JP2004111952A - Laminated glass and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce cracking on a device when laminated glass is manufactured, in which a solar cell device is sealed between two glass plates. <P>SOLUTION: Between two glass plates 11 and 15, the following members are disposed: a solar cell device 16, two resin films 12 and 14 for sandwiching a device surface, and a resin member 13 disposed between a conductor 17 drawn from the light-receiving surface of the device 16 and the resin film making contact with the non-light receiving surface of a device 26. These members are integrated. The resin member 13 disposed under the conductor 17 reduces local stress concentration. When the first resin film 12 is increased in thickness (e.g. 1.0 mm or larger), cracking on the device is further prevented. <P>COPYRIGHT: (C)2004,JPO

Description

The present invention relates to a method for producing a laminated glass in which a solar cell element (solar cell, photoelectric conversion element) is encapsulated, and a laminated glass that can be produced by this production method.

太陽 A solar cell module in which a solar cell element is fixed in a pair of plate-like bodies is known, for example, from Patent Document 1. Patent Literature 1 discloses a method for manufacturing a solar cell module in which a plurality of solar cell elements are sandwiched between a translucent member such as glass and a back member such as aluminum foil. As disclosed in this document, a solar cell element is usually installed in a chamber together with a translucent member, a back surface member, and a resin film disposed between these members and the element. By heating while reducing the pressure, the resin film is softened and sandwiched between the translucent member and the back surface member.

Patent Document 2 proposes inserting a glass fiber nonwoven fabric or an organic resin fiber nonwoven fabric into a laminate to be used as a module so that no air bubbles remain in the solar cell module.

Patent Document 3 proposes to insert a base material having an opening into a laminate serving as a solar cell module, for the purpose of preventing the solar cell element from being displaced.

Patent Document 4 proposes to insert a sealing material film having an uneven structure on the surface into a laminate to be a module so that air bubbles do not remain in the solar cell module.

On the other hand, a laminated glass in which a pair of glass plates is joined by a resin film (intermediate film) such as polyvinyl butyral (PVB) or ethylene-vinyl acetate copolymer (EVA) to be used as a window glass for vehicles or buildings. Has been mass-produced. The bonding step involving heating for bonding is industrially performed using a heating furnace and an autoclave, or using only a heating furnace.
JP-A-10-214987 JP-A-11-112007 JP 2001-60709 A JP 2002-134768 A

(4) When a solar cell element is fixed between a pair of glass plates, photoelectric conversion is performed in a region where the device is arranged, and a light-transmitting module with a photoelectric conversion function of taking in light from a region other than the region can be obtained. However, when applying a known airbag or a bonding method using a single chamber to fix the solar cell element between a pair of glass plates, force is concentrated on the solar cell element before the intermediate film is sufficiently softened. , The local stress is generated, and the solar cell element is frequently cracked.

Therefore, in the present invention, a resin member is disposed between the glass plates separately from the two resin films conventionally used.

That is, the present invention is a method for producing a laminated glass in which a solar cell element is sandwiched between first and second glass plates,
On a first glass plate, a first resin film, a solar cell element, and a second resin film are arranged in this order, and a resin member is arranged under a conductive wire electrically connected to the element. ,
Place a second glass plate on the second resin film,
A method for manufacturing a laminated glass in which first and second glass plates, the element, the first and second resin films, and the resin member are integrated is provided.

The present invention also provides a laminated glass that can be produced by the above method. The laminated glass is, for example, a laminated glass in which a plurality of solar cell elements are sandwiched between two glass plates, and a resin film is interposed between the two glass plates and the plurality of elements. The plurality of elements are arranged such that the light receiving surfaces face in the same direction, and at least a part of the plurality of elements is electrically connected in series, and a resin film in contact with the light receiving surface and a resin film in contact with the non-light receiving surface It is a laminated glass having a different thickness from the film.

The number and shape of the resin members are not limited.

According to the present invention, since the resin member relaxes the local stress applied to the solar cell element, the solar cell element can be fixed in the laminated glass while suppressing cracks.

Hereinafter, embodiments of the present invention will be described.

