JP2001308352A - Photovoltaic element, solar cell module using this photovoltaic element and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a photovoltaic element having a shape which prevents the photovoltaic element from breaking through a coating member, caused in manufacturing, installation, transportation, handling, or the form after installa tion and so forth of a solar cell module, a photovoltaic element having a shape excellent in safety in handling, a solar cell module excellent in long-term reliabil ity in various shape, and to provide a method of manufacturing the solar cell module. SOLUTION: Protection members (502) are provided at corners of the periphery of a photovoltaic element (501). In a solar cell module, at least one photovoltaic element (101) is provided between an uppermost front surface member (103) and a lowest rear surface member (105) via a sealing material (102, 104). In this solar cell module, protection members (502) are provided at corners of a periphery of the photovoltaic element (101, 501).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a photovoltaic element, a solar cell module using the photovoltaic element, and a method for manufacturing the solar cell module. In particular, the present invention relates to a photovoltaic device having a substrate made of an inorganic material, and a solar cell module in which at least one of the front surface and the back surface of the photovoltaic device is coated with a polymer material.

[0002]

2. Description of the Related Art In recent years, awareness of environmental problems has been increasing worldwide. Above all, the danger of global warming caused by CO ₂ emission is serious, and the demand for clean energy is increasing.
Also, while the depletion of energy resources is a problem, there is a need for the development of new energy resources. As an alternative energy source, at present solar cells are promising as a clean energy source because of their safety and ease of handling. There are various types of solar cells. Representative examples include single crystal silicon solar cells, polycrystalline silicon solar cells, amorphous silicon solar cells (where the amorphous silicon includes microcrystals), copper indium selenide solar cells,
There are compound semiconductor solar cells and the like. Among them, thin-film crystalline silicon solar cells, compound semiconductor solar cells, and amorphous silicon solar cells can be made relatively large in area at relatively low cost.

[0003] Such a solar cell is generally used in the form of a solar cell module by forming a module using a covering member. As a typical example of such a solar cell module, the configuration shown in FIG. 1 can be mentioned.
In the solar cell module shown in FIG. 1, the photovoltaic element 101 is sealed with a front sealing material 102 and a back sealing material 104, and the light receiving surface side of the photovoltaic element 101 sealed with the sealing material. Is covered with a transparent outermost member 103, and the non-light receiving surface side of the photovoltaic element 101 sealed with the sealing material is covered with a lowermost member 105. When the rearmost member 105 is a metal member having conductivity such as a metal steel plate, the rearmost member 105 and the photovoltaic element 1
01, an insulating material such as an electrical insulating film represented by polyethylene terephthalate (PET) and nylon is provided. In a solar cell module having such a configuration, generally, a glass plate or a transparent polymer resin film such as a fluororesin film or an acrylic resin film is used for the outermost member 103, and glass, steel plates, hard material or the like is used for the lowermost member 105. Plastics, flexible films and the like are used. Further, the surface sealing material 102 and the back surface sealing material 104 are made of ethylene-vinyl acetate copolymer (EVA),
(Meth) acrylic acid ester copolymer, ethylene- (meth) acrylic acid copolymer, polyvinyl butyral (PV
Organic polymer resins such as B) are used.

A solar cell module in which a transparent polymer material is used for the outermost member 103 and a flexible material is used for the outermost member 105 has flexibility and uses glass as the outermost member. It is lighter in weight and has strong impact resistance. The solar cell module having such flexibility can be freely changed in shape, unlike a general solar cell module with a glass cover. For example, the backmost member 1
When 05 is a steel plate, it can correspond to a flat or curved surface of a building, and can be a building material-integrated solar cell module. Further, when the rearmost member 105 is a flexible film, the degree of freedom in shape change is increased and the weight is light, unlike the case of steel sheets, so that sheet-like outdoor leisure articles and portable articles are used. For example, the solar cell module can be easily attached to, for example, a solar cell module that can be used for various purposes. However,
In this case, as compared with the case where the outermost member is a glass plate, scratch resistance is inferior, and the photovoltaic element may be damaged due to scratches from the outside. The electrical characteristics of the module may be significantly impaired, and metals used for the photovoltaic element may be corroded due to intrusion of moisture from the damaged portion. As a way to prevent this from happening,
A method of including a reinforcing material such as a glass fiber material in the surface sealing material 102 and a method of increasing the hardness of the surface sealing material 102 have been proposed. As described above, various proposals have been made for protecting the photovoltaic element from external factors, but the photovoltaic element is protected from tearing, damage, etc. of the solar cell module due to the force from the inside of the solar cell module. There is no specific proposal to do so.

[0005]

The tear and damage of the solar cell module caused by the force from the inside of the solar cell module are the following phenomena. When a flexible material such as a polymer material is used for the outermost surface member 103, the solar cell module is sealed in the solar cell module under the influence of a handling method and means such as installation, transportation, and handling of the solar battery module, and a form after the installation. The corner of the photovoltaic element 101 breaks through the outermost surface member 103 and impairs the appearance of the solar cell module. Further, when the solar cell module breaks out after being installed outdoors, the material penetrates through the penetrated portion due to moisture penetration. It causes deterioration and the like. This is the same when the outermost member 105 is a polymer material. This breakthrough occurs depending on the shape of the photovoltaic element. That is, when the photovoltaic element has a shape having a corner, the corner protrudes sharply,
As shown in FIG. 2, the force generated when the solar cell module or the like is bent or bent concentrates on the projection 206 of the photovoltaic element 201, and the sealing material (2
02, 204), the top surface member 203 and the bottom surface portion may be broken through. In particular, when the substrate of the photovoltaic element is a metal, the projection has a large tear property, and the solar cell module is likely to be damaged by breaking through.

[0006] The shape of the photovoltaic element also depends on the form of the solar cell to be formed. The shape of a photovoltaic element used in the case of a single-crystal silicon solar cell depends on the shape of a single-crystal silicon wafer, and the manufacturing method is generally the CZ method (Czochralski method). The single crystal silicon wafer is obtained by cutting a silicon ingot manufactured by the CZ method, and the cut surface is circular. In the case of a circular shape, there is no possibility of breakthrough as described above, but there is a problem that the filling efficiency of the photovoltaic element filled in the solar cell module is deteriorated, leading to an increase in the size of the solar cell module and an increase in cost. Therefore, the shape of the single crystal silicon wafer is processed as shown in FIG. 3 to improve the filling efficiency. However, the shape of the single crystal silicon wafer has a corner, which may cause the breakthrough phenomenon described above. In the case of a crystalline silicon wafer, in a shape having a corner, an external force is applied to the corner, whereby a local force is applied to the wafer, and the wafer may be damaged.

