JP2008117926A - Solar battery module manufacturing method and its manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar battery module manufacturing method for manufacturing a solar battery module whose crosslink degree varies little easily and with high productivity, and its manufacturing apparatus. <P>SOLUTION: The solar battery module manufacturing method includes a step of pressurizing a laminated body 7 in which at least a sealing thermal crosslinkable resin sheet and a surface protection member are sequentially laminated on at least one surface of a solar battery element in the direction of lamination and irradiating the laminated body with light which exhibits a maximum spectral radiance between wavelengths, 1.2 μm and 12 μm, preferably 1.2 μm and 3.6 μm, and whose spectral radiance at the wavelength of 1.1 μm is equal to or less than 30% of the maximum spectral radiance through a light transmissive pressurizing sheet 13 from at least one surface side to heat the laminated body, and thereby performing the pressure bonding of the laminated body. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method and an apparatus for manufacturing a solar cell module.

  Solar cells have been put into practical use as devices that convert solar energy into electrical energy. In order to protect solar cell elements (cells) made of silicon or the like from physical impacts and wind and rain, solar cells are generally transparent resins such as PVB (polyvinyl butyral) and EVA (ethylene vinyl acetate) and heat resistant glass. It is manufactured as a solar cell module sealed with.

  FIG. 11 shows an example of a depressurization apparatus (vacuum lamination apparatus) used when manufacturing a solar cell module. This apparatus 30 is called a double vacuum system, and includes upper and lower vacuum chambers 31 and 32, a heating plate 33, a diaphragm (fluorine rubber sheet, silicone rubber sheet, etc.) 36, and the like. The upper and lower vacuum chambers 31 and 32 are partitioned by a diaphragm 36 and have intake / exhaust ports 34 and 35 respectively leading to a vacuum pump.

  When manufacturing a solar cell module with such an apparatus 30, on the heating plate 33, for example, glass 45, EVA (resin sheet for sealing) 43, solar cell element 41, EVA (resin sheet for sealing) 42, The back surface protective film 44 is laminated in this order. Next, the insides of the upper and lower vacuum chambers 31 and 32 are brought into a reduced pressure state, and are heated at, for example, 130 ° C. for 5 to 10 minutes to melt the EVAs 42 and 43 without crosslinking. Then, by returning the inside of the upper vacuum chamber 31 to the atmospheric pressure, the laminated body 40 is uniformly pressurized by the silicone rubber sheet 36, and is pressed with almost no bubbles between the EVA 42, 43 and the solar cell element 41. Such a process is called temporary assembly (temporary pressure bonding), and in order to improve strength, heat resistance, etc., the temporarily assembled laminated body 40 is transferred in the same apparatus 30 or another heating apparatus, and EVA 42 is used. , 43 is heated at 30 ° C. for 30 to 40 minutes, for example, at 150 ° C. to perform main pressure bonding. Thereby, the solar cell module with which each member of the laminated body 40 was integrated can be manufactured (for example, refer nonpatent literature 1 and patent document 1).

  On the other hand, FIG. 12 shows an example of a single vacuum apparatus. In this apparatus 50, a single vacuum chamber is formed by the heating plate 51 and the silicone rubber sheet 53. By depressurizing through the exhaust port 52 formed in the heating plate 51, the laminate 40 can be pressure-bonded between the silicone rubber sheet 53 and the heating plate 51 to form a module.

  In the manufacture of solar cell modules, a vacuum lamination apparatus 30 using a double vacuum system is frequently used. For example, a method for controlling the heating temperature and the pressure difference between the upper and lower vacuum chambers 31 and 32, and a heating plate and module that can be raised and lowered are held Various devices and the like provided with a means to do so have been proposed (for example, see Patent Documents 2 to 4).

  As a heat source, a heating plate 33 provided with a heat conduction heating type heater is widely used. However, in order to perform crosslinking treatment on the sealing resin sheets 42 and 43 such as EVA, a solar cell is provided on the heating plate 33. A heating time of 10 minutes or more is required after the module member (laminated body) 40 is installed. For the solar cell module, the solar cell module is heated by the contribution of only the heat conduction from the cover sheet 45 in contact with the heating plate 33. When the material of the cover sheet 45 in contact with the heating plate 33 is glass or resin, Since the thermal conductivity is lower than that of metal, a large limit is imposed on the temperature increase rate of the sealing resin sheet (EVA), and it is difficult to perform a crosslinking process at a high speed. Therefore, there is a problem that the tact time becomes long and the productivity is low.

On the other hand, a method for manufacturing a solar cell module using light irradiation has also been proposed. For example, EVA is used as a sealing resin, and after EVA is thermally cured, a method of improving transparency by irradiating light containing ultraviolet rays (see Patent Document 5), irradiating ultraviolet rays, or further irradiating infrared rays. A method of manufacturing a solar cell module that is cured in a short time (see Patent Document 6) has been proposed.
However, since the solar cell element also absorbs light in the ultraviolet to near-infrared region, the temperature in the vicinity of the solar cell element is relatively higher than that of the portion without the solar cell element. For this reason, the cross-linking degree of the sealing resin in the vicinity of the solar cell element is higher than the cross-linking degree of the encapsulating resin in the portion where there is no solar cell element, and the non-uniform cross-linking degree in the solar cell module plane It is easy to present.
If the variation in the degree of crosslinking increases in the plane of the solar cell module, the reliability of the module may be impaired. For example, if there is a portion where the degree of crosslinking is too high, yellowing may occur in the sealing resin due to deterioration over time such as oxidation by ultraviolet light or thermal cycle, which may cause uneven color. As a result, in addition to appearance deterioration, reliability of electrical insulation resistance degradation, local temperature rise (hot spot), electrical insulation breakdown, cracking of solar cell elements due to foaming of sealing resin that has become hot, etc. There is a risk of lowering. In addition, if there is a portion where the degree of crosslinking is too low, there is a possibility that the creep resistance and impact resistance of the solar cell module will be inferior. Further, the sealing resin is further deteriorated by the ultraviolet light, and there is a possibility that the lifetime is shortened.

  Further, a laminating apparatus including two or more temperature control systems has been proposed as an apparatus for manufacturing a laminate such as a solar cell module (see Patent Document 7). As the heat source of this apparatus, various heat sources including an infrared lamp are listed. However, when an infrared lamp is used as the heat source, depending on the spectral emission spectrum of the light radiated to the solar cell module, it may be difficult to simultaneously apply a uniform crosslinking treatment to the sealing resin in the module surface. .

"Solar Cell Handbook", The Institute of Electrical Engineers of Japan, Solar Cell Research Committee, Corona, p166, (1985) JP-A-9-36405 Japanese Examined Patent Publication No. 6-52801 JP 2001-177119 A Registered Utility Model No. 3017231 JP 61-44741 A JP 2001-36118 A Japanese Patent Laid-Open No. 11-216832

  An object of this invention is to provide the manufacturing method and manufacturing apparatus of a solar cell module which can manufacture the solar cell module with small dispersion | variation in a crosslinking degree easily with high productivity.

