JP2006032811A - Solar battery element/solar-battery-module manufacturing method, and the solar battery module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar battery module wherein the faultiness of its external appearance is eliminated, and its characteristics are not degraded in its long-term reliability test. <P>SOLUTION: In the solar battery module, there are performed continuously a processing for forming a resin film 2 made of fluororesin on the surface of the side of the light-receiving surface of a solar battery element and a processing for so further temporarily laminating a sheet-form EVA thereon as to form an adhesive layer 3. Then, by the resin film 2, a water, etc. permeated its upper-layer portion can be prevented from reaching the solar battery element. As a result, peeling of its laminated portion, etc. can be so prevented as not to generate the faultiness of its external appearance too. Also, since the rigidity of the solar battery element is improved by the adhesive layer so formed as to laminate temporarily the sheet-form adhesive on it, its deformation such as curling can be prevented from occurring, when the solar battery element is cut. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a solar cell element / solar cell module comprising a thin film solar cell, and a solar cell module.

  At present, solar energy is attracting attention as clean energy, and research and development of solar cells that convert the light energy into electric energy is being promoted. Among them, thin film solar cells are considered to become the mainstream in the future because they are thin and light in the form of a film substrate and can have a large capacity. In this thin film solar cell, for example, a photoelectric conversion element, a transparent electrode, and a connection electrode made of an amorphous silicon (a-Si) thin film semiconductor layer are patterned on a flexible plastic sheet substrate (for example, Patent Document 1). reference).

  FIG. 4 is a perspective view showing a configuration example of such a thin film solar cell. The thin film solar cell (solar cell element) includes a plastic substrate 41, an amorphous silicon photoelectric conversion layer 42, a transparent electrode 43, a back electrode 44 of the photoelectric conversion layer 42, a connection electrode 45 formed on the back surface of the plastic substrate 41, a plastic substrate. A current collecting hole (through hole) 46 passing through 41 and conducting between the transparent electrode 43 and the connecting electrode 45, a connecting hole 47 conducting between the connecting electrode 45 and the back electrode 44, and light incident on the plastic substrate 41 The transparent electrode 43 formed on the side, the photoelectric conversion layer 42, and the back electrode 44 are laser-scribing to separate the plurality of unit cells into cell dividing grooves 48, and the connection electrode 45 formed on the back side of the plastic substrate 41 is connected to the unit cells and the half. It is composed of divided grooves 49 in which the plurality of unit cells are connected in series by laser scribing with a pitch shift.

  Such thin-film solar cells are lightweight, can be applied to a roll-to-roll process, and are excellent in mass productivity, and thus are being applied to various applications. In particular, in the electric power field, solar cell modules in which a thin film solar cell is provided with an exterior such as a sealing protective layer and a reinforcing plate so as to sufficiently withstand use in an outdoor environment have already been put into practical use.

  Specifically, the light-receiving surface and the back surface of the thin-film solar cell are sealed with a sheet-like protective layer, and the metal reinforcing plate is lined. And the terminal box for taking out the electric power of a thin film solar cell is provided in the back surface side of this metal reinforcement board. In the portion where the terminal box is provided, the metal reinforcing plate and the back surface side protective layer are opened, and the lead electrode and the terminal box of the thin-film solar cell are wired with lead wires through the opening. And the electric power of a solar cell is taken out from a terminal box (for example, refer patent document 2).

FIG. 5 is a schematic sectional view showing an assembly structure of a conventional solar cell module.
In the manufacturing process of this solar cell module, a film-like adhesive layer using EVA (ethylene vinyl acetate) or the like that is considerably thicker than the solar cell element is preliminarily provided at a low temperature on the light receiving surface of the solar cell element. Laminated. And the solar cell element 50 which cut this temporary laminate body into the predetermined dimension further is used. Then, a film-like adhesive layer 51 using EVA or the like, a moisture-proof layer 52 using ETFE (ethylene trifluoroethylene) or the like, and glass on EVA so as to cover the entire surface of the solar cell element 50 on the light receiving surface side. A reinforcing layer 53 filled with fibers to increase mechanical strength, and a surface protective layer 54 using ETFE or the like are sequentially laminated. In addition, a film-like adhesive layer 55 using EVA, an insulating layer 56 using ETFE, polyimide, etc., a film-form using EVA, etc. so as to cover the entire back surface of the solar cell element 50 on the non-light-receiving surface side. The adhesive layer 57 is sequentially laminated. Furthermore, a reinforcing plate 58 made of a steel plate or the like is lined on the outermost surface. In the manufacturing process of the solar cell module, the layers are integrated by thermally fusing the layers while applying pressure using a vacuum laminator or the like in a state where the layers are stacked.

