JP2001267596A - Solar cell module and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module, whose long-term reliability is high and whose productivity is superior by preventing moisture from creeping from its end part and by preventing the exfoliation of a coating material, and to provide its manufacturing method. SOLUTION: In the manufacturing method for the solar cell module, a rear coating material 111, a photovoltaic element 105 and a surface coating material 112 are stacked, and the element 105 is pasted to be coated. The peripheral part of the material 112 is situated between the peripheral part of the element 105 and the peripheral part of the material 111 to be stacked.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a photovoltaic module in which a photovoltaic element is resin-sealed on a supporting substrate and a method of manufacturing the same. In particular, the photovoltaic element is formed on a light-receiving surface of a building material. The present invention relates to a solar cell module and a method for manufacturing the same.

[0002]

2. Description of the Related Art A conventional method for manufacturing a solar cell module will be described with reference to FIGS. Solar cell modules include a superstrate type (see FIG. 7) and a substrate type (see FIG. 8).

[0003] In the super straight type, first, a glass 201 is prepared as a surface member, and a surface sealing material 202, a photovoltaic element 203, a back surface sealing material 204, and a back film 205 are sequentially stacked on the glass 201 to form a laminate. I do. On this occasion,
Front sealing material 202, back sealing material 204, back film 2
05 uses a thing larger than the glass 201.

In the substrate type, a reinforcing plate 301 is prepared, and a first back surface sealing material 302, a back surface insulating material 303, a second
The back sealing material 304, the photovoltaic element 305, the surface sealing material 306, and the surface member 307 are sequentially laminated to form a laminate. At this time, the first back surface sealing material 302, the back surface insulating material 303, the second back surface sealing material 304, the front surface sealing material 306, and the surface member 3
07 is larger than the reinforcing plate 301.

[0005] The laminate thus prepared is heated and pressurized by using a so-called double vacuum chamber type laminating apparatus or a roll laminator having a chamber section comprising an upper chamber and a lower chamber separated by a diaphragm. Then, the sealing material is fused and integrated. After that, the sealing material, the back surface insulator, and the front surface member protruding from the glass or the reinforcing plate are trimmed.

A substrate type solar cell module that does not use glass as a surface member can be bent by using a steel plate as a reinforcing plate, and can be formed into a shape similar to a general roofing material. Such a solar cell module can be installed in a house or the like in the same manner as a general roofing material.

However, the solar cell module manufactured by the above-described manufacturing method has a covering material even at a bent portion or an unnecessary portion which is hidden after construction, which causes an increase in cost. In addition, when there is a covering material in the bent portion, when the sealing material is peeled off from the surface member, the back surface insulating material, and the reinforcing plate due to the stress generated by the bending during use under high temperature and high humidity. There is.

As a method for preventing such peeling of the bent portion, Japanese Patent Application Laid-Open No. 5-121773 has proposed a solar cell module in which a reinforcing plate is partially covered. This is to eliminate the covering material of the bent portion and prevent the occurrence of peeling due to the stress generated by the bending.

[0009]

SUMMARY OF THE INVENTION However, Japanese Patent Application Laid-Open No.
Japanese Patent No. 21773 does not describe processing of an end portion of a covered portion. In other words, the interface between the surface member and the surface sealing material has a structure that is exposed at the end, and such a structure may cause separation from the interface between the surface member and the surface coating material. . Also, there is no description about the manufacturing method.

In the case of such a partial coating, in the face-down method, the manner in which pressure is applied changes between a portion having a coating and a portion having no coating, and the reinforcing plate may bend. Furthermore, in this proposal, a method of protecting the photovoltaic element by increasing the thickness of the surface coating material is taken, and the thickness is as large as 1 mm, which leads to an increase in the cost of the solar cell module. Become.

A solar cell module in which a rigid material such as glass is not used for the surface member has a problem that the protection ability of the photovoltaic element is insufficient. As means for increasing the ability of the coating material to protect the photovoltaic element, the thickness of the surface coating material is increased as described above, and glass fibers are included in the surface coating material. However, increasing the thickness of the coating increases the cost of the solar cell module.

