JP2013030541A - Manufacturing method of solar cell module, solar cell module, manufacturing device, and blade member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a solar cell module capable of preventing occurrence of an external shape defect caused by a resin residue of a sealing resin protruding from a sealing resin part which seals a solar cell by the resin, a solar cell module manufactured by this manufacturing method, a manufacturing device which manufactures the solar cell module, and a blade member applied when the solar cell module is manufactured.SOLUTION: A solar cell module 1 comprises: a solar cell 2 having a first surface 2f and a second surface 2s; a first protective substrate 4 disposed so as to face the first surface 2f; a second protective substrate 5 disposed so as to face the second surface 2s; and a resin sealing part 6 which seals the solar cell 2 between the first protective substrate 4 and the second protective substrate 5. In the resin sealing part 6, an end 6t is formed so as to be recessed toward the inside.

Description

  The present invention provides a method for manufacturing a solar cell module provided with a resin sealing portion for sealing solar cells between two protective substrates, a solar cell module manufactured by the manufacturing method, and a solar cell module. The present invention relates to a manufacturing apparatus and a blade member that removes a sealing resin protruding from a resin sealing portion of a solar cell module.

  A solar cell (solar cell) is known as a device that photoelectrically converts sunlight to generate electric energy. It has been proposed that a large number of solar cells that generate clean energy are connected to form a solar cell module for environmental measures.

  In the solar battery cell, a translucent substrate is disposed on the light receiving surface side, and the periphery is sealed with a resin to improve environmental resistance and ensure reliability. When a solar battery cell is resin-sealed, several techniques have been proposed in order to adjust the external shape because the sealing resin flows out around the translucent substrate.

  It has been proposed to laminate a surface protective member, a sealing member, a solar battery cell, a sealing member, and a back surface protective member to form a laminated structure, and then laminate the laminated structure to perform resin sealing. (For example, refer to Patent Document 1). In the technique of Patent Literature 1, the periphery of the laminated structure is covered with a heat resistant sheet to prevent the sealing resin from flowing out when the lamination process is performed.

  In addition, a photoelectric conversion element is formed on one side of the module substrate, a sealing member that protects the photoelectric conversion element is formed into a photoelectric conversion module, and trimming is performed to remove an excess portion of the sealing member that protrudes around the module substrate A method has been proposed (see, for example, Patent Document 2).

  In the technique of Patent Document 2, for example, a glass plate is applied as the module substrate. Since the glass substrate has a dimensional tolerance, it is not easy to remove the sealing resin protruding from the edge portion, and a large-scale apparatus is required. In addition, removal of the sealing resin that protrudes from the edge portion may depend on human hands, which causes problems such as workability.

JP 2009-272376 A JP 2001-320069 A

  The present invention has been made in view of such a situation, and in the protruding resin removal step of removing the protruding sealing resin, the convexly curved blade edge portion (blade member) is disposed at the outer peripheral end of the first protective substrate and A method of manufacturing a solar cell module capable of preventing the occurrence of external defects due to the resin residue by reliably removing the protruding sealing resin so that the resin residue does not occur by running along the outer peripheral edge of the second protective substrate The purpose is to provide.

  Moreover, this invention is a solar cell module manufactured with the manufacturing method of the solar cell module which concerns on this invention, Comprising: Since the external shape of the resin sealing part which seals a photovoltaic cell with sealing resin is arranged in concave shape Another object of the present invention is to provide a solar cell module that can prevent external defects at the end surfaces of the first protective substrate and the second protective substrate and the end portion of the resin sealing portion due to the protruding of the sealing resin.

  Moreover, this invention is a manufacturing apparatus which manufactures the solar cell module which concerns on this invention, Comprising: The blade holding part holding the blade member which removes sealing resin, The traveling control part which controls driving | running | working of a blade holding part, In addition, since the elastic pressing portion is provided along the blade member on the first protective substrate and the second protective substrate, the sealing resin protruding from the resin sealing portion formed between the first protective substrate and the second protective substrate is provided. Another object of the present invention is to provide a manufacturing apparatus that can be reliably removed with high productivity.

  Further, the present invention is a blade member for removing the sealing resin that protrudes from the resin sealing portion of the solar cell module according to the present invention, and is formed on the plate-like base portion and one end surface of the base portion. Since the first protection substrate and the second protection substrate of the solar cell module are misaligned due to, for example, dimensional tolerance, the first protection substrate (outer peripheral edge) and the second protection are provided. Another object is to provide a blade member that can reliably remove the protruding sealing resin because the blade edge portion is aligned (contacted) with the substrate (outer peripheral edge).

  A method for manufacturing a solar cell module according to the present invention includes a solar battery cell having a first surface and a second surface, a first protective substrate disposed to face the first surface, and the second surface. A solar cell module comprising: a second protective substrate disposed; and a resin sealing portion that seals the solar cells between the first protective substrate and the second protective substrate, In the resin sealing step of sealing the solar battery cell positioned between the first protective substrate and the second protective substrate with a sealing resin to form the resin sealing portion, the resin sealing step A protruding resin removing step of removing the sealing resin protruding from between the first protective substrate and the second protective substrate, and in the protruding resin removing step, a blade member having a convexly curved blade edge portion is provided. The outer peripheral edge of the first protective substrate and And along the outer peripheral end of the serial second protective substrate, characterized in that to travel.

