JP2003209273A - Solar battery module and its manufacturing method - Google Patents

Solar battery module and its manufacturing method

Info

Publication number
JP2003209273A
JP2003209273A JP2002008213A JP2002008213A JP2003209273A JP 2003209273 A JP2003209273 A JP 2003209273A JP 2002008213 A JP2002008213 A JP 2002008213A JP 2002008213 A JP2002008213 A JP 2002008213A JP 2003209273 A JP2003209273 A JP 2003209273A
Authority
JP
Japan
Prior art keywords
solar cell
cell module
protection
peripheral
adhesive resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP2002008213A
Other languages
Japanese (ja)
Other versions
JP4069405B2 (en
Inventor
Yujiro Watanuki
勇次郎 綿貫
Original Assignee
Fuji Electric Co Ltd
富士電機株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fuji Electric Co Ltd, 富士電機株式会社 filed Critical Fuji Electric Co Ltd
Priority to JP2002008213A priority Critical patent/JP4069405B2/en
Publication of JP2003209273A publication Critical patent/JP2003209273A/en
Application granted granted Critical
Publication of JP4069405B2 publication Critical patent/JP4069405B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar battery module wherein permeation of water content from a peripheral edge of a solar battery module is prevented, generation of corrosive product such as acetic acid is excluded, stable use is enabled for a long term and productivity is superior, and to provide a method for manufacturing the solar battery module. <P>SOLUTION: In this solar battery module, a solar battery 1 in which a plurality of solar battery elements are connected in series or in parallel is sealed between a surface protecting member 2 and a back protecting member 3 by using adhesive resin sealing member 4. An outer peripheral part of the adhesive resin sealing member 4 in the peripheral edge of the solar battery module is provided with a weather-resistant protecting layer 40 composed of organic polymer or mixture of organic polymer and the adhesive resin sealing member. Outer peripheral parts of the weather-resistant protecting layer, the surface protecting member and the backside protecting member are formed on almost the same plane in a side surface part 30 of the solar battery module. <P>COPYRIGHT: (C)2003,JPO

Description

【発明の詳細な説明】Detailed Description of the Invention
【0001】[0001]
【発明の属する技術分野】この発明は、屋外に設置され
た架台や屋根などに設置される太陽電池モジュール、特
に太陽電池モジュールの周縁部からの水分侵入を防止す
るための封止構造を備えた太陽電池モジュールとその製
造方法に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention has a solar cell module installed on a pedestal or a roof installed outdoors, and in particular, has a sealing structure for preventing moisture from entering from the peripheral portion of the solar cell module. A solar cell module and a method for manufacturing the same.
【0002】[0002]
【従来の技術】現在、環境保護の立場から、クリーンな
エネルギーの研究開発が進められている。中でも、太陽
電池はその資源(太陽光)が無限であること、無公害で
あることから注目を集めている。同一基板上に形成され
た複数の太陽電池素子が、直列接続されてなる太陽電池
(光電変換装置)の代表例は、非晶質系薄膜太陽電池で
ある。
2. Description of the Related Art Currently, from the standpoint of environmental protection, research and development of clean energy is in progress. Above all, solar cells are attracting attention because of their unlimited resources (sunlight) and no pollution. A typical example of a solar cell (photoelectric conversion device) in which a plurality of solar cell elements formed on the same substrate are connected in series is an amorphous thin film solar cell.
【0003】薄膜太陽電池は、薄型で軽量、製造コスト
の安さ、大面積化が容易であることなどから、今後の太
陽電池の主流となると考えられ、電力供給用以外に、建
物の屋根や窓などにとりつけて利用される業務用,一般
住宅用にも需要が広がってきている。一般住宅用とし
て、太陽電池付き屋根瓦なども開発されている。
Thin-film solar cells are considered to become the mainstream of solar cells in the future because they are thin and lightweight, have low manufacturing costs, and can easily be made large in area. In addition to supplying power, roofs and windows of buildings are also considered. Demand is also expanding for commercial and residential use, which are used by attaching to such things. Roof tiles with solar cells have also been developed for general housing.
【0004】近年では、プラスチックフィルムを用いた
フレキシブルタイプの太陽電池の研究開発が進められて
おり、このフレキシブル性を生かし、ロールツーロール
方式やステップロール方式の製造方法により大量生産が
可能となっている。
In recent years, research and development of a flexible type solar cell using a plastic film has been advanced, and by utilizing this flexibility, mass production is possible by a roll-to-roll system or a step roll system manufacturing method. There is.
【0005】上記薄膜太陽電池を用いたモジュールとし
ては、電気絶縁性を有するフィルム基板上に形成された
太陽電池を、電気絶縁性の保護材により封止するため
に、太陽電池の受光面側および非受光面側の双方に保護
層を設けたものが知られている。
As a module using the above-mentioned thin-film solar cell, a solar cell formed on a film substrate having an electric insulation property is sealed with an electrically insulating protective material. It is known that a protective layer is provided on both the non-light-receiving surface side.
【0006】図4および図5は、従来の太陽電池モジュ
ールの模式的構造の一例を示し、図4は、太陽電池モジ
ュールの側断面図、図5は、断面コ字形の金属製枠体を
有するフレームに装着した状態の太陽電池モジュールの
側断面図を示す。
4 and 5 show an example of a schematic structure of a conventional solar cell module. FIG. 4 is a side sectional view of the solar cell module, and FIG. 5 has a metal frame body having a U-shaped cross section. The side sectional view of the solar cell module in the state attached to the frame is shown.
【0007】図4において、太陽電池1は、複数個の太
陽電池素子が直列または並列接続されており、その受光
面側にガラス板などの表面保護部材2、裏面側にアルミ
箔の両面に一弗化エチレン(商品名:テドラー,デュポ
ン社製)を接着した防湿保護シートなどの裏面保護部材
3が設けられ、接着封止性に優れかつ安価なEVA(エ
チレン−酢酸ビニル共重合樹脂)などの接着性樹脂封止
材4により熱融着封止されている。
In FIG. 4, a solar cell 1 has a plurality of solar cell elements connected in series or in parallel, a surface protection member 2 such as a glass plate on the light receiving surface side, and one surface on both sides of an aluminum foil on the back surface side. A back protective member 3 such as a moisture-proof protective sheet to which ethylene fluoride (trade name: Tedlar, manufactured by DuPont) is adhered is provided, and EVA (ethylene-vinyl acetate copolymer resin) having excellent adhesive sealing property and inexpensive It is heat-sealed and sealed by the adhesive resin sealing material 4.
【0008】また太陽電池1は、そのプラス(+)極とマ
イナス(−)極に、内部リード線5、6が電気的に接続さ
れ、この内部リード線5、6は、裏面保護部材3に接着
固定された端子ボックス7に、裏面保護部材3を貫通し
て導かれ、端子ボックス7の内部で外部リード線として
のケーブル8の芯線9、10と電気的に接続され、これ
ら全体として太陽電池モジュール11を形成している。
Further, in the solar cell 1, internal lead wires 5 and 6 are electrically connected to the plus (+) pole and the minus (-) pole thereof, and the internal lead wires 5 and 6 are connected to the back surface protecting member 3. The back surface protection member 3 is penetrated and guided to the terminal box 7 that is fixed by adhesion, and is electrically connected to the core wires 9 and 10 of the cable 8 as an external lead wire inside the terminal box 7, and the solar cell as a whole. The module 11 is formed.