  In order to achieve the above object, the present invention provides the following solar cell module manufacturing method and manufacturing apparatus.

<1> A laminate in which at least a sealing heat-crosslinkable resin sheet and a surface protective member are sequentially stacked on at least one surface of a solar cell element is pressed in the stacking direction, and at least one surface side of the laminate is pressed. From the above, by irradiating with light that shows the maximum spectral radiance between the wavelengths of 1.2 μm and 12 μm and whose spectral radiance at the wavelength of 1.1 μm is 30% or less of the maximum spectral radiance, The manufacturing method of the solar cell module characterized by including the process of crimping | bonding the said laminated body.

<2> Using a pressure reducing apparatus equipped with a light-transmitting pressure sheet that transmits light, pressurizing the laminate in the stacking direction with the light-transmitting pressure sheet, and against the laminate, The maximum spectral radiance is exhibited at a wavelength of 1.2 μm to 3.6 μm through the light-transmitting pressure sheet, and the spectral radiance at a wavelength of 1.1 μm is 30% or less of the maximum spectral radiance. The method for producing a solar cell module according to <1>, wherein the laminate is pressure-bonded by irradiation with light and heating.

<3> After the laminate is pressure-bonded by the light transmissive pressure sheet, the irradiation of light is stopped, and a cooling gas is sprayed on the light transmissive pressure sheet. The manufacturing method of the solar cell module as described in <2>.

<4> An apparatus for manufacturing a solar cell module,
A vacuum chamber;
In the vacuum chamber, on at least one surface of the solar cell element, a support base for supporting a laminate in which at least a heat-crosslinking resin sheet for sealing and a surface protection member are sequentially stacked,
The maximum spectral radiance between wavelengths of 1.2 μm and 3.6 μm is exhibited with respect to the laminate supported on the support, and the spectral radiance at a wavelength of 1.1 μm is the maximum spectral radiance. Light irradiation heating means for irradiating and heating light that is 30% or less of
A light-transmitting pressure sheet that transmits light from the light irradiation heating means and pressurizes and press-bonds the laminated body supported on the support base in the laminating direction. Manufacturing equipment for solar cell modules.

<5> The vacuum chamber has a first vacuum chamber in which the inside of the vacuum chamber is partitioned by the light transmissive pressure sheet, the support is disposed, and a second vacuum chamber in which the light irradiation heating unit is disposed. <4> The solar cell module manufacturing apparatus according to <4>.

<6> The apparatus for producing a solar cell module according to <4> or <5>, further comprising gas injection means for blowing a cooling gas to the light transmissive pressure sheet. .

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method and manufacturing apparatus of a solar cell module which can manufacture a solar cell module with small dispersion | variation in a crosslinking degree easily with high productivity are provided.
Moreover, even if discharge occurs during production, there is no possibility of inducing performance degradation or damage of the solar cell module due to excessive discharge current.

Hereinafter, a manufacturing method and a manufacturing apparatus of a solar cell module will be specifically described with reference to the accompanying drawings.
The present inventors provide means for suppressing variation in the degree of crosslinking of the sealing resin in the solar cell module surface by light irradiation, the spectral transmittance spectrum of the light-transmitting pressure sheet, heat resistance, mechanical properties, solar cell We have conducted intensive research and investigations on means for efficiently heating the module sealing resin sheet until a crosslinking reaction occurs. As a result, it is effective to use infrared light having most of radiant energy in the wavelength range of 1.2 μm or more and 12 μm or less, particularly 3.6 μm or less, as a heat source when manufacturing a solar cell module by vacuum lamination. I found out.

  As a result of further studies and studies, the present inventors pressurized in the stacking direction a laminate in which at least a heat-crosslinking resin sheet for sealing and a surface protection member are sequentially stacked on at least one surface of the solar cell element. In addition, with respect to the laminate, the maximum spectral radiance is exhibited at a wavelength of 1.2 μm to 12 μm from at least one side, and the spectral radiance at a wavelength of 1.1 μm is 30% or less of the maximum spectral radiance. It is found that the resin sheet for sealing (thermally crosslinkable resin sheet) mainly inside the solar cell module can be efficiently heated and melted and the crosslinking can be promoted by irradiating and heating the light to be It was. And according to such a method, it discovered that the solar cell module with few variations in bridge | crosslinking density could be manufactured easily and with high productivity, and came to completion of this invention.

FIG. 1 shows an example of a solar cell module manufacturing apparatus according to the present invention. The apparatus 20 includes upper and lower vacuum chambers 8 and 9, a support base 10 for supporting the laminated body 7, a light irradiation unit 14, a light transmissive pressure sheet 13, a gas injection unit 16, and the like.
In such a solar cell module manufacturing apparatus 20, the light-transmitting pressure sheet 13 and the solar cell module laminate 7 are stacked in order from the direction in which the light from the light irradiation unit 14 is incident, A surface pressure acts on the laminated body 7 through the light-transmitting pressure sheet 13 by the pressure. On the other hand, light including infrared light in a specific wavelength range radiated from the light irradiation unit 14 is irradiated to the stacked body 7 being pressed through the light-transmitting pressure sheet 13. Part or all of the light including infrared light is absorbed by the cover sheet of the laminate 7 or the resin sheet for sealing, and the sealing resin sheet undergoes a crosslinking reaction with melting, so that the solar cell element and the cover The laminate 7 can be modularized by bonding to a sheet.
Hereinafter, each component will be specifically described.

<Vacuum chamber>
The apparatus 20 shown in FIG. 1 is a double vacuum system, and is divided into an upper (first) vacuum chamber 8 and a lower (second) vacuum chamber 9 by a light transmissive pressure sheet 13. The chambers 8 and 9 are respectively provided with intake and exhaust ports 11 and 12 leading to a vacuum pump (not shown), and are configured so that the pressure in the chambers 8 and 9 can be controlled independently. . The upper vacuum chamber 8 is provided with a cooling air exhaust port 17 for discharging cooling air introduced from the gas injection means 16.
The upper and lower chambers 8 and 9 are of an open / close type, and after the laminated body 7 to be a solar cell module is installed inside the apparatus, the laminated body 7 is heated by light irradiation, and further, the light irradiation is stopped and cooled. Until then, the laminated body 7 (solar cell module 21) is pressurized by the support base 10 and the light transmissive pressure sheet 13, and then the integrated solar cell module 21 can be taken out.

  With such a double-vacuum device 20, the pressure on the laminate 7 (solar cell module 21) can be easily made uniform, and the air gaps between the members can be easily removed by deaeration. Thus, the solar cell module 21 having a large area can be sealed with a surface pressure of about atmospheric pressure. In addition, the decompression method of the solar cell module manufacturing apparatus according to the present invention is not particularly limited, and may be a single vacuum method.

