JP2009246208A - Solar cell module, and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar cell module capable of effectively preventing degradation of appearance due to presence of lateral wiring; and to provide a method for manufacturing the module. <P>SOLUTION: This solar cell module is composed by including: a light reception surface-side sealing layer 3 laminated on a translucent substrate 2; a plurality of solar cell elements C laminated on the light reception surface-side sealing layer 3; lateral wiring cover layers 4 stacked on the light reception surface-side sealing layer 3; lateral wiring sealing layers 5 laminated on the lateral wiring cover layers 4 to expose the respective ends on the respective solar cell element C side; the lateral wirings 7 laminated on the lateral wiring sealing layers 5, and connecting respective tab wirings 8 to one another in common; fixation members 6 fixing three items such as the lateral wirings 7, exposure ends 31 of the lateral wiring cover layers 4, and the solar cell elements C to one another; a back-side sealing layer 9 laminated on the light reception surface-side sealing layer 3, and sealing the respective solar cell elements C, the lateral wiring cover layers 4, the lateral wiring sealing layers 5, the tab wirings 8, the lateral wirings 7 and the fixation members 6 between the light reception surface-side sealing layer 3 and itself; and a back sheet 10 laminated on the back-side sealing layer 9. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

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

  In recent years, as interest in the global warming issue has increased, expectations for solar power generation, which is a clean energy source, have increased as an alternative energy to fossil fuels. A solar cell element used for photovoltaic power generation is an element that directly converts sunlight energy into electric energy, and is often manufactured using a single crystal silicon substrate or a polycrystalline silicon substrate.

  Since a solar cell element has a small electric output generated by itself, generally several to several tens of solar cell elements are wired in series or in parallel so that a practical electric output can be taken out. In addition, in order to protect the solar cell element from the surrounding environment such as rainwater for a long time, between the translucent substrate disposed on the light receiving surface side of the solar cell element and the back sheet disposed on the back surface side. In general, a solar cell module is produced by encapsulating a solar cell element with a filler mainly composed of EVA (ethylene vinyl acetate copolymer) or the like.

  The structure of a conventional solar cell module will be described. The solar cell module includes a translucent substrate disposed on the light receiving surface side, a light receiving surface side filler, a plurality of solar cell elements disposed in a matrix on a single plane, a back surface side filler, and a back sheet. Are stacked in this order.

  The solar cell element has a tab wiring, and adjacent solar cell elements are connected by this tab wiring. One end of the solar cell module and the other end on the opposite side of the one end are provided with a horizontal wiring, and are located close to the one end and the other end in the solar cell element group connected by tab wiring. Is connected to the horizontal wiring via the tab wiring. In this way, the solar cell elements are connected in series or in parallel, and the lateral wiring is connected to an external circuit inside the terminal box via the outer lead wiring.

  For these horizontal wiring and tab wiring, copper foil is usually used, and the entire surface covered with solder is cut into a predetermined length. The lateral wiring and the tab wiring thus formed have a silver metallic luster in appearance due to the solder coating.

  In the solar cell module, the back sheet and the module frame that can be visually recognized from the light receiving surface side are usually colored in a suitable color tone that does not cause a sense of incongruity depending on the building such as a house to be installed and the surrounding environment. . Therefore, when such a solar cell module is viewed from the light receiving surface side, the lateral wiring and the tab wiring are conspicuous in appearance. In particular, the lateral wiring is very conspicuous because it is formed so that the width of the wiring is wider than that of the tab wiring. Thereby, the design of the whole external appearance, such as a building in which the solar cell module is installed, was deteriorated.

  In order to solve such a problem, for example, Patent Document 1 proposes coloring the remaining portion of the light-transmitting substrate except the portion facing the solar cell element.

JP 7-326789 A

  In the method proposed in Patent Document 1, glass containing a pigment is dissolved in a special liquid, printed on a portion to be colored, and baked at a high temperature for coloring. In order to carry out such a method, a material such as a pigment or a dedicated liquid and a new process for coloring are required, and there is a problem that the manufacturing cost of the solar cell module increases.

  This invention is made | formed in view of such a problem, The objective is to provide the solar cell module which can suppress effectively the fall of the aesthetics by presence of a horizontal wiring, and its manufacturing method. is there.