【0009】なお、前記表面保護部材2としては、ガラ
ス板などの無機系材料の外に、透光性のアクリル樹脂板
やポリカーボネイト樹脂板などの有機系材料を用いるこ
ともある。また、裏面保護部材3としては、上記金属箔
入り樹脂以外に、フッ素系フィルムなどの有機系フィル
ム単体、有機系フィルムと金属箔を貼り合せた複合材
料、もしくは金属板やガラス板などの金属・無機系材料
を用いることもある。
As the surface protection member 2, in addition to an inorganic material such as a glass plate, an organic material such as a translucent acrylic resin plate or polycarbonate resin plate may be used. Further, as the back surface protecting member 3, in addition to the resin containing the metal foil, a single organic film such as a fluorine-based film, a composite material obtained by bonding an organic film and a metal foil, or a metal such as a metal plate or a glass plate. Inorganic materials may also be used.
【0010】図5は、フレームに装着した太陽電池モジ
ュールの一例を示し、図5において、太陽電池モジュー
ル11は、その周囲にフレーム12が配置され、太陽電
池モジュール11の周縁部が、金属製フレーム12の断
面コ字形の枠体を有する保持部12aの内部に挿入さ
れ、隙間を埋めるように注入された接着性シール材13
で固定保持されている。ここで、接着性シール材13
は、加熱流動性のあるブチルゴムや液状で硬化後に固体
となるシリコーンゴムなどの接着性のある弾性シール材
が用いられ、ガラス板などの表面保護部材2やフレーム
12の熱膨張を吸収するとともに、水分侵入を抑制して
いる。
FIG. 5 shows an example of a solar cell module mounted on a frame. In FIG. 5, a solar cell module 11 is provided with a frame 12 around the periphery thereof, and a peripheral portion of the solar cell module 11 is a metal frame. An adhesive sealing material 13 is inserted into a holding portion 12a having a frame body having a U-shaped cross section and is injected to fill the gap.
It is fixedly held in. Here, the adhesive sealing material 13
Is made of an adhesive elastic sealing material such as butyl rubber having heat fluidity or silicone rubber which becomes solid after being liquid, and absorbs thermal expansion of the surface protection member 2 such as a glass plate or the frame 12, and Suppresses water invasion.
【0011】次に太陽電池モジュール11の製造方法に
関わる各構成部材のラミネート(熱融着封止)方法につ
いて、図6により説明する。図6において、太陽電池モ
ジュール11は、予め表面保護部材2、接着性樹脂封止
材4、リード線5、6が取付けられた太陽電池1、接着
性樹脂封止材4、裏面保護部材3が順次積層されてラミ
ネート装置100に入れられる。しかる後、ラミネート
装置100の上筐体101が閉じられて密閉され、加熱
板103で所定温度に加熱されるとともに下筐体102
に取り付けられた排気管104から図示しない排気装置
でモジュール11が置かれている空間部105の空気が
排気されて真空に保たれる。
Next, a method of laminating (heat-sealing) the respective constituent members related to the method of manufacturing the solar cell module 11 will be described with reference to FIG. In FIG. 6, the solar cell module 11 includes a surface protection member 2, an adhesive resin sealing material 4, a solar cell 1 to which lead wires 5 and 6 are attached, an adhesive resin sealing material 4, and a back surface protection member 3. The sheets are sequentially laminated and placed in the laminating apparatus 100. Thereafter, the upper casing 101 of the laminating apparatus 100 is closed and hermetically sealed, heated to a predetermined temperature by the heating plate 103, and the lower casing 102.
The air in the space 105 in which the module 11 is placed is exhausted from the exhaust pipe 104 attached to the exhaust gas by an exhaust device (not shown), and is kept in vacuum.
【0012】また同時に上筐体101に取り付けられた
給排気管106からもゴム製ダイヤフラム107と上筐
体101とで形成する空間部108の空気が排気されて
真空となり、ゴム製ダイヤフラム107は上筐体101
の内壁面109に張り付いている。この状態で太陽電池
モジユール11が所定温度で所定時間、加熱された後、
給排気管106から空気が導入され、空間部105と空
間部108の圧力差(略大気圧差)で太陽電池モジュー
ル11はゴム製ダイヤフラム107により加圧され、図
4で示す断面構造の太陽電池モジュール11を形成す
る。
At the same time, the air in the space 108 formed by the rubber diaphragm 107 and the upper housing 101 is also evacuated from the air supply / exhaust pipe 106 attached to the upper housing 101 to form a vacuum, and the rubber diaphragm 107 is lifted up. Case 101
Is attached to the inner wall surface 109 of the. In this state, after the solar cell module 11 is heated at a predetermined temperature for a predetermined time,
Air is introduced from the air supply / exhaust pipe 106, and the solar cell module 11 is pressurized by the rubber diaphragm 107 due to the pressure difference (substantial atmospheric pressure difference) between the space portion 105 and the space portion 108, and the solar cell having the cross-sectional structure shown in FIG. The module 11 is formed.
【0013】ところで、前記図4または5に示すような
従来の太陽電池モジュールを、屋外に設置された架台や
住宅の屋根もしくは屋根瓦内に設置した場合、下記のよ
うな問題がある。
When the conventional solar cell module as shown in FIG. 4 or 5 is installed on a pedestal installed outdoors, a roof of a house or a roof tile, the following problems occur.
【0014】前記図5に示す太陽電池モジュールにおい
て、太陽電池モジュール11とフレーム12との間の接
着性シール材13に、その材料の透湿率に応じて水分が
浸透する。続いて、図5に示した微小な隙間15に充填
されている接着性樹脂封止材4を介して太陽電池モジユ
ール内部に水分が浸透する。長期的には、太陽光や風雨
に曝されて接着性シール材13や接着性樹脂封止材4は
劣化を生じ、劣化とともに水分の侵入量は増大する。
In the solar cell module shown in FIG. 5, water permeates into the adhesive sealing material 13 between the solar cell module 11 and the frame 12 according to the moisture permeability of the material. Subsequently, moisture penetrates into the inside of the solar cell module through the adhesive resin sealing material 4 filled in the minute gaps 15 shown in FIG. In the long term, the adhesive sealing material 13 and the adhesive resin sealing material 4 are deteriorated by being exposed to sunlight and wind and rain, and the amount of intrusion of water increases with the deterioration.
【0015】この侵入した水分は、ついには太陽電池1
や内部リード線5、6、並びにその接続部分に到達して
これらに腐食を発生させる。特に、接着性樹脂封止材4
にEVA(エチレン−酢酸ビニル共重合樹脂)を用いた
場合、EVAが水分で加水分解して酢酸が生成され、腐
食をさらに加速する。
The infiltrated water finally becomes the solar cell 1.
And reaches the internal lead wires 5 and 6 and their connecting parts to cause corrosion. In particular, the adhesive resin sealing material 4
When EVA (ethylene-vinyl acetate copolymer resin) is used for, EVA is hydrolyzed with water to generate acetic acid, which further accelerates corrosion.
【0016】そこで、上記水分の侵入量を軽減するため
に、出願人は、図3に示すような構造の太陽電池モジュ
ールを発明し、特願2001−181242号により出
願している。図3に示す太陽電池モジュールにおいて
は、その表面保護部材202は、ガラス板,アクリル樹
脂,ポリカーボネート樹脂等の透光性矩形平板からな
り、裏面保護部材203は、表面保護部材の主面の周囲
4辺の所定幅に対向して設けてなる額縁状の平坦部20
3aと、太陽電池201を接着性樹脂封止材204とと
もに収納するために設けてなる中央凹部203bと、平
坦部と中央凹部とを連結する連結部203cとを有する
薄板矩形盆からなり、表面保護部材と裏面保護部材との
間に接着性樹脂封止材を充填し、かつ裏面保護部材の額
縁状の平坦部と表面保護部材との間を接着性樹脂封止材
により接着して太陽電池を封止する構成としている。
Therefore, in order to reduce the amount of invasion of water, the applicant invented a solar cell module having a structure as shown in FIG. 3 and applied for a patent application No. 2001-181242. In the solar cell module shown in FIG. 3, the surface protection member 202 is made of a translucent rectangular flat plate such as a glass plate, an acrylic resin, a polycarbonate resin, and the back surface protection member 203 is a peripheral surface 4 of the main surface of the surface protection member. A frame-shaped flat portion 20 provided so as to face a predetermined width of the side.
