JP2008258269A - Solar cell module and manufacturing process of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar cell module that can be manufactured easily for effectively preventing inflow of water from an end part of the module and also for effectively preventing generation of crack and missing of the solar cell in the manufacturing process. <P>SOLUTION: The solar cell module 1A is provided with a solar cell array 2 including a plurality of solar cells 3, a rear surface side plate glass 11 located in the side not receiving the light of the solar cell array 2, a front surface side plate glass 12 located in the light receiving side of the solar cell array 2, a frame spacer member 6 located between the rear surface side plate glass 11 and the front surface side plate glass 12 surrounding the solar cell array 2 to acquire a space to arrange the solar cell array 2 in the thickness direction of the solar cell array 2, and a light transmitting resin sealing layer 20 located between the rear surface side plate glass 11 and the front surface side plate glass 12 in close contact with the rear surface side plate glass 11, front surface side plate glass 12 and a frame type spacer member 6 in order to seal therein the solar cell array 2. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a solar cell module and a method for manufacturing the solar cell module, and more particularly to a solar cell module having a laminated glass structure used for residential use and industrial use and a method for manufacturing the solar cell module.

  There are various types of solar cell modules depending on the application, usage environment, and the like. One such solar cell module is a solar cell module having a laminated glass structure. This solar cell module having a laminated glass structure has a structure in which a solar cell array composed of a plurality of solar cells electrically connected to each other is sandwiched between a front side plate glass and a back side plate glass and sealed inside the module. I have it.

  In the solar cell module provided with this laminated glass structure, the sunlight that has passed through the front side plate glass and entered the solar cell module passes through the translucent resin sealing layer of the portion where the solar cells do not exist, and the back surface. Sunlight reaching the side plate glass and reaching the back side plate glass is transmitted outside the solar cell module through the back side plate glass. Therefore, the solar cell module provided with the laminated glass structure is suitably used as a so-called daylighting type solar cell module capable of collecting sunlight even in a space located on the back side of the solar cell module.

  The solar cell module provided with the laminated glass structure uses a back side plate glass instead of the back side back film of the solar cell module provided with an assembly structure generally called a super straight structure. In the solar cell module provided with this laminated glass structure, tempered glass is used as the front side plate glass and the back side plate glass, and the thickness is designed to a thickness that can withstand the required wind pressure load. As a result, it can be installed on various building structures such as windows and skylights of buildings such as houses and buildings, sound insulation walls of roads, and arcades.

  In addition, as a solar cell module provided with the industrial laminated glass structure, what laminated | stacked the solar cell module provided with the said laminated glass structure through the spacer member made from aluminum, etc. also exists. Even in the solar cell module having such a multilayer structure, the same lighting effect as that of the above-described solar cell module can be obtained.

As literatures which disclosed the solar cell module provided with the laminated glass structure mentioned above, there exist JP, 2003-26455, A (patent documents 1) and JP, 2004-288777, A (patent documents 2), for example. In the solar cell module having the laminated glass structure disclosed in these documents, the solar cell cell array is sealed with a translucent resin sealing layer, and the solar cell cell array sealed with the translucent resin sealing layer Is inserted into a subassembly made of a front side plate glass and a back side plate glass to form a module.
JP 2003-26455 A JP 2004-288777 A

  In the solar cell module provided with the laminated glass structure disclosed in Patent Documents 1 and 2, in order to provide an air layer for heat insulation and sound insulation inside the module, a translucent resin sealing layer is provided on the surface side plate glass or / In addition, sealing to the back side plate glass is not performed. However, in manufacturing a solar cell module having a laminated glass structure that does not particularly require such an air layer, the assembly of sealing the translucent resin sealing layer to both the front side glass plate and the rear side glass plate. It is envisaged that a structure will be adopted. A solar cell module employing such an assembly structure is shown in FIG. FIG. 17 is an exploded perspective view for specifically explaining the assembly structure.

  As shown in FIG. 17, first, solar cells 3 made of a thin film semiconductor material typified by a crystalline or amorphous semiconductor having a semiconductor junction such as a pn junction are arranged in an array, and these arrays are arranged. The solar cells 3 are manufactured by electrically connecting the solar cells 3 to each other using a wiring 4 made of a conductive material such as a metal wire. Next, the solar cell cell array 2 is sandwiched between the first and second laminate films 21 and 22 from above and below. Next, these laminated bodies are inserted | pinched from the up-down direction using the surface side plate glass 12 and the back surface plate glass 11. FIG. By heating the laminate composed of the front side plate glass 12 / second laminate film 22 / solar cell array 2 / first laminate film 21 / back side plate glass 11 thus obtained while applying pressure under vacuum, Lamination is performed. As described above, the solar cell module 1X having a laminated glass structure in which the solar cell cell array 2 is sealed through the translucent resin sealing layer inside the front-side plate glass 12 and the back-side plate glass 11 arranged to face each other is manufactured. The

  By the way, in the recent solar cell module, the request | requirement with respect to the design property, such as harmony with a building structure and a surrounding environment, increases, and the request | requirement which enlarges a solar cell module according to it increases. Normally, solar cell modules used for residential or industrial use that are installed only for power generation are not particularly designed, and the four sides of the solar cell panel are made of aluminum. The structure installed in a mount etc. in the state hold | maintained using the frame etc. is employ | adopted. In order to prevent moisture such as rainwater from flowing into the module, a buffer rubber material (for example, elastomer rubber) is interposed between the solar cell panel and the frame. In addition, as another water-stopping treatment, the module end may be sealed with silicon resin. However, in the daylighting type solar cell module, it is not preferable to perform the water-stopping treatment, and the solar cell module is installed in the building structure with the light-transmitting resin sealing layer exposed at the end of the module.