The solar cell module of the present invention comprises a translucent substrate,
A light-receiving surface side sealing layer laminated on the translucent substrate;
A plurality of solar cell elements having tab wiring, which are stacked on the light-receiving surface side sealing layer;
On the light-receiving surface side sealing layer, a lateral wiring cover layer laminated on the side of each solar cell element and along each solar cell element;
On the horizontal wiring cover layer, a horizontal wiring sealing layer that is laminated so that the end of each solar cell element side of the horizontal wiring cover layer is exposed,
Laminate wiring on the horizontal wiring sealing layer, and connect the tab wiring in common,
A fixing member for fixing the three members of the horizontal wiring, the exposed end portion of the horizontal wiring cover layer and the solar cell element;
Each solar cell element, horizontal wiring cover layer, horizontal wiring sealing layer, tab wiring, horizontal wiring, and fixing member are sealed between and laminated on the light receiving surface side sealing layer. A back side sealing layer to stop,
And a back sheet laminated on the back side sealing layer.

Moreover, the manufacturing method of the solar cell module of the present invention includes a step of laminating a translucent substrate and a light-receiving surface side sealing layer,
A step of laminating a horizontal wiring cover layer on the light-receiving surface side sealing layer;
Laminating a lateral wiring sealing layer on the lateral wiring cover layer so that one end of the lateral wiring cover layer is exposed;
Laminating a plurality of solar cell elements connected by lateral wiring on the light-receiving surface side sealing layer so that the lateral wiring is positioned on the lateral wiring cover layer;
A step of fixing the exposed wiring portion of the horizontal wiring, the horizontal wiring cover layer and the three of the solar cell elements with a fixing member;
By laminating the back surface side sealing layer on the light receiving surface side sealing layer, each solar cell element, horizontal wiring cover layer, horizontal wiring sealing is provided between the light receiving surface side sealing layer and the back surface side sealing layer. Sealing the layer, the horizontal wiring and the fixing member;
Laminating a back sheet on the back side sealing layer.

  According to the present invention, by providing the horizontal wiring cover layer and the horizontal wiring sealing layer at predetermined positions, it is possible to effectively suppress a decrease in the appearance of the solar cell module due to the presence of the horizontal wiring.

≪First embodiment≫
FIG. 1 is an exploded perspective view showing the structure of the solar cell module 1 according to the first embodiment of the present invention. FIG. 2 is a partial cross-sectional view of the solar cell module 1 shown in FIG. 1 cut along a virtual plane perpendicular to the X direction, and shows the vicinity of one end 2a and the other end 2b of the translucent substrate 2. A cross section is shown. 1 and 2, the upper side of the drawing is the light receiving surface side of the solar cell module 1, and the lower side of the drawing is the back side of the solar cell module 1.

<Solar cell module>
The solar cell module 1 according to the present embodiment includes a panel unit 12 and an output unit 20 provided on the back sheet 10. The panel unit 12 includes a translucent substrate 2, a light-receiving surface side sealing layer 3 stacked on the light-transmitting substrate 2, and two horizontal wiring covers stacked on the light-receiving surface side sealing layer 3. Layers 4a and 4b (generally referred to as horizontal wiring cover layer 4) and horizontal wiring sealing layers 5a and 5b stacked on the horizontal wiring cover layers 4a and 4b, respectively A plurality of solar cell elements C ₁₁ , C arranged between the horizontal wiring cover layers 4a, 4b and stacked on the light-receiving surface side sealing layer 3 and arranged in a matrix. ₁₂ ,..., C _{m−1, n} , C _{m, n} (m and n are positive integers) (collectively referred to as C _{i, j} ), a plurality of fixing tapes 6 as fixing members, Horizontal wirings 7a and 7b (collectively referred to as horizontal wiring 7 when collectively referred to) stacked on the horizontal wiring sealing layers 5a and 5b, respectively, and a solar cell Child _{C p, 1 (p = 1,2} , ..., m) and the wiring member 8a for electrically connecting the transverse wires 7a and the solar cell element _{C p, n (p = 1,2} , ..., m) Tab wiring 8b that electrically connects the horizontal wiring 7b and the adjacent solar cell elements C _{p, q} , C _{p, q + 1} (p = 1, 2,..., M; q = 1, 2,..., N -1) Tab wiring 8c that electrically connects each other, outer lead wiring 11 that electrically connects each horizontal wiring 7 and a terminal provided in the output unit 20 described later, and a plurality of solar cell elements Ci _{, j} and the back surface side sealing layer 9 laminated | stacked on the horizontal wiring sealing layer 5, and the back sheet 10 laminated | stacked on the back surface side sealing layer 9 are comprised. The panel part 12 is formed in a rectangular plate shape, and the panel part 12 further includes an opening sealing layer 13 and an opening back sheet 14 as shown in FIG.