The occurrence of such breakthrough is caused by a method of manufacturing a solar cell module, in particular, a method in which a photovoltaic element is used as an outermost member,
It also depends on the lamination method of sealing with the rearmost member and the sealing material. As the lamination method used for manufacturing the solar cell module, a vacuum lamination method using a double vacuum and a single vacuum chamber method, a roll lamination method using a roll laminator, and the like are known. In a method for manufacturing a solar cell module using a flexible polymer material or the like for one or both of a top surface member and a bottom surface member, a manufacturing method by a roll lamination method utilizing the flexibility of the material. Are disclosed in JP-A-7-193266, JP-A-8-64852, JP-A-9-70886, and JP-A-10-6.
No. 5194. According to the roll lamination method, it is possible to continuously supply the material, to improve the mass productivity and to reduce the production cost as compared with the vacuum heating method (vacuum lamination method).

However, when the roll lamination method is used, the above-described phenomenon of breaking through the photovoltaic element is more likely to occur. This is because the roll lamination method is significantly different from the vacuum heating method in the thermocompression bonding method. That is, when a roll laminator is used, heat and pressure are partially applied to the laminate before thermocompression bonding of the solar cell module by a roll. In this case, as shown in FIG. 4, the photovoltaic element 40 is locally compressed at a boundary between a portion where the photovoltaic element 401 present in the laminate is sandwiched and a portion where the photovoltaic element 401 is not present.
There is a risk that the outermost member 403 or the outermost member 405 may be broken through at the end of the first member, particularly at the corner. Such breakthrough causes a decrease in yield. The influence of the shape of the photovoltaic element is not limited to the quality of the solar cell module and the manufacturing method. In the case of a photovoltaic element having a sharp corner at the peripheral edge, it is necessary to pay attention to work safety when handling the photovoltaic element. That is, if there is a sharp corner in the peripheral shape of the photovoltaic element, there is a possibility that the photovoltaic element may be scratched or torn to the operator. As described above, the shape of the photovoltaic element affects the quality of the solar cell module, the yield at the time of manufacturing, and also affects the work safety.

The present invention solves the above-mentioned problems in the prior art, and prevents the photovoltaic element from being pierced by the influence of the production, installation, transportation, and handling of the solar cell module, and the configuration after installation. An object of the present invention is to provide a photovoltaic element having a shape in consideration of safety during handling of the photovoltaic element, and to provide a solar cell module excellent in long-term reliability for various shapes and a method of manufacturing the same. And

[0010]

According to the present invention, which solves the above-mentioned problems in the prior art and achieves the above object, a photovoltaic element covers only a corner portion and a peripheral portion of a peripheral shape of the photovoltaic element. The protection member is disposed as described above. Further, for a solar cell module in which at least one photovoltaic element is sealed between a top surface member and a bottom surface member via a sealing material, a corner portion of a peripheral shape of the photovoltaic element and a peripheral portion thereof It is characterized in that a protective member is arranged so as to cover only the protective member. The present invention also provides an improved method for manufacturing a solar cell module. In the manufacturing method of the present invention, at least one photovoltaic element provided with a protective member so as to cover only the corner portion of the peripheral shape and the peripheral portion has a sealing material between the outermost member and the outermost member. It is a method of manufacturing a solar cell module of a configuration sealed via, wherein, by a roll lamination method, the top surface member, the top surface member and the sealing material are thermocompression bonded to the photovoltaic element. Features.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described with reference to the drawings. One example of the solar cell module of the present invention has a similar configuration as that shown in FIG. 1 except that the photovoltaic element has a special configuration as described below. In FIG. 1, 101 indicates a photovoltaic element, 102 indicates a front surface sealing material, 103 indicates a top surface member, 104 indicates a back surface sealing material, and 105 indicates a back surface member. Photovoltaic element 1
Reference numeral 01 denotes a photovoltaic element having a special configuration according to the present invention. That is, as shown in FIG. 5, the photovoltaic element according to the present invention has a protective member 5 at a corner 503.
02 is arranged.

Photovoltaic device (solar cell) in the present invention
Is different depending on the type of constituent material of the photoelectric conversion semiconductor layer. Hereinafter, an amorphous silicon-based photovoltaic element (a photoelectric conversion semiconductor layer made of a crystalline (amorphous) silicon material) and a crystalline silicon photovoltaic element (a photoelectric conversion semiconductor layer is made of a single-crystal silicon material or polycrystalline silicon) ) Will be specifically described.

[0013]

[Amorphous Silicon-Based Photovoltaic Device] FIG. 7 is a schematic cross-sectional view schematically showing an example of the configuration of an amorphous silicon-based photovoltaic device (solar cell) in which light enters from the side opposite to the substrate. In FIG. 7, reference numeral 701 denotes a substrate, and 702 denotes a lower electrode. 703, 713, and 723 each represent an n-type semiconductor layer, 704, 714, and 724 each represent an i-type semiconductor layer, 705, 715, and 725 each represent a p-type semiconductor layer, 706 represents an upper electrode, and 707 represents an upper electrode. Indicates a collecting electrode. Hereinafter, each component of the amorphous silicon-based photovoltaic element shown in FIG. 7 will be described.

(Substrate) The substrate 701 is a member that mechanically supports a semiconductor layer in the case of a thin-film photovoltaic element (solar cell) such as an amorphous silicon photovoltaic element (solar cell). Therefore, the substrate 701 is required to have heat resistance enough to withstand the heating temperature when forming the semiconductor layer.
When the substrate 701 also functions as an electrode, the substrate is made of a conductive material. Such conductive materials include, for example, Fe, Ni, Cr, Al, Mo, Au, Nb, Ta, V, Ti, P
metals such as t, Pb or alloys thereof, such as brass,
Examples include a thin plate of stainless steel or the like, a composite thereof, a carbon sheet, a galvanized steel plate, and the like. The substrate 701 may be made of an electrically insulating material. Examples of such electrically insulating materials include films or sheets of heat-resistant synthetic resins such as polyester, polyethylene, polycarbonate, cellulose acetate, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamide, polyimide, and epoxy, glass, and ceramics. No. In addition, heat-resistant synthetic resin, glass fiber, carbon fiber, boron fiber,
Or a composite with a metal fiber or the like, and a metal thin film of a different material and / or SiO ₂ , Si ₃ N on the surface of a metal thin plate, a resin sheet, or the like.
₄ , an insulating thin film of Al ₂ O ₃ , AlN, etc.
A substrate that has been subjected to a surface coating treatment by plating or the like can also be used as the substrate 701.

