JP2002083978A - Method of manufacturing solar battery module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method by which a solar battery module hardly influenced by the thermal shrinkage of a plastic film when heat treatment is performed for thermally crosslinking resin layers to each other can be manufactured. SOLUTION: A protective film 5 is obtained by heat-treating the plastic film 500 composed of a laminated body of an outer PVDF film and an inner PET film (a). Then a glass plate 1 having a reinforced surface, a first resin layer 2, a solar battery cell row 3 formed by electrically connecting a plurality of solar battery cells 3a through copper foil 3b, a second resin layer 4, and the protective film 5 are laminated upon another in this order (b). After the laminated plate 1, layer 2, row 3, layer 4, and film 5 are temporarily bonded to each other through a vacuum laminating step (c), the first and second resin layers 2 and 4 are crosslinked to each other through heat treatment and the solar battery module (10) is obtained by uniting the plate 1, layers 2 and 4, row 3, and film 5 in one body in a state where the row 3 is sealed with a sealing layer 6 (d).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a solar cell module, and more particularly, to a method for manufacturing a solar cell module having a plastic film.

[0002]

2. Description of the Related Art Photovoltaic power generation, which converts light energy into electric energy by utilizing the photoelectric conversion effect, is widely used as a means for obtaining clean energy. With the improvement in the photoelectric conversion efficiency of the solar cell, a solar power generation system has been provided in many private houses. In order to use such a solar power generation system as an actual energy source, a solar cell module having a configuration in which a plurality of solar cells are electrically connected in series is used.

FIG. 7 is a diagram showing a configuration of an example of this solar cell module. As shown in FIG. 7, in the solar cell module, a plurality of solar cells 102 are, for example, EVA (Ethyle) between a glass plate 100 and a back surface film 101 in which, for example, an aluminum foil is sandwiched between plastic films.
ne Vinyl Acetate (ethylene vinyl acetate) resin is sealed with a sealing layer 103 made of resin. Adjacent solar cells 102 are electrically connected by a connection member 104 made of, for example, copper foil.

There is also known a solar cell module configured to utilize light incident not only from the front side but also from the back side of the solar cell module in order to effectively use the light of the solar cell. . FIG. 8 is a diagram showing a configuration of such a solar cell module. In FIG.
The same parts as those in FIG. 7 are denoted by the same reference numerals, and description thereof will be omitted. In the solar cell module shown in FIG. 8, for example, PET (Poly-Ethylene Terephth
alate: polyethylene terephthalate) A transparent plastic film is used in which a film and a fluorine film are laminated.

Further, a solar cell module in which a transparent plastic film is used for the back film 201 as shown in FIG. 8 to improve the power generation performance has been proposed (Japanese Patent Application No. 2000-22094). ).
FIG. 9 is a diagram showing a configuration of such a solar cell module. 9, the same parts as those in FIG. 8 are denoted by the same reference numerals, and description thereof will be omitted. In the solar cell module shown in FIG. 9, the glass plate 100 and the solar cell 102
A transparent plastic film 301 made of, for example, a PET film for suppressing the diffusion of an alkali component eluted from the glass plate 100 is provided in the sealing layer 103 between them.

Further, there is known a solar cell module which can be used as a building material by using a metal plate for a back surface film. FIG. 10 is a diagram illustrating a configuration of such a solar cell module. 10, the same parts as those of FIG. 7 are denoted by the same reference numerals, and the description thereof will be omitted. In the solar cell module shown in FIG. 10, for example, a steel plate is used as the back film 401, and the solar cell 102 and the back film 401 are used.
Between them, a plastic film 402 made of, for example, a PET film for insulation prevention is provided.

[0007]

When a solar cell module as shown in FIG. 8 is manufactured, conventionally, a glass plate, a first resin layer (sealing layer), and a copper foil (connecting member) are electrically connected. After laminating a plurality of connected solar cells, a second resin layer (sealing layer) and a plastic film (back surface film) in this order, a vacuum laminating step is performed to temporarily bond the layers, and then a heat treatment is performed. The first resin layer and the second resin layer are thermally crosslinked, and the solar cell is sealed between the glass plate and the back film with a resin.

Similarly, when a solar cell module as shown in FIG. 9 is manufactured, conventionally, a glass plate, a first resin layer (sealing layer), a plastic film (barrier film), and a second resin layer (Sealing layer), a plurality of solar cells electrically connected by a copper foil (connecting member), a third resin layer (sealing layer), and a plastic film (back film) are laminated in this order, and then vacuum laminated. The first resin layer, the second resin layer, and the third resin layer are thermally cross-linked by performing a process and temporarily bonding, and then a heat treatment is performed. Seal the battery cells.

