JP2004153137A - Method and apparatus for manufacturing solar cell module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simplify an apparatus for manufacturing a solar cell module and to reduce the manufacturing costs by cutting a predetermined portion including a part to form a solar cell out of a long flexible substrate without using a vacuum suction conveyance system as conventional. <P>SOLUTION: On a supporting sheet in which a front side protecting member or a rear side protecting member and an adhesive resin sealant are simply laminated, the predetermined portion including the part to form the solar cell is overlapped, pressed and heated to be cut out of the long substrate. For example, the apparatus for implementation is provided with a first conveyance line for conveying a long substrate 131 on which a plurality of sets of solar cells are formed, a second conveyance line which is orthogonal with the first conveyance line for conveying a supporting sheet 132 in which the front side protecting member or the rear side protecting member and the adhesive resin sealant are laminated, a means for pressing and heating the predetermined portion including a part 131a to form the solar cell while overlapping the portion at a predetermined position on the adhesive resin sealant of the supporting sheet, and a means for cutting out the predetermined portion including the part to form the solar cell out of the long substrate. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for manufacturing a solar cell module, and in particular, to a solar cell forming section of each set from a flexible long substrate formed of a plurality of sets of solar cells in which a plurality of solar cell elements are connected in series or in parallel. The present invention relates to a method and an apparatus for manufacturing a solar cell module formed by cutting out a predetermined portion including the above and sealing between a front surface protection member and a back surface protection member via an adhesive resin sealing material.
[0002]
[Prior art]
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 or in parallel is a thin film solar cell.
[0003]
Thin-film solar cells are considered to be the mainstream of solar cells in the future because they are thin, lightweight, inexpensive in manufacturing cost, and easy to increase in area, so they are used not only for power supply but also for building roofs and windows. Demand is expanding for business use and general residential use. Roof tiles with solar cells have also been developed for general residential use.
[0004]
In recent years, research and development of flexible solar cells using plastic film or thin sheet metal coated with insulation have been promoted, and by utilizing this flexibility, mass production is possible by roll-to-roll or step-roll manufacturing methods. It has become.
[0005]
As the thin-film solar cell module, in order to seal a solar cell formed on an electrically insulating film substrate with an electrically insulating protective material, both on the light-receiving side and the non-light-receiving side of the solar cell. A device provided with a protective layer is known.
[0006]
FIG. 4 shows a schematic side sectional view of an example of the structure of a conventional solar cell module.
[0007]
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 a light receiving surface side, and a resin containing a metal foil, for example, an aluminum foil on the back side. A back surface protection member 3 made of ethylene monofluoride is provided on both surfaces. The back surface protection member 3 is provided with an adhesive resin sealing material 4 such as EVA (ethylene-vinyl acetate copolymer resin) which is excellent in bonding and sealing properties and is inexpensive. Sealed.
[0008]
In the solar cell 1, the lead wires 5 and 6 of the internal lead wire are electrically connected to the plus (+) and minus (-) poles. The connection terminal box 7 adhered and fixed to the back surface protection member 3 is guided through the back surface protection member 3 and electrically connected to the core wires 9 and 10 of the cable 8 as an external lead inside the connection terminal box 7. The solar cell module 11 is formed as a whole.
[0009]
As the surface protection member 2, an organic material such as a transparent acrylic plate may be used in addition to an inorganic material such as a glass plate. In addition to the above-mentioned resin containing a metal foil, an organic film alone such as a fluorine-based film, a composite material obtained by laminating an organic film and a metal foil, or a metal such as a metal plate or a glass plate may be used as the back surface protective member 3. -In some cases, inorganic materials are used.
[0010]
As a method of the solar cell 1, a method of forming a connection electrode layer on one surface of a substrate or a method of forming a connection electrode layer on a back surface, for example, a so-called SCAF (Series Connection Through Properties on Film) type solar cell according to the proposal of the present applicant. There are various types such as batteries.
