JP2005079170A - Solar cell module and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problems, wherein a copper foil whose whole surface is coated with solder is usually used as a part of an interconnect line, such as a lateral interconnect line, a connecting interconnect line or the like located at the end of the solar cell module, so that its external appearance has silver metallic luster, the lateral interconnect line or the connecting interconnect line becomes very conspicuous because it is silver or has metallic luster, when the color of a module frame, a rear filler, or a rear protective material is set white, blue or black, and resultantly the lateral interconnect line or the connecting interconnect line deteriorates the whole external appearnce of a building where the solar cell module is installed. <P>SOLUTION: A colored light receiving surface-side filler is arranged at the peripheral end of the solar cell module so as to hide a part of the interconnect line, such as the lateral interconnect line, the connecting interconnect line or the like located at the end of the solar cell module, so that the solar cell module can be provided which matches well with a building, where the solar cell module is installed and its ambient environment and exhibits the superior external appearance of its light-receiving surface. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a solar cell module, and more particularly to a solar cell module with improved aesthetics, decorativeness, and appearance from the light-receiving surface side, and a method for manufacturing the same.

  Although the solar cell element is manufactured using a single crystal silicon substrate, a polycrystalline silicon substrate, or the like, the solar cell element is weak against physical impact. In addition, when a solar cell is installed outdoors, it must be protected from rain.

  Furthermore, since the electric output generated by one solar cell element is small, a plurality of solar cell elements are connected in series and parallel so that a practical electric output can be taken out. A plurality of solar cell elements are connected to each other and further sealed with a filler mainly composed of ethylene vinyl acetate copolymer (EVA) or the like, thereby forming a solar cell module.

  A conventional solar cell module will be described with reference to FIGS.

  FIG. 5 is a schematic cross-sectional structure of a solar cell panel portion of this solar cell module, where 1 is a translucent substrate, 2 is a light receiving surface side filler, 3 is a solar cell element, 4 is a back surface side filler, 5 is A back surface protective material 6 is a connection wiring.

  A plurality of solar cell elements 3 are arranged in a matrix to form a solar cell element group. Moreover, although the solar cell elements 3 arranged in a line in the vertical direction are connected by the connection wiring 6, so-called lateral wiring 7 that further connects the connection wiring 6 is provided around the solar cell element group. Provide.

  As described above, the translucent substrate 1, the light-receiving surface side filler 2, the plurality of solar cell elements 3, the back surface side filler 4, and the back surface protective material 5 connected by the lateral wiring 7 and the connection wiring 6 are arranged in this manner. It is made into the structure laminated | stacked in order, and it sets to the apparatus called a laminator, and it presses and integrates, heating under reduced pressure.

  FIG. 6 is an external view of the light receiving surface side of a conventional solar cell module. In addition, the same code | symbol is attached | subjected to the same location as the member shown in FIG.

  According to the solar cell module shown in the figure, the module frame 8 is provided around the solar cell panel portion shown in FIG. Specifically, the module frame 8 is attached to the outer peripheral portion of the solar cell panel, and the corner portion is screwed to fix the module frame.

  In such a solar cell module, the horizontal wiring 7 is provided in order to match the arrangement of the solar cell elements 3 to the outer dimensions of the solar cell module. On the other hand, the coupling wiring 9 is provided to connect the connection wirings 6 having the same polarity in the solar cell elements at the ends of the plurality of solar cell elements 3 connected in series or in parallel.

  These lateral wiring 7 and coupling wiring 9 are usually cut to a predetermined length by solder-coating the entire surface using a copper foil having a thickness of about 0.1 to 0.3 mm and a width of about 2 to 7 mm. It is used as.

  The color tone of the module frame 8, the back surface side filler 4, and the back surface protection material 5 is colored in a suitable color tone with no sense of incongruity depending on the building such as a house where the solar cell module is installed and the surrounding situation. Since the lateral wiring 7 and the coupling wiring 9 are formed by solder-coating the entire surface of the copper foil as described above, the appearance is silver metallic luster.

  Therefore, there were the following problems.

  When the module frame 8, the back surface side filler 4, and the back surface protective material 5 are, for example, white, blue, or black, the lateral wiring 7 and the coupling wiring 9 are very conspicuous because of the silver metallic luster. The design of the overall appearance of the building or the like where the solar cell module was installed was deteriorated.

In order to solve such a problem, it has been devised to cover a wiring member used for the lateral wiring 7 and the coupling wiring 9 with a colored resin or film (see Patent Document 1 and Patent Document 2).
JP 2001-339089 A JP 2003-86820 A

  However, if it is going to coat | cover the wiring member used for the horizontal wiring 7, the coupling wiring 9, etc. with the colored resin and film, the material cost was added by using the resin and film for it.

  Further, a process for covering the wiring material is added, and as a result, there is a problem that the manufacturing cost of the solar cell module is greatly increased.

  In addition, when connecting the connection wiring 6, the lateral wiring 7 or the coupling wiring 9 to the solar cell element 3, it is normally performed by soldering. As a result, as described above, the lateral wiring 7 and the coupling wiring are performed. In the conventional technique of covering the wiring member used for 9 or the like with a colored resin or film, there is a problem that the resin or film is denatured and discolored by the heat of soldering and the original purpose is not achieved. .

  The present invention has been made in view of such problems, and the object thereof is to make the non-transparent wiring provided in the peripheral portion of the solar cell element group inconspicuous by a simple method, whereby the solar cell module is installed. It is to provide a solar cell module having a good appearance on the light receiving surface side in harmony with a building and its surrounding environment.

  Another object of the present invention is to provide a solar cell module that is adapted to the color tone of a solar cell module mounting body such as a roof and has an enhanced aesthetic appearance.

  Another object of the present invention is to provide a method for manufacturing a solar cell module that achieves the object of the present invention by reducing the manufacturing cost.

