JP2003224287A - Solar cell module and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar cell module and a method for manufacturing the same, for improving weather resistance by preventing separation between a coated substrate and a sealant that bonds a solar cell to the substrate, which is caused by the low adhesion between the coating material and the sealant, and for preventing the weather resistance of the substrate from lowering by not applying a coating material thereto. <P>SOLUTION: Both sides of the substrate 1 are coated to form thereon, as (a), coating films 4, respectively. The coating film 4 on a plane portion 1a onto which the solar cell is to be bonded through the sealant 2, is removed, as (b). The sealant 2 and a solar cell panel 3 are stacked on the plane portion 1a and subjected to thermocompression bonding, as (c). <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module in which a solar cell is adhered to a substrate with a sealant, and the substrate is coated to improve weather resistance, and a method for producing the same.

[0002]

2. Description of the Related Art When a solar cell module is manufactured by adhering a solar cell to a flat surface of a base with a sealant, a metal plate such as a steel plate or an aluminum plate is used as the base to improve the weather resistance of the base. To improve, the substrate is painted. FIG. 6 is an explanatory diagram of a conventional method for manufacturing a solar cell module. In the figure, 1 is a base made of a rectangular steel plate, and both surfaces of the base 1 are coated with a fluorine-based paint to form coatings 4 and 4 in order to improve weather resistance. (Fig. 6 (a)).

A flat surface portion 10a, which is the central portion of the coated substrate 10, is left at both ends of the coated substrate 10, leaving a bending margin for forming an engaging portion for engaging with another solar cell module.
Then, the sealant 2 using EVA resin and the solar cell panel 3 to which a plurality of solar cell elements are connected are laminated and thermocompression bonded (FIG. 6B). Further, the bending margin of the coated substrate 10 is bent and projected to the front surface side (the surface side to which the solar cell panel 3 is adhered) and the rear surface side (the surface side to which the solar cell panel 3 is not adhered) of the coated substrate 10. A pair of engaging parts 1
0b and 10b are formed (FIG. 6C).

It should be noted that one end of the coated substrate 10 is bent to form an engaging portion 10b projecting to the back side of the coated substrate 10, and the other end is bent and engaged with a flat plate coated with a fluorine-based paint. The pair of engaging portions 10b and 5a may be formed by adhering the engaging member 5 having the portion 5a formed thereon and projecting the engaging portion 5a toward the front side of the coated substrate 10 (FIG. 6).
(D)).

[0005]

However, the coating film 4
Since the adhesiveness between the fluorine-based paint forming the resin and the EVA resin used as the sealant 2 is low, the adhesiveness between the coated substrate 10 and the sealant 2 is, for example, the metal plate (base 1) and the EV.
The adhesiveness is lower than that of the A resin (sealant 2), and when the solar cell module is used for a long period of time, peeling may occur between the coated substrate 10 and the sealant 2, and moisture may be removed from the peeled portion. There is a problem in that the solar cell elements that make up the solar cell panel 3 are short-circuited by short-circuiting, and the output of the solar cell module is reduced.

Further, when the solar cell panel 3 is directly adhered to the substrate 1 by the encapsulant 2 without the intervening the film 4, the adhesiveness between the substrate 1 and the encapsulant 2 is high, and therefore the film 4 can be prevented from being peeled off due to the low adhesiveness between the sealant 2 and the sealant 2, but the weather resistance of the base 1 is lowered because the base 1 is directly exposed to moisture, and, for example, rust is generated on the base 1 and There was also the problem of a loss of aesthetics.

The present invention has been made to solve the above problems, and a solar cell is adhered to the above-mentioned flat surface of a substrate having a flat surface which is a metal surface and a coated surface by a sealant. The purpose of the present invention is to provide a solar cell module capable of preventing peeling between the base and the sealant without lowering the weather resistance of the base. Still another object of the present invention is to bond a solar cell to the flat surface portion of a base body having a flat surface portion which is a metal surface and a coated surface by an adhesive and a sealant, thereby providing a base material. It is an object of the present invention to provide a solar cell module capable of improving the adhesiveness with a sealant.