3a, a central concave portion 203b provided for accommodating the solar cell 201 together with the adhesive resin encapsulant 204, and a thin plate rectangular tray having a connecting portion 203c connecting the flat portion and the central concave portion. An adhesive resin encapsulant is filled between the member and the back surface protection member, and the frame-shaped flat portion of the back surface protection member and the surface protection member are adhered by the adhesive resin encapsulant to form a solar cell. It is configured to be sealed.
【0017】上記構成によれば、水分侵入経路となる前
記裏面保護部材の額縁状の平坦部と表面保護部材との間
の隙間が僅小で、かつ太陽電池モジュールの周縁部から
内側に向かって平坦部がその幅に相当する距離を有する
ので、水分侵入は長期間にわたって阻止できる。しかし
ながら、上記構成によっても、水分侵入を完全に阻止で
きるわけではない。
According to the above structure, the gap between the frame-shaped flat portion of the back surface protection member and the front surface protection member, which serves as a moisture intrusion path, is small, and the solar cell module is inwardly directed from the peripheral portion thereof. Since the flat portion has a distance corresponding to its width, moisture intrusion can be prevented for a long period of time. However, even with the above configuration, it is not possible to completely prevent the intrusion of water.
【0018】水分侵入防止を図った前記とは異なる太陽
電池モジュールの構成としては、前記EVAのように接
着封止性に優れかつ安価ながらも水分侵入に伴う前記問
題を生じないような樹脂封止材を用いた太陽電池モジュ
ール(特開平7−302926号公報参照)や、モジュ
ール外周部に樹脂材料を塗布して保護層を設けたもの
(特開2001−102615号公報参照)などが知ら
れている。
As a constitution of a solar cell module different from the above for preventing moisture invasion, a resin encapsulation which is excellent in adhesive sealing property like EVA and which is inexpensive but does not cause the above problems associated with moisture infiltration. A solar cell module using a material (see Japanese Patent Application Laid-Open No. 7-302926), one having a protective layer formed by coating a resin material on the outer peripheral portion of the module (see Japanese Patent Application Laid-Open No. 2001-102615), and the like are known. There is.
【0019】上記特開平7−302926号公報に記載
された太陽電池モジュールは、表面保護部材側の樹脂封
止材として、エチレンと不飽和脂肪酸エステルとの共重
合樹脂を用いるもので、接着封止性に優れかつ安価に封
止可能な機能を犠牲にして、水分侵入の弊害を軽減した
ものである。上記モジュールにおいて、裏面保護部材側
の樹脂封止材としては、柔軟性のあるEVAのような材
料を用いる構成となっており、水分侵入防止に関しては
まだ充分とはいえない。また、前述のように、接着封止
性においても従来と比較して劣る問題がある。
The solar cell module described in JP-A-7-302926 uses a copolymer resin of ethylene and an unsaturated fatty acid ester as a resin encapsulant on the surface protection member side. The sacrifice of the function of excellent sealing property and inexpensive sealing reduces the harmful effect of moisture intrusion. In the above module, a flexible material such as EVA is used as the resin encapsulant on the back surface protection member side, and it cannot be said that water penetration is sufficiently prevented. Further, as described above, there is also a problem that the adhesive sealing property is inferior to the conventional one.
【0020】また、前記特開2001−102615号
公報においては、例えば、図7に示すような太陽電池モ
ジュールを開示している。図7において、35は、透明
電極層32と、半導体光電変換層33と、裏面電極層3
4とからなる太陽電池セルで、31の透明絶縁基板と、
37の背面カバーフィルムとの間に、例えばEVAから
なる充填材36により封止されている。なお、38はハ
ンダ層、39はバスバー電極である。
Further, in the above-mentioned Japanese Patent Laid-Open No. 2001-102615, for example, a solar cell module as shown in FIG. 7 is disclosed. In FIG. 7, 35 is a transparent electrode layer 32, a semiconductor photoelectric conversion layer 33, and a back electrode layer 3
A solar cell consisting of 4 and 31 transparent insulating substrates,
A space between the back cover film 37 and the back cover film 37 is sealed with a filler 36 made of EVA, for example. In addition, 38 is a solder layer and 39 is a bus bar electrode.
【0021】上記太陽電池モジュールは、透明絶縁基板
31の上面に防眩膜30を備え、また、EVAからなる
充填材36の側面には、例えば、有機ポリマーからなる
保護コート20が形成されている。この太陽電池モジュ
ールの場合には、保護コート20の形成により、EVA
からなる充填材36が被覆されるので、水分侵入防止に
関しては優れている。しかしながら、信頼性の高い保護
コート20を形成するためには形成治具などの特殊設備
を必要とする。また、保護コート20が太陽電池モジュ
ールの外周部の輪郭を形成することとなるので、寸法精
度が出難く、また、モジュール側面に衝撃を与えて保護
コート20に損傷を与えないような取り扱いが必要とな
る。従って、上記太陽電池モジュールは、量産には適さ
ない。
In the solar cell module, an antiglare film 30 is provided on the upper surface of a transparent insulating substrate 31, and a protective coat 20 made of, for example, an organic polymer is formed on the side surface of a filler 36 made of EVA. . In the case of this solar cell module, by forming the protective coat 20, EVA
Since it is covered with the filling material 36 made of, it is excellent in preventing water from entering. However, in order to form the highly reliable protective coat 20, special equipment such as a forming jig is required. Further, since the protective coat 20 forms the outline of the outer peripheral portion of the solar cell module, it is difficult to obtain dimensional accuracy, and it is necessary to handle the protective coat 20 so as not to damage the side face of the module and damage the protective coat 20. Becomes Therefore, the solar cell module is not suitable for mass production.
【0022】[0022]
【発明が解決しようとする課題】この発明は、上記のよ
うな問題点に鑑みてなされたもので、本発明の課題は、
太陽電池モジュール周縁部からの水分侵入を防止し、腐
食性の酢酸などの生成物を発生させること無く長期的に
安定して用いることが出来、かつ量産性に優れた太陽電
池モジュールとその製造方法を提供することにある。
SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to
A solar cell module that prevents moisture from entering the periphery of the solar cell module, can be stably used for a long period of time without generating corrosive acetic acid and other products, and is excellent in mass productivity, and a method for manufacturing the same To provide.
【0023】[0023]
【課題を解決するための手段】前述の課題を解決するた
め、この発明においては、表面保護部材と裏面保護部材
との間に、複数個の太陽電池素子を直列または並列接続
した太陽電池を接着性樹脂封止材により封止してなる太
陽電池モジュールにおいて、太陽電池モジュール周縁部
における前記接着性樹脂封止材の外周部は、有機ポリマ
ーもしくは有機ポリマーと前記接着性樹脂封止材との混
合物からなる耐候性保護層を有してなり、かつ、前記耐
候性保護層外周部と表面保護部材外周部と裏面保護部材
外周部とは、太陽電池モジュール側面部において、略同
一平面上に形成してなるものとする(請求項1の発
明)。
In order to solve the above-mentioned problems, in the present invention, a solar cell having a plurality of solar cell elements connected in series or in parallel is bonded between a front surface protection member and a back surface protection member. In a solar cell module which is sealed with an organic resin encapsulant, the outer periphery of the adhesive resin encapsulant in the periphery of the solar cell module is an organic polymer or a mixture of an organic polymer and the adhesive resin encapsulant. Which has a weather resistant protective layer, and the weather resistant protective layer outer peripheral portion, the front surface protective member outer peripheral portion and the back surface protective member outer peripheral portion are formed on substantially the same plane in the solar cell module side surface portion. (Invention of Claim 1).