(Lower electrode) The lower electrode 702 is one electrode for extracting electric power generated in the semiconductor layer, and is required to have a work function for forming an ohmic contact with the semiconductor layer. The constituent materials of the lower electrode 702 include Al, Ag, Pt, Au, Ni, Ti, Mo, Fe, V, and C.
Metals such as r and Cu, alloys such as stainless steel, brass and nichrome, and transparent conductive oxides (TCO) such as SnO ₂ , In ₂ O ₃ , ZnO and ITO are used. The surface of the lower electrode 702 is preferably smooth. However, when irregular reflection of light is caused, the surface may be textured. When the substrate 701 is conductive, the lower electrode 702 does not need to be provided. The lower electrode 702 can be formed by, for example, a method such as plating, vapor deposition, or sputtering.

(Semiconductor layer) As an amorphous silicon semiconductor layer, for example, a triple cell having a three-pin junction (a stack of a p-type semiconductor layer, an i-type semiconductor layer, and an n-type semiconductor layer) as shown in FIG. It can be of a configuration. In addition, a double cell configuration having two pin junctions or pn junctions (a stack of a p-type semiconductor layer and an n-type semiconductor layer), or one pin junction or p-type junction
It may be of a single cell configuration having an n-junction. In the structure shown in FIG.
3, 713, 723), i-type semiconductor layer (704, 71)
4, 724) and p-type semiconductor layers (705, 715, 7)
25) is made of an amorphous silicon (a-Si) semiconductor material. p-type semiconductor layers (705, 715, 72)
5) is microcrystal silicon (μc
-Si) It may be composed of a semiconductor material. In particular, i
A- forming the semiconductor layers (704, 714, 724)
As the Si semiconductor material, in addition to the a-Si semiconductor material, a so-called Group 4 and Group 4 alloy amorphous semiconductor material such as an a-SiGe semiconductor material and an a-SiC semiconductor material can be used. These amorphous silicon semiconductor layers are formed by evaporation, sputtering, high-frequency plasma CVD,
, Microplasma CVD, ECR, thermal CVD, LPCVD, and other known film forming methods. As a film forming apparatus, a batch type apparatus, a continuous film forming apparatus, or the like can be used as desired.

(Upper electrode) The upper electrode 706 is an electrode for extracting an electromotive force generated in the semiconductor layer, and forms a pair with the lower electrode 702. The upper electrode 706 is necessary when the semiconductor layer is made of a semiconductor material having a high sheet resistance such as amorphous silicon (a-Si), and is not particularly necessary in a crystalline solar cell because the sheet resistance is low. . In addition, since the upper electrode 706 is located on the light incident side, it needs to be transparent, and is sometimes called a transparent electrode. The upper electrode 706 desirably has a light transmittance of 85% or more in order to efficiently absorb light from the sun, a white fluorescent lamp, or the like into the semiconductor layer. Is desirably 100 Ω / □ or less in order to cause the lateral flow in the semiconductor layer. The upper electrode 706 is made of a material having such characteristics. Specific examples of such materials include SnO ₂ , In ₂ O ₃ , ZnO, CdO, CdSnO ₄ , and ITO (In ₂ O ₃ + Sn
O ₂ ) and other metal oxides.

(Current Collecting Electrode) The current collecting electrode 707 is generally formed in a comb shape, and a suitable width and pitch are determined from the sheet resistance of the semiconductor layer and the upper electrode 706. The collector electrode 707 is required to have a low specific resistance and not become a series resistance of the solar cell, and a preferable specific resistance is 10 ⁻² Ωcm to 10
^-6 Ωcm. As a constituent material of the current collecting electrode 707, for example, a metal such as Ti, Cr, Mo, W, Al, Ag, Ni, Cu, Sn, or Pt, or an alloy or solder thereof is used. In general,
A metal paste in which a metal powder and a polymer resin binder are in the form of a paste is used, but is not limited thereto.

[0019]

[Crystalline Silicon Photovoltaic Device] FIG. 8 is a schematic sectional view schematically showing an example of the structure of a crystalline silicon photovoltaic device (solar cell). In the crystalline silicon photovoltaic element, the photoelectric conversion semiconductor layer is made of a single crystal silicon material or a polycrystalline silicon material. In FIG.
Reference numeral 800 indicates the entire crystalline silicon solar cell. 80
Reference numeral 1 denotes a semiconductor layer made of a silicon substrate; 802, a semiconductor layer forming a pn junction with the semiconductor layer 801; 803, a back electrode; 804, a current collecting electrode; and 805, an antireflection film. In the case of a single crystal silicon photovoltaic element (solar cell) or a polycrystalline silicon photovoltaic element (solar cell), a supporting substrate is not provided, and a single crystal wafer or a polycrystalline wafer serves as a substrate.

The single crystal silicon wafer is obtained by a method of cutting a silicon ingot pulled up by the CZ method.
The shape of the silicon ingot obtained in this manner is generally cylindrical, and a single crystal silicon wafer can be obtained by cutting the silicon ingot thinly. When the single crystal silicon wafer has a circular shape, it is processed into a shape (see FIG. 3) in consideration of the charging efficiency in the solar cell module. In the case of a polycrystalline silicon wafer, there are a casting method for cutting a silicon ingot formed by a mold, a ribbon method for obtaining a sheet-like polycrystal, and the like.

The semiconductor layer 802 forming a pn junction with the semiconductor layer 801 is formed by a gas phase diffusion method using POCl ₃ ,
It can be formed by a coating diffusion method using O ₂ , SiO ₂ , or P ₂ O ₅ , an ion implantation method of directly doping ions, or the like.
The back surface electrode 803 can be formed by, for example, forming a metal film by vapor deposition or sputtering. In addition, it can be formed by screen printing of silver paste or the like. The anti-reflection film 805 is formed in order to prevent a decrease in efficiency due to reflection of light on the surface of the photovoltaic element.
SiO ₂ , Ta ₂ O ₅ , Nb ₂ O ₅ or the like is used.

A plurality of the photovoltaic elements manufactured as described above are connected in series or in parallel to form a photovoltaic element group (solar cell) so that a desired voltage or current can be obtained. . In this case, a desired voltage or current can be obtained by integrating a plurality of photovoltaic elements on an insulated substrate. A transparent hard organic resin thin film layer for imparting moisture resistance or scratch resistance can be provided on the light incident side of the photovoltaic element (photovoltaic element group) thus manufactured. As a constituent material of such a transparent hard organic resin thin film layer, for example, an acrylic resin, a silicon resin, a fluorine resin, a polyester resin, a urethane resin, an epoxy resin, an alkyd resin, a polysilazane resin, and the like can be given. However, from the viewpoint of weather resistance, an acrylic resin, a silicon resin, and a fluorine resin are preferable. In addition, considering the use of the solar cell module at high temperature, it is preferable to improve the heat resistance by crosslinking, and a method using an organic peroxide or isocyanate is generally used as a crosslinking method.