Further, when a solar cell module as shown in FIG. 10 is manufactured, conventionally, a plurality of solar cells are electrically connected by a glass plate, a first resin layer (sealing layer), and a copper foil (connection member). After laminating a solar cell, a second resin layer (sealing layer), a plastic film (insulation preventing film), a third resin layer (sealing layer) and a steel plate (back metal plate) in this order, a vacuum laminating step is performed. Then, the first resin layer, the second resin layer, and the third resin layer are thermally cross-linked by performing a heat treatment, and the solar cell and the insulating layer are formed between the glass plate and the back metal plate by the resin. Seal the prevention film.

Since a plastic film is used as a back film, a barrier film or an insulation preventing film,
In the above-described heat treatment step for thermal crosslinking, the plastic film thermally shrinks, a stress of thermal shrinkage is applied to the electrically connected solar battery cells, and a copper foil (connecting member) connecting the solar battery cells is formed. There is a problem that the solar cell is deformed or the interval between adjacent solar cells is changed. Such a problem occurs more remarkably in a large-area solar cell module in which a large number of solar cells are electrically connected.

When a plastic film is used as the back surface film, if the size of the plastic film before the vacuum laminating step is the same as the size of the glass plate, the plastic film thermally shrinks in the heat treatment step for thermal crosslinking. At the periphery, the plastic film that functions as a protective material is lost,
There is a problem that water resistance is reduced. In order to prevent this, it is conceivable to use a plastic film having a size sufficiently larger than the glass plate in advance, but in this case, there is a problem that an excess plastic film must be cut off at the end.

The present invention has been made in view of the above circumstances, and a method of manufacturing a solar cell module which is hardly affected by heat shrinkage of a plastic film generated during a heat treatment for thermally crosslinking a resin layer. The purpose is to provide.

[0013]

According to a first aspect of the present invention, there is provided a method of manufacturing a solar cell module including a solar cell and a plastic film, wherein the plastic film is heat-shrinked in advance by a heat treatment. It is characterized by using a plastic film that has been made to have been made.

In the method for manufacturing a solar cell module according to the first aspect, a plastic film that has been thermally contracted by heat treatment in advance is used. Therefore, the plastic film hardly undergoes heat shrinkage during the manufacturing process, and is hardly affected by the heat shrinkage.

According to a second aspect of the present invention, there is provided a method for manufacturing a solar cell module having a structure in which a plurality of solar cells are sealed between a glass member and a protective film with a resin. A step of sealing the solar cell with a resin between the glass member and the protective film by performing a heat treatment, and using a plastic film that has been previously thermally contracted by heat treatment as the protective film. It is characterized by.

In the method for manufacturing a solar cell module according to the second aspect, a plastic film which has been previously thermally contracted by heat treatment is used as a protective film to be a back surface film. Therefore, since the protective film has been thermally contracted in advance, it hardly undergoes thermal contraction in the vacuum laminating step and the heat treatment step for thermal crosslinking, and deformation of the copper foil (connecting member) and displacement of the solar cell occur. do not do. Even if the protective film is cut to the same size as the glass member (glass plate), there is almost no heat shrinkage during the manufacturing process, no loss of the protective film occurs, and the water resistance does not decrease.

According to a third aspect of the present invention, in the method for manufacturing a solar cell module, a plurality of solar cells are sealed with a resin between a glass member and a protective film. In a method of manufacturing a solar cell module having a configuration in which a barrier film is provided, a heat treatment is performed to seal the barrier film and the solar cell with a resin between the glass member and the protective film. A plastic film that has been subjected to a heat treatment in advance by heat treatment and is used as the barrier film and / or the protective film.

In the method for manufacturing a solar cell module according to the third aspect, a plastic film thermally contracted by heat treatment in advance is used as a barrier film between a glass member (glass plate) and a solar cell. Therefore,
Since the barrier film has been thermally contracted in advance, it hardly undergoes thermal contraction in the vacuum laminating step and the heat treatment step for thermal crosslinking, and the copper foil (connecting member) is not deformed and the solar cell is not displaced.

According to a fourth aspect of the present invention, in the method for manufacturing a solar cell module, a plurality of solar cells are sealed with a resin between a glass member and a back metal plate. In a method of manufacturing a solar cell module having a configuration in which an insulating prevention film is provided between the glass member and the back metal plate, a heat treatment is performed to insulate the solar cell and the resin between the glass member and the back metal plate. The method further includes a step of sealing the prevention film, wherein a plastic film that has been thermally contracted by heat treatment in advance is used as the insulation prevention film.