[0011]
FIG. 5 is a simplified perspective view of the configuration of the thin-film solar cell for facilitating understanding of the structure of the SCAF solar cell. In FIG. 5, the unit photoelectric conversion element 62 formed on the front surface of the substrate 61 and the connection electrode layer 63 formed on the back surface of the substrate 61 are completely separated into a plurality of unit units, respectively, and are formed with their separation positions shifted. ing. For this reason, the current generated in the photoelectric conversion layer 65, which is the amorphous semiconductor portion of the element 62, is first collected in the transparent electrode layer 66, and then through the current collecting hole 67 formed in the transparent electrode layer region, the current on the back surface is collected. Through the connection electrode layer 63, and further through the connection hole 68 for series connection formed outside the transparent electrode layer region of the device in the connection electrode layer region, outside the transparent electrode layer region of the device adjacent to the device. The extended lower electrode layer 64 is reached, and the two devices are connected in series.
[0012]
Next, FIGS. 6 and 7 show that a solar cell in which a plurality of solar cell elements are connected in series or in parallel between a front surface protection member and a back surface protection member is sealed with an adhesive resin sealing material, and FIG. 6 shows a schematic configuration diagram of a solar cell module in which a solar cell and an internal lead wire are connected, FIG. 6 is a plan view, and FIG. 7 is a partial side sectional view of the solar cell module including an AA cross section in FIG. Show.
[0013]
6 and 7, the same functional members as those of the solar cell module shown in FIG. 4 are denoted by the same reference numerals, and detailed description is omitted. The solar cell module shown in FIGS. 6 and 7 shows a typical configuration in which a plurality of solar cell elements 1a are connected in series, and an internal lead wire 12 is connected to and pulled out from the end solar cell element 1a. I have. However, the upper surface and the lower surface of the connection body between the solar cell 1 composed of the plurality of solar cell elements 1a and the internal lead wires 12 are respectively provided with the surface protection member 2 and the back surface protection member 3 via the adhesive resin sealing material 4. Are provided.
[0014]
The electrical connection between the solar cell 1 and the internal lead wire 12 is usually made by soldering or a conductive adhesive tape. Note that the shape and number of the internal lead wires 12 and the arrangement in the entire solar cell module and the like differ depending on the required specifications for the solar cell module, and are not necessarily limited to the simple configuration shown in FIGS. 6 and 7. However, once the required specifications are determined, the electrical connection part usually has a predetermined pattern.
[0015]
By the way, when mass-producing the thin-film solar cell, the substrate is a long substrate, and the thin-film solar cell connected in series on the long substrate, and an electrode for extracting electric power for extracting electric power to the outside. A set of thin-film solar cells having a plurality of layers, patterning them at predetermined intervals in the longitudinal direction of the substrate to form a plurality of pairs, and using the marker holes for positioning provided in the interval region of the substrate as reference points, Forming of each layer such as one electrode layer, photoelectric conversion layer, transparent electrode layer, connection electrode layer, and processing such as patterning, etc., and furthermore, evaluation of device characteristics and cutting for each thin film solar cell group using marker holes as reference points. Etc. are adopted.
[0016]
FIG. 8 is a schematic plan view showing a schematic configuration of a thin-film solar cell in which a plurality of thin-film solar cell groups are formed on a long substrate, which relates to the above-described manufacturing method. FIG. 8 mainly shows the positional relationship between the thin-film solar cells separated on the substrate by laser processing and the positioning marker holes, 131 denotes a long substrate, 1 denotes a solar cell, and 20 denotes a marker hole. The solar cell 1 is appropriately divided into a plurality of unit cells 1a and an electrode layer 27 for extracting electric power by a patterning line 28 according to the application.
[0017]
The marker hole 20 is provided in the interval region of the solar cell. The marker hole for positioning is detected by a light transmission type or light reflection type sensor, and the positioning is performed using this hole as a reference point. The formation of each layer and the respective patterning processes are performed.
[0018]
Here, in order to minimize the non-power generation area of the solar cell, that is, the ineffective area, the marker hole 20 provided in the space area is provided inside the long substrate 1 and at least in the substrate long direction. Are provided inwardly from the outermost extension line of.
[0019]
In FIG. 8, a portion indicated by a part number 29 indicates an overrun portion of the patterning line. In the case of laser processing, the scanning speed is slowed at the end point of the line, so if scanning is stopped at the intersection of the lines, there is a risk that the substrate and the thin film may be damaged due to the concentration of the laser beam, so to prevent this, Overrun.
[0020]
Further, the thin-film solar cell group in the manufacturing method in FIG. 8 is not limited to the SCAF-type thin-film solar cell shown in FIG. 5, and the first electrode layer, the photoelectric conversion layer, and the transparent electrode layer are sequentially laminated only on one surface of the substrate. Then, a single-sided thin-film solar cell group may be formed by patterning a unit portion, dividing the unit cell into a plurality of unit photoelectric conversion portions (unit cells), and electrically connecting the unit cells to each other in series. The manufacturing method is the same as the above-mentioned method.