  In the solar cell element 50, pre-laminating a film-like adhesive layer using EVA or the like in advance prevents damage and deterioration of the surface of the solar cell element and curls the solar cell element itself (rounds off). ) Is intended to prevent.

  That is, in the solar cell element, for example, as shown in FIG. 4, a plurality of types of layers are laminated on the front and back of the film substrate (plastic substrate 41), and the thickness of the laminated portion is particularly on the light receiving surface side. It is thick. For this reason, after the solar cell element is manufactured in a roll-to-roll process, there is no particular problem because a predetermined tension is applied to the front and back of the film substrate while it is wound up in a roll shape. When cutting into a predetermined size when modularizing, there is a problem that the film substrate curls differently when the tension is released on the front and back of the film substrate, and cannot be assembled.

  Further, when performing a reliability evaluation test of the solar cell element itself, it is necessary to perform unwinding / winding work by passing the solar cell element between rolls of a predetermined characteristic measuring device. The surface of the element comes into contact with a roll or a jig for measuring characteristics. For this reason, in the worst case, the surface of the solar cell element is scratched, which is one of the causes for the deterioration of the characteristics.

Therefore, an adhesive layer that is thick and can withstand deformation is temporarily laminated on the surface of the solar cell element, and as a result, the surface of the solar cell element is protected.
Further, from the viewpoint of preventing deterioration of the characteristics of the solar cell element, a method of forming a resin layer on the current collecting electrode on the surface of the solar cell element by screen printing is known in order to prevent deterioration of characteristics due to intrusion of moisture. (For example, refer to Patent Document 3).

  In the manufacturing process of this solar cell module, a reactive monomer or reactive oligomer with a high reactivity mixed with a curing agent is applied on a collecting electrode formed on the surface of the solar cell element, and the reactive monomer or The reactive oligomer is infiltrated into the voids in the collecting electrode, and then dried by heating. Accordingly, it is possible to prevent moisture from entering the gap and to prevent an increase in leakage current. As a result, it is possible to prevent deterioration of the characteristics of the solar cell element.

  Furthermore, other proposals for a manufacturing method suitable for mass production of a highly reliable solar cell module and a solar cell module manufactured thereby have been made (see, for example, Patent Document 4).

In the production of this solar cell module, after preheating a sheet-like filling material such as a cover member such as a glass plate or a resin, the step of pressure bonding to the cover member while cutting the sheet-like filling material smaller than the cover member, A step of mounting a plurality of solar cells electrically connected in series or in parallel to a cover member to which the sheet-like filling material is crimped, and a cover member and a sheet-like filling material having a size smaller than that of the cover member. The step of mounting, the step of transporting the module constructed in this way to the evacuated room and laminating by a vacuum heating press method, and the upper surface side end of this laminate with another sealing material After the sealing process, a step of curing in a curing furnace is provided together with the sheet-like filling material.
JP 2000-223727 A (page 3, FIG. 6) Japanese Patent Laid-Open No. 2002-111032 (Page 2, FIGS. 5 to 7) Japanese Patent No. 3006783 Japanese Patent Laid-Open No. 11-238898 (page 5, FIGS. 4 to 8)

However, the conventional solar cell module has the following problems.
First, in the solar cell modules described in Patent Document 1 and Patent Document 2, when a solar cell module is manufactured using a solar cell element in which a film-like adhesive layer using EVA or the like is temporarily laminated, there are outdoor exposures. During the reliability evaluation test under temperature and humidity conditions, the leakage current of the solar cell element increases or the solar cell element peels off due to the influence of acetate ions generated from EVA and the intrusion of moisture from the periphery of the solar cell module As a result, there has been a problem that the characteristics of the solar cell module are deteriorated and the life is shortened.