In the method for manufacturing a solar cell module according to a fourth aspect, a plastic film thermally contracted by heat treatment in advance is used as an insulation preventing film between the solar cell and the back metal plate. Therefore, since the insulation preventing film (plastic film) has been thermally shrunk in advance, it hardly undergoes thermal shrinkage in the vacuum laminating step and the heat treatment step for thermal crosslinking, and the copper foil (connecting member) is deformed, Does not occur.

According to a fifth aspect of the present invention, in the method for manufacturing a solar cell module including a solar cell and a plastic film, the plastic film has a heat shrinkage of 1 at 150 ° C. for 30 minutes. It is characterized by using a plastic film of not more than 0.0%, preferably not more than 0.3%.

In the method for manufacturing a solar cell module according to claim 5, the heat shrinkage at 150 ° C. for 30 minutes is 1.
A plastic film of 0% or less, preferably 0.3% or less is used. Therefore, during the manufacturing process, the heat shrinkage of the plastic film is small, and the influence thereof is also small. In the case of a rectangular solar cell module having a side length of 1 m or less, the heat shrinkage is 1.0%.
Use the following plastic film, and the length of one side is 1
In the case of a solar cell module of about m to 2 m, a 100% yield can be realized by using a plastic film having a heat shrinkage of 0.3% or less.

According to a sixth aspect of the present invention, in the method for manufacturing a solar cell module having a configuration in which a plurality of solar cells are sealed with a resin between a glass member and a protective film, A step of performing a heat treatment to seal the solar cell with a resin between the glass member and the protective film;
A plastic film having a heat shrinkage at 1.0 ° C. for 30 minutes of 1.0% or less, preferably 0.3% or less is used as the protective film.

In the method for manufacturing a solar cell module according to the sixth aspect, the protective film serving as the back surface film may have a thickness of 150 mm.
A plastic film having a heat shrinkage of 1.0% or less, preferably 0.3% or less at 30 ° C. for 30 minutes is used. Therefore, since the thermal shrinkage of the protective film is low, the thermal shrinkage of the protective film in the vacuum laminating step and the heat treatment step for thermal crosslinking is slight, and the copper foil (connecting member)
No deformation of the photovoltaic cells and no displacement of the solar cells occur. Also,
Even if the protective film is cut to the same size as the glass member (glass plate), the heat shrinkage during the manufacturing process is slight, the protective film is not damaged, and the water resistance does not decrease.

According to a seventh aspect of the present invention, in the method for manufacturing a solar cell module, a plurality of solar cells are sealed with a resin between the glass member and the protective film. In a method of manufacturing a solar cell module having a configuration in which a barrier film is provided, a heat treatment is performed to seal the barrier film and the solar cell with a resin between the glass member and the protective film. Process, 150 ℃, 3
The heat shrinkage at 0 minute is 1.0% or less, preferably 0.1%.
3% or less of a plastic film is used as the barrier film and / or the protective film.

In the method for manufacturing a solar cell module according to claim 7, the heat shrinkage at 150 ° C. for 30 minutes is 1.
A plastic film of 0% or less, preferably 0.3% or less is used as a barrier film between a glass member (glass plate) and a solar cell. Therefore, the thermal shrinkage of the barrier film is low,
The heat shrinkage in the heat treatment step for thermal crosslinking is slight, and no deformation of the copper foil (connection member) and no displacement of the solar cell occurs.

[0027] In the method for manufacturing a solar cell module according to claim 8, a plurality of solar cells are sealed with a resin between a glass member and a back metal plate. In a method of manufacturing a solar cell module having a configuration in which an insulating prevention film is provided between the glass member and the back metal plate, a heat treatment is performed to insulate the solar cell and the resin between the glass member and the back metal plate. It has a step of sealing the prevention film,
A plastic film having a heat shrinkage of not more than 1.0%, preferably not more than 0.3% in 30 minutes is used as the insulating film.

In the method for manufacturing a solar cell module according to claim 8, the heat shrinkage at 150 ° C. for 30 minutes is 1.
A plastic film of 0% or less, preferably 0.3% or less is used as an insulation preventing film between the solar cell and the back metal plate. Therefore, since the heat shrinkage of the insulation preventing film is low, the heat shrinkage in the vacuum laminating step and the heat treatment step for thermal crosslinking is slight, and deformation of the copper foil (connecting member) and misalignment of the solar cell occur. do not do.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to the drawings showing the embodiments.

(First Embodiment) FIG. 1 shows a first embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. First, the outer PVDF (Poly-VinyliD
ene Fluoride (polyvinylidene fluoride) film (thickness 20μm) and inner PET film (thickness 100μm)
The same heat treatment (15) as in the later-described thermal crosslinking step is applied to a plastic film 500 as a back film formed of a laminate of
(0 ° C., 30 minutes) and heat shrinkage to obtain a protective film 5 (FIG. 1A). In addition, this PVDF film is coated or kneaded with an ultraviolet ray cut material,
It has an ultraviolet cut function. Thereby, it is possible to prevent ultraviolet rays from entering the PET film and the EVA resin and yellowing.