[0021]
Next, a conventional apparatus for manufacturing a solar cell module will be described. FIG. 9 shows a manufacturing apparatus described in the related art section of Patent Document 1. In this apparatus, one end of a delivery roll 21 of an insulating flexible film 131 such as an ethylene naphthalate (PEN) film and a delivery roll 22 of a transparent heat-adhesive resin film 31 such as an ethylene vinyl acetate (EVA) film are connected. Then, the two heating rolls 41 and 42, which are thermally bonded with the films interposed therebetween, the punching heating device 60 for the portion of the thin film photoelectric conversion element (solar cell) 1 from the insulating flexible film, and the winding roll 71 are They are arranged in a line.
[0022]
At right angles to the row and the punching heating device 60, the delivery roll 23 of the translucent weather-resistant film 81 as a protective film is provided at one end, and the heating rolls 43 and 44, the heating rolls 45 and 46, and the winding roll 72. Are arranged in a line. In the punching heating device 60, the position where the element 1 of the flexible film 131 is formed on the surface which is the lower surface in the drawing of the insulating flexible film 131 is detected by the marker hole 20 provided between the elements. At the same time, the weather-resistant film 81 is heat-bonded to the transparent electrode side of the film 31 with the heat-adhesive resin of the film 31.
[0023]
The heating rolls 43 and 44 coat the conductive tape 9 delivered from the delivery roll 24 on the back surface of the substrate 131 and on the auxiliary electrode connected to the device electrode on the front surface on the surface of the auxiliary electrode. The melted solder is melted and connected, and is thermally fixed to the weather-resistant film 81. The heating rolls 45 and 46 thermally bond the weather-resistant film 82 for the back surface protective film sent from the delivery roll 25 via the heat-adhesive resin film 32 sent from the delivery roll 26.
[0024]
If the above-mentioned apparatus is used, the device 35 on the substrate is punched out for each heat-adhesive resin film except for the portion of the element having poor characteristics, and the light-receiving surface is laminated with the weather-resistant protective film 81 via the heat-adhesive resin film 31. The thin flexible substrate 131 is reinforced by the protective film, and the connection between the devices using the exposed auxiliary electrodes and the modularization can be easily performed, so that the module including no defective device can be formed. Further, by adopting an apparatus configuration in which the element supply line and the transport line for the module base film are orthogonal to each other, module assembly can be performed continuously on both lines, and thin film photoelectric conversion modules can be manufactured with high production efficiency.
[0025]
The invention described in Patent Document 1 discloses an apparatus and a manufacturing method for solving the problems of the apparatus shown in FIG. That is, the apparatus described in Patent Document 1 discloses that "a substrate is sandwiched between a roll cutter having a blade having the same shape as the outer shape of an element on a surface thereof and a suction roll, and both rolls are rotated to cut out the element. The element is vacuum-sucked on a suction roll. When mounting the element on a weather-resistant film, the suction chamber inside the suction roll is set to atmospheric pressure to separate the element from the suction roll surface. " When the thin film photoelectric conversion element formed thereon is cut out from the substrate and mounted on a weather-resistant film, the surface is prevented from waving. "
[0026]
Further, Patent Documents 2 and 3 disclose an apparatus for providing a photoelectric conversion module manufacturing apparatus with a high production efficiency capable of continuously feeding out a protective film from a transport line and manufacturing modules of various shapes. Is disclosed. To achieve this object, the device disclosed in Patent Document 2 is configured as follows.
[0027]
That is, "a cutting means having a flexible film substrate transport line on which a plurality of photoelectric conversion units are formed and a protective film transport line, and cutting the unit from the film substrate on the former transport line. And a mounting means for stacking the cut unit on a protective film, and a heating roll for thermally bonding the stacked unit and the protective film, in the apparatus for manufacturing a photoelectric conversion module, There are two cutting blades for making the first two cuts parallel to the line, and two cutting blades for making the second two cuts while moving vertically in the latter transport line. "
Further, in Patent Document 3, in order to further improve the production efficiency, "the mounting means is a suction table, a film substrate and a photoelectric conversion unit are sandwiched between the suction table and a pre-heating roll which is preliminarily heat-bonded. The device is described.