<Support stand>
The support base 10 is disposed in the lower chamber 9 and supports the stacked body 7 (solar cell module 21). About the material of the support stand 10, what has high mechanical strength and heat resistance, such as a metal, a ceramic, glass, etc. is suitable.
An electric heater, a heat pipe that circulates the heat medium oil, and a water-cooled cooling circuit may be embedded in the support base 10 so that the structure can be maintained at a constant temperature without light irradiation.

<Light irradiation unit>
The light irradiation unit (light irradiation heating means) 14 is disposed in the upper vacuum chamber 8 and exhibits a maximum spectral radiance between wavelengths of 1.2 μm and 3.6 μm, and a spectrum at a wavelength of 1.1 μm. It is configured to emit light having a radiance of 30% or less of the maximum spectral radiance. Here, the spectral radiance represents the unit time, unit solid angle, unit area, and radiant energy per unit wavelength of light emitted from the light irradiation unit 14, and is obtained by radiation measurement. For the measurement of the spectral radiance of the light emitted from the light irradiation unit 14, a general-purpose spectroradiometer, for example, OL-750 general-purpose spectroradiometry system manufactured by OPTRONIC LABORATORIES, USA can be used.

  The light irradiation unit 14 that emits light as described above includes, for example, a light source 14a such as a light emitting diode, an infrared radiation heater (hereinafter, abbreviated as an infrared heater) using radiation from a heating element, and the laminate 7. Depending on the shape, size, etc. of the (solar cell module 21), the irradiation direction and irradiation area of the light emitted from the light source 14a are controlled, and a large amount of radiation energy is in the wavelength range of 1.2 μm to 3.6 μm. If necessary, the optical component 14b can be configured to control the wavelength range of the light emitted from the light source 14a.

As a specific example of the light source 14a, when the light source 14a is a laser, Ho (holmium), Tm (thulium), and Er having an oscillation wavelength in the range of 1.8 μm to 3.0 μm in a solid laser, for example. Examples thereof include a YAG laser doped with (erbium) and a fiber laser. Examples of the gas laser include a carbon monoxide laser and a carbon dioxide gas laser. In addition, a laser including a quantum cascade laser or an optical parametric resonator may be used.
On the other hand, when the light source 14a is an infrared heater, a halogen heater, a carbon heater combining a carbon wire and a quartz tube, or the like can be used.

  Examples of the optical component 14b include a mirror, a lens, a prism, a mask, an optical fiber, and a wavelength filter. The wavelength filter selectively transmits part of the wavelength component of the light emitted from the light source 14a. In the case of the wavelength filter, for example, by removing a part of the wavelength component emitted from the light source 14a by using a silicon filter with respect to the halogen heater, light having a wavelength of 1.1 μm or less is substantially cut, and the wavelength is 1.2 μm. Infrared light having the maximum radiation intensity can be produced in the range of 3.6 μm or less. In combination with a plurality of optical components 14b, light can be selectively irradiated to a specific region, scanned, or time-division controlled by output pulsing or the like. The transmission path and irradiation method may be freely changed.

  For the laminate 7 (solar cell module 21) having a large area, the light source 14a is preferably suspended above the inside of the upper vacuum chamber 8 in order to achieve uniform heating within the surface of the solar cell module by light irradiation. . In order to uniformly heat a wide area, it is preferable to use an infrared heater as the light source 14a, and it is preferable to use a plurality of line heaters in which linear heating elements are arranged in parallel. When the infrared heater is a line heater, each line-shaped heating element preferably includes a housing having a metal reflection mirror and a cooling mechanism such as an air cooling or water cooling jacket.

<Light transmission pressure sheet>
As the light-transmitting pressure sheet 13, a sheet having high transmittance with respect to light (wavelength: 1.2 μm to 3.6 μm) used for heating the laminated body 7 for the solar cell module is used. The light transmitting pressure sheet 13 preferably has a spectral transmittance of the above light as high as possible from the viewpoint of realizing high-speed heating by absorption of infrared light of the laminate 7, specifically, a wavelength of 1.2 μm or more 3 Those having a spectral transmittance of 50% or more in the range of 6 μm or less are preferable. Here, as the spectral transmittance spectrum data of the light transmissive pressure sheet 13, data measured at room temperature by a transmission method using a general-purpose spectrometer can be adopted.
More specifically, the wavelength range of 0.2 μm to 2.3 μm is measured with a bandwidth of 4 nm and a scanning speed of 200 nm / min using a V-570 manufactured by JASCO Corporation as a spectrometer, and a wavelength of 2.3 μm. From 10 to 10 μm, measurement is performed with a resolution of 4 cm ⁻¹ using a FTS-6000 manufactured by Bio-Rad as a spectrometer.

  The light-transmitting pressure sheet 13 covers the surface of the laminate 7 on the light irradiation side, and light irradiation is performed in a series of steps from heating to cooling of the laminate 7 (solar cell module 21) after pressurization. It keeps contact with the cover sheet (surface protection member) located on the side and plays a role of a pressure partition between the upper vacuum chamber 8 and the lower vacuum chamber 9. Accordingly, the light-transmitting pressure sheet 13 has high transparency to the infrared light to be used, has high heat resistance and mechanical strength, and is easily elastically deformed so as not to damage the surface of the solar cell module 21. It is preferable that the resin is excellent in low contamination and releasability from the solar cell module 21.

  For example, a fluorine resin sheet is mentioned as a preferable light transmission pressure sheet. Among the fluororesin sheets, in particular, the low crystalline fluororesin sheet is preferably used because it easily transmits infrared light in the wavelength range of 0.8 μm to 3.6 μm. Examples of such a resin include tetrafluoroethylene perfluoroalkyl vinyl ether copolymer (PFA) and tetrafluoroethylene-hexafluoropropylene copolymer (FEP). Further, the resin sheet may be subjected to electron beam crosslinking in order to further increase the tensile strength and creep strength. Furthermore, for infrared light in the wavelength range of 0.8 μm or more to 3.6 μm, fluorine such as PTFE or PFA is used on a glass cloth made of an inorganic fiber having high translucency such as silica or alumina. An airtight fluororesin-containing glass cloth sheet impregnated or laminated with a resin may be used. In these cases, since the tensile strength and creep strength of the resin sheet are improved, the sheet thickness can be reduced.

  The thickness of the light-transmitting pressure sheet 13 is not particularly limited as long as the light from the light irradiation unit 14 can be transmitted and the laminate 7 can be modularized, and may be set as appropriate according to the material and the like. Usually, if it is the thickness of the range of 20 micrometers or more and 3 mm or less, it can be set as the light transmissive pressurization sheet 13 which satisfy | fills light transmittance, heat resistance, a softness | flexibility, mechanical strength, etc. In addition, when light including infrared light to be used is emitted from a halogen heater or a carbon heater and a PFA sheet is used as the light transmissive pressure sheet 13, the light transmissive pressure sheet 13 The thickness is preferably thin in terms of ensuring high light transmittance and flexibility, but is preferably 100 μm or more and 2 mm or less in consideration of creep resistance.

