JP2011198886A - Solar battery module, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance adhesiveness of a frame body to a sealing member of a solar battery module.SOLUTION: The sealing member 20 seals an entire surface of the solar battery cell 10, that is entire surfaces of a front surface and rear surface, and is flexible. The frame body 100 is formed on an edge of the sealing member 20, and has a shape fitting to a front surface, side surface, and rear surface of the sealing member 20. A protective film 22 is arranged on a light incident side front surface of the sealing member 20. An adhesive layer 30 is positioned between the frame body 100 and the protective film 22, and tightly adheres to both of the frame body 100 and the protective film 22.

Description

  The present invention relates to a solar cell module in which solar cells are covered with a flexible sealing material, and a method for manufacturing the solar cell module.

  In recent years, environmentally friendly movements have been spreading, and along with this, the spread of solar cells is progressing. In order to use a solar cell, it is necessary to coat the solar cell with a sealing material. Solar cell sealing materials include flexible materials such as laminate films. In this case, corrosives that corrode solar cells and wiring, such as moisture, can enter from the end face of the sealing material. There is sex.

  As a method for solving this problem, Patent Document 1 describes that the edge of the sealing material is covered with a frame formed by RIM (reaction injection molding). Patent Document 2 describes that the edge of the sealing material is covered with a frame formed by a polymer injection integral molding method.

JP 2007-19499 A JP 11-68136 A

  Since durability is required for the sealing material, the surface needs to be formed of a highly durable material. However, depending on the material of the sealing material, the frame formed by injection molding or the like may not adhere to the sealing material, and the end face of the sealing material may not be sufficiently protected.

  This invention is made | formed in view of the said situation, The place made into the objective is to provide the manufacturing method of a solar cell module with high adhesiveness of the frame with respect to a sealing material, and a solar cell module.

  The first solar battery module according to the present invention includes a solar battery cell, a sealing material, a protective material, a resin frame, and an adhesive layer. The sealing material seals the entire surface of the solar battery cell. The frame has an opening at least on the light incident side to the solar battery cell, and covers a sealing material positioned other than the opening. The protective material is provided in a region located at least in the opening of the sealing material. The adhesive layer is in close contact with the region located on the edge side of the sealing material from the opening in the frame.

  According to the present invention, the adhesive layer is in close contact with the frame. For this reason, the adhesiveness of the frame to the sealing material can be increased.

  The second solar battery module according to the present invention includes a solar battery cell, a sealing material, a resin frame, and a protective material. The sealing material seals the entire surface of the solar battery cell. The frame has an opening at least on the light incident side to the solar battery cell, and covers a sealing material positioned other than the opening. The protective material is provided only in the region located in the opening of the sealing material. The frame is in close contact with the region of the sealing material located on the edge side of the sealing material from the opening.

  Since the protective material is required to have durability, the adhesion to the frame body is often lower than that of the sealing material. On the other hand, in the present invention, since the protective material is provided only in the region located in the opening, the frame can directly contact the sealing material. Therefore, the adhesion of the frame body to the sealing material can be increased.

  The manufacturing method of the 1st solar cell module which concerns on this invention has the following processes. First, the entire surface of the solar battery cell is sealed with a sealing material. Next, a protective material is brought into close contact with at least the light incident side surface of the sealing material. Next, an adhesive layer is provided on the edge of the surface of the protective material. Next, a resinous frame is formed on the sealing material, and a resin frame is formed by an injection molding method. This frame has an opening at least on the light incident side to the solar battery cell, and has a shape that covers a sealing material positioned other than the opening. In this injection molding method, the adhesive layer is brought into close contact with the frame.

  The manufacturing method of the 2nd solar cell module which concerns on this invention has the following processes. First, the entire surface of the solar battery cell is sealed with a flexible sealing material. Then, a protective material is provided in the area | region except the edge among the surfaces of the sealing material. Next, a resin frame having a shape along the front surface, side surface, and back surface of the sealing material is formed on the edge of the sealing material by an injection molding method.

  ADVANTAGE OF THE INVENTION According to this invention, the adhesiveness of the frame with respect to a sealing material can be made high in a solar cell module.