The photovoltaic element referred to in the present invention includes an element provided with the above transparent hard organic resin thin film layer. The thickness of the photovoltaic element manufactured as described above is desirably 50 μm or more. If the thickness is smaller than 50 μm, the rigidity of the photovoltaic element is lost, so that the peripheral shape of the photovoltaic element has a corner, and even when an external force is applied thereto, the photovoltaic element is not affected by the force. Following and curving makes it difficult for breakthrough and other phenomena to occur. Therefore, when the thickness is smaller than 50 μm, it is not always necessary to carry out the present invention.

In the photovoltaic element of the present invention, protective members are attached to the peripheral corners and the periphery thereof. As a material used for the protection member, an organic polymer material is preferable. This is because the organic polymer material is excellent in flexibility and flexibility and does not limit the processability of the solar cell module. More specifically, epoxy resin, silicone resin, phenol resin, polyethylene, polypropylene, polystyrene, styrene-acrylonitrile copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), polycarbonate, polyethylene terephthalate ( Various resins such as a rubber elastic body such as PET) and butadiene rubber can be used, and these resins may be used in combination. It is also possible to form a composite material with a reinforcing material such as glass fiber, and by using the reinforcing material, it is possible to more effectively prevent breakthrough of the photovoltaic element. The thickness of the protective member from the photovoltaic element surface is 50 μm
It is desirable that the thickness be not less than 150 μm. If the thickness of the protective member is less than 50 μm, it does not have sufficient protective ability to prevent the corner of the photovoltaic element from breaking through. If the thickness of the protective member is larger than 150 μm, there is a problem that irregularities are formed on the surface of the solar cell module. Furthermore, if the protection member has a certain degree of strength, a breakthrough phenomenon may occur. As a method of attaching the protective member to the corner portion of the photovoltaic element and the peripheral portion thereof, a method of disposing a sealing material such as an epoxy resin or a silicone resin on the corner portion and curing, a method of attaching a resin tape, a molded product There are various methods, such as a method of fitting.

As the mounting form of the protection member, for example, in addition to the form shown in FIG. 5, the form shown in FIG. 6 can also be adopted. In particular, in the case of a flexible solar cell module, it is preferable that the protective member also has flexibility, and a silicone resin or a resin tape is suitably used. Further, in consideration of productivity, it is preferable to use a resin tape member which is easy to handle and does not require a curing time. Also, in the shape of the solar cell module, when the piercing direction of the photovoltaic element is considered only in one direction, it is only necessary to attach a protective member such as a tape to only one side of the corner of the photovoltaic element, It is necessary to consider that the flexibility of the solar cell module is limited and the workability of the solar cell module is limited. Regarding the shape of the photovoltaic element, the corners of the photovoltaic element are processed so as to have a radius of curvature, and the protrusions at the corners are loosened, and then a protective member is attached to effectively prevent defects such as breakthrough. It is possible to prevent it.

FIG. 5 schematically shows a preferred example of a photovoltaic element having a protective member attached to a corner as described above. In the photovoltaic element according to the present invention, it is preferable that the inner angle of the corner is 100 ° or less. When the internal angle of the corner is larger than 100 °, the occurrence of the breakthrough phenomenon is negligible. However, 100
If the angle is less than or equal to °, the breakthrough phenomenon may occur significantly. This is because when the inner angle of the corner is 100 ° or less, the sharpness of the angle is large. If the substrate of the photovoltaic element is made of an inorganic material and the photovoltaic element has a corner, the breakthrough phenomenon may occur significantly. On the other hand, when the substrate is made of an organic material, compared to the case where the substrate is made of an inorganic material, the substrate has high flexibility and low hardness, so that phenomena such as breakthrough hardly occur. Therefore, in the present invention, when the substrate of the photovoltaic element is made of an inorganic material, the effects of the present invention are more remarkably exhibited.

Hereinafter, the configuration of a solar cell module using the photovoltaic element of the present invention manufactured by the above method will be described with reference to FIG. First, the rearmost member 105
Is necessary for maintaining electrical insulation between the conductive substrate of the photovoltaic element 101 and the outside. Examples of the material include glass and insulating resin which can secure sufficient electric insulation with the conductive substrate and have excellent long-term durability and can withstand thermal expansion and thermal contraction. In particular, nylon, polyethylene terephthalate (PET), and the like can be cited as the film that is preferably used for the outermost member 105 as a material having flexibility. Further, a reinforcing plate may be attached to the outside of the rearmost member 105 in order to increase the mechanical strength of the solar cell module or to prevent distortion or warpage due to a temperature change. As the reinforcing plate, for example, a steel plate, a plastic plate,
An FRP (glass fiber reinforced plastic) plate is preferably used. In particular, the photovoltaic element in the present invention is
The structure has a structure for preventing breakage to 05, and the effect of the present invention can be maximized by using a polymer material such as nylon or polyethylene terephthalate (PET) for the rearmost member 105. .

Since the outermost member 103 is located on the outermost layer of the solar cell module, the outermost member 103 ensures long-term reliability in outdoor exposure of the solar cell module, including weather resistance, water repellency, stain resistance, and mechanical strength. Performance is required. Outermost surface member 103 suitably used in the present invention
Examples of constituent materials include glass, ethylene tetrafluoride-ethylene copolymer (ETFE), polyvinyl fluoride resin (PVF), polyvinylidene fluoride resin (PVDF),
Fluororesin films such as polytetrafluoroethylene resin (TFE), ethylene tetrafluoride-propylene hexafluoride copolymer (FEP), polychlorotrifluoroethylene resin (CTFE), and polymethyl methacrylate (PMMA) Acrylic resin films and the like can be mentioned. In particular, the photovoltaic element according to the present invention has a structure for preventing breakage to the outermost member 103, and by using a polymer material such as a fluororesin film or an acrylic resin film for the outermost member 103, The effect can be maximized. When a resin film is used for the outermost surface member 103, the thickness of the film must be increased to some extent in order to secure mechanical strength against external stress. However, making it unnecessarily thick has a problem, particularly in terms of cost. Considering these points, the thickness is
It is preferably from 10 to 200 μm, more preferably from 25 to 100 μm. In order to improve the adhesiveness with the surface sealing material 102, the surface of the resin film as the outermost member 103 is brought into contact with the surface sealing material by corona discharge treatment, plasma treatment, chemical treatment, or the like. It is desirable that it be processed.