When glass fibers are used, the protection ability of the photovoltaic element can be improved even if the thickness of the coating material is reduced. However, when glass fiber is used, when the end portion of the glass fiber reaches the end of the sealing material, moisture infiltrates from the interface between the glass fiber and the sealing material, and lowers the insulation of the solar cell module. There are cases.

In order to prevent the end of the glass fiber from reaching the end of the sealing material, Japanese Unexamined Patent Publication No. 7-288333 proposes that the glass fiber nonwoven fabric be made smaller in advance than the sealing material. Have been. However, this method requires an alignment at the time of laminating the coating material, which increases the man-hours and increases the manufacturing cost.

SUMMARY OF THE INVENTION In view of the above problems, an object of the present invention is to provide a solar cell module which is capable of preventing moisture from entering from the end of a solar cell module and peeling of a coating material, and having high long-term reliability and excellent productivity. An object of the present invention is to provide a battery module and a method of manufacturing the same.

[0015]

In order to achieve the above object, a method for manufacturing a solar cell module according to the present invention comprises a method of laminating a back cover material, a photovoltaic element, and a surface cover material to form a photovoltaic element. In a method for manufacturing a solar cell module to be bonded and covered, a peripheral portion of a surface covering material is laminated between a peripheral portion of a photovoltaic element and a peripheral portion of a back surface covering material.

In the method for manufacturing a solar cell module, it is preferable that the surface covering material comprises at least a surface member and a surface sealing material.

Alternatively, it is preferable that the above-mentioned surface covering material comprises at least a surface member, a surface sealing material, and a protective reinforcing material.

Further, it is preferable that the surface coating material is an integrated laminated member in which at least the same shape is temporarily bonded.

Further, it is preferable that the back surface covering material is an integrated laminated member composed of at least a back surface sealing material and an insulating material and having the same shape temporarily bonded.

The above-mentioned surface coating material, photovoltaic element,
It is preferable to laminate the back cover material face-up.

Preferably, the surface member is a resin film.

Further, the back cover material, the photovoltaic element,
It is preferable that the front surface covering material is laminated on the support substrate, and the peripheral surface of the back surface covering material is located inside the peripheral portion of the support substrate.

On the other hand, according to the solar cell module of the present invention, the solar cell module is manufactured by any one of the manufacturing methods described above.

In the above solar cell module, it is preferable that the solar cell module is formed as a building material-integrated solar cell module in which a solar cell and a building material are integrated.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below, but the present invention is not limited to these embodiments.

FIG. 1 is a schematic diagram showing a cross-sectional structure of the solar cell module of the present embodiment. FIG. 2 is an explanatory diagram illustrating a method for manufacturing the solar cell module of the present embodiment. 1 and 2, 101 is a reinforcing plate, 111 is a back surface covering material, 105 is a photovoltaic element, and 112 is a surface covering material. The back surface covering material 111 is formed of the first back surface sealing material 10.
2, a back surface insulating material 103, and a second back surface sealing material 104. The surface covering material 112 includes a surface protection reinforcing material 106, a surface sealing material 107, and a surface member 108.

Hereinafter, a method for manufacturing a solar cell module according to the present invention will be described step by step.

1) Preparation of Reinforcement Plate The reinforcement plate 101 supports the solar cell module. Examples of the installation form of the solar cell module include a case where the solar cell module is used as a building material integrated type and a case where a frame is attached to the module and installed on a gantry via the frame. In particular, a module in which the surface is covered with a resin film or the like without using a glass plate for the surface member is effective in imparting rigidity with a reinforcing plate.

The reinforcing plate used in the present invention is a coated steel plate,
Glass fiber reinforced plastics, hard plastics, timbers and the like can be mentioned. In the case of a building material integrated type, the rigidity can be further improved by bending. An existing roller former or bender machine can be used for the bending process. A steel plate or a stainless steel plate is suitable for these bending processes. These materials are not easily melted or deformed even by a high-temperature flame, and are suitably used as roofing materials. For such a use, it is preferable that the rust prevention property and the weather resistance are excellent. Due to the above characteristics, coatings having excellent weather resistance are generally applied. It is preferable to make a hole in order to further enhance degassing.