Although the manufacturing method of the present invention can be applied to the manufacture of a solar cell module using one solar cell element, a plurality of solar cell elements, specifically, arranged so that the light receiving surface faces the same direction, at least The effect is great when applied to the manufacture of a solar cell module using a plurality of solar cell elements, some of which are electrically connected in series. Further, the manufacturing method of the present invention can be applied irrespective of the type of an apparatus used for bonding.

A conductor that bridges between the elements for electrical connection of the solar cell element may be fixed to two elements to be connected in advance, or the conductor that is fixed to only one of the elements is a glass plate. In the bonding step, the element may be brought into contact with the other element to ensure conduction. When the conductor is fixed to the element in advance, it may be performed by soldering or the like.

In any case, the plurality of solar cell elements are configured such that the wires drawn from the light-receiving surface or the non-light-receiving surface are sequentially connected to the surface from which the wires of the elements adjacent to the element from which the wires were drawn (wire-leading surface). By connecting to the opposite surface (the surface from which the lead wire is not drawn out), it is preferable to electrically connect in series.

す る と If the conducting wire lead-out surface is a light receiving surface, the conducting wire non-leading surface is a non-light receiving surface. In consideration of the operation of connecting the conductors and the quality of the solar cell module, it is preferable that the lead-out surface be the light receiving surface.

In a manufacturing process of a laminated glass including solar cell elements electrically connected in series, usually, a first resin film is to be disposed below these elements, and the first resin film is formed between these elements and the first resin film. A part of the conductor is interposed between them. In this case, when the thickness of the first resin film is 1.0 mm or more, cracking of the solar cell element can be further suppressed. Further, the first resin film is preferably thicker than the second resin film. According to these preferred embodiments, it is possible to reduce cracking of the element in the vicinity of the conductive wire that contacts the first resin film.

In the manufacturing method of the present invention, the plurality of elements are arranged in a matrix so that the plurality of solar cell elements respectively form a predetermined number of element columns and element rows, and the plurality of elements forming the element columns are electrically connected. It can also be applied to a form connected in series. In this mode, a region between element columns and a region between element rows can be used as a light-transmitting region through which light passes. The electrical connection of the solar cell elements constituting the element row may be ensured by conducting wires arranged as described above.

In this case, a resin member may be arranged in a region between element columns and a region between element rows. The resin member may be arranged in the region so as to cross at least one selected from a plurality of element columns and a plurality of element rows. This is because the placement work can be performed efficiently.

Further, two or more members may be used as the resin member. For example, the above-mentioned resin member disposed below the conducting wire may be used as a first resin member, and the second resin member may be used together with the first resin member. It is preferable to further arrange the resin members so that the total thickness of the resin members is larger in at least a part of the region where the second resin member is arranged than in the region where only the first resin member is arranged. This is because stress applied to the end of the element can be reduced.

と お り As described above, the shape of the resin member is not limited. However, when a plurality of elements are arranged in a matrix, it is preferable to use a strip-shaped resin member. In addition, a strip-shaped resin member traversing a plurality of element rows and a strip-shaped resin member traversing a plurality of element rows are provided in an intersection area where a region between element columns and a region between element rows overlap. You may arrange so that it may overlap. According to this arrangement, the resin member in the intersecting region becomes relatively thick, and it is possible to suppress concentration of force on the element end portion until the resin film and the resin member obtain fluidity by heating.

で は In the manufacturing method of the present invention, it is preferable that the resin member is arranged so as not to overlap with the solar cell element. In addition, when the resin member is arranged so that a gap is secured between the solar cell element and the resin member, there is an effect of suppressing remaining air bubbles after the combination. In particular, when the resin members are arranged such that the gap is conducted to the end of the laminated glass in a state where the respective members are stacked (a state before the resin film is softened), bubbles are less likely to remain.

When at least one selected from the resin film and the resin member is EVA in the production method of the present invention, the cooling time from the maximum temperature to room temperature in the bonding step for integration is preferably 30 minutes or less. . In this case, in the bonding step for integration, the average rate of temperature rise from room temperature to 70 ° C. is preferably 1.5 ° C./min or more.

According to the present invention, any one of the light receiving surface and the non-light receiving surface which are in front and back of each other in the solar cell element may be used as the conducting wire lead-out surface, and may be arranged upward in the combining step. However, when the light-receiving surface is arranged upward, the second resin film in contact with the light-receiving surface can be kept thin even if the first resin film in contact with the non-light-receiving surface is thickened. Can be maintained. As a result, a laminated glass with high power generation efficiency can be manufactured while suppressing cracking of the element.