<Gas injection means>
The apparatus 20 shown in FIG. 1 includes a cooling air pipe 15 and a blow nozzle 16 as gas injection means for blowing a cooling gas onto the light transmissive pressure sheet 13. Such gas injection means 15 and 16 transmit light in a state in which surface pressure is applied while maintaining contact with the surface of the solar cell module 21 after heating the laminated body 7 (solar cell module 21) by light irradiation. It arrange | positions in the upper vacuum chamber 8 so that cooling air can be injected toward the property pressurizing sheet 13.

  The blow nozzle 16 is an outlet for cooling air in the cooling air pipe 15, and has a role of blowing cooling air toward the light transmissive pressure sheet 13. For example, a side spray type nozzle, a flat spray type nozzle, or the like can be used. For example, as shown in FIG. 1, a plurality of blow nozzles 16 are arranged along the cooling air pipe 15 between the individual light sources 14 a arranged in a line by the light irradiation unit 14. As the position of the blow nozzle 16 in the height direction, for example, it is provided at a position where the light emitted from the light source 14a does not directly hit.

  As a material of the blow nozzle 16, a metal such as an aluminum alloy, brass, stainless steel, or a resin having heat resistance can be used. Examples of the resin having heat resistance include PTFE and PFA.

On the other hand, examples of the material of the cooling air pipe 15 include metals such as aluminum, stainless steel, and brass, and heat-resistant resins such as polyamide and PFA. In order to make the cooling air pipe 15 less susceptible to temperature changes due to the atmosphere in the upper vacuum chamber 8, a heat insulating material and a glossy metal thin film layer such as aluminum that can efficiently reflect radiant heat to the outer periphery of the heat insulating material are provided. It is good also as a structure which keeps the temperature rise by an atmosphere low by wrapping and winding the heat-resistant tape etc. which have.
In the apparatus 20, when the gas injection means (cooling air introduction system) 15 and 16 as described above are provided, variation in the degree of crosslinking between batch processes can be suppressed, and productivity can be further improved. . The cooling air introduced into the upper vacuum chamber 8 is discharged through the cooling air exhaust port 17.

<Buffer layer>
Further, a soft metal sheet, a soft resin sheet, a rubber sheet or the like is used as the buffer layer 22 between the support 10 and the laminate 7 in order to protect the surface of the laminate 7 and improve the uniformity of the surface pressure. You may arrange. Examples of the material of the rubber sheet include heat-resistant rubbers such as silicone rubber and fluorine-based rubber.

<Solar cell module laminate>
When manufacturing a solar cell module according to the present invention, a laminate 7 in which at least a heat-crosslinking resin sheet (sealing resin sheet) for sealing and a surface protection member are sequentially stacked on at least one surface of the solar cell element. Use. In the present invention, the laminate 7 itself is heated at a high speed by the heat generated by the light absorption of the surface protection member and the sealing resin sheet. Therefore, the sealing resin sheet and the cover sheet are laminated at least on the incident light side.
For example, as shown in FIG. 3, a laminated body 7 in which heat-crosslinkable resin sheets 2 and 4 for sealing such as EVA and surface protective members 1 and 5 are sequentially laminated on both surfaces of the solar cell element 3. The light from the light irradiation unit 14 can be efficiently absorbed by the sealing resin sheets 2 and 4 and the surface protection sheets 1 and 5 and heated at high speed, and integrated sealing as shown in FIG. The entire solar cell element 3 can be reliably protected through the resin layer 6.

  As the solar cell element 3, a known element can be used. For example, the solar cell element 3 may be selected from a single crystal silicon solar cell, a polycrystalline silicon solar cell, an amorphous silicon solar cell, a compound semiconductor solar cell, and the like according to the purpose. .

As the heat-crosslinkable resin sheets (sealing resin sheets) 2 and 4 for sealing, while being melted by irradiation with infrared light having a specific wavelength from the light irradiation unit 14 and causing a crosslinking reaction, Compared to the resin composition that improves the mechanical strength and heat resistance of the sealing resin sheets 2 and 4 themselves, and a strong bond is formed by a chemical action at the bonding interface with the sealing resin sheets 2 and 4. The resin composition etc. which have the thermal crosslinking property and chemical adhesiveness which are made can be used. In any case, it is important that the sealing resin sheets 2 and 4 have transparency and adhesiveness after heating and melting by irradiation with infrared light having a specific wavelength. The non-fluorinated resin sheet is suitable as the sealing resin sheets 2 and 4 because it easily absorbs infrared light having a wavelength in the range of 1.2 μm to 3.6 μm. Specific materials for the sealing resin sheets 2 and 4 are based on resins such as low crystalline ethylene-vinyl acetate copolymer (EVA), saponified products thereof, polyvinyl butyral (PVB), and soft polyolefin. , A resin composition containing a radical initiator, a crosslinking aid, a silane coupling agent, and the like. The surface of the sealing resin sheets 2 and 4 may be embossed to facilitate the elimination of bubbles.
When a plurality of sealing resin sheets 2 and 4 are used, the same material, thickness, and area may be used, or they may be different from each other. Moreover, even if the material is the same, a plurality of sealing resin sheets 2 and 4 having different thicknesses may be used.

Examples of the material of the surface protection members (cover sheets) 1 and 5 include various resin sheets, inorganic material substrates, and composite sheets made of a resin material and an inorganic material. In any case, as the surface protection members 1 and 5, at least the light receiving surface has translucency. The surface protection members 1 and 5 may be the same or different in material, thickness and area. Further, the surface protection members 1 and 5 may be made of the same material or different in thickness or area.
Specific materials for the surface protection members 1 and 5 include, in the case of a resin sheet, polyethylene, polypropylene, polybutene, poly-4-methyl-1-pentene, polyolefins such as ethylene-cyclic olefin copolymer, and ethylene-acrylic acid copolymer. Polymer, polyester such as ethylene polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyamide such as nylon 6, nylon 66, nylon 46, nylon 12, MXD nylon, acrylic polymer such as polymethyl methacrylate, polyacrylic acid, Halogen-containing polymers such as polystyrene, polyacrylonitrile, acrylonitrile-butadiene-styrene copolymers, vinyl chloride, polyvinylidene chloride, polyfluoroethylene, polyvinylidene fluoropolymer, Synthetic rubbers such as rebutadiene and polyisoprene, and their hydrogenated products, thermoplastic elastomers such as styrene-butadiene-styrene block copolymers and their hydrogenated products, liquid crystal polymers, polyurethane, polycarbonate, polysulfone, polyetheretherketone And polyimide.