2) Lamination of Back Covering Material Subsequently, the back covering material 111 is laminated on the reinforcing plate 101. The back surface covering material 111 is not particularly limited as long as it is disposed on the back surface of the photovoltaic element 105 and has a function of further ensuring insulation between the photovoltaic element 105 and the outside.

In the present invention, the back cover material 111 is made of the first material.
Preferably, a three-layer structure of the back surface sealing material 102 / back surface insulating material 103 / second back surface sealing material 104 is used. Further, in order to increase the working efficiency of the lamination, a laminated film is preferable.
The first and second back surface sealing materials 102 and 104 have weather resistance,
The material is not particularly limited as long as it is excellent in heat resistance and adhesion to the back surface insulating material 103, the reinforcing plate 101, and the photovoltaic element 105. When the resin itself does not satisfy the above-mentioned properties, it is preferable to add an additive. For example, to improve weather resistance, it is preferable to add an ultraviolet absorber, a light stabilizer, an antioxidant, a secondary antioxidant, and the like. The ultraviolet absorber prevents light deterioration of the sealing material. It is preferable to add an antioxidant to prevent thermal oxidation of the resin.

In the case of a solar cell module integrated with a roofing material, the operating temperature of the solar cell module is lower than the ambient temperature by 20 degrees.
Since the temperature is raised to about 40 ° C., a resin having high heat resistance is preferable. When the heat resistance of the resin itself is low, the heat resistance can be increased by crosslinking. The method of crosslinking is not particularly limited, but a method of adding an organic peroxide to the resin in advance and heating is preferred. The organic peroxide is not particularly limited as long as it has a high crosslinking efficiency of the sealing material and does not adversely affect the weather resistance of the sealing material. Further, it is preferable to add a coupling agent in order to improve the adhesive strength with the photovoltaic element.

Specific materials for the sealing material include ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), ethylene-ethyl acrylate copolymer (EEA), butyral Examples thereof include a polyolefin resin such as a resin, a urethane resin, and a silicone resin.

It is preferable that the back surface sealing materials 102 and 104 are subjected to a treatment for increasing the deaeration during lamination.
When the back surface sealing materials 102 and 104 and the back surface insulating material 103 are not integrally laminated, processing is performed on both surfaces. When the back surface sealing materials 102 and 104 and the back surface insulating material 103 are integrally laminated, the reinforcement plate side and the photovoltaic element side may be processed.
For example, an embossing process is performed. The height difference between the mountain and the valley is 10
To 30 μm are preferred. Further, by forming a hole in the reinforcing plate 101 on the back surface, the degassing property is improved.

The back surface insulating material 103 generally includes non-woven fabric of biaxially stretched polyethylene terephthalate, polyethylene naphthalate, nylon, polyphenylene sulfide, polyimide, polycarbonate, acrylic, fluororesin, glass fiber, and plastic fiber.

In the present invention, the back cover 111 is smaller than the reinforcing plate 101 and larger than the front cover 112.
The size of the back cover material 111 is determined by the bent shape of the completed solar cell module. It is necessary to make the size such that the back surface covering material 111 does not hang on the bent portion. Further, the size is preferably set in consideration of the flow of the sealing material in the coating step.

3) Lamination of Photovoltaic Elements Subsequently, the photovoltaic elements 105 are laminated on the back surface sealing material 111. The photovoltaic element used in the present invention is not particularly limited. All types of photovoltaic elements can be used.

4) Lamination of Surface Coating Material Subsequently, the surface coating material 112 is laminated on the photovoltaic element 105. The surface coating material 112 is not particularly limited as long as it is excellent in transparency, weather resistance, and adhesion to the photovoltaic element. For example, a two-layer configuration of the surface member 108 and the surface sealing material 107, the surface member 108 and the surface sealing material 10
7 and the surface protection reinforcing material 106.
It is more preferable that these surface covering materials 112 are members integrally laminated. In the present embodiment, the surface member 108
The three-layer configuration of the surface sealing material 107 and the surface protection reinforcing material 106 will be described.