  The translucent substrate 2 has translucency and is formed in a rectangular plate shape with glass or polycarbonate resin. In the case of a glass substrate, it is composed of white plate glass, tempered glass, double tempered glass, heat ray reflective glass, etc., but generally white plate tempered glass having a thickness of about 3 mm to 5 mm is used. On the other hand, in the case of a substrate made of a synthetic resin such as polycarbonate resin, a substrate having a thickness of about 5 mm is used.

  The light-receiving surface side sealing layer 3, the lateral wiring sealing layer 5, the back surface side sealing layer 9, and the opening portion sealing layer 13 all contain, for example, a crosslinking agent in a thermosetting resin or a thermoplastic resin. Then, the resin having thermosetting properties is formed into a sheet having a thickness of about 0.4 to 1 mm by a T die and an extruder, and then cut and used.

  As the thermosetting resin, for example, an acrylic resin, a silicone resin, an epoxy resin, or the like can be used.

  The thermoplastic resin is mainly composed of a thermoplastic resin such as ethylene vinyl acetate copolymer (EVA), polyvinyl butyral (PVB) or ethylene-ethyl acrylate copolymer (EEA), and contains a crosslinking agent. What was made to use is used suitably. A crosslinking agent has a role which couple | bonds between the molecules of a thermoplastic resin, For example, the organic peroxide which decomposes | disassembles at the temperature of 70-180 degreeC and generate | occur | produces a radical can be used. Examples of the organic peroxide include 2,5-dimethyl-2,5-bis (t-butylperoxy) hexane and tert-hexylperoxypivalate. For example, about 1 part by mass with respect to 100 parts by mass of EVA. It is preferable to make it contain in a ratio.

  The light receiving surface side sealing layer 3, the lateral wiring sealing layer 5, the back surface side sealing layer 9, and the opening portion sealing layer 13 are all translucent. For example, EVA (ethylene vinyl acetate co-polymer) Formed). These sealing layers 3, 5, 9, and 13 are made of sheet material having a thickness of about 0.4 to 1.0 mm, and are heated and pressurized under reduced pressure by a laminator described later (hereinafter, under reduced pressure by a laminator). The heating and pressurizing process may be referred to as a laminating process), whereby each sealing layer is softened and fused to be integrated with another member. Moreover, the crosslinking process which heats each sealing layer on the temperature conditions more than crosslinking temperature after that is performed.

If the light-receiving surface side sealing layer 3 is colored white or the like, the amount of light incident on the solar cell element C _{i, j} decreases, and the power generation efficiency decreases. On the other hand, the remaining sealing layers 5, 9, 13 may be transparent, and contain white oxide or the like by containing titanium oxide or a pigment according to the surrounding environment where the solar cell module 1 is installed. It may be colored.

The sealing layer will be further described. The light-receiving surface side sealing layer 3 and the back surface side sealing layer 9 are formed of a rectangular sheet material having a surface having substantially the same dimensions as the main surface of the translucent substrate 2. . Between the light receiving surface side sealing layer 3 and the back surface side sealing layer 9, a plurality of solar cell elements C _{i, j} , a horizontal wiring cover layer 4, a horizontal wiring sealing layer 5, a fixing tape 6, a horizontal wiring 7. , And tab wiring 8a, 8b, 8c (collectively referred to as tab wiring 8). An opening 9 a for allowing the outer lead wiring 11 to pass therethrough is formed in the back surface side sealing layer 9.

The horizontal wiring sealing layers 5a and 5b are arranged so as to face the one end 2a and the other end 2b on the opposite side of the one end 2a of the translucent substrate 2, respectively. It is formed of a sheet material extending along the extending direction of the portion 2b (that is, the X direction). The lateral wiring sealing layer 5 laminated on the lateral wiring cover layer 4 is shaped so as to expose a part or the whole of the end of the lateral wiring cover layer 4 on the side close to the solar cell element Ci _{, j.} Is formed. Hereinafter, the exposed end portion of the horizontal wiring cover layer 4 is referred to as an exposed end portion 31. The exposed end portion 31 is used when the horizontal wiring cover layer 4 is fixed by a fixing tape 6 described later.