  In addition, the solar cell module described in Patent Document 3 has a problem that it is difficult to improve mass productivity because a resin layer is formed on the current collecting electrode formed on the surface of the solar cell element by screen printing.

  Furthermore, since the solar cell module described in Patent Document 4 uses a glass plate that has relatively high rigidity and is free from wrinkles, the solar cell (solar cell element) is not subjected to temporary lamination. Therefore, when this solar cell module manufacturing method is applied to a solar cell element made of a film substrate such as plastic, problems such as the above-mentioned curl occur.

  This invention is made | formed in view of such a point, and it aims at providing the solar cell module without an external appearance defect and a characteristic fall not being seen in a long-term reliability test.

  In the present invention, in order to solve the above-mentioned problem, in a method for manufacturing a solar cell module that converts light energy into electric energy, a resin material is coated on the light-receiving surface side surface of a solar cell element formed in a film substrate shape. Forming a resin film by heating and drying, a temporary laminating step of temporarily laminating a sheet-like adhesive on the resin film side of the solar cell element on which the resin film is formed, and the temporary laminating A cutting step of cutting the solar cell element into a predetermined size, a sealing step of sealing the light-receiving surface side and the non-light-receiving surface side of the cut solar cell element with a protective material, respectively, and a module, A method for manufacturing a solar cell module is provided.

  According to such a solar cell module, the process of forming the resin film on the light-receiving surface side surface of the solar cell element and the process of temporarily laminating a sheet-like adhesive are continuously performed. The battery element is cut into a predetermined size.

  For this reason, the resin film formed at this time can prevent moisture or the like permeating the upper layer portion from reaching the solar cell element, and as a result, peeling of the laminated portion can be prevented. Further, since the rigidity of the solar cell element is increased by the adhesive layer formed by temporarily laminating the sheet-like adhesive, it is possible to prevent the occurrence of deformation such as curling when the solar cell element is cut. it can.

  In addition, if a fluororesin material is selected as the resin material used in the resin film forming step, the effect of preventing intrusion of moisture and the like is particularly remarkable.

  According to the method for manufacturing a solar cell module of the present invention, a resin film is formed on the light-receiving surface side surface of the solar cell element, and further, a sheet-like adhesive is temporarily laminated, so that there is no appearance defect and characteristic deterioration. Can be provided.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is an explanatory diagram schematically showing the structure and manufacturing method of a solar cell element according to the present embodiment, and FIG. 2 is an explanatory diagram schematically showing the structure of a solar cell module including this solar cell element. It is.

  In the manufacturing process of this solar cell element, a roll-to-roll process as described later is applied. First, as shown in FIG. 1A, for example, a solar cell element 1 having a thickness of about 50 μm similar to the thin film solar cell shown in FIG. 4 is prepared. In addition, since it has already demonstrated about the structure of this solar cell element 1, description here is abbreviate | omitted. And as shown in FIG.1 (B), the fluororesin material is coated on the surface by the side of the light-receiving surface of the solar cell element 1, and the resin film 2 with a thickness of 5-50 micrometers is formed. Further, as shown in FIG. 1C, a film-like adhesive having a thickness of about 300 μm using EVA is temporarily laminated on the resin film 2 to form an adhesive layer 3, and the solar cell element 4. And

  That is, the inventors examined various things suitable as a vapor deposition film, a coating film, etc. on the surface of a solar cell element in order to investigate the cause of the characteristic deterioration of the solar cell module mentioned above. As a result, it was confirmed that an increase in leakage current, peeling of the solar cell element, and the like can be prevented by using a resin material, particularly a fluororesin coating, on the surface of the solar cell element.