It is important that the surface member has excellent weather resistance. Preferably, the surface member 108 is made of a resin film. More preferably, it is a fluororesin film. As the fluororesin, tetrafluoroethylene-
Hexafluoropropylene copolymer, tetrafluoroethylene-perfluoroalkylvinyl ether copolymer, polychlorotrifluoroethylene, polyvinyl fluoride, polyvinylidene fluoride, ethylene-tetrafluoroethylene copolymer, ethylene-chlorotrifluoroethylene copolymer Coalescence. The surface of these films may be subjected to functional treatment. For example, an antireflection layer and an antifouling layer may be formed.

It is preferable that the surface member made of such a resin is subjected to a treatment for ensuring the adhesive strength with the surface sealing material. For example, it is preferable to perform corona discharge treatment, plasma discharge treatment, ozone treatment, or primer coating. Furthermore, it is preferable to perform a treatment for enhancing the adhesive force also on the end of the surface member around which the sealing material is wrapped.

The front sealing material 107 includes a back sealing material 102,
It is preferable to use the same as 104.

The surface protection reinforcing material 106 is made of the surface sealing material 10.
7 has the function of improving the strength. Surface protection reinforcement material 1
Known materials such as glass fiber and glass beads can be used as 06. The filler suitably used in the present invention includes a glass fiber nonwoven fabric. It is more preferable that the glass fiber nonwoven fabric is previously formed into a film integrally laminated with the surface member 108 and the surface sealing material 107. The mixing amount of the filler used in the present invention is 5 parts by weight or more and 50 parts by weight or less based on 100 parts by weight of the sealing material. If the amount is less than 5 parts by weight, the scratch resistance is reduced in the case of a module whose surface member is made of a film. Also 5
If the amount is more than 0 parts by weight, a filling failure may occur.

5) Coating material and photovoltaic element are integrated.
05 is integrated. At this time, the method of heating and pressing is not particularly limited, and examples thereof include a double vacuum chamber type laminator and a roll laminator.

The laminated bodies laminated up to 4) are integrated by heating and pressing. At this time, the surface sealing material 107 and the back surface sealing materials 102 and 104 are melted by heat, pass around the end surface of the surface member 108 to the front side by pressurization, and cover the end of the back surface insulating material 103.

Through the above steps 1) to 5), a solar cell module having a laminated structure as shown in FIG. 1 is manufactured.

[0046]

Embodiments of the present invention will be described below, but the present invention is not limited to these embodiments.

Example 1 In this example, a solar cell module having the structure shown in FIG. 3 was prepared as an evaluation module.

As shown in the figure, the solar cell module includes a reinforcing plate 401, a laminated film 402 of a back surface covering material,
It was prepared by first preparing a photovoltaic element 403 and a laminated member 404 of a surface coating material.

[Reinforcing Plate] As the reinforcing plate 401, a galvanized steel plate (0.4 mm thick) 472 mm × 2600 mm
Was prepared. Two holes (15φ) for taking out the back surface electrode were previously formed in the reinforcing plate.

[Laminated Film of Back Covering Material] As a laminated film 402 of back covering material, a double-sided corona-treated 2
Axial stretched polyethylene terephthalate film (thickness 1
(100 μm, width 1000 mm), 100 parts by weight of ethylene-vinyl acetate copolymer (EVA) (vinyl acetate content 28% by weight), 1.5 parts by weight of t-butyl peroxy 2-ethylhexyl carbonate as a crosslinking agent, 0.3 parts by weight of 2-hydroxy-4-n-octoxybenzophenone as an ultraviolet absorber, 0.2 parts by weight of tris (mono-nonylphenyl) phosphite as an antioxidant, and (2,2) as a light stabilizer. 0.1 parts by weight of (2,6,6-tetramethyl-4-piperidyl) sebacate were mixed, and the first and second back surface sealing materials having a thickness of 200 μm were formed on both sides of the film using an extruder and a T-die. Was laminated.
On both sides of this laminated film, 15
A μm emboss was applied. Subsequently, it was slit to a width of 390 mm. The length direction was cut to 2450 mm. Furthermore,
A 6φ hole was punched at a position corresponding to the electrode extraction of the photovoltaic element.

[Photovoltaic Element] In the present invention, the photovoltaic element is not particularly limited. In this embodiment, an amorphous silicon photovoltaic element is used. Photovoltaic element 4
As 03, the one having the configuration shown in FIG. 4 was prepared as follows.

