JP2012084721A - Manufacturing method of solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a solar cell module which prevents moisture from intruding into solar cells and improves the durability of the solar cells.SOLUTION: A solar cell module 18 is produced by attaching a flexible holder 1 having a U shaped cross section to a periphery of a solar cell 3 through a sealing member 2 and covering an outer surface of the flexible holder 1 with a frame 17 having a U shaped cross section. The manufacturing method includes a process in which the flexible holder 1 is attached to the periphery of the solar cell 3 through the sealing member 2 and a process in which the sealing member 2 attached to the periphery of the solar cell 3 is heated to a predetermined temperature while being pressurized with a predetermined pressure from the exterior of the flexible holder 1.

Description

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

  Conventionally, a solar cell module in which a solar cell and a frame that supports the solar cell are integrated has been used to install the solar cell on a rooftop of a building or the like.

Solar cells are required to have durability against various environments such as humidity and wind and rain. Therefore, a solar cell is provided with, for example, a solar cell element between a cover glass that is a light-transmitting plate and a back sheet that ensures moisture resistance, and an ethylene-vinyl acetate copolymer (EVA) or the like as a main component therebetween. It is manufactured by enclosing a transparent sealing material.
When moisture enters a solar cell element sealed inside, the solar cell has a problem in durability, such as an increase in electrical resistance of the electrode layer of the solar cell element and a decrease in output.
Therefore, the solar cell module is manufactured by mounting a frame on the solar cell through a sealing material such as butyl rubber in order to protect the inside of the solar cell.

  For example, first, butyl rubber is filled in the frame as a sealing material, and then the butyl rubber is softened by heating. Next, it is known that a solar cell module is manufactured by inserting the periphery of a solar cell into a frame filled with butyl rubber and then fixing the frame to the solar cell with cooled butyl rubber (for example, Patent Documents). 1).

JP 11-103086 A

  However, in the conventional method for manufacturing a solar cell module, there is a portion that does not adhere between the butyl rubber and the cover glass and between the butyl rubber and the back sheet, and there may be a slight gap between the solar cell and the butyl rubber. Therefore, when the water | moisture content which exists in a clearance gaps in into a solar cell inside between the cover glass and back sheet | seat of a solar cell periphery, the problem that the output reduction of a solar cell arises may arise.

  In order to eliminate such inconveniences, an object of the present invention is to provide a method for manufacturing a solar cell module that prevents moisture from entering the solar cell and increases the durability of the solar cell.

  The present invention includes a solar cell, a U-shaped flexible holder attached to the periphery of the solar cell via a sealing material, and a U-shaped frame covering the outer surface of the flexible holder. A method of manufacturing a solar cell module provided with the step of mounting the flexible holder with the sealing material inserted on the periphery of the solar cell, and the periphery of the solar cell from the outside of the flexible holder The method includes a step of heating the attached sealing material to a predetermined temperature while applying a predetermined pressure, and a step of covering the outer surface of the flexible holder with the frame.

  In the method for manufacturing a solar cell module of the present invention, first, a flexible holder having a U-shaped cross section with a sealing material inserted is attached to the periphery of the solar cell. The sealing material is a material that is easily deformed and is made of a material that has a predetermined elasticity after being heated under pressure. For example, natural rubber (NR), isoprene rubber, chloroprene rubber, styrene-butadiene rubber ( SBR), acrylonitrile-butadiene rubber (NBR), ethylene-propylene-diene rubber (EPDM), butyl rubber, silicone rubber, fluorine rubber and the like.

  By attaching the flexible holder to the periphery of the solar cell, the periphery of the solar cell is covered with the sealing material, and the sealing material covering the periphery of the solar cell is also covered with the flexible holder.

  Next, the sealing material attached to the periphery of the solar cell is heated from the outside of the flexible holder to a predetermined temperature while being pressed at a predetermined pressure.

  The peripheral edge of the solar cell and the sealing material can be brought into close contact with each other by heating to a predetermined temperature while pressurizing the sealing material with a predetermined pressure from the outside of the flexible holder. The flexible holder can maintain a tight contact state between the peripheral edge of the solar cell and the sealing material, and a U-shaped flexible holder having a desired shape that can be covered by a U-shaped frame. Can be manufactured.

  Therefore, there is no gap in which moisture exists between the periphery of the solar cell and the sealing material, so that it is possible to prevent moisture from entering the solar cell from the periphery of the solar cell. As a result, the durability of the solar cell can be increased.