  By providing the horizontal wiring sealing layer 5 between the horizontal wiring 7 and the horizontal wiring cover layer 4, bubbles remain in the vicinity of the horizontal wiring 7 in the laminating process, or the horizontal wiring 7 is formed by each sealing layer. A decrease in reliability due to not being completely enclosed can be suppressed.

The opening sealing layer 13 is disposed in the vicinity of the outer lead wiring 11 and between the outer lead wiring 11 and the solar cell element Ci _{, j,} and is formed of a rectangular sheet material.

The solar cell element C _{i, j} is made of a single crystal silicon substrate or a polycrystalline silicon substrate having a thickness of about 0.15 to 0.4 mm and a main surface size of about 150 mm square. Inside the solar cell element C _{i, j} is formed a PN junction in which a P layer containing a large amount of P-type impurities such as boron and an N layer containing a large amount of N-type impurities such as phosphorus are in contact. . Further, electrodes are formed on the light receiving side main surface and the back side main surface of the solar cell element C _{i, j} by screen printing silver paste or the like.

Inside the solar cell module 1, a plurality of such solar cell elements C _{i, j} are arranged in a matrix on one plane and sealed. As shown in FIG. 1, each of the plurality of solar cell elements C _{i, j} is electrically connected to the light receiving surface side electrode and the back surface side electrode in the adjacent solar cell elements C _{p, q} , C _{p, q + 1} . As shown, the connection is made by the tab wiring 8c.

The adjacent solar cell elements C _{p, q} , C _{p, q + 1} are continuously connected along the Y direction perpendicular to the X direction. Further, between adjacent solar cell elements C _{p, 1} , C _{p + 1,1} disposed on the one end 2a side of the translucent substrate 2 is laminated on the horizontal wiring sealing layer 5a and extends in the X direction. The light receiving surface side electrode and the back surface side electrode are connected via the horizontal wiring 7a and the tab wiring 8a that connects each of the solar cell elements C _{p, 1} , C _{p + 1,1} and the horizontal wiring 7a. Similarly, between adjacent solar cell elements C _{p, n} , C _{p + 1, n} arranged on the other end 2b side of the translucent substrate 2 is laminated on the horizontal wiring sealing layer 5b and extends in the X direction. The light receiving surface side electrode and the back surface side electrode are connected via the existing horizontal wiring 7b and the tab wiring 8b that connects each of the solar cell elements C _{p, n} , C _{p + 1, n} and the horizontal wiring 7b. .

  The tab wiring 8 is used by cutting a copper foil having a thickness of about 0.1 mm and a width of about 1 to 2 mm by covering the entire surface with solder into a predetermined length and soldering one and the other. And electrically connect.

  Further, the horizontal wiring 7 is a copper foil having a width longer than that of the tab wiring 8 (for example, about 3 to 8 mm) and a thickness of about 0.1 to 0.5 mm covered with solder, and having a predetermined length. It is cut and used, and one and the other are electrically connected by soldering.

The outer lead wiring 11 transmits an electrical output generated by the solar cell elements C _{i, j} to the output unit 20 and is made of a copper foil having a width of about 3 to 8 mm and a thickness of about 0.1 to 0.5 mm. The entire surface is covered with solder, cut to a predetermined length, one end is soldered to the horizontal wiring 7, and the other end is soldered to a terminal provided in the output unit 20.

  Further, the outer lead wiring 11 is disposed so that an intermediate portion between one end portion and the other end portion is interposed between the back sheet 10 and the opening back sheet 14, and the back side sealing layer 9. Passing through the opening 9 a provided in the back and the opening 10 a provided in the backsheet 10, it is connected to the terminal of the output unit 20.

  The back sheet 10 and the opening back sheet 14 are made of a synthetic resin such as PET (polyethylene terephthalate), PEN (polyethylene naphthalate), and PVF (polyvinyl fluoride), or a combination thereof to form a multilayer structure. Become.