First, a cleaned belt-like stainless steel substrate was prepared, and an Al layer (thickness 5000 °) and a ZnO layer (thickness 5000 °) were formed on the substrate by sputtering as a back reflection layer.
Å) was sequentially formed. Then, by plasma CVD, an n-type amorphous silicon layer is formed using a mixed gas of SiH ₄ , PH ₃ and H ₂ , an i-type amorphous silicon layer is formed using a mixed gas of SiH ₄ and H ₂ , and SiH ₄ is formed. B
A method of forming a p-type microcrystalline μc-Si layer using a mixed gas of F ₃ and H ₂ , wherein an n-layer thickness of 150 ° / i-layer thickness of 4000
Å / p layer thickness 100Å / n layer thickness 100Å / i layer thickness 8
A tandem-type amorphous silicon photoelectric conversion semiconductor layer having a layer configuration of 00 / p layer thickness of 100% was formed.

Next, as a transparent conductive layer, an In ₂ O ₃ thin film (thickness: 700 °) was formed by depositing In by a resistance heating method in an O ₂ atmosphere. The thus obtained product was cut into 356 mm × 239 mm to obtain a stainless steel substrate 500 on which a photoelectric conversion semiconductor layer and a transparent conductive layer were laminated.

[Preparation of current collecting electrode] The current collecting electrode 502 was formed as follows. 100μ diameter for metal wire
m copper wire was used.

A carbon paste for forming the conductive resin of the coating layer was prepared as follows. First, 2.5 g of ethyl acetate and 2.5 g of isopropyl alcohol as solvents
Was put in a shaker bottle for dispersion. Next, 22.0 g of a urethane resin as a main agent was added to the shake bottle, and sufficiently stirred by a ball mill. Next, 1.1 g of a blocked isocyanate as a curing agent was added to glass beads 10 for dispersion.
g was added to the solution. Next, 2.5 g of carbon black having an average primary particle size of 0.05 μm as conductive particles.
Was added to the solution.

The shake bottle into which the above-mentioned materials were put was dispersed by a paint shaker for 10 hours. Thereafter, when the average particle diameter of the paste was measured, it was about 1 μm.

Next, a coating layer was formed using a vertical wire coater as follows. First, a reel around which a copper wire was wound was set on a delivery reel, and the copper wire was stretched toward a take-up reel.

Next, the following coating is performed by a coater.
The coating speed was 40 m / min, the residence time was 2 sec, the temperature of the drying oven was 120 ° C., and the coating was performed five times. The diameter of the enamel coating die used is from 110 μm to 200 μm
Were used in order. Under these conditions, the paste is present in an uncured state due to evaporation of the solvent. The average thickness of the coating layer is 20μ
m.

[Preparation of Photovoltaic Element] First, a stainless steel substrate 500 having a photoelectric conversion semiconductor layer and a transparent conductive layer laminated thereon
Using a commercially available printing machine and an etching paste containing ferric chloride as a main component, a part of the transparent conductive layer was removed so that the power generation area became 800 cm ^2. Regions were formed on the transparent conductive layer.

Next, hard copper (thickness: 100 μm, width: 7 mm) was provided on the back surface of the stainless steel substrate 500 by soldering as the negative electrode terminal member 504.

Next, the insulating adhesive 501 (silicone adhesive thickness 50 μm / polyimide thickness 25 μm / silicone adhesive thickness 25 μm / polyethylene terephthalate thickness 75 μm / silicone adhesive thickness 50 μm) is applied to the non-power generation region on the transparent conductive layer by polyimide. Adhered to be placed in the non-power generation area on the side.

Then, the collecting electrodes 502 were arranged at intervals of 5.5 mm, and the ends were fixed with the insulating adhesive 501.

As the positive electrode terminal member 503, silver-plated hard copper (thickness 100 μm, width 5.5 mm) was disposed on the current collecting electrode 502 and the insulating adhesive 501.

Next, in order to adhere the current collecting electrode 502 to the transparent conductive layer, heat compression was performed at 200 ° C. and about 2 × 10 ⁵ Pa for one minute.

Next, the current collecting electrode 502 and the positive electrode terminal member 5
03 on the positive electrode terminal member to further adhere
The thermocompression bonding was performed at a temperature of about 6 × 10 ⁵ Pa for 15 seconds.