  Then, the outer surface of the flexible holder is covered with a frame. By covering the outer surface of the flexible holder with a frame, the solar cell, a flexible holder having a U-shaped cross section that is attached to the periphery of the solar cell via a sealing material, and the outer surface of the flexible holder A solar cell module including a frame having a U-shaped cross section for covering can be manufactured.

  Therefore, the frame having a U-shaped cross-section can reliably maintain the close contact state between the peripheral edge of the solar cell and the sealing material maintained by the flexible holder.

  In the method for manufacturing a solar cell module of the present invention, the solar cell includes, for example, a cover glass, a solar cell element disposed on a surface opposite to the light receiving surface of the cover glass, and the solar cell element while covering the solar cell element. A back sheet in which a sealing material is enclosed between the cover glass and the cover glass.

  In this case, the sealing material can be brought into close contact with the cover glass and the back sheet of the solar cell by heating to a predetermined temperature while pressing the sealing material with a predetermined pressure from the outside of the flexible holder. Therefore, there is no gap in which moisture exists between the cover glass and back sheet of the solar cell and the sealing material, so that moisture enters the inside of the solar cell from between the cover glass and the back sheet of the solar cell. Can be prevented.

  In the method for manufacturing a solar cell module according to the present invention, it is preferable that the method further includes a step of holding the sealing material at the predetermined temperature for a predetermined time after heating the sealing material. After the sealing material is heated to a predetermined temperature and held at the predetermined temperature for a predetermined time, the peripheral edge of the solar cell and the sealing material can be reliably adhered.

In the method for manufacturing a solar cell module of the present invention, the sealing material is butyl rubber, and the pressure for pressurizing the butyl rubber attached to the periphery of the solar cell from the outside of the flexible holder is ^{2 to 4} N / cm ² . A pressure in the range is preferred.

When the pressure for pressurizing butyl rubber from the outside of the flexible holder is less than ² N / cm ² , a gap may be generated between the solar cell and butyl rubber. Therefore, it may not be possible to prevent moisture present in the gap from entering the solar cell from between the cover glass and the back sheet.

On the other hand, when the pressure which presses butyl rubber from the exterior of a flexible holder exceeds 4 N / cm < ² >, a pressurization apparatus becomes large-scale and reduction of the manufacturing cost of a solar cell module cannot be achieved.

  In the method for manufacturing a solar cell module of the present invention, the temperature for heating the butyl rubber is preferably in the range of 80 to 120 ° C.

  When the temperature for heating the butyl rubber is less than 80 ° C., a gap may be formed between the solar cell and the butyl rubber. Therefore, as described above, it may not be possible to prevent moisture present in the gap from entering the solar cell.

  On the other hand, if the temperature for heating the butyl rubber becomes too high, the butyl rubber may be deteriorated or the flexible holder may be deformed. Also, excessive energy is required for heating. Raise. Therefore, the heating temperature is preferably 120 ° C. or lower.

  Furthermore, in the manufacturing method of the solar cell module of this invention, it is preferable to hold | maintain the said butyl rubber for the time for less than 5 minutes at the temperature of the range of 80-120 degreeC.

  By holding the butyl rubber at a temperature within the above range for a period of 5 minutes or less, the solar cell and the butyl rubber can be brought into close contact with each other. On the other hand, when the butyl rubber is held at a temperature in the above range for more than 5 minutes, it is difficult to reduce the manufacturing time of the solar cell module.

Process drawing which shows the manufacturing process of the solar cell module of this embodiment. The figure which shows the solar cell of this embodiment. The figure explaining a part of manufacturing process of FIG. The figure explaining the method to measure the adhesiveness of a glass sheet and butyl rubber. The figure which shows the relationship between a pressurized pressure and shear strength. The figure which shows the relationship between heat press temperature and shear strength.

  Next, embodiments of the present invention will be described in more detail with reference to the accompanying drawings.

  In the method for manufacturing a solar cell module according to the present embodiment, first, as shown in FIG. 1A, uncured butyl rubber 2 is inserted as a sealing material into a flexible holder 1 having a U-shaped cross section, and butyl rubber 2 The flexible holder 1 in which is inserted is attached to the periphery of the solar cell 3. The flexible holder 1 is attached to the periphery of the solar cell 3, for example, by heating the butyl rubber 2 in the flexible holder 1 and pressing the flexible holder 1 together with the heated butyl rubber 2 against the periphery of the solar cell 3. To do.