【0024】上記構成により、接着性樹脂封止材の外周
部が耐候性保護層によって覆われるので、接着性樹脂封
止材層への水分侵入が阻止できる。また、後述するよう
に、量産性に優れた太陽電池モジュールが提供できる。
With the above structure, since the outer peripheral portion of the adhesive resin encapsulating material is covered with the weather resistant protective layer, it is possible to prevent moisture from entering the adhesive resin encapsulating material layer. Moreover, as described later, a solar cell module having excellent mass productivity can be provided.
【0025】前記請求項1の発明の実施態様としては、
下記請求項2ないし3の発明が好ましい。即ち、前記請
求項1に記載の太陽電池モジュールにおいて、前記表面
保護部材はガラス板,アクリル樹脂,ポリカーボネート
樹脂等の透光性平板からなり、前記裏面保護部材は金属
箔に有機樹脂製フィルムを貼り合わせた防湿保護シート
からなり、前記接着性樹脂封止材はEVA(エチレン−
酢酸ビニル共重合樹脂)からなり、前記有機ポリマーは
液状のフッ素系樹脂,シリコーン樹脂,アクリル系樹脂
もしくは前記樹脂の混合物からなるものとする(請求項
2の発明)。
As an embodiment of the invention of claim 1,
The inventions of claims 2 to 3 below are preferable. That is, in the solar cell module according to claim 1, the front surface protection member is made of a light-transmissive flat plate such as a glass plate, an acrylic resin, or a polycarbonate resin, and the back surface protection member is formed by attaching an organic resin film to a metal foil. The adhesive resin encapsulant is made of EVA (Ethylene-
(Vinyl acetate copolymer resin), and the organic polymer is a liquid fluororesin, silicone resin, acrylic resin or a mixture of the resins (invention of claim 2).
【0026】また、周縁部に断面コ字形の金属製枠体を
有する太陽電池モジュールであって、請求項1または2
に記載の太陽電池モジュールを、前記枠体のコ字形開口
部に挿入し、前記モジュールと枠体との間を、接着性シ
ール材を介して固定してなるものとする(請求項3の発
明)。
A solar cell module having a metal frame body having a U-shaped cross-section at a peripheral edge thereof, which is defined by claim 1.
The solar cell module according to claim 1 is inserted into the U-shaped opening of the frame body, and the module and the frame body are fixed to each other via an adhesive sealant (the invention of claim 3). ).
【0027】さらに、太陽電池モジュールの製造方法と
しては、下記請求項3ないし8の発明が好ましい。即
ち、請求項1または2に記載の太陽電池モジュールの製
造方法であって、上下に分割された筐体と加熱板と加圧
用のダイヤフラムと給排気装置とを有するラミネート装
置により、前記加熱板とダイヤフラムとの間に、前記表
面保護部材,接着性樹脂封止材,太陽電池,裏面保護部
材等を順次積層し、前記接着性樹脂封止材を加熱融着
し、かつ加圧することにより太陽電池モジュールを形成
する製造方法において、前記接着性樹脂封止材の硬化が
進行する途中で、半硬化状態の太陽電池モジュールを前
記ラミネート装置から取り出す工程と、前記接着性樹脂
封止材の外周部であって前記裏面保護部材と表面保護部
材との間に、前記有機ポリマーを注入し、この有機ポリ
マーを前記半硬化状態の接着性樹脂封止材と共に硬化さ
せて、前記耐候性保護層を形成する工程と、前記耐候性
保護層外周部と表面保護部材外周部と裏面保護部材外周
部とが略同一平面を形成すべく、太陽電池モジュール外
周部をトリミングする工程とを含むこととする(請求項
4の発明)。
Further, as a method of manufacturing a solar cell module, the inventions of claims 3 to 8 below are preferable. That is, the method for manufacturing a solar cell module according to claim 1 or 2, wherein the heating plate is provided by a laminating device having a vertically divided casing, a heating plate, a diaphragm for pressurization and an air supply / exhaust device. The surface protection member, the adhesive resin sealing material, the solar cell, the back surface protection member, and the like are sequentially laminated between the diaphragm and the solar cell, and the adhesive resin sealing material is heat-fused and pressure-applied to the solar cell. In the manufacturing method for forming a module, in the course of curing of the adhesive resin encapsulant, a step of taking out a semi-cured solar cell module from the laminating device, and an outer peripheral portion of the adhesive resin encapsulant. Then, the organic polymer is injected between the back surface protection member and the surface protection member, and the organic polymer is cured together with the adhesive resin sealing material in the semi-cured state to obtain the weather resistance. And a step of trimming the outer peripheral portion of the solar cell module so that the outer peripheral portion of the weather resistant protective layer, the outer peripheral portion of the front surface protective member, and the outer peripheral portion of the back surface protective member form substantially the same plane. (Invention of Claim 4).
【0028】上記製造方法によれば、従来の製造方法と
同様にラミネート装置を用いて、接着性樹脂封止材を半
硬化状態とした太陽電池モジュールに、有機ポリマーを
注入して、例えば、乾燥機に半硬化状態の太陽電池モジ
ュールを容れて硬化させ、外周部をトリミングする単純
な工程により製造できる。従って、量産性がよく、また
前記寸法精度上の問題もない。
According to the above manufacturing method, an organic polymer is injected into a solar cell module whose adhesive resin encapsulant is in a semi-cured state by using a laminating apparatus as in the conventional manufacturing method. It can be manufactured by a simple process in which a semi-cured solar cell module is placed in a machine and cured, and the outer peripheral portion is trimmed. Therefore, mass productivity is good, and there is no problem in the dimensional accuracy.
【0029】前記請求項4の発明の実施態様としては、
下記請求項5ないし8の発明が好ましい。即ち、請求項
4に記載の製造方法において、前記有機ポリマーを半硬
化状態の接着性樹脂封止材と共に硬化させるための加熱
処理温度は140℃以上とし、加熱処理時間は20分〜
60分とする(請求項5の発明)。
As an embodiment of the invention of claim 4,
The inventions of claims 5 to 8 below are preferable. That is, in the manufacturing method according to claim 4, the heat treatment temperature for curing the organic polymer together with the semi-cured adhesive resin encapsulant is 140 ° C. or higher, and the heat treatment time is 20 minutes to
60 minutes (the invention of claim 5).
【0030】また、前記請求項4に記載の製造方法にお
いて、トリミング前の前記裏面保護部材の寸法は表面保
護部材より大であって、表面保護部材の外周から少なく
とも10mm張り出す寸法とし、前記有機ポリマーの注
入は、前記張り出し部において行なう(請求項6の発
明)。張り出す寸法が、10mm未満の場合には、加熱
時に溶融した有機ポリマーや接着性樹脂封止材が、裏面
保護部材から溢れて、例えば、乾燥機におけるモジュー
ル載置棚上に接着して乾燥機内を汚染し、ひいては、モ
ジュールの品質不良に及ぶ可能性がある。
Further, in the manufacturing method according to claim 4, the dimension of the back surface protecting member before trimming is larger than that of the surface protecting member, and the dimension is such that the back surface protecting member projects at least 10 mm from the outer periphery of the surface protecting member. Polymer is injected at the projecting portion (the invention of claim 6). When the overhanging dimension is less than 10 mm, the organic polymer or the adhesive resin sealing material that is melted during heating overflows from the back surface protection member and is adhered to, for example, a module mounting shelf in a dryer to be dried inside the dryer. Can be contaminated, which in turn can lead to poor module quality.