  Therefore, in the method for manufacturing a solar cell module according to the present invention, a blade member having a convexly curved blade edge portion is provided on both the outer peripheral end of the first protective substrate and the outer peripheral end of the second protective substrate facing each other. Therefore, even when the end face of the first protective substrate and the end face of the second protective substrate are misaligned due to dimensional tolerances, the protruding sealing resin is surely cut off so that no resin residue is generated, and the resin residue It is possible to prevent the appearance defect due to.

  In the method for manufacturing a solar cell module according to the present invention, a length between both ends of the blade edge portion is larger than a thickness of the resin sealing portion.

  Therefore, the manufacturing method of the solar cell module according to the present invention makes it possible to bring the blade edge portion into contact with both the first protective substrate and the second protective substrate (both outer peripheral ends), and from the resin sealing portion. The protruding sealing resin can be more reliably cut off.

  The method for manufacturing a solar cell module according to the present invention includes a tape attaching step of attaching a masking tape to each end face of the first protective substrate and the second protective substrate before the resin sealing step. Features.

  Therefore, the manufacturing method of the solar cell module according to the present invention removes the masking tape because the protruding sealing resin is guided to the surface of the masking tape instead of the respective end surfaces of the first protective substrate and the second protective substrate. By doing so, the protruding sealing resin can be efficiently removed at the same time, so that contamination on the end surface of the first protective substrate and the end surface of the second protective substrate can be more reliably prevented.

  In the method for manufacturing a solar cell module according to the present invention, in the protruding resin removal step, the blade member is caused to travel in a direction from a central portion to an end portion of each side of the first protective substrate and the second protective substrate. It is characterized by.

  Therefore, the method for manufacturing a solar cell module according to the present invention can reliably reduce the remaining sealing resin at the corners of the first protective substrate and the second protective substrate.

  In the method for manufacturing a solar cell module according to the present invention, in the resin sealing step, a first protective substrate disposing step of disposing the first protective substrate, and a first sealing resin film formed of the sealing resin. The first sealing resin film disposing step disposed on the first protective substrate, the cell disposing step disposing the solar cell on the first sealing resin film, and the sealing resin. A second sealing resin film arranging step of arranging the second sealing resin film so as to overlap the solar battery cell, and a second protective substrate arranging step of arranging the second protective substrate so as to overlap the second sealing resin film. It is characterized by providing.

  Therefore, in the method for manufacturing a solar cell module according to the present invention, the resin sealing portions (first sealing resin film and second sealing resin film) are arranged on both sides of the solar battery cell, and the outside of the resin sealing portion. For example, a laminated glass solar cell module in which the first protective substrate and the second protective substrate are arranged can be easily manufactured.

  In the method for manufacturing a solar cell module according to the present invention, in the resin sealing step, before forming the resin sealing portion, an end portion of the outer surface of the first protective substrate and an outer surface of the second protective substrate. A resin stopper film that covers the sealing resin is disposed between the two ends.

  Therefore, since the manufacturing method of the solar cell module according to the present invention prevents the sealing resin protruding from between the first protective substrate and the second protective substrate from flowing out more than necessary by the resin sealing film in the resin sealing step. In addition, it is possible to prevent the resin shortage of the resin sealing portion formed between the first protective substrate and the second protective substrate.

  In the method for manufacturing a solar cell module according to the present invention, the resin sealing step is performed by applying pressure to the sealing resin through the first protective substrate and the second protective substrate in a heated state. It is characterized by that.

  Therefore, since the manufacturing method of the solar cell module according to the present invention performs the laminating process on the first protective substrate, the second protective substrate, the solar battery cell, and the resin sealing portion in the resin sealing step, reliability and productivity are improved. Can be improved.

  In the method for manufacturing a solar cell module according to the present invention, the first protective substrate is white plate glass, the second protective substrate is blue plate glass, and the light receiving surface of the solar cell is located on the white plate glass side. It is characterized by.

  Therefore, the solar cell module manufacturing method according to the present invention can easily manufacture a solar cell module in the form of laminated glass.

  The solar cell module according to the present invention is a solar cell module manufactured by the method for manufacturing a solar cell module according to the present invention, and the resin sealing portion has an end portion that is concave toward the inside. It is characterized by.

  Therefore, the solar cell module according to the present invention is arranged between the first protective substrate and the second protective substrate, and the outer shape of the resin sealing portion that seals the solar cells with the sealing resin is arranged in a concave shape. Further, it is possible to prevent the appearance defects at the end surfaces of the first protective substrate and the second protective substrate and the end portions of the resin sealing portion due to the protrusion of the sealing resin.

  A manufacturing apparatus for manufacturing a solar cell module according to the present invention includes a solar cell having a first surface and a second surface, a first protective substrate disposed to face the first surface, and a second surface. A solar cell module comprising: a second protective substrate disposed oppositely; and a resin sealing portion that seals the solar cell with a sealing resin between the first protective substrate and the second protective substrate. A manufacturing apparatus for manufacturing, comprising: a blade holding unit that holds a blade member that cuts off the sealing resin protruding from the resin sealing unit; and a travel control unit that controls travel of the blade holding unit, and the blade The holding portion includes an elastic pressing portion that causes the blade member to be along the first protective substrate and the second protective substrate.