[0028]
[Patent Document 1]
JP-A-9-64393 (pages 1 to 3, FIGS. 1 and 2)
[Patent Document 2]
JP-A-10-12906 (page 1, page 4, FIG. 1)
[Patent Document 3]
JP-A-10-135496 (page 1, pages 4 to 5, FIG. 1)
[0029]
[Problems to be solved by the invention]
By the way, the conventional solar cell module manufacturing apparatuses described in Patent Documents 1 to 3 described above are all complicated in that the cut solar cell forming units are conveyed by vacuum suction on suction rolls. However, there has been a problem that the manufacturing cost of the module increases.
[0030]
In particular, in the case of the SCAF type thin-film solar cell shown in FIG. 5, the series connection between adjacent solar cell elements is performed through the current collecting holes 67 and the connection holes 68 penetrating the flexible substrate. Therefore, when performing the vacuum suction, it is necessary to cover a hole penetrating the above-mentioned flexible substrate by pasting a protective film or the like in advance. Therefore, there is a problem that the manufacturing procedure and the device are further complicated, and the manufacturing cost of the module is increased.
[0031]
SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a solar cell forming unit from a flexible long substrate without using a vacuum suction transfer system as in the related art. Therefore, it is possible to cut out a predetermined portion including the above, thereby achieving simplification of a solar cell module manufacturing apparatus and reduction in manufacturing cost.
[0032]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, in the present invention, each of the sets of solar cell forming portions is formed from a flexible long substrate in which a plurality of sets of solar cells in which a plurality of solar cell elements are connected in series or in parallel are formed. A method for manufacturing a solar cell module in which a predetermined portion including the above is cut out and sealed between a front surface protection member and a back surface protection member via an adhesive resin sealing material includes the following steps. Item 1)).
1) transporting the long substrate on which the plural sets of solar cells are formed to a predetermined position by a first transport line.
2) A support sheet, in which a surface protection member or a back surface protection member and the adhesive resin sealing material are laminated by a second conveyance line orthogonal to the first conveyance line, to a predetermined portion including the solar cell forming portion. Is transported to a predetermined position facing the adhesive resin sealing material.
3) a step of superposing a predetermined portion including the solar cell forming portion on a predetermined position on the adhesive resin sealing material of the support sheet and applying pressure and heat to bond the predetermined portion and the support sheet.
4) A step of cutting out a predetermined portion including the solar cell forming portion from the long substrate, and transporting the long substrate to which the predetermined portion and the support sheet are adhered, to a predetermined position.
[0033]
According to the above manufacturing method, a predetermined portion including a solar cell forming portion is overlapped on a support sheet in which a surface protection member or a back surface protection member and the adhesive resin sealing material are simply laminated, and heated and pressed, Since it can be cut out from the substrate, there is no vacuum suction step, and the manufacturing process is simplified as a whole and the cost can be reduced.
[0034]
Further, a sheet (hereinafter, referred to as a solar cell sheet) in which the support sheet and the solar cell forming portion are bonded to each other, and a second solar cell protective layer as a second solar cell protective layer is provided on a solar cell formation surface opposite to the support sheet. In order to complete the module by adhering the support sheet, the invention of claim 2 below is preferable. That is, in the manufacturing method according to the first aspect, the second support sheet in which the back surface protection member or the front surface protection member and the adhesive resin sealing material are laminated is further transported from the third transport line to a predetermined position. And bonding the predetermined portion and the second support sheet via the adhesive resin sealing material.
[0035]
In this case, similarly to the apparatus shown in FIG. 9, the process can be performed in a continuous process. As described in detail later, the solar cell sheet is once wound around a roll, and the roll of the second support sheet is rolled. It can also be connected to a transport line. Further, the solar cell sheet can be cut into a predetermined size in advance and bonded to the second support sheet by a vacuum laminator.
[0036]
Next, as an apparatus for carrying out the invention of claim 1, the following invention of claim 3 is preferable. That is, an apparatus for carrying out the manufacturing method according to claim 1, wherein the first transport line transports a long substrate on which a plurality of sets of solar cells are formed, and a front surface protection member or a rear surface protection member. A second transport line that is orthogonal to the first transport line that transports the support sheet on which the adhesive resin sealing material is laminated, and a predetermined portion including the solar cell forming portion are formed by using an adhesive resin of the support sheet. It is provided with means for overlapping and heating at a predetermined position on the sealing material and means for cutting out a predetermined portion including the solar cell forming portion from the long substrate.