で は In the present invention, the lead-out surface may be arranged either upward or downward. When the light receiving surface is a lead wire drawing surface, the lead wire drawing surface should be upward from the above viewpoint, but one end of the lead wire pulled out from the element in the glass plate bonding step is connected to the adjacent element. In the case of successive contact, it is preferable that the lead-out surface is downward and the lead-out surface is upward in consideration of workability.

It is preferable that the difference in thickness between the two resin films in contact with both surfaces of the element after the laminating step (that is, in the state of laminated glass) is, for example, 0.2 mm or more.

Hereinafter, the details of the present invention will be described with reference to the drawings.

First, the contents of the preliminary experiment will be described. If it is attempted to fix a plurality of solar cell elements between glass plates in a state where they are separated from each other, there is a problem that the element is displaced or bubbles remain, along with the element crack. Therefore, in this preliminary experiment, in order to solve these problems, a countermeasure that was initially considered to be optimal, that is, a resin film 53 (in which a portion in which a plurality of elements are arranged is cut out and a window 10 and an air vent slit 18 are provided) is provided. FIG. 1) was interposed as a third resin film between two resin films used for bonding the element surfaces. This preliminary experiment is based on the disclosure of Patent Document 3.

積 層 The order of lamination of each member was as follows. First, a first resin film is disposed on a lower glass plate. Next, the solar cell elements are arranged in a matrix on the first resin film, and the elements are connected in series in the element column direction. Each element is formed by sequentially interposing a lead wire drawn from a peripheral end of an upper surface (a light receiving surface in this element) between a lower surface (non-light receiving surface) of an adjacent element and the first resin film. They were connected in series with each other. Then, the end of the conductive wire was connected to the external lead wire. Further, the resin film 53 shown in FIG. 1 is disposed as a third resin film from above the conductor so that each element is disposed in the window 10. Finally, a second resin film and an upper glass plate are laminated on the resin film in this order. In this case, the conducting wire lead-out surface is set as the upper surface. However, in consideration of workability, the conducting wire lead-out surface (light receiving surface) may be arranged so as to be the lower surface.

(4) A matching test was conducted on this laminate and a conventional laminate in which the third resin film was not disposed. As a result, the displacement of the element and the residual air bubbles could be substantially solved by the arrangement of the third resin film. However, even if the third resin film 53 was arranged, the probability of element cracking could hardly be improved.

(4) When the results of the preliminary experiment were analyzed, element cracks could be classified into the following three patterns (FIG. 2). The first is a crack 41 around the connecting portion (tab fixing portion) of the conductive wire (tab wire) 17 drawn out from the upper surface of the element 16. The second is a crack 42 that occurs along the conductor 7 that contacts the lower surface of the element 16. The third is a crack 43 generated near a corner (even angle) of the rectangular element 16 in plan view.

The first crack 41 is generated when the second resin film (upper resin film) 14 and the upper glass plate 15 press the conductive wire 17 between the elements 16 and 26 from above when viewed from the site where the first crack 41 is generated. It is considered that they have been performed (FIG. 3). Due to the pressure from above, the wire 17 is pushed down so as to wind the element 16, and as a result, the end of the element 16 becomes a lever, and stress is applied to the narrow connection portion with the wire 17 on the periphery of the element upper surface 16 a. concentrate.

As shown in FIG. 3, the end of the conductive wire 17 drawn out from the upper surface 16 a of the element is formed between the first resin film 12 held on the lower glass plate 11 and the adjacent element 26. Placed between. The conductive wire 17 is fixed between the first resin film 12 and the lower surface 26b of the element 26 by bonding a glass plate, and connects the elements 16 and 26 via a conductive non-light receiving surface 26b. The element 26 is further connected to an adjacent element (not shown) via a lead wire 27 drawn out from its upper surface 26a, and similarly, the element 16 is adjacent to the opposite side via a conductive wire 7 contacting its lower surface 16b. It is connected to an element (not shown). .., 16, 26... Are sequentially electrically connected in series.