  Therefore, the manufacturing apparatus for manufacturing the solar cell module according to the present invention can reliably cut off the sealing resin protruding from the resin sealing portion formed between the first protective substrate and the second protective substrate with high productivity. it can.

  The blade member according to the present invention is disposed so as to face the second surface, the solar cell having the first surface and the second surface, the first protective substrate disposed to face the first surface, and the second surface. From the resin sealing part of the solar cell module comprising: a second protective substrate; and a resin sealing part that seals the solar battery cell with a sealing resin between the first protective substrate and the second protective substrate. A blade member for cutting off the protruding sealing resin, having a length direction along a stacking direction of the first protective substrate and the second protective substrate, a width direction intersecting the length direction, and a plate thickness direction A substrate portion and a blade edge portion formed in an intermediate region of the substrate portion in the length direction are provided, and the blade edge portion is curved in a convex shape.

  Therefore, the blade member according to the present invention has the first protective substrate (outer peripheral end) and the second protective substrate even when the first protective substrate and the second protective substrate of the solar cell module are displaced due to, for example, dimensional tolerance. Since the blade edge portion can be brought into contact (contact) to the (outer peripheral end), the protruding sealing resin can be surely cut off.

  The blade member according to the present invention includes a curved portion in which the substrate portion is curved in a convex shape toward one side in the plate thickness direction in the intermediate region, and the blade edge portion extends in the length direction of the curved portion. It is formed at the end along.

  Therefore, the blade member according to the present invention can cut off the sealing resin protruding from between the first protective substrate and the second protective substrate with high accuracy.

  The blade member according to the present invention includes a curved portion that is curved in a convex shape by projecting the substrate portion to one side in the width direction in the intermediate region, and the blade edge portion is formed at an end of the curved portion. It is characterized by being.

  Therefore, the blade member according to the present invention can cut off the sealing resin protruding from between the first protective substrate and the second protective substrate with high accuracy.

  The manufacturing method of the solar cell module according to the present invention includes a resin sealing step and a protruding resin removing step of removing the sealing resin protruding from between the first protective substrate and the second protective substrate in the resin sealing step. In the protruding resin removal step, the blade member having the convexly curved blade edge portion is caused to travel along the outer peripheral end of the first protective substrate and the outer peripheral end of the second protective substrate. Since the blade member having the cutting edge curved in a convex shape is caused to travel along both the outer peripheral end of the substrate and the outer peripheral end of the second protective substrate, the end surface of the first protective substrate and the end surface of the second protective substrate are dimensioned. Even when the positional deviation is caused by the tolerance, the protruding sealing resin can be surely cut out so that the resin residue does not occur, and the appearance defect due to the resin residue can be prevented.

  In the solar cell module manufactured by the method for manufacturing a solar cell module according to the present invention, since the resin sealing portion is concave toward the inside, the first protective substrate and the second protective substrate Since the outer shape of the resin sealing portion that is filled in between and seals the solar cells with the sealing resin is arranged in a concave shape, the end surfaces of the first protective substrate and the second protective substrate due to the protrusion of the sealing resin, resin sealing There exists an effect that the external appearance defect in the edge part of a part can be prevented.

  A manufacturing apparatus for manufacturing a solar cell module according to the present invention includes a blade holding unit that holds a blade member that cuts off the sealing resin protruding from the resin sealing unit, and a travel control unit that controls the travel of the blade holding unit. Since the blade holding portion includes an elastic pressing portion that causes the blade member to run along the first protective substrate and the second protective substrate, the blade holding portion protrudes from the resin sealing portion formed between the first protective substrate and the second protective substrate. There is an effect that the sealing resin can be reliably cut off with high productivity.

  The blade member according to the present invention is a blade member that cuts off the sealing resin that protrudes from the resin sealing portion of the solar cell module according to the present invention, and includes a substrate portion and a blade tip portion that is curved in a convex shape. Therefore, even when the first protective substrate and the second protective substrate of the solar cell module are misaligned due to, for example, dimensional tolerance, the blade edge portion is moved to the first protective substrate (outer peripheral end) and the second protective substrate (outer peripheral end). , The protruding sealing resin can be surely cut off.