  The opening 10a is formed in the backsheet 10 as described above, and the opening backsheet 14 is disposed at a position facing the opening 10a so as to cover the opening 10a. Thereby, the terminal box 21 of the output part 20 attached from the outside on the back surface side so as to cover the opening 10a can be made invisible from the light receiving surface side.

  The back sheet 10 and the opening back sheet 14 are colored so as to have the same color or similar colors when viewed from the light receiving surface side, for example, black. In the case of a multilayer structure, the colors are arranged so that the color of the layer closest to the light receiving surface is unified. The backsheet 10 and the opening backsheet 14 are formed to have a thickness of 50 to 200 μm, for example.

  The horizontal wiring cover layer 4 has a dimension in the longitudinal direction (that is, the X direction) determined so as to cover a plurality of the horizontal wirings 7 arranged. Further, the dimension in the short direction (that is, the Y direction) is determined so as to be at least longer than the width of the horizontal wiring 7 in order to allow the horizontal wiring 7 to be covered. In this embodiment, since the horizontal wiring cover layer 4 is configured to have a width that extends to the vicinity of the end of the solar cell element C, the tab wiring 8 positioned between the horizontal wiring 7 and the solar cell element C and The outer lead wiring 11 can also be covered so as to be inconspicuous.

  Such a horizontal wiring cover layer 4 is preferably made of a material that is not easily deformed under pressure and temperature conditions in the laminating process and the cross-linking process, from the viewpoint of suppressing positional deviation during the laminating process and the cross-linking process. As with the backsheet 10 and the opening backsheet 14, formed by a synthetic resin such as PET (polyethylene terephthalate), PEN (polyethylene naphthalate), and PVF (polyvinyl fluoride), or a combination of these to form a multilayer structure It is preferred that

Since the horizontal wiring cover layer 4 is provided so as to cover the horizontal wiring 7 in this way, the horizontal wiring 7 can be made inconspicuous when viewed from the light receiving surface side. Further, by providing the horizontal wiring cover layer 4 so as to cover the tab wirings 8a and 8b connected to the horizontal wiring 7, not only the horizontal wiring 7 but also the tab wirings 8a and 8b can be made inconspicuous. It is possible to make the place other than the place where the elements C _{i, j} are arranged as inconspicuous as possible, and to improve the appearance of the solar cell module 1.

  Further, since such a horizontal wiring cover layer 4 can be formed in the same manner as the back sheet 10 and the opening back sheet 14, the manufacturing cost can be reduced without requiring a dedicated material and a new process, The appearance of the solar cell module 1 can be improved.

  The horizontal wiring cover layer 4 is preferably arranged so as to have the same color or the same color as the back sheet 10 and the opening back sheet 14 when viewed from the light receiving surface side. Thus, the external appearance of the solar cell module 1 can be further improved by unifying the colors of the horizontal wiring cover layer 4, the back sheet 10, and the opening back sheet 14 that can be viewed from the light receiving surface side. .

  Further, as described above, when the horizontal wiring sealing layer 5, the back surface side sealing layer 9, and the opening sealing layer 13 are colored white or the like, these sealing layers 5, 9, 13 are used. The colors may be the same or similar colors.

  If the thickness of the horizontal wiring cover layer 4 is, for example, about 20 μm, it will be wrinkled due to heat during laminating or cross-linking treatment, so it is preferably 50-100 μm, for example. Moreover, it is preferable to set it as the thickness which does not exceed the thickness of the back sheet 10 at the maximum, and the same sheet as the sheet used for the back sheet 10 may be used. By using the same sheet, it is not necessary to prepare a new sheet, and the color of the surface of the sheet inevitably becomes the same color, so that the appearance of the solar cell module 1 can be further improved very economically. it can.

The output unit 20 includes a terminal box 21, a connection cable 22, and a connection plug 23. The terminal box 21 is provided therein with a terminal to which one end portion of the outer lead wiring 11 for transmitting an electric output from the solar cell element C _{i, j} is electrically connected, and is further electrically connected to this terminal. The electrical output from the solar cell element C _{i, j} is transmitted to an external circuit through the connection cable 22 and the connection plug 23. The terminal box 21 has a rectangular parallelepiped shape made of, for example, polyphenylene ether resin.

  The terminal box 21 is attached to the back sheet 10 from the outside on the back surface side so as to cover the opening 10a provided in the back sheet 10 using an adhesive such as silicone, for example. The size of the terminal box 21 is optimally determined depending on the size of the solar cell module 1 to be attached. For example, one side is about 5 to 15 cm and the thickness is about 1 to 5 cm.