  The solar cell module of the present invention includes a light-receiving surface side sealing material on a translucent substrate, a solar cell element group in which a plurality of solar cell elements are arranged, a whitened or colored back side sealing material, and a back surface. A light-receiving surface in which protective materials are sequentially stacked and non-transparent wiring is provided in the peripheral portion of the solar cell element group among the wirings for electrically connecting the solar cell elements, and is further disposed at a portion facing the solar cell element group. The side sealing material portion is made of a transparent material, and the light-receiving surface side sealing material portion arranged in a portion facing the peripheral portion of the solar cell element group is made of a light-shielding material that is whitened or colored. And

  Another solar cell module of the present invention includes a light receiving surface side sealing material, a solar cell element group in which a plurality of solar cell elements are arranged on a translucent substrate, a transparent back surface side sealing material, and whitening. Alternatively, a colored back surface protective material is sequentially laminated, and a non-transparent wiring among the wirings that electrically connect each solar cell element is provided in the periphery of the solar cell element group, and further, a portion that faces the solar cell element group The light-receiving surface side sealing material portion disposed on the light-receiving surface side sealing material portion is made of a transparent material, and the light-receiving surface side sealing material portion disposed on the portion facing the peripheral portion of the solar cell element group is whitened or colored by a light-shielding material It is characterized by that.

  In still another solar cell module of the present invention, the light-shielding material extends a light-receiving surface side sealing material portion disposed in a portion corresponding to the solar cell element group, and a light-shielding portion is formed in the extending portion. It is characterized by comprising.

  The installation structure of the solar cell module of the present invention is characterized in that the solar cell module of the present invention is mounted on a mounting body for fixing the solar cell module.

  The manufacturing method of the solar cell module according to the present invention includes the steps (1) to (5) below, followed by heating and pressurization under reduced pressure, and a light-receiving surface side seal disposed at a portion facing the solar cell element group. The stop material portion is made of a transparent material, and the light receiving surface side sealing material portion arranged in the portion facing the peripheral portion of the solar cell element group is integrated by being made of whitened or colored light shielding material. It is characterized by that.

  (1) A light-receiving surface side sealing material made of a transparent material and a light-shielding material is disposed on a light-transmitting substrate.

  (2) A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.

  (3) While electrically connecting the said solar cell element group by wiring, non-transparent wiring is provided in the peripheral part of a solar cell element group among this wiring.

  (4) A whitened or colored back side sealing material is disposed on the solar cell element group.

  (5) A back surface protective material is disposed on the back surface side sealing material.

  The other solar cell module manufacturing method of the present invention sequentially receives the following (1) to (5), followed by heating and pressurization under reduced pressure, and a light receiving surface disposed at a portion facing the solar cell element group. The side sealing material part is made of a transparent material, and the light-receiving surface side sealing material part arranged in a portion facing the peripheral part of the solar cell element group is made of a light-shielding material that is whitened or colored. It is characterized by that.

  (1) A light-receiving surface side sealing material made of a transparent material and a light-shielding material is disposed on a light-transmitting substrate.

  (2) A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.

  (3) While electrically connecting the said solar cell element group by wiring, non-transparent wiring is provided in the peripheral part of a solar cell element group among this wiring.

  (4) A back surface side sealing material is disposed on the solar cell element group.

  (5) A whitened or colored back surface protective material is disposed on the back surface side sealing material.

  According to the present invention, in the solar cell module in which the non-transparent wiring is provided in the peripheral portion of the solar cell element group among the wirings for electrically connecting the solar cell elements, the solar cell element group is disposed at a portion facing the solar cell element group. The light-receiving surface side sealing material portion is made of a light-shielding material that is whitened or colored, thereby hiding the non-transparent wiring, thereby obtaining a solar cell module having a good light-receiving surface-side appearance. It was possible to harmonize with the mounting body on which the solar cell module is installed, for example, a house, a building, and the surrounding environment.

  Further, according to the present invention, the light receiving surface side sealing material portion disposed in the portion facing the solar cell element group is made of a transparent material, and the light receiving surface side disposed in the portion facing the peripheral portion of the solar cell element group. By integrating the sealing material part with a whitened or colored light-shielding material, the light-receiving surface side sealing material part that is transparent and the light-receiving surface side sealing that has light shielding properties such as coloring The boundary between the two parts with the stop material portion was almost linear, and in this respect, it was possible to achieve a good finish with a good appearance.

  Furthermore, according to the manufacturing method of the present invention, in the step (1), it is only necessary to arrange the light-receiving surface side sealing material made of a transparent material and a light-shielding material on the translucent substrate. The set time when setting a laminated member consisting of a translucent substrate, a light-receiving surface side sealing material, a solar cell element group, a back surface side sealing material and a back surface protection material can be shortened. Cost was reduced.

  Furthermore, according to the solar cell module and the solar cell module installation structure of the present invention, the back surface side sealing material or the back surface protection material is colored white or other various types, so that the color tone of the solar cell module itself can be The decorativeness can be set as required, and as a result, it was possible to achieve harmony with the building and roof where this solar cell module is installed.

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

  FIG. 1 is a schematic cross-sectional view showing the main structure of a solar cell panel section in the solar cell module of the present invention. FIG. 2 is an external view of the light receiving surface side of the solar cell module.

  In FIG. 1, 11 is a translucent substrate, and on this translucent substrate 11, the transparent light-receiving surface side filling as a light-receiving surface side sealing material part arrange | positioned in the site | part facing the said solar cell element group is carried out. A material 12a is provided. Further, a light-receiving surface side filler 12b that is colored or whitened to make it light-shielding is disposed as a light-receiving surface side sealing material portion disposed in a portion facing the peripheral portion of the solar cell element group. And it is the structure which distribute | arranged the solar cell element group which arranges the several solar cell element 13 on them, the back surface side filler 14 which is the said back surface side sealing material, and the back surface protection material 15 in order.

  According to this example, a plurality of solar cell elements 13 are arranged in a matrix to form a solar cell element group. According to this arrangement, the solar cell elements 13 arranged in a line in the vertical direction are connected. A so-called lateral wiring 17 connected by the wiring 16 and further connecting these connecting wirings 16 is provided around the solar cell element group.