  There is no restriction | limiting in particular in the molding method of such a resin sheet, A well-known method can be used. Specific examples include an extrusion molding method, a solution casting method, an injection molding method, a press molding method, and a blow molding method. The resin sheet may have a single layer structure or a multilayer structure. The resin sheet having a multilayer structure can be molded by a known method such as coextrusion molding, extrusion lamination, dry lamination, press molding, or the like.

On the other hand, when the material of the surface protection members 1 and 5 is an inorganic material substrate, an electrically insulating ceramic crystal substrate, a glass substrate, and a metal plate are exemplified. Examples of the electrically insulating ceramic crystal substrate include oxide ceramic crystals such as quartz, alumina, magnesia and zirconia, and nitride ceramic crystals such as silicon nitride, silicon nitride and aluminum nitride. Examples of the glass substrate include crown glasses such as borosilicate glass and white plate glass. Examples of the metal plate include a plate material made of an aluminum alloy, a copper alloy, steel, or the like. The surface of the metal plate may be subjected to a known surface treatment such as plating, painting, alumite treatment, or insulation coating.
Moreover, when the material of the surface protection members 1 and 5 is a composite sheet made of a resin material and an inorganic material, a resin sheet in which an inorganic material is deposited on the surface, a composite sheet in which a metal sheet and a resin sheet are laminated in advance, a resin Examples include a composite sheet in which an inorganic material is dispersed inside the sheet.

Next, a method for manufacturing a solar cell module using the device 20 as described above will be exemplified.
For example, as shown in FIG. 3, the solar cell element 3 is placed on the support table 10 in the lower vacuum chamber 9 through the sealing resin sheets 2 and 4, the front and back surface protection members (cover sheets) 1, The laminated body 7 sandwiched by 5 is placed on and supported on the support base 10. Next, the two vacuum chambers 8 and 9 are exhausted simultaneously through the intake and exhaust ports 11 and 12 of the upper and lower vacuum chambers 8 and 9, respectively, and the air between the layers of the laminate 7 is sufficiently exhausted. Only the upper vacuum chamber 8 is returned to atmospheric pressure. Thereby, a surface pressure corresponding to substantially atmospheric pressure is applied to the laminate 7 through the light transmissive pressure sheet 13. After that, as described above, light including infrared light in a specific wavelength range is irradiated to the laminate 7 through the light-transmitting pressure sheet 13 from the light irradiation unit 14 in the upper part of the upper vacuum chamber 8. 7 is heated.

  During heating, for example, light having a maximum spectral radiance below a wavelength of 1.2 μm, or a maximum spectral radiance at a wavelength of 1.2 μm to 3.6 μm, the spectral radiance at a wavelength of 1.1 μm is maximum. When light exceeding 30% of the spectral radiance is used, there arises a problem that the variation in the degree of cross-linking of the sealing resin within the solar cell module surface becomes large.

  On the other hand, when the light having the maximum spectral radiance in the range exceeding the wavelength of 3.6 μm is used, the spectral transmittance of the light exceeding the wavelength of 3.6 μm is lowered if the light-transmitting pressure sheet 13 is a fluororesin sheet. To do. Therefore, in the case of using the light-transmitting pressure sheet 13 made of a fluororesin, the maximum spectral radiance is shown between wavelengths of 1.2 μm and 3.6 μm, and the spectral radiance at a wavelength of 1.1 μm is high. It is preferable to irradiate light that is 30% or less of the maximum spectral radiance. Further, when the light-transmitting pressure sheet 13 is not used, the maximum spectral radiance is shown between wavelengths of 1.2 μm and 12 μm, and the spectral radiance at a wavelength of 1.1 μm is the maximum spectral radiance. By irradiating with light of 30% or less, the encapsulating resin sheets 2 and 4 can be efficiently heated to promote crosslinking throughout.

  When the laminate 7 is pressed in the laminating direction by the light-transmitting pressure sheet 13, the maximum spectral radiance is exhibited at a wavelength of 1.2 μm to 3.6 μm, and the spectral radiance at a wavelength of 1.1 μm. Is irradiated with light that is 30% or less of the maximum spectral radiance to heat the laminate 7. By such heating, the sealing resin sheets 2 and 4 of the laminate 7 are melted as a whole and are in close contact with the solar cell element 3 and the cover sheets 1 and 5. Furthermore, a crosslinking reaction or adhesion proceeds due to the crosslinking property or chemical adhesion property of the sealing resin sheets 2 and 4.

After irradiating infrared light having a specific wavelength as described above and pressing the laminate 7 with the light-transmitting pressure sheet 13, the irradiation with light having the wavelength is stopped. At this time, the temperature of the support 10 in the upper vacuum chamber 8 including the light-transmitting pressure sheet 13 and the lower vacuum chamber 9 is affected by the light irradiation, and may increase compared to before the light irradiation. is there. Therefore, it is preferable to blow a cooling gas on the light transmissive pressure sheet 13.
By blowing the cooling gas, the degree of cross-linking of the sealing resin sheets 2 and 4 is less likely to vary between batch processes.

  Specifically, with the surface pressure applied to the solar cell module 21 by the light transmissive pressure sheet 13, the cooling air is sent to the cooling air pipe 15 by, for example, a blower or a compressor. Then, cooling air is blown from the blow nozzle 16 toward the light transmissive pressure sheet 13 to quickly cool the light transmissive pressure sheet 13, the upper vacuum chamber 8, and the support 10. The temperature of the air to be blown is preferably room temperature or lower.

The injection of the cooling air as described above facilitates stable temperature control in the heating / cooling cycle for each batch process, and variation in the degree of crosslinking of the sealing resin sheets 2 and 4 of the solar cell module 21 between the batch processes. Can be small. Moreover, while being able to perform the stable bridge | crosslinking process of the resin sheets 2 and 4 for sealing of the solar cell module 21 for every batch process, the time (molding cycle) required for one batch process can be sped up. The injection of cooling air may be used for the purpose of cooling the inside of the upper vacuum chamber 8 including the light transmissive pressure sheet 13 even when the solar cell module 21 is not provided.
After cooling, the inside of the lower vacuum chamber 9 is returned to atmospheric pressure, and the integrated solar cell module 21 is taken out.

  As described above, in the apparatus 20 having the configuration as shown in FIG. 1, the laminated body 7 in which the solar cell element 3, the thermally crosslinkable resin sheets 2 and 4, and the surface protection members 1 and 5 are sequentially stacked. In the state where surface pressure is applied by the light-transmitting pressure sheet 13, the maximum spectral radiance is exhibited at a wavelength of 1.2 μm to 12 μm, more preferably at a wavelength of 1.2 μm to 3.6 μm. Irradiate the laminated body 7 with infrared light having a spectral radiance at 1 μm of 30% or less of the maximum spectral radiance through a light-transmitting pressure sheet 13 made of a low crystalline fluororesin or the like. Heat at high speed. As a result, the sealing resin sheets 2 and 4 are melted and a crosslinking reaction is caused to integrate the members at a high speed and a high degree of crosslinking.