【0031】さらに、前記請求項4に記載の製造方法に
おいて、前記接着性樹脂封止材の寸法は表面保護部材よ
り小であって、表面保護部材の外周から5〜10mm短
縮した寸法とし、前記有機ポリマーの注入は、前記短縮
部に対して行なうこととする(請求項7の発明)。前記
短縮する寸法は、太陽電池をカバーする接着性樹脂封止
材の好適寸法の目安であり、有機ポリマーと前記接着性
樹脂封止材との混合物からなる耐候性保護層の適切な厚
さが確保できれば、接着性樹脂封止材の寸法を、かなら
ずしも表面保護部材より小とする必要はない。
Further, in the manufacturing method according to claim 4, the size of the adhesive resin sealing material is smaller than that of the surface protection member, and the dimension is shortened by 5 to 10 mm from the outer periphery of the surface protection member. The organic polymer is injected into the shortened portion (the invention of claim 7). The dimension to be shortened is a measure of a suitable dimension of the adhesive resin encapsulant covering the solar cell, and an appropriate thickness of the weather resistant protective layer made of a mixture of an organic polymer and the adhesive resin encapsulant is If secured, the size of the adhesive resin sealing material does not necessarily need to be smaller than that of the surface protection member.
【0032】また、前記請求項4に記載の製造方法にお
いて、前記太陽電池モジュール外周部のトリミングは、
前記表面保護部材表面を吸着装置により吸着固定した状
態で、カッター等の裁断具により行なう(請求項8の発
明)。これにより、作業性が向上する。
Further, in the manufacturing method according to claim 4, the trimming of the outer peripheral portion of the solar cell module is performed.
The cutting is performed by a cutting tool such as a cutter with the surface of the surface protection member fixed by suction by a suction device (the invention of claim 8). This improves workability.
【0033】[0033]
【発明の実施の形態】図面に基づき、本発明の実施例に
ついて以下に述べる。
BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.
【0034】図1および図2は、この発明の太陽電池モ
ジュールおよびその製造方法に関わる実施例の模式図を
示し、図1は太陽電池モジュールの側断面図を示し、図
2は図1に示すモジュールの製造方法を説明する図であ
って、製造の途中段階の状態を簡略化して示す。図1お
よび図2において、図4に示した太陽電池モジュールの
構成部材と同一機能を有する部材には、同一番号を付し
て、詳細な説明を省略する。
1 and 2 are schematic views of a solar cell module of the present invention and an embodiment relating to a method for manufacturing the same, FIG. 1 is a side sectional view of the solar cell module, and FIG. 2 is shown in FIG. It is a figure explaining the manufacturing method of a module, and simplifies and shows the state of the intermediate stage of manufacture. 1 and 2, members having the same functions as the constituent members of the solar cell module shown in FIG. 4 are designated by the same reference numerals, and detailed description thereof will be omitted.
【0035】図1に示す太陽電池モジュール11が、図
4に示すものと構成上異なる点は、図1においては、太
陽電池モジュール周縁部における接着性樹脂封止材4の
外周部は、有機ポリマーもしくは有機ポリマーと前記接
着性樹脂封止材との混合物からなる耐候性保護層40を
有してなり、かつ、前記耐候性保護層外周部と表面保護
部材外周部と裏面保護部材外周部とは、太陽電池モジュ
ール側面部30において、略同一平面上に形成してなる
点である。
The solar cell module 11 shown in FIG. 1 is structurally different from that shown in FIG. 4 in that the outer periphery of the adhesive resin sealing material 4 at the periphery of the solar cell module is an organic polymer. Alternatively, the weather resistant protective layer 40 is made of a mixture of an organic polymer and the adhesive resin encapsulant, and the outer peripheral portion of the weather resistant protective layer, the outer peripheral portion of the front surface protective member, and the outer peripheral portion of the back surface protective member are The point is that they are formed on substantially the same plane in the side surface portion 30 of the solar cell module.
【0036】製造手順の実施例の詳細は後述するとし
て、図2に基づき、上記耐候性保護層40の形成方法に
ついて、以下に述べる。図2(a)は、耐候性保護層4
0の形成前のモジュールの状態、即ち、接着性樹脂封止
材4の硬化が進行する途中で、半硬化状態の太陽電池モ
ジュールをラミネート装置から取り出した段階を示す。
The details of the embodiment of the manufacturing procedure will be described later, and the method for forming the weather resistant protective layer 40 will be described below with reference to FIG. FIG. 2A shows a weather resistant protective layer 4
The state of the module before the formation of 0, that is, the stage where the semi-cured solar cell module is taken out from the laminating apparatus while the adhesive resin sealing material 4 is being cured.
【0037】トリミング前であるから、裏面保護部材3
は、表面保護部材2の外周から少なくとも10mm張り
出す寸法としており、有機ポリマーの注入は、前記張り
出し部によって形成された上部空間3aに対して行なわ
れる。
Since it is before trimming, the back surface protecting member 3
Has a dimension overhanging at least 10 mm from the outer periphery of the surface protection member 2, and the injection of the organic polymer is performed in the upper space 3a formed by the overhang portion.
【0038】図2(b)は、前記有機ポリマー40aの
注入がなされた状態を示す。有機ポリマー40aが注入
されると、接着性樹脂封止材4の1部と混合する部分が
生ずるが、混合層の程度の差は、諸条件によって異なる
ものの、いずれにせよ、有機ポリマーを半硬化状態の接
着性樹脂封止材と共に加熱硬化させることにより、前記
耐候性保護層40を形成することができる。
FIG. 2B shows a state in which the organic polymer 40a is injected. When the organic polymer 40a is injected, a part that mixes with a part of the adhesive resin encapsulant 4 is generated, but the difference in the degree of the mixed layer varies depending on various conditions, but in any case, the organic polymer is semi-cured. The weather resistant protective layer 40 can be formed by heating and curing the adhesive resin sealing material in the state.
【0039】図2(b)に示す状態で、図2(b)に示
す一点鎖線の部分で、太陽電池モジュール外周部をトリ
ミングすることにより、耐候性保護層40の外周部と表
面保護部材2の外周部と裏面保護部材3の外周部とを、
前記図1に示すように、略同一平面上に形成することが
できる。
In the state shown in FIG. 2 (b), the outer peripheral portion of the weather resistant protective layer 40 and the surface protective member 2 are trimmed by trimming the outer peripheral portion of the solar cell module at the portion indicated by the alternate long and short dash line in FIG. 2 (b). And the outer peripheral portion of the back surface protection member 3,
As shown in FIG. 1, they can be formed on substantially the same plane.
【0040】なお、図2(a)において、接着性樹脂封
止材4の外周寸法を、図2(a)に示した状態よりも大
としても、接着性樹脂封止材4の1部と有機ポリマー4
0aとが混合する部分は、接着性樹脂封止材4単独に比
べて、水分侵入防止効果が大きいので、場合によって
は、表面保護部材2の外周寸法と同程度またはそれより
大であってもかまわない。
2A, even if the outer peripheral dimension of the adhesive resin sealing material 4 is larger than that in the state shown in FIG. Organic polymer 4
The portion mixed with 0a has a larger effect of preventing water intrusion than the adhesive resin sealing material 4 alone, and therefore, in some cases, even if the outer peripheral dimension of the surface protection member 2 is the same or larger. I don't care.
【0041】(実施例)図1および図2に示すように、
まず前記表面保護部材2として、ガラス板(厚さ3.2
mm)をセット後、接着性樹脂封止材4として、厚さ
0.4mmで、かつガラス板より5mm短い寸法のEV
A(ブリヂストン製)をセットし、引き続き、太陽電池
1を所定の位置にセット後、外部取出し用電極としての
絶縁処理された内部配線5,6を太陽電池1の所定の場
所にセットし、前記内部配線5,6の絶縁処理されてい
ない端部と太陽電池1間を半田接続により直列接続す
る。
(Example) As shown in FIGS. 1 and 2,
First, as the surface protection member 2, a glass plate (thickness 3.2
mm), and as an adhesive resin sealing material 4, an EV having a thickness of 0.4 mm and a dimension shorter by 5 mm than the glass plate.