  As shown in FIG. 2, the solar cell 3 in the solar cell module manufactured by the manufacturing method of the present embodiment includes a solar cell element 4, a cover glass 5 having translucency, and a back sheet 6 that ensures moisture resistance. The transparent sealing material 7 which has EVA etc. as a main component and is enclosed between these is comprised.

  Examples of the solar cell element 4 include a crystalline solar cell, a thin film solar cell including a chalcopyrite thin film solar cell including a CIGS layer made of a chalcopyrite compound (Cu (In + Ga) Se2) in a p-type light absorption layer, and the like. Is mentioned. Examples of the cover glass 5 include a hard transparent plate such as tempered glass.

  The back sheet 6 has excellent moisture resistance such as a laminate of polyvinyl fluoride (PVF) or PET film on a moisture-proof layer such as silica-deposited PET film or aluminum foil in order to ensure moisture-proof property inside the solar cell module. Sheet is used.

  In addition, although not shown in figure, between each solar cell element 4 is connected and connected in the sealing material 7, and by connecting with the output terminal provided on the back seat | sheet 6, a power generation output can be taken out outside.

  The flexible holder 1 is a member attached over the entire periphery of the solar cell 3, and is a U-shaped holder that can hold the periphery of the solar cell 3. In addition, opposing protrusions 1 a and 1 b are provided on the inner surfaces of both ends of the U-shaped cross section of the flexible holder 1. The flexible holder 1 is formed of rubber having flexibility and insulating properties, such as an olefin-based thermoplastic elastomer.

  The protrusions 1a and 1b of the flexible holder 1 are mounted on the periphery of the solar cell 3 with the flexible holder 1 into which the butyl rubber 2 is inserted, the protrusion 1a is attached to the cover glass 5 of the solar cell 3, and the protrusion 1b. Is installed in the back sheet 6 of the solar cell 3, a space capable of holding a predetermined amount of butyl rubber is formed in the flexible holder 1.

  Further, the protrusions 1 a and 1 b of the flexible holder 1 are such that even when the butyl rubber 2 is pressurized from the outside of the flexible holder 1, the butyl rubber 2 is the protrusion 1 a and 1 b having a U-shaped cross section of the flexible holder 1. Prevent leakage from the side.

  Next, as shown in FIG. 1B, the jig 8 is attached to the solar cell 3 to which the flexible holder 1 is attached. The jig 8 includes, for example, an L-shaped pedestal member 8a that holds the flexible holder 1, and an opening / closing member 8c that can be rotated via a hinge 8b provided on the pedestal member 8a. When the butyl rubber 2 is pressurized from the outside of the flexible holder 1 by closing the opening / closing member 8c, the jig has a U-shaped cross section.

  Moreover, in this embodiment, as shown to Fig.3 (a), the four jig | tools 8 are mounted | worn over the peripheral periphery of the solar cell 3. FIG. In addition, in the state shown in FIG. 3A, a gap 9 is provided between the jigs 8 so as to move in the center direction of the solar cell 3.

  Next, as shown in FIG. 1C and FIG. 3B, each jig 8 is moved toward the center of the solar cell 3 with the opening / closing member 8 c of the jig 8 being opened. By moving each jig 8 toward the center of the solar cell 3, the solar cell 3 is surely inserted into the butyl rubber 2 inserted into the flexible holder 1 and added to the butyl rubber 2 due to the flexibility of the holder 1. The applied force is released in the opening direction of the opening / closing member 8c of the jig 8.

Next, as shown in FIG. 1 (d), while pressing the butyl rubber 2 mounted on the periphery of the solar cell 3 from the outside of the flexible holder 1 with a pressure in the range of 2 to 4 N / cm ² , the butyl rubber 2 Is heated to a temperature in the range of 80-120 ° C.

  In order to improve the durability of the solar cell 3, the present inventors prevent moisture from entering the solar cell 3 from the interface between the cover glass 5 and the back sheet 6 around the solar cell 3 with the butyl rubber 2. In addition, a suitable condition that allows the solar cell 3 and the butyl rubber 2 to be in close contact with each other was selected.

  In the solar cell 3, for example, when there is a gap between the cover glass 5 and the butyl rubber 2, when the butyl rubber 2 is peeled from the cover glass 5, destruction occurs at the interface between the butyl rubber 2 and the cover glass 5. On the other hand, when the cover glass 5 and the butyl rubber 2 are in close contact with each other, no breakage occurs at the interface between the butyl rubber 2 and the cover glass 5, and a cohesive failure occurs in which the butyl rubber 2 breaks. Further, when the glass cover glass 5 and the resin back sheet 6 are compared, the back sheet 6 has better adhesion to butyl rubber.