More preferably, after the light irradiation, with the surface pressure applied to the solar cell module 21, cooling air is blown toward the light transmissive pressure sheet 13 to further pressurize the light inside the upper vacuum chamber 8. The solar cell module 21 and the support base 10 in the lower vacuum chamber 9 are cooled via the sheet 13. Thereby, the solar cell module 21 having a stable quality with little variation in the degree of cross-linking of the sealing resin layer 6 between each batch process and in the surface of the solar cell module in each batch process is improved. Can be manufactured in cycles.

Hereinafter, the present invention will be described more specifically with reference to examples and comparative examples.
<Example 1>
[Laminated body for solar cell module]
In order to manufacture a solar cell module, a laminate 7 having a configuration as shown in FIG. 3 was prepared. Table 1 shows member configurations of the solar cell modules used in the examples and comparative examples.

  As shown in Table 1, a white glass substrate (thickness 1 mm) as the front cover sheet 1 and the back cover sheet 5, and an ethylene-vinyl acetate copolymer sheet as the upper sealing resin sheet 2 and the lower sealing resin sheet 4 (Mitsui Chemicals Fabro Co., Ltd. “Solar Eva” standard cross-linking brand SC50B, thickness 0.6 mm), a silicon crystal element (thickness 0.3 mm) on which a conductive wiring pattern is formed as a solar cell element 3 Using. The distance between silicon crystal elements was 15 mm.

[Solar cell module manufacturing equipment]
A double vacuum type solar cell module manufacturing apparatus (vacuum lamination apparatus) 20 as shown in FIG. 1 was assembled.
A linear halogen heater was used as the light source 14a of the light irradiation unit 14, and a silicon plate was mounted as a wavelength filter 14b at the radiation end of the light irradiation unit 14 as shown in FIG. The light emitted from the halogen heater is irradiated downward through the wavelength filter 14b.

The cooling air introduction system was provided with cooling air pipes 15 arranged in parallel between the line-shaped halogen heaters. As the blow nozzle 16, a flat spray nozzle was used, and the cooling air was jetted vertically downward along the cooling air pipe 15. Both the cooling air pipe 15 and the blow nozzle 16 were made of stainless steel. The cooling air was used at room temperature.
Further, in the upper vacuum chamber 8, both the light irradiation unit 14 and the cooling air pipe 15 are suspended and incorporated in the upper part of the upper vacuum chamber 8 so that the line-shaped halogen heater light is irradiated downward.

An aluminum plate (thickness 10 mm) with an electric heater embedded therein was used on the upper part of the support base 10. Moreover, as shown in FIG. 6, as the buffer layer 22 between the solar cell module 21 and the support base 10, an aluminum sheet 18 (thickness 50 μm) and a silicone rubber sheet 19 (thickness 2 mm) were provided in this order from the top. .
For temperature control, the aluminum sheet 18 of the buffer layer 22 is placed below the center of the surface of the solar cell element 3 of the solar cell module member (laminated body 7) with a sheath type thermocouple (outer diameter of the sheath temperature contact portion 0.25 mm). And the temperature of the solar cell module was monitored.

  On the other hand, a PFA sheet (thickness 1 mm) was prepared as the light transmissive pressure sheet 13. The spectral transmittance spectrum of this PFA sheet from a wavelength of 0.2 μm to 10 μm is as shown in FIG. That is, the spectral transmittance of the used PFA sheet was 60% or more in the wavelength range of 1.2 μm to 3.6 μm.

[Manufacture of solar cell modules]
Using the apparatus 20 configured as described above, the solar cell module 21 was manufactured through the following steps.
The temperature of the support 10 of the lower vacuum chamber 9 was previously maintained at 75 ° C. by an electric heater. A solar cell module member (laminated body 7) is placed on the buffer layer 22 of the support 10 of the lower vacuum chamber 9 in the apparatus 20. Immediately thereafter, the upper vacuum chamber 8 is closed and kept in contact with the light-transmitting pressure sheet (PFA sheet) 13 and the upper surface of the white glass substrate above the solar cell module. The upper and lower vacuum chambers 8 and 9 are depressurized simultaneously. The pressure at this time was kept at 0.1 kPa. Next, the inside of the upper vacuum chamber 8 was gradually returned to atmospheric pressure while maintaining the reduced pressure inside the lower vacuum chamber 9. Thereby, a uniform surface pressure is applied to the white glass substrate above the solar cell module. The time required to return the upper vacuum chamber 8 to atmospheric pressure after placing the solar cell module 21 on the support base 10 was 2 minutes.

As light irradiation conditions, light corresponding to a constant light irradiation power (irradiance) of 6 W / cm ² per unit area until the thermocouple indication temperature reaches 105 ° C. (spectral radiance spectrum is shown in FIG. 7). Irradiated. After the temperature reached 105 ° C., the irradiance was controlled so that the temperature became constant at 105 ° C. Light irradiation was continued so that the total heating time from placing the solar cell module 21 on the support 10 to turning off the energization of the infrared heater was 6 minutes. FIG. 7 shows that the wavelength indicating the maximum spectral radiance is 1.3 μm, and the spectral radiance at the wavelength of 1.1 μm is 30% or less of the maximum spectral radiance.

  Immediately after the light irradiation, that is, after turning off the power to the infrared heater, cooling air was immediately supplied from the blow nozzle 16 to cool the temperature to 75 ° C. The time required for the temperature to drop to 75 ° C. after flowing the cooling air was 2 minutes. Thereafter, the injection of cooling air was stopped, and the lower vacuum chamber 9 was returned to atmospheric pressure. The solar cell module 21 was taken out and placed on an aluminum plate having a thickness of 2 mm. After light irradiation, the light-transmitting pressure sheet 13 did not show any damage such as creep deformation, melting marks, rupture, and holes. Moreover, the solar cell module 21 was transparent from the light-receiving surface side, and the sealing resin layer 6 had transparency, and defects such as bubbles were not recognized.

  Furthermore, the light irradiation conditions for each member of the stacked solar cell module, that is, the light irradiance at the time of temperature rise, the holding time, the heating time, the cooling operation by cooling air, and the series of operations from taking out the solar cell module 21 from the apparatus. The process was a batch process, and such a batch process was repeated 10 times including the batch process described above.

[Measurement of gel fraction (crosslinking degree) of sealing resin]

  After heating and cooling, in order to examine whether or not the crosslinking of the sealing resin layer 6 of the solar cell module 21 has progressed, the gel fraction was examined as a measure of the degree of crosslinking. From the viewpoint of imparting mechanical strength and creep resistance, a practical gel fraction guideline is approximately 70% or more. However, if the variation in the degree of cross-linking in the module surface becomes large or the degree of cross-linking is too high, yellowing occurs in the sealing resin sheets 2 and 4 due to aging deterioration such as oxidation due to ultraviolet light or thermal cycle, resulting in uneven color. Is likely to occur. As a result, in addition to appearance deterioration, reliability of electrical insulation resistance degradation, local temperature rise (hot spot), electrical insulation breakdown, cracking of solar cell elements due to foaming of sealing resin that has become hot, etc. There is a risk of lowering. For this reason, the uniformity of the gel fraction in a solar cell module surface is so preferable that it is high.