Another object of the present invention is to use a substrate having a flat surface portion having an exposed metal surface and a coated surface, and to bond the solar cell to the flat surface portion with a sealant to form a base material. Another object of the present invention is to provide a method for manufacturing a solar cell module capable of preventing peeling between a substrate and a sealant without deteriorating the weather resistance. Another object of the present invention is to use a substrate having a flat surface having an exposed metal surface and a coated surface, apply an adhesive to the flat surface, and then apply the adhesive to the flat surface. Another object of the present invention is to provide a method for manufacturing a solar cell module, which can improve the adhesiveness between a substrate and a sealant by bonding the solar cell with the sealant.

[0009]

A solar cell module according to a first aspect of the present invention is a solar cell module in which a solar cell is adhered to a plane portion of a metal base with a sealant, wherein the base is coated. Characterized in that the flat portion is a metal surface. In the first aspect of the invention, for example, in the case of a base body using a flat plate made of metal, an engaging portion that engages with another solar cell module or a bending allowance (having an engaging portion) for forming the engaging portion. Adhesive allowance for adhering the engaging member) and the surface (back side) where the solar cell is not adhered
And the four end faces are coated with a paint (for example, a fluorine-based paint) that improves weather resistance, and the flat part is not coated. Therefore, the flat part is a metal surface, and the flat part is sealed. The solar cell is bonded with a stopper (for example, a thermoplastic resin).
As described above, the base body is coated except for the flat surface portion, and the flat surface portion which is not coated and is a metal surface is sealed by bonding the solar cell to the flat surface portion with a sealant. Since it is in close contact with the substrate, the substrate is not directly exposed to the outside air or water, and the weather resistance of the substrate can be improved.

Further, since the base and the sealant are directly adhered to each other, and there is no contact portion between the sealant and the coating material having low adhesiveness with the sealant, there is no contact between the base and the sealant. Can be prevented, and the weather resistance of the solar cell module can be improved. It should be noted that the solar cell uses a sealant on a substrate formed by laminating a metal first flat plate having a flat surface which is a metal surface and a metal second flat plate coated with a paint that improves weather resistance. You can glue it. In this case, since the flat surface portion of the first flat plate is a metal surface and the solar cell is adhered to the flat surface portion with the sealant, peeling between the substrate and the sealant can be prevented. Further, since the unpainted flat surface portion is in close contact with the sealant and the second flat plate is coated, it is possible to prevent the substrate from being directly exposed to the outside air or moisture.
Further, even when the first flat plate and the second flat plate are peeled off, the moisture that has penetrated from the peeled portion does not short-circuit the solar cell, so that it is possible to prevent the output from decreasing due to the infiltration of moisture.

The solar cell module according to the second aspect of the invention is characterized in that an adhesive agent is interposed between the sealing agent and the flat surface portion. According to the second aspect of the invention, since an adhesive having high adhesiveness to the base and adhesiveness to the sealant is interposed between the base and the sealant, adhesion between the base and the sealant is achieved. It is possible to improve the property.

A method of manufacturing a solar cell module according to a third aspect of the present invention is a method of manufacturing a solar cell module in which a solar cell is adhered to a flat surface of a metal base with a sealant, and a coated surface, It is characterized in that a metal base having a flat surface portion having an exposed metal surface is used. In the third invention, for example, when a metal flat plate is used as the base body, a bending margin for forming the engaging portion or a gluing margin for adhering the engaging member, and a surface on which the solar cell is not adhered The back surface and the four end surfaces are coated with a paint that improves weather resistance (for example, a fluorine-based paint), and the flat surface is not painted. For this reason, the metal surface is exposed in the flat portion. The base and the sealant are brought into close contact with each other by bonding the solar cell to the flat surface where the metal surface is exposed with a sealant (for example, a thermoplastic resin). Therefore, the substrate is not directly exposed to the outside air or moisture, and the solar cell module capable of improving the weather resistance of the substrate can be manufactured.