  In the solar cell module that employs the assembly structure shown in FIG. 17 described above, in order to prevent the solar cells from being cracked or chipped under a pressure environment during the lamination process, It is necessary to interpose a plurality of sheet-like resin members interposed between the two. Therefore, the thickness as a solar cell module will increase and the exposed surface to the exterior of the translucent resin sealing layer in the module edge part will increase. As a result, the translucent resin encapsulating layer absorbs more moisture, which causes a problem of facilitating the discoloration of the translucent resin encapsulating layer and the deterioration of the characteristics of the solar battery cell. In particular, when a thin-film solar battery cell is used as the solar battery cell, there is a problem that a peeling phenomenon occurs in the solar battery cell due to the inflow of moisture.

  Further, in the solar cell module employing the assembly structure shown in FIG. 17 described above, the end of the module is caused by the pressure applied to the front side glass sheet and the back side glass sheet by the sheet-like resin member that has been softened during the laminating process. There is also the problem of eating out in large quantities. When such protrusions occur, it is necessary to cut the protrusions separately, which causes a problem that the manufacturing process becomes complicated.

  Furthermore, in the solar cell module that employs the above-described assembly structure, as the solar cell module becomes larger, the front side plate glass and the back side plate glass also increase in area and increase in weight. Along with the increase in weight of the front side plate glass and the back side plate glass, the pressure applied to the solar battery cell increases during the lamination before the lamination process, and there is a problem that the possibility that the solar battery cell is cracked or chipped increases. Similarly, even during the laminating step, pressure is applied to the solar cells more than necessary, and a problem arises in that the solar cells are cracked or chipped.

  As described above, when the assembly structure shown in FIG. 17 described above is employed, various problems arise with an increase in the size of the solar cell module.

  Therefore, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a solar cell module that can be easily manufactured and that can effectively prevent the inflow of moisture from the end of the module. And providing a manufacturing method thereof. Another object of the present invention is to provide a solar cell module that can be easily manufactured and that can effectively prevent the occurrence of cracking or chipping of the solar cells in the manufacturing process, and a method for manufacturing the solar cell module.

  A solar cell module according to the present invention includes a solar cell cell array, a first plate member, a second plate member, a frame spacer member, and a translucent resin sealing layer. The solar cell array includes a plurality of solar cells arranged in an array and electrically connected to each other. The first plate-like member is located on the non-light-receiving surface side of the solar cell array. The second plate member is made of a translucent member and is located on the light receiving surface side of the solar cell array. The frame spacer member is located between the first plate member and the second plate member so as to surround the solar cell array, and the solar cell array is disposed in the thickness direction of the solar cell array. Space is secured. The translucent resin sealing layer is located between the first plate-like member and the second plate-like member, and is disposed on the first plate-like member, the second plate-like member, and the frame-like spacer member. The solar cell array is sealed inside and sealed.

  In the solar cell module according to the present invention, it is preferable that the frame-shaped spacer member is located between the periphery of the first plate member and the periphery of the second plate member.

  In the solar cell module according to the present invention, the frame-shaped spacer member may include a terminal box part for drawing out the output of the solar cell cell array.

  In the solar cell module according to the present invention, the solar cell module is located between the first plate member and the second plate member and outside the frame spacer member, and the solar cell cell array. There may be further provided a terminal box for drawing out the output of.

  In the solar cell module according to the present invention, the frame-shaped spacer member is preferably a glass member, a resin member, or a metal member.

  In the solar cell module according to the present invention, the first plate member may be a translucent member.

  The manufacturing method of the solar cell module based on this invention is equipped with a lamination process and a sealing process. The stacking step includes a solar cell array composed of a plurality of solar cells electrically connected to each other, a first plate member, a translucent second plate member, a frame spacer member, and first to fourth sheets. The first sheet-shaped resin member is sandwiched between the first plate-shaped member and the frame-shaped spacer member, and the second sheet-shaped resin member is the second plate-shaped member and the frame-shaped spacer member. And the third sheet-like resin member is sandwiched between the first sheet-like resin member and the non-light-receiving surface side of the solar cell array in the space surrounded by the frame-like spacer member, and The fourth sheet-shaped resin member is sandwiched between the second sheet-shaped resin member and the light receiving surface side of the solar cell array in a space surrounded by the frame-shaped spacer member. A step of laminating to. In the sealing step, by performing a laminating process, the first to fourth sheet-like resin members are heated and pressurized to form a light-transmitting resin sealing layer, and the first plate-like member and the second plate-like member A step of sealing the solar cell array with the translucent resin sealing layer in a space defined by the member and the frame spacer member.

  In the manufacturing method of the solar cell module based on this invention, it is preferable to use the glass-made, resin-made, or metal-made members which can endure the heating in the said sealing process as said frame-shaped spacer member.

  In the method for manufacturing a solar cell module according to the present invention, at least one of the third sheet-shaped resin member and the fourth sheet-shaped resin member is a sheet-shaped resin member group in which a plurality of sheet-shaped resin members are stacked. It may be.

  In the method for manufacturing a solar cell module according to the present invention, at least one of the third sheet-like resin member and the fourth sheet-like resin member is partially bent or curved in the laminating step. May be arranged.

  In the method for manufacturing a solar cell module according to the present invention, a translucent member may be used as the first plate member.

  ADVANTAGE OF THE INVENTION According to this invention, it can be set as the solar cell module which can be manufactured easily and can prevent the inflow of the water | moisture content from a module edge part effectively. Moreover, according to this invention, it can be set as a solar cell module which can be manufactured easily and can prevent the generation | occurrence | production of the crack of a photovoltaic cell in a manufacturing process, or a chip | tip.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following embodiment, a daylighting type solar cell module having a laminated glass structure will be described as an example.