  Therefore, using the test apparatus 20 shown in FIG. 4, the sample 11 is pressed while pressing the butyl rubber, which is the sample 11 inserted between two glass sheets 10a and 10b of the same material as the cover glass 5, with a predetermined pressure. Heat to predetermined temperature. And after hold | maintaining for a predetermined time at predetermined temperature, the adhesiveness of glass sheet 10a, 10b and the sample 11 was evaluated by peeling the butyl rubber which is the sample 11 on glass sheet 10a, 10b.

  As shown in FIG. 4, the test apparatus 20 is configured such that the sample 11 is inserted and placed between the two glass sheets 10 a and 10 b on the table heater 12 that heats the butyl rubber that is the sample 11. ing. In addition, the test apparatus 20 is provided with a temperature sensor 13 that measures the surface temperature of the table heater 12, a temperature sensor 14 that measures the surface temperature of the glass sheet 10b, and a temperature sensor 15 that measures the temperature of the sample 11. ing.

(Experiment 1)
First, after the temperature of the sample 11 reached the test temperature of 100 ° C., the weight 16 was placed on the glass sheet 10a, pressure was applied to the sample 11, and the temperature of the sample 11 was held at 100 ° C. for 5 minutes. . The pressure at this time was changed within a range of 0 to 4 N / cm ² to prepare Sample 11. And the destruction of the sample 11 which generate | occur | produced was observed by peeling glass sheet 10a, 10b.

As shown in FIG. 5, as the pressure for pressurizing the sample 11 was increased, the peeling at the interface changed to cohesive failure. Specifically, cohesive failure occurred by applying a pressure of 1.8 N / cm ² or more.

As a result, as the pressurizing pressure is increased, the glass sheets 10a and 10b and the butyl rubber as the sample 11 are brought into close contact with each other, and the temperature of the sample 11 is maintained at 100 ° C. for 5 minutes at a pressure of ² N / cm ² or more. It was found that the glass sheets 10a and 10b and the butyl rubber as the sample 11 were sufficiently adhered by pressurization.

(Experiment 2)
Next, the test temperature was changed in the range of 28 to 120 ° C. Specifically, after the temperature of the sample 11 reached the test temperature by heating, the sample 11 was created by pressurizing at a pressure of ² N / cm ² for 5 minutes while maintaining the temperature of the sample 11 at the test temperature. And destruction of the sample 11 which generate | occur | produces by peeling off glass sheet 10a, 10b was observed.

As shown in FIG. 6, fracture at the interface occurred at test temperatures of 28 ° C. and 40 ° C., cohesive failure and fracture at the interface occurred at 60 ° C., and cohesive failure occurred at 80 ° C. or higher. As a result, as the heating temperature increases, the glass sheets 10a and 10b and the butyl rubber as the sample 11 are in close contact with each other, and the pressure of ² N / cm ² or higher is maintained while maintaining the temperature of the sample 11 at 80 ° C. or higher for 5 minutes. It was found that the glass sheets 10a and 10b and the butyl rubber as the sample 11 were sufficiently adhered by pressurizing with.

(Experiment 3)
Furthermore, an experiment was conducted to determine the time for heating and pressurization. After the temperature of the sample 11 reaches the test temperature, the weight 16 is placed on the glass sheet 10a so that the pressure becomes ² N / cm ² , and the pressurization time after reaching the test temperature and the temperature of the sample 11 are tested. Held at temperature. Thus, the sample 11 according to heating temperature and pressurization time was created. And destruction of the sample 11 which generate | occur | produces by peeling off glass sheet 10a, 10b was observed. The measured results are shown in Table 1.

  As shown in Table 1, when the heating temperature is 40 to 60 ° C. and the pressurizing time is within 5 minutes, the glass sheets 10a and 10b and the butyl rubber as the sample 11 are not sufficiently adhered to each other because of peeling at the interface. When the temperature was 100 ° C. or higher, it was found that even when the pressurization time was within 5 minutes, cohesive failure occurred and the glass sheets 10a and 10b and the butyl rubber as the sample 11 were sufficiently adhered.

