JP2012204458A - Method for manufacturing solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method capable of manufacturing a light and low-cost thin-film solar cell module with high mechanical and impact strengths of a surface protection layer.SOLUTION: A method for manufacturing a solar cell module comprises: a step of laminating and arranging an adhesive filling material, a water vapor barrier film, a first adhesive filling layer, and a plastic sheet which serves as a surface protection layer on a surface side of a solar cell submodule and then laminating and arranging a second adhesive filling layer and a rear surface protection layer on a rear side of the solar cell submodule; and a step of vacuum-laminating the solar cell module with a plurality of layers being laminated and arranged. The method also comprises: a step of performing heat treatment before arranging the plastic sheet which serves as the surface protection layer; a step of corona-treating a surface of the side which is in contact with the first adhesive filling layer; and a step of applying a primer to a corona-treated surface of the plastic sheet. This plastic sheet is arranged so that the surface to which the primer was applied faces the first adhesive filling layer.

Description

  The present invention relates to a method for manufacturing a solar cell module using CIGS for a photoelectric conversion layer, and in particular, the solar protective layer has high mechanical strength and impact strength, is lightweight, and can be manufactured at low cost. The present invention relates to a method for manufacturing a battery module.

  A solar cell is formed by connecting a number of solar cells in a stacked structure in which a light absorption layer of a semiconductor that generates current by light absorption is sandwiched between a lower electrode (back electrode) and an upper electrode (transparent electrode). It is configured and formed on a substrate. A solar cell having such a configuration is attracting attention as clean energy. Therefore, research on solar cells has been actively conducted, and improvements have been attempted from various viewpoints.

As an example, solar cells are weak in moisture, and when moisture enters, characteristics such as conversion efficiency deteriorate. In particular, CIS (CuInSe ₂ ) having a chalcopyrite structure composed of Ib group, IIIb group, and VIb element, CIGS (Cu (In, Ga) Se ₂ ) obtained by further dissolving Ga in CIS, and the like, absorb light. A chalcopyrite solar cell used as a layer uses a ZnO film or the like as a transparent electrode, so that the transparent electrode is altered by the ingress of moisture. As a result, the resistance value of the transparent electrode is increased, and the conversion efficiency is greatly decreased.
However, as is well known, solar cells are often installed outdoors, such as mounts, roofs or rooftops installed outdoors. Therefore, various proposals for improving the waterproofness of the solar cell module have been made (Patent Documents 1 to 7, etc.).

  In Patent Document 1, a plurality of CIS-based thin-film solar cell device portions laminated in the order of an alkali barrier layer, a metal back electrode layer, a light absorption layer, a buffer layer, and a window layer on a glass substrate are electrically connected by a conductive pattern. Semi-strengthened white plate by using an ethylene vinyl acetate (hereinafter referred to as EVA) resin film (or sheet) cross-linked by heating and causing a polymerization reaction to the connected CIS thin film solar cell circuit (or submodule) A CIS thin film solar cell module having a structure in which a cover glass made of glass or the like is attached is described.

Patent Document 2 discloses a surface protective layer, a filler layer comprising a resin layer having at least transparency, cushioning properties, heat resistance, and excellent non-degradation or non-degradability with respect to the action of heat, solar cell An element, a filler layer, and a back surface protective layer are sequentially laminated, and at least one or more of an antifouling layer, an ultraviolet shielding layer, or a weathering layer is laminated on either the layer or the interlayer. An integrated solar cell module is described.
Patent Document 2 describes that the surface protective layer or the back surface protective layer is made of a vapor deposition film in which a vapor deposition film of an inorganic oxide is provided on a base film.

Patent Document 3 describes a solar cell module including a solar cell submodule that receives sunlight and generates power and a sealing material that seals the entire solar cell submodule. This sealing material is a protective sheet that seals the solar cell sub-module and prevents moisture inflow from the outside. The light-receiving surface side sealing material that covers the light-receiving surface side of the solar cell module is opposite to the light-receiving surface. It consists of the back side sealing material which covers the surface of the side.
The light receiving surface side sealing material and the back surface side sealing material have a plane size larger than the plane size of the solar cell submodule, and can cover the entire plane of the solar cell submodule.
Moreover, the light-receiving surface side sealing material and the back surface side sealing material are made of a fluororesin, and the thickness is about 50 to 200 μm from the viewpoint of realizing durability and weight reduction during use. It is described that it is suitable.

In Patent Document 4, a transparent synthetic resin substrate, a plurality of solar cells arranged on the substrate with a light receiving surface facing the substrate and a gap portion provided on the substrate, and wiring in the gap portion on the substrate In addition, a solar battery panel is described which includes an interconnector for connecting the electrodes of solar battery cells and a synthetic resin coating that covers the back surface of the cells and joins the gaps of the substrate.
Patent Document 4 describes that a polycarbonate resin plate or a methyl methacrylate resin plate, or a laminate plate of a polycarbonate resin and a methyl methacrylate resin is used for the synthetic resin substrate.

  In Patent Document 5, in a solar cell module that seals a filler and a solar cell element by a solar cell element, a surface protective layer and a back surface protective layer for sealing the solar cell element, and spacers on both sides, heat resistance, weather resistance, moisture resistance, etc. In order to satisfy these functions, as a surface protection sheet for solar cell modules, a surface protection sheet in which a resin film such as PET film, acrylic or polycarbonate is laminated on the inner surface of a cyclic olefin copolymer film or a cyclic olefin copolymer film via an adhesive A solar cell module using is described.

  Patent Document 6 describes a solar cell module in which a photovoltaic element having a semiconductor photoactive layer as a light conversion member is covered with a filler. This solar cell module has a hard resin layer made of a resin having a Shore hardness of D50 or more on the light receiving surface side of the photovoltaic element, an adhesive layer made of a thermoplastic resin blended with an ultraviolet absorber, and an outermost layer having a light receiving surface. They are stacked in this order from the side. The thickness of the hard resin layer is 25 μm or more and 200 μm or less, and the hard resin layer is selected from polycarbonate resin and polyester resin. Further, it is described that the resin constituting the outermost layer is a fluororesin, for example, ETFE.

Patent Document 7 discloses an ethylene polymer (A) that simultaneously satisfies the following requirements a) to e):
A radically polymerizable unsaturated compound (B1) comprising an ethylenically unsaturated silane compound;
Selected from hydroxyl group-containing ethylenically unsaturated compounds, amino group-containing ethylenically unsaturated compounds, epoxy group-containing ethylenically unsaturated compounds, aromatic vinyl compounds, unsaturated carboxylic acids or their derivatives, vinyl ester compounds, vinyl chloride and carbodiimide compounds An ethylene-based resin composition containing a modified product obtained by modification with a radically polymerizable unsaturated compound (B2) comprising at least one kind of compound is described.
a) Density is 900-940 kg / m ³
b) 90-125 ° C melting peak based on DSC
c) Melt flow rate (MFR2) measured at 190 ° C. and 2.16 kg load in accordance with JISK-6721 is 0.1 to 100 g / 10 min d) Mw / Mn is 1.2 to 3.5
e) 0.1-50 ppm of metal residue

  In Patent Document 7, (i) a modified product (1) obtained by modifying an ethylene polymer (A) with a radically polymerizable unsaturated compound (B1), or an ethylene polymer (A) and ethylene a modified product selected from a modified product (3) obtained by modifying a mixture of an α-olefin copolymer (C) with a radical polymerizable unsaturated compound (B1), and (ii) an ethylene-based polymer (A). Radical polymerizable unsaturated compound (2) obtained by modification with radical polymerizable unsaturated compound (B2) or a mixture of ethylene polymer (A) and ethylene / α-olefin copolymer (C) An ethylene resin composition containing a modified product selected from a modified product (4) obtained by modification with a compound (B2) is described.

The ethylene-based resin composition of Patent Document 7 is used for a solar cell encapsulating sheet used for a solar cell module. In Patent Document 7, as a configuration of the solar cell module, a solar cell module protective sheet (surface protective sheet) / solar cell sealing sheet / solar cell element / solar cell sealing sheet / solar cell module protective sheet ( The structure of the back surface protection sheet) is described.
In Patent Document 7, as a material for a solar cell module surface protective sheet suitably used for a solar cell module, polyester resin, fluororesin, acrylic resin, cyclic olefin (co) polymer, ethylene-vinyl acetate copolymer, and the like Other than the resin film made of, a glass substrate and the like are mentioned.

JP 2007-123725 A JP 2001-196614 A JP 2009-194114 A Japanese Patent Laid-Open No. 10-190034 JP 2006-165434 A Japanese Patent No. 3530595 JP 2011-12243 A

As described above, Patent Document 1 retains impact strength and waterproofness by providing the most common white plate tempered glass as the surface protective layer. However, the commonly used glass has a thickness of 3 mm. When the thickness is 3 mm, the weight is 7.5 kg / m ² . For this reason, in Patent Document 1, it is difficult to reduce the weight.

On the other hand, in patent documents 2-7, the surface protection layer is comprised with the resin film or the resin sheet as a glass substitute material. In Patent Document 2, polyethylene, polypropylene, fluorine-based, polyolefin, acrylic, and the like are exemplified as resins having transparency, cushioning properties, heat resistance, and the like. However, in these, waterproofing required for CIGS solar cells is realized. Is not.
In patent document 3, although the light-receiving surface side sealing material and the back surface side sealing material use the fluorine-type film of 50-200 micrometers thickness, there exists a problem that mechanical strength and impact strength are weak, and also a water vapor | steam barrier film | membrane Therefore, there is also a problem that long-term reliability cannot be obtained due to lack of moisture resistance with respect to CIGS solar cells.

In Patent Document 4, the surface protective layer is made of a synthetic resin substrate and is made of a laminate of polycarbonate, methacrylate, and both. However, the entire structure does not include a water vapor barrier layer and uses a CIGS film as a light absorption layer ( Hereinafter, there is a problem that long-term reliability cannot be obtained due to lack of moisture resistance. In addition, when the module is manufactured, there is a problem in that the module is warped due to thermal contraction of the synthetic resin substrate in the vacuum laminating process.
Moreover, in patent document 5, although it is the structure which laminated | stacked resin films, such as PET, an acryl, and a polycarbonate, on the inner surface of the cyclic olefin polymer film as a surface protection sheet on the light-receiving side, the surface protection sheet is an olefin polymer film. The impact strength is weak, and a constituent material having a water vapor barrier property is required for CIGS solar cells.