Further, since the base and the sealant are directly adhered to each other, there is no contact portion between the sealant and the coating material having low adhesiveness to the sealant. It is possible to manufacture a solar cell module that can prevent peeling of the solar cell and improve weather resistance. The base having a flat surface with a metal surface exposed is obtained by coating the flat surface of the metal base with a removable protective sheet or a water-soluble protective film.
It may be formed by coating the substrate with a paint that improves weather resistance and finally removing the protective sheet or rinsing the protective film with water. Alternatively, the metal base may be coated with a paint that improves weather resistance, and then the coating film attached to the flat surface portion may be removed by, for example, blasting.

Further, it may be formed by bonding a first flat plate having a flat portion where a metal surface is exposed and a second flat plate coated with a paint for improving weather resistance. In this case, by bonding the first flat plate and the second flat plate with the sealing agent, when the solar cell is thermocompression bonded with the sealing agent,
The first flat plate and the second flat plate can be bonded together by thermocompression bonding at the same time, and it is not necessary to separately prepare an adhesive for bonding the first flat plate and the second flat plate. Alternatively, a solar cell may be laminated on a flat surface of a metal flat plate (the metal surface is exposed because it is not coated), and then the flat plate may be coated.

A method of manufacturing a solar cell module according to a fourth aspect of the present invention is characterized in that an adhesive is applied to the flat surface portion and then the solar cell is bonded. In the fourth invention, for example, a flat surface portion where the metal surface is exposed is subjected to a primer treatment, and then a liquid adhesive (for example, an epoxy-based adhesive) having high adhesiveness to the substrate and adhesiveness to the sealing agent is applied. Adhesive) to the flat part. Finally, since the solar cell is adhered to the flat part coated with the adhesive with the encapsulant, the adhesiveness between the substrate and the encapsulant can be improved by interposing the adhesive between the substrate and the encapsulant. It is possible to manufacture a solar cell module having improved temperature.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below with reference to the drawings showing the embodiments thereof. Embodiment 1. 1 and 2 are explanatory views of a method for manufacturing a solar cell module according to Embodiment 1 of the present invention. In the figure, reference numeral 1 is a base made of a rectangular steel plate. First, the center of the base 1 is covered with a removable protective sheet 40, leaving the bending margins for forming the engaging portions at both ends of the base 1 (FIG. 1A). At this time, the portion covered with the protective sheet 40 becomes the flat surface portion 1a to which the solar cell is to be bonded with the sealant. Next, both surfaces of the substrate 1 are coated with a fluorine-based coating material that improves weather resistance to form a coating film 4 (FIG. 1 (b)).

The protective sheet 40 is removed (see FIG. 1).
(C)). At this time, the flat surface portion 1a is not covered with the coating film 4, and the metal surface of the substrate 1 is exposed. Further, the sealant 2 made of EVA resin and the solar cell panel 3 to which a plurality of solar cell elements are connected are laminated on the flat surface 1a and thermocompression bonded (FIG. 2A). Finally, the folding margin covered with the coating film 4 is bent to bond the front surface (the surface on which the solar cell panel 3 is adhered with the sealant 2) of the substrate 1 and the rear surface (the solar cell panel 3 is adhered). A pair of engaging portions 1c and 1b projecting toward the (non-surface) side are respectively formed (FIG. 2B).

In the solar cell module as described above, the substrate 1 is covered with the coating film 4 formed of a coating material for improving the weather resistance except the flat portion 1a, and the coating film 4 is not coated. The plane portion 1a is a metal surface, and the plane portion 1a
Since the solar cell panel 3 is adhered to a by the sealant 2 with the sealant 2, the base 1 is not directly exposed to the outside air or moisture, and the weather resistance of the base 1 is improved. You can Further, the substrate 1 and the sealant 2 are directly brought into close contact with each other, and the coating film 4 having low adhesiveness between the sealant 2 and the sealant 2.
Since there is no contacting portion with the base material 1, peeling between the base 1 and the sealant 2 can be prevented, and the weather resistance of the solar cell module can be improved.