Next, the glass plate 1 whose surface has been strengthened
(Thickness: 3 to 5 mm), a first resin layer 2 (thickness: 1 mm) made of EVA resin, and a plurality of solar cells 3a of about 100 mm square are electrically connected by a copper foil 3b. Cell row 3 and second resin layer 4 made of EVA resin
(Thickness: 0.6 mm) and the protective film 5 are laminated in this order (FIG. 1B). At this time, the size of the protective film 5 is the same as the size of the glass plate 1.

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 1C). Thereafter, a heat treatment (150 ° C., 30 minutes) is performed to thermally crosslink the first resin layer 2 and the second resin layer 4, and the solar cell array 3 is formed by the sealing layer 6 made of EVA resin.
The solar cell module 10 is manufactured by integrating the whole in a sealed state (FIG. 1D).

When the plastic film is subjected to heat treatment to be thermally contracted in advance, the heat shrinkage of the plastic film after heating at 150 ° C. for 30 minutes is 1.0% or less, preferably 0.3%. Heat treatment is preferably performed under the following conditions. For example, 1
When manufacturing a rectangular solar cell module having a side length of 1 m or less, a plastic film pre-heat-shrinked so that the heat shrinkage rate at 150 ° C. for 30 minutes is 1.0% or less. By using as a protective film, a solar cell module can be manufactured with high yield. When manufacturing a large-area solar cell module having a side length of about 1 m to 2 m, the heat shrinkage rate at 150 ° C. for 30 minutes is 0.1 mm.
By using a plastic film that has been heat-shrinked in advance so as to be 3% or less as a protective film, a solar cell module can be manufactured with good yield.

As the plastic film, besides a laminate of a PVDF film / PET film, PVF (Poly-Vinyl Fluorid) is used.
A film or a polyphenylene sulfide film may be used. Even with such a configuration, a similar effect can be obtained.

In the first embodiment, since the plastic film that has been heat-shrinked in advance by the heat treatment is used for the protective film 5, the plastic film is protected during the above-described manufacturing process (vacuum lamination process, cross-linking heat treatment process). Film 5
Hardly shrinks thermally. As a result, the copper foil 3
There is no deformation of b and no displacement of the solar cell 3a. Further, the protective film 5 is attached to the glass plate 1.
Even if cut into the same size as above, there is almost no heat shrinkage during the manufacturing process, there is no area where the protective film 5 is damaged, and the weather resistance and water resistance do not decrease. Also, since the size of the protective film 5 is the same as the size of the glass plate 1,
It is not necessary to cut off the extra protective film 5 at the end as in the related art.

(Second Embodiment) FIG. 2 shows a second embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. The method for manufacturing a solar cell module according to the present embodiment is different from the first embodiment in that a plastic film having a small heat shrinkage is used as a protective film. In the present embodiment, first, a glass plate 11 (thickness 3 to 5 mm) whose surface has been strengthened
A first resin layer 12 (1 mm thick) made of VA resin;
A solar cell array 13 in which a plurality of solar cells 13a each having a size of about 00 mm square are electrically connected by a copper foil 13b.
And a second resin layer 14 (0.6 m thick) made of EVA resin.
m) and a protective film 15 made of a PVDF film (120 μm in thickness) are laminated in this order (FIG. 2).
(A)).

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 2B). After that, the first resin layer 12 and the second resin layer 1
4 is subjected to a heat treatment (150 ° C., 30 minutes) so as to thermally crosslink, and the entire solar cell array 13 is sealed with a sealing layer 16 made of EVA resin to form a solar cell module. 20 (FIG. 2C).

In the second embodiment, since the protective film 15 having a small heat shrinkage is used, the heat shrinkage of the protective film 15 is small during the above-described manufacturing steps (vacuum laminating step, heat treatment step for crosslinking). It is. As a result, the copper foil 13b is deformed or the solar cells 13a
Does not shift. Even if the protective film 15 is cut to the same size as the glass plate 11, the heat shrinkage during the manufacturing process is slight,
There is no region in which No. 5 is lost, and the weather resistance and water resistance do not decrease. Further, since the size of the protective film 15 is the same as the size of the glass plate 11, it is not necessary to cut off the extra protective film 15 at the end as in the related art.