  However, since the film thickness of the fluororesin coating is as thin as 5 to 50 μm, curling of the solar cell element itself composed of a film substrate cannot be prevented. Therefore, a temporary laminate of sheet-like adhesive was considered indispensable. For this reason, a two-stage method was used in which a sheet-like adhesive EVA or the like was temporarily laminated on a fluorine resin-coated solar cell element using a further laminating apparatus under predetermined conditions.

  The temporarily laminated solar cell element 4 is cut into a predetermined size and then assembled as a solar cell module shown in FIG. That is, a film-like adhesive layer 11 using EVA and a surface protective layer 12 using ETFE are laminated on the light-receiving surface side of the cut solar cell element 10, and EVA on the non-light-receiving surface side of the solar cell element 10. A film-like adhesive layer 13 using is laminated. Further, the reinforcing plate 14 is lined on the back surface.

  Next, the manufacturing process of a solar cell module is demonstrated concretely. FIG. 3 is a schematic view showing a manufacturing apparatus and manufacturing process of a solar cell element which is a main part of the solar cell module.

  This solar cell element manufacturing apparatus includes a resin coating device unit 21 that coats a resin on a solar cell element along a work conveyor line that includes a plurality of transport rollers, and temporarily laminates EVA on the resin-coated solar cell element. The temporary laminating device unit 22 is continuously arranged side by side.

  The resin coating device section 21 is provided with an element unwinding section 23, a resin coating section 24, and a heating and drying furnace 25 from the upstream process side. The temporary laminating apparatus section 22 has a laminating roll section from the upstream process side. 26, an EVA unwinding portion 27, a release sheet unwinding portion 28, a release sheet winding portion 29, and an element winding portion 30 are provided.

  That is, the solar cell element 1 (see FIG. 1A) similar to the thin film solar cell shown in FIG. 4 is wound around the element unwinding portion 23 by a predetermined winding roller. The element 1 is unwound from the take-up roller as the work starts and is transported along the work conveyor line.

  And the solar cell element 1 unwound at this time is introduced into the resin coating part 24, and resin is applied. The resin coating part 24 is provided with a liquid supply pan part 32 in which a fluororesin-based paint 31 is stored. As the paint 31, for example, a fluororesin paint New Gammet (DC # 230) manufactured by Toupe can be used.

  Moreover, the liquid supply pan part 32 is comprised as what coats a fluororesin to the solar cell element 1 using what is called a gravure system. That is, the liquid supply pan portion 32 is provided with a small-diameter roll 33 in which a coating liquid made of a fluororesin is stored and a mesh-shaped micro groove is formed in the vicinity of the introduction port. A blade 34 is provided near the outlet. When the film-like solar cell element 1 is introduced, the small-diameter roll 33 scoops up the internal coating liquid and applies it to the surface on the light receiving surface side of the solar cell element 1, and the blade 34 scrapes off the excess coating liquid. . The coating thickness at this time is formed to a film thickness of 15 μm by adjusting the roughness and rotation speed of the mesh of the small-diameter roll 33. The solar cell element 1 is transported at a transport speed of about 2 m / min by guide rolls 35 and 36 disposed at the inlet and the outlet of the liquid supply pan 32, respectively.

  In addition, although the film thickness of the fluororesin applied by this treatment was 15 μm as described above, it is preferably 5 to 50 μm. That is, the coating film thickness in the liquid supply pan 32 is controlled by the mesh (groove size) of the small-diameter roll 33 and the number of rotations. Defects such as unpainted parts are likely to occur on the part. That is, in this case, the mesh of the small-diameter roll 33 becomes smaller and the rotation speed becomes faster, so that the supply of the coating liquid is insufficient and a partially unpainted state occurs. Although there is no difference in appearance, there is a possibility that deterioration of characteristics and peeling phenomenon may occur due to moisture intrusion from an unpainted portion in a reliability test described later. On the other hand, when the thickness is 50 μm or more, the mesh of the small-diameter roll 33 becomes large, and the rotation speed becomes slow. Therefore, an excessive supply state of the coating liquid occurs, a phenomenon such as the coating liquid dripping occurs, and the film thickness is uniform. This is because it becomes difficult to make it.