It is sectional drawing which shows schematic sectional shape of the solar cell module which concerns on embodiment of this invention. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is a perspective view which shows the state of the 1st protective substrate (2nd protective substrate) prepared by affixing a masking tape on an end surface (end surface). In the method for manufacturing a solar cell module according to the embodiment of the present invention, a resin stopper film (see FIG. 2C) that covers the outer surface of the first protective substrate (see FIG. 2C) and reaches the outer surface of the second protective substrate (see FIG. 2C). It is sectional drawing which shows the state which has arrange | positioned on the lamination stand in a cross section. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is sectional drawing which shows the state which aligned the edge part of the outer surface of a 1st protective substrate, and has arrange | positioned on the lamination | stacking stand. In the method for manufacturing a solar cell module according to the embodiment of the present invention, a state in which a first sealing resin film, a solar battery cell, a second sealing resin film, and a second protection substrate are sequentially stacked on the first protection substrate. FIG. In the method for manufacturing a solar cell module according to the embodiment of the present invention, a first sealing resin film is formed by disposing a resin stopper film from the outer surface of the first protective substrate to the end portion of the outer surface of the second protective substrate. FIG. 5 is a cross-sectional view showing a state in which a second sealing resin film is covered. In the method for manufacturing a solar cell module according to the embodiment of the present invention, the first protection is performed when the first laminating resin film and the second encapsulating resin film are subjected to a vacuum laminating process by heating and pressing with a vacuum laminator. It is sectional drawing which shows typically the state which sealing resin protruded from the resin sealing part between a board | substrate and a 2nd protective substrate in a cross section. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is sectional drawing which shows the state which peeled the resin stop film | membrane after the vacuum lamination process in a cross section. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, the state which cuts off sealing resin which protruded from the resin sealing part between the 1st protective substrate and the 2nd protective substrate with a blade edge part (blade member) is modeled It is a principal part sectional view shown with a principal part section. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is principal part sectional drawing which shows the state after removing sealing resin in a cross section. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is a top view which shows the driving | running | working state of the blade member (blade edge part) when cutting off the protruding sealing resin planarly. In FIG. 3A, it is a top view which shows in plan the driving | running | working state of the blade member (blade edge part) in the state which cut off some protruding sealing resin. In the method for manufacturing a solar cell module according to the embodiment of the present invention, the action of the blade portion curved in a convex shape when there is a misalignment between the first protective substrate and the second protective substrate is shown in a cross-section of the main part. It is principal part sectional drawing. It is a perspective view which shows the outline | summary of the blade member (blade edge part) applied to the manufacturing method of the solar cell module which concerns on embodiment of this invention. It is the side view which shows the state which looked at the blade edge | tip part of the blade member shown to FIG. 5A from the side surface. It is sectional drawing which shows the cross-sectional state of the curved part in the arrow CC of FIG. 5B, and a blade edge | tip part. It is the front view which looked at the board | substrate part of the blade member shown to FIG. 5A from the front. It is a top view which shows the planar state of the blade member (blade edge part) applied to the manufacturing method of the solar cell module which concerns on embodiment of this invention. It is sectional drawing which shows the cross-sectional state of the blade member (blade edge part) in the arrow FF of FIG. 5E. It is a schematic block diagram which shows notionally the schematic structure of the manufacturing apparatus which manufactures the solar cell module applied when performing the manufacturing method of the solar cell module which concerns on embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to FIGS.

  With reference to FIG. 1, the schematic shape of the solar cell module 1 according to the present embodiment will be described.

  FIG. 1 is a cross-sectional view showing a schematic cross-sectional shape of a solar cell module 1 according to an embodiment of the present invention.

  The solar cell module 1 according to the present embodiment includes a solar cell 2 having a first surface 2f and a second surface 2s, a first protective substrate 4 disposed to face the first surface 2f, and a second surface. The second protective substrate 5 disposed to face 2s, and the resin sealing portion 6 that seals the solar cells 2 between the first protective substrate 4 and the second protective substrate 5 are provided.

  The 1st protective substrate 4 and the 2nd protective substrate 5 have translucency, for example, are comprised with a glass plate. It is also possible to make only the side corresponding to the light receiving surface of the solar battery cell 2 translucent. For example, when the first protective substrate 4 is disposed on the light receiving surface side, only the first protective substrate 4 can be made translucent.

  As the solar battery cell 2, for example, various solar batteries such as a crystalline solar battery and a thin film solar battery are applied. Moreover, when arrange | positioning the 1st protective substrate 4 facing the light-receiving surface (1st surface 2f) of the photovoltaic cell 2, the photovoltaic cell 2 is directly formed in the 1st protective substrate 4 (for example, a thin film solar cell is 1st) 1 may be laminated on the protective substrate 4).

  When the first protective substrate 4 is disposed on the light receiving surface side of the solar battery cell 2, the first protective substrate 4 can be white glass, and the second protective substrate 5 can be blue glass. That is, the light receiving surface of the solar battery cell 2 is located on the white glass side. Since the white plate glass has a higher light transmittance than the blue plate glass, the white plate glass is disposed on the side facing the light receiving surface of the solar battery cell 2. The solar battery cell 2 can be directly formed on a white plate glass to form a thin film solar battery. The planar shape of the first protective substrate 4 and the second protective substrate 5 can be, for example, about 1 m × 1.4 m, and the thickness can be several mm to about 5 mm. It can be.

  In addition, although the thickness of the photovoltaic cell 2 changes with element structures, it is about several mm normally.

  The resin sealing portion 6 (sealing resin 6r) is usually formed of EVA (ethylene / vinyl acetate / ethylene / vinyl acetate copolymer) resin. The thickness of the resin sealing portion 6 can be set to an appropriate thickness as with the glass plate. Any thickness may be used as long as the solar cell 2 can be resin-sealed with high reliability.

  In the present embodiment, the solar cells 2 are resin-sealed by filling the space between the first protective substrate 4 and the second protective substrate 5 with the sealing resin 6r. When the solar battery cell 2 is resin-sealed with the sealing resin 6r, the sealing resin 6r is placed at the end of the resin sealing portion 6 to the extent that no bubbles remain in order to suppress the remaining of the bubbles in the resin sealing portion 6. It flows out from 6t. Since the sealing resin 6r flowing out to the outside is deleted by the blade member 30 (see FIGS. 2H and 4) having the curved cutting edge portion 32, the resin sealing portion 6 has a concave shape with the end 6t facing inward. Has been.