(Embodiment 1)
First, with reference to FIG. 1 thru | or FIG. 4, the structure of the solar cell module in this Embodiment is demonstrated. FIG. 1 is a plan view of the solar cell module according to Embodiment 1 of the present invention. 2 is a schematic cross-sectional view taken along the line II-II of the solar cell module shown in FIG. 1, and FIG. 3 is taken along the line III-III of the solar cell module shown in FIG. It is a schematic cross section. FIG. 4 is an enlarged cross-sectional view showing the structure of the end portion of the solar cell module shown in FIG.

  As shown in FIG. 1, solar cell module 1 </ b> A in the present embodiment has a substantially rectangular shape in plan view, and a main surface on one side thereof is configured as a light receiving surface (front surface) for receiving sunlight. ing. As shown in FIGS. 2 and 3, the solar cell module 1 </ b> A includes a back side plate glass 11 as a first plate member, a front side plate glass 12 as a second plate member, the back side plate glass 11 and the front side. The solar cell array 2, the frame spacer member 6, and the translucent resin sealing layer 20 disposed between the plate glasses 12 are mainly provided.

  The back side plate glass 11 and the front side plate glass 12 are arranged in parallel with a certain distance so that the main surfaces thereof face each other. As the back side plate glass 11 and the front side plate glass 12, for example, blue plate glass, white plate glass, mold plate glass, tempered glass, double tempered glass or netted glass can be used. The back side plate glass 11 and the front side plate glass 12 are not necessarily the same type of plate glass, and different types of plate glass may be used. What kind of plate glass is used can be appropriately selected in consideration of the surrounding environment where the solar cell module 1A is installed. The solar cell module 1A in the present embodiment is configured as a daylighting type solar cell module, and is not only the second plate member positioned on the light receiving surface side but also the first surface positioned on the non-light receiving surface side. The plate-like member is also made of translucent plate glass.

  A frame-shaped spacer member 6 is interposed between the back surface side glass plate 11 and the front surface side glass plate 12. This frame-shaped spacer member 6 has a surrounding shape in which edge portions arranged at the four end portions of the solar cell module 1A are respectively connected to adjacent edge portions at the end portions. Has a space. The four edge portions of the frame-shaped spacer member 6 are arranged so as to be positioned between the peripheral edge of the back surface side glass plate 11 and the peripheral edge of the front surface side glass plate 12, respectively. The outer shape of the frame-shaped spacer member 6 is configured to be approximately the same size as the back side plate glass 11 and the front side plate glass 12. The frame-shaped spacer member 6 has a predetermined thickness in the thickness direction of the solar cell module, and plays the role of separating the back side plate glass 11 and the front side plate glass 12 in the thickness direction. As the frame spacer member 6, for example, glass, resin, metal, or the like having heat resistance at least enough to withstand the heat applied in the laminating process described later (that is, deformation or modification by the heat is not caused). These members are available.

  The space defined by the back side plate glass 11, the front side plate glass 12, and the frame-like spacer member 6, which is the space inside the solar cell module 1 </ b> A, is filled with the translucent resin sealing layer 20. Further, as shown in FIG. 4, a slight gap formed between the rear surface side glass plate 11 and the frame-shaped spacer member 6 and a slight gap formed between the front surface side glass plate 12 and the frame-shaped spacer member 6. In addition, a part 20a of the translucent resin sealing layer 20 extends. The translucent resin sealing layer 20 is in close contact with the back side plate glass 11, the front side plate glass 12, and the frame spacer member 6. As the translucent resin sealing layer 20, it is necessary to use a material that does not easily damage the solar cells 3 in the laminating process described later, and it is exposed to a high-temperature and high-humidity environment for a long time from the viewpoint of weather resistance. However, it is preferable to use a material that does not easily deteriorate. From this point of view, examples of the resin material constituting the translucent resin sealing layer 20 include resin materials including ethylene vinyl acetate copolymer (EVA) resin, polyvinyl butyral (PVB) resin, silicon resin, and the like. It can be suitably used. The translucent resin sealing layer 20 is a layer formed by causing a cross-linking reaction by heating and melting first to fourth laminate films described later in a laminating step.

  The solar cell array 2 is arranged inside the translucent resin sealing layer 20 located in the space defined by the back side plate glass 11, the front side plate glass 12 and the frame-like spacer member 6. The solar cell array 2 includes a plurality of solar cells 3 arranged in an array and wiring 4 made of a conductive material such as a metal wire that electrically connects the plurality of solar cells 3 to each other. ing. Here, the solar cell 3 is a power generation element made of a thin film semiconductor material typified by a crystalline or amorphous semiconductor having a semiconductor junction such as a pn junction. The solar cell array 2 is hermetically sealed by the above-described translucent resin sealing layer 20.

  As shown in FIGS. 1 and 3, a terminal box 8 is provided at one end of the solar cell module 1A. This terminal box 8 is for drawing out the output of the solar cell array 2 arranged inside the solar cell module 1A. The terminal box 8 is provided with a terminal (not shown), and the end of the wiring 4 embedded in the translucent resin sealing layer 20 is electrically connected to the terminal. The terminals provided in the terminal box 8 are electrically connected to the connection cable 9, and thereby the output of the solar cell array 2 can be derived via the connection cable 9. In the solar cell module 1A in the present embodiment, a through-hole is provided in the frame-like spacer member 6 where the terminal box 8 is attached, and the wiring 4 is closed so as to close the through-hole. The connection end is inserted. The connection end of the wiring 4 drawn out of the frame-shaped spacer member 6 is electrically connected to a terminal provided in the terminal box 8.

  Next, with reference to FIG. 5 and FIG. 6, the assembly structure and manufacturing procedure of the solar cell module in the present embodiment will be described. 5 and 6 are views for explaining the assembly structure and manufacturing procedure of the solar cell module in the present embodiment, FIG. 5 is an exploded perspective view, and FIG. 6 is an exploded sectional view.