As mentioned above, in this embodiment, in order to make the solar cell 3 and the butyl rubber 2 adhere, the pressure of the butyl rubber 2 attached to the periphery of the solar cell 3 from the outside of the flexible holder 1 is in the range of 2 to 4 N / cm ^2. While pressurizing with, the butyl rubber 2 is heated to a temperature in the range of 80 to 120 ° C. to advance the vulcanization reaction.

  Accordingly, the butyl rubber 2 is brought into close contact with the cover glass 5 and the back sheet 6 at the periphery of the solar cell 3. Moreover, the solar cell 3 and the butyl rubber 2 are cooled while being in close contact with each other, so that the solar cell 3 is kept in close contact with the butyl rubber 2. Furthermore, the state in which the butyl rubber 2 is brought into close contact with the cover glass 5 and the back sheet 6 by the flexible holder 1 is reliably maintained.

  As a result, there is no gap in which moisture can exist between the solar cell 3 and the butyl rubber 2, so moisture enters the solar cell 3 from between the cover glass 5 and the back sheet 6 around the solar cell 3. To prevent that.

  And after removing the jig | tool 8, as shown in FIG.1 (e), the outer surface of the flexible holder 1 with which the peripheral edge of the solar cell 3 is mounted | worn via the butyl rubber 2 is used with the frame 17 of a U-shaped cross section. Cover. The frame 17 is a U-shaped member that covers the flexible holder 1 and is attached to the entire periphery of the solar cell 3, for example, a metal frame formed of aluminum or the like.

  By covering the outer surface of the flexible holder 1 with a frame 17 having a U-shaped cross section, the solar cell 3, the flexible holder 1 attached to the periphery of the solar cell 3 via the butyl rubber 2, and the flexibility A solar cell module 18 having a U-shaped frame 17 covering the outer surface of the holder 1 is manufactured.

  In addition, since the solar cell module manufactured by the manufacturing method of this embodiment attaches the flexible holder 1 to the periphery of the solar cell 3 via the butyl rubber 2, the insulation reliability of the butyl rubber 2 increases the insulation reliability. An excellent solar cell module 18 can be manufactured.

  Further, by forming the flexible holder 1 with an insulating olefin-based thermoplastic elastomer or the like, the insulation state between the solar cell 3 and the frame 17 can be maintained, and the insulation reliability is further improved. The solar cell module 18 can be manufactured.

DESCRIPTION OF SYMBOLS 1 ... Flexible holder, 2 ... Butyl rubber, 3 ... Solar cell, 4 ... Solar cell element, 5 ... Cover glass, 6 ... Back sheet, 7 ... Sealing material, 8 ... Jig, 17 ... Frame, 18 ... Sun Battery module.

Claims (6)

A solar cell comprising: a solar cell; a U-shaped flexible holder attached to the periphery of the solar cell via a sealing material; and a U-shaped frame covering the outer surface of the flexible holder A method of manufacturing a module,
Attaching the flexible holder with the sealing material inserted to the periphery of the solar cell;
Heating the sealing material attached to the periphery of the solar cell from the outside of the flexible holder to a predetermined temperature while pressurizing at a predetermined pressure;
And a step of coating the outer surface of the flexible holder with the frame. In the manufacturing method of the solar cell module of Claim 1,
The solar cell covers a cover glass, a solar cell element disposed on a surface opposite to the light receiving surface of the cover glass, and the solar cell element, and a sealing material is enclosed between the cover glass and the solar cell element. A method for manufacturing a solar cell module, comprising: a back sheet. In the manufacturing method of the solar cell module of Claim 1 or Claim 2,
A method of manufacturing a solar cell module, comprising: heating the sealing material to the predetermined temperature, and holding the sealing material at the predetermined temperature for a predetermined time. In the manufacturing method of the solar cell module as described in any one of Claims 1 thru | or 3,
The sealing material is butyl rubber;
The method for producing a solar cell module, wherein the pressure for pressurizing the butyl rubber attached to the periphery of the solar cell from the outside of the flexible holder is a pressure in the range of ^{2 to 4} N / cm ² . In the manufacturing method of the solar cell module of Claim 4,
The method for manufacturing a solar cell module, wherein the temperature for heating the butyl rubber is in the range of 80 to 120 ° C. In the manufacturing method of the solar cell module of Claim 5,
The said butyl rubber is hold | maintained for the time for less than 5 minutes at the temperature of the range of 80-120 degreeC, The manufacturing method of the solar cell module characterized by the above-mentioned.

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