Since the variation in the degree of crosslinking in the solar cell module surface is also taken into consideration, as shown in FIG. 5, the sample 6 a mainly in the vicinity of both surfaces of the silicon crystal element 3 and the sample 6 b between the silicon crystal elements 3 are used as measurement samples. Were collected.
As a method for measuring the gel fraction, 300 mg of a sample was weighed on a stainless steel screen having a nominal opening of 45 μm as defined in JIS Z8801 “Sieving for testing—Part 1: Metal screen” and a Soxhlet extraction device. Was extracted with xylene for 3 hours, and the weight percentage (extraction residual ratio) of the xylene-insoluble portion remaining in the stainless steel net was determined as the gel fraction as shown by the following formula.

(B / A) × 100 [%]
A: Sample weight before extraction [mg]
B: Weight of insoluble part of xylene remaining in stainless steel mesh cage [mg]

The predetermined heating time from placing the laminate 7 on the support 10 to turning off the infrared heater is 6 minutes, and for the sealing resin obtained in the first and tenth batch processing, The gel fraction in the vicinity of the silicon crystal elements and between the silicon crystal elements was examined.
Table 2 shows the gel fraction evaluation results, visual observation results, and the like.

<Example 2>
As the light source 14a of the light irradiation unit 14, a linear carbon heater in which a carbon wire is enclosed in a quartz tube was used instead of the linear halogen heater in the first embodiment. Note that no wavelength filter is used. The light emitted from the carbon heater was irradiated through a reflection mirror. In the same manner as in Example 1, the light irradiation unit 14 was incorporated into the upper vacuum chamber 8 shown in FIG. Hereinafter, light irradiation conditions for the light transmissive pressure sheet 13, the cooling air introduction systems 15 and 16, the thermocouple thermometer, the support 10, and each of the stacked solar cell module members, that is, light emission at the time of temperature rise The solar cell module 21 was manufactured in the same manner as in Example 1 until the illuminance, the holding temperature, the heating time, the cooling operation with cooling air, and the removal of the solar cell module 21 from the apparatus.
In addition, the spectral radiance spectrum of the light radiated | emitted from the light irradiation unit 14 at the time of temperature rising was as showing in FIG. FIG. 8 shows that the wavelength showing the maximum spectral radiance is 2.4 μm, and that the spectral radiance at the wavelength of 1.1 μm is 30% or less of the maximum spectral radiance.

After light irradiation, the light-transmitting pressure sheet 13 did not show any damage such as creep deformation, melting marks, rupture, and holes. Further, the solar cell module 21 was externally viewed from the light receiving surface side, and the sealing resin layer 6 was transparent, and no defects such as bubbles were observed.
The same method as in Example 1 was adopted as the method for evaluating the bonding property to the solar cell module 21. The gel fraction of the sealing resin layer 6 which is held at 105 ° C. immediately after the solar cell module 21 is placed on the support 10 and is processed with a predetermined heating time of 6 minutes until the infrared heater is turned off. Was measured. The obtained results are shown in Table 2.

<Example 3>
Using the vacuum lamination apparatus used in Example 2, batch processing was repeated up to 10 times without injection of cooling air. After one batch processing, that is, after the integrated solar cell module 21 was taken out, the solar cell module member for the next batch was placed in the vacuum lamination device without interruption for the next batch processing. Except for removing the solar cell module 21 from the apparatus without cooling by jetting of cooling air, the light to the light transmissive pressure sheet 13, the thermocouple thermometer, the support 10 and the stacked solar cell module members The irradiation conditions, that is, the light irradiance at the time of temperature rise, the holding temperature, and the heating time were the same as in Example 2 to obtain a solar cell module 21.

Although the sealing resin layer 6 of the solar cell module 21 obtained in the 10th batch had transparency in appearance when viewed from the light receiving surface side, some bubbles were observed.
The same method as in Example 2 was adopted as the method for evaluating the bonding property to the solar cell module 21. That is, the solar cell module 21 is held at 105 ° C. immediately after being placed on the support base 10 and the predetermined heating time until the infrared heater is turned off is set to 6 minutes. The gel fraction in the vicinity of the silicon crystal element and between the silicon crystal elements was measured for the sealing resin layer 6 thus obtained. The results are shown in Table 2.

<Comparative Example 1>
As the solar cell module member (laminated body 7), one having the same member configuration and dimensions as those used in the examples was used.
On the other hand, as for the solar cell module manufacturing apparatus, a line-shaped halogen heater was used as the light source 14a of the light irradiation unit 14, and the vacuum lamination apparatus 60 was configured as shown in FIG. Here, no wavelength filter is used. Note that the spectral radiance spectrum of the light emitted from the light irradiation unit 14 when the temperature was raised was as shown in FIG. FIG. 10 shows that the wavelength exhibiting the maximum spectral radiance is 0.9 μm, light including a little ultraviolet light, a lot of visible light, and infrared light having a wavelength of 0.8 μm to about 5 μm. Show.
Hereinafter, except that the holding temperature is 115 ° C., light irradiation conditions for the light transmissive pressure sheet 13, the cooling air introduction system, the thermocouple thermometer, the support 10, and each member of the stacked solar cell module That is, the solar cell module 21 was obtained in the same manner as in Example 1 until the light irradiance during heating, the heating time, the cooling operation with cooling air, and the removal of the solar cell module 21 from the apparatus.

The sealing resin layer 6 of the integrated solar cell module 21 was transparent in appearance as viewed from the light receiving surface side, and no defects such as bubbles were observed.
The same method as in Example 1 was adopted as the method for evaluating the bonding property to the solar cell module 21. That is, the solar cell module 21 is held at 115 ° C. immediately after being placed on the support base 10, and the predetermined heating time until turning off the infrared heater is 6 minutes, and the sealing obtained by the first batch processing is performed. The gel fraction of the silicon crystal element vicinity part 6a and the silicon crystal element part 6b was measured with respect to the stopping resin layer 6. The results are shown in Table 2.

<Comparative example 2>
The vacuum lamination apparatus has the same structure as that used in the embodiment, except that the light irradiation unit 14, the cooling air introduction systems 15 and 16, and the buffer layer 22 on the support base 10 are removed, and the light-transmitting pressure sheet 13 is replaced with a diaphragm. It changed into the fluororubber sheet (thickness 1mm) as (pressure partition).