  Therefore, the solar cell module 1 according to the present embodiment is filled between the first protective substrate 4 and the second protective substrate 5, and the resin sealing portion 6 that seals the solar cells 2 with the sealing resin 6r. Since the outer shape (end portion 6t) of the first protective substrate 4 and the second protective substrate 5 are protruded from the outer shape (end portion 6t), the outer shape is poor at the end surfaces (end surface 4c, end surface 5c) of the first protective substrate 4 and the second protective substrate 5. It is possible to prevent the appearance defect at the end portion 6t of 6.

  With reference to FIG. 2A thru | or FIG. 3B, the manufacturing method of the solar cell module which manufactures the solar cell module 1 which concerns on this Embodiment is demonstrated sequentially according to a process.

  FIG. 2A shows the first protective substrate 4 (second protective substrate 5) prepared by attaching the masking tape 8 to the end surface 4c (end surface 5c) in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention. It is a perspective view which shows a state.

  A masking tape 8 is attached to the end face 4c of the first protective substrate 4 constituting the solar cell module 1. Similarly, a masking tape 8 is attached to the end face 5c of the second protective substrate 5 constituting the solar cell module 1. Since both the first protective substrate 4 and the second protective substrate 5 are in the same state, both shapes are shown in one drawing.

  The masking tape 8 is applied in advance in order to prevent the sealing resin 6r used when forming the resin sealing portion 6 (see FIG. 2F) from adhering to the end surface 4c and the end surface 5c. As described above, the first protective substrate 4 is made of, for example, white plate glass, and the second protective substrate 5 is made of, for example, blue plate glass. In addition, below, it may be set as the solar cell module 1 including the state before completion.

  That is, in the manufacturing method of the solar cell module 1 according to the present embodiment, before the resin sealing step (see FIG. 2F), the end surface 4c and the end surface 5c of each of the first protective substrate 4 and the second protective substrate 5 are provided. A tape attaching step for attaching the masking tape 8 is provided.

  Therefore, in the manufacturing method of the solar cell module 1 according to the present embodiment, the protruding sealing resin 6rr (see FIG. 2F) is not the end face 4c and the end face 5c of the first protective substrate 4 and the second protective substrate 5, respectively. Since the sealing resin 6rr that protrudes by removing the masking tape 8 can be efficiently and simultaneously removed by guiding to the surface of the masking tape 8, the end surface 4c of the first protective substrate 4 and the end surface 5c of the second protective substrate 5 are removed. Dirt (adhesion of sealing resin 6rr) can be prevented more reliably.

  The thickness of the masking tape 8 is preferably about 30 μm to 100 μm, for example. If it is too thick, there is a possibility that the cutting edge portion 32 (see FIG. 2H) cannot be placed (contacted) with the first protective substrate 4 and the second protective substrate 5 with high accuracy. On the other hand, if it is too thin, the strength cannot be ensured, and it is peeled off by the protruding sealing resin 6rr, and the sealing resin 6r (sealing resin 6rr) becomes the first protective substrate 4 (end face 4c) and the second protective substrate 5. There is a possibility of adhering to the (end face 5c).

  As a material of the masking tape, a polyimide film coated with a silicone-based adhesive material can be applied. The polyimide film is excellent in insulation and heat resistance, and can be sufficiently masked against heating and pressurization with a vacuum laminator.

  FIG. 2B covers the outer surface 4s of the first protective substrate 4 (see FIG. 2C) and further reaches the outer surface 5s of the second protective substrate 5 in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention. It is sectional drawing which shows the state which has arrange | positioned the resin stopper film | membrane 9 (refer FIG. 2E) made into the magnitude | size to the lamination stand 20.

  The stacking table 20 is a cart for easily moving the solar cell module 1 to a laminator base 21 (see FIG. 2F) of a vacuum laminator (not shown) in which a resin sealing process, which is a subsequent process, is performed. ing. By using the carriage, workability in the introduction work from the stacking process to the vacuum laminator can be improved.

  In the present embodiment, since the resin sealing portion 6 is formed by applying a vacuum laminator (see FIG. 2F), before the solar cell module 1 is transferred to the laminator base 21 (see FIG. 2F) provided in the vacuum laminator. Members constituting the solar cell module 1 (first protective substrate 4, first sealing resin film 6f, solar cell 2, second sealing resin film 6s, second protective substrate 5. First sealing resin film 6f and For the second sealing resin film 6s, see FIG. 2D).

  Further, in order to prevent contamination of the first protective substrate 4 in the resin sealing step (FIG. 2F), the outer surface 4s of the first protective substrate 4 is covered with a resin stopper film 9 in advance. Since the sealing resin 6r protrudes when the resin sealing portion 6 is formed, the resin stopper film 9 is preliminarily attached to the first protective substrate 4 in order to suppress the protruding amount of the protruding sealing resin 6rr (see FIG. 2F). To the second protective substrate 5. That is, the resin stopper film 9 having a shape larger than the planar shape of the solar cell module 1 is arranged on the stacking table 20 in advance.

  The resin stopper film 9 is preferably a resin film having resistance to heat during heating and pressurization with a vacuum laminator. In this embodiment, it is made of PET (polyethylene terephthalate) resin. The thickness of the resin stopper film 9 is about several tens of μm.