Then, an insulating tape 505 (black polyethylene terephthalate thickness 100 μm / acrylic adhesive thickness 30 μm, width 9 mm) was provided on the positive electrode terminal member 503.

Thus, a desired photovoltaic element 403 was obtained.

The above steps were repeated to produce 70 photovoltaic elements having a power generation area of 800 cm ² .

[Preparation of Photovoltaic Element Group] Ten photovoltaic elements having a power generation frequency area of 800 cm ² were placed face down on a jig such that the photovoltaic element spacing was 2 mm, and the intervals were equal. Side by side. Next, the positive electrode terminal member was electrically connected to the negative electrode terminal member of one of the photovoltaic elements by soldering.

[Extraction of Back Electrode] An operation of extracting electrodes from the elements at both ends of the ten photovoltaic elements to the back was performed.
The method of taking out the positive electrode is as follows. That is, as shown in FIG.
m / Acrylic adhesive thickness 25 μm, width 40 mm) to prevent internal short circuit and double-sided tape (acrylic adhesive thickness 40 μm)
m) through soft copper foil 602 (thickness 100 μm, width 25 m)
m) was attached to the back surface of the photovoltaic element 603. Both ends of the soft copper foil 602 were soldered 605 to the positive electrode terminal member 604 on the surface side.

A glass cloth 606 is provided between the insulating tape 601 and the soft copper foil 602 in order to solder the soft copper foil 602 at the center of the element on the back surface and the lead serving as an output terminal.
(Thickness: 100 μm, length and width: 30 mm) to provide a heat-resistant structure.

The method of taking out the negative electrode is as follows.
That is, the soft copper foil 602 (thickness 100 μm, width 25 mm) is applied via a double-sided tape (acrylic adhesive thickness 40 μm).
It was attached to the back surface of the photovoltaic element 603. Soft copper foil 60
2 were soldered 605 to the negative electrode terminal member 607 on the back side.

A glass cloth 606 is provided between the photovoltaic element 603 and the soft copper foil 602 in order to solder the soft copper foil 602 located at the center of the element on the back side and the lead wire serving as an output terminal similarly to the positive electrode side. (Thickness 100μm, 30m both vertically and horizontally)
m) to provide a heat-resistant structure.

[Preparation of Laminated Member of Surface Coating Material] The lamination member 404 of the surface coating material was prepared by the following method. Ethylene-tetrafluoroethylene copolymer (ETFE) (thickness 50 μm, width 1000 mm) was used as a surface member. One side was subjected to a plasma treatment, and a surface sealing material having a thickness of 460 μm was laminated on the surface using an extruder and a T-die. Subsequently, a glass fiber nonwoven fabric (acrylic binder, wire diameter 1
0 μm, a fiber length of 13 mm, and a basis weight of 40 g / m ² ) were prepared and bonded to a sealing material side of a laminate of a surface member and a surface sealing material using a heat roll. Thereafter, it was slit to a width of 380 mm, and cut in a length direction to 2530 mm.

[Coating Step] An embodiment using a single vacuum laminating apparatus will be described. The vacuum laminating equipment used is
This is an apparatus proposed in Japanese Patent Application Laid-Open No. 9-51111.
Details of this device will not be described here. A PFA film (thickness: 50 μm) is spread on the above-described vacuum device to prevent contamination, and the reinforcing plate 401 thus prepared,
Back coating material 402, photovoltaic element 403, front coating material 4
04 was laminated. A sheet (thickness: 3 mm) of a heat-resistant silicon rubber was placed on the laminate, and the lid was closed. The pressure inside the laminate was reduced to 1.33 × 10 ³ Pa by a vacuum pump.

After the pressure was sufficiently reduced, it was put into a hot air drying oven at 175 ° C. while continuing evacuation, and was taken out after 40 minutes. Thereafter, the system was cooled to room temperature while continuing evacuation. Thus, a plurality of photovoltaic element modules were obtained.

[Bending Process] Next, as shown in FIG. 6, a 30 mm end portion of the solar cell module 701 was bent toward the coating material side using a roller former molding machine. At this time, the photovoltaic element is formed so that the roller does not hit the photovoltaic element.