  As shown in FIG. 5 and FIG. 6, in manufacturing the solar cell module 1 </ b> A in the present embodiment, the solar cells 3 arranged in an array are electrically connected in advance by the wiring 4, thereby generating a power generation circuit. The solar cell array 2 is prepared in advance. Next, the solar cell cell array 2 is accommodated in the space inside the frame-shaped spacer member 6. At this time, the connection end of the wiring 4 positioned at the end of the solar cell array 2 is inserted into a through hole provided in the frame-shaped spacer member 6, and the connection end is drawn out of the frame-shaped spacer member 6.

  Next, the solar cell array 2 arranged in the space inside the frame-shaped spacer member 6 is moved up and down by a third laminate film 23 that is a third sheet-like resin member and a fourth laminate film 24 that is a fourth sheet-like resin member. Insert from the direction. At this time, the sizes of the third laminate film 23 and the fourth laminate film 24 are adjusted in advance so that the third laminate film 23 and the fourth laminate film 24 are accommodated in the space inside the frame-shaped spacer member 6. Keep it. Specifically, the size of the third laminate film 23 and the fourth laminate film 24 is set to be equal to or equivalent to the size of the space inside the frame-shaped spacer member 6.

  Next, the first laminating film 21 and the first laminating film 21 which are first sheet-like resin members which are larger than the third laminating film 23 and the fourth laminating film 24 and have the same size as the outer shape of the frame-like spacer member 6. The solar cell array 2, the third laminate film 24, and the fourth laminate film 24 accommodated in the space inside the frame-shaped spacer member 6 and the frame-shaped spacer member 6 by the second laminate film 22 that is a two-sheet resin member. The laminated body consisting of is sandwiched from above and below. At this time, the periphery of the first laminate film 21 is in contact with the lower surface of the frame-shaped spacer member 6, and the periphery of the second laminate film 22 is in contact with the upper surface of the frame-shaped spacer member 6. And the laminated body comprised in this way is inserted | pinched by the back surface side plate glass 11 and the surface side plate glass 12 from an up-down direction.

  Next, the laminated body obtained through the above lamination process is heated while applying pressure from above and below under vacuum conditions. Thereby, the back surface side plate glass 11 and the surface side plate glass 12 are heat-welded using the 1st thru | or 4th laminate films 21-24. At that time, the first to fourth laminate films 21 to 24 are melted and flowed around the solar cell array 2 without a gap, and then cured by a crosslinking reaction. As described above, the translucent resin sealing layer 20 (see FIGS. 2 to 4) is formed in the space defined by the back side plate glass 11, the front side plate glass 12, and the frame-like spacer member 6, and the back side plate glass. A portion 20a (see FIG. 4) of the translucent resin sealing layer 20 extends between 11 and the lower surface of the frame-shaped spacer member 6 and between the front side glass sheet 12 and the upper surface of the frame-shaped spacer member 6. The solar cell array 2 is sealed in the space by the translucent resin sealing layer 20. A part 20a of the translucent resin sealing layer 20 formed between the back side plate glass 11 and the lower surface of the frame-like spacer member 6 and between the front side plate glass 12 and the upper surface of the frame-like spacer member 6 is formed. In order to improve the adhesion between the part 20a of the translucent resin sealing layer 20 and the frame-shaped spacer member 6 at the position where it is positioned, the upper surface and the lower surface of the frame-shaped spacer member 6 should be planar. desirable.

  Subsequently, the terminal box 8 is attached to the end of the module formed by the above laminating process. At that time, the connection end of the portion of the wiring 4 drawn from the frame spacer member 6 is connected to the terminal of the terminal box 8. Thus, the manufacture of solar cell module 1A in the present embodiment described above is completed.

  In addition, in the above, it demonstrated and demonstrated the operation | work procedure which laminates | stacks so that another member may be inserted | pinched sequentially from the up-down direction centering on the solar cell cell array 2. FIG. However, in the above-described lamination process, it is only necessary that the members are laminated in the positional relationship described above after lamination, and these members may be laminated in another order. As another work procedure, for example, a procedure in which other members are sequentially placed from above on the basis of the rear glass plate 11 and laminated can be considered.

  In solar cell module 1A in the present embodiment described above, the area of translucent resin sealing layer 20 exposed at the end of the module is significantly narrower than that of conventional solar cell module 1X shown in FIG. To do. That is, since most of the translucent resin sealing layer 20 is surrounded by the frame-shaped spacer member 6, the exposed area of the translucent resin sealing layer 20 at the module end is reduced. . Therefore, the amount of water absorbed by the translucent resin sealing layer 20 is greatly reduced as compared with the conventional solar cell module 1X shown in FIG. 17, and the reliability is drastically improved. Therefore, it can be set as the solar cell module with long life and performance maintained over a long period of time. As the frame-shaped spacer member 6, it is preferable to employ a member having heat resistance at least enough to withstand the heat applied in the laminating process as described above, but the frame-shaped spacer member 6 itself absorbs moisture. It is preferable that it is comprised with the material which is hard to carry out, and also from this viewpoint, it is made of a member made of glass, resin (however, its water absorption is lower than that of the translucent resin sealing layer 20) or metal, etc. It is preferable to do.

  Further, in solar cell module 1A in the present embodiment, since the area of translucent resin sealing layer 20 exposed at the end of the module is significantly narrowed as described above, it is in a softened state in the laminating process. In addition, the risk that the first to fourth laminated films 21 to 24 protrude from the end of the module due to the pressure applied to the front surface side glass plate 12 and the back surface side glass plate 11 is very small. Therefore, complication of the manufacturing process such that an operation for separately cutting out the protruding portion is not required, and the manufacturing becomes very easy as compared with the conventional solar cell module 1X shown in FIG.