It is a perspective view which shows the structure of the solar cell module which concerns on 1st Embodiment. It is AA 'sectional drawing of FIG. It is sectional drawing which shows the manufacturing method of the solar cell module shown in FIG.1 and FIG.2. It is sectional drawing which shows the structure of the solar cell module which concerns on 2nd Embodiment. It is sectional drawing which shows the structure of the solar cell module which concerns on 3rd Embodiment. It is sectional drawing which shows the structure of the solar cell module which concerns on 4th Embodiment. It is sectional drawing which shows the structure of the solar cell module which concerns on 5th Embodiment. It is sectional drawing which shows the structure of the solar cell module which concerns on 6th Embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In all the drawings, the same reference numerals are given to the same components, and the description will be omitted as appropriate.

  FIG. 1 is a perspective view showing the configuration of the solar cell module according to the first embodiment, and FIG. 2 is a cross-sectional view taken along the line AA ′ of FIG. The solar cell module shown in these drawings includes at least one solar cell 10, a sealing material 20, a protective film (protective material) 22, a resin frame 100, and an adhesive layer 30. The sealing material 20 seals the entire surface of the solar battery cell 10, that is, the entire surface of the front and back surfaces, and has flexibility. A protective film 22 is provided on the light incident surface side of the solar battery cell 10 via a sealing material 20. The frame 100 is provided at the edge of the sealing material 20 and has a shape along the side and back surfaces of the sealing material 20 and the end of the protective film 22 provided on the light incident surface side. The frame 100 has an opening 104 on the light incident side to the solar battery cell 10. The protective film 22 is provided on the entire surface including the region located in the opening 104 on the light incident surface side of the sealing material 20. The adhesive layer 30 is located between the frame body 100 and the protective film 22, and is in close contact with the region of the frame body 100 located on the edge side of the sealing material 20 from the opening 104. Specifically, the adhesive layer 30 is in close contact with both the frame 100 and the protective film 22 in the above-described region. Details will be described below.

  The solar battery cell 10 is formed of, for example, a flexible substrate. In this case, the solar battery cell 10 has flexibility. The substrate of the solar battery cell 10 is, for example, polyimide, polyamide, polyimideamide, polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyetherimide (PEI), polyetheretherketone (PEEK), and polyethersulfone (PES). ).

  The sealing material 20 is made of, for example, a resin material such as ethylene vinyl acetate copolymer (hereinafter referred to as EVA), vinyl chloride copolymer, epoxy resin, silicon resin, polyethylene, polyvinyl alcohol (PVA), or polyvinyl butyral (PVB). Become.

  Moreover, in this embodiment, the location which is not covered with the frame 100 has the protective film 22 on the surface. The protective film 22 is made of, for example, a film made of fluorine resin, polymethyl methacrylate, polysulfone, polyether sulfone, polyvinyl chloride, polycarbonate, or the like, and is bonded to the sealing material 20 by being formed by a laminating method. .

  The frame 100 is directly formed with respect to the solar cell module comprised by the photovoltaic cell 10, the sealing material 20, and the protective film 22 by the injection molding method, for example, the reaction injection molding method. The frame 100 is made of, for example, a thermosetting resin that uses dicyclopentadiene as a raw material.

  The adhesive layer 30 is adhered to the sealing material 20 via the protective film 22. The adhesive layer 30 preferably has heat softening properties, and is formed of, for example, ethylene vinyl acetate or polyethylene.

  Further, the frame body 100 of FIG. By having the back surface covering portion 102, the frame body 100 covers the entire back surface of the sealing material 20. The adhesive layer 30 is provided between the protective film 22 and the frame body 100 over the entire circumference of the edge of the protective film 22.

  As shown in FIG. 1, the output terminals 12 and 14 of the solar battery cell 10 are exposed from the frame body 100.