  In the solar cell module of Patent Document 6, the outermost layer ETFE, the adhesive layer, and the hard resin layer are laminated from the light receiving side, and the hard resin layer is made of polycarbonate, ester resin, or the like having a thickness of 25 to 200 μm. However, since the solar cell module of Patent Document 6 has a thin hard resin layer, the impact resistance is not sufficient. Moreover, since the solar cell module of patent document 6 is not provided with the water vapor | steam barrier layer, there exists a problem that moisture resistance is also inadequate.

  Although Patent Document 7 discloses an ethylene-based resin composition containing an ethylene / α-olefin copolymer, a polyester resin, a fluororesin, an acrylic resin, a cyclic olefin (copolymer) is used as a surface protective sheet for a solar cell module. ) Resin films made of polymers, ethylene-vinyl acetate copolymers and the like. For this reason, there exists a problem that impact resistance is not enough.

  Here, as a characteristic required for the solar cell module having a long-term reliability of 20 to 30 years, it is a matter of course that the conversion efficiency of the solar cell itself is high, but weather resistance, heat resistance, flame retardancy, It is excellent in water resistance, moisture resistance, wind pressure resistance, yield resistance, and other characteristics. In addition, it is necessary to reduce the construction cost for installing the solar cell module and the panel itself together with lowering the price. In order to reduce the overall cost of conventional heavy-duty solar cell panels and solar cell modules that use tempered glass as the surface protective layer, it also takes costs such as reinforcement work to fix to ordinary houses or slate roofs, etc. It is desired to realize a solar cell module that is light in weight and excellent in performance.

  An object of the present invention is to manufacture a thin-film solar cell module that eliminates the problems based on the above-described prior art, has a high mechanical strength and impact strength of the surface protective layer, is lightweight, and can be manufactured at low cost. It is to provide a method.

  In order to achieve the above object, according to a first aspect of the present invention, an adhesive filler, a water vapor barrier film, a first adhesive filler layer, and a surface protective layer are provided on the surface side of the solar cell submodule, A method of manufacturing a solar cell module in which a second adhesive filling layer and a back surface protective layer are provided on the back side of the solar cell submodule, wherein the solar cell submodule is made of aluminum on the surface of a metal sheet. A substrate on which an anodized film is formed is formed with a light absorption layer composed of a CIGS film, and at least the surface protective layer of the surface protective layer and the back surface protective layer is composed of a plastic sheet. A step of heat-treating the plastic sheet in advance, and a process of corona treating the surface of the plastic sheet on the side in contact with the first adhesive filling layer. And applying a primer to the corona-treated surface of the plastic sheet; and laminating the adhesive filler, the water vapor barrier film, and the first adhesive filler layer on the surface side of the solar cell submodule, A plastic sheet that has been subjected to the heat treatment and the corona treatment, and further coated with a primer, is disposed with the surface coated with the primer facing the first adhesive filling layer, and the solar cell submodule A solar cell module comprising: a step of laminating and arranging a second adhesive filling layer and a back surface protective layer on the back surface side; and a step of vacuum laminating in a state where the plurality of layers are laminated and disposed. The manufacturing method of this is provided.

In this case, the plastic sheet is made of a polycarbonate resin or an acrylic resin, and the thickness of the plastic sheet is preferably 0.5 to 2.0 mm. In this case, the plastic sheet is preferably made of a polycarbonate resin.
Further, the heat treatment step of the plastic sheet is preferably performed at a temperature of 100 to 140 ° C.

Furthermore, although the said primer is a silane coupling agent, an aluminate coupling agent, etc., it is preferable to use a titanate coupling agent especially.
Further, the first adhesive filling layer is made of a thermoplastic olefin polymer resin, and the temperature in the vacuum laminating step is preferably 120 to 145 ° C.
Moreover, it is preferable that the said plastic sheet is provided with an embossed structure in the surface in the side which contact | connects the said 1st adhesion filling layer. The embossed structure preferably has an unevenness height of 10 to 1000 μm.

The step of stacking and disposing preferably includes a step of disposing an intermediate sealing material for preventing water vapor intrusion inside 5 to 30 mm from the peripheral edge of the back surface protective layer.
In the step of stacking and arranging, a peripheral sealing material for preventing water vapor intrusion is disposed at the peripheral portions of the front surface protective layer and the back surface protective layer, and the solar cell submodule and the adhesive are disposed inside the peripheral sealing material. It is preferable to include a step of laminating the filler, the water vapor barrier film, the first adhesive filling layer, the plastic sheet, and the second adhesive filling layer.
After the vacuum laminating step, it is preferable to include a step of providing a frame member provided with a sealing material on the inner side of the outer frame material at a peripheral portion of the vacuum laminated member.

According to the present invention, the mechanical strength and impact strength such as wind pressure resistance and yield resistance, which are equal to or higher than those of white tempered glass, can be obtained. And if it is the same thickness, since a density is 2.5-g / cm < ³ > of glass and a plastic sheet is 1.1-1.2 g / cm < ³ >, mass can be made 50% or less.
In general, the white tempered glass has a thickness of 3.2 mm, but further, by reducing the thickness of the surface protective layer to 1 to 2 mm, the mass per unit area is 1.2 to 2.4 kg. / M ² . In this case, the weight can be reduced to 16 to 32% of the white plate tempered glass.

Moisture or water vapor may diffuse from the surface or end face (peripheral part) of the solar cell module and cause defects such as performance deterioration and wiring corrosion. However, a water vapor barrier film is provided on the front side and the end face (peripheral part) is provided. By providing the intermediate sealing material, the peripheral sealing material or the frame member, it is possible to more reliably suppress defects such as performance deterioration and wiring corrosion due to moisture or water vapor. Even if moisture enters, it is possible to prevent reaching a transparent electrode such as a solar battery cell.
As described above, according to the present invention, it is possible to realize a solar cell module that can prevent moisture from entering the solar cell module, exhibit stable performance over a long period of time, and can be used stably.

Here, when a plastic sheet is used as a constituent material, the linear expansion coefficient is large, and the adhesion between the plastic sheet and the adhesive filling layer is very poor. I have big problems such as peeling. For this reason, selection of a constituent material and improvement of adhesiveness are essential. ADVANTAGE OF THE INVENTION According to this invention, a solar cell module can be manufactured, improving adhesiveness and suppressing curvature, peeling, etc. by selecting the constituent material of a solar cell module appropriately.
Moreover, the adhesiveness of a surface protective layer can be improved by an anchor effect by making the surface by the side of the adhesion filling layer of a surface protective layer into an embossed structure.
In addition, according to the manufacturing method of the solar cell module of this invention, the solar cell module which has the above-mentioned outstanding characteristic can be manufactured suitably.

(A) is typical sectional drawing which shows the arrangement | positioning state of each member before the vacuum lamination of the solar cell module of the 1st Embodiment of this invention, (b) is the 1st Embodiment of this invention. It is typical sectional drawing which shows a solar cell module. It is typical sectional drawing which shows an example of the solar cell submodule used for the solar cell module of the 1st Embodiment of this invention. (A) is typical sectional drawing which shows the arrangement | positioning state of each member before the vacuum lamination of the solar cell module of the 2nd Embodiment of this invention, (b) is the 2nd Embodiment of this invention. It is typical sectional drawing which shows a solar cell module. (A) is typical sectional drawing which shows the arrangement | positioning state of each member before the vacuum lamination of the solar cell module of the 3rd Embodiment of this invention, (b) is the 3rd Embodiment of this invention. It is typical sectional drawing which shows a solar cell module. It is typical sectional drawing which shows the conventional solar cell module. It is typical sectional drawing which shows the other conventional solar cell module.

Below, based on suitable embodiment shown to an accompanying drawing, the manufacturing method of the solar cell module of this invention is demonstrated in detail.
Fig.1 (a) is typical sectional drawing which shows the arrangement | positioning state of each member before the vacuum lamination of the solar cell module of the 1st Embodiment of this invention, (b) is 1st implementation of this invention. It is typical sectional drawing which shows the solar cell module of a form.

  As shown in FIG. 1B, in the solar cell module 10, the solar cell submodule 12 is sealed with an adhesive filler 20 and a second adhesive filler layer 14. An intermediate sealing material 18 is provided around the adhesive filler 20. The intermediate sealing material 18 is provided at a position of a distance m from the peripheral edge α of the solar cell module 10, that is, inside the solar cell module 10. In this case, the intermediate sealing material 18 is disposed at a distance m, for example, 5 to 30 mm inside from the peripheral edge α of each member.

A second adhesive filling layer 14 is provided on the back surface 12 b of the solar cell submodule 12, and a back sheet (back surface protective layer) 16 is provided below the second adhesive filling layer 14.
A water vapor barrier film 22 is provided on the surface 12 a side of the solar cell submodule 12 so as to cover the adhesive filler 20 and the intermediate sealing material 18. A first adhesive filling layer 24 is provided on the water vapor barrier film 22, and a surface protective layer 26 is provided on the first adhesive filling layer 24.
In the solar cell module 10, the second adhesive filling layer 14, the back sheet 16, the water vapor barrier film 22, the first adhesive filling layer 24, and the surface protective layer 26 are joined at the peripheral edge α.

  In the solar cell module 10 shown in FIG. 1B, the solar cell submodule 12 is an integrated structure of solar cells 40 that are photoelectric conversion elements, as shown in FIG. One solar cell 40 is also included in the solar cell submodule. Specific examples of the solar cell submodule 12 will be described later in detail.

  The adhesive filler 20 is for sealing the solar cell submodule 12. As the adhesive filler 20, for example, EVA (ethylene vinyl acetate), PVB (polyvinyl butyral), PE (polyethylene), a thermoplastic olefin polymer resin, or the like can be used. In addition to this, various kinds of materials used as sealing materials in known solar cell modules can be used. The thermoplastic olefin polymer resin is preferable as the adhesive filler 20 because of its excellent adhesiveness.