[0037]
As an embodiment of the third aspect of the present invention, the following fourth or fifth aspect is preferable. That is, in the manufacturing apparatus according to claim 3, the means for pressurizing and heating is a heated flat plate press having a predetermined dimension for pressurizing and heating the solar cell forming portion, and the cutting means is a mold blade for cutting out the predetermined portion. And the heated flat plate press is disposed inside a die blade of the die press (the invention of claim 4).
[0038]
Further, in the manufacturing apparatus according to claim 3, the means for pressurizing and heating is a heating roll press having a predetermined size for pressurizing and heating the solar cell forming portion, and the cutting means is a mold blade for cutting out the predetermined portion. And a rotary die cutter, and the heating roll press and the rotary die cutter are means for individually positioning the press and the cutter at predetermined positions in the longitudinal direction of the long substrate, respectively, and further, the pressurizing heating and Means are provided for moving out in the vertical direction for cutting out (the invention of claim 5).
[0039]
The details of the fourth and fifth aspects of the present invention will be described later.
[0040]
BEST MODE FOR CARRYING OUT THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
[0041]
1 to 3 each show a schematic configuration for explaining a different apparatus for manufacturing a solar cell module according to the present invention. First, the apparatus of FIG. 1 will be described below. FIG. 1 relates to the device according to the third aspect of the present invention. FIG. 1 (a) is a plan view and FIG. 1 (b) is a side sectional view.
[0042]
The flexible long substrate 131 supplied from the delivery roll 121 in the first transport line is positioned so that the solar cell forming section 131a to be mounted is at the position of the cut outer shape 161 and the solar cell forming section 131a is cut off. After that, it is taken up by a take-up roll 122 as waste material. A second moving stage 151a that moves in a direction perpendicular to the direction of transport of the flexible long substrate 131 below the positioned solar cell forming portion 131a and that can be positioned with respect to the solar cell forming portion 131a. A transport mechanism 151 as a transport line is provided.
[0043]
The support sheet 132 having an upper surface to which a heat-adhesive film 133 as an adhesive resin sealing material is adhered is positioned and fixed to the moving stage 151a by a supply device (not shown). Above the positioned solar cell forming portion 131a, an upper die base 141 supported by a guide post 147 so as to be vertically movable from the die base 148 is disposed.
[0044]
An upper blade 142 is mounted on the upper die base 141 via the upper die 143 in accordance with the cut outer shape 161 of the solar cell forming portion 131a to be cut off, and a guide pin 144 guides the inner side of the upper blade 142 with the guide pin 144. The heating flat plate 145 as a main element of the pressurizing and heating means is attached in a state where it is pressed down by the spring pressure of the spring 146. When the upper die base 141 is at the upper end position, the lower surface of the heating flat plate 145 is in a state of protruding from the cutting edge of the bik blade 142.
[0045]
After positioning the solar cell forming portion 131a and the support sheet 132 at the position of the cut outer shape 161, the upper die base 141 is lowered by a press unit (not shown), and the heating flat plate 145 sandwiches the solar cell forming portion 131a with the support sheet 132. Is stopped while the heat-adhesive film 133 on the upper surface is pressed. In this state, only the heating range 162 of the heat-adhesive film 133 is heated by the heating flat plate 145 to bond and fix the solar cell forming portion 131a on the support sheet 132. Then, the upper mold base 141 is lowered, and the By pressing the 142 against the flexible long substrate 131, the solar cell forming portion 131a can be cut out and cut off.
[0046]
Next, the apparatus of FIG. 2 according to the invention of claim 5 will be described. 2A is a plan view, and FIG. 2B is a side sectional view. In FIG. 2, the supply of the flexible long substrate 131 and the support sheet 132, and the positional relationship between the cut outer shape 161 and the heating range 162 are the same as in the above-described embodiment of FIG.
[0047]
Above the positioned solar cell forming portion 131a, a heating roll press unit 172 having a vertically movable heating roller 172a, and a rotary cutter unit 173 having a vertically movable rotary die cutter 173a, The flexible elongate substrate 131 is guided by the guide rail 170, and is arranged so as to be movable in the transport direction of the flexible elongate substrate 131 and positioned.