  As a pressure bonding method, the support base was previously held at 150 ° C., and in this state, each member of the solar cell module was placed on the support base, and the upper and lower vacuum chambers were decompressed to a pressure of 0.1 kPa. Thereafter, the upper vacuum chamber was returned to atmospheric pressure to apply a uniform surface pressure to the solar cell module via the fluororubber sheet. The time required to return the upper vacuum chamber to atmospheric pressure after placing the solar cell module on the support was 2 minutes. Immediately after placing the solar cell module on the support, the solar cell module was held in a state where surface pressure was applied to the three levels of 6 minutes, 8 minutes, and 15 minutes as the heating time. Immediately thereafter, the lower vacuum chamber was returned to atmospheric pressure, and the integrated solar cell module was immediately taken out. It mounted on the aluminum plate of thickness 2mm similarly to the Example, and it stood to cool at room temperature.

As viewed from the light receiving surface side, the solar cell module was observed to have slight bubbles generated on the top of the silicon crystal element (solar cell element).
Moreover, the same method as Example 1 was employ | adopted for the evaluation method of the adhesiveness with respect to a solar cell module. Immediately after placing the solar cell module on the support stand, it is held at 150 ° C., and with a predetermined heating time (6 minutes, 8 minutes, and 15 minutes), for the sealing resin obtained in the first batch process, The gel fraction in the vicinity of the silicon crystal elements and between the silicon crystal elements was measured. The results are shown in Table 2. It was found that the gel fraction was less than 1% when the heating time was 6 minutes and finally reached 70% or more after 15 minutes.

Although the present invention has been described above, the present invention is not limited to the above embodiments and examples. For example, a single vacuum method may be adopted as the vacuum pressurization method.
Moreover, in the said embodiment and Example, after pressing the laminated body for solar cell modules with a light transmissive pressurization sheet, it is between wavelengths 1.2micrometer-3.6 micrometers via a light transmissive pressurization sheet. However, the present invention has been mainly described in the case where heating is performed by irradiating light having a spectral radiance at a wavelength of 1.1 μm that is 30% or less of the maximum spectral radiance. It is not limited to. For example, with respect to a laminate for a solar cell module, the maximum spectral radiance is exhibited at a wavelength of 1.2 μm to 12 μm without using a light-transmitting pressure sheet, and the spectral radiance at a wavelength of 1.1 μm. May be heated by irradiating with light that is 30% or less of the maximum spectral radiance, and then pressed by a pressure sheet to be pressure-bonded.

  Furthermore, the direction in which infrared light having a specific wavelength as described above is irradiated is not particularly limited. For example, for a laminate in which a sealing resin sheet and a surface protection member are sequentially stacked on one surface of a solar cell element. The infrared light having the specific wavelength may be irradiated from the solar cell element side to be crimped.

It is the schematic which shows the structure of an example of the manufacturing apparatus of the solar cell module used in Example 1. FIG. It is a figure which shows the spectral transmittance spectrum of a PFA sheet (thickness 1mm). It is the schematic which shows an example of a structure of the laminated body used when manufacturing a solar cell module. It is the schematic which shows the cross section of the solar cell module which integrated the laminated body shown in FIG. It is the schematic which shows the extraction | collection location of the resin sample for sealing for gel fraction measurement. It is the schematic which shows the structure of the buffer layer inserted between the support stand and the solar cell module in the Example. It is a figure which shows the spectral radiance spectrum of the light used in Example 1. FIG. It is. It is a figure which shows the spectral radiance spectrum of the light used in Example 2. FIG. It is the schematic which shows the structure of an example of the manufacturing apparatus of the solar cell module used by the comparative example 1. FIG. It is a figure which shows the spectral radiance spectrum of the light used in the comparative example 1. It is the schematic which shows the conventional solar cell module manufacturing apparatus of a double vacuum system. It is the schematic which shows the conventional single vacuum system solar cell module manufacturing apparatus.

Explanation of symbols

1 ... Surface cover sheet (surface protection member)
2 ... Upper sealing resin sheet 3 ... Solar cell element 4 ... Lower sealing resin sheet 5 ... Back cover sheet (surface protective member)
6 ... Resin layer for sealing 7 ... Laminated body for solar cell module 8 ... Upper vacuum chamber 9 ... Lower vacuum chamber 10 ... Support base 11 ... Intake / exhaust port for upper vacuum chamber 12 ... Intake / exhaust port for lower vacuum chamber 13 ... Light transmitting pressure sheet 14 ... Light irradiation unit (heater)
14a ... light source 14b ... wavelength filter (optical component)
15 ... Cooling air piping 16 ... Blow nozzle (gas injection means)
17 ... Cooling air exhaust port 20 ... Solar cell module manufacturing apparatus 21 ... Solar cell module 22 ... Buffer layer

Claims (6)

  At least one side of the solar cell element is pressed in the laminating direction with a laminate in which at least a heat-crosslinking resin sheet for sealing and a surface protection member are sequentially laminated, and the wavelength is applied to the laminate from at least one side. The laminate is produced by irradiating and heating light having a maximum spectral radiance between 1.2 μm and 12 μm and a spectral radiance at a wavelength of 1.1 μm of 30% or less of the maximum spectral radiance. The manufacturing method of the solar cell module characterized by including the process of crimping | bonding.   Using a pressure reduction type apparatus equipped with a light-transmitting pressure sheet that transmits light, the laminate is pressed in the stacking direction by the light-transmitting pressure sheet, and the light-transmitting property is applied to the stack. Irradiates light with a maximum spectral radiance between 1.2 μm and 3.6 μm through the pressure sheet, and the spectral radiance at a wavelength of 1.1 μm is 30% or less of the maximum spectral radiance. The method for manufacturing a solar cell module according to claim 1, wherein the laminate is pressure-bonded by heating.   3. The light-transmitting pressure sheet is pressed against the laminate, and then the light irradiation is stopped, and a cooling gas is sprayed on the light-transmitting pressure sheet. The manufacturing method of the solar cell module of description. An apparatus for manufacturing a solar cell module,
A vacuum chamber;
In the vacuum chamber, on at least one surface of the solar cell element, a support base for supporting a laminate in which at least a heat-crosslinking resin sheet for sealing and a surface protection member are sequentially stacked,
The maximum spectral radiance between wavelengths of 1.2 μm and 3.6 μm is exhibited with respect to the laminate supported on the support, and the spectral radiance at a wavelength of 1.1 μm is the maximum spectral radiance. Light irradiation heating means for irradiating and heating light that is 30% or less of
A light-transmitting pressure sheet that transmits light from the light irradiation heating means and pressurizes and press-bonds the laminated body supported on the support base in the laminating direction. Manufacturing equipment for solar cell modules.   The inside of the vacuum chamber is partitioned by the light transmissive pressure sheet, and has a first vacuum chamber in which the support base is disposed, and a second vacuum chamber in which the light irradiation heating means is disposed. The manufacturing apparatus of the solar cell module according to claim 4, wherein   The apparatus for manufacturing a solar cell module according to claim 4 or 5, further comprising gas injection means for spraying a cooling gas to the light transmissive pressure sheet.

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