The surface sealing material 102 covers the unevenness of the photovoltaic element, protects the element from a severe external environment such as temperature change, humidity, impact, scratch and the like. Necessary to ensure adhesion with Further, it is necessary to suppress a decrease in the amount of light reaching the photovoltaic element. Therefore, the surface sealing material 102 is required to have weather resistance, adhesion, filling properties, heat resistance, impact resistance, scratch resistance, transparency, and the like. As a constituent material of the surface sealing material 102 satisfying these requirements, a resin made of a polyolefin-based copolymer is suitably used. Specific examples of the resin include ethylene-vinyl acetate copolymer (EVA), ethylene- (meth) acrylate copolymer, and ethylene- (meth) which are excellent in weather resistance, adhesiveness, filling properties, and transparency.
Acrylic acid copolymers, ethylene- (meth) acrylic acid ester multi-component copolymers, ethylene- (meth) acrylic acid multi-component copolymers and the like can be mentioned. As the (meth) acrylate, methyl (meth) acrylate and ethyl (meth) acrylate are preferred from the viewpoint of transparency and the like. Further, as a means for improving the heat resistance of the surface sealing material 102, a resin constituting the surface sealing material may be crosslinked. In the case of an ethylene-vinyl acetate copolymer (EVA), the crosslinking is generally performed with an organic peroxide. In that case, it is desirable to use a crosslinking aid in order to efficiently perform the crosslinking reaction.

The above-mentioned resin constituting the surface sealing material 102 may be added with a thermal oxidation inhibitor in order to impart stability at high temperatures. Although the resin constituting the surface sealing material 102 is excellent in weather resistance, an ultraviolet absorber is further added to further protect the layer located under the sealing material. You may. As a method for imparting weather resistance other than the ultraviolet absorber, a hindered amine light stabilizer may be used. By using the hindered amine-based light stabilizer in combination with the ultraviolet absorber, a remarkable synergistic effect is brought about in improving the weather resistance.
In consideration of the usage environment of the solar cell module, it is preferable to use a low-volatile ultraviolet absorber, a light stabilizer and a thermal antioxidant. In order to minimize the decrease in the amount of light reaching the photovoltaic element, the total light transmittance of the surface sealing material 102 is desirably 80% or more in a visible light wavelength region of 400 nm or more and 800 nm or less.
% Is more desirable. Further, in order to facilitate the incidence of light from the atmosphere, the refractive index is preferably from 1.1 to 2.0, and more preferably from 1.1 to 1.6.

The back sealing material 104 is a photovoltaic element 101
And the outermost member 105.
As a constituent material of the back surface sealing material 104, a material which can secure sufficient adhesiveness to the substrate, has excellent long-term durability, can withstand thermal expansion and thermal contraction, and has flexibility is preferable.
Specific materials suitably used for the back surface sealing material 104 include ethylene-vinyl acetate copolymer, ethylene- (meth) acrylate copolymer, ethylene- (meth)
Hot melt materials such as acrylic acid copolymer, ethylene- (meth) acrylic acid ester multi-component copolymer, ethylene- (meth) acrylic acid multi-component copolymer, polyvinyl butyral, double-sided tape, flexible epoxy adhesive, etc. Is mentioned.

As the sealing material (102, 104), a silane coupling agent, an organic titanate compound or the like is used as a means for further improving the adhesion to the photovoltaic element 101, the outermost member 103, and the lowermost member 105. May be added to the sealing material as needed.

A method for manufacturing a solar cell module using the above constituent materials will be described below. Various methods such as a vacuum lamination method and a roll lamination method which are conventionally known can be selected and used as a method for manufacturing a solar cell module. The photovoltaic element according to the present invention can exhibit its effects to the maximum when manufacturing a solar cell module particularly through a roll lamination method.

Hereinafter, an example of a method for manufacturing a solar cell module via a roll lamination method will be described. FIG. 9 is a schematic diagram schematically showing a configuration of an example of the roll laminator device. In the roll laminator apparatus shown in FIG. 9, first, a top surface member roll 903, a top surface sealing material roll 902, a back surface sealing material roll 904, and a bottom surface member roll 905 are supplied to the first stage heating roller portion.
At this time, the outermost member 903 and the surface sealing material 902 and the outermost member 905 and the back surface sealing material 904 may be integrated.
Next, the photovoltaic element group 901 of the present invention is supplied to the first-stage heating roller portion so as to be disposed between the front surface sealing material 902 and the rear-surface sealing material 904. Upper stage 911 and lower stage 91 of the first stage heating roller
The stacked body is heated in 2 and the heated stacked body is supplied to the second-stage heating roller unit, and the second-stage heating roller upper stage 921,
The laminate is heated in the lower stage 922 and pressure is applied to the laminate in the second stage heating roller upper stage 921 to perform thermocompression bonding of the laminate. After thermocompression bonding, supply the laminate to the cooling roller section,
By cooling the laminate, the solar cell module 9 of the present invention is cooled.
06 can be obtained.

[0035]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to embodiments. However, the present invention is not limited to the following embodiments, and can be appropriately modified within the scope of the present invention.

[0036]

Example 1 In this example, a solar cell module having the structure shown in FIG. 1 was manufactured as described below.

(Preparation of Photovoltaic Element) An amorphous silicon photovoltaic element 700 having the structure shown in FIG. 7 was prepared. Nine cleaned rectangular stainless steel substrates (thickness: 200 μm) were prepared as the substrates 701. On each stainless steel substrate, first, as the lower electrode 702, an Al layer (electrode layer) / Zn0 layer (backside reflection layer) (total thickness: 1.3)
μm) was formed by a known sputtering method. Then, a known plasma CVD is applied on the back surface reflective layer of the lower electrode 702.
The n-type semiconductor layer 703 (thickness: 0.01 μm)
m), i-type semiconductor layer 704 (thickness: 0.15 μm), p
Semiconductor layer 705 (thickness: 0.01 μm), n-type semiconductor layer 713 (thickness: 0.01 μm), i-type semiconductor layer 714
(Thickness: 0.1 μm), p-type semiconductor layer 715 (thickness:
0.01 μm), n-type semiconductor layer 723 (thickness: 0.01
μm), an i-type semiconductor layer 724 (thickness: 0.1 μm), and a p-type semiconductor layer 725 (thickness: 0.01 μm) are stacked in this order, and a triple-cell amorphous silicon photoelectric conversion having a three pin junction. A semiconductor layer was formed.
The n-type semiconductor layers 703, 713, and 723 are formed of an a-Si semiconductor material, respectively, and the p-type semiconductor layers 705,
15 and 725 are microcrystalline silicon (μc-S
i) Made of semiconductor material. The i-type semiconductor layer 704 was formed using an a-Si semiconductor material, and the i-type semiconductor layer 714 and the i-type semiconductor layer 724 were each formed using an a-SiGe semiconductor material. Thereafter, a transparent electrode layer (layer thickness: 0.07 μm) made of ITO is formed as the upper electrode 706 on the p-type semiconductor layer 725 of the amorphous silicon photoelectric conversion semiconductor layer by a known sputtering method. A grit electrode (thickness: 110 μm) made of a silver-clad wire as a current collecting electrode 707 was mounted on the electrode layer by a known method. Thus, an amorphous silicon photovoltaic device was manufactured. The rectangular interior angle of the rectangular stainless steel substrate used here was 90 °. Thus, nine amorphous silicon photovoltaic elements were produced. The shapes of the obtained nine amorphous silicon photovoltaic elements were all rectangular depending on the shape of the stainless steel substrate, and had corners at four corners. Therefore, epoxy resin is applied to the four corners of these nine photovoltaic elements as shown in FIG. 5B, and the thickness from the photovoltaic element surface is 20 μm, 40 μm,
50μm, 70μm, 90μm, 120μm, 150μ
m, 170 μm, and 200 μm were respectively attached and cured. In this way, nine photovoltaic elements having epoxy resin attached to the four corners were obtained.