  FIG. 3 is a cross-sectional view showing a method for manufacturing the solar cell module shown in FIGS. 1 and 2. First, as shown to Fig.3 (a), the photovoltaic cell 10 is prepared, the sealing material 20 is arrange | positioned at the surface side (light incident side) and back surface side of the prepared photovoltaic cell 10, and a protective film is provided on the surface side. After arranging 22, the protective film 22 and the sealing material 20 are laminated together by, for example, heat welding. The laminating method here may be a vacuum laminating method or a roll laminating method. Thereby, the entire surface of the solar battery cell 10 is sealed with the sealing material 20, and the light incident side is further covered with the protective film 22. The protective film 22 is in close contact with the sealing material 20. At this time, the sealing material 20 is formed so that the output terminals 12 and 14 come out of the sealing material 20.

  Next, as shown in FIG. 3B, the adhesive layer 30 is formed over the entire periphery of the edge of the protective film 22. The adhesive layer 30 can be formed by, for example, heat welding or pressure bonding.

  Next, as shown in FIG. 1, the frame body 100 is formed by an injection molding method, for example, a reaction injection molding method. At this time, the adhesive layer 30 is heated by the resin to be the frame body 100 and softens. Thereafter, as the frame 100 is cooled, the adhesive layer 30 is also cooled. By this step, the adhesive layer 30 is in close contact with both the frame body 100 and the protective film 22. When the frame 100 is formed, the output terminals 12 and 14 are made to come out of the frame 100.

  Next, the operation and effect of this embodiment will be described. According to the present embodiment, the frame 100 and the protective film 22 are in contact with each other via the adhesive layer 30. Thereby, it is possible to suppress the entry of a corrosive substance that corrodes the solar battery cell or the wiring, for example, moisture, from the end face of the sealing material 20.

  Moreover, since the frame 100 is formed of resin, the frame 100 can be flexible. As described above, each of the solar battery cell 10, the sealing material 20, and the protective film 22 has flexibility. For this reason, flexibility can be given to the solar cell module.

  Further, since the back surface covering portion 102 is provided on the frame body 100, the back surface side of the solar battery cell 10 and the sealing material 20 is supported by the frame body 100. That is, the frame 100 is in a state where only the surface side that is the light incident side is opened, and the planar shape of the opening is smaller than the planar shape of the protective film 22. Therefore, even if the adhesive layer 30 is provided only on the surface side of the sealing material 20, the frame body 100 is suppressed from being detached from the protective film 22.

  Moreover, since the back surface side is supported by the back surface coating | coated part 102 by the frame 100, the solar cell 10 and the sealing material 20 are the members for ensuring the intensity | strength of a solar cell module in the back surface side of the sealing material 20. For example, it is not necessary to provide a separate metal sheet.

  When a metal sheet is attached to the back surface side of the sealing material 20, thermal distortion occurs in the solar cell module when the frame body 100 is formed due to the difference in thermal expansion coefficient between the sealing material 20 and the metal sheet. There is. However, in this embodiment, since the frame body 100 is formed of resin, the difference in thermal expansion coefficient between the frame body 100 and the sealing material 20 is small. Therefore, it can suppress that a thermal strain arises in a solar cell module.

  Further, since the adhesive layer 30 is formed of a material having heat softening properties, the adhesive layer 30 can be bonded to the frame body 100 and the protective film 22 when the frame body 100 is formed. Therefore, the manufacturing process can be simplified.

  In addition, after forming the adhesive layer 30, before forming the frame body 100, the adhesive layer 30 is heated and softened, and then cooled to cool the adhesive layer 30 before forming the frame body 100. It may be adhered to. In this case, for example, even when the surface of the adhesive layer 30 in contact with the protective film 22 does not rise to a temperature that softens in the step of forming the frame 100, the adhesive layer 30 is formed on both the frame 100 and the protective film 22. Can be adhered to.

  FIG. 4 is a cross-sectional view showing the configuration of the solar cell module according to the second embodiment, and corresponds to FIG. 2 in the first embodiment. The solar cell module according to the present embodiment is the same as the solar cell module according to the first embodiment, except that the protective layer 110 is provided on the surface of the frame 100 that is exposed to the outside. It is a configuration.