Embodiment 2. FIG. 3 is an explanatory diagram of a method for manufacturing a solar cell module according to Embodiment 2 of the present invention. First, the coating film 4 is formed on both surfaces of the substrate 1 (see FIG. 3).
(A)). Next, the coating film 4 attached to the central portion of the substrate 1 is removed by blasting, leaving the bending margins for forming the engaging portions at both ends of the substrate 1 (FIG. 3).
(B)). At this time, the portion where the coating film 4 is removed and the metal surface of the substrate 1 is exposed becomes the flat surface portion 1a to which the solar cell is bonded with the sealant. Further, the sealant 2 and the solar cell panel 3 are stacked on the flat surface portion 1a and thermocompression bonded (see FIG. 3).
(C)).

The other parts corresponding to those of the first embodiment are designated by the same reference numerals and the description thereof will be omitted. The solar cell module as described above can obtain the same effect as that of the first embodiment.

Embodiment 3. FIG. 4 is an explanatory diagram of a method for manufacturing a solar cell module according to Embodiment 3 of the present invention. First, the center of the base 1 is subjected to a primer treatment, leaving a bending allowance for forming the engaging portion and a glue allowance for adhering the engaging member at both ends of the base 1 to obtain an epoxy liquid adhesive. 60 is applied (FIG. 4A). At this time, the portion to which the liquid adhesive 60 is applied becomes the flat surface portion 1a to which the solar cell is to be adhered with the sealant. Next, before the liquid adhesive 60 is dried and cured, the sealant 2 and the solar cell panel 3 are laminated on the liquid adhesive 60 and thermocompression bonded (FIG. 4B). At this time, the liquid adhesive 60 is cured to become the layered adhesive 6. Next, both surfaces of the substrate 1 are coated with a fluorine-based paint to form a coating film 4 (FIG. 4 (c)).

Further, one end portion of the base body 1 is bent to form an engaging portion 1b projecting to the back surface side of the base body 1, and the other end portion thereof is
Bending a flat plate coated with fluorine-based paint to engage the part 5a
The engaging member 5 formed with is bonded and the engaging portion 5a is projected to the front surface side of the base 1 (FIG. 4 (d)). The other parts corresponding to those of the first or second embodiment are designated by the same reference numerals and the description thereof will be omitted.

The solar cell module as described above can obtain the same effect as that of the first or second embodiment. Further, since the adhesive 6 having high adhesiveness to the base 1 and adhesiveness to the sealant 2 is interposed between the base 1 and the sealant 2, the base 1 and the sealant 2 are The adhesiveness between them can be improved.

Embodiment 4. FIG. 5: is explanatory drawing of the manufacturing method of the solar cell module which concerns on Embodiment 4 of this invention. Reference numeral 11 in the figure is a first flat plate made of a rectangular steel plate. First, the flat surface portion 1 on which the sealant and the solar cell are to be laminated
The engaging portion 11 is formed by bending one end of the first flat plate 11 to the plane portion 11a side, leaving 1a, and projecting to the plane portion 11a side.
b is formed (FIG. 5A). Further, the coating film 4 is formed on both surfaces of the second flat plate 12 made of a rectangular steel plate (see FIG. 5).
(B)). The area of the second flat plate 12 has an area for adhering the flat surface portion 11a of the first flat plate 11 and a bending margin area for forming the engaging member.

Next, the sealant 2 and the solar cell panel 3 are laminated on the flat portion 11a of the first flat plate 11, and the first flat plate 11 is further laminated on the second flat plate 12 via the EVA resin.
Thermocompression bonding (FIG. 5 (c)). At this time, the first flat plate 11 and the second flat plate 12 are integrated to form the base body 13. Also,
When the first flat plate 11 and the second flat plate 12 are stacked, the engaging portion 11b formed on the first flat plate 11 is replaced by the second flat plate 1
2 is arranged at one end, and a bending margin is arranged at the other end.
Further, the bending margin of the second flat plate 12 is bent to form the engaging portion 12a protruding to the back surface side (FIG. 5 (d)). In addition, the same reference numerals are given to the portions corresponding to any of the first to third embodiments, and the description thereof will be omitted.