The intermediate sealing material 18 is for suppressing the penetration of moisture from the adhesive filler 20 into the solar cell submodule 12. The intermediate sealing material 18 can more reliably suppress defects such as performance deterioration and wiring corrosion due to moisture or water vapor.
The intermediate sealing material 18 is provided at a distance m from the peripheral edge α of the solar cell module 10. This distance m is preferably 5 to 30 mm as a distance that does not reduce manufacturing variations and module efficiency. The width of the intermediate sealing material 18 is preferably 5 to 20 mm.
For the intermediate sealing material 18, for example, butyl rubber, polyisoprene, isoprene, polyolefin, or the like that exhibits thermoplasticity is used.

  The second adhesive filling layer 14 is for adhering the back sheet 16. For example, the same adhesive filler 20 as the adhesive filler 20 can be used for the second adhesive filler layer 14. For this reason, detailed description is omitted.

The back sheet 16 protects the solar cell module 10 from the back side.
For example, the back sheet 16 has a structure in which an aluminum foil is sandwiched between resin films such as PET (polyethylene terephthalate), PEN (polyethylene naphthalate), and PVF (polyvinyl fluoride). It is not particularly limited.
The back sheet 16 is not limited to a film, and a metal plate such as a galvalume steel plate, a stainless steel plate, and a clad steel plate of aluminum and stainless steel can be used. In addition to this, various known solar cell modules that are used as the back sheet 16 or the support can be used. As the back sheet 16, in particular, a plastic sheet or a plastic resin honeycomb structure similar to the surface protective layer 26 described in detail later is used in order to prevent warpage of the rubber sheet and the module, not a steel plate for weight reduction. It is also possible.

The water vapor barrier film 22 is for protecting the solar cell submodule 12 from moisture. The water vapor barrier film 22 is not particularly limited, and various known water vapor barrier films can be used.
As the water vapor barrier film 22, a water vapor barrier film having a water vapor transmission rate of 1 × 10 ⁻² (g / (m ² · day)) or less is particularly preferably used. By using such a water vapor barrier film 22, it is possible to more reliably prevent the solar cell module 10 from being deteriorated by moisture over a long period of time.

As a suitable example of the water vapor barrier film 22, an inorganic material that exhibits water vapor barrier properties (gas barrier properties) using various resin films (plastic films) such as PET films and PEN films having a thickness of about 50 to 100 μm as a base material. A water vapor barrier film formed by forming a compound layer (hereinafter also referred to as an inorganic layer) may be mentioned.
In the water vapor barrier film 22, if the required transparency can be ensured, the surface of the gas water vapor barrier film 22 has 1 layer exhibiting various functions such as an adhesion layer, a planarization layer, and an antireflection layer. More than one layer may be formed.

In the water vapor barrier film 22, the inorganic compound exhibiting the water vapor barrier property is, for example, a diamond-like compound, a metal oxide, a metal nitride, a metal carbide, a metal oxynitride, or a metal oxycarbide. The inorganic compound contains, for example, one or more metals selected from diamond-like carbon (DLC), diamond-like carbon containing silicon, Si, Al, In, Sn, Zn, Ti, Cu, Ce, or Ta. Examples thereof include oxides, nitrides, carbides, oxynitrides, and oxide carbides.
Among these, a metal oxide, nitride, or oxynitride selected from Si, Al, In, Sn, Zn, and Ti is preferable. In particular, a metal oxide, nitride, or oxynitride of Si or Al is preferable. preferable.
These inorganic layers are formed by, for example, a plasma CVD method, a sputtering method, or the like.

As a more preferable example of the water vapor barrier film 22, various organic resin films such as a PET film and a PEN film are used as a base material, and an organic compound layer (hereinafter also referred to as an organic layer) is used as an underlayer. A water vapor barrier film formed by forming the above-described inorganic layer on the top is mentioned. According to this water vapor barrier film 22, higher water vapor barrier properties can be obtained.
The water vapor barrier film 22 formed by depositing the above-described inorganic layer on such an organic layer prevents the water diffusion through various resin films (base materials) such as a PET film and a PEN film. It is preferable to arrange the surface on which the inorganic layer is formed on the lower solar cell submodule 12 side.

In addition, as an organic compound used as an underlayer, acrylic resin, methacrylic resin, epoxy resin, polyester, methacrylic acid-maleic acid copolymer, polystyrene, transparent fluororesin, polyimide, fluorinated polyimide, polyamide, polyamideimide, polyether Examples include imide, cellulose acylate, polyurethane, polyether ketone, polycarbonate, fluorene ring-modified polycarbonate, alicyclic ring-modified polycarbonate, and fluorene ring-modified polyester. Of these, acrylic resins and methacrylic resins are particularly preferable.
Such an organic layer is formed by, for example, a coating method using a known coating means such as a roll coating method or a spray coating method, a flash vapor deposition method, or the like.

The first adhesive filling layer 24 is for bonding the gas water vapor barrier film 22 and the surface protective layer 26. As the first adhesive filling layer 24, for example, the same one as the adhesive filling material 20 can be used. For this reason, detailed description is omitted.
In the first adhesive filling layer 24 as well, the thermoplastic olefin polymer resin is optimal because it is excellent in adhesiveness.

When the solar cell module 10 is installed outdoors, the surface protective layer 26 may come into contact with rain, hail, hail, snow, stones, and the like. A protective material having high mechanical strength such as wind pressure resistance and drooping resistance, and high impact strength is used.
The surface protective layer 26 protects the solar cell module 10 from dirt and the like, and suppresses a decrease in the amount of incident light on the solar cell submodule 12 due to dirt and the like.

The surface protective layer 26 is composed of a plastic sheet, and has various properties such as transparency, weather resistance, heat resistance, flame resistance, water resistance, moisture resistance, wind pressure resistance, yield resistance, chemical resistance, and others. It must be excellent. The surface protective layer 26 is made of, for example, polycarbonate resin, acrylic resin or methacrylic resin, or a laminate thereof. In the surface protective layer 26, there are structural deterioration due to UV light and yellowing as weather resistance, but it can be improved by mixing a UV absorber with these resins. Furthermore, an inorganic coat layer may be provided as a hard coat layer on the surface of the surface protective layer 26 in order to retain scratch resistance.
In addition, the thickness of the surface protective layer 26 (the thickness of the plastic sheet) is, for example, 0.5 to 2.0 mm, and preferably 1.0 to 1.5 mm.
If the thickness of the surface protective layer 26 is less than 0.5 mm, the solar cell submodule 12 cannot be sufficiently protected from external force applied from the outside, impact, or the like. On the other hand, if the thickness of the surface protective layer 26 exceeds 2.0 mm, the temperature distribution increases in the vertical direction during vacuum lamination, and the surface protective layer 26 may be warped. Further, it is desirable that the material is thin in view of material cost.

In addition, the plastic sheet which comprises the surface protective layer 26 is a plastic sheet which comprises the surface protective layer 26 by heat-processing a plastic sheet beforehand at 100 to 140 degreeC, Preferably it is 120 to 130 degreeC, before vacuum laminating. It is possible to suppress thermal contraction of the sheet, relieve the residual stress of the plastic sheet, and suppress warping during vacuum lamination. In this case, the heat treatment time is, for example, 0.5 to 10 hours, preferably 1 to 3 hours.
Further, the heat treatment suppresses the generation of wrinkles and the like in the surface protective layer 26 due to the thermal contraction that occurs during the vacuum lamination, and the decrease in the amount of light incident on the solar cell submodule 12 can also be suppressed. .
Further, when the plastic sheet is manufactured by an extrusion method, residual strain is generated in the drawing direction (RD direction), and when this is vacuum-laminated, warping occurs to release the strain. On the other hand, the heat shrinkage rate can be reduced to 0.04% or less by performing heat treatment in advance.

In the present embodiment, in order to improve the adhesion between the plastic sheet constituting the surface protective layer 26 and the first adhesive filling layer 24, the back surface 26b of the surface protective layer 26 bonded to the first adhesive filling layer 24 ( The corona discharge treatment is performed on the back surface of the plastic sheet, and after corona treatment, a silane coupling agent, aluminate coupling agent, or titanate coupling agent is further applied as a primer to the back surface 26b of the surface protective layer 26, and then at room temperature. Dry for 5 to 2 hours. Thereafter, the surface protective layer 26 is disposed with the surface coated with the primer facing the first adhesive filling layer 24. In addition, when the plastic sheet which comprises the surface protective layer 26 is a polycarbonate, a titanate coupling agent is suitable as a primer.
As will be described later, the plastic sheet constituting the surface protective layer 26 is disposed with the corona treatment and the surface coated with the primer, that is, the back surface 26 b facing the first adhesive filling layer 24.

In the plastic sheet constituting the surface protective layer 26, at least the surface 26b (hereinafter also referred to as the back surface 26b) on the first adhesive filling layer 24 side may have an embossed structure. The height of the unevenness of this embossed structure is, for example, 10 to 1000 μm.
Thus, by making the embossed structure, the adhesion with the first adhesive filling layer 24 can be improved by the anchor effect. The embossed structure is formed, for example, by heating a plastic sheet above the glass transition point.

  When the plastic sheet constituting the surface protective layer 26 is polycarbonate, for example, it is easy to use the unevenness of the glass cloth used at the time of vacuum lamination as an embossing mold and press it with a vacuum laminator at 140 to 160 ° C. for 15 to 30 minutes Can be produced. Of course, other hot pressing methods using a mold can be used for producing the embossed structure.

  Further, by using the same plastic sheet as the surface protective layer 26 for the back sheet 16, the warpage caused by the surface protective layer 26 can be offset, thereby suppressing the warpage that occurs during vacuum lamination. Further, as the first adhesive filling layer 24 provided under the plastic sheet constituting the surface protective layer 26, a hot melt type adhesive resin film having a low melt adhesion temperature, for example, a urethane type adhesive resin film, Warpage that occurs during vacuum lamination can be suppressed.