  Thus, the translucent substrate 11, the light-receiving surface side fillers 12a and 12b, the plurality of solar cell elements 13 (solar cell element group) connected by the lateral wiring 17 and the connection wiring 16, the back surface side filler 14, and the back surface The protective material 15 is laminated in this order, set in a device called a laminator, and pressed and integrated while heating under reduced pressure.

  According to the solar cell module shown in FIG. 2, the module frame 18 is attached to the outer peripheral portion of the solar cell panel portion shown in FIG. 1, the corner portion is screwed, and the module frame 18 is fixed.

  In this solar cell module, the lateral wiring 17 is provided in order to match the arrangement of the solar cell elements 13 (solar cell element group) with the outer dimensions of the solar cell module. On the other hand, in FIG. 1 and FIG. 2, the coupling wiring (corresponding to the coupling wiring 9 shown in FIG. 6) is not clearly shown, but the plurality of solar cell elements 13 connected in series or in parallel with respect to this coupling wiring. In the solar cell element at the end of the (solar cell element group), it is provided to connect the connection wires 16 having the same polarity.

  These lateral wiring 17 and coupling wiring are usually cut to the required length by soldering the entire surface using copper foil having a thickness of about 0.1 to 0.3 mm and a width of about 2 to 7 mm. Used.

  Next, each member is explained in full detail about the solar cell module of the said structure.

  As the translucent substrate 11, a substrate made of a synthetic resin material such as a glass material or a polycarbonate resin is used.

  As the glass plate, white plate glass, tempered glass, double tempered glass, heat ray reflective glass and the like are used, but generally white plate tempered glass having a thickness of about 3 mm to 5 mm is used.

  On the other hand, when a substrate made of a synthetic resin such as polycarbonate resin is used, a substrate having a thickness of about 5 mm is used.

  The light receiving surface side fillers 12a and 12b and the back surface side filler (back surface side sealing material) 14 are made of an ethylene-vinyl acetate copolymer (hereinafter, ethylene-vinyl acetate copolymer is abbreviated as EVA), and have a thickness. The sheet-like form of about 0.4 to 1 mm is used. These are fused and integrated with other members by applying heat and pressure under reduced pressure using a laminating apparatus.

  In addition, with respect to the light receiving surface side fillers 12a and 12b and the back surface side filler 14, the vinyl acetate content is preferably 10% by weight or more and less than 40% by weight, and most preferably 20 to 30% by weight.

  If the content of vinyl acetate is less than 10% by weight, the melting point becomes high and it may be difficult to process into a sheet. On the other hand, if it is 40% by weight or more, it is not preferable in that the EVA sheet after molding becomes highly fluid.

  The light receiving surface side filling material 12a is a transparent light receiving surface side sealing material portion laminated on the solar cell element 13, whereas the light receiving surface side filling material 12b is made of a white or colored light shielding material. . That is, all or part of the portion not facing the solar cell element 13 is whitened or colored.

  In this example, as shown in FIG. 2, in the rectangular solar cell element group, the light receiving surface side fillers 12b are arranged in a strip shape along the opposite sides.

  The width of the light receiving surface side filler 12b is substantially the same as the dimensions of the end portions of the solar cell element 13 and the translucent substrate 11 in the portion where the lateral wiring 17 and the coupling wiring are present, or is received during lamination. Considering the spread when the surface-side filler 12a is melted, it may be about 2 to 10 mm smaller than this dimension.

  In the EVA constituting the light receiving surface side filler (light receiving surface side sealing material portion) 12a, the amount of light incident on the solar cell element 13 is reduced by coloring, so that the power generation efficiency tends to decrease. And However, it may be colored as long as the transparency is maintained.

  The light-receiving surface-side filler (light-receiving surface-side sealing material portion) 12b is colored in a required color by containing EVA with titanium oxide or a known pigment. As a result, the lateral wiring 17 and the coupling wiring (not shown) which are the non-transparent wiring can be covered and made invisible from the light receiving surface side, and as a result, the appearance of the solar cell module is improved. Can do.

  The solar cell element 13 is made of single crystal silicon or a polycrystalline silicon substrate having a thickness of about 0.3 to 0.4 mm. A PN junction is formed inside the substrate, electrodes are provided on the light receiving surface and the back surface, and an antireflection film is provided on the light receiving surface.

  The size of the substrate is about 100 to 150 mm square in a polycrystalline silicon solar cell, and a plurality of such solar cell elements 13 are connected in series or in parallel by connection wirings 16 such as copper foil. Connected to form a solar cell element group.

  About the connection wiring 16, the solar cell elements are electrically connected to each other. Usually, a copper foil having a thickness of about 0.1 mm and a width of about 2 mm is used, and the entire surface of the copper foil is solder coated. It is cut into a required length and soldered onto the electrode of the solar cell element 13 for use.

  The back surface side filler (back surface side sealing material) 14 may be formed of a transparent material such as EVA, but the EVA may contain titanium oxide, a pigment, or the like, thereby coloring it to a required color. . That is, the color tone of the back surface side filler 14 may be a color tone harmonized with the building where the solar cell module is installed and the surrounding environment.

  In particular, in a solar cell module that is installed in a place that is not very visible such as the roof of a building or the roof of a factory, the solar cell element 13 such as a gap between the solar cell element 13 and the solar cell element 13 of the solar cell module. It is preferable to improve the power generation efficiency by reflecting the light incident on the non-existing portion and reflecting the reflected light again on the light-transmitting substrate 11 and entering the solar cell element 13. In this respect, it is preferable to whiten the light so that the light is easily reflected (so that light is not easily absorbed or transmitted).

  Moreover, about the back surface side filler 14 which concerns on this invention, by putting a conventionally well-known pigment in EVA resin and coloring, the mounting body which fixes a solar cell module, for example, the wall of a building, a roof, etc. Harmony in terms of color can be achieved.