In the second embodiment, unlike the first embodiment, there is no need to previously perform a process of thermally shrinking the plastic film, and the number of steps can be reduced. By using a plastic film having a heat shrinkage of 1.0% or less (150 ° C., 30 minutes) as a protective film, the length of one side is 1
m can be manufactured with good yield, and a plastic film having a heat shrinkage (150 ° C., 30 minutes) of 0.3% or less has a side length of about 1 m to 2 m. Large solar cell module can be manufactured with good yield. As such a plastic film, an olefin film can be used in addition to the above-mentioned PVDF film.

The invention according to the first and second embodiments is also applied to an amorphous solar cell module in which a plurality of solar cells made of an amorphous semiconductor are directly formed on a glass plate. can do. In this case, the EVA resin layer and the protective film made of a heat-shrinkable plastic film are laminated in this order on the surface of the glass plate on which the solar cells are formed, and are integrated. Even in this case, the same effect as in the above-described example can be obtained.

(Third Embodiment) FIG. 3 shows a third embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. First, the outer PVDF film (thickness 20μm) and the inner PET film (thickness 100μm)
The same heat treatment (150 ° C., 30 minutes) as the later-described thermal crosslinking step is applied to the plastic film 700 composed of
And heat shrink to obtain a protective film 27 (FIG. 3).
(A)). In addition, this PVDF film is provided with an ultraviolet ray cut function similarly to the first embodiment.

A plastic film 600 (thickness: 0.05 to 0.3 mm) made of a PET film is subjected to the same heat treatment (150 ° C., 30 minutes) as a thermal crosslinking step described later.
And heat shrink to obtain a barrier film 23 (FIG. 3).
(B)).

Next, a glass plate 2 whose surface has been strengthened
1 (thickness 3 to 5 mm), a first resin layer 22 (0.4 mm thick) made of EVA resin, and the barrier film 23
And a second resin layer 24 (0.4 m thick) made of EVA resin.
m) and a plurality of solar cells 2 of about 100 mm square.
A solar cell array 25 formed by electrically connecting 5a with a copper foil 25b, a third resin layer 26 (0.6 mm thick) made of EVA resin, and the protective film 27 are laminated in this order (FIG. 3 (c)). At this time, the protective film 27
Is the same as the size of the glass plate 21. The size of the barrier film 23 is larger than the size of the solar cell row 25 and smaller than the sizes of the first, second, and third resin layers 22, 24, and 26.

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 3D). After that, the first resin layer 22 and the second resin layer 24
And a heat treatment (15) to thermally crosslink the third resin layer 26.
(0 ° C., 30 minutes) to form a sealing layer 28 made of EVA resin.
The solar cell module 30 is manufactured by integrating the entire solar cell array 25 and the barrier film 23 in a sealed state (FIG. 3 (e)).

When heat-shrinking the plastic film by heat treatment in advance, the heat shrinkage of the plastic film after the heat treatment at 150 ° C. for 30 minutes is 1.0% or less, preferably 0.3%. Heat treatment is preferably performed under the following conditions. For example, 1
When manufacturing a rectangular solar cell module having a side length of 1 m or less, a plastic film pre-heat-shrinked so that the heat shrinkage rate at 150 ° C. for 30 minutes is 1.0% or less. By using as a barrier film and a protective film, a solar cell module can be manufactured with good yield. Also, the length of one side is 1
In manufacturing a solar cell module having a large area of about m to about 2 m, a plastic film that has been previously heat-shrinked such that the heat shrinkage rate at 150 ° C. for 30 minutes is 0.3% or less is obtained. By using it as a barrier film and a protective film, a solar cell module can be manufactured with good yield.

As the plastic film, a laminate of PVDF film / PET film, PE
In addition to the T film, a PVF film or a polyphenylene sulfide film may be used. Even with such a configuration, a similar effect can be obtained.

In the third embodiment, since the barrier film 23 and the protective film 27 made of a plastic film that has been heat-shrinked in advance by heat treatment are used, the above-described manufacturing process (vacuum laminating process, heating for crosslinking) In the processing step), the barrier film 23 and the protective film 27 hardly shrink. As a result, the copper foil 25b is not deformed and the solar cell 25a is not displaced as in the related art. Further, the barrier film 23 can reliably cover the surface of the solar cell array 25, and the end surface of the barrier film 23 is covered with the EVA resin, so that the weather resistance and water resistance do not decrease. In addition, since the size of the protective film 27 is the same as the size of the glass plate 1, an extra protective film 27
There is no need to cut off.