After setting A (manufactured by Bridgestone), subsequently setting the solar cell 1 at a predetermined position, the insulated internal wirings 5 and 6 as external extraction electrodes are set at predetermined positions of the solar cell 1, and The non-insulated ends of the internal wirings 5 and 6 and the solar cell 1 are connected in series by soldering.
【0042】さらに、接着性樹脂封止材4としてのEV
Aに、あらかじめ、内部配線5,6の外部への取り出し
穴をあけたものに、内部配線5,6を貫通させ、その
後、裏面保護部材3としての防湿保護フィルムであるテ
ドラーフィルム(デュポン製)をセットした。なお、こ
のテドラーフィルムも前述のEVAと同じく、あらかじ
め、内部配線5,6の外部への取り出し穴をあけたもの
を使用し、内部配線5,6を貫通後、内部配線5,6を
直線に伸ばして四弗化エチレンテープでテドラーフィル
ム上に穴を塞ぐように貼り付けた。
Furthermore, EV as the adhesive resin sealing material 4
The internal wirings 5 and 6 are penetrated through the A in which holes for taking out the internal wirings 5 and 6 to the outside are formed in advance, and then, a Tedlar film (made by DuPont) which is a moisture-proof protective film as the back surface protection member 3. ) Was set. As with EVA, the Tedlar film is also used with holes for taking out the internal wirings 5 and 6 to the outside in advance. After penetrating the internal wirings 5 and 6, the internal wirings 5 and 6 are straightened. Then, it was attached to a Tedlar film with ethylene tetrafluoride tape so as to close the holes.
【0043】前記組立て品をラミネート装置により、所
定の条件にて真空加熱圧着した後、接着性樹脂封止材4
の半硬化状態でラミネート装置から取り出し、一時保管
した。数十枚ラミネート品がたまった時点で、ガラス板
が上になるように、ラミネート品を裏返し、ガラス板周
縁部とテドラーフィルム間に有機ポリマー40aとし
て、液状のフッ素樹脂(商品名:ルミフロン、旭硝子
製)を注入し、乾燥機の棚にセットし、所定の温度(1
50℃、60分)で架橋・硬化させた。なお、有機ポリ
マーとしては、液状のアクリル系樹脂(商品名:ボンド
アクリルコーク、コニシ製)でもよい。
The above-mentioned assembly is vacuum-pressed under a predetermined condition by a laminating apparatus, and then the adhesive resin sealing material 4 is used.
It was taken out of the laminating apparatus in the semi-cured state and was temporarily stored. When several tens of laminated products have accumulated, the laminated product is turned over so that the glass plate is on top, and a liquid fluororesin (trade name: Lumiflon, which is an organic polymer 40a between the peripheral portion of the glass plate and the Tedlar film, is used. Asahi Glass Co., Ltd. is poured in and set on the shelf of the dryer, at the specified temperature (1
It was crosslinked and cured at 50 ° C. for 60 minutes. The organic polymer may be a liquid acrylic resin (trade name: Bond Acrylic Coke, manufactured by Konishi).
【0044】上記有機ポリマーと接着性樹脂封止材を乾
燥機において硬化後、ガラス板表面を吸着装置で吸着固
定し、ガラス板周縁部に沿ってカッターで裁断した。
After the organic polymer and the adhesive resin sealing material were cured in a dryer, the surface of the glass plate was adsorbed and fixed by an adsorbing device and cut along the peripheral edge of the glass plate with a cutter.
【0045】引き続き、図5に示すものと同様に、断面
コ字形の枠体を有するアルミ製フレーム12の保持部1
2aの内部に接着性シリコーンシール材13(商品名:
シリコーンKE45、信越シリコーン製)を注入し、モジュ
ールを挿入・固定保持した。
Subsequently, like the one shown in FIG. 5, the holding portion 1 of the aluminum frame 12 having a frame body having a U-shaped cross section.
Adhesive silicone sealant 13 (product name:
Silicone KE45, made by Shin-Etsu Silicone) was injected, and the module was inserted and fixedly held.
【0046】裏面保護部材3の一部に貫通処理された外
部取り出し用電極としての内部配線5,6の端部を引き
起こし、端子箱7の内部で外部リード線としてのケーブ
ル8の芯線9,10と電気的に接続し、端子箱本体内お
よび半田接続部に、シリコーン樹脂材料を注入・硬化さ
せて水分侵入防止を兼ねた絶縁処理を行い、端子箱の蓋
を取り付け、太陽電池モジュール11とした。
The end portions of the internal wirings 5 and 6 as external extraction electrodes, which have been through-processed, are caused in a part of the back surface protection member 3, and inside the terminal box 7, the core wires 9 and 10 of the cable 8 as external lead wires. Electrically connected to the main body of the terminal box and the solder connection portion, and then injected and cured with a silicone resin material to carry out an insulation treatment also for preventing moisture intrusion, and a lid of the terminal box was attached to obtain a solar cell module 11. .
【0047】(比較例)有機ポリマーもしくは有機ポリ
マーと前記接着性樹脂封止材との混合物からなる耐候性
保護層を有しない太陽電池モジュール、即ち図5に示す
太陽電池モジュールと同等のものを作成し、前記実施例
の太陽電池モジュールと、下記の比較実験を行なった。
Comparative Example A solar cell module having no weather resistant protective layer made of an organic polymer or a mixture of the organic polymer and the adhesive resin encapsulant, that is, a solar cell module equivalent to the solar cell module shown in FIG. 5 was prepared. Then, the following comparative experiment was performed with the solar cell module of the above-mentioned example.
【0048】高温高湿(85℃、95%RH)試験を2
500時間行った結果、前記実施例では、外観変化は無
く、水分侵入の形跡はなかった。また、電気的不良(絶
縁不良)等の発生もなかった。一方、比較例において
は、電気的不良等の発生はなかったが、外観上、凹凸部
の発生と微小クラックの発生がみられた。
Two high temperature and high humidity (85 ° C., 95% RH) tests
As a result of 500 hours, in the above example, there was no change in appearance and there was no evidence of water penetration. In addition, no electrical failure (insulation failure) occurred. On the other hand, in the comparative example, no electrical failure or the like occurred, but in terms of appearance, irregularities and microcracks were observed.