  Subsequently, the solar cell element derived from the liquid supply pan unit 32 is introduced into the heating and drying furnace 25. The heating and drying furnace 25 has a length in the transport direction of about 4 m, and the furnace temperature is maintained at about 150 ° C. The solar cell element is continuously transported in the heating / drying furnace 25 at a transport speed of about 2 m / min. At this time, the resin material on the solar cell element 1 is heat-cured to form the resin film 2 (see FIG. 1B).

  The temperature of the heating and drying furnace 25 is preferably 150 to 180 ° C. and the conveyance speed is preferably 0.5 to 5 m / min. That is, the curing condition of the fluororesin is approximately 150 ° C. and 10 minutes. For this reason, when the temperature of the drying furnace is lower than 150 ° C., the curing time of the fluororesin is required to be long, and it is necessary to slow down the conveying speed or to improve the dimensions of the heating and drying furnace 25 itself. When the fluororesin is insufficiently cured, it may stick to the roll, that is, may cause a blocking phenomenon with the roll. On the contrary, if it is 180 degreeC or more, there will be no problem in particular, but if the temperature is too high, a deterioration mode of the fluororesin is entered, which is not preferable. Here, the conveyance speed can be adjusted in the range of 0.5 to 5 m / min. However, it is necessary to determine the combination based on the relationship between the furnace temperature and the conveyance speed with respect to the required film thickness.

  The solar cell element that has exited the heating and drying furnace 25 is further conveyed and guided to the laminating roll unit 26 via the step roll 37. In addition, this level | step difference roll 37 adjusts the tension | tensile_strength of the strip | belt-shaped solar cell element conveyed along a work conveyor line, and makes smooth introduction | transduction of the solar cell element from the resin coating apparatus part 21 to the temporary laminating apparatus part 22. FIG. Is.

  The laminating roll unit 26 is provided with a laminating roll (opposing roller) in which a metal roll 38 and a rubber roll 39 are opposed to each other. The laminating roll is heated to 110 ° C. where EVA can be melted, and the clearance between both rollers is set to 250 μm. The laminate roll portion 26 is unwound from the solar cell element on which the resin film 2 is formed, the film-like adhesive EVA unwound from the EVA unwinding portion 27, and the release sheet unwinding portion 28. The film-like release sheet 28a is introduced and laminated at a conveyance speed of about 2 m / min.

  The release sheet 28a is made of a polymethylpentene resin film (eg, Mitsui Petrochemical: TPX film X22MT4) having a thickness of about 50 μm. In order to prevent adhesion between the heat-melted EVA and the metal roll 38, a metal It is inserted between the roll 38 and EVA. The EVA is configured as a sheet-like adhesive having a thickness of about 300 μm (for example, EVA SAFE manufactured by Bridgestone).

  The solar cell element 4 (see FIG. 1C) on which the EVA is temporarily laminated in this way and the adhesive layer 3 is formed is wound around the element winding portion 30 via the step roll 40. The EVA constituting the adhesive layer 3 is naturally cooled and cured before passing through the laminate roll part 26 and reaching the element winding part 30. For this reason, the blocking phenomenon described above does not occur in the element winding unit 30.

  In addition, the release sheet 28 a passes through the laminate roll portion 26 and passes through the step roll 40, and then is separated from the solar cell element 4 and wound around the release sheet winding portion 29. Since the release sheet 28a is unwound and wound while maintaining a predetermined tension between the release sheet unwinding section 28 and the release sheet winding section 29, it is reused without wrinkles. Is possible. Here, the release sheet 28a is wound around the release sheet winding unit 29. However, the release sheet 28a separated from the solar cell element 4 is returned to the release sheet unwinding unit 28 and used continuously. A belt-type peeling method can also be used. In this way, the release sheet winding unit 29 becomes unnecessary.