The second crack 42 is considered to be directly caused by the bending stress generated when the conductor 17 is interposed below the element 26, in view of the fact that the crack occurs along the conductor 27 (for example). (Fig. 4). On the lower glass plate 11 placed on the flat support surface of the support member 30, the element 26 is pressed from above on both sides of the conductor 17, so that stress concentrates on the area 55 along both sides of the conductor 17. I do.

The third crack 43 is caused by a stress generated when the glass plate 15 bends slightly inward in a region where the band-shaped region between the element columns and the band-shaped region between the element rows intersect (intersecting region 20; FIG. 1). It is thought that.

の う ち Of the first to third cracks, the first crack 41 was the most frequent. Then, when the third resin film 13 was disposed under the conductive wire 17 to suppress the first crack (FIG. 5), the probability of occurrence of the element crack was drastically reduced. This is presumably because the third resin film 13 supported the conductor 17 from below, and alleviated stress concentration at the conductor connection portion on the upper surface 16a. As described above, the first crack is caused by the resin films 12 and 14 used for bonding the element surfaces between the conductive wire 17 drawn out from the upper surface 16a of the element and the resin film 12 in contact with the lower surface 16b of the element. This can be suppressed by disposing another resin film 13.

The thickness of the resin member is preferably equal to or slightly larger than the thickness of the solar cell element. Here, a resin film is used as the resin member disposed below the conductor. However, the shape and the like are not particularly limited as long as stress concentration on the conductor connection part can be reduced. For example, a resin rod or a resin piece is used. May be used as a resin member.

Since the first crack is dramatically reduced by the addition of the third resin film 13, it is possible to obtain a sufficiently practical production yield without taking any special measures against the second and third cracks. It is. Even if the first crack 41 is suppressed, the second and third cracks 42 and 43 do not increase significantly. However, in order to obtain a higher production yield, the following measures should be taken for these cracks 42 and 43.

To suppress the second crack 42, it is preferable to increase the thickness of the lower resin film (first resin film) 12 to increase the "cushion effect" of the resin film. This effect is effective in alleviating the bending stress that causes the second crack. In a normal alignment step, it is sufficient that the resin films 12 and 14 have a thickness of about 0.8 mm. However, in order to prevent this kind of crack 42, the thickness of the resin film is preferably 1.0 mm or more. In the range confirmed by the experiment using EVA, when the film thickness is set to 1.2 mm or more, the second crack 42 is not seen at all. Even in the cooling step after heating, stress is applied to the vicinity of the conductive wire 17, but if the lower resin film 12 is made thicker, the stress accompanying the temperature decrease of the resin film can also be reduced.

It seems that the rate of temperature rise of the resin film is also affecting the generation of the second crack 42. This is because if the fluidity of the resin film can be secured before the bending stress exceeds the strength of the element, the bending stress is reduced. The bending stress is reduced if the resin film 12 is plastically deformed to such an extent that a part of the conductive wire 17 disposed under the element is buried in the resin film 12. This degree of fluidity can be obtained, for example, by heating to 70 ° C. in the case of EVA. Therefore, when EVA is used as the resin film, it is necessary to heat the resin film so that the average rate of temperature rise of the resin film from room temperature to 70 ° C. becomes a predetermined value or more, for example, 1.5 ° C./min or more. Is preferred. In particular, since the second crack is considered to occur in a temperature range of 50 to 70 ° C. until the EVA starts to soften and obtains fluidity, the average heating rate in this temperature range is at least 1.5. C / min, and more preferably 3.0 to 5.0 C / min.

The third crack 43 can be suppressed by increasing the thickness of the third resin film 13 in or near the intersection region 20 or by increasing the temperature rising rate to a predetermined value or more. This is because stress applied to the corners of the element 16 during heating and cooling is reduced. Specifically, it is preferable that the resin film 13 in this region 20 be thicker than the resin films in other regions. In addition, by setting the average rate of temperature rise of the resin film from room temperature to 70 ° C. to 1.5 ° C./min or more, the edge of the solar cell element can be obtained until the resin film or the resin member acquires fluidity. Can be prevented from being concentrated.