  For example, by making white with titanium oxide or the like, the light incident on the gap between the solar cell element 13 and the solar cell element 13 can be reflected by the white EVA resin, and the reflected light is again It can reflect on the surface of translucent board | substrates 11, such as glass, can enter into the solar cell element 13, and can improve the power generation efficiency of the solar cell element 13. FIG.

  Such a light reflection effect can also be obtained by forming the back surface side filler 14 as a transparent material and making the inner surface of the back surface protective material 15 white. Is close to the surface of the translucent substrate 11, a great effect is obtained.

  In addition, about the point of such power generation efficiency improvement, although it is desirable to whiten the back surface side filler 14, if it is a color tone which can obtain light reflectivity other than white, for example, yellow, green, It may be colored light blue.

  As the back surface protective material 15, a weather-resistant fluorine-based resin sheet in which an aluminum foil is sandwiched so as not to transmit moisture, a polyethylene terephthalate (PET) sheet in which alumina or silica is deposited, and the like are used.

  In particular, the back surface protection material 15 using PET resin is annealed before use, so there is almost no heat shrinkage at the time of lamination, and wrinkles or the like are generated at the time of lamination with the back surface side filler 14. This is preferable in that it does not occur.

  For example, in the case of using a PET resin material, a three-layer structure is preferable, and the innermost side (the surface side in contact with the back surface side filler) is whitened or colored with a PET resin material such as titanium oxide. Pigment is added and its thickness is 50 μm. On the outside, a 12-μm thick PET sheet deposited with silica is pasted. This is because silica is vapor-deposited only on one side between the inner white PET resin material. On the outside, a PET sheet having a hydrolysis resistance of 50 μm is used so that the PET resin does not hydrolyze due to rain or the like.

  The back surface protective material 15 is made of a weather-resistant fluorine-based resin sheet sandwiched with an aluminum foil so as not to transmit moisture, or a polyethylene terephthalate (PET) sheet deposited with alumina or silica.

  As described above, the solar cell element 13 connected to the translucent substrate 11, the transparent light receiving surface side filler 12a, the white or colored light receiving surface side filler 12b, the connection wiring 16 that connects the lateral wiring 17, and the like, The back surface side filler 14 and the back surface protection material 15 are sequentially laminated, set in a device called a laminator, pressed and integrated while heating under reduced pressure, to produce a solar cell panel.

  Next, the module frame 18 is attached to the four sides of the integrated solar cell panel. The module frame 18 is made of an aluminum metal material or a synthetic resin in consideration of the strength and cost required for the solar cell module.

  In the case of producing an aluminum metal material, the aluminum material is extruded and anodized or clear-coated on the surface.

  Furthermore, a solar cell module is completed by attaching a terminal box (not shown) for connecting the solar cell element to an external circuit on the back side of the solar cell panel with an adhesive.

  Hereinafter, in the solar cell module and the installation structure of the solar cell module of the present invention, improvement of the aesthetics will be described.

  According to the solar cell module of the present invention, the light receiving surface side sealing material 12 (the light receiving surface side filler 12a and the light receiving surface side filler 12b) and the white or colored back surface side filler 4 are fused. And the fusion | melting part is filled with the clearance gap between each solar cell element 13, and the clearance gap between the module frame 18 and the solar cell element 13. As shown in FIG. In this example, it is called a filling part.

  Such a filling portion is a combination of the light receiving surface side filler 12 (particularly, the light receiving surface side filler 12a) and the colored or whitened back surface side filler (back surface side sealing material) 14.

  According to the present invention, in coloring the light receiving surface side filler 12b and the filling portion, the light receiving surface side appearance, the mounting body on which the solar cell module is installed, for example, a house or a building, and the surrounding environment are harmonized. You just have to decide the color tone.

  By the way, an antireflection film (not shown) is formed on the light-receiving surface side of the silicon crystal solar cell element 13 in order to reduce light reflection as much as possible. , Often black.

  When a solar cell module is produced using these, if a transparent material is used for the back surface side filler 14 and a white material is used for the back surface protective material 15, the space between the solar cell elements 13 such as blue When this was installed on the rooftop of a building or the like, the white color between the solar cell elements 13 was conspicuous, and the appearance of the entire building was sometimes deteriorated.

  On the other hand, for example, when the light receiving surface side filler 12b and the filling portion (back surface side filler 14) have a color tone substantially similar to or similar to that of the light receiving surface of the solar cell element 13, the solar cell module may stand out. This eliminates the harmony between the solar cell module and the building.

  Furthermore, when the color tone of the outer wall or roof portion of the building is brown, green, gray, magenta, etc., the refractive index and film thickness of the antireflection film of the solar cell element 13 described above are adjusted corresponding to these color tones. By doing so, the color of the light receiving surface of the solar cell element 13 can be made brown, green, gray, and magenta, and the light receiving surface side filler 12b and the filling portion (back surface side filler 14) according to these colors. Can be colored as desired, and can be harmonized with the building where the solar cell module is installed, thereby enhancing its decorativeness.

  The antireflection film is provided, for example, during the production of a solar cell element.

  That is, the antireflection film provided on the light-receiving surface of the solar cell element is, for example, an electrode formed after thermally diffusing N-type impurities such as phosphorus on a P-type solar cell silicon substrate to form a PN junction. Film is formed before performing.

  For example, silicon nitride is used for the antireflection film. This silicon nitride film is formed using a plasma CVD apparatus using monosilane gas, ammonia gas, or the like as a source gas. Such a layer is, for example, a single layer film.

  The color tone when such a silicon nitride film is formed on a polycrystalline silicon substrate is determined by its refractive index and film thickness. That is, when forming a silicon nitride film, the gas CVD plasma conditions (generally increasing the ratio of monosilane gas increases the refractive index of the silicon nitride film formed) and the film formation time. The film thickness can be determined, and various colors can be produced as required.

  Further, according to the present invention, in order to improve the decorativeness in this way, when the back surface side filler 14 is colored, the melt flow rate of the light receiving surface side filler 12 made of EVA is changed to the back surface made of EVA. By making it larger than the melt flow rate of the side filler 14, bubbles and voids are not left inside the solar cell module, and the appearance can be further improved.