【0049】[0049]
【発明の効果】この発明によれば前述のように、表面保
護部材と裏面保護部材との間に、複数個の太陽電池素子
を直列または並列接続した太陽電池を接着性樹脂封止材
により封止してなる太陽電池モジュールにおいて、太陽
電池モジュール周縁部における前記接着性樹脂封止材の
外周部は、有機ポリマーもしくは有機ポリマーと前記接
着性樹脂封止材との混合物からなる耐候性保護層を有し
てなり、かつ、前記耐候性保護層外周部と表面保護部材
外周部と裏面保護部材外周部とは、太陽電池モジュール
側面部において、略同一平面上に形成してなるものとす
ることにより、また、前記太陽電池モジュールの製造方
法としては、上下に分割された筐体と加熱板と加圧用の
ダイヤフラムと給排気装置とを有するラミネート装置に
より、前記加熱板とダイヤフラムとの間に、前記表面保
護部材,接着性樹脂封止材,太陽電池,裏面保護部材等
を順次積層し、前記接着性樹脂封止材を加熱融着し、か
つ加圧することにより太陽電池モジュールを形成する製
造方法において、前記接着性樹脂封止材の硬化が進行す
る途中で、半硬化状態の太陽電池モジュールを前記ラミ
ネート装置から取り出す工程と、前記接着性樹脂封止材
の外周部であって前記裏面保護部材と表面保護部材との
間に、前記有機ポリマーを注入し、この有機ポリマーを
前記半硬化状態の接着性樹脂封止材と共に硬化させて、
前記耐候性保護層を形成する工程と、前記耐候性保護層
外周部と表面保護部材外周部と裏面保護部材外周部とが
略同一平面を形成すべく、太陽電池モジュール外周部を
トリミングする工程とを含むこととすることにより、太
陽電池モジュール周縁部からの水分侵入を防止すること
ができる。また、接着性樹脂封止材として、安価にして
優れた樹脂封止が可能なEVAを用いる場合、腐食性の
酢酸などの生成物を発生させることなく、太陽電池モジ
ュールの長期特性安定や長期信頼性が確保できる。さら
に、本発明の製造方法によれば、単純な工程で製造可能
で、量産性がよく、従来の前記寸法精度上の問題も解消
できる。
As described above, according to the present invention, a solar cell having a plurality of solar cell elements connected in series or in parallel is sealed by an adhesive resin sealing material between the front surface protection member and the back surface protection member. In the solar cell module that is stopped, the outer peripheral portion of the adhesive resin encapsulant in the peripheral portion of the solar cell module is a weather resistant protective layer made of an organic polymer or a mixture of an organic polymer and the adhesive resin encapsulant. And, the weather-resistant protective layer outer peripheral portion, the front surface protective member outer peripheral portion and the back surface protective member outer peripheral portion, in the solar cell module side surface portion, by being formed on substantially the same plane Further, as the method for manufacturing the solar cell module, the heating plate is obtained by a laminating apparatus having a casing vertically divided, a heating plate, a pressurizing diaphragm, and an air supply / exhaust device. The surface protection member, the adhesive resin sealing material, the solar cell, the back surface protection member, and the like are sequentially laminated between the diaphragm and the solar cell, and the adhesive resin sealing material is heat-fused and pressure-applied to the solar cell. In the manufacturing method for forming a module, in the course of curing of the adhesive resin encapsulant, a step of taking out a semi-cured solar cell module from the laminating device, and an outer peripheral portion of the adhesive resin encapsulant. Between the back surface protecting member and the front surface protecting member, the organic polymer is injected, and the organic polymer is cured together with the semi-cured adhesive resin sealing material,
A step of forming the weather resistant protective layer, and a step of trimming the solar cell module outer peripheral portion so that the weather resistant protective layer outer peripheral portion, the front surface protective member outer peripheral portion, and the back surface protective member outer peripheral portion form substantially the same plane; By including, it is possible to prevent water from entering from the peripheral portion of the solar cell module. In addition, when EVA is used as an adhesive resin encapsulant, which is inexpensive and capable of excellent resin encapsulation, stable long-term characteristics and long-term reliability of the solar cell module can be achieved without generating products such as corrosive acetic acid. You can secure the sex. Further, according to the manufacturing method of the present invention, it is possible to manufacture in a simple process, the mass productivity is good, and the conventional problem of dimensional accuracy can be solved.
【図面の簡単な説明】[Brief description of drawings]
【図1】本発明の実施例に関わる太陽電池モジュールの
模式的構成の側断面図
FIG. 1 is a side sectional view of a schematic configuration of a solar cell module according to an embodiment of the present invention.
【図2】図1の太陽電池モジュールの製造方法を説明す
る図
FIG. 2 is a diagram illustrating a method of manufacturing the solar cell module of FIG.
【図3】従来の太陽電池モジュールの一例を示す模式的
構成の側断面図
FIG. 3 is a side sectional view of a schematic configuration showing an example of a conventional solar cell module.
【図4】図3とは異なる従来の太陽電池モジュールの一
例を示す模式的構成の側断面図
FIG. 4 is a side sectional view of a schematic configuration showing an example of a conventional solar cell module different from that of FIG.
【図5】図4の太陽電池モジュールをフレームに取り付
けた太陽電池モジュールの模式的構成の側断面図
5 is a side sectional view of a schematic configuration of a solar cell module in which the solar cell module of FIG. 4 is attached to a frame.
【図6】太陽電池モジュールの製造方法に関わるラミネ
ート装置の側断面図
FIG. 6 is a side sectional view of a laminating apparatus relating to a method for manufacturing a solar cell module.
【図7】図3とはさらに異なる従来の太陽電池モジュー
ルの一例を示す側断面図
FIG. 7 is a side sectional view showing an example of a conventional solar cell module which is different from that of FIG.
【符号の説明】[Explanation of symbols]
1:太陽電池、2:表面保護部材、3:裏面保護部材、
4:接着性樹脂封止材、5,6:内部リード線、7:端
子ボックス、8:外部リード線、11:太陽電池モジュ
ール、12:フレーム、13:接着性シール材、30:
太陽電池モジュール側面部、40:耐候性保護層、40
a:有機ポリマー、100:ラミネート装置。
1: solar cell, 2: front surface protection member, 3: back surface protection member,
4: Adhesive resin sealing material, 5, 6: Internal lead wire, 7: Terminal box, 8: External lead wire, 11: Solar cell module, 12: Frame, 13: Adhesive sealing material, 30:
Solar cell module side surface, 40: weather resistant protective layer, 40
a: organic polymer, 100: laminating device.

Claims (8)

    【特許請求の範囲】[Claims]
  1. 【請求項1】 表面保護部材と裏面保護部材との間に、
    複数個の太陽電池素子を直列または並列接続した太陽電
    池を接着性樹脂封止材により封止してなる太陽電池モジ
    ュールにおいて、 太陽電池モジュール周縁部における前記接着性樹脂封止
    材の外周部は、有機ポリマーもしくは有機ポリマーと前
    記接着性樹脂封止材との混合物からなる耐候性保護層を
    有してなり、かつ、前記耐候性保護層外周部と表面保護
    部材外周部と裏面保護部材外周部とは、太陽電池モジュ
    ール側面部において、略同一平面上に形成してなること
    を特徴とする太陽電池モジュール。
    1. Between the front surface protection member and the back surface protection member,
    In a solar cell module obtained by sealing a solar cell in which a plurality of solar cell elements are connected in series or in parallel with an adhesive resin encapsulant, the outer peripheral portion of the adhesive resin encapsulant in the periphery of the solar cell module, A weather resistant protective layer made of an organic polymer or a mixture of an organic polymer and the adhesive resin encapsulant, and the outer peripheral portion of the weather resistant protective layer, the outer peripheral portion of the front surface protective member, and the outer peripheral portion of the back surface protective member. Is a solar cell module formed on substantially the same plane in a side surface portion of the solar cell module.
  2. 【請求項2】 請求項1に記載の太陽電池モジュールに
    おいて、前記表面保護部材はガラス板,アクリル樹脂,
    ポリカーボネート樹脂等の透光性平板からなり、前記裏
    面保護部材は金属箔に有機樹脂製フィルムを貼り合わせ
    た防湿保護シートからなり、前記接着性樹脂封止材はE
    VA(エチレン−酢酸ビニル共重合樹脂)からなり、前
    記有機ポリマーは液状のフッ素系樹脂,シリコーン樹
    脂,アクリル系樹脂もしくは前記樹脂の混合物からなる
    ことを特徴とする太陽電池モジュール。
    2. The solar cell module according to claim 1, wherein the surface protection member is a glass plate, an acrylic resin,
    The translucent flat plate made of a polycarbonate resin or the like, the back surface protection member is a moisture-proof protection sheet in which an organic resin film is attached to a metal foil, and the adhesive resin sealing material is E.