(4) It is easy to partially increase the thickness of the resin film in the intersection region 20 by using a strip-shaped resin film (FIG. 6). The strip-shaped resin film is simply formed of a region between element columns (region between element columns) composed of elements 16 connected in series with each other by a conductive wire 17 and a row of virtual elements 16 extending in a direction orthogonal to the element columns. What is necessary is just to arrange | position along the area | region (element row area | region) between (element row), in other words, to cross each element column and each element row. The strip-shaped resin film 23 arranged along the inter-element-row region and the strip-shaped resin film 33 arranged along the inter-element-row region overlap in the intersection region, and become locally thick at the overlapping portion 21.

In the preferred embodiment shown in FIG. 6 as well, the resin film 33 arranged along the element row region is arranged below the conductor 17 connecting the elements 16.

(4) The element 16 and the third resin films 13, 23, and 33 are preferably arranged so as not to contact each other. As shown in FIG. 6, it is preferable to secure a gap around the entire element. A preferred distance between the element and the third resin film is about 0.5 mm to 5 mm. When the resin film is softened, the gap functions as an air bleeding passage for bleeding air when the resin film is softened. It does not cause the rest.

In the embodiment shown in FIG. 6, the air vent passages 29, 39 extend vertically and horizontally along the strip-shaped resin films 23, 33 (that is, the passages are in contact with the entire periphery of the element). , 39 are conducted to the end of the laminated glass, so that the air inside can be reliably discharged.

れ ば The larger the glass plate, the greater the importance of the air vent passage. For each element, it is preferable to arrange the third resin film so as to secure an air vent passage leading to the end of the laminated glass.

(4) The strip-shaped resin film may be divided to give priority to more reliable release of the air inside (FIG. 7). FIG. 7 illustrates an example in which the resin film 23 extending along the inter-element-row region is divided into a plurality of resin films 23 ′ so that the resin films do not overlap. In this case, in order to suppress the third crack 43, it is preferable that the resin film 23 'be thicker than the resin film 33 passing under the conductive wire. Further, the resin film 33 may be divided like the resin film 23 '.

As described above, in order to suppress the third crack 43, an additional resin film (second resin member) is arranged in addition to the resin film (first resin member) for supporting the conductive wire, and this additional In at least a part of the region where the resin film is disposed, specifically, the region other than the portion where the first resin member supports the conductor, the region is smaller than the region where only the resin film for supporting the conductor is disposed. It is preferable to increase the total thickness (total thickness) of the resin film. In the embodiment shown in FIG. 6, since the resin films 23 and 33 intersect, the sum of the thicknesses of the two resin films becomes the total thickness of the resin films.

総 The total thickness is preferably equal to or more than the entire thickness of the element including the thickness of the conductive wire. For example, when the thickness of the element body is 0.4 mm and the thickness of the conductor is 160 μm, the total thickness of the element is about 0, considering that the conductor 17 overlaps the light receiving surface 16a and the non-light receiving surface 16b of the element. .72 mm. Therefore, in this case, the total thickness of the resin film is preferably 0.72 mm or more. In order to realize this thickness, the thickness of the strip-shaped resin film is preferably 0.4 to 0.8 mm. In the present specification, the thickness of the resin film is evaluated by the thickness before the alignment step.

The glass plate is not particularly limited, and general-purpose soda lime silica glass may be used. In particular, the glass plate 15 disposed on the light receiving surface side has a reduced iron content in order to secure the amount of light transmitted to the element. It is preferable to use glass. Specifically, the total amount of iron as Fe ₂ O ₃ as a coloring component is preferably 0.2 wt% or less.

As the resin film, PVB or EVA, which has been conventionally used for manufacturing laminated glass, is suitable, but not limited thereto, and polyurethane or the like may be used. EVA is suitable for encapsulation of a solar cell element because of its high fluidity when softened. When EVA is used, an autoclave does not necessarily need to be used for bonding two glass plates. There is no particular limitation on the material of the third resin film (resin member), but it is sufficient to use a resin of the same material as the resin film used in combination.

外形 There are no restrictions on the outer shape or internal structure of the solar cell element. In the present specification, the form in which the conducting wire (tab wire) drawn from the upper surface is connected to the lower surface of the element has been described. However, the form of the tab wire connection is not limited to this, and another connecting member may be prepared. Further, instead of connecting the elements to each other in the alignment step, an element group in which a plurality of solar cell elements are connected in advance may be used. Also in this case, an element group is used in which a lead wire drawn out of an element is electrically connected to a surface on the opposite side of an adjacent element (a non-light receiving surface if the lead wire drawing surface is a light receiving surface) by solder or the like. Good.