(Fabrication of Solar Cell Module) Each of the nine photovoltaic elements obtained above was subjected to ETFE as the outermost member 103 by a roll lamination method.
Film (thickness: 50 μm), EVA film (thickness: 450 μm) as front surface sealing material 102, back surface sealing material 1
04, and an ETEF film (thickness: 50 μm) as the rearmost member 105.
μm), and the light receiving surface side of the photovoltaic element is covered with a surface sealing material 102 and a top surface member 103, and the non-light receiving surface side of the photovoltaic element is a back surface sealing material 104 and a top surface member. 105 to obtain a solar cell module coated with the same. Thus, nine solar cell modules were obtained. 9
Each solar cell module was repeatedly manufactured in the same manner, and 100 solar cell modules were manufactured for each solar cell module.

The obtained solar cell module was evaluated as described below.

[Appearance evaluation] The appearance of each solar cell module was observed. At this time, the photovoltaic element in which the protective member at the corner protruded from the surface of the solar cell module was regarded as defective. Table 1 shows the percentage of the number of the solar cell modules determined to be defective (that is, the defective rate), the points of improvement according to the present invention according to the present embodiment, and the improvement rates. The improvement point and the improvement rate are obtained when the inner corner angle and the thickness of the photovoltaic element are the same, and the protective member is not provided (see Comparative Example 1 described later).
Is calculated based on the following equation. Improvement point = (defective rate of comparative example)-(defective rate of example) Improvement rate = [(improvement point) / (defective rate of comparative example)]
x 100

[Evaluation of photovoltaic elements breaking through solar cell module]
About the obtained solar cell module, evaluation of the penetration of the solar cell module of the photovoltaic element was performed through a penetration test shown in FIG. Table 1 shows the evaluation results. (Penetration test) As shown in FIG.
002, 1003, or back surface coating material 1004, 100
5 was bent 180 °, and a force of 5 kg was applied. At this time, the photovoltaic element in which the breakthrough phenomenon occurred was regarded as NG. Table 1 shows the NG occurrence rate, the improvement points according to the present invention according to the present embodiment, and the improvement rate. At this time, the breakthrough test was performed 100 times. The improvement point and the improvement rate are calculated based on the following formulas in comparison with the case where the inner corner angle and the thickness of the photovoltaic element are the same and the protective member is not provided (see Comparative Example 1 described later). It is calculated. Improvement point = (NG rate of comparative example)-(NG rate of example) Improvement rate = [(improvement point) / (NG rate of comparative example)] x 100

[0040]

Embodiment 2 According to the method described in Embodiment 1, the shape of the photovoltaic element is a parallelogram having a corner interior angle of 80 ° and 100 °, a rectangle (corner interior angle of 90 °), a regular pentagon (corner interior angle of 108 °).
°), a regular hexagon (120 ° inside corner), and a regular octagon (135 ° inside corner) to produce a plurality of photovoltaic elements. FIG. 5 shows a protective member having a thickness of 80 μm from the power element surface.
A solar cell module was manufactured in the same manner as in Example 1 except that the solar cell module was arranged as shown in (b). The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results. In addition, Comparative Example 2 described later was used as a comparative control in the evaluation.

[0041]

Embodiment 3 Substrate 70 for Photovoltaic Device in Embodiment 1
1, thicknesses of 20 μm, 30 μm, and 40 μm, respectively
m, 50 μm, 80 μm, 100 μm, 200 μm, 3
A plurality of photovoltaic elements are manufactured using the photovoltaic element substrate 701 having a thickness of 00 μm, and the corners of each of the photovoltaic elements are placed on a PET tape (100 μm thick from the photovoltaic element surface).
m) was mounted as shown in FIG. 5B, and a solar cell module was produced in the same manner as in Example 1.
The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results. The comparison in the evaluation was Comparative Example 3 described later.
Was used.

[0042]

Embodiment 4 Substrate 70 for Photovoltaic Element in Embodiment 1
1, thicknesses of 20 μm, 30 μm, and 40 μm, respectively
m, 50 μm, 80 μm, 100 μm, 200 μm, 3
A plurality of photovoltaic devices are manufactured using the photovoltaic device substrate 701 having a thickness of 00 μm, and the corners of each photovoltaic device are glass fiber reinforced PET tape (1100 μm thick from the surface of the photovoltaic device). Was mounted as shown in FIG. 5 (b), and a solar cell module was produced in the same manner as in Example 1. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results. In addition, Comparative Example 4 described later was used as a comparative control in the evaluation.

[0043]

Embodiment 5 A plurality of photovoltaic elements made of a polycrystalline silicon wafer (shape is square, corner inside angle 90 °) were manufactured by cutting, polishing and grinding a silicon ingot obtained by a casting method. Silicon rubber (thickness from the photovoltaic element surface: 80 μm) was attached to the inner corner of each of the obtained photovoltaic elements as shown in FIG. A battery module was manufactured. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results. In addition, Comparative Example 5 described later was used as a comparative control in the evaluation.

[0044]

[Embodiment 6] In the same manner as in Embodiment 1, the corner inner corner 9
A plurality of photovoltaic elements having a rectangular shape of 0 ° were manufactured. Each of the obtained photovoltaic elements was roll-laminated with an ETFE film (50 μm) as the outermost member 103, an EVA film (450 μm) as the surface sealing material 102, and an EVA as the back surface sealing material 104.
A film (450 μm) and a steel plate (400 μm) whose surface as the outermost member 105 had been subjected to insulation treatment were thermocompression bonded to obtain a solar cell module. At this time, a PET tape (100 μm thick from the photovoltaic element surface) was attached to the corner of each photovoltaic element on the surface member side of the photovoltaic element as shown in FIG. 5B. . Thus, a plurality of solar cell modules were obtained. The appearance of the obtained solar cell module was evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results. In the solar cell module obtained in this example, since the rearmost member was a steel plate and bending at 180 ° could not be performed, evaluation of the photovoltaic element breaking through the solar cell module was not performed. Comparative Example 6 described later was used as a comparative control in the appearance evaluation of this example.