  In addition, as described above, when the surface side plate glass 12 and the back side plate glass 11 are increased in area by increasing the size of the solar cell module and the weight thereof is increased, the surface side plate glass 12 in the lamination step before the lamination step. And the pressure added to the photovoltaic cell 3 increases with the weight increase of the back surface side plate glass 11. Therefore, there arises a problem that the possibility that the solar battery cell 3 is cracked or chipped increases. Similarly, even during the laminating step, pressure is applied to the solar cells more than necessary, and a problem arises in that the solar cells are cracked or chipped. However, the weight of the front side plate glass 12 and the rear side plate glass 11 is obtained by using the solar cell module 1A having the frame spacer member 6 interposed between the front side plate glass 12 and the rear side plate glass 11 as described above. Since the pressure generated as a result of the increase is avoided from being directly applied to the solar cells 3, the above-described cracking and chipping of the solar cells 3 are not generated, and the yield is greatly improved. Therefore, the manufacturing cost can be greatly reduced.

  Further, the solar cell module 1A in the present embodiment has a simple configuration in which the frame-like spacer member 6 is increased as a component compared to the conventional solar cell module 1X shown in FIG. When manufacturing the solar cell module 1A in the present embodiment, the frame-like spacer member 6 is only laminated and arranged together with other members in the laminating step before the laminating step, and the conventional solar cell module shown in FIG. It is not particularly complicated as compared with the production of 1X. Therefore, solar cell module 1A in the present embodiment can be manufactured very simply.

  Thus, by adopting the manufacturing method as in the present embodiment and manufacturing the solar cell module configured as in the present embodiment, the inflow of moisture from the module end can be effectively prevented, It becomes possible to easily manufacture a solar battery module that can effectively prevent cracking or chipping of the solar battery cells in the manufacturing process.

  Next, with reference to FIG. 7 thru | or FIG. 10, the assembly | attachment structure and manufacturing procedure which concern on the 1st thru | or 4th modification of the solar cell module in this Embodiment are demonstrated. 7 to 10 are exploded cross-sectional views for explaining the assembly structure and the manufacturing procedure according to the first to fourth modified examples of the solar cell module in the present embodiment.

  In the above-described first embodiment, the solar cell module 1A is manufactured by laminating the third laminated film 23 and the fourth laminated film 24 that are cut into a rectangular shape in plan view in a developed state. It was. However, when the thickness of the frame-shaped spacer member 6 is relatively large, there is a possibility that the molten resin is insufficient in the laminating process with a thin laminated film. In addition, since the solar cell array 2 is not located in a portion near the periphery of the space inside the frame-shaped spacer member 6 (that is, a portion near the inner peripheral portion of the frame-shaped spacer member 6), this portion In the laminating process, the molten resin may be insufficient. When such a shortage of molten resin occurs, there is a risk that bubbles (voids) or cell cracks may occur in the portion, resulting in a problem that reliability is lowered.

  Therefore, in the assembly structure according to the first modification shown in FIG. 7, the third and fourth laminate films 23 and 24 are each composed of a plurality of laminate films to prevent the shortage of the molten resin, In the assembly structure according to the second to fourth modifications shown in FIGS. 8 to 10, the entire periphery of the end portion of the third laminate film 23 and / or the fourth laminate film 24 is folded during the laminating process, or The shortage of molten resin is prevented by bending.

  Specifically, as shown in FIG. 7, in the solar cell module 1 </ b> B according to the first modification, the third laminate film 23 is composed of three laminate films 23 </ b> A to 23 </ b> C and these are laminated. While accommodated in the space inside the frame-shaped spacer member 6, the fourth laminate film 24 is similarly composed of three laminate films 24 </ b> A to 24 </ b> C, and these are laminated in the space inside the frame-shaped spacer member 6. Contained. By constituting in this way, even when the thickness of the frame-shaped spacer member 6 is relatively large, it is possible to prevent the molten resin from being insufficient during the lamination process, and to the solar cells 3 during the lamination process and the lamination process. It is possible to enhance the function of buffering the application of pressure. In addition, as the number of laminated layers of the third laminate film 23 and the fourth laminate film 24, the thickness of the translucent resin sealing layer formed after the third laminate film 23 and the fourth laminate film 24 are softened and cured is a frame. It is a guideline to consider that the thickness of the spacer member 6 is equal to or greater than the thickness.

  In addition, in the solar cell module 1C according to the second modification as shown in FIG. 8, the folded portion 23a is formed by folding the end portion of the third laminate film 23 over the entire circumference, and the folded portion 23a is formed. In this state, the third laminate film 23 is accommodated in the space inside the frame-shaped spacer member 6. The folded portion 23a is maintained in a laminated state by the own weight of other members (for example, the surface side plate glass 12) to be laminated later, and the folded portion 23a is softened in the laminating process, so that the solar cell array 2 and the space between the frame-shaped spacer members 6 are sufficiently filled. By constituting in this way, it is possible to prevent the shortage of the molten resin in the portion near the inner periphery of the frame-shaped spacer member 6 where the solar cell array 2 is not located.

  Further, as shown in FIG. 9, in the solar cell module 1D according to the third modification, the folded portion 24a is formed by folding the end portion of the fourth laminate film 24 over the entire circumference, and the folded portion 24a is formed. In this state, the fourth laminate film 24 is accommodated in the space inside the frame-shaped spacer member 6. The folded portion 24a is maintained in a laminated state by the weight of other members (for example, the surface side plate glass 12) laminated later, and the folded portion 24a is softened in the laminating process, so that the solar cell array 2 and the space between the frame-shaped spacer members 6 are sufficiently filled. By constituting in this way, it is possible to prevent the shortage of the molten resin in the portion near the inner periphery of the frame-shaped spacer member 6 where the solar cell array 2 is not located.