(4) In the production of the laminated glass of the present invention, an element encapsulating apparatus (a single-chamber method, a decompression chamber of an airbag method or the like) which has been conventionally used may be applied. In addition, an autoclave that has been used for manufacturing laminated glass may be further applied. When heated to a predetermined temperature in a reduced-pressure atmosphere to soften the resin film and fix the element (temporary bonding), and subsequently heated to a temperature equal to or higher than the predetermined temperature in a pressurized atmosphere (final bonding), the first In addition, the space between the second glass plate and the element can be filled with a resin to remove the unfilled portion.

In order to further ensure the effects of the present invention, the lower surface of the lower glass plate is preferably supported by a support member 30, as shown in FIG. It is preferable that the support is held on the support member at each stage. At the stage when the final bonding is completed, the solar cell module may be stored vertically or may be reversed and its front and back may be switched.

In the final bonding, unless the temperature is maintained at the maximum temperature range for 20 to 30 minutes, a sufficient bonding strength of the laminated glass cannot be obtained. For this reason, it is not appropriate to shorten the holding time in the maximum temperature range, and it is necessary to increase the heating rate and the cooling rate as much as possible in order to improve the workability of the bonding step. However, if the speed is too high, the in-plane temperature difference of the laminated glass becomes large, and adhesion failure occurs, and the laminated glass may be deformed. Therefore, it is preferable to control the temperature raising rate and the cooling rate to 1.5 to 7.0 ° C./min, particularly 3.0 to 5.0 ° C./min. An autoclave is suitable for precise control of the heating rate and the cooling rate.

(4) When EVA is used as the resin film or the resin member, the cooling time in the final bonding greatly affects the characteristics regardless of the presence or absence of the temporary bonding. According to an experiment, it was found that when the time required for cooling from the maximum temperature (for example, 150 ° C.) to room temperature in the actual bonding (cooling time) exceeds 30 minutes, EVA becomes cloudy. This is considered because EVA crystallized. When at least one selected from the resin film and the resin member is EVA, the cooling time from the maximum temperature to room temperature in the bonding step is preferably 30 minutes or less.

Hereinafter, the present invention will be described in more detail with reference to examples.

Soda lime silica glass (dimensions 1400 mm x 2800 mm, thickness 5.0 mm) and EVA interlayer (Bridgestone Corporation (WG1820, WG1620, WG1420): thickness 0.4 mm, 0.6 mm or 0.8 mm, final bonding temperature) 150 ° C.) and a solar cell (manufactured by Kyocera Corporation). Here, the final bonding temperature is a temperature to be set as a maximum temperature in an autoclave using the resin film.

As soda-lime silica glass, a high transmission glass having a total iron content of 0.2 wt% or less disposed on the light receiving surface side and a normal glass disposed on the non-light receiving surface side were prepared.

The photovoltaic cell has a rectangular shape of dimensions 150 mm × 155 mm and a thickness of 0.35 to 0.40 mm, and a pair of conducting wires (tab wires) is led out from the periphery of the light receiving surface. The width and thickness of the tab line are 2 mm and 0.2 mm, respectively. The non-light-receiving surface of this cell is a back electrode made of aluminum, and the electromotive force of the cell can be extracted from between the tab line and the back electrode.

Further, a strip-shaped EVA film was prepared as a third resin film. This EVA film is obtained by cutting a 0.4 mm thick EVA film prepared as an EVA intermediate film (first and second resin films) into a 10 mm wide strip.

These members were laminated in the following order: a lower glass plate, a first EVA intermediate film, a solar cell and a strip-shaped EVA film, a second EVA intermediate film, and an upper glass plate. However, in order to obtain a predetermined film thickness, two or three EVA intermediate films were appropriately used as the first EVA intermediate film. The second EVA intermediate film was formed to have a thickness of 0.8 mm by stacking two EVA films having a thickness of 0.4 mm.