Further, in order to enhance the heat resistance and flame retardancy of the solar cell module 10, ETFE (tetrafluoroethylene), PTFE (polytetrafluoroethylene), PFA (perfluoroalkoxyethylene) is formed on the surface 26 a of the surface protective layer 26. Fluorine-based transparent resin films such as PVDF (polyvinylidene fluoride) and FEP (tetrafluoroethylene / hexafluoropropylene copolymer) may be provided. In this case, for example, the fluorinated transparent resin film is provided via an adhesive filling layer. Further, a fluorine-based transparent resin film may be formed on the plastic sheet constituting the surface protective layer 26 by a coextrusion method or the like.
In addition, the fluororesin film has a thickness of 20 to 100 μm, for example.

The solar cell module 10 of the present embodiment can be manufactured as follows.
First, as shown to Fig.1 (a), the 2nd adhesion filling layer 14 and the back sheet | seat 16 are laminated | stacked and arrange | positioned at the back surface 12b side of the solar cell submodule 12. FIG. Next, on the surface 12 a side of the solar cell submodule 12, the adhesive filler 20 and the intermediate sealing material 18 around the adhesive filler 20 are arranged at a distance m from the peripheral portion α, for example, 5-30 mm inside. Further, the water vapor barrier film 22 is laminated and disposed so as to cover the adhesive filler 20 and the intermediate sealing material 18.
A first adhesive filling layer 24 is disposed on the water vapor barrier film 22, and a surface protective layer 26 is disposed on the first adhesive filling layer 24. Thereby, as shown to Fig.1 (a), it will be in the state by which each member was laminated | stacked and arrange | positioned.
The surface protective layer 26 is heat-treated in advance, for example, under the above-described conditions, and is further subjected to corona treatment and primer application on the back surface 26b bonded to the first adhesive filling layer 24.

  Thereafter, in a state where the respective members are stacked and arranged, for example, using a vacuum laminator having a lifting means, a buffer plate, and a heating means, for example, at a temperature of 125 to 140 ° C., a total of 15 vacuum / press / holds. Vacuum laminate for ~ 30 minutes. Thereby, the solar cell module 10 of this embodiment shown in FIG.1 (b) is produced.

Next, the solar cell submodule 12 of this embodiment will be described in detail with reference to FIG.
As shown in FIG. 2, the solar cell submodule 12 has a plurality of solar cells 40 including a lower electrode 32, a light absorption layer 34, a buffer layer 36, and an upper electrode 38 connected in series on a substrate 50. It will be. This solar cell (photoelectric conversion element) 40 uses a CIGS semiconductor compound as the light absorption layer 34. The solar cell submodule 12 has a first conductive member 42 and a second conductive member 44.

In the solar cell submodule 12, the substrate 50 is a flexible substrate including a base material 52, an Al (aluminum) layer 54, and an insulating layer 56.
The base material 52 and the Al layer 54 are integrally formed. The insulating layer 56 is an anodic oxide film having an Al porous structure formed by anodizing the surface of the Al layer 54. The clad substrate in which the base material 52 and the Al layer 54 are laminated and integrated is referred to as a metal substrate 55.

In the solar cell submodule 12 of the present invention, mild steel, heat resistant steel, or stainless steel is used as the (metal) base material 52 constituting the substrate 50.
The thickness of the substrate 52 is not particularly limited, but is preferably 10 to 1000 μm in consideration of the balance between flexibility and strength (rigidity), handling properties, and the like.

The Al layer 54 is a layer mainly composed of Al, and various types of Al and Al alloys can be used. In particular, Al having a purity of 99% by mass or more with few impurities is preferable. As purity, for example, 99.99 mass% Al, 99.96 mass% Al, 99.9 mass% Al, 99.85 mass% Al, 99.7 mass% Al, 99.5 mass% Al, etc. are preferable. .
Moreover, even if it is not high purity Al, industrial Al can also be utilized. Use of industrial Al is advantageous in terms of cost. However, it is important that Si is not precipitated in Al in terms of the insulating property of the insulating layer 56.

The thickness of the Al layer 54 is not particularly limited and can be appropriately selected. In the state where the solar cell submodule 12 is obtained, the thickness of the Al layer 54 is preferably 0.1 μm or more and less than the thickness of the base material 52. .
The Al layer 54 is formed by pretreatment of the Al surface, formation of the insulating layer 56 by anodic oxidation, generation of an intermetallic compound on the surface of the Al layer 54 and the substrate 52 during the formation of the light absorption layer 34, and the like. The thickness decreases. Therefore, the thickness at the time of forming an Al layer 54 to be described later is Al between the base material 52 and the insulating layer 56 in a state where the solar cell submodule 12 is formed in consideration of thickness reduction due to these. It is important that the thickness be such that layer 54 remains. For this reason, the thickness of the Al layer 54 is required to be 10 to 50 μm in order to form an insulating layer by anodic oxidation.

An insulating layer 56 is formed on the Al layer 54 (on the side opposite to the substrate 52). The insulating layer 56 is an Al anodic oxide film formed by anodizing the surface of the Al layer 54.
Here, various anodic oxide films formed by anodizing Al can be used for the insulating layer 56, but a porous anodic oxide film is preferable. This anodic oxide film is an alumina oxide film having pores of several tens of nanometers. Since the Young's modulus of the film is low, the film is highly resistant to bending and cracking caused by a difference in thermal expansion at high temperatures.

  The thickness of the insulating layer 56 is preferably 2 μm or more, and more preferably 5 μm or more. When the thickness of the insulating layer 56 is excessively large, it is not preferable because flexibility is lowered and cost and time required for forming the insulating layer 56 are required. Actually, the thickness of the insulating layer 56 is 50 μm or less, preferably 30 μm or less at maximum. For this reason, the preferable thickness of the insulating layer 56 is 2 to 50 μm.

Although the solar cell module 10 of this embodiment is a rigid type, a flexible substrate is used for the solar cell submodule 12, and for example, an insulation having a plurality of pores by anodization on a metal substrate 55 having a thickness of 50 to 200 μm. A layer 56 (insulating oxide film) is formed, and high insulation is ensured.
The substrate 50 used in the solar cell submodule 12 of this embodiment may be subjected to a specific sealing process after the Al layer 54 is anodized to form the insulating layer 56. The manufacturing process may include various processes other than the essential processes. For example, a degreasing process for removing the adhering rolling oil, a desmutting process for dissolving the smut on the surface of the Al layer 54, a roughening process for roughening the surface of the Al layer 54, and an anode on the surface of the Al layer 54 The substrate 50 is preferably subjected to an anodizing process for forming an oxide film and a sealing process for sealing the micropores of the anodized film.

In addition, the board | substrate 50 becomes flexible as the board | substrate 50 whole by making all the base material 52, Al layer 54, and the insulating layer 56 have flexibility, ie, a flexible thing. Thereby, for example, an alkali supply layer, a lower electrode, a light absorption layer, an upper electrode, and the like described later can be formed on the insulating layer 56 side of the substrate 50 by a roll-to-roll method.
In the present invention, a solar cell structure may be produced by continuously forming a plurality of layers from one roll unwinding to winding, or roll unwinding, film forming, winding The solar cell structure may be formed by performing the taking step a plurality of times. Further, as will be described later, an integration in which a plurality of solar cells 40 are electrically connected in series by adding a scribing process for separating and integrating the elements between the respective film forming processes to the production by the roll-to-roll method. Type solar cell submodule can be manufactured.

In the present invention, the Al layer 54 and the insulating layer 56 are not limited to be formed only on one surface of the base material 52, and the substrate in which the Al layer 54 and the insulating layer 56 are formed on both surfaces of the base material 52 is used. Alternatively, the Al layer may be a single layer, that is, an Al substrate provided with an insulating layer composed of the above-described anodized film.
As the metal substrate, a material in which a metal oxide film formed on the surface of the metal substrate by anodic oxidation is an insulator can be used. Therefore, in addition to aluminum (Al), specifically, zirconium (Zr), titanium (Ti), magnesium (Mg), copper (Cu), niobium (Nb), tantalum (Ta), etc., and their Alloys can be used. Aluminum is most preferable from the viewpoint of cost and characteristics required for the solar cell module.
Further, a so-called clad material may be used in which the metal layer is formed by rolling or hot dipping on a steel plate such as mild steel or stainless steel in order to improve heat resistance.

Here, an alkali supply layer 58 (an alkali metal supply source to the light absorption layer 34) is formed between the insulating layer 56 (substrate 50) and the lower electrode 32, that is, on the surface 56a of the insulating layer 56.
It is known that when an alkali metal (particularly Na) is diffused into the light absorption layer 34 made of CIGS, the photoelectric conversion efficiency is increased.
The alkali supply layer 58 is a layer for supplying an alkali metal to the light absorption layer 34 and is a layer of a compound containing an alkali metal. In the present invention, such an alkali supply layer 58 is provided between the insulating layer 56 and the lower electrode 32, so that when the light absorption layer 34 is formed, the alkali metal passes through the lower electrode 32 to the light absorption layer 34. It can diffuse and improve the conversion efficiency of the light absorption layer 34.

The alkali supply layer 58 is not limited, and a compound containing an alkali metal (a composition containing an alkali metal compound) such as NaO ₂ , Na ₂ S, Na ₂ Se, NaCl, NaF, or sodium molybdate is a main component. Various things are available. In particular, a compound containing SiO ₂ (silicon oxide) as a main component and NaO ₂ (sodium oxide) is preferable.
The compound of SiO ₂ and NaO ₂ have poor moisture resistance, since tends to carbonate was separated Na component, a metal component with added Ca more oxide that was three components Si-Na-Ca preferable.

In the present invention, the alkali metal supply source to the light absorption layer 34 is not limited to the alkali supply layer 58 alone.
For example, when the insulating layer 56 is the above-described porous anodic oxide film, a compound containing an alkali metal is introduced into the porous layer of the insulating layer 56 in addition to the alkali supply layer 58, so that the light absorption layer 34 may be an alkali metal supply source. Alternatively, the alkali supply layer 58 may not be provided, and a compound containing an alkali metal may be introduced only into the porous layer of the insulating layer 56 to serve as an alkali metal supply source to the light absorption layer 34.
As an example, when the alkali supply layer 58 is formed by sputtering, only the alkali supply layer 58 in which no compound containing an alkali metal exists in the insulating layer 56 can be formed. In addition, the insulating layer 56 is a porous anodic oxide film, and when the alkali supply layer 58 is formed by sol-gel reaction or dehydration drying of a sodium silicate aqueous solution, not only the alkali supply layer 58 but also the insulating layer 56 is formed. By introducing a compound containing an alkali metal into the porous layer, both the insulating layer 56 and the alkali supply layer 58 can serve as an alkali metal supply source to the light absorption layer 34.