[0045]

Comparative Example 1 A plurality of solar cell modules were manufactured in the same manner as in Example 1 except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0046]

Comparative Example 2 A plurality of solar cell modules were produced in the same manner as in Example 2 except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0047]

Comparative Example 3 A plurality of solar cell modules were produced in the same manner as in Example 3, except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0048]

Comparative Example 4 A plurality of solar cell modules were produced in the same manner as in Example 4 except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0049]

Comparative Example 5 A plurality of solar cell modules were produced in the same manner as in Example 5, except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module and the evaluation of the photovoltaic element breaking through the solar cell module were evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0050]

Comparative Example 6 A plurality of solar cell modules were produced in the same manner as in Example 6, except that no protective member was attached to the corner of the photovoltaic element. The appearance of the obtained solar cell module was evaluated in the same manner as in Example 1. Table 1 shows the obtained evaluation results.

[0051]

[Summary of Evaluation Results] As is clear from the results shown in Table 1, the following facts are understood. That is, when the protective member is not attached to the corner of the photovoltaic element, in the piercing test, the photovoltaic element pierces the outermost member and the surface sealing material, or the outermost member and the back surface sealing material, and Brings a defect. In addition, even when the solar cell module is manufactured by the roll lamination method, the breakthrough phenomenon shown in FIG. 4 frequently occurs. On the other hand, in the case where the protective member is attached to the corner of the photovoltaic element, in the breakthrough test, the appearance defect and the failure due to the breakthrough when manufacturing the solar cell module by the roll lamination method are greatly improved.

FIG. 11 is a graph showing the percentage of improvement of the defect after the piercing test and lamination with respect to the thickness of the protective member attached to the corner of the photovoltaic element in Example 1. From the graph, it can be seen that when the thickness of the protective member is small, the improvement effect is small, and when the thickness is too large, a breakthrough phenomenon occurs. Specifically, as shown in the graph of FIG. 11, the thickness of the protective member is 50 μm or more and 15 μm or more.
When it is 0 μm or less, the improvement rate of the breakthrough defect in the breakthrough test and the production of the solar cell module by the roll lamination method is excellent. This is because the thickness of the protective member is 5
This is because if the thickness is less than 0 μm, the photovoltaic element does not have sufficient protective ability to prevent the corner of the photovoltaic element from breaking through. If the protective member is thicker than 150 μm, irregularities are formed on the surface of the solar cell module, and furthermore, since the protective member is an epoxy resin having a certain strength,
This is because the breakthrough phenomenon is easily caused. Therefore, the breakthrough phenomenon can be more effectively prevented by attaching a protective member having a thickness in the range of 50 μm to 150 μm to the corner of the peripheral shape of the photovoltaic element.

FIG. 12 is a graph showing breakthrough tests for the inner corners of the peripheral shape of the photovoltaic element and the improvement points of defects after lamination in Example 2.
As is clear from Table 1 in comparison with Comparative Example 2, the breakthrough test NG generation rate was obtained by disposing the protective members at the corners of the periphery of the photovoltaic element for various inner corners of the photovoltaic element, The appearance defect rate after roll lamination is remarkably improved. In particular, as shown in FIG. 12, when the inside angle of the corner of the photovoltaic element is 100 ° or less, the breakthrough phenomenon can be more effectively prevented by attaching the protective member to the corner of the photovoltaic element. .

FIGS. 13 and 14 show breakthrough tests for the thickness of the photovoltaic element (that is, the thickness of the photovoltaic element substrate) in Examples 3 and 4, and points of improvement of defects after lamination. It is a graph. As is clear from Table 1 in comparison with Comparative Examples 3 and 4, the breakthrough test NG generation rate was obtained by disposing protective members at the corners of the periphery of the photovoltaic element for various thicknesses of the photovoltaic element. In addition, the appearance defect rate after roll lamination is remarkably improved. In particular, as shown in FIGS. 13 and 14, when the thickness of the photovoltaic element (the thickness of the photovoltaic element substrate) is 50 μm or more, the breakthrough phenomenon can be more effectively prevented. Further, in Example 3, a PET tape was used as a protective member, and in Example 4, a glass fiber reinforced PET tape was used. However, as shown in FIGS. By using the reinforced PET tape, it is possible to more effectively prevent the breakthrough phenomenon as compared with the case of using only the resin as in the case of the PET tape.

In Example 5 and Comparative Example 5, the substrate was a polycrystalline silicon wafer. However, as in the case of the stainless steel substrate, when the protective member was not attached to the corner of the photovoltaic element, the breakthrough phenomenon occurred. The breakthrough phenomenon can be prevented by attaching the protective member to the corner of the peripheral shape of the photovoltaic element made of a crystalline silicon wafer as in the case of the stainless steel substrate. Further, in a metal substrate such as a stainless steel substrate (see Comparative Examples 1 to 4) and a silicon wafer, the breakthrough phenomenon occurs more frequently in the metal substrate. This is because the metal substrate has sharpness as compared with the silicon wafer, and it can be said that the protective member of the present invention is more effective for a metal substrate having high sharpness.

Example 6 and Comparative Example 6 are solar cell modules in which the outermost member is a resin film and the outermost member is a steel plate. In Example 6, the corner portion of the photovoltaic element on the outermost member side was used. Only the protection member is attached.
In this case, the flexibility of the solar cell module was inferior, and a breakthrough test could not be performed, but breakthrough after roll lamination occurred in Comparative Example 6,
By attaching the protection member, it is possible to prevent breakthrough.

[0057]

[Table 1]

[0058]

The photovoltaic element of the present invention has a protective member attached to the corner of the peripheral shape of the photovoltaic element. By attaching the protective member to the corner, the safety during handling is excellent. It is possible to provide a photovoltaic element. Moreover, in the solar cell module manufactured using the photovoltaic element of the present invention, since the corners of the photovoltaic element are covered with the protective member, the production, installation, transportation, handling, and further installation of the solar cell module are performed. A manufacturing method that can prevent a covering member of a photovoltaic element from breaking through due to the influence of a later configuration, provide a solar cell module having excellent long-term reliability for various shapes, and have excellent productivity or yield. Can be provided.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view schematically illustrating a configuration of an example of a solar cell module.

FIG. 2 is a schematic diagram for explaining an example of a breakthrough phenomenon of a photovoltaic element.