At this time, the photovoltaic cells were arranged such that the light receiving surface was on the lower surface. In addition, the cells were arranged in a matrix of 4 × 10, and the ends of the tab lines were sequentially interposed between adjacent cells and the EVA intermediate film for the four columns, and the cells in this column were connected in series. . Approximately 15 mm intervals were secured between the four columns and ten rows of the cell.

(6) The strip-shaped EVA film and the solar cell were arranged such that the EVA film crossing the element row passed under the tab line as shown in FIG. An average distance of about 2.5 mm was secured between the strip-shaped EVA film and the cell.

積 層 The thus obtained laminate was subjected to primary bonding by a single chamber method under the following conditions.

[Primary bonding conditions]
・ Average temperature in chamber: 110 ° C (resin film temperature: 85 to 95 ° C)
-Chamber pressure: about 98 kPa
-Holding time of the above average temperature: 40 minutes-Temperature rising rate: about 1.5 ° C / minute After the primary bonding, secondary bonding was performed using an autoclave under the following conditions.

[Secondary bonding conditions]
・ Set temperature: 150 ℃
・ Set pressure: 490 kPa
・ Average heating rate to the set temperature: 4.0 ° C./min ・ Holding time of the above set temperature: 30 minutes Time of a series of heat treatment steps from room temperature to set temperature to room temperature: 90 minutes

合 わ せ For comparison, a laminated glass was produced in the same manner as above except that the third resin film (EVA film) was not used (Comparative Example 1). Further, a laminated glass was produced in the same manner as described above except that the third resin film (EVA film) was arranged on the tab line (Comparative Example 2). Further, a laminated glass (Comparative Example 3) produced in the same manner as in Comparative Example 2 except that a strip-shaped EVA film was replaced with an EVA film (see FIG. 1) in which a cell was disposed was used. And Comparative Example 3 corresponds to the result of the preliminary experiment described above. The EVA film used in Comparative Example 3 was formed by stacking two 0.4 mm thick EVA films.

に つ い て About a plurality of laminated glasses thus obtained, “bubble remaining”, “cell shift” and “cell cracking” were visually confirmed. As the “cell shift”, the moving distance of the cell which was most shifted from the position before the primary bonding was evaluated, and the moving distance of 0.5 mm or less was within the allowable range. The results are summarized in Table 1.

(Table 1)
―――――――――――――――――――――――――――――――――――
Lower intermediate film Resin member Laminated glass Thickness Shape Thickness Positional relationship Bubble remaining Cell shift Cell crack (mm) (mm) (pcs) (%)
―――――――――――――――――――――――――――――――――――
Example 1 0.8 Strip 0.4 Lower 0 Allowable range 0.25
2 1.0 Strip 0.4 Lower 0 Allowable range 0.11
3 1.2 Strip 0.4 Lower 0 Allowable range 0.06
―――――――――――――――――――――――――――――――――――
Comparative Example 1 0.8 None--10 5mm or more 20
2 0.8 Strip 0.4 Top 0 Allowable range 20
3 0.8 Hollow 0.8 Top 0 Allowable range 20
―――――――――――――――――――――――――――――――――――
“Lower (upper)” of the resin member indicates that the resin member is arranged “lower (upper)” of the tab line.

合 わ せ In order to examine the relationship between the cooling time in the actual bonding and the crystallization of EVA, a laminated glass was produced in the same manner as in Example 1 except that only the cooling rate was changed. Specifically, three sheets were produced at an average cooling rate of 7.0 ° C./min (Example 4), and three sheets were produced at an average cooling rate of 3.0 ° C./min (Reference Example). With respect to these laminated glasses, a portion having no solar cell element was cut out and the haze ratio of the portion was measured. As a result, the laminated glasses of Example 1 and Example 4 were both 1.0% on average. The haze ratio of the laminated glass of Reference Example was 15.0% on average. Considering the cooling time (40 minutes) in the reference example, it is understood that the cooling time is preferably 30 minutes or less.

合 わ せ The laminated glass encapsulating the solar cell element is expected to be used as a translucent member with excellent photoelectric conversion function with excellent durability in various fields such as window glass and roofing materials of buildings and vehicles.