  In addition, according to the filling part as described above, the transparent light-receiving surface side filler 12a and the colored or whitened back surface side filler 14 are described in combination. Even if the light receiving surface side filler 12 and the transparent back surface side filler 14 are further combined with a whitened or colored back surface protective material 15, the same effects can be obtained.

  Other decoration examples will be described.

  The color tone to be colored is the same or the same color tone as the color tone of the back surface side filler 14 or the back surface protection material 15, so that the color tone of the entire solar cell module can be unified and the appearance is good. desirable.

  For example, when the back surface side filler 14 is transparent and the back surface protection material 15 is blue, it can be seen between the solar cell element 13 and the solar cell element 13 or between the solar cell element 13 and the module frame 18 at the end. Is the blue color of the back surface protection material 15. In this case, the color tone of the light-receiving surface side filler 12b can be unified with the same color tone as that of the back surface protection material 15 or the same color as the amber or sky blue color of the back surface protection material 15. When the back side filler 14 is red, the back side filler 14 is visible between the solar cell element 13 and the solar cell element 13 or between the solar cell element 13 and the module frame 18 at the end. It becomes red. In this case, the color tone of the solar cell module can be unified by setting the color tone of the light receiving surface side filler 12b to the same red color as the back surface side filler material 14 or the same color orange or pink color.

(Method for manufacturing solar cell module)
Next, the production direction of the present invention will be described.

  The manufacturing method of the solar cell module of the present invention goes through the steps (1) to (5) sequentially as follows, and the laminate obtained thereby is heated and pressurized under reduced pressure.

  In addition, according to the manufacturing method of the present invention, the light-receiving surface side sealing material portion disposed in the portion facing the solar cell element group is made of a transparent material and disposed in the portion facing the peripheral portion of the solar cell element group. The light-receiving surface side sealing material portion is heated and pressed under reduced pressure so as to be formed of a light-shielding material, and integrated.

  (1) Process: The light-receiving surface side sealing material which consists of a transparent material and a light-shielding material is distribute | arranged on a translucent board | substrate.

  That is, on the rectangular translucent substrate 11, a rectangular light-receiving surface-side filler 12a made of an ethylene-vinyl acetate copolymer (EVA resin) and a strip-shaped light-receiving surface-side filler 12b are disposed. The light receiving surface side filler 12b is disposed on the opposite side of the light receiving surface side filler 12a.

  (2) Step: A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.

  That is, a plurality of solar cell element groups in which a plurality of solar cell elements are arranged in a row are arranged on the light receiving surface side sealing material composed of the light receiving surface side filler 12a and the light receiving surface side filler 12b.

  (3) Step: The solar cell element group is electrically connected, for example, by a wiring such as the connection wiring 16, and a non-transparent wiring, for example, a lateral wiring 17 or a coupling wiring (not shown) among these wirings. It is provided at the periphery of the solar cell element group.

  (4) Process: The back surface side sealing material whitened or colored is arranged on the said solar cell element group.

  That is, the rectangular backside filler 14 made of EVA resin that is whitened or colored is disposed on the solar cell element group.

  (5) Process: The back surface protective material 15 is disposed on the back surface side sealing material (back surface side filler 14).

  Through the above steps, the light-transmitting substrate 11, the light-receiving surface side sealing material 12 (light-receiving surface-side filler 12a and light-receiving surface-side filler 12b), solar cell element group, back surface-side filler 14 and back surface The laminated body of the protective material 15 is bonded and integrated, but it is desirable that the EVA resin does not protrude from the translucent substrate 11 when each member is laminated before such lamination.

  Therefore, the back surface side filler 14 is arranged so as to cover the light receiving side filler material 12, but the peripheral edge portion of the back surface side filler material 14 is further arranged inside the peripheral edge portion of the translucent substrate 11. And it laminates | stacks so that the peripheral edge part of the light-receiving surface side sealing (filling) material 12 may be arrange | positioned inside the peripheral edge part of the back surface side filler 14.

  After such lamination, the laminate is set in a device called a laminator that is heated and pressurized in a depressurized state, and then depressurized to about 50 to 150 Pa in order to remove the air inside the solar cell module. Pressurize while heating at a temperature of ˜200 ° C. for 15 minutes to 1 hour. As a result, the light receiving surface side filler 12 and the back surface side filler 14 were softened and fused, so that the respective members were bonded and integrated, and the panel portion of the solar cell module could be produced.

  Next, a module frame (not shown) is attached to the four sides of the integrated solar cell panel, and a terminal box (not shown) is attached to the back side of the solar cell panel with an adhesive, whereby the solar cell. The module is complete.

  Thus, according to the solar cell module of the present invention, the non-transparent wirings such as the lateral wirings 17 and the coupling wirings (not shown) are blocked by the light-receiving surface-side filler (light-receiving surface-side sealing material portion) 12b. By covering, it can be made invisible from the light receiving surface side, further colored as desired, can enhance the decorativeness and beauty of the solar cell module, and as a result, a mounting body for installing the solar cell module, for example, It was possible to harmonize with the home, building, and surrounding environment.

  Further, according to the manufacturing method of the present invention, in the step (1), the light receiving surface side filler 12 (the light receiving surface side filler 12a and the light receiving surface side filler 12b) is disposed on the translucent substrate 11. When the laminated member which consists of the translucent board | substrate 11, the light-receiving surface side filler 12, the solar cell element group, the back surface side sealing material (filler) 14, and the back surface protection material 15 is set to a laminator. The set time can be shortened, thereby reducing the manufacturing cost.

  According to the above-described example of the present invention, the light receiving surface side sealing material portion disposed in the portion facing the peripheral portion of the solar cell element group is made of the light shielding material, so that the object of the present invention can be achieved. However, such a light shielding material may have various other configurations.

  For example, a light-shielding metal plate or ceramic plate may be disposed in a portion facing the peripheral portion of the solar cell element group, and thereby whitened or colored.

