps of: arranging an auxiliary wiring and an internal wiring made of the thin plate-shaped wiring material on the back surface of the solar cell element to make an electrical connection; and thermally curing the resin. 3. The method for manufacturing a thin-film solar cell module according to claim 1, wherein the internal wiring is buried in advance in the back surface side sealing resin or the surface of the structural support. 2. The manufacturing method according to claim 1, wherein the structural support is made by impregnating a thermosetting resin into a glass woven cloth, and the impregnated resin is cured in a step of thermosetting the resin. A method for manufacturing a thin-film solar cell module, comprising: 3. The manufacturing method according to claim 1, wherein the front-side sealing resin and the rear-side sealing resin are ethylene-vinyl acetate copolymer (EVA), and the solar cell element has a resin substrate. A method for producing a thin-film solar cell module, comprising: an a-Si solar cell element. 4. The method of manufacturing a thin-film solar cell module according to claim 1, wherein said thin plate-like wiring member is a copper foil plated with an anticorrosive metal. . 5. The method according to claim 4, wherein the anticorrosive metal is tin, and the plating thickness is 0.5 to 15 mm.
A method for manufacturing a thin-film solar cell module, characterized in that the thickness is set to μm. 6. A step of disposing at least a weather-resistant surface protective film, a surface-side sealing resin, a solar cell element, a rear-side sealing resin, and a structural support from the light-receiving surface side, and for taking out an electric output to the outside. A step of arranging the auxiliary wiring and the internal wiring made of the thin plate-shaped wiring material on the back surface of the solar cell element to make electrical connection, a step of thermally curing the resin, and Forming a reinforcing rib on at least two opposing sides of the module outer periphery by partially bending the module, in advance, after partially bending the non-power generation region, A method for manufacturing a thin-film solar cell module, comprising thermally curing a resin. 7. A thin-film solar cell module manufacturing apparatus for performing the manufacturing method according to claim 6, comprising: a first vacuum tank having a diaphragm for pressurizing the solar cell module; A second vacuum chamber for heating and shaping, the second vacuum chamber having a portion on which the solar cell module is mounted and a pressure receiving surface portion for partially bending the non-power generation area; An apparatus for manufacturing a thin-film solar cell module, comprising: an installation plate; a pressurizing device for pressing the bent portion; and a heater for heating the module.