In the solar cell submodule 12, the lower electrode 32 is formed on the alkali supply layer 58 so as to be arranged with a predetermined gap 33 from the adjacent lower electrode 32. Further, a light absorption layer 34 is formed on the lower electrode 32 while filling the gaps 33 of the lower electrodes 32. A buffer layer 36 is formed on the surface of the light absorption layer 34.
The light absorption layer 34 and the buffer layer 36 are arranged on the lower electrode 32 with a predetermined gap 37. Note that the gap 33 between the lower electrode 32 and the light absorption layer 34 (buffer layer 36) are formed at different positions in the arrangement direction of the solar cells 40.

Further, an upper electrode 38 is formed on the surface of the buffer layer 36 so as to fill the gap 37 of the light absorption layer 34 (buffer layer 36).
The upper electrode 38, the buffer layer 36 and the light absorption layer 34 are arranged with a predetermined gap 39. The gap 39 is provided at a position different from the gap between the lower electrode 32 and the gap between the light absorption layer 34 (buffer layer 36).
In the solar battery submodule 12, each solar battery cell 40 is electrically connected in series in the longitudinal direction of the substrate 50 (arrow L direction) by the lower electrode 32 and the upper electrode 38.

The lower electrode 32 is composed of, for example, a Mo electrode. The light absorption layer 34 is composed of a semiconductor compound having a photoelectric conversion function, for example, a CIGS film. Further, the buffer layer 36 is made of, for example, CdS, and the upper electrode 38 is made of, for example, ZnO.
The solar battery cell 40 is formed to extend long in the width direction orthogonal to the longitudinal direction L of the substrate 50. For this reason, the lower electrode 32 and the like also extend long in the width direction of the substrate 50.

As shown in FIG. 2, a first conductive member 42 is connected on the lower electrode 32 at the right end. The first conductive member 42 is for taking out an output from a negative electrode to be described later.
The first conductive member 42 is, for example, an elongated belt-like member, extends substantially linearly in the width direction of the substrate 50, and is connected to the lower electrode 32 at the right end. As shown in FIG. 2, the first conductive member 42 is, for example, a copper ribbon 42 a covered with a coating material 42 b made of indium copper alloy. The first conductive member 42 is connected to the lower electrode 32 by, for example, ultrasonic soldering. Alternatively, the first conductive member 42 may be a conductive tape having an embossed structure formed by hot-plating In-Sn on a copper foil, and this conductive tape is connected by being bonded to the lower electrode 32 by pressure bonding with a roller. The

On the other hand, a second conductive member 44 is formed on the lower electrode 32 at the left end.
The second conductive member 44 is for taking out the output from the positive electrode, which will be described later, to the outside. Like the first conductive member 42, the second conductive member 44 is a strip-like member that extends substantially linearly in the width direction of the substrate 50. And connected to the lower electrode 32 at the left end.
The second conductive member 44 has the same configuration as that of the first conductive member 42. For example, the copper ribbon 44a is coated with a coating material 44b of indium copper alloy. You may connect.

  In addition, the light absorption layer 34 of the photovoltaic cell 40 of this embodiment is comprised by CIGS, and can be manufactured with the manufacturing method of a well-known CIGS type solar cell.

  In the solar cell submodule 12, when light enters the solar cell 40 from the upper electrode 38 side, this light passes through the upper electrode 38 and the buffer layer 36, and an electromotive force is generated in the light absorption layer 34. For example, a current from the upper electrode 38 toward the lower electrode 32 is generated. Note that the arrows shown in FIG. 2 indicate the direction of current, and the direction of movement of electrons is opposite to the direction of current. For this reason, in the photoelectric conversion unit 48, the leftmost lower electrode 32 in FIG. 2 is a positive electrode (positive electrode), and the rightmost lower electrode 32 is a negative electrode (negative electrode).

In the present embodiment, the electric power generated in the solar cell submodule 12 can be taken out of the solar cell submodule 12 from the first conductive member 42 and the second conductive member 44.
In the present embodiment, the first conductive member 42 is a negative electrode, and the second conductive member 44 is a positive electrode. Further, the first conductive member 42 and the second conductive member 44 may have opposite polarities, and are appropriately changed depending on the configuration of the solar battery cell 40, the solar battery submodule 12 configuration, and the like.
Moreover, in this embodiment, although each photovoltaic cell 40 was formed so that it might be connected in series with the longitudinal direction L of the board | substrate 50 by the lower electrode 32 and the upper electrode 38, it is not limited to this. For example, each solar battery cell 40 may be formed such that each solar battery cell 40 is connected in series in the width direction by the lower electrode 32 and the upper electrode 38.

  In the solar cell 40, the lower electrode 32 and the upper electrode 38 are both for taking out the current generated in the light absorption layer 34. Both the lower electrode 32 and the upper electrode 38 are made of a conductive material. The upper electrode 38 on the light incident side needs to have translucency.

The lower electrode (back electrode) 32 is made of, for example, Mo, Cr, or W, and a combination thereof. The lower electrode 32 may have a single layer structure or a laminated structure such as a two-layer structure. The lower electrode 32 is preferably made of Mo.
The lower electrode 32 preferably has a thickness of 100 nm or more, and more preferably 0.45 to 1.0 μm.
The method for forming the lower electrode 32 is not particularly limited, and can be formed by a vapor phase film forming method such as an electron beam evaporation method or a sputtering method.

The upper electrode (transparent electrode) 38 is composed of, for example, ZnO to which Al, B, Ga, In, Sb or the like is added, ITO (indium tin oxide), SnO ₂ , or a combination thereof. . The upper electrode 38 may have a single layer structure or a laminated structure such as a two-layer structure. Further, the thickness of the upper electrode 38 is not particularly limited, and is preferably 0.3 to 1 μm.
The formation method of the upper electrode 38 is not particularly limited, and can be formed by a vapor deposition method such as an electron beam evaporation method or a sputtering method, or a coating method.

The buffer layer 36 is formed to protect the light absorption layer 34 when the upper electrode 38 is formed and to transmit light incident on the upper electrode 38 to the light absorption layer 34.
The buffer layer 36 is made of, for example, CdS, ZnS, ZnO, ZnMgO, ZnS (O, OH), or a combination thereof.
The buffer layer 36 preferably has a thickness of 0.03 to 0.1 μm. The buffer layer 36 is formed by, for example, a CBD (chemical bath) method.

The light absorption layer 34 is a layer that absorbs light that has passed through the upper electrode 38 and the buffer layer 36 and generates a current, and has a photoelectric conversion function. The light absorption layer 34 is composed of a CIGS film, and the CIGS film is made of a semiconductor having a chalcopyrite crystal structure. The composition of the CIGS film is, for example, Cu (In _1-x Ga _x ) Se ₂ (CIGS).

As a CIGS film forming method, 1) a multi-source deposition method, 2) a selenization method, 3) a sputtering method, 4) a hybrid sputtering method, and 5) a mechanochemical process method are known.
Other CIGS film formation methods include screen printing, proximity sublimation, MOCVD, and spray (wet film formation). For example, a fine particle film containing a group Ib element, a group IIIb element, and a group VIb element is formed on a substrate by a screen printing method (wet film forming method) or a spray method (wet film forming method), and then pyrolyzed ( At this time, a crystal having a desired composition can be obtained by performing a thermal decomposition treatment in a VIb group element atmosphere (JP-A-9-74065, JP-A-9-74213, etc.).
Such a film forming method shows good photoelectric conversion efficiency if CIGS is formed on the substrate as long as the temperature is 500 ° C. or higher, but the process time is short in consideration of manufacturing in a roll-to-roll method. Multisource deposition is preferred. In particular, the bilayer method is suitable.

As described above, the solar cell sub-module 12 of the present invention is manufactured by manufacturing the solar cells 40 in series on the substrate 50 described above. What is necessary is just to perform like a battery.
Hereinafter, an example of the manufacturing method of the solar cell submodule 12 shown in FIG. 2 will be described.

First, the substrate 50 formed as described above is prepared. Next, the alkali supply layer 58 is formed on the surface of the insulating layer 56 of the substrate 50 by, for example, sputtering using soda lime glass as a target or a sol-gel method using an alkoxide containing Si and Na.
Next, a Mo film to be the lower electrode 32 is formed on the surface of the alkali supply layer 58 by sputtering using, for example, a film forming apparatus.
Next, using a laser scribing method, for example, a predetermined position of the Mo film is scribed to form a gap 33 extending in the width direction of the substrate 50. Thereby, the lower electrodes 32 separated from each other by the gap 33 are formed.

Next, a CIGS film is formed as a light absorption layer 34 (p-type semiconductor layer) so as to cover the lower electrode 32 and fill the gap 33. This CIGS film is formed by any of the film forming methods described above.
Next, a CdS layer (n-type semiconductor layer) to be the buffer layer 36 is formed on the light absorption layer 34 (CIGS film) by, for example, a CBD (chemical bath) method. Thereby, a pn junction semiconductor layer is formed.
Next, a gap 37 extending in the width direction of the substrate 50 and reaching the lower electrode 32 is formed by scribing a predetermined position different from the gap 33 in the arrangement direction of the solar cells 40 using, for example, a laser scribing method. To do.

Next, on the buffer layer 36, for example, an ITO layer, a ZnO layer to which Al, B, Ga, Sb, or the like is added is formed by sputtering or coating so as to fill the gap 37. To do.
Next, the gaps 33 and 37 are gaps reaching a lower electrode 32 extending in the width direction of the substrate 50 by scribing a predetermined position different in the arrangement direction of the solar cells 40 using, for example, a laser scribing method. 39 is formed. Thereby, the photovoltaic cell 40 is formed.