(Other manufacturing method of solar cell module)
Next, another production direction of the present invention will be described.

  According to the manufacturing method described above, in the step (4), the back surface side sealing material that is whitened or colored is disposed on the solar cell element group. A back-surface protective material that has been colored or colored is used.

  Although the manufacturing method of the other solar cell module of this invention goes through each process (1)-(5) sequentially as follows, the laminated body obtained by this is heat-pressed under pressure reduction.

  In addition, according to the manufacturing method of the present invention, the light-receiving surface side sealing material portion disposed in the portion facing the solar cell element group is made of a transparent material and disposed in the portion facing the peripheral portion of the solar cell element group. The light-receiving surface side sealing material portion is heated and pressed under reduced pressure so as to be formed of a light-shielding material, and integrated.

  (1) Process: The light-receiving surface side sealing material which consists of a transparent material and a light-shielding material is distribute | arranged on a translucent board | substrate.

  That is, on the rectangular translucent substrate 11, a rectangular light-receiving surface-side filler 12a made of an ethylene-vinyl acetate copolymer (EVA resin) and a strip-shaped light-receiving surface-side filler 12b are disposed. The light receiving surface side filler 12b is disposed on the opposite side of the light receiving surface side filler 12a.

  (2) Step: A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.

  That is, a solar cell element group in which a plurality of solar cell elements are arranged in a row is arranged on the light-receiving surface side sealing material composed of the light-receiving surface-side filler 12a and the light-receiving surface-side filler 12b.

  (3) Step: Each solar cell element group is electrically connected by, for example, a wiring such as the connection wiring 16, and a non-transparent wiring, for example, a lateral wiring 17 or a coupling wiring (not shown) among these wirings. Provided in the periphery of each solar cell element group.

  (4) Process: A back surface side sealing material is disposed on the solar cell element group.

  That is, the rectangular back surface side filler 14 made of transparent EVA resin is disposed on the solar cell element group.

  (5) Process: The back surface protective material 15 that has been whitened or colored is disposed on the back surface side sealing material (back surface side filler 14).

  Through the above steps, the light-transmitting substrate 11, the light-receiving surface side sealing material 12 (light-receiving surface-side filler 12a and light-receiving surface-side filler 12b), solar cell element group, back surface-side filler 14 and back surface The laminated body by the protective material 15 is bonded and integrated.

  After such lamination, the laminate is set in a device called a laminator that is heated and pressurized in a depressurized state, and then depressurized to about 50 to 150 Pa in order to remove the air inside the solar cell module. Pressurize while heating at a temperature of ˜200 ° C. for 15 minutes to 1 hour. As a result, the light receiving surface side filler 12 and the back surface side filler 14 were softened and fused, so that the respective members were bonded and integrated, and the panel portion of the solar cell module could be produced.

  Next, a module frame (not shown) is attached to the four sides of the integrated solar cell panel, and a terminal box (not shown) is attached to the back side of the solar cell panel with an adhesive, whereby the solar cell. The module is complete.

  Next, another example of the present invention will be described.

  An example of the light-shielding material formed by extending the light-receiving surface side sealing material portion disposed in the portion facing the solar cell element group and forming the light-shielding portion in the extended portion will be described with reference to FIGS.

  FIG. 3 is a schematic cross-sectional view showing an enlarged main part showing the end of the light-receiving surface side sealing material, and FIG. 4 is a solar cell in the solar cell module of the present invention using such light-receiving surface side sealing material. It is a schematic sectional drawing which shows the main structures of a panel part. In addition, the same code | symbol is attached | subjected to the same location as the solar cell module shown in FIG. 1 and FIG.

  In the solar cell module shown in FIG. 1 and FIG. 2 described above, the light receiving surface side filler 12b is provided as a light shielding material in addition to the light receiving surface side filler 12a, but instead of this, the light receiving surface side filler 20a. The light shielding portion 20b is formed in the extending portion.

  Such a light receiving surface side filler 20a is a light receiving surface side sealing material that becomes transparent by polymerization crosslinking, such as a synthetic resin such as EVA, and the light shielding portion 20b includes such a synthetic resin containing a pigment or the like. It is a colored light-receiving surface side sealing material.

  The light shielding part 20b colored in this way may be made of the same material as the light receiving surface side filler 12b described above.

  Further, the colored light-shielding portion 20b is cut into a strip shape, and the light-shielding portion 20b is fused in advance to a predetermined position at the end of the light-receiving surface-side filler 20a that is transparent. This fusion is, for example, ultrasonic fusion or thermal fusion.

  And in the (1) process of the manufacturing method mentioned above, the light-receiving surface side filler 20a which the light-shielding part 20b was fuse | melted in that way on the translucent board | substrate 11 is distribute | arranged. Other manufacturing processes are as described above.

  In this example, the size of the light-receiving surface-side filler 20a that is transparent is the same as the size of the light-transmitting substrate 11, or the light-receiving surface-side filler 20a spreads due to the influence of heating and pressing in the laminating apparatus. As a result, the size is made about 2 to 10 mm smaller than the translucent substrate 11.

  Further, the width of the colored light-shielding portion 20b is also the same as the dimension between the outermost solar cell element 13 and the translucent substrate 11, or is reduced by about 2 to 10 mm in consideration of the spread in the laminate.

  Such a translucent substrate 11, a transparent light-receiving surface-side filler 20a, a colored light-shielding portion 20b, a solar cell element 13 connected to a connection wiring 16 that connects the lateral wiring 17, etc., a back-side filler 14; The back surface protection material 15 is laminated | stacked one by one, is set to a laminator, presses and integrates, heating under reduced pressure, and produces a solar cell panel.

  Thus, also in the solar cell module of the present invention, the non-transparent wiring such as the lateral wiring 17 and the coupling wiring (not shown) can be covered with the light shielding portion 20b so as to be invisible from the light receiving surface side. In coloring the portion 20b and the filling portion, it is only necessary to determine the color tone in harmony with the light-receiving surface side appearance and the mounting body on which the solar cell module is installed, such as a house or building, and the surrounding environment. As a result, the decorativeness and aesthetics of the solar cell module can be improved, and the mounting body on which the solar cell module is installed, for example, a house or a building, and the surrounding environment can be harmonized.