  FIG. 2C is a cross-sectional view showing a state in which the end portion 4f of the outer surface 4s of the first protective substrate 4 is aligned and arranged on the stacking table 20 in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention. It is sectional drawing.

  The first protective substrate 4 (the end portion 4f of the outer surface 4s) is aligned with the stopper ST set as appropriate and disposed on the stacking table 20. As described with reference to FIG. 2A, the masking tape 8 is attached in advance to the end surface 4 c of the first protective substrate 4.

  FIG. 2D shows a method for manufacturing the solar cell module 1 according to the embodiment of the present invention. The first sealing resin film 6f, the solar cell 2, the second sealing resin film 6s, and the second protective resin 4 are formed on the first protective substrate 4. It is sectional drawing which shows the state which has arrange | positioned the protective substrate 5 one after another in a cross section.

  The first sealing resin film 6f (sealing resin 6r), the solar battery cell 2, the second sealing resin film 6s (sealing resin 6r), and the second protective substrate 5 are sequentially aligned with the first protective substrate 4. And stack (arrange).

  In other words, the first protective substrate placement step for placing the first protective substrate 4 and the first sealing resin film for placing the first sealing resin film 6f formed of the sealing resin 6r on the first protective substrate 4 in an overlapping manner. Arrangement step, cell arrangement step of arranging solar cell 2 overlaid on first sealing resin film 6f, and second sealing resin film 6s formed of sealing resin 6r overlaid on solar cell 2 A second sealing resin film disposing step, and a second protective substrate disposing step of disposing the second protective substrate 5 on the second sealing resin film 6s.

  The alignment of the second protective substrate 5 with respect to the first protective substrate 4 can be positioned with high accuracy by applying the stopper ST as it is.

  In the manufacturing method according to the present embodiment, the first protective substrate arrangement step (FIG. 2C), the first sealing resin film arrangement step, the cell arrangement step, the second sealing resin film arrangement step, and the second protective substrate arrangement step are performed. It can be positioned as a part of the resin sealing step.

  Therefore, in the method for manufacturing solar cell module 1 according to the present embodiment, resin sealing portions 6 (first sealing resin film 6f and second sealing resin film 6s) are arranged on both surfaces of solar battery cell 2, For example, the solar cell module 1 in the form of laminated glass in which the first protective substrate 4 and the second protective substrate 5 are disposed outside the resin sealing portion 6 can be easily manufactured.

  In the cell arranging step, the sealing resin films (the film-like first sealing resin film 6f and the second sealing are formed on both surfaces of the solar battery cell 2 by the first sealing resin film arranging step and the second sealing resin film arranging step. The stop resin film 6s) can be disposed in an overlapping manner. The first sealing resin film 6f and the second sealing resin film 6s are formed by forming the sealing resin 6r into a sheet shape, and are melted and cured by heating and pressurizing with a vacuum laminator, and are resin-sealed. Since the part 6 is formed (refer FIG. 2F), the photovoltaic cell 2 can be resin-sealed.

  As described with reference to FIG. 2A, the masking tape 8 is attached in advance to the end surface 5 c of the second protective substrate 5. The planar shape of the first sealing resin film 6f and the second sealing resin film 6s is set to a size that is slightly outside the planar shape of the first protective substrate 4 and the second protective substrate 5, Sufficient sealing resin 6r can be supplied. With this configuration, it is possible to solve the problem that the sealing resin 6r is insufficient at the end 6t of the resin sealing portion 6 formed between the first protective substrate 4 and the second protective substrate 5. Note that the planar shapes of the first sealing resin film 6f and the second sealing resin film 6s and the planar shapes of the first protective substrate 4 and the second protective substrate 5 may be approximately the same.

  In addition, it is preferable that the first protective substrate 4 is white plate glass, the second protective substrate 5 is blue plate glass, and the light receiving surface of the solar battery cell 2 is positioned on the white plate glass side. With this configuration, the method for manufacturing solar cell module 1 according to the present embodiment can easily manufacture solar cell module 1 in the form of laminated glass. Since the resin stopper film 9 completely covers the outer surface 4s of the first protective substrate 4, the first protective substrate 4 facing the light receiving surface of the solar battery cell 2 can be reliably protected from contamination. . That is, the resin stopper film 9 acts as an antifouling film.

  FIG. 2E shows a method for manufacturing a solar cell module 1 according to the embodiment of the present invention, in which resin is stopped from the outer surface 4s of the first protective substrate 4 to the end portion 5f of the outer surface 5s of the second protective substrate 5. It is sectional drawing which shows the state which has arrange | positioned the film | membrane 9 and covered the 1st sealing resin film 6f and the 2nd sealing resin film 6s.

  After removing the stopper ST, a resin is applied so as to cover the outer periphery of the laminate of the first protective substrate 4, the first sealing resin film 6f, the solar battery cell 2, the second sealing resin film 6s, and the second protective substrate 5. A stop film 9 is disposed. That is, before laminating (before forming the resin sealing portion 6), between the end 4 f of the outer surface 4 s of the first protective substrate 4 and the end 5 f of the outer surface 5 s of the second protective substrate 5. A resin stopper film 9 covering the sealing resin 6r is arranged over the entire area. In addition, this process (FIG. 2E) can be positioned as a part of resin sealing process.