    A solar cell module comprising VA (ethylene-vinyl acetate copolymer resin), wherein the organic polymer is a liquid fluororesin, silicone resin, acrylic resin or a mixture of the resins.
  3. 【請求項3】 周縁部に断面コ字形の金属製枠体を有す
    る太陽電池モジュールであって、請求項1または2に記
    載の太陽電池モジュールを、前記枠体のコ字形開口部に
    挿入し、前記モジュールと枠体との間を、接着性シール
    材を介して固定してなることを特徴とする太陽電池モジ
    ュール。
    3. A solar cell module having a metal frame body having a U-shaped cross-section at a peripheral edge thereof, wherein the solar cell module according to claim 1 or 2 is inserted into a U-shaped opening portion of the frame body, A solar cell module, characterized in that the module and the frame are fixed to each other via an adhesive sealing material.
  4. 【請求項4】 請求項1または2に記載の太陽電池モジ
    ュールの製造方法であって、上下に分割された筐体と加
    熱板と加圧用のダイヤフラムと給排気装置とを有するラ
    ミネート装置により、前記加熱板とダイヤフラムとの間
    に、前記表面保護部材,接着性樹脂封止材,太陽電池,
    裏面保護部材等を順次積層し、前記接着性樹脂封止材を
    加熱融着し、かつ加圧することにより太陽電池モジュー
    ルを形成する製造方法において、 前記接着性樹脂封止材の硬化が進行する途中で、半硬化
    状態の太陽電池モジュールを前記ラミネート装置から取
    り出す工程と、 前記接着性樹脂封止材の外周部であって前記裏面保護部
    材と表面保護部材との間に、前記有機ポリマーを注入
    し、この有機ポリマーを前記半硬化状態の接着性樹脂封
    止材と共に硬化させて、前記耐候性保護層を形成する工
    程と、 前記耐候性保護層外周部と表面保護部材外周部と裏面保
    護部材外周部とが略同一平面を形成すべく、太陽電池モ
    ジュール外周部をトリミングする工程と、を含むことを
    特徴とする太陽電池モジュールの製造方法。
    4. The method for manufacturing a solar cell module according to claim 1, wherein the laminating apparatus includes a vertically divided casing, a heating plate, a pressing diaphragm, and an air supply / exhaust device. Between the heating plate and the diaphragm, the surface protection member, the adhesive resin sealing material, the solar cell,
    In a method of manufacturing a solar cell module by sequentially stacking back surface protection members and the like, heat-sealing the adhesive resin encapsulant, and pressurizing the adhesive resin encapsulant during curing. In the step of taking out the semi-cured solar cell module from the laminating device, the organic polymer is injected between the back surface protection member and the surface protection member which is the outer peripheral portion of the adhesive resin sealing material. A step of curing the organic polymer together with the semi-cured adhesive resin encapsulant to form the weather resistant protective layer, the weather resistant protective layer outer peripheral portion, the surface protective member outer peripheral portion, and the back surface protective member outer peripheral portion. And a step of trimming the outer peripheral portion of the solar cell module so as to form substantially the same plane with the section.
  5. 【請求項5】 請求項4に記載の製造方法において、前
    記有機ポリマーを半硬化状態の接着性樹脂封止材と共に
    硬化させるための加熱処理温度は140℃以上とし、加
    熱処理時間は20分〜60分とすることを特徴とする太
    陽電池モジュールの製造方法。
    5. The manufacturing method according to claim 4, wherein the heat treatment temperature for curing the organic polymer together with the semi-cured adhesive resin encapsulant is 140 ° C. or higher, and the heat treatment time is 20 minutes to 20 minutes. A method for manufacturing a solar cell module, which is 60 minutes.
  6. 【請求項6】 請求項4に記載の製造方法において、ト
    リミング前の前記裏面保護部材の寸法は表面保護部材よ
    り大であって、表面保護部材の外周から少なくとも10
    mm張り出す寸法とし、前記有機ポリマーの注入は、前
    記張り出し部において行なうことを特徴とする太陽電池
    モジュールの製造方法。
    6. The manufacturing method according to claim 4, wherein the size of the back surface protection member before trimming is larger than that of the front surface protection member, and at least 10 from the outer periphery of the front surface protection member.
    The method for manufacturing a solar cell module is characterized in that the dimension is overhanging mm, and the injection of the organic polymer is performed in the overhanging portion.
  7. 【請求項7】 請求項4に記載の製造方法において、前
    記接着性樹脂封止材の寸法は表面保護部材より小であっ
    て、表面保護部材の外周から5〜10mm短縮した寸法
    とし、前記有機ポリマーの注入は、前記短縮部に対して
    行なうことを特徴とする太陽電池モジュールの製造方
    法。
    7. The manufacturing method according to claim 4, wherein the adhesive resin sealing material has a size smaller than that of the surface protection member and is shortened by 5 to 10 mm from the outer periphery of the surface protection member. The method for manufacturing a solar cell module, wherein the polymer is injected into the shortened portion.
  8. 【請求項8】 請求項4に記載の製造方法において、前
    記太陽電池モジュール外周部のトリミングは、前記表面
    保護部材表面を吸着装置により吸着固定した状態で、カ
    ッター等の裁断具により行なうことを特徴とする太陽電
    池モジュールの製造方法。
    8. The manufacturing method according to claim 4, wherein trimming of the outer peripheral portion of the solar cell module is performed by a cutting tool such as a cutter in a state where the surface of the surface protection member is fixed by suction by a suction device. And a method for manufacturing a solar cell module.
JP2002008213A 2002-01-17 2002-01-17 Manufacturing method of solar cell module Expired - Fee Related JP4069405B2 (en)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006286893A (en) * 2005-03-31 2006-10-19 Mitsubishi Heavy Ind Ltd Thin film solar cell, method of manufacturing thin film solar cell
JP2007165531A (en) * 2005-12-13 2007-06-28 Mitsubishi Heavy Ind Ltd Solar cell and manufacturing method thereof
JP2008147382A (en) * 2006-12-08 2008-06-26 Honda Motor Co Ltd Solar cell module and its manufacturing method
WO2009133822A1 (en) * 2008-05-01 2009-11-05 シャープ株式会社 Method for manufacturing solar battery module
DE112008001045T5 (en) 2007-05-11 2010-06-10 Showa Shell Sekiyu K.K. solar cell module
JP2012174774A (en) * 2011-02-18 2012-09-10 Honda Motor Co Ltd Method of manufacturing solar cell module
WO2013070000A1 (en) * 2011-11-09 2013-05-16 Lg Innotek Co., Ltd. Solar cell apparatus

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006286893A (en) * 2005-03-31 2006-10-19 Mitsubishi Heavy Ind Ltd Thin film solar cell, method of manufacturing thin film solar cell
JP2007165531A (en) * 2005-12-13 2007-06-28 Mitsubishi Heavy Ind Ltd Solar cell and manufacturing method thereof
JP2008147382A (en) * 2006-12-08 2008-06-26 Honda Motor Co Ltd Solar cell module and its manufacturing method
DE112008001045T5 (en) 2007-05-11 2010-06-10 Showa Shell Sekiyu K.K. solar cell module
WO2009133822A1 (en) * 2008-05-01 2009-11-05 シャープ株式会社 Method for manufacturing solar battery module
JP2009272376A (en) * 2008-05-01 2009-11-19 Sharp Corp Method of manufacturing solar-battery module
JP4512650B2 (en) * 2008-05-01 2010-07-28 シャープ株式会社 Manufacturing method of solar cell module
JP2012174774A (en) * 2011-02-18 2012-09-10 Honda Motor Co Ltd Method of manufacturing solar cell module
WO2013070000A1 (en) * 2011-11-09 2013-05-16 Lg Innotek Co., Ltd. Solar cell apparatus

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