  In this treatment, it is preferable that the temperature of the temporary laminate is 80 to 120 ° C. and the conveyance speed is 0.5 to 5 m / min. That is, EVA, which is a sheet-like adhesive that is temporarily laminated here, is heated to a temperature equal to or higher than the melting point (76 ° C.) so that the EVA exhibits flexibility and adhesiveness. It is necessary to apply the pressure more securely. However, when the temperature of the temporary laminate is 80 ° C. or less, the temperature is around or below the melting point of EVA, so that the flexibility is insufficient and the attachment becomes difficult. On the other hand, if the temperature is 120 ° C. or higher, the flexibility becomes so large that it is in a state of being melted and may flow too much. In addition, continuous formation is attained by making conveyance speed the same speed as the process of apply | coating a fluororesin.

  The solar cell element 4 wound around the element winding part 30 as described above is advanced to the subsequent initial characteristic measurement step (not shown). In this initial measurement step, the temporarily laminated solar cell element 4 is unwound and supplied to a predetermined measuring device. And about the part which passed the characteristic evaluation test, a reverse bias process and light irradiation measurement are performed, and it winds up again in roll shape.

Subsequently, the solar cell element 4 is advanced to a cutting process, and is sequentially cut into a predetermined dimension (here, 200 × 825 mm), and is configured as the solar cell element 10 shown in FIG.
That is, a film-like adhesive layer 11 using EVA and a surface protective layer 12 (protective material) using ETFE are sequentially laminated so as to cover the entire surface of the cut solar cell element 10 on the light receiving surface side. . Further, a film-like adhesive layer 13 (protective material) using EVA is laminated so as to cover the entire back surface of the solar cell element 10 on the non-light-receiving surface side. Further, a reinforcing plate 14 made of a steel plate or the like is lined on the outermost surface. For the reinforcing plate 14, for example, a coated galvanized steel plate having a thickness of 0.8 mm is used. In addition, although the external output lead wire from the solar cell element 10 is taken out from the opening hole provided in the reinforcement board 14, it abbreviate | omits about illustration. And using a vacuum laminator etc. in the state which laminated | stacked each layer, it heat-pressure-bonded and hardens | cures and integrates it on predetermined conditions (here 150 degreeC, 20 minutes), and a solar cell module is obtained.

  When the solar cell module configured as described above was subjected to a conversion efficiency measurement test, a good conversion efficiency of 8.5% was obtained. The solar cell module was also subjected to a temperature and humidity test as a reliability evaluation test. In this temperature / humidity test, the solar cell module was installed in an atmosphere of 85 ° C. and 85% RH for 1000 hours, and changes in its characteristics and appearance were observed. However, the characteristics could be maintained without any particular problems.

In addition, in order to confirm the effect of the said embodiment, the same test was done also about the following comparative examples 1 and 2. FIG.
[Comparative Example 1]
In Comparative Example 1, the laminating roll unit 26, the EVA unwinding unit 27, the release sheet unwinding unit 28, and the release sheet winding unit 29 in the manufacturing apparatus of FIG. 3 are omitted, and the solar cell element coated with the resin film is left as it is. The film was wound up and temporarily laminated with a separately prepared laminator. That is, the solar cell element on which the resin film made of the fluororesin material was formed in the resin coating apparatus unit 21 shown in FIG. 3 was wound up by a winding roll (not shown) through the step roll 37. And the solar cell element of the state wound up by this winding roll was stored in the desiccator. The next day, when trying to temporarily laminate with a separately prepared laminator, a blocking phenomenon occurred in which the resin film adhered to the back surface of the solar cell element wound into a roll, and a part of the fluororesin peeled off and transferred. .

  For this reason, attempts were made to cool the EVA to a temporary laminate or to increase the temperature of the drying furnace, but it was not possible to prevent the occurrence of the blocking phenomenon.

And the solar cell module similar to what was shown in FIG. 2 using the solar cell element of this state was produced, and the measurement test and temperature / humidity test of the conversion efficiency mentioned above were done. As a result, a conversion efficiency of 5.5% was obtained in the conversion efficiency measurement test. That is, the characteristics were considerably deteriorated due to the influence of partial peeling of the resin film. Further, in the temperature and humidity test, discoloration that was thought to be due to the ingress of moisture was observed in the peeled portion.
[Comparative Example 2]
In Comparative Example 2, a solar cell module similar to that shown in FIG. 2 was prepared for the other components by using only a temporary EVA laminate without forming a resin film on the solar cell element. A conversion efficiency measurement test and a temperature / humidity test were conducted.