The evaluation results of the solar cell module obtained in this example are shown in Table 1, and the evaluation method will be described later.

Example 2 The procedure of Example 1 was followed, except that the backing material was laminated on each sheet. The evaluation results are shown in Table 1.

Example 3 A surface reinforcing material was omitted from the surface coating material, and the thickness of the surface sealing material was changed to 1000 μm.
Example 1 was followed. The evaluation results are shown in Table 1.

Example 4 Example 1 was followed, except that the reinforcing plate was omitted, and the back surface sealing material on the support substrate side was omitted from the back surface covering material. The evaluation results are shown in Table 1. However,
The insulation test after the high temperature and high humidity test was not performed.

Example 5 The surface member was made of glass (3.3 m
m thickness) according to Example 1. The surface member was prepared as follows. A glass having a width of 380 mm and a length of 2,530 mm was prepared, and a surface sealing material and a surface protection reinforcing material larger than the glass were bonded to the glass with a hot roll, and the protruding portion was cut into the glass along the periphery. The evaluation results are shown in Table 1.

[Comparative Example 1] The surface coating material was 410 mm in width.
Example 1 was followed except that the length was changed to 2500 mm. The evaluation results are shown in Table 1.

[Comparative Example 2] The surface covering material was a sheet material, and the surface member and the surface sealing material were 500 mm in width and 2700 m in length.
m, 390 mm wide and 2450 mm long surface protection reinforcement
Example 1 was followed, except that The evaluation results are shown in Table 1.

The solar cell modules obtained in the above Examples and Comparative Examples were evaluated by the following methods.

[Durability to Changes in Temperature and Humidity] For the solar cell module, -40 ° C./30 minutes, 85 ° C./8
After repeating the temperature / humidity cycle test of 5% RH / 22 hours for 50 cycles, the external appearance of the solar cell module was visually evaluated. The evaluation results are shown in Table 1 based on the following evaluation criteria. ：: no change in appearance ×: peeling occurred (the state is shown in the table)

[High Temperature and High Humidity Test] The solar cell module was exposed to high temperature and high humidity of 85 ° C./85% RH / 2000 hours. The change in appearance of the solar cell module was evaluated, and the insulation was measured.

The measurement of the insulating property will be described below. First, the anode and the cathode of the solar cell module are short-circuited. Attach the cathode of the power supply to the reinforcing plate, and connect the anode of the power supply to the output terminal of the sample. A voltage of 2000 V is applied from a power supply, and the leakage current is measured.

The evaluation results are shown in Table 1 based on the following evaluation criteria. The insulation resistance was shown by the numerical value of the leakage current. O: No change in appearance ×: Detachment or the like (the state is shown in the table)

[Weather Resistance Test] A part of the solar cell module cut into a square of 100 mm was put into a sunshine weather meter, and 2,000 cycles were carried out with 48 minutes of light irradiation and 12 minutes of rainfall as one cycle. The change in the appearance of the solar cell module of the sample was evaluated. The evaluation results are shown in Table 1 based on the following evaluation criteria. ：: no change in appearance ×: peeling occurred (the state is shown in the table)

[Time Required for Laminating Coating Material] The time required for laminating the reinforcing plate, the back coating material, the photovoltaic element, and the surface coating material was measured. Table 1 shows the measurement results.

[0092]

[Table 1]

As is clear from Table 1, the periphery of the back cover is located inside the periphery of the support substrate, and the periphery of the front cover is the periphery of the photovoltaic element and the periphery of the back cover. The solar cell module manufactured by being stacked so as to be located between the parts is extremely excellent in durability against changes in temperature and humidity, durability against high temperature and high humidity, and weather resistance, and the time required for manufacturing is 2/3. It was found that it could be reduced.

The solar cell module according to the present invention is not limited to the above-described embodiment, but can be variously modified within the scope of the invention.

[0095]

As described above, according to the present invention,
Since the interface between the sealing material and the other coating material is not exposed at the end of the solar cell module, deterioration of the adhesive strength at the interface between the sealing material and the other coating material is suppressed. Accordingly, it is possible to prevent moisture from entering the solar cell element from the outside, and to obtain a solar cell module having high long-term reliability.