  Furthermore, as shown in FIG. 10, in the solar cell module 1E according to the fourth modification, the folded portion 23a is formed by folding the end portion of the third laminate film 23 over the entire circumference, and the fourth laminate film 24 The folded portion 24a is formed by folding the end portion around the entire periphery, and the third laminated film 23 and the fourth laminated film 24 are placed in the space inside the frame-shaped spacer member 6 in a state where the folded portions 23a, 24a are formed. Contained. The folded portions 23a and 24a are maintained in a laminated state by the weight of other members (for example, the front side plate glass 12) to be laminated later, and the folded portions 23a and 24a are softened in the laminating process. The space generated between the solar cell cell array 2 and the frame-shaped spacer member 6 is sufficiently filled. By constituting in this way, it is possible to prevent the shortage of the molten resin in the portion near the inner periphery of the frame-shaped spacer member 6 where the solar cell array 2 is not located.

  As described above, the third laminate film 23 and the fourth laminate film 24 are each composed of a plurality of sheets, or the third laminate film 23 and the fourth laminate film 24 are partially folded and bent, thereby allowing the molten resin to be formed. It becomes possible to prevent the occurrence of deficiency and improve the buffer function of the third laminate film 23 and the fourth laminate film 24. In the above description, the case where the entire periphery of the end portion of the third laminate film 23 and / or the fourth laminate film 24 is folded is described as an example. However, only a part of the end portion may be folded. It is good also as turning up in parts other than an edge part. Moreover, it is good also as bending on the cross-section L character, without folding up the edge part of the 3rd laminate film 23 and / or the 4th laminate film 24. FIG.

(Embodiment 2)
Next, with reference to FIG. 11 and FIG. 12, the solar cell module in Embodiment 2 of this invention is demonstrated. FIG. 11 is a plan view of the solar cell module according to Embodiment 2 of the present invention, and FIG. 12 is an exploded cross-sectional view for explaining the assembly structure and manufacturing procedure of the solar cell module shown in FIG. In addition, the same code | symbol is attached | subjected in the figure about the part similar to the solar cell module in the above-mentioned Embodiment 1, and the description is not repeated here.

  As shown in FIG. 11, solar cell module 1 </ b> F in the present embodiment is similar to that of solar cell module 1 </ b> A in the above-described first embodiment in the configuration within the space surrounded by frame-shaped spacer member 6. However, the configuration of the module end provided with the terminal box 8 is different from that of the solar cell module 1A in the first embodiment described above. Specifically, in the solar cell module 1 </ b> F in the present embodiment, the rear surface side glass plate 11 and the front surface side glass plate 12 are on the end on the side where the terminal box 8 is provided rather than the outer shape of the frame spacer member 6. It is formed so as to be large at the side, and a configuration is adopted in which the terminal box 8 is sandwiched from above and below. If such a structure is employ | adopted, the terminal box 8 will be protected by the back surface side plate glass 11 and the surface side plate glass 12, and it will become possible to prevent the damage and omission of the terminal box 8 at the time of enforcement. In this case, the thickness of the terminal box 8 is preferably the same as or thinner than the thickness of the frame-shaped spacer member 6, and more than the total thickness including the solar cells 3 and the wirings 4 of the solar cell array 2. Larger is preferred.

  In manufacturing the solar cell module 1F having the above configuration, as shown in FIG. 12, the terminal box 8 is fixed at a predetermined position of the frame-shaped spacer member 6 in advance in the stacking process of each component. Then, not only the frame-shaped spacer member 6 but also the terminal box 8 is sandwiched between the first laminate film 21 and the second laminate film 22, and the upper and lower surfaces of these laminates are further covered by the back side plate glass 11 and the front side plate glass 12. Try to pinch the entire surface. As described above, by simultaneously sealing the terminal box 8 in the laminating step, the solar cell module 1F having the structure shown in FIG. 11 can be obtained. From this point of view, the terminal box 8 is preferably formed of a material having heat resistance enough to withstand the heating during the laminating process described above. For example, polyphenyl sulfide as a phenyl resin is used. Resin-made things represented by (PPS) etc., ceramic-made things, metal-made things, etc. are used suitably.

  In addition, when it is set as the solar cell module 1F in this Embodiment, it cannot be overemphasized that the effect similar to the case where it is set as the solar cell module 1A in the above-mentioned Embodiment 1 is acquired, and the above-mentioned Embodiment 1 is obtained. Of course, it is also possible to apply the configuration as in the various modifications shown in Fig. 2 to the solar cell module 1F in the present embodiment.

(Embodiment 3)
Next, with reference to FIG. 13 and FIG. 14, the solar cell module in Embodiment 3 of this invention is demonstrated. FIG. 13 is a plan view of the solar cell module according to Embodiment 3 of the present invention, and FIG. 14 is an exploded sectional view for explaining the assembly structure and manufacturing procedure of the solar cell module shown in FIG. In addition, the same code | symbol is attached | subjected in the figure about the part similar to the solar cell module in the above-mentioned Embodiment 1, and the description is not repeated here.

  As shown in FIG. 13, the solar cell module 1G in the present embodiment is the same as that of the solar cell module 1A in the above-described first embodiment in the configuration within the space surrounded by the frame-shaped spacer member 6. However, the solar cell module 1A in the first embodiment described above is that the terminal box is not particularly provided outside the frame-shaped spacer member 6 and is configured as the terminal box portion 7 at a predetermined position of the frame-shaped spacer member 6 itself. The configuration is different. If such a configuration is adopted, the work of attaching the terminal box to the module becomes unnecessary, and the terminal box portion 7 is protected by the back side plate glass 11 and the front side plate glass 12, and the terminal box at the time of enforcement It becomes possible to prevent breakage or omission of the portion 7. In addition, since it is possible to reduce the number of electrical connection points, it is possible to reduce characteristic defects and appearance defects due to human factors.

  In manufacturing the solar cell module 1F having the above-described configuration, as shown in FIG. 14, a frame-shaped spacer member 6 having a terminal box portion 7 formed in advance at a predetermined position of the edge portion is prepared. Can be realized by laminating together with other components in the laminating process, and then laminating in the laminating process.