Next, the solar cells 40 formed on the lower electrodes 32 at the left and right ends in the longitudinal direction L of the substrate 50 are removed by, for example, laser scribing or mechanical scrub, and the lower electrodes 32 are exposed. Next, the first conductive member 42 is connected to the lower electrode 32 at the right end, and the second conductive member 44 is connected to the lower electrode 32 at the left end using, for example, a conductive tape.
Thereby, as shown in FIG. 2, the solar cell submodule 12 in which the plurality of solar cells 40 are electrically connected in series can be manufactured.

In the solar cell module 10 of the present embodiment shown in FIG. 1 (b), the mechanical strength such as wind pressure resistance and sag resistance, and impact strength can be set to be equal to or higher than those of white sheet tempered glass. And if it is the same thickness, since a density is 2.5-g / cm < ³ > of glass and a plastic sheet is 1.1-1.2 g / cm < ³ >, mass can be made 50% or less.
In general, the white tempered glass has a thickness of 3.2 mm, but further, by reducing the thickness of the surface protective layer to 1 to 2 mm, the mass per unit area is 1.2 to 2.4 kg. / M ² . In this case, the weight can be reduced to 16 to 32% of the white plate tempered glass.

  Here, when a plastic sheet is used for the surface protective layer as in the solar cell module 10, the linear expansion coefficient is large and the adhesion between the plastic sheet and the adhesive filling layer is very poor. For this reason, the solar cell module has major problems such as warping as the temperature rises or peeling between constituent layers of the solar cell. Therefore, it is essential to select constituent materials and improve adhesion. According to the solar cell module of the present embodiment, as a countermeasure for this, a heat treatment is performed in advance on the polycarbonate sheet to be the surface protective layer, followed by corona treatment, primer application of a titanate coupling agent and drying, By using a thermoplastic olefin polymer resin for one adhesive filling layer 24, it is possible to manufacture a solar cell module while improving adhesion and suppressing warpage, peeling and the like.

Moisture or water vapor may diffuse from the surface or end face (peripheral part) of the solar cell module and cause defects such as performance degradation and wiring corrosion. However, a water vapor barrier film 22 is provided on the front side and the end face (peripheral part). By providing the intermediate seal material 18 on the surface, it is possible to more reliably suppress defects such as performance deterioration and wiring corrosion due to moisture or water vapor. Even if moisture enters, it is possible to prevent reaching a transparent electrode such as a solar battery cell.
In particular, the water vapor barrier film 22 can prevent moisture diffusion through the base material by disposing it on the solar cell submodule side with the surface on which the organic layer and the inorganic layer are formed.
As described above, according to the present invention, it is possible to realize a solar cell module that can prevent moisture from entering the solar cell module, exhibit stable performance over a long period of time, and can be used stably.

By forming a CIGS film as a light-absorbing layer using a substrate in which an anodized film of aluminum is formed on the surface of a metal sheet that can be manufactured by a roll-to-roll manufacturing method, instead of a glass substrate as the solar cell submodule 12 A light-weight and low-cost solar cell module can be obtained.
In addition, according to the manufacturing method of the solar cell module 10 of this embodiment, the solar cell module 10 which has the above-mentioned outstanding characteristic can be manufactured suitably.

Here, the typical sectional view of the conventional solar cell module is shown in FIG. 5 and FIG. In a conventional solar cell module 100 a shown in FIG. 5, a solar cell submodule 110 is surrounded by an adhesive filling layer 102, and a surface protective layer 104 is provided on the upper surface of the adhesive filling layer 102. Further, a back surface protective layer 106 is provided on the lower surface of the adhesive filling layer 102.
Further, the conventional solar cell module 100b of FIG. 6 differs from the solar cell module 100a shown in FIG. 5 in that a sealing material 112 is provided on the side end face 108, and the other configuration is a solar cell module. The same as 100a.

  In general, the surface of the solar cell submodule is formed of a transparent conductive film such as an ITO film, a ZnO (Al) film, or a ZnO (B) film. These transparent conductive films are very sensitive to moisture due to their materials. In the case of the solar cell module 100a having the configuration shown in FIG. 5, the side end face 108 of the adhesive filling layer 102 surrounding the solar cell submodule 110 is exposed to the outside, and moisture enters the side end face 108 to It reaches the surface of the battery submodule 110 and raises the resistance of the transparent conductive film, or reaches the junction under the transparent conductive film to generate a leakage current, thereby deteriorating the characteristics of the solar cell module. cause.

  On the other hand, in the case of the solar cell module 100b having the configuration shown in FIG. 6, since the side end face 108 of the adhesive filling layer 102 is covered with the sealing material 112, at first glance, moisture intrusion from the side end face 108 is prevented. Looks like you can. However, the outer periphery of the solar cell module 100b bends due to the difference in thermal expansion and contraction of the adhesive filling layer 102, the surface protective layer 104, the back surface protective layer 106, etc. in a high temperature and high humidity environment, and the peripheral edge of the sealing material 112 As a result, the intrusion of moisture from the side end face 108 of the solar cell module 100b cannot be prevented.

  On the other hand, in the solar cell module 10 shown in FIG. 1B, the intermediate seal material 18 is arranged on the inner side of the periphery of the back sheet 16, so that the water vapor barrier film 22 and the back sheet 16 have Since it is located inside the solar cell module 10 joined, it is not exposed to the outside, and the intermediate sealing material 18 is not bent or peeled off due to the difference between thermal expansion and thermal contraction. The intermediate sealing material 18 is provided at least from the back surface 12b of the solar cell submodule 12 to the water vapor barrier film 22, and the intermediate sealing material 18 contacts the water vapor barrier film 22 and seals the adhesive filling material 20. It becomes possible to prevent moisture from entering from the 20 side surfaces, and at least moisture entry from the surface 12a side (upper side) of the solar cell submodule 12 can be suppressed. In addition, the solar cell module 10 can reduce the generation of corrosive substances generated by the reaction of moisture and the adhesive constituting the adhesive filler 20, for example, acetic acid, and can exhibit stable performance over a long period of time. can do.

  In the solar cell module 10 shown in FIG. 1B, the intermediate sealing material 18 is provided from the back surface 12b of the solar cell submodule 12 to the water vapor barrier film 22, but the intermediate sealing material 18 is used as a back sheet. 16, the second adhesive layer 14 may be separated by contacting it. With such a configuration, the intermediate sealing material 18 can also suppress moisture intrusion from the second adhesive layer 14, and corrosive substances generated by the reaction between the moisture and the second adhesive layer 14 can be prevented. It becomes possible to reduce more effectively, and it is possible to suppress a decrease in conversion efficiency of the solar cell submodule 12 due to an improvement in resistance due to alteration of the transparent electrode of the solar cell submodule 12 and to exhibit stable performance over a long period of time. The solar cell module 10 can be made.

Next, a second embodiment will be described.
Fig.3 (a) is typical sectional drawing which shows the arrangement | positioning state of each member before the vacuum lamination of the solar cell module of the 2nd Embodiment of this invention, (b) is 2nd implementation of this invention. It is typical sectional drawing which shows the solar cell module of a form.
In addition, in this embodiment, the same code | symbol is attached | subjected to the same structure as the solar cell module 10 of 1st Embodiment shown to Fig.1 (a), (b), and the detailed description is abbreviate | omitted.

  The solar cell module 10a of the present embodiment shown in FIG. 3B is compared with the solar cell module 10 of the first embodiment (see FIG. 1B) and the adhesive filler 20 and the second adhesive filling. The structure for sealing the solar cell submodule 12 with the layer 14 and the intermediate seal material 18 are not provided, and the peripheral seal material 19 is provided between the back sheet 16 and the surface protective layer 26 to surround the periphery. The other structures are different, and the other configurations are the same as those of the solar cell module 10 of the first embodiment, and thus detailed description thereof is omitted.

  In the solar cell module 10a of the present embodiment shown in FIG. 3B, the peripheral sealing material 19 increases the mechanical resistance of the solar cell module 10a as well as the intermediate sealing material 18 of the first embodiment. This is to increase moisture diffusion resistance and moisture resistance from the periphery of the battery module 10a. The peripheral sealing material 19 can be the same as the intermediate sealing material 18, and for example, butyl rubber, polyisoprene, isoprene or polyolefin showing thermoplasticity is used.

The solar cell module 10a of this embodiment can be produced as follows.
First, as shown in FIG. 3A, the second adhesive filling layer 14 and the back sheet 16 are laminated and disposed on the back surface 12 b side of the solar cell submodule 12. Next, as in the first embodiment, the adhesive filler 20, the water vapor barrier film 22, the first adhesive filler layer 24, and the surface protective layer 26 are disposed on the surface 12a side of the solar cell submodule 12.
Further, the second adhesive filling layer 14, the back sheet 16, the adhesive filler 20, the water vapor barrier film 22, and the first adhesive filling layer 24 are surrounded between the back sheet 16 and the surface protective layer 26. The peripheral seal material 19 is disposed. Thereby, as shown to Fig.3 (a), it will be in the state by which each member was laminated | stacked and arrange | positioned.
Thereafter, in a state where the respective members are stacked and arranged, for example, using a vacuum laminator having an elevating means, a buffer plate, and a heating means, for example, at a temperature of 120 to 145 ° C., a total of 15 vacuum / press / holds. Vacuum laminate for ~ 30 minutes. Thereby, the solar cell module 10a of this embodiment shown in FIG.3 (b) is produced.
In manufacturing the solar cell module 10a, the peripheral sealing material 19 may be attached to the back surface 26b of the surface protective layer 26, and each member of the solar cell module 10 may be laminated, temporarily fixed, and vacuum laminated. .

In addition, also in this embodiment, when producing the solar cell module 10a, similarly to the first embodiment, on the surface 26a of the surface protective layer 26, the above-described fluorine-based transparent resin film is laminated and disposed. In this state, the solar cell module can be manufactured by vacuum lamination.
In the solar cell module 10a of this embodiment, the periphery sealing material 19 is provided, and the same effect as the solar cell module 10 of 1st Embodiment can be acquired.

Next, a third embodiment will be described.
FIG. 4A is a schematic cross-sectional view showing the arrangement state of each member before vacuum lamination of the solar cell module of the third embodiment of the present invention, and FIG. 4B is the third embodiment of the present invention. It is typical sectional drawing which shows the solar cell module of a form.
In addition, in this embodiment, the same code | symbol is attached | subjected to the same structure as the solar cell module 10 of 1st Embodiment shown to Fig.1 (a), (b), and the detailed description is abbreviate | omitted.