  The resin stopper film 9 may be disposed at least in the range from the end 4f of the first protective substrate 4 (outer surface 4s) to the end 5f of the second protective substrate 5 (outer surface 5s). 1 In order to protect the outer surface 4 s of the protective substrate 4, it is preferably disposed on the entire outer surface 4 s.

  Therefore, in the manufacturing method of the solar cell module 1 according to the present embodiment, the sealing resin 6r protruding from between the first protective substrate 4 and the second protective substrate 5 flows out more than necessary in the resin sealing step (FIG. 2F). Since this is prevented by the resin stopper film 9, it is possible to prevent the resin sealing portion 6 formed between the first protective substrate 4 and the second protective substrate 5 from being insufficient of resin (insufficient of the sealing resin 6r). it can.

  In the laminating process (see FIG. 2F), an appropriate pressing force (pressure due to atmospheric pressure by a diaphragm not shown) acts on the resin stopper film 9 from the outside. Therefore, the resin stopper film 9 does not need to be adhered more strongly than necessary to the end 4f of the outer surface 4s of the first protective substrate 4 and the end 5f of the outer surface 5s of the second protective substrate 5. In the present embodiment, the end of the resin stopper film 9 arranged to face the end portion 5f of the second protective substrate 5 (outer surface 5s) is fixed to the outer surface 5s with a heat resistant adhesive tape 10. The overlap of the resin stopper film 9 with respect to the end portion 5f was about 50 mm to 100 mm.

  FIG. 2F shows a method for manufacturing the solar cell module 1 according to the embodiment of the present invention, in which a vacuum laminating process is performed on the first sealing resin film 6f and the second sealing resin film 6s by heating and pressurizing with a vacuum laminator. It is sectional drawing which shows typically the state which sealing resin 6rr protruded from the resin sealing part 6 between the 1st protective substrate 4 and the 2nd protective substrate 5 when it gave.

  A heat and pressure treatment is performed by a vacuum laminator. That is, the solar cell module 1 (first sealing resin film 6f, second sealing) is formed by a pressure member (diaphragm: not shown) disposed on the laminator base 21 (heating member) and the second protective substrate 5. The resin film 6s) is heated and pressurized.

  The sealing resin 6r (first sealing resin film 6f, second sealing resin film 6s) is melted by a laminating process and then cured. The pressurizing condition may be at least atmospheric pressure. Moreover, the air bubble which the sealing resin 6r encloses can be reliably discharged | emitted by the vacuum state to the exterior of the resin sealing part 6. FIG. The first protective substrate 4, the first sealing resin film 6 f, the solar battery cell 2, the second sealing resin film 6 s, and the second protective substrate 5 are pressure-bonded (welded) to each other by heating and pressing (resin sealing). Stop process).

  A part of the molten sealing resin 6r protrudes from between the first protective substrate 4 and the resin sealing portion 6, but the amount of the sealing resin 6rr that protrudes when the resin stopper film 9 is disposed in advance is limited. The resin shortage between the first protective substrate 4 and the second protective substrate 5 does not occur.

  That is, a resin sealing process is performed by applying pressure to the sealing resin 6r through the first protective substrate 4 and the second protective substrate 5 under a heated state (resin sealing process).

  Therefore, since the manufacturing method of the solar cell module 1 which concerns on this Embodiment performs the lamination process with respect to the 1st protective substrate 4, the 2nd protective substrate 5, the photovoltaic cell 2, and the resin sealing part 6 at a resin sealing process. , Reliability and productivity can be improved.

  FIG. 2G is a cross-sectional view showing a state where the resin stopper film 9 is peeled off after the vacuum laminating process in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention.

  In preparation for removing the sealing resin 6rr protruding from between the first protective substrate 4 and the second protective substrate 5 constituting the outer surface of the solar cell module 1, the resin stopper film 9 is peeled off. It is also possible to remove the sealing resin 6rr with the resin stopper film 9 attached. In the present embodiment, for convenience of explanation (easiness to see the drawing), the resin stopper film 9 is shown as a state in which it is peeled off in advance, but the adhesive state of the resin stopper film 9 to the resin sealing portion 6 is taken into consideration. Then you can choose one.

  The protruding sealing resin 6rr remains over the surface of the masking tape 8 attached to the end surface 5c of the second protective substrate 5 from the surface of the masking tape 8 attached to the end surface 4c of the first protective substrate 4. It has become a state. In this state, the outer shape becomes defective, and therefore, in the method for manufacturing the solar cell module 1 according to the present embodiment, a removing step (extruding resin removing step) is added.

  FIG. 2H shows a cutting edge portion of the sealing resin 6rr protruding from the resin sealing portion 6 between the first protective substrate 4 and the second protective substrate 5 in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention. It is principal part sectional drawing which shows the state cut by 32 (blade member 30) typically with a principal part cross section.

  The sealing resin 6rr protruding from between the first protective substrate 4 and the second protective substrate 5 in the resin sealing step (FIG. 2F) is removed (cut off) by the blade member 30 (blade edge portion 32) (extruded resin removing step). .

  That is, in the protruding resin removal step, the sealing resin 6rr is moved by running the cutting edge 32 curved in a convex shape along the outer peripheral end 4t of the first protective substrate 4 and the outer peripheral end 5t of the second protective substrate 5. Can be removed.