[0048]
After positioning the solar cell forming unit 131a and the support sheet 132 at the position of the cutting outer shape 161, the heating roll press unit 172 aligns the axis of the heating roller 172a with the end of the heating range 162 and positions it. Next, the heating roller press unit 172 transports the flexible elongate substrate 131 while the heating roller 172a is lowered to press the thermal adhesive film 133 on the upper surface of the support sheet 132 with the solar cell forming portion 131a interposed therebetween. After heating only the heating range 162 to bond and fix the solar cell forming portion 131a on the support sheet 132, the heating roller 172a is raised and then moved in the transport direction of the flexible long substrate 131. Then, it is retracted from the position of the heating range 162.
[0049]
Next, the rotary cutter unit 173 aligns the axis of the rotary die cutter 173a with the end of the cut outer shape 161 and performs positioning. At this time, the positioning is completed so that the cutting blade 173b in the width direction of the rotary die cutter 173a is aligned with the end of the cutting outline 161. Next, with the rotary die cutter 173a lowered and the cutting blade 173b pressed against the flexible elongate substrate 131, the rotary cutter unit 173 is moved in the transport direction of the flexible elongate substrate 131 to form a solar cell. After the portion 131a is cut out by cutting off, the rotary die cutter 173a is raised, and then moved in the transport direction of the flexible long substrate 131 to be retracted from the position of the cutting outline 161.
[0050]
By the apparatus shown in FIG. 1 or FIG. 2, as described above, a predetermined portion including a solar cell forming portion is provided on a support sheet obtained by simply laminating the front surface protection member or the back surface protection member and the adhesive resin sealing material. Can be cut out from a long substrate by heating under pressure.
[0051]
Next, according to the invention of claim 2, on the solar cell sheet on which the support sheet and the solar cell formation portion are bonded, on the solar cell formation surface opposite to the support sheet, a second solar cell protection layer is provided. An embodiment in which a second support sheet is bonded to complete a module will be described with reference to FIG.
[0052]
In FIG. 3, reference numeral 92 denotes a roll around which a solar cell sheet 93 to which a back surface protection member is bonded is wound, reference numeral 94 denotes a roll of a composite sheet 95 wherein an adhesive resin sealing material is bonded to a surface protection member, and reference numeral 98 denotes the composite sheet. And a cutting device 91, which is disposed on the transport path of the solar cell sheet 93 drawn out from the roll 92.
[0053]
Here, a solar cell sheet 93 is wound around the roll 92 with its light incident surface facing inward, and the roll 94 has an adhesive resin sealing material of the composite sheet 95 on the outside and a surface protection member on the inside. It is wound so that it faces. Then, while feeding the solar cell sheet 93 fed from the roll 92 with the light incident surface on the upper side and the back surface on the lower side, the composite of the adhesive resin sealing material and the surface protection member first fed from the roll 94 in the middle of the conveyance. The sheet 95 is superimposed on the surface (light incident side surface) of the solar cell sheet 93, and both are pasted when passing through the hot roll 98.
[0054]
Subsequently, the solar cell sheet 93 whose front and back surfaces are covered with the composite sheet 95 proceeds to the next cutting device 91, where the solar cell sheet 93 is cut to a predetermined size to complete a module in which both surfaces are resin-sealed. It should be noted that, instead of the process of the apparatus of FIG. 3, as described above, a continuous process can be performed similarly to the apparatus of FIG. 9, and further, the solar cell sheet is cut into a predetermined size first. By using a vacuum laminator, it can be bonded to the second support sheet.