  FIG. 3: is the fragmentary top view which looked at the panel part 12 of the solar cell module 1 of 1st embodiment of this invention from the back surface side, The state before laminating | stacking the back surface side sealing layer 9 and the back sheet | seat 10 is shown. Show. Note that the tab wiring 8c is omitted.

The fixing tape 6 is used to integrally fix the solar cell element C _{p, 1} or C _{p, n} , the horizontal wiring 7 and the horizontal wiring cover layer 4. More specifically, the fixing tape 6 has an adhesive surface to which an adhesive is applied, and the adhesive surface is bonded to the horizontal wiring 7 laminated on the horizontal wiring sealing layer 5 and the horizontal wiring sealing layer. The exposed end portion 31 of the horizontal wiring cover layer 4 exposed from 5 and the back surface of the solar cell element _{Cp, 1} or _{Cp, n} are fixed together by being integrally attached. Such a fixing tape 6 may be realized by, for example, a PET tape having a thickness of about 0.1 to 0.5 mm and a width of about 3 to 10 mm, in which an adhesive is applied to one side of a PET (polyethylene terephthalate) material. good.

  The lateral wiring cover layer 4 is sealed on the light receiving surface side before the panel portion 12 is laminated and crosslinked, that is, at the stage where the members constituting the panel portion 12 are simply laminated without being integrated. Since it is in a state of being simply placed without being fixed on the layer 3, there has been a possibility that positional displacement may occur with the softening of each sealing layer during the laminating process and the crosslinking process. Thus, by fixing with the fixing tape 6, it is possible to suppress the occurrence of positional deviation.

Further, by forming a notch 37 in the horizontal wiring sealing layer 5 so that the exposed end 31 is provided in advance, the solar cell element C _{p, 1} or C _{p, n} , the horizontal wiring 7, The wiring cover layer 4 can be easily fixed with the fixing tape 6. Such a notch 37 is preferably formed avoiding the portion where the tab wirings 8a and 8b are in contact.

  Hereinafter, the horizontal wiring cover layer 4 and the horizontal wiring sealing layer 5 used in the solar cell module 1 of the present embodiment will be further described.

In the present embodiment, the horizontal wiring sealing layer 5 includes the horizontal wiring 7 and has a width extending to each solar cell element C _{p, 1} or C _{p, n} arranged along the horizontal wiring 7 and the horizontal wiring 7. The first base 32 extends along the wiring 7, and the first base 32 has a recess 33 that is recessed from a portion _where the tab wiring 8 a, 8 b of each solar cell element C _{p, 1} or C _{p, n} is disposed. Is formed.

Such a recess 33 is formed in the solar cell element C _{p in the} lateral wiring sealing layers 5a and 5b, for example, the tab wires 8a and 8b connected to the solar cell elements C ₂₁ and C _{1, n} in FIG. _{, 1} or _Cp, one end of which is connected to the light-receiving surface side electrode, and the other end is formed at a portion in contact with the tab wiring 8a, 8b connected to the lateral wiring 7a, 7b.

Providing such a recess 33 makes it easy to place a portion other than the recess 33 in the first base 32 close to the solar cell element C _{i, j} regardless of the presence of the tab wiring 8. It is possible to effectively fill the horizontal wiring sealing layer 5 up to the end of the solar cell element C _{i, j} located in the vicinity of 33 to suppress the remaining of bubbles. Therefore, in manufacturing the solar cell module 1 having the horizontal wiring cover layer 4, the yield can be improved.

<Method for manufacturing solar cell module>
Hereinafter, the manufacturing method of the solar cell module 1 of this embodiment is demonstrated.

First, the light receiving surface side sealing layer 3 is laminated on the translucent substrate 2, the horizontal wiring cover layer 4 is laminated on the light receiving surface side sealing layer 3, and the horizontal wiring is formed on the horizontal wiring cover layer 4. The horizontal wiring sealing layer 5 is laminated so that one end of the cover layer 4 is exposed, and a plurality of wirings in which the horizontal wiring 7, the tab wiring 8, and the outer lead wiring 11 are connected on the light receiving surface side sealing layer 3. The solar cell elements C _{i, j} are stacked such that the horizontal wiring 7 is positioned on the horizontal wiring cover layer 4, the horizontal wiring 7, the exposed end portion 31 of the horizontal wiring cover layer 4, and the solar cell elements C _{p, 1} or _{Cp, n} is fixed using the fixing tape 6, the opening sealing layer 13 is stacked on the solar cell element, and the opening backsheet 14 is stacked on the opening sealing layer 13. Thus, a laminated body is formed.