  In addition, when it is set as the solar cell module 1G in this Embodiment, it cannot be overemphasized that the effect similar to the case where it is set as the solar cell module 1A in the above-mentioned Embodiment 1 is acquired, and the above-mentioned Embodiment 1 is obtained. Of course, it is also possible to apply the configuration as in the various modifications shown in Fig. 2 to the solar cell module 1G in the present embodiment.

  In Embodiment 1 thru | or 3 of this invention demonstrated above, plate glass is utilized as the 1st plate-shaped member arrange | positioned at the light-receiving surface side of a solar cell module, and the 2nd plate-shaped member arrange | positioned at the non-light-receiving surface side. However, the present invention is not necessarily limited to such a configuration. For example, a solar cell module employing a so-called super straight structure using a film-like resin member made of polyethylene terephthalate (PET) resin or polyvinyl fluoride (PVF) resin as the second plate-like member disposed on the non-light-receiving surface side The present invention can also be applied to.

  Moreover, in Embodiment 2 and 3 of this invention mentioned above, the terminal box 8 and the terminal box part 7 are comprised so that it may follow the module shape of the solar cell modules 1F and 1G after an assembly, respectively. In the following, an example will be described with reference to the drawings. FIG. 15 is an exploded perspective view showing an example of the structure of the terminal box that can be employed in the solar cell module according to Embodiment 2 of the present invention described above, and FIG. 16 shows the sun according to Embodiment 3 of the present invention described above. It is a disassembled perspective view which shows an example of the structure of the terminal box part employable in a battery module.

  As shown in FIG. 15, the terminal box 8 having a structure suitable for the solar cell module 1F according to the second embodiment of the present invention described above is attached so as to close the box-shaped body 8a having one surface opened and the opening. A terminal box having a structure including the lid 8b is conceivable. The box-shaped body 8a is made of a molded product having a recess 25 formed therein. The bottom wall of the box-shaped body 8a is provided with a through-hole through which the connection end of the wiring 4 drawn out to the outside of the frame-shaped spacer member is inserted. A terminal 26 to which the connection end of the wiring 4 drawn through the hole is connected is provided. A through hole through which the connection end of the connection cable 9 is inserted is provided in the side wall of the box-shaped body 8a.

  When assembling the terminal box 8, the laminating process described above is performed in a state where the connection end of the wiring 4 is drawn into the recess 25 of the box-like body 8 through the through hole provided in the bottom wall of the box-like body 8. Or the connection end of the wiring 4 is drawn into the recess 25 of the box-like body 8 through the through hole provided in the bottom wall of the box-like body 8 and connected to the terminal 26 as described above. Lamination process is performed. Thereafter, in the former case, the connection end of the wiring 4 is connected to the terminal 26. Subsequently, the connection end of the connection cable 9 is connected to the terminal 26 in the recess 25 by soldering or welding. Next, for example, the module is set in a leaning state, and an insulating resin material typified by silicon resin is poured into the recess 25 of the box-like body 8 to be cured. At least the conductive member is sealed with this resin material. To be stopped. Thereafter, the lid body 8b is attached and fixed so as to close the opening of the box-shaped body 8a.

  By adopting such a structure, since the insulating resin material for sealing in the connection cable 9 and the terminal box 8 can be assembled after the laminating process, these members are heated by the laminating process. Therefore, it is not necessary to use a member having heat resistance enough to withstand. Therefore, the solar cell module 1F can be manufactured at low cost. In particular, for the insulating resin material for sealing in the terminal box 8, a two-liquid mixed type high fluidity filler can be used, and the workability is greatly improved.

  Moreover, as shown in FIG. 16, as the terminal box part 7 having a structure suitable for the solar cell module 1G according to the third embodiment of the present invention described above, a recess 25 provided at a predetermined position of the frame-shaped spacer member 6 and A terminal box portion having a structure including a lid 7b attached to the frame-like spacer member 6 so as to close the opening surface of the concave portion is conceivable. The shape of the recess 25 provided in the frame-shaped spacer member 6 is not limited as long as it does not hinder the function of the frame-shaped spacer member 6 that separates the back side plate glass 11 and the front side plate glass 12 in the thickness direction of the solar cell module. It may be a simple shape. A through hole through which the connection end of the wiring 4 is inserted is provided in the bottom wall of the recess 25, and a terminal to which the connection end of the wiring 4 drawn out through the through hole is connected in the recess 25. 26 is provided. Further, the lid body 7b is divided into, for example, two parts in the vertical direction so that the connection cable 9 can be pulled out.

  When assembling the terminal box portion 7, the above-described laminating process is performed in a state where the connection end of the wiring 4 is drawn into the recess 25 through a through hole provided in the bottom wall of the recess 25, or The laminating process described above is performed in a state in which the connection end of the wiring 4 is drawn into the recess 25 through the through hole provided in the bottom wall of the recess 25 and connected to the terminal 26. Thereafter, in the former case, the connection end of the wiring 4 is connected to the terminal 26. Subsequently, the connection end of the connection cable 9 is connected to the terminal 26 in the recess 25 by soldering or welding. Next, for example, the module is set in a standing state, and an insulating resin material typified by silicon resin or the like is poured into the recess 25 and cured, so that at least the conductive member is sealed with the resin material. To do. Thereafter, the lid body 7b is combined and fixed so as to close the opening surface of the recess 25.

  If such a structure is adopted, since the insulating resin material for sealing in the recess 25 provided in the connection cable 9 and the frame-like spacer member 6 can be assembled after the laminating process, these There is no need to configure the member with a member having heat resistance enough to withstand the heat applied during the laminating process. Therefore, the solar cell module 1G can be manufactured at a low cost. In particular, for the insulating resin material for sealing in the terminal box 8, a two-liquid mixed type high fluidity filler can be used, and the workability is greatly improved. When the lid 7b is not divided and configured, only the connection cable 9 may have heat resistance enough to withstand the heat applied in the laminating step.