Further, since the periphery of the surface covering material is covered with the back surface covering material, the surface member and the surface sealing material constituting the surface covering material can have the same dimensions. This makes it easy to previously configure the surface coating material as an integral laminated member, reduces the number of members required for lamination of the solar cell element, and reduces the restriction on the laminating position between the members. Can be improved.

[Brief description of the drawings]

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

FIG. 2 is a schematic view showing a manufacturing process in a method for manufacturing a solar cell module according to the present invention.

FIG. 3 is a schematic diagram illustrating a cross-sectional configuration of a solar cell module in an example.

FIG. 4 is a schematic diagram of a photovoltaic element in an example.

FIG. 5 is a schematic view showing a structure of a back electrode extraction of a photovoltaic element in an example.

FIG. 6 is a schematic diagram showing a bent state of the solar cell module in the example.

FIG. 7 is a schematic view showing an example of a conventional solar cell module.

FIG. 8 is a schematic view showing another example of a conventional solar cell module. DESCRIPTION OF SYMBOLS 101 Reinforcement plate 102 1st back surface sealing material 103 Back surface insulating material 104 2nd back surface sealing material 105 Photovoltaic element 106 Surface protection reinforcing material 107 Surface sealing material 108 Surface member 111 Surface covering material 112 Back surface covering material 201 Glass 202 Surface sealant 203 Photovoltaic element 204 Backside sealant 205 Resin film 301 Reinforcement plate 302 First backside sealant 303 Backside insulating material 304 Second backside sealant 305 Photovoltaic element 306 Surface seal Stopping material 307 Surface member 401 Reinforcement plate 402 Back surface covering material 403 Photovoltaic element 404 Surface covering material 500 Stainless steel substrate on which photoelectric conversion semiconductor layer and transparent conductive layer are laminated 501 Insulating adhesive 502 Current collecting electrode 503 Positive terminal member 504 Negative terminal Member 505 Insulating tape 601 Insulating tape 602 Soft copper foil 603 Photovoltaic element 604 positive terminal member 605 soldered 606 glass cloth 607 negative terminal member 701 solar cell module

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hidetoshi Zenko 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc. (72) Inventor Hidenori Shiozuka 3-30-2 Shimomaruko, Ota-ku, Tokyo Non-corporation F term (reference) 2E108 GG16 KK01 LL03 MM00 NN07 5F051 AA04 AA05 BA03 BA14 BA18 CA15 DA04 DA15 FA02 FA06 GA02 JA03 JA04 JA05 JA20

Claims (10)

[Claims] 1. A method for manufacturing a solar cell module, comprising: laminating a back surface coating material, a photovoltaic element, and a surface coating material, and bonding and covering the photovoltaic element. A method for manufacturing a solar cell module, wherein the solar cell module is positioned and stacked between a peripheral portion of an element and a peripheral portion of a back surface covering material. 2. The method for manufacturing a solar cell module according to claim 1, wherein the surface covering material comprises at least a surface member and a surface sealing material. 3. The method according to claim 1, wherein the surface covering material comprises at least a surface member, a surface sealing material, and a protective reinforcing material. 4. The method for manufacturing a solar cell module according to claim 1, wherein the surface covering material is an integrated laminated member in which at least the same shape is temporarily bonded. 5. The integrated backing member according to claim 1, wherein the back surface covering material is made of at least a back surface sealing material and an insulating material, and has the same shape and is temporarily bonded.
The method for manufacturing a solar cell module according to any one of the above. 6. The method for manufacturing a solar cell module according to claim 1, wherein the surface covering material, the photovoltaic element, and the back surface covering material are stacked face-up. 7. The method according to claim 2, wherein the surface member is a resin film. 8. The back cover material, the photovoltaic element, and the front surface cover material are laminated on a support substrate, and the back cover material is laminated so that the peripheral portion is located inside the peripheral portion of the support substrate. The method for manufacturing a solar cell module according to claim 1. 9. A solar cell module manufactured by the manufacturing method according to claim 1. Description: 10. The solar cell module according to claim 9, wherein the solar cell module is formed as a building material integrated solar cell module in which a solar cell and a building material are integrated.