  Next, this laminated body is set in an apparatus called a laminator, and is integrated by applying pressure while heating at a temperature of about 100 to 200 ° C. under a reduced pressure of about 50 to 150 Pa for about 15 to 60 minutes.

  Next, the integrated laminate is subjected to a crosslinking treatment in which each sealing layer is heated under a temperature condition equal to or higher than the crosslinking temperature.

  Next, a terminal box 21 is attached to the panel portion 12 of the solar cell module 1 that has been crosslinked so as to cover the opening 10 a formed in the back sheet 10.

Thus, in the manufacturing method of the solar cell module 1 including the horizontal wiring cover layer 4 covering the horizontal wiring 7, before performing the laminating process and the crosslinking process, the horizontal wiring 7 and the exposed end 31 of the horizontal wiring cover layer 4 are used. And the solar cell element C _{p, 1} or C _{p, n} are fixed by the fixing tape 6, so that the exposed end portion of the horizontal wiring 7 and the horizontal wiring cover layer 4 (at the time of the laminating process and the cross-linking process) 31) and the positional relationship of the three members of the horizontal wiring cover layer 4 can be prevented from shifting. Therefore, the solar cell module 1 having the horizontal wiring cover layer 4 for making the portion other than the portion where the solar cell elements C _{i, j} are arranged as inconspicuous as possible can be manufactured with improved yield. .

<< Second Embodiment >>
FIG. 4 is a partial plan view of the panel unit 12 of the solar cell module 1 according to the second embodiment of the present invention viewed from the back side, and shows a state before the back side sealing layer 9 and the back sheet 10 are laminated. Show. Note that the tab wiring 8c is omitted. In addition, parts corresponding to those of the first embodiment are denoted by the same reference numerals, and redundant description is omitted.

  The solar cell module 1 of this embodiment is characterized by the shape of the horizontal wiring sealing layer 5c. The horizontal wiring sealing layer 5c has the same width as the horizontal wiring 7a and extends along the horizontal wiring 7a, and the outer lead wiring protruding from the portion where the outer lead wiring 11 of the second base 34 is disposed. And a tab wiring protrusion 35 protruding from a portion where the tab wiring 8a of the second base 34 is disposed.

  In this way, even when the shape of the horizontal wiring sealing layer 5c is the minimum necessary configuration for making the horizontal wiring 7a inconspicuous, bubbles remain in the vicinity of the horizontal wiring 7a in the laminating process, Since it is possible to suppress a decrease in reliability due to the wiring 7a not being completely encapsulated by each sealing layer, the manufacturing cost can be reduced as much as possible, which is economical. In addition, the outer lead wiring 11 can be made inconspicuous because the outer lead wiring protrusion 36 is provided, and the tab wiring 8a can be made inconspicuous because the tab wiring protrusion 35 is provided. it can. The shape of the lateral wiring sealing layer 5c may be configured to have only one of the outer lead wiring protrusion 36 and the tab wiring protrusion 35.

  In addition, this invention is not limited to the said embodiment, Many corrections and changes can be added within the scope of the present invention.

  For example, in the above-described embodiment, as shown in FIG. 2, the plurality of solar cell elements C are connected to each other by the tab wiring 8 on different main surfaces (light receiving surface and back surface). The solar cell elements C can be applied to a configuration in which the solar cell elements C are connected to each other by the tab wiring 8 on the same main surface side (for example, only the back surface).

For example, in the manufacturing method of the above embodiment, a plurality of solar cell elements C _{i, j} are connected to the light-receiving surface side sealing layer 3 in a state where the plurality of solar cell elements C _{i, j} are connected by the lateral wiring 7, the tab wiring 8, and the outer lead wiring 11. However, instead of this, a plurality of solar cell elements C _{i, j} , lateral wiring 7, tab wiring 8, and outer lead wiring 11 that are separately placed on the light-receiving surface side sealing layer 3. May be connected.