  In addition, the said embodiment disclosed this time is an illustration in all the points, Comprising: It is not restrictive. The technical scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a top view of the solar cell module in Embodiment 1 of this invention. It is a schematic cross section along the II-II line in the figure of the solar cell module shown in FIG. It is a schematic cross section along the III-III line in the figure of the solar cell module shown in FIG. It is an expanded sectional view which shows the structure of the edge part of the solar cell module shown in FIG. It is a disassembled perspective view for demonstrating the assembly structure and manufacturing procedure of the solar cell module shown in FIG. FIG. 2 is an exploded cross-sectional view for explaining the assembly structure and manufacturing procedure of the solar cell module shown in FIG. 1. It is an exploded sectional view for explaining the assembly structure and manufacturing procedure concerning the 1st modification of the solar cell module in Embodiment 1 of the present invention. It is an exploded sectional view for explaining the assembly structure and manufacturing procedure concerning the 2nd modification of the solar cell module in Embodiment 1 of the present invention. It is an exploded sectional view for explaining the assembly structure and manufacturing procedure concerning the third modification of the solar cell module in Embodiment 1 of the present invention. It is an exploded sectional view for explaining the assembly structure and manufacturing procedure concerning the 4th modification of the solar cell module in Embodiment 1 of the present invention. It is a top view of the solar cell module in Embodiment 2 of this invention. FIG. 12 is an exploded sectional view for explaining the assembly structure and manufacturing procedure of the solar cell module shown in FIG. 11. It is a top view of the solar cell module in Embodiment 3 of this invention. FIG. 14 is an exploded cross-sectional view for explaining the assembly structure and manufacturing procedure of the solar cell module shown in FIG. 13. It is a disassembled perspective view which shows an example of the structure of the terminal box employable in the solar cell module in Embodiment 2 of this invention. It is a disassembled perspective view which shows an example of the structure of the terminal box part employable in the solar cell module in Embodiment 3 of this invention. It is a disassembled perspective view for demonstrating the assembly | attachment structure and manufacturing procedure of the solar cell module provided with the laminated glass structure which does not require an air layer in particular.

Explanation of symbols

  1A-1G, 1X Solar cell module, 2 solar cell array, 3 solar cell, 4 wiring, 6 frame spacer member, 7 terminal box part, 7b lid, 8 terminal box, 8a box, 8b lid, DESCRIPTION OF SYMBOLS 9 Connection cable, 11 Back surface side plate glass, 12 Front side plate glass, 20 Translucent resin sealing layer, 20a (a part of translucent resin sealing layer) 21-24, 23A-23C, 24A-24C Laminated film , 23a, 24a Folded portion, 25 concave portion, 26 terminals.

Claims (11)

A solar cell array composed of a plurality of solar cells electrically connected to each other;
A first plate-like member located on the non-light-receiving surface side of the solar cell array;
A translucent second plate member located on the light receiving surface side of the solar cell array;
A frame shape that is positioned between the first plate-like member and the second plate-like member so as to surround the solar cell array, and secures a space in which the solar cell cell array is arranged in the thickness direction of the solar cell cell array. A spacer member;
Located between the first plate-like member and the second plate-like member, is in close contact with the first plate-like member, the second plate-like member, and the frame-like spacer member, and has the solar cell array inside. The solar cell module provided with the translucent resin sealing layer to seal.   The solar cell module according to claim 1, wherein the frame-shaped spacer member is located between a peripheral edge of the first plate-shaped member and a peripheral edge of the second plate-shaped member.   3. The solar cell module according to claim 1, wherein the frame-shaped spacer member includes a terminal box portion for pulling out an output of the solar cell cell array to a part thereof.   The terminal box for extracting the output of the said solar cell array to the exterior which is located in the outer side of the said frame-shaped spacer member between the said 1st plate-shaped member and the said 2nd plate-shaped member, It was further provided. 1. The solar cell module according to 1.   The solar cell module according to any one of claims 1 to 4, wherein the frame-shaped spacer member is a member made of glass, resin, or metal.   The solar cell module according to any one of claims 1 to 5, wherein the first plate-like member is a translucent member. A solar cell array comprising a plurality of solar cells electrically connected to each other, a first plate member, a translucent second plate member, a frame spacer member, and first to fourth sheet resin members, The first sheet resin member is sandwiched between the first plate member and the frame spacer member, and the second sheet resin member is sandwiched between the second plate member and the frame spacer member. The third sheet-shaped resin member is sandwiched between the first sheet-shaped resin member and the non-light-receiving surface side of the solar cell array in a space surrounded by the frame-shaped spacer member, and the fourth sheet-shaped resin The members are stacked so as to be sandwiched between the second sheet-shaped resin member and the light receiving surface side of the solar cell array in a space surrounded by the frame-shaped spacer member. And the layer process,
By laminating, the first to fourth sheet-like resin members are heated and pressed to form a light-transmitting resin sealing layer, and the first plate-like member, the second plate-like member, and the frame-like spacer A solar cell module manufacturing method comprising: a sealing step of sealing the solar cell cell array with the translucent resin layer in a space defined by a member.   The said frame-shaped spacer member is a manufacturing method of the solar cell module of Claim 7 which is the members made from glass, resin, or metal which can endure the heating in the said sealing process.   The solar cell module according to claim 7 or 8, wherein at least one of the third sheet-shaped resin member and the fourth sheet-shaped resin member is composed of a sheet-shaped resin member group in which a plurality of sheet-shaped resin members are laminated. Manufacturing method.   At least one of the third sheet-shaped resin member and the fourth sheet-shaped resin member is disposed in the frame-shaped spacer member in a state where a part thereof is bent or curved in the lamination step. Item 10. A method for producing a solar cell module according to any one of Items 7 to 9.   The method for manufacturing a solar cell module according to any one of claims 7 to 9, wherein the first plate-like member is a translucent member.

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