  The protective layer 110 is formed by, for example, applying a weather resistant paint to the frame 100 after forming the frame 100. The protective layer 110 is formed on the entire back surface, the entire side surface, the entire top surface, and the entire surface of the side surface of the opening 104 of the frame 100.

  Also according to this embodiment, the same effect as that of the first embodiment can be obtained. Moreover, since the frame body 100 is coat | covered with the protective layer 110, it can suppress that the resin-made frame body 100 deteriorates.

  In each embodiment described later, the protective layer 110 shown in this embodiment may be provided.

  FIG. 5 is a cross-sectional view showing the configuration of the solar cell module according to the third embodiment, and corresponds to FIG. 2 in the first embodiment. The solar cell module according to the present embodiment is the same as that of the first embodiment except that the frame body 101 is used instead of the frame body 100 and the protective layer film 22 and the adhesive layer 30 are formed in different locations. It is the structure similar to the shown solar cell module.

  In this embodiment, the solar cell module is provided with a protective film 22 on both sides of the solar battery cell 10 via the sealing material 20 and laminated. And unlike the frame 100 like FIG. 2, the frame 101 does not have the back surface coating | coated part 102, but only the edge part of the protective film 22 of the side surface of the sealing material 20, and a surface and a back surface. Covering. For this reason, the protective film 22 is also exposed to the outside on the back side. The adhesive layer 30 is provided between the protective film 22 and the frame body 101 on both the front surface (light incident side) and the back surface of the solar cell module.

  Also in this embodiment, the same effects as those of the first embodiment can be obtained except for the effects caused by the back surface covering portion 102. Moreover, since the back surface covering portion 102 is not formed, the structure of the frame body can be simplified and the manufacturing cost can be reduced.

  FIG. 6 is a cross-sectional view showing the configuration of the solar cell module according to the fourth embodiment, and corresponds to FIG. 2 in the first embodiment. The solar cell module according to the present embodiment has the same configuration as the solar cell module according to the first embodiment except for the following points.

  First, the dimension of the protective film 22 is the same as the opening dimension of the opening 104, and is formed only in the region located in the opening 104 on the light incident side surface of the sealing material 20. The adhesive layer 30 is not provided, and the frame 100 is in close contact with the region of the sealing material 20 located on the edge side of the sealing material 20 from the opening 104 over the entire circumference.

  In this embodiment, the sealing material 20 is formed of EVA, a vinyl chloride copolymer, an epoxy resin, a silicone resin, polyethylene, polyvinyl alcohol (PVA), or polyvinyl butyral (PVB). Adhesion can be increased because the adhesive layer 20 is directly bonded.

  In addition, the manufacturing method of the solar cell module which concerns on this embodiment is 1st except the point which forms the protective film 22 only in the opening area | region of the frame 100, and the point which does not have the process of forming the contact bonding layer 30. This is the same as the method for manufacturing the solar cell module according to the embodiment.

  Also according to this embodiment, the same effect as that of the first embodiment can be obtained. Moreover, since it is not necessary to form the adhesive layer 30, the manufacturing process of the solar cell module is simplified, and the manufacturing cost of the solar cell module is reduced.

  FIG. 7 is a cross-sectional view showing the configuration of the solar cell module according to the fifth embodiment. The solar cell module according to the present embodiment has the same configuration as the solar cell module according to the fourth embodiment except for the following points.

  First, the frame 101 shown in the third embodiment is used as the frame. The protective film 22 is provided on the front and back surfaces of the solar cell module, and the frame body 101 is directly bonded to the sealing material 20.

  Also in this embodiment, the same effect as that of the fourth embodiment can be obtained. In addition, since the frame body 101 is used, the structure of the frame body can be simplified and the manufacturing cost can be further reduced.

  FIG. 8 is a cross-sectional view showing the configuration of the solar cell module according to the sixth embodiment. In the solar cell module according to the present embodiment, the portion of the sealing material 20 that is covered with the frame 100 and does not have the protective film 22, that is, the opening 104, of the edge portion on the surface side of the sealing material 20. The solar cell module has the same configuration as that of the solar cell module according to the fourth embodiment except that the adhesive layer 30 is provided in the region located on the edge side.