  As shown in FIG.4 (b), the solar cell module 10b of this embodiment is an adhesive filler compared with the solar cell module 10 (refer Fig.1 (a) and (b)) of 1st Embodiment. 20 and the second adhesive filling layer 14 are sealed with the solar cell submodule 12 and the intermediate sealing material 18 is not provided. The solar cell submodule 12, the second adhesive filling layer 14, and the back sheet 16, the frame member 60 is provided at the peripheral edge β of the solar cell laminate 30 including the water vapor barrier film 22, the first adhesive filling layer 24, and the surface protective layer 26. Since it is the structure similar to the solar cell module 10 of 1 embodiment, the detailed description is abbreviate | omitted.

  In the solar cell module 10b of the present embodiment, the frame member 60 improves the mechanical resistance of the solar cell module 10a, and in addition to the moisture diffusion resistance and moisture resistance from the peripheral edge β as in the intermediate sealing material 18 of the first embodiment. It is for improving the property. The frame member 60 includes an outer edge sealing material 62 and an outer frame material 64, the outer edge sealing material 62 is provided on the inner side, and the outer frame material 64 is provided on the outer side.

For the outer edge sealing material 62, for example, butyl rubber, polyisoprene, isoprene, or polyolefin exhibiting thermoplasticity is used.
The outer frame member 64 may be formed of a foil shape or a frame shape. The outer frame material 64 can be formed using, for example, aluminum, an aluminum alloy, copper, or a copper alloy. For example, when a metal foil is used as the outer frame member 64, aluminum, an aluminum alloy, copper, or a copper alloy can be used. The thickness of the metal foil is, for example, 50 to 300 μm. The metal foil may be provided with an adhesive material in advance.

The outer frame member 64 may be a metal foil tape in which a black PET film is bonded to a metal foil from the viewpoint of the aesthetics and design of the solar cell module 10b.
When further moisture resistance is required, for example, butyl rubber is used for the outer edge sealing material 62, and an L-shaped aluminum frame is used for the outer frame material 64.
Also in the solar cell module 10b of this embodiment, the above-mentioned fluorine-based transparent resin film can be provided on the surface 26a of the surface protective layer 26 as in the first embodiment.

The solar cell module 10a of this embodiment can be produced as follows. First, the second adhesive filling layer 14 and the back sheet 16 are laminated and disposed on the back surface 12b side of the solar cell submodule 12 as in the first embodiment. Next, as in the first embodiment, the adhesive filler 20, the water vapor barrier film 22, the first adhesive filler layer 24, and the surface protective layer 26 are laminated and disposed on the surface 12a side of the solar cell submodule 12. To do. Thereby, as shown to Fig.4 (a), it will be in the state by which each member was laminated | stacked and arrange | positioned. Thereafter, in a state where the respective members are stacked and arranged, similarly to the first embodiment, for example, vacuum lamination is performed at a temperature of 120 to 145 ° C. under conditions of vacuum / press / hold for a total of 15 to 30 minutes. Thereby, the solar cell laminated body 30 is formed.
Thereafter, the outer edge sealing material 62 of the frame member 60 is provided so as to cover the peripheral edge β of the solar cell stack 30, a part of the surface protective layer 26 surface, and a part of the surface of the backsheet 16. Thereafter, the outer frame material 64 is bonded onto the outer edge sealing material 62. Thereby, the solar cell module 10b of this embodiment shown in FIG.4 (b) is produced.

In the present embodiment, when the solar cell module 10b is manufactured, the above-described fluorine-based transparent resin film is laminated on the surface 26a of the surface protective layer 26, as in the first embodiment, In this state, the solar cell module can be manufactured by vacuum lamination.
In the solar cell module 10b of the present embodiment, by providing the frame member 60, the same effect as that of the solar cell module 10 of the first embodiment can be obtained. Furthermore, mechanical resistance, moisture diffusion resistance and moisture resistance can be further improved.

  The present invention is basically configured as described above. As mentioned above, although the manufacturing method of the solar cell module of this invention was demonstrated in detail, this invention is not limited to the said embodiment, You may make various improvement or change in the range which does not deviate from the main point of this invention. Of course. Furthermore, mechanical resistance, moisture diffusion resistance and moisture resistance can be further improved.

Hereinafter, the solar cell module of the present invention will be described more specifically.
In this example, in order to examine the adhesiveness of the solar cell module structure, test structures of Experimental Examples 1 to 4 having a structure of a surface protective layer (polycarbonate) / adhesive filling layer / back surface protective layer (polycarbonate) were prepared. did. And about the test structure of Experimental example 1-4, it changed and produced the surface treatment conditions of the polycarbonate which comprises a surface protective layer, and after performing 85 degreeC and 85% RH 500HR dump heat test, the adhesion test was done. .

In the test structures of Experimental Examples 1 to 4, polycarbonate was used for the surface protective layer and the back surface protective layer. For this polycarbonate, Iupilon NF-2000 (manufactured by Mitsui Gas Chemical Co., Ltd.) having a thickness of 1 mm was used. Note that the test structures of Experimental Examples 1 to 4 have a width of 15 mm and a length of 150 mm.
For the adhesive filling layer, a thermoplastic olefin polymer resin sealing material Z68 (manufactured by DNP) is used as the olefin (indicated as “olefin” in Table 1 below), and EVA (indicated as “EVA” in Table 1 below). As a result, Solar Eva (EVA) manufactured by Mitsui Chemicals Fabro Co., Ltd. was used.
As a primer, 1200 OS which is a titanate coupling agent of Toray Dow Corning Co., Ltd. (indicated as “Primer A” in Table 1 below) or DY39-067 (indicated as “Primer B” in Table 1 below) Was used.

  In the test structures of Experimental Examples 1 to 4, the polycarbonate sheet used for the surface protective layer was previously heat-treated in air at 125 ° C. for 3 hours.

In Experimental Example 1, a primer is not applied. In Experimental Example 1, a test structure was obtained by adhering polycarbonate to an adhesive filling layer using olefin or EVA without subjecting the polycarbonate sheet to corona treatment. For Experimental Example 1, the adhesion surface of the polycarbonate sheet with the adhesive filling layer was corona-treated, and then the polycarbonate was adhered to the adhesive filling layer using olefin or EVA to obtain a test structure.
Regarding the corona treatment, using a corona discharger manufactured by Kasuga Denki, the adhesive surface of the polycarbonate sheet with the adhesive filling layer was corona treated at a power of 150 W and a treatment speed of 0.5 m / min to make it hydrophilic.

In Experimental Example 2, when corona treatment was not performed, 1200 OS (primer A), which is a titanate coupling agent of Toray Dow Corning Co., Ltd., was impregnated into Ben cotton as a primer on the adhesive surface of the polycarbonate sheet with the adhesive filling layer. Then, after drying at room temperature for 1 hour, polycarbonate was adhered to the adhesive filling layer using olefin or EVA to obtain a test structure.
In Experimental Example 2, the adhesive surface of the polycarbonate sheet with the adhesive filling layer was subjected to corona treatment under the same conditions as in Experimental Example 1, and then 1200 OS (primer as a titanate coupling agent of Toray Dow Corning Co., Ltd.) was used as a primer on this adhesive surface. A) was soaked in Ben cotton and then dried at room temperature for 1 hour, and then a polycarbonate was adhered to the adhesive filling layer using olefin or EVA to obtain a test structure.

In Experimental Example 3, when corona treatment is not performed, DY39-067 (primer B), which is a titanate coupling agent of Toray Dow Corning Co., is impregnated into Ben cotton as a primer on the adhesive surface of the polycarbonate sheet with the adhesive filling layer. Then, after drying at room temperature for 1 hour, a polycarbonate was adhered to the adhesive filling layer using olefin or EVA to obtain a test structure.
In Experimental Example 3, the adhesive surface of the polycarbonate sheet with the adhesive filling layer was subjected to corona treatment under the same conditions as in Experimental Example 1, and then DY39-067, a titanate coupling agent manufactured by Toray Dow Corning, was used as a primer on this adhesive surface. Primer B) was soaked in Ben cotton and then dried at room temperature for 1 hour, and then a polycarbonate was adhered to the adhesive filling layer using olefin or EVA to obtain a test structure.

In Experimental Example 4, after embossing was formed on the adhesive surface of the embossed sheet with the adhesive filling layer, and when corona treatment was not performed, the titanate cup of Toray Dow Corning Co., Ltd. was used as a primer on the adhesive surface with the adhesive filling layer of the polycarbonate sheet. The ring structure DY39-067 (Primer B) was soaked in Ben cotton and then dried at room temperature for 1 hour, and then the polycarbonate was adhered to the adhesive filling layer using olefin or EVA. Got.
In Experimental Example 4, after embossing was formed on the adhesive surface of the embossed sheet with the adhesive filling layer, the adhesive surface of the polycarbonate sheet with the adhesive filling layer was subjected to corona treatment under the same conditions as in Experimental Example 1, and then a primer was applied to this adhesive surface. DY39-067 (Primer B), a titanate coupling agent manufactured by Toray Dow Corning Co., Ltd., was soaked in Ben cotton and then dried at room temperature for 1 hour, and then olefin or EVA was used for the adhesive filling layer. The test structure was obtained by bonding polycarbonate.
The embossed structure was formed by placing a glass cloth (FGF-400-22 manufactured by Chuko Kasei) on one side of a polycarbonate sheet and pressing it with a vacuum laminator at a temperature of 155 ° C. for 30 minutes.

The test results of the adhesion test in each of Experimental Examples 1 to 4 are shown in Table 1 below.
In the adhesion test shown in Table 1 below, a laminated test structure having a size of 15 mm × 150 mm was pulled by a T-type peeling method using a tensile tester, and the upper and lower polycarbonate sheets were pulled in a 180 ° direction at a peeling rate of 10 cm / min. The peel strength at that time was measured. Evaluation of the adhesion test shown in Table 1 below is that the peel strength by the adhesion test is 5N or more, ◎, 2N or more and less than 5N is ◯, 1N or more and less than 2N is △, and 1N or less. X.