In the solar cell module as described above, the substrate 13 has the second flat plate 12 covered with the coating film 4 and the flat surface portion 11 not covered with the coating film 4 and having a metal surface exposed.
a first flat plate 11 having a
Since the flat surface portion 11a and the sealant 2 are in close contact with each other by the solar cell panel 3 being bonded to the a by the sealant 2, the base body 13 is not directly exposed to outside air or moisture, and the weather resistance of the base body 13 is improved. It is possible to improve the property. Also, the first flat plate 11
The (planar portion 11a) and the sealant 2 are directly adhered to each other,
Since there is no contact portion between the sealant 2 and the second flat plate 12, peeling between the base 13 and the sealant 2 can be prevented, and the weather resistance of the solar cell module can be improved.

Further, since the engaging portion 11b is provided at one end and the engaging portion 12a is provided at the other end of the base body 13 formed by laminating the first flat plate 11 and the second flat plate 12, the engagement is performed. The parts 11b and 12a can be used to engage with other solar cell modules. Also, the first flat plate 11 and the second flat plate 1
2 and the EVA resin forming the sealant 2 are bonded to each other, the sealant 2 and the solar cell panel 3 are bonded to each other by the first flat plate 1
Simultaneously with the first flat plate 1 when laminated by thermocompression bonding
1 and the second flat plate 12 can be bonded by thermocompression bonding,
It is not necessary to separately prepare an adhesive for bonding the first flat plate 11 and the second flat plate 12.

[0028]

According to the solar cell module of the present invention,
It is possible to prevent the base body from being directly exposed to the outside air or moisture, prevent peeling between the base body and the sealant, and improve the weather resistance of the solar cell module. Therefore, weather resistance can be improved. Furthermore, according to the method for manufacturing a solar cell module of the present invention,
A solar cell module can be manufactured which can prevent the substrate from being directly exposed to outside air or moisture, can prevent peeling between the substrate and the sealant, and can improve the weather resistance of the solar cell module. .. Therefore, the present invention has excellent effects such as the ability to manufacture a solar cell module capable of improving weather resistance.

[Brief description of drawings]

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

FIG. 2 is an explanatory diagram of a method for manufacturing the solar cell module according to the first embodiment of the present invention.

FIG. 3 is an explanatory diagram of a method for manufacturing the solar cell module according to the second embodiment of the present invention.

FIG. 4 is an explanatory diagram of a method for manufacturing the solar cell module according to the third embodiment of the present invention.

FIG. 5 is an explanatory diagram of a method for manufacturing a solar cell module according to Embodiment 4 of the present invention.

FIG. 6 is an explanatory diagram of a conventional method for manufacturing a solar cell module.

[Explanation of symbols]

1 base 1a flat part 11 First flat plate 11a flat part 12 Second flat plate 13 Base 2 Sealant 3 solar panel 4 coating film 6 adhesive

Claims (4)

[Claims] 1. A solar cell module in which a solar cell is adhered to a flat surface of a metal base by a sealant, wherein the base has a coated surface, and the flat surface is a metal surface. The solar cell module is characterized by: 2. The solar cell module according to claim 1, wherein an adhesive is interposed between the sealant and the flat surface portion. 3. A method for manufacturing a solar cell module, in which a solar cell is adhered to a flat surface of a metal base by a sealant, wherein a coated surface and a flat surface where the metal surface is exposed are provided. A method for manufacturing a solar cell module, which comprises using the metal base body. 4. The method for manufacturing a solar cell module according to claim 3, wherein the solar cell is adhered after applying an adhesive to the flat surface portion.