(Fourth Embodiment) FIG. 4 shows a fourth embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. The method for manufacturing a solar cell module according to the present embodiment is different from the third embodiment in that a plastic film having a small heat shrinkage is used for the barrier film and the protective film. In the present embodiment, first, a glass plate 31 (thickness: 3 to 5 mm) whose surface has been subjected to strengthening treatment and a first resin layer 32 made of EVA resin
(Thickness: 0.4 mm), a barrier film 33 made of PET film (thickness: 0.05 to 0.3 mm), and EVA
A second resin layer 34 (0.4 mm thick) made of resin;
A photovoltaic cell array 35 in which a plurality of photovoltaic cells 35a each having a size of about 00 mm square are electrically connected by a copper foil 35b.
And a third resin layer 36 (0.6 m thick) made of EVA resin.
m) and a protective film 37 made of a PVDF film (120 μm in thickness) are laminated in this order (FIG. 4).
(A)).

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 4B). After that, the first resin layer 32 and the second resin layer 34
And a heat treatment (15) to thermally crosslink the third resin layer 36.
(0 ° C., 30 minutes) to form a sealing layer 38 made of EVA resin.
The solar cell module 40 is manufactured by integrating the entire solar cell array 35 and the barrier film 33 in a sealed state (FIG. 4C).

In the fourth embodiment, since a plastic film having a small heat shrinkage is used for the barrier film 33 and the protective film 37, the barrier film is formed during the above-described manufacturing steps (vacuum laminating step, heat treatment step for crosslinking). The heat shrinkage of the film 33 and the protective film 37 is slight.
As a result, there is no deformation of the copper foil 35b and no displacement of the solar cell 35a as in the conventional case. Further, since the barrier film 33 can surely cover the surface of the solar cell array 35 and the end surface of the barrier film 33 is covered with the EVA resin, the weather resistance and the water resistance do not decrease. Further, since the size of the protective film 37 is the same as the size of the glass plate 31, as in the related art,
Finally, there is no need to cut off the extra protective film 37.

In the fourth embodiment, unlike the third embodiment, there is no need to previously perform a process of thermally shrinking the plastic film, and the number of steps can be reduced. The heat shrinkage rate (150 ° C., 30 minutes) of the barrier film and the protective film is 1.
By using a plastic film of 0% or less, a small solar cell module having a side length of 1 m or less can be manufactured with good yield, and a heat shrinkage rate (150 ° C., 30
By using a plastic film having a content of 0.3% or less, a large-sized solar cell module having a side length of about 1 m to 2 m can be manufactured with good yield. As such a plastic film, an olefin film can be used in addition to the above-mentioned PET film and PVDF film.

(Fifth Embodiment) FIG. 5 shows a fifth embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. First, a plastic film 800 (thickness: 100 μm) made of a PET film is subjected to the same heat treatment (150 ° C., 30 minutes) as in the later-described thermal crosslinking step to be thermally shrunk to obtain the insulation preventing film 45 (FIG.
(A)).

Next, the glass plate 4 whose surface has been strengthened
1 (thickness: 3 to 5 mm), a first resin layer 42 (0.4 mm in thickness) made of EVA resin, and a plurality of solar cells 43a of about 100 mm square are electrically connected by a copper foil 43b. A solar cell array 43, a second resin layer 44 (0.4 mm in thickness) made of EVA resin, the above-described insulating film 45, and a third resin layer 46 (0.6 mm in thickness) made of EVA resin. And a back metal plate 47 made of a steel plate are laminated in this order (FIG. 5B). At this time, the size of the insulation preventing film 45 is larger than the size of the solar cell row 43, and the first, second, and third resin layers 42, 44, and 4 are formed.
6 smaller than the size.

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 5C). After that, the first resin layer 42 and the second resin layer 44
And a heat treatment (15) to thermally crosslink the third resin layer 46.
(0 ° C., 30 minutes) to form a sealing layer 48 made of EVA resin.
The solar cell module 50 is manufactured by integrally integrating the solar cell array 43 and the insulation preventing film 45 in a state in which the solar cell module 43 is sealed (FIG. 5D).

When heat-shrinking the plastic film by heat treatment in advance, the heat shrinkage of the plastic film after the heat treatment at 150 ° C. for 30 minutes is 1.0% or less, preferably 0.3% or less. Heat treatment is preferably performed under the following conditions. For example, 1
When manufacturing a rectangular solar cell module having a side length of 1 m or less, a plastic film pre-heat-shrinked so that the heat shrinkage rate at 150 ° C. for 30 minutes is 1.0% or less. By using as an insulating film, a solar cell module can be manufactured with good yield. When manufacturing a large-area solar cell module having a side length of about 1 m to 2 m, the heat shrinkage rate at 150 ° C. for 30 minutes should be 0.3% or less. By using a plastic film that has been heat shrunk in advance as an insulation prevention film,
A solar cell module can be manufactured with good yield.