  Further, according to the manufacturing method of the present invention, the light receiving surface side sealing material 20 (the light receiving surface side filler 20a and the light shielding portion 20b) is simply disposed on the translucent substrate 11 in the step (1). Since it is good, when setting the laminated member which consists of the translucent board | substrate 11, the light-receiving surface side sealing material 20, the solar cell element group, the back surface side sealing material (filler) 14, and the back surface protection material 15 to a laminator. The set time could be shortened, thereby reducing the manufacturing cost.

  Furthermore, as described above, when the member is set on the laminator by using the one in which the colored light-shielding portion 20b is previously fused on the end portion of the light-receiving surface-side filler 20a that is transparent, Compared to the step of separately setting the light receiving surface side filler 12a and the colored light receiving surface side filler 12b separately, the time can be shortened.

  Further, according to this example, in the finished state of the solar cell panel after lamination, as shown in FIG. 1, when the light-receiving surface side filler 12a that is transparent and the colored light-receiving surface side filler 12b are arranged side by side, Since EVA is softened and melted by heating and pressurization under reduced pressure in a laminator, the transparent light receiving surface side filler 12a and the colored light receiving surface side filler 12b are interlaced with each other, and the boundary is a clean straight line. In other words, the finished state may not be good. However, according to this example, since the colored light-shielding portion 20b is disposed on the end portion of the light-receiving surface-side filler 20a that is transparent, the upper surface of the light-shielding portion 20b colored in the state before lamination and the sun Even when EVA is softened and melted in the lamination, the movement of the colored light-shielding portion 20b is blocked, and the solar cell after lamination is obtained. When the panel portion is viewed from the light-receiving surface portion, the boundary between the transparent light-receiving surface-side filler 20a and the colored light-shielding portion 20b is a clean straight line, and a satisfactory finish can be achieved.

  As the translucent substrate 11, a rectangular white plate tempered glass having a size of 1280 × 980 mm and a thickness of 3.2 mm is used, and a light receiving surface side filler 12a and a light receiving surface side filler as shown in FIGS. A rectangular light receiving surface side sealing material 12 (1274 × 974 mm, thickness of about 0.9 mm) made of 12b is placed.

  On top of this, 48 polycrystalline silicon solar cell elements of approximately 150 mm square are connected in series with a copper foil solder coated on the surface and placed in place.

  Then, the solar cell elements 13 arranged in a line in the vertical direction are connected by connection wirings 16 to form solar cell elements, and lateral wirings 17 further connecting these connection wirings 16 are connected to the solar cell element group. Provide around. And in the solar cell element of the edge part of the several solar cell element 13 (solar cell element group) connected in series or in parallel, it provides in order to connect the connection wiring 16 with the same polarity by coupling wiring.

  A rectangular-shaped back side filler 14 that is whitened or colored is placed thereon. The back side filler 14 has a size of 1277 × 977 mm and a thickness of 0.7 mm.

  Further, a rectangular back surface protective material 15 is placed thereon. The back surface protective material 15 was a polyethylene terephthalate (PET) sheet having a size of 1280 × 980 mm and vapor-deposited silica.

  The superposed one is set in a laminator, and after reducing the pressure to about 100 Pa, pressurizing while heating at 140 ° C. for 10 minutes, and then heating to 150 ° C. for 45 minutes to produce a crosslinked solar cell module, The condition of the solar cell module after lamination was examined.

  And according to such a solar cell module, the light-receiving surface side filler (light-receiving surface side sealing material) 12 that is transparent after polymerization crosslinking is used, but the other back surface-side filler (light-receiving surface side) About the sealing material 14 and the light-receiving surface side filler 12a, what was colored as needed was used.

  According to this solar cell module, the light receiving surface side filler 12 and the back surface side filler 14 do not protrude from the translucent substrate 11, and the solar cell element 13 is cracked or chipped by pressurization during lamination. Further, there was no deterioration in adhesiveness, and the finish was very good.

  And it fixed on the outer wall and roof of the building which is the above-mentioned mounting body, colored the back surface side filler 14, and aimed at harmony with the building which installs a solar cell module, and was able to improve the decorating property. .

  For example, the antireflection film formed on the light receiving surface side of the silicon crystal solar cell element 13 is colored in various colors of blue, amber and black, and further filled with the back surface side filler 14 and the light receiving surface side. About the material 12a, the conventionally well-known pigment etc. were mixed, and it was able to improve the external appearance and the decoration property by coloring blue, amber, and black similarly to the said filling part and light-shielding material.

  When the solar cell module of Example 1 is fixed to the outer wall or roof of the building, which is the above described object, when the color of the outer wall or roof portion of the building is brown, green, gray, magenta, etc. The color of the light receiving surface of the solar cell element 13 is brown, green, gray, red purple, or the like by adjusting the refractive index and film thickness of the antireflection film of the solar cell element 13 corresponding to the color tone of In addition, the back side filler 14 and the light receiving side filler 12a are colored as desired by mixing conventionally known pigments or the like in accordance with these color tones, and as a result, the solar cell module is installed. In harmony with the outer walls and roof of the building, the decoration was improved.

  For example, the back surface side filler 14 and the light receiving surface side filler 12a may be brown, green, gray, magenta, or a color tone similar to them.

  About Example 1 and Example 2, it is said that aesthetics and decorativeness can be obtained by making the same color tone, but instead, the light receiving surface side filler 12a, the mounting body, and the solar cell element Depending on the preference of the four sides of the 13 surfaces (antireflection film) and the back surface side filler 14 (filling portion), various color tones may be set. And while maintaining harmony in the color tone in this way, the hue may be matched to enhance the beauty and decoration.

  For example, the antireflection film of the solar cell element is made magenta, and the color of the back surface side filler and the light receiving surface side filler 12a used for the solar cell module is made red and the whole color tone is made red, A chic feeling may be produced by installing the solar cell module on a black roof of a house.