  As shown in Table 1 above, even when polycarbonate is used for the surface protective layer, the adhesion can be improved by applying the primer and applying a corona treatment.

  In this example, the solar cell modules of Examples 1 to 3 and Comparative Examples 1 and 2 shown below were produced and their performance was evaluated.

Example 1
A solar cell module 10 having a substrate structure and including a solar cell submodule 12 using a CIGS film as a light absorption layer was manufactured as shown in FIG.
As the water vapor barrier film 22, a PET film was used as a base material, and an organic layer and an inorganic layer were laminated. The surface on which the organic layer and inorganic layer surfaces of the water vapor barrier film 22 were formed was disposed on the lower solar cell submodule 12 side in order to prevent moisture diffusion through the substrate.

For the first adhesive filling layer 24, a thermoplastic olefin polymer resin sealing material Z68 (manufactured by DNP) was used. Mitsui Chemicals Fabro Solar Eva (EVA) was used for the adhesive filler 20 and the second adhesive filler layer 14.
For the surface protective layer 26, a polycarbonate sheet subjected to heat treatment described later was used, and for this polycarbonate sheet, Iupilon NF-2000 (manufactured by Mitsui Gas Chemical Co., Ltd.) having a thickness of 1 mm was used.
The polycarbonate sheet to be the surface protective layer 26 was previously heat treated in air at 125 ° C. for 3 hours in order to suppress warpage due to heat shrinkage in the vacuum laminating process.
Thereafter, the corona treatment was performed on the adhesive surface with the first adhesive filling layer 24. About this corona treatment, it was made hydrophilic by corona treatment using a corona discharger manufactured by Kasuga Electric at a power of 150 W and a treatment speed of 0.5 m / min.
DY39-067 (primer B), which is a titanate coupling agent manufactured by Toray Dow Corning Co., was applied as a primer to the adhesive surface after the corona treatment, soaked in Ben cotton, and then dried at room temperature for 1 hour.

Further, in order to suppress warpage, the back sheet 16 is a sheet having a three-layer structure of a back sheet (PVF / Al / PVF), EVA layer, 0.5 mm thick Iupilon NF-2000NS manufactured by M Package. Using.
Moreover, as the intermediate sealing material 18, a sheet material of hot melt butyl rubber (M-155) manufactured by Yokohama Rubber Co., Ltd. is used, cut into a mouth shape, the width of the intermediate sealing material 18 is 5 mm, the outer periphery of the intermediate sealing material 18 and the sun. The distance from the periphery of the battery module 10 was 10 mm.
In the production of Example 1, a total of 20 vacuums / presses / holds at a temperature of 140 ° C. using a vacuum laminator having lifting and lowering means, buffer plates, and heating means in a state where such materials are laminated and arranged. The solar cell module 10 was produced under the lamination conditions for 1 minute.

(Example 2)
A solar cell module 10a shown in FIG. In addition, the same thing as Example 1 was used except having provided the peripheral sealing material 19 without providing the intermediate sealing material 18.
B-Dry tape (10 mm width) manufactured by SAES Getters was used for the peripheral sealing material 19.
In the production of Example 2, the peripheral sealing material 19 was previously attached to the surface protective layer (polycarbonate sheet), the above-mentioned respective sheets were laminated on the inside, and the laminated ones were temporarily fixed with a tape. Then, using a vacuum laminator having a lifting means, a buffer plate, and a heating means, a solar cell module 10a was produced at a temperature of 140 ° C. under lamination conditions of vacuum / press / hold for a total of 20 minutes.

(Example 3)
A solar cell module 10b shown in FIG. 4B was produced. In addition, the solar cell module 10b of Example 3 is provided with the frame member 60 without providing the intermediate sealing material 18.
In Example 3, the same thing as Example 1 except the frame member 60 was used. A silicone seal material is used for the frame member 60 as the outer edge seal material 62. The RTV sealing material KE-45 of Shin-Etsu Chemical Co., Ltd. was used for the silicone sealing material. Further, an L-shaped aluminum frame was used for the outer frame member 64.
In the production of Example 3, a laminated material was produced in the same manner as in Example 2, and then a silicone sealant was applied and embedded in the L-shaped aluminum frame groove in advance, and the four sides of the laminated material were The aluminum frame was fixed by screwing it in the groove of the aluminum frame. Thereafter, the frame was formed by allowing the silicone sealing material to harden for 7 days at room temperature, thereby providing the solar cell module 10b.

(Comparative Example 1)
A solar cell module 10 shown in FIG. Comparative Example 1 is the same as Example 1 except that the polycarbonate sheet to be the surface protective layer 26 is pre-heated under the same conditions as in Example 1 but is not subjected to corona treatment and primer application. The solar cell module 10 was manufactured under the same manufacturing conditions as in Example 1.

(Comparative Example 2)
A solar cell module 10a shown in FIG. In Comparative Example 2, the polycarbonate sheet to be the surface protective layer 26 was previously heat-treated under the same conditions as in Example 1, but was different in that no corona treatment and primer application were performed. Otherwise, the same configuration as in Example 2 A solar cell module 10a was produced under the same manufacturing conditions as in Example 2.

  With respect to the five types of solar cell modules of Examples 1 to 3 and Comparative Examples 1 and 2, the conversion efficiency after a dump heat test (left in an environment of temperature 85 ° C. and humidity 85% RH for 1000 hours) was measured. The results are shown in Table 2 below.

  In the dump heat test, when the conversion efficiency of the solar cell module maintained 90% or more of the initial value, it was evaluated as ○, and the conversion efficiency of the solar cell module was 80% or more and less than 90% of the initial value. It evaluated as (triangle | delta) and the thing whose conversion efficiency of the solar cell module was 60% or more and less than 80% of the initial value was evaluated as x.

As shown in Table 2 above, in all of Examples 1 to 3, good results were obtained regarding the conversion efficiency after the dump heat test. On the other hand, in Comparative Examples 1 and 2, the conversion efficiency deteriorated after the dump heat test, and good results were not obtained.
In Comparative Example 1, peeling occurred between the surface protective layer and the water vapor barrier film. However, since water diffusion has a water vapor barrier film, deterioration was suppressed.
Moreover, in the comparative example 2, the periphery seal | sticker also peeled between the surface protective layer and the water vapor | steam barrier film. For this reason, in the comparative example 2, it is estimated that the water | moisture-content diffusion from a periphery becomes large compared with the comparative example 1, and deterioration is large.
From the above results, the effects of the present invention are clear.

DESCRIPTION OF SYMBOLS 10, 10a, 10b Solar cell module 12 Solar cell submodule 14 2nd adhesion filling layer 16 Back sheet 18 Intermediate sealing material 19 Peripheral sealing material 20 Adhesion filling material 22 Barrier film 24 1st adhesion filling layer 26 Surface protective layer 40 Solar cell 50 Substrate 60 Frame member 62 Outer edge seal material 64 Outer frame material

Claims (11)

An adhesive filler, a water vapor barrier film, a first adhesive filling layer, and a surface protective layer are provided on the front side of the solar cell submodule, and the second adhesive filling layer and the back side are provided on the back side of the solar cell submodule. A method for manufacturing a solar cell module in which a protective layer is provided by being laminated,
The solar cell submodule is a substrate in which an anodized film of aluminum is formed on the surface of a metal sheet, and a light absorption layer composed of a CIGS film is formed.
Of the surface protective layer and the back surface protective layer, at least the surface protective layer is composed of a plastic sheet,
Pre-treating the plastic sheet in advance;
Corona treating the surface of the plastic sheet on the side in contact with the first adhesive filling layer;
Applying a primer to the corona treated surface of the plastic sheet;
On the surface side of the solar cell submodule, the adhesive filler, the water vapor barrier film, the first adhesive filling layer are laminated, the heat treatment and the corona treatment, and a plastic sheet coated with a primer, The surface coated with the primer is laminated and arranged toward the first adhesive filling layer, and the second adhesion filling layer and the back surface protective layer are laminated and arranged on the back surface side of the solar cell submodule. Process,
And a step of vacuum laminating in a state where the plurality of layers are stacked and disposed.   The method for manufacturing a solar cell module according to claim 1, wherein the plastic sheet is made of polycarbonate resin or acrylic resin, and the thickness of the plastic sheet is 0.5 to 2.0 mm.   The method for manufacturing a solar cell module according to claim 1 or 2, wherein the heat treatment step of the plastic sheet is performed at a temperature of 100 to 140 ° C.   The said primer has a silane coupling agent, an aluminate coupling agent, or a titanate coupling agent, The manufacturing method of the solar cell module of any one of Claims 1-3. The first adhesive filling layer is composed of a thermoplastic olefin polymer resin,
The temperature of the said vacuum lamination process is 120-145 degreeC, The manufacturing method of the solar cell module of any one of Claims 1-4.   The said plastic sheet is a manufacturing method of the solar cell module of any one of Claims 1-5 comprised by polycarbonate resin.   The said plastic sheet is a manufacturing method of the solar cell module of any one of Claims 1-6 provided with an embossed structure in the surface of the side which contact | connects the said 1st adhesion filling layer.   The method for manufacturing a solar cell module according to claim 7, wherein the embossed structure has an unevenness height of 10 to 1000 μm.   The step of stacking and arranging includes a step of arranging an intermediate sealing material for preventing water vapor intrusion inside 5 to 30 mm from the peripheral edge of the back surface protective layer. Manufacturing method for solar cell module.   In the step of stacking and arranging, a peripheral sealing material for preventing water vapor intrusion is disposed at the peripheral portions of the front surface protective layer and the back surface protective layer, and the solar cell submodule and the adhesive are disposed inside the peripheral sealing material. The solar cell module according to any one of claims 1 to 8, further comprising a step of laminating a filler, the water vapor barrier film, the first adhesive filling layer, the plastic sheet, and a second adhesive filling layer. Production method.   The solar cell module according to any one of claims 1 to 9, further comprising, after the vacuum laminating step, a step of providing a frame member provided with a seal material on the inner side of an outer frame member on a peripheral portion of the vacuum laminated member. Manufacturing method.

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