As the plastic film, a PVF film or a polyphenylene sulfide film may be used in addition to the PET film. Even with such a configuration, a similar effect can be obtained.

In the fifth embodiment, since the insulation preventing film 45 made of a plastic film that has been thermally shrunk in advance by heat treatment is used, the above-described manufacturing process (vacuum lamination process, heat treatment process for cross-linking) is used. In addition, the insulation preventing film 45 hardly shrinks by heat. As a result, the copper foil 43b is deformed or the solar cell 4
There is no displacement of 3a. Further, the insulation preventing film 45 can surely cover the surface of the solar cell array 43, and the end surface of the insulation preventing film 45 is
Since it is covered with the resin A, the weather resistance and the water resistance do not decrease.

(Sixth Embodiment) FIG. 6 shows a sixth embodiment of the present invention.
It is a figure showing a process of a manufacturing method of a solar cell module by an embodiment. The method for manufacturing a solar cell module according to the present embodiment is different from the fifth embodiment in that a plastic film having a low heat shrinkage in terms of material is used for the insulating prevention film. In the present embodiment, first, a glass plate 51 (thickness: 3 to 5 mm) whose surface has been subjected to strengthening treatment
And a first resin layer 52 (0.4 m thick) made of EVA resin.
m) and a plurality of solar cells 5 of about 100 mm square.
3a are electrically connected by a copper foil 53b, a solar cell row 53, a second resin layer 54 (0.4 mm thick) made of EVA resin, and an insulation prevention film 55 (100 μm thick) made of PVDF film ), A third resin layer 56 (0.6 mm thick) made of EVA resin, and a back metal plate 57 made of a steel plate are laminated in this order (FIG. 6A).

A vacuum laminating step (90 to 90)
Temporary bonding is performed by applying pressure at 130 ° C. for 2 to 10 minutes (FIG. 6B). After that, the first resin layer 52 and the second resin layer 54
And a heat treatment (15) to thermally crosslink the third resin layer 56.
(0 ° C., 30 minutes) to form a sealing layer 58 made of EVA resin.
The solar cell module 60 is manufactured by integrating the entire solar cell array 53 and the insulation preventing film 55 in a sealed state (FIG. 6 (c)).

In the sixth embodiment, since a plastic film having a small heat shrinkage is used for the insulation preventing film 55, the manufacturing process (the vacuum laminating process,
The heat shrinkage of the insulation preventing film 55 during the crosslinking heat treatment step) is slight. As a result, the copper foil 53b is not deformed and the solar cell 53a is not displaced as in the related art. In addition, the insulation prevention film 55 can surely cover the surface of the solar cell array 53, and the end surface of the insulation prevention film 55 is covered with the EVA resin, so that the weather resistance and the water resistance do not decrease.

In the sixth embodiment, the process of heat shrinking the plastic film in advance as in the fifth embodiment is unnecessary, and the number of steps can be reduced. By using a plastic film having a heat shrinkage (1.0 ° C., 30 minutes) of 1.0% or less as an insulation preventing film, a small solar cell module having a side length of 1 m or less can be manufactured with good yield. 0.3% heat shrinkage (150 ° C, 30 minutes)
By using the following plastic film,
A large solar cell module having a side length of about 1 m to 2 m can be manufactured with good yield. As such a plastic film, an olefin film can be used in addition to the above-mentioned PVDF film.

The inventions according to the fifth and sixth embodiments are also applied to an amorphous solar cell module in which a plurality of solar cells made of an amorphous semiconductor are directly formed on a glass plate. can do. In this case, the EVA resin layer and the above-mentioned insulating film made of a heat-shrinked plastic film and the EVA resin layer are laminated and integrated in this order on the surface of the glass plate on which the solar cells are formed. Even in this case, the same effect as in the above-described example can be obtained.

[0063]

As described above, according to the present invention, a plastic film which has been previously heat-shrinked by heat treatment can be used to obtain a protective film as a back surface film, a barrier film for suppressing diffusion of alkali components, and electrical insulation. Or use a plastic film with low heat shrinkage as a protective film as a back surface film, a barrier film to suppress the diffusion of alkali components, and an insulating film to obtain electrical insulation. Since it is used, it is not affected by the heat shrinkage of the film during the manufacturing process of the solar cell module, and the deformation of the copper foil and the displacement of the solar cell do not occur. Even if the protective film is cut to the same size as the glass member, the weather resistance and water resistance do not decrease, and the process of finally cutting off the protective film becomes unnecessary.

[Brief description of the drawings]

FIG. 1 is a diagram showing steps of a method for manufacturing a solar cell module according to a first embodiment of the present invention.

FIG. 2 is a diagram showing steps of a method for manufacturing a solar cell module according to a second embodiment of the present invention.