  As a result, the conversion efficiency was as good as 8.5%. However, in the temperature and humidity test, a minute crack was generated in the current collecting hole portion of the solar cell element, and as a result, the conversion efficiency was reduced to 7.5%.

  As described above, in the solar cell module according to the present embodiment, the process of forming the resin film 2 made of fluororesin on the light-receiving surface side surface of the solar cell element and the sheet-like EVA are temporarily laminated. Thus, the process of forming the adhesive layer 3 is continuously performed. The resin film 2 can prevent moisture or the like that has permeated the upper layer portion from reaching the solar cell element. As a result, peeling of the laminated portion can be prevented, and appearance defects do not occur. Further, since the rigidity of the solar cell element is increased by the adhesive layer formed by temporarily laminating the sheet-like adhesive, it is possible to prevent the occurrence of deformation such as curling when the solar cell element is cut. it can. In addition, it was found that the characteristics of the solar cell module can be secured without providing the moisture-proof layer 52, the reinforcing layer 53, and the insulating layer 56 as shown in FIG. It was.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the specific embodiments, and changes and modifications can be made within the spirit of the present invention. Not too long.

  For example, in the said embodiment, as shown in FIG. 3, the resin coating apparatus part 21 and the temporary laminating apparatus part 22 are continuously arranged along the work conveyor line, and the fluororesin to a solar cell element is arranged. Although the example which performed the coating process and the EVA temporary lamination process continuously was shown, both processes can also be performed separately. That is, a resin is applied in the resin coating part 24 in the coating process, and the resin film side of the solar cell element heated and dried in the heating and drying furnace 25 is made of the same material as the release sheet 28a. The paper is taken up by a predetermined take-up roll so as to insert an interleaving paper having a larger width. Then, in the temporary laminating step, the solar cell element wound around the take-up roll is unwound, and at the same time, the interleaf is removed and introduced into the laminating roll unit 26 to perform temporary lamination. Even if it does in this way, the characteristic similar to the solar cell module concerning the said embodiment as a solar cell module is acquired. However, the cost increases because it is necessary to provide a roll facility for winding and unwinding the solar cell element between the coating process and the temporary laminating process and to prepare a separate paper at that time. For this reason, it can be said that the structure of the said embodiment is more preferable.

  In addition, the inventors conducted an experiment in which a slip sheet having a width smaller than that of the solar cell element was inserted, but when the film was wound on a winding roll, a part of the resin film adhered to the sheet and a blocking phenomenon occurred. There were problems that abnormal noise was generated during winding and that the rotation of the roll became uneven. In addition, wrinkles sometimes entered on the slip sheets. For this reason, as described above, it is necessary to insert a slip sheet having a width wider than that of the solar cell element.

  In the above embodiment, an example in which a fluororesin material is used in the resin film coating process has been described. However, for example, an acrylic silicon resin material or the like can be used.

It is explanatory drawing which represents typically the structure and manufacturing method of the solar cell element which concern on embodiment. It is explanatory drawing which represents typically the structure of the solar cell module containing a solar cell element. It is the schematic showing the manufacturing apparatus and manufacturing process of the solar cell element which are the principal parts of a solar cell module. It is a perspective view showing the structural example of a thin film solar cell. It is a schematic sectional drawing showing the assembly structure of the conventional solar cell module.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,4,10 Solar cell element 2 Resin film 3,11,13 Adhesive layer 12 Surface protective layer 14 Reinforcement plate 21 Resin coating apparatus part 22 Temporary laminating apparatus part 23 Element unwinding part 24 Resin coating part 25 Heating drying furnace 26 Laminate roll section 27 EVA unwinding section 28 Release sheet unwinding section 28a Release sheet 29 Release sheet winding section 30 Element winding section 31 Paint 32 Liquid supply pan section 33 Small diameter roll 34 Blade 35, 36 Guide roll 37, 40 Step roll 38 Metal roll 39 Rubber roll