  In the present embodiment, the curved cutting edge portion 32 (blade member 30) is caused to travel along both the outer peripheral end 4t of the first protective substrate 4 and the outer peripheral end 5t of the second protective substrate 5 facing each other. Therefore, even when the end surface 4c of the first protective substrate 4 and the end surface 5c of the second protective substrate 5 are misaligned due to the dimensional tolerance (see FIG. 4), the sealing resin 6rr protrudes so as not to remain. It is possible to reliably remove the sealing resin 6rr and prevent the appearance defect due to the resin residue.

  In FIG. 2H, although the thickness of the masking tape 8 is described as being thick, the masking tape 8 is hardly scraped by the cutting edge portion 32 because the actual thickness is thin.

  The outer peripheral end 4t is a side where the end surface 4c of the first protective substrate 4 is in contact with the resin sealing portion 6, and the outer peripheral end 5t is a side where the end surface 5c of the second protective substrate 5 is in contact with the resin sealing portion 6. is there. By placing the cutting edge portion 32 along the outer peripheral end 4t and the outer peripheral end 5t, the removal of the sealing resin 6rr can be performed with high accuracy. In addition, it is preferable that the state when the cutting edge portion 32 is placed along the outer peripheral end 4t and the outer peripheral end 5t is a state where the cutting edge portion 32 is in contact with the substantially outer peripheral end 4t and the outer peripheral end 5t.

  Further, the length Lc between both ends of the blade edge portion 32 is preferably larger than the thickness Tr of the resin sealing portion 6. That is, by making the length Lc between both ends of the blade edge portion 32 larger than the thickness Tr of the resin sealing portion 6, the outer peripheral ends (the outer peripheral end 4t and the outer peripheral end of both the first protective substrate 4 and the second protective substrate 5). The blade edge portion 32 can be brought into contact with the end 5t), and the sealing resin 6rr protruding from the resin sealing portion 6 can be more reliably removed.

  In the present embodiment, the thickness Tr of the resin sealing portion 6 is a value obtained by adding the thickness of the resin sealing portion 6 to the thickness of the solar battery cell 2 and is, for example, about 5 mm. Can be, for example, about 20 mm to 40 mm. Further, the curved shape (radius φ (see FIG. 5B)) of the cutting edge portion 32 can be appropriately set according to the thickness Tr of the resin sealing portion 6.

  The blade member 30 (the substrate portion 31, the blade edge portion 32, the thickness Tc of the substrate portion 31, etc.) will be further described with reference to FIGS. 5A to 5F.

  FIG. 2J is a cross-sectional view of a principal part showing the state after removing the sealing resin 6rr in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention.

  After the sealing resin 6rr is removed by the blade edge part 32, the protruding sealing resin 6rr remains in the state of remaining only on the surface of the masking tape 8. Therefore, by peeling off the masking tape 8, the sealing resin 6rr can be removed at the same time to ensure a normal outer shape (clean outer shape). Since the masking tape 8 has peelability, the sealing resin 6rr can be removed with good workability.

  By peeling off the masking tape 8, the end surface 4c of the first protective substrate 4 and the end surface 5c of the second protective substrate 5 are exposed in a clean state (an original state without adhesion of the sealing resin 6r). Moreover, the edge part 6t of the resin sealing part 6 is shape | molded by the blade edge | tip part 32, and it becomes possible to reduce external appearance defect.

  By removing the masking tape 8, the completed solar cell module 1 can be obtained (see FIG. 1).

  FIG. 3A is a plan view illustrating in plan the traveling state of the blade member 30 (the blade edge portion 32) when the protruding sealing resin 6rr is cut out in the method for manufacturing the solar cell module 1 according to the embodiment of the present invention. is there.

  FIG. 3B is a plan view illustrating the running state of the blade member 30 (blade tip portion 32) in a state where a part of the protruding sealing resin 6rr is cut out in FIG. 3A.

  In the protruding resin removing step, the blade member 30 (the blade edge portion 32) is caused to travel along each side of the first protective substrate 4 and the second protective substrate 5 (in contact with the outer peripheral end 4t and the outer peripheral end 5t). When traveling, it is preferable not to travel from the end portions Rt of the first protective substrate 4 and the second protective substrate 5, but to travel from the central portion Rf with the traveling start position as the central portion Rf.

  In other words, in the method for manufacturing solar cell module 1 according to the present embodiment, the blade is cut in the direction (running direction Rc) from the central portion Rf to the end portion Rt of each side of the first protective substrate 4 and the second protective substrate 5. It is preferable to run the member 30 (the blade edge portion 32). With this configuration, the method for manufacturing the solar cell module 1 according to the present embodiment accurately removes the sealing resin 6rr at the corner portion Rtc of the first protective substrate 4 and the second protective substrate 5, so that the sealing resin Residue (cutout leakage) of 6 rr can be reliably reduced.

  The inclination angle of the blade edge portion 32 with respect to the sides of the first protective substrate 4 and the second protective substrate 5 is about 30 to 60 degrees from the edge, but is appropriately set according to the inclination of the blade of the blade edge portion 32.

  With reference to FIG. 4, the specific effect in the manufacturing method of the solar cell module which manufactures the solar cell module 1 which concerns on this Embodiment