[0055]
【The invention's effect】
According to the present invention, as described above, a predetermined portion including a solar cell forming portion is superimposed on a support sheet in which a surface protection member or a back surface protection member and the adhesive resin sealing material are simply laminated, and heated under pressure. , Cut out from a long board,
As an apparatus for implementing the method, a first transport line for transporting a long substrate on which a plurality of sets of solar cells are formed, and a support sheet on which a surface protection member or a back surface protection member and the adhesive resin sealing material are laminated are transported. Means for overlapping and heating a second transport line orthogonal to the first transport line and a predetermined portion including the solar cell forming portion at a predetermined position on the adhesive resin sealing material of the support sheet. And means for cutting out a predetermined portion including the solar cell forming portion from the long substrate,
It is possible to cut out a predetermined portion including a solar cell forming portion from a flexible long substrate without using a vacuum suction transfer method as in the related art, thereby simplifying a solar cell module manufacturing apparatus and reducing manufacturing costs. Reduction can be achieved.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of an apparatus for manufacturing a solar cell module according to an embodiment of the present invention; FIG. 2 is a schematic configuration diagram of an apparatus for manufacturing a solar cell module according to an embodiment different from FIG. 1; FIG. 4 is a schematic cross-sectional view of an example of a solar cell module manufacturing apparatus according to the invention of claim 2. FIG. 4 is a side cross-sectional view of an example of a solar cell module. FIG. FIG. 7 is a cross-sectional view taken along the line AA in FIG. 6; FIG. 8 is a schematic plan view showing a schematic configuration in which a plurality of solar cells are formed on a long substrate; FIG. 9 is a perspective view showing an example of a conventional solar cell module manufacturing apparatus.
1: solar cell, 1a: solar cell element, 2: front surface protection member, 3: rear surface protection member, 4: adhesive resin sealing material, 93: solar cell sheet, 121: delivery roll, 122: take-up roll, 131 : Long substrate, 131a: solar cell forming part, 132: support sheet, 133: thermal adhesive film, 142: big blade, 145: heated flat plate, 161: cut outer shape, 162: heating range, 170: guide rail, 172 : Heating roll press unit, 172a: heating roller, 173: rotary cutter unit, 173a: rotary die cutter, 173b: cutting blade.

Claims (5)

From a flexible long substrate formed with a plurality of sets of solar cells in which a plurality of solar cell elements are connected in series or in parallel, a predetermined portion including the solar cell forming portion of each set is cut out, and an adhesive resin sealing material is formed. A method for manufacturing a solar cell module, wherein the method includes the following steps in a method for manufacturing a solar cell module sealed between a front surface protection member and a back surface protection member.
1) transporting the long substrate on which the plural sets of solar cells are formed to a predetermined position by a first transport line.
2) A support sheet, in which a surface protection member or a back surface protection member and the adhesive resin sealing material are laminated by a second conveyance line orthogonal to the first conveyance line, to a predetermined portion including the solar cell forming portion. Is transported to a predetermined position facing the adhesive resin sealing material.
3) a step of superposing a predetermined portion including the solar cell forming portion on a predetermined position on the adhesive resin sealing material of the support sheet and applying pressure and heat to bond the predetermined portion and the support sheet.
4) A step of cutting out a predetermined portion including the solar cell forming portion from the long substrate, and transporting the long substrate to which the predetermined portion and the support sheet are adhered, to a predetermined position. The manufacturing method according to claim 1, further comprising: transporting a second support sheet on which a back surface protection member or a surface protection member and an adhesive resin sealing material are laminated to a predetermined position from a third transportation line; A method for manufacturing a solar cell module, comprising a step of bonding the predetermined portion and a second support sheet via the adhesive resin sealing material. An apparatus for carrying out the manufacturing method according to claim 1, wherein the first transport line transports a long substrate on which a plurality of sets of solar cells are formed, a front surface protection member or a rear surface protection member, and the adhesiveness. A second transport line orthogonal to the first transport line for transporting the support sheet on which the resin sealing material is laminated, and a predetermined portion including the solar cell forming portion, the adhesive resin sealing material for the support sheet. An apparatus for manufacturing a solar cell module, comprising: means for applying pressure and heating to an upper predetermined position; and means for cutting a predetermined portion including the solar cell forming portion from a long substrate. 4. The manufacturing apparatus according to claim 3, wherein the pressurizing and heating unit is a heated flat plate press having a predetermined dimension for pressurizing and heating the solar cell forming unit, and the cutting unit includes a die blade for cutting the predetermined portion. 5. An apparatus for manufacturing a solar cell module, characterized in that the heating flat plate press is disposed inside a die blade of the die cutting press as a die cutting press. 4. The manufacturing apparatus according to claim 3, wherein the pressurizing and heating unit is a heating roll press having a predetermined dimension for pressurizing and heating the solar cell forming unit, and the cutting unit includes a die blade for cutting the predetermined portion. 5. A rotary die cutter, and the heating roll press and the rotary die cutter are means for individually positioning the press and the cutter at predetermined positions in the longitudinal direction of the long substrate, respectively, and further, the pressurizing heating and cutting A means for moving the solar cell module in the vertical direction.

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