  Also according to this embodiment, the same effect as that of the first embodiment can be obtained. The adhesive layer 30 is in contact with the sealing material 20 instead of the protective layer film 22.

  As mentioned above, although embodiment of this invention was described with reference to drawings, these are the illustrations of this invention, Various structures other than the above are also employable.

DESCRIPTION OF SYMBOLS 10 Solar cell 12 Output terminal 14 Output terminal 20 Sealing material 22 Protective film 30 Adhesive layer 100 Frame body 101 Frame body 102 Back surface covering part 104 Opening part 110 Protective layer

Claims (15)

Solar cells,
A sealing material for sealing the entire surface of the solar battery cell;
A resin-made frame having an opening on at least a light incident side to the solar battery cell and having a shape covering the sealing material positioned other than the opening;
A protective material provided at least in a region located in the opening of the sealing material;
An adhesive layer that is in close contact with a region located on the edge side of the sealing material from the opening in the frame;
A solar cell module comprising: The solar cell module according to claim 1, wherein
The protective material is larger than the opening size of the frame,
The said contact bonding layer closely_contact | adheres to the area | region located in the edge side of the said sealing material from the said opening part among the said protective materials and the said frame. The solar cell module according to claim 1, wherein
The protective material is the same as the opening size of the frame,
The said contact bonding layer closely_contact | adheres to the area | region located in the edge side of the said sealing material from the said opening part among the said sealing material and the said frame. In the solar cell module according to any one of claims 1 to 3,
The protective material is a fluorine resin layer,
The solar cell module, wherein the adhesive layer is ethylene vinyl acetate or polyethylene. In the solar cell module according to any one of claims 1 to 4,
The said frame is a solar cell module which has the back surface coating | coated part which coat | covers the whole back surface of the said sealing material. Solar cells,
A sealing material for sealing the entire surface of the solar battery cell;
A resin-made frame having an opening on at least a light incident side to the solar battery cell and having a shape covering the sealing material positioned other than the opening;
A protective material provided only in a region located in the opening of the sealing material,
The said frame is closely_contact | adhered over the perimeter with respect to the area | region located in the edge side of the said sealing material rather than the said opening part among the said sealing materials. In the solar cell module according to claim 6,
The solar cell module, wherein the protective material is a fluorine resin layer. In the solar cell module according to claim 7,
The said frame is a solar cell module which has a back surface coating | coated part which coat | covers the whole back surface of the said sealing material. In the solar cell module according to any one of claims 1 to 8,
The sealing material is a solar cell module formed by a laminating method. In the solar cell module according to any one of claims 1 to 9,
The solar battery module is a solar battery module formed using a flexible substrate. Sealing the entire surface of the solar battery cell with a sealing material;
Adhering a protective material to at least the light incident side surface of the sealing material;
Providing an adhesive layer on the edge of the surface of the protective material;
Forming at least a resin frame having an opening on the light incident side to the solar battery cell and having a shape covering the sealing material positioned other than the opening by an injection molding method; and A step of bringing the adhesive layer into close contact with the frame;
A method for manufacturing a solar cell module comprising: In the manufacturing method of the solar cell module of Claim 11,
A method for manufacturing a solar cell module, wherein a thermosoftening resin layer is used as the adhesive layer. In the manufacturing method of the solar cell module according to claim 12,
A method for manufacturing a solar cell module, wherein the adhesive layer is in close contact with both the frame and the sealing material when the frame is formed by an injection molding method. In the manufacturing method of the solar cell module according to claim 12,
Before the frame body is formed by injection molding, the adhesive layer is adhered to the protective material,
A method for manufacturing a solar cell module, wherein the adhesive layer is in close contact with the frame when the frame is formed by an injection molding method. Sealing the entire surface of the solar battery cell with a flexible sealing material;
Providing a protective material in a region excluding an edge of the surface of the sealing material;
Forming a resin frame having a shape along the front surface, side surface, and back surface of the sealing material on the edge of the sealing material by an injection molding method;
A method for manufacturing a solar cell module comprising:

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