It is a top view of the resin film used in the preliminary experiment. FIG. 3 is a plan view of the solar cell element as viewed from a light receiving surface, in which a typical pattern of cell cracks is written in order to explain element (cell) cracks. FIG. 4 is a cross-sectional view illustrating an arrangement of a resin film in a preliminary experiment. It is II sectional drawing of FIG. FIG. 9 is a cross-sectional view for explaining an example of the arrangement of a resin member (third resin film) in the manufacturing method of the present invention. It is a top view for showing the example of arrangement of a strip-shaped resin film used as a 3rd resin film, and a solar cell element. It is a top view for showing another example of arrangement of a 3rd resin film and a solar cell element.

Explanation of reference numerals

11, 15 Glass plate 12, 14 First and second resin films 13, 23, 23 ', 33 Third resin film (resin member)
16,26 Solar cell elements (cells)
16a, 26a Light-receiving surface 16b, 26b Non-light-receiving surface 7, 17, 27 Conductor 18 Air vent slit of third resin film 20 Intersecting area 21 Overlapping portion of third resin film 29, 39 Air vent passage 30 Support member 41, 42,43 Cell crack

Claims (16)

A method for producing a laminated glass in which a solar cell element is sandwiched between first and second glass plates,
A first resin film, the element, and a second resin film are arranged on the first glass plate in this order, and a resin member is arranged below a conductive wire electrically connected to the element. ,
Disposing the second glass plate on the second resin film;
A method for manufacturing a laminated glass by integrating the first and second glass plates, the element, the first and second resin films, and the resin member. The method for manufacturing a laminated glass according to claim 1, wherein a plurality of solar cell elements, each of which has a light-receiving surface facing in the same direction and at least a part of which is electrically connected in series, are used as the elements. The method for producing a laminated glass according to claim 2, wherein the thickness of the first resin film is 1.0 mm or more. 4. The method for manufacturing a laminated glass according to claim 2, wherein the first resin film is thicker than the second resin film. The plurality of solar cells are arranged in a matrix so that each of the plurality of solar cells constitutes a predetermined number of element columns and element rows, and the plurality of elements constituting the element columns are electrically connected in series. 5. The method for producing a laminated glass according to any one of 2 to 4. 6. The method of manufacturing a laminated glass according to claim 5, wherein the resin member is disposed in a region between the element columns and a region between the element rows. 7. The method for manufacturing a laminated glass according to claim 6, wherein the resin member is disposed so as to cross at least one selected from a plurality of element columns and a plurality of element rows. The first resin member is a resin member disposed below the conductive wire, and the second resin member is moved together with the first resin member in at least a part of the region where the second resin member is disposed. The method for manufacturing a laminated glass according to any one of claims 5 to 7, wherein the resin member is further arranged so that the total thickness of the resin member is larger than a region where only the resin member is arranged. A strip-shaped first resin member traversing a plurality of element columns and a strip-shaped second resin member traversing a plurality of element rows overlap an area between element columns and an area between element rows. The method for producing a laminated glass according to claim 8, wherein the laminated glass is arranged so as to overlap in the intersecting region. (10) The method for manufacturing a laminated glass according to any one of (1) to (9), wherein the resin member is arranged so as not to overlap with the element. The method for manufacturing a laminated glass according to claim 10, wherein the resin member is disposed such that a gap is secured between the solar cell element and the resin member. The method for manufacturing a laminated glass according to claim 11, wherein the resin member is arranged such that the gap is conducted to an end of the laminated glass. At least one selected from a resin film and a resin member is an ethylene-vinyl acetate copolymer, and a cooling time from a maximum temperature to room temperature in a bonding step for integration is 30 minutes or less. The method for producing a laminated glass according to any one of the above. 14. The resin film according to claim 1, wherein the resin film is an ethylene-vinyl acetate copolymer, and in the bonding step for integration, the average temperature rising rate from room temperature to 70 ° C. is 1.5 ° C./min or more. A method for producing a laminated glass according to any one of the above. 合 わ せ A laminated glass obtained by the method according to any one of claims 1 to 14. A laminated glass in which a plurality of solar cell elements are sandwiched between two glass plates, and a resin film is interposed between the two glass plates and the element,
The plurality of elements are arranged so that a light receiving surface faces in the same direction, and at least a part of the plurality of elements are electrically connected in series,
A laminated glass in which the thickness of the resin film in contact with the light receiving surface and the thickness of the resin film in contact with the non-light receiving surface are different.