Claims (13)

In a method for manufacturing a solar cell module that converts light energy into electrical energy,
A resin film forming step of coating a resin material on the light-receiving surface side surface of the solar cell element formed in a film substrate shape, and heating and drying this to form a resin film,
A temporary laminating step of temporarily laminating a sheet-like adhesive on the resin film side of the solar cell element on which the resin film is formed;
A cutting step of cutting the temporarily laminated solar cell element into a predetermined size;
A sealing step of sealing the light-receiving surface side and the non-light-receiving surface side of the cut solar cell element with a protective material to form a module;
The manufacturing method of the solar cell module characterized by the above-mentioned.   The resin film forming step and the temporary laminating step are continuously connected on a common work conveyor line, and are continuously processed while transporting the solar cell element formed in a strip shape. The method for manufacturing a solar cell module according to claim 1.   The method for manufacturing a solar cell module according to claim 1, wherein a fluororesin-based paint is used as the resin material used in the resin film forming step.   The method for manufacturing a solar cell module according to claim 3, wherein a thickness of the resin material coated on the solar cell element in the resin film forming step is set in a range of 5 to 50 µm. The resin film forming step includes
A coating step of coating the fluororesin-based paint on the light-receiving surface side surface of the solar cell element by a gravure method,
The solar cell element coated in the coating step is passed through a predetermined drying furnace, and is heated and dried to be cured to form the resin film, and
It consists of these, The manufacturing method of the solar cell module of Claim 3 characterized by the above-mentioned.   The furnace temperature in the drying furnace in the heating and drying step is set to 150 to 180 ° C., and the conveyance speed of the solar cell element in the drying furnace is set to a range of 0.5 to 5 m / min. The manufacturing method of the solar cell module of Claim 5.   In the temporary laminating step, the solar cell element on which the resin film is formed in the resin film forming step, the sheet-like adhesive disposed on the resin film side of the solar cell element, and the sheet-like adhesion By passing a release sheet having a width equal to or greater than that of the adhesive disposed on the opposite side of the adhesive from the solar cell element, between opposing rollers heated to a predetermined melting temperature of the adhesive, The method for manufacturing a solar cell module according to claim 5, wherein an adhesive is temporarily laminated on the solar cell element.   In the temporary laminating process, the strip-shaped release sheet is unwound from a predetermined release sheet unwinding portion and supplied between the opposing rollers, and passes between the opposing rollers and temporarily laminated to the solar cell element. 8. The solar cell module according to claim 7, wherein after the agent is cured from a molten state, the part of the release sheet that has passed through the counter roller is wound and collected by a predetermined release sheet winding unit. Manufacturing method.   The heating temperature of the counter roller is set to 80 ° C. to 120 ° C., and the conveyance speed when the solar cell element, the adhesive and the release sheet pass through the counter roller is in the range of 0.5 to 5 m / min. The method for manufacturing a solar cell module according to claim 8, wherein the method is set.   9. The method for manufacturing a solar cell module according to claim 8, wherein the facing roller is composed of a metal roll and a rubber roll arranged to face each other.   The method for manufacturing a solar cell module according to claim 8, wherein a step roll is installed between the resin film forming step and the temporary laminating step, and the tension of the solar cell element to be conveyed can be adjusted. . In solar cell modules that convert light energy into electrical energy,
A light-receiving surface side and a non-light-receiving surface side of a solar cell element formed by sequentially laminating a resin film made of a fluororesin material and a sheet-like adhesive on the light-receiving surface side surface of a film substrate-shaped main body, and cutting to a predetermined size A solar cell module formed by sealing each with a protective material to form a module. In the method of manufacturing a solar cell element that converts light energy into electrical energy,
A resin film forming step of coating a resin material on the light-receiving surface side surface of the solar cell element formed in a film substrate shape, and heating and drying this to form a resin film,
A temporary laminating step of temporarily laminating a sheet-like adhesive on the resin film side of the solar cell element formed continuously with the resin film forming step;
The manufacturing method of the solar cell element characterized by the above-mentioned.

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