FIG. 3 is a schematic view illustrating an example of a single crystal silicon wafer.

FIG. 4 is a schematic diagram for explaining an example of a breakthrough phenomenon of a photovoltaic element that occurs when a solar cell module is manufactured by a roll lamination method.

FIG. 5 is a schematic view illustrating an example of a method of arranging the protection member of the present invention at a corner of a photovoltaic element and a peripheral part thereof.

FIG. 6 is a schematic view illustrating an example of a method of disposing the protective member of the present invention at a corner of a photovoltaic element and a peripheral part thereof.

FIG. 7 is a schematic cross-sectional view schematically illustrating a configuration of an example of an amorphous silicon-based photovoltaic element.

FIG. 8 is a schematic cross-sectional view schematically illustrating a configuration of an example of a crystalline silicon-based photovoltaic element.

FIG. 9 is a schematic view illustrating an example of a method for manufacturing a solar cell module of the present invention using a roll lamination method.

FIG. 10 is a conceptual diagram showing a method of a breakthrough test in Examples and Comparative Examples.

FIG. 11 is a graph showing an NG generation rate improvement rate and a penetration failure improvement rate after lamination in a break-through test for a thickness of a protective member attached to a corner of a photovoltaic element in Example 1.

FIG. 12 is a graph showing an NG generation rate improvement point and a breakthrough failure improvement point after lamination in a breakthrough test for a corner inside corner of the photovoltaic element in Example 2.

FIG. 13 is a graph showing NG generation rate improvement points and break-through failure improvement points after lamination in a break-through test for the thickness of the photovoltaic element substrate in Example 3.

FIG. 14 is a graph showing NG generation rate improvement points and breakage failure improvement points after lamination in a breakthrough test for the thickness of the photovoltaic element substrate in Example 4.

[Explanation of symbols]

101, 201, 401, 901 Photovoltaic element (or photovoltaic element group) 102, 202, 402, 1002 Surface sealing material 103, 203, 403, 1003 Top surface member 104, 204, 404, 1004 Back surface sealing Material 105, 205, 405, 1005 Backmost member 206, 503, 1006 Photovoltaic element corner 207 Breakthrough part by photovoltaic element 300 Single crystal silicon wafer 406 Upper stage of heating / pressing roll of roll laminator 407 Roll laminator Heating / pressing roll lower stage 501, 601, 700, 800, 1001 Photovoltaic element 502, 602 Protective member 701 Photovoltaic element substrate 702 Lower electrode 703, 713, 723 n-type semiconductor layer 704, 714, 724 i- Semiconductor layer 705, 715, 725 p-type semiconductor Layer 706 Upper electrode 707, 804 Current collecting electrode 801, 802 Semiconductor layer 803 Back electrode 805 Antireflection film 902 Surface sealing material roll 903 Top surface member roll 904 Back surface sealing material roll 905 Top surface member roll 906 Solar cell module 911 First First stage heating roller upper stage 912 First stage heating roller lower stage 921 Second stage heating roller upper stage 922 Second stage heating roller lower stage 931 Cooling upper stage roller 932 Cooling lower stage roller 941,942,951,952,961,962 Rubber rubber

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Satoshi Yamada 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc. (72) Inventor Hidenori Shiotsuka 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Co., Ltd. F-term (reference) 5F051 AA02 AA03 AA05 AA08 AA09 AA10 BA11 BA14 BA15 EA01 JA02 JA05

Claims (22)

[Claims] 1. A photovoltaic element having a corner with a peripheral shape having a corner, wherein a protection member is provided so as to cover only the corner and the periphery thereof. 2. The photovoltaic device according to claim 1, wherein the photovoltaic device has a thickness of 50 μm or more. 3. The corner of the photovoltaic element has an interior angle of an interior angle.
3. The photovoltaic device according to claim 1, which is at most 100 °. 4. The photovoltaic device according to claim 1, wherein the photovoltaic device has a substrate made of an inorganic material. 5. The photovoltaic device according to claim 1, wherein at least one of the materials forming the protective member is an organic polymer material. 6. The photovoltaic element according to claim 1, wherein the protection member is arranged at the corner of the photovoltaic element such that a thickness from a surface of the photovoltaic element is not less than 50 μm and not more than 150 μm. The photovoltaic device according to any one of the preceding claims. 7. A solar cell module having at least one photovoltaic element sealed between a top member and a bottom member via a sealing material, wherein the peripheral shape of the photovoltaic element is a corner. And a protective member is provided so as to cover only the corner portion and a peripheral portion thereof. 8. The solar cell module according to claim 7, wherein the photovoltaic element has a thickness of 50 μm or more. 9. The photovoltaic element, wherein the inner angle of the corner is 100.
9. The solar cell module according to claim 7, wherein the angle is equal to or less than 0 °. 10. The solar cell module according to claim 7, wherein the photovoltaic element has a substrate whose substrate is made of an inorganic material. 11. The solar cell module according to claim 7, wherein at least one of the materials forming the protective member is an organic polymer material. 12. The thickness from the photovoltaic element surface is 50 μm.
12. The solar cell module according to claim 7, wherein the protection member is disposed at the corner of the photovoltaic element so as to have a thickness of 150 μm or less. 13. The solar cell module according to claim 7, which has flexibility. 14. The solar cell module according to claim 7, wherein the outermost member is made of a polymer material. 15. A photovoltaic element in which a peripheral shape has a corner and a protection member disposed so as to cover only the corner and the periphery thereof is sealed between a top surface member and a bottom surface member. In a method for manufacturing a solar cell module through a material, the solar cell module is a roll lamination method,
The outermost member, the outermost member, the photovoltaic element,
And a method for manufacturing a solar cell module, which is formed by thermocompression bonding a sealing material. 16. The method according to claim 15, wherein the photovoltaic element has a thickness of 50 μm or more. 17. The internal angle of the corner of the photovoltaic element is 100.
17. The method for manufacturing a solar cell module according to claim 15, wherein the temperature is equal to or less than 0 °. 18. The method of manufacturing a solar cell module according to claim 15, wherein the photovoltaic element has a substrate made of an inorganic material. 19. The method for manufacturing a solar cell module according to claim 15, wherein at least one of the constituent materials of the protection member is an organic polymer material. 20. A thickness from the photovoltaic element surface of 50 μm.
20. The method of manufacturing a solar cell module according to claim 15, wherein the protection member is arranged at the corner of the photovoltaic element so as to have a thickness of 150 μm or less. 21. The method for manufacturing a solar cell module according to claim 15, wherein the solar cell module has flexibility. 22. The method for manufacturing a solar cell module according to claim 15, wherein the outermost surface member is made of a polymer material.