  Alternatively, a brown solar cell module as a whole may be installed on the roof of a green house to give a calm feeling.

  Furthermore, when the white or bright back side sealing material 14 (filling portion) or the light receiving surface side filling material 12a is used, the light reflection increases there, and the power generation efficiency of the solar cell module increases. Can be made more effective in terms of design.

  For example, when a gray solar cell element is used and a white back surface side filler 14 (filling portion) or a light receiving surface side filler 12a is used, the back surface side filler 14 or the light receiving surface is interposed between the gray solar cell elements. Although the white color of the side filler 12a can be seen, the color of the concrete material constituting the mounting body is close to gray, so that the solar cell module can be harmonized without being raised or protruding.

  In addition, this invention is not limited to the said embodiment, A various change, improvement, etc. do not interfere at all within the scope of the present invention.

  For example, the solar cell element is not limited to a crystalline solar cell such as single crystal or polycrystalline silicon, but can be applied to a thin film solar cell.

  Further, in this example, as shown in FIG. 2, in the rectangular solar cell element group, the light receiving surface side fillers 12b are respectively arranged in a strip shape along the opposite side, but instead of this, a rectangular shape is used. The structure which forms the frame shape corresponding to a solar cell panel of a shape may be sufficient.

  Moreover, although it demonstrated with the rectangular-shaped solar cell module, solar cell modules, such as a trapezoid, a triangle, a hexagon, etc. which are suitable for a ridge roof etc. besides this, may be sufficient.

  Furthermore, the color tone of the mounting body, the surface of the solar cell element 13 (antireflection film), the back surface side filler 14 (filling portion), and the light shielding material (light receiving surface side filler 12a) has been described above. The embodiment is merely an example, and in addition to these, various colors may be used, and various selections can be made according to the user's preference.

It is a schematic sectional drawing which shows an example of the structure of the solar cell panel part of the solar cell module of this invention. It is a top view which shows an example of the external appearance by the side of the light-receiving surface of the solar cell module of this invention. It is another example which concerns on the solar cell module of this invention, and is a principal part enlarged view which shows the edge part of the light-receiving surface side sealing material. It is a schematic sectional drawing which shows an example of the structure of the solar cell panel part of the other solar cell module of this invention. It is a schematic sectional drawing which shows an example of the structure of the solar cell panel part of the conventional solar cell module. It is a top view which shows an example of the external appearance by the side of the light-receiving surface of the conventional solar cell module.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 11 ... Translucent board | substrate 2 ... Light-receiving surface side filler 3, 13 ... Solar cell element 4, 14 ... Back surface side filler 5, 15 ... Back surface protective material 6, 16 ... Connection wires 7, 17 ... Horizontal wires 8, 18 ... Module frame 9 ... Coupling wires 12a, 12b, 20a ... Light-receiving surface side filler 20b ... Light shielding part

Claims (5)

A light-receiving surface side sealing material, a solar cell element group in which a plurality of solar cell elements are arrayed, a whitened or colored back side sealing material and a back surface protective material are sequentially laminated on a light-transmitting substrate, Of the wirings for electrically connecting the solar cell elements, non-transparent wiring is provided in the peripheral part of the solar cell element group, and the light-receiving surface side sealing material portion disposed in the part facing the solar cell element group is transparent A solar cell module comprising: a light-receiving surface side sealing material portion disposed in a portion facing the peripheral portion of the solar cell element group, and a light-shielding material that is whitened or colored. A light-receiving surface side sealing material, a solar cell element group in which a plurality of solar cell elements are arranged, a transparent back surface side sealing material, and a whitened or colored back surface protection material are sequentially laminated on a translucent substrate. And a non-transparent wiring among the wirings for electrically connecting the respective solar cell elements, and a light-receiving surface side sealing material portion disposed in a portion facing the solar cell element group. Is formed of a transparent material, and a light-receiving surface side sealing material portion disposed in a portion facing the periphery of the solar cell element group is formed of a light-shielding material that is whitened or colored. . 2. The light-shielding material is formed by extending a light-receiving surface side sealing material portion disposed at a portion corresponding to the solar cell element group, and forming a light-shielding portion in the extended portion. 2. The solar cell module according to 2. After sequentially passing through the following steps (1) to (5), heating and pressurizing under reduced pressure, and forming a light-receiving surface side sealing material portion disposed in a portion facing the solar cell element group with a transparent material, A method for manufacturing a solar cell module, wherein a light-receiving surface side sealing material portion disposed in a portion facing a peripheral portion of a solar cell element group is integrated by being formed of a whitened or colored light-shielding material .
(1) A light-receiving surface side sealing material made of a transparent material and a light-shielding material is disposed on a light-transmitting substrate.
(2) A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.
(3) While electrically connecting the said solar cell element group by wiring, non-transparent wiring is provided in the peripheral part of a solar cell element group among this wiring.
(4) A whitened or colored back side sealing material is disposed on the solar cell element group.
(5) A back surface protective material is disposed on the back surface side sealing material. After sequentially passing through the following steps (1) to (5), heating and pressurizing under reduced pressure, and forming a light-receiving surface side sealing material portion disposed in a portion facing the solar cell element group with a transparent material, A method for manufacturing a solar cell module, wherein a light-receiving surface side sealing material portion disposed in a portion facing a peripheral portion of a solar cell element group is integrated by being formed of a whitened or colored light-shielding material .
(1) A light-receiving surface side sealing material made of a transparent material and a light-shielding material is disposed on a light-transmitting substrate.
(2) A plurality of solar cell element groups in which a plurality of solar cell elements are arranged on the light receiving surface side sealing material are arranged.
(3) While electrically connecting the said solar cell element group by wiring, non-transparent wiring is provided in the peripheral part of a solar cell element group among this wiring.
(4) A back surface side sealing material is disposed on the solar cell element group.
(5) A whitened or colored back surface protective material is disposed on the back surface side sealing material.

Images