FIG. 3 is a diagram showing steps of a method for manufacturing a solar cell module according to a third embodiment of the present invention.

FIG. 4 is a view showing steps of a method for manufacturing a solar cell module according to a fourth embodiment of the present invention.

FIG. 5 is a diagram showing steps of a method for manufacturing a solar cell module according to a fifth embodiment of the present invention.

FIG. 6 is a diagram illustrating a process of a method for manufacturing a solar cell module according to a sixth embodiment of the present invention.

FIG. 7 is a diagram illustrating a configuration of an example of a solar cell module.

FIG. 8 is a diagram showing a configuration of another example of a solar cell module.

FIG. 9 is a diagram showing a configuration of still another example of the solar cell module.

FIG. 10 is a diagram showing a configuration of still another example of the solar cell module.

[Explanation of symbols]

1,11,21,31,41,51 Glass plate 2,12,22,32,42,52 First resin layer 3,13,25,35,43,53 Solar cell row 3a, 13a, 25a, 35a , 43a, 53a Solar cell 3b, 13b, 25b, 35b, 43b, 53b Copper foil 4, 14, 24, 34, 44, 54 Second resin layer 5, 15, 27, 37 Protective film 6, 16, 28, 38, 48, 58 Sealing layer 10, 20, 30, 40, 50, 60 Solar cell module 26, 36, 46, 56 Third resin layer 23, 33 Barrier film 45, 55 Insulation prevention film 47, 57 Back metal plate 500,600,700,800 plastic film

Claims (8)

[Claims] 1. A method for manufacturing a solar cell module comprising a solar cell and a plastic film,
A method for manufacturing a solar cell module, wherein a plastic film that has been thermally shrunk in advance by heat treatment is used as the plastic film. 2. A method for manufacturing a solar cell module having a configuration in which a plurality of solar cells are sealed with a resin between a glass member and a protective film, wherein the glass member and the protective member are subjected to heat treatment. Having a step of sealing the solar cell with a resin between the film and
A method for manufacturing a solar cell module, wherein a plastic film that has been thermally contracted by heat treatment in advance is used as the protective film. 3. A plurality of solar cells are sealed between a glass member and a protective film with a resin, and a barrier film is provided between the glass member and the solar cells. The method for manufacturing a solar cell module includes a step of performing a heat treatment to seal the barrier film and the solar cell with a resin between the glass member and the protective film, and heat-treats in advance by heat treatment. A method for manufacturing a solar cell module, wherein a shrinked plastic film is used as the barrier film and / or the protective film. 4. A plurality of solar cells are sealed between a glass member and a back metal plate with a resin, and an insulation preventing film is provided between the solar cells and the back metal plate. A method of manufacturing a solar cell module having a configuration, comprising a step of performing a heat treatment to seal the solar cell and the insulating film with a resin between the glass member and the back metal plate. A method for manufacturing a solar cell module, wherein a plastic film that has been thermally contracted by heat treatment in advance is used as the insulation preventing film. 5. A method for manufacturing a solar cell module comprising a solar cell and a plastic film,
A method for manufacturing a solar cell module, wherein a plastic film having a heat shrinkage of 1.0% or less, preferably 0.3% or less at 150 ° C. for 30 minutes is used as the plastic film. 6. A method for manufacturing a solar cell module having a structure in which a plurality of solar cells are sealed between a glass member and a protective film with a resin, wherein the glass member and the protection member are subjected to heat treatment. Having a step of sealing the solar cell with a resin between the film and
A method for manufacturing a solar cell module, wherein a plastic film having a heat shrinkage at 150 ° C. for 30 minutes of 1.0% or less, preferably 0.3% or less is used as the protective film. 7. A plurality of solar cells are sealed between a glass member and a protective film with a resin, and a barrier film is provided between the glass member and the solar cells. The method for manufacturing a solar cell module includes a step of performing a heat treatment to seal the barrier film and the solar cell with a resin between the glass member and the protective film, wherein 150
A method for manufacturing a solar cell module, comprising using a plastic film having a heat shrinkage of 1.0% or less, preferably 0.3% or less at 30 ° C. for 30 minutes as the barrier film and / or the protective film. 8. A plurality of solar cells are sealed between a glass member and a back metal plate with a resin, and an insulation preventing film is provided between the solar cell and the back metal plate. A method of manufacturing a solar cell module having a configuration, comprising a step of performing a heat treatment to seal the solar cell and the insulating film with a resin between the glass member and the back metal plate. Yes, 15
A method for manufacturing a solar cell module, comprising using a plastic film having a heat shrinkage of 1.0% or less, preferably 0.3% or less at 0 ° C. for 30 minutes as the insulation preventing film.