It is a disassembled perspective view which shows the structure of the solar cell module 1 of 1st embodiment of this invention. It is the fragmentary sectional view which cut | disconnected the panel part 12 of the solar cell module 1 shown in FIG. 1 by the virtual one plane perpendicular | vertical to the X direction. It is the partial top view which looked at the panel part 12 of the solar cell module 1 of 1st embodiment of this invention from the back surface side. It is the partial top view which looked at the panel part 12 of the solar cell module 1 of 2nd embodiment of this invention from the back surface side.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Translucent substrate 3 Light-receiving surface side sealing layer 4, 4a, 4b Horizontal wiring cover layer 5, 5a, 5b, 5c Horizontal wiring sealing layer 6 Fixing tape 7, 7a, 7b Horizontal wiring 8, 8a 8b, 8c Tab wiring 9 Back surface side sealing layer 10 Back sheet 11 Outer lead wiring 12 Panel portion 13 Opening portion sealing layer 14 Opening portion back sheet 20 Output portion 21 Terminal box 22 Connection cable 23 Connection plug 31 Exposed end portion 32 First base 33 Recess 34 Second base 35 Tab wiring protrusion 36 Outer lead wiring protrusion 37 Notch

Claims (6)

A translucent substrate;
A light-receiving surface side sealing layer laminated on the translucent substrate;
A plurality of solar cell elements having tab wiring, which are stacked on the light-receiving surface side sealing layer;
On the light-receiving surface side sealing layer, a lateral wiring cover layer laminated on the side of each solar cell element and along each solar cell element;
On the horizontal wiring cover layer, a horizontal wiring sealing layer that is laminated so that the end of each solar cell element side of the horizontal wiring cover layer is exposed,
Laminate wiring on the horizontal wiring sealing layer, and connect the tab wiring in common,
A fixing member for fixing the three members of the horizontal wiring, the exposed end portion of the horizontal wiring cover layer and the solar cell element;
Each solar cell element, horizontal wiring cover layer, horizontal wiring sealing layer, tab wiring, horizontal wiring, and fixing member are sealed between the light receiving surface side sealing layer and the light receiving surface side sealing layer. A back side sealing layer to stop,
A backsheet laminated on the back side sealing layer;
A solar cell module comprising:   2. The body water battery module according to claim 1, wherein the light receiving surface side surface of the horizontal wiring cover layer has the same color or a similar color as the light receiving surface side surface of the back sheet.   The horizontal wiring sealing layer includes a base portion that includes the horizontal wiring and extends to the solar cell elements disposed along the horizontal wiring and extends along the horizontal wiring. The solar cell module according to claim 1, wherein the solar cell module has a concave portion that is recessed from a portion where the tab wiring of the battery element is disposed. An outer lead wiring connected to the horizontal wiring and extending to the outside through the back side sealing layer;
The lateral wiring sealing layer includes a base portion having substantially the same width as the lateral wiring and extending along the lateral wiring, and an outer lead wiring protrusion projecting from a portion of the base where the outer lead wiring is disposed. The solar cell module according to claim 1 or 2.   The horizontal wiring sealing layer has a base portion that is substantially the same width as the horizontal wiring and extends along the horizontal wiring, and a tab wiring protrusion that protrudes from a portion of the base where the tab wiring is disposed. The solar cell module according to claim 1 or 2, characterized by the above. Laminating a translucent substrate and a light-receiving surface side sealing layer;
A step of laminating a horizontal wiring cover layer on the light-receiving surface side sealing layer;
Laminating a lateral wiring sealing layer on the lateral wiring cover layer so that one end of the lateral wiring cover layer is exposed;
Laminating a plurality of solar cell elements connected by lateral wiring on the light-receiving surface side sealing layer so that the lateral wiring is positioned on the lateral wiring cover layer;
A step of fixing the exposed wiring portion of the horizontal wiring, the horizontal wiring cover layer and the three of the solar cell elements with a fixing member;
By laminating the back surface side sealing layer on the light receiving surface side sealing layer, each solar cell element, horizontal wiring cover layer, horizontal wiring sealing is provided between the light receiving surface side sealing layer and the back surface side sealing layer. Sealing the layer, the lateral wiring and the fixing member;
A step of laminating a back sheet on the back side sealing layer;
The manufacturing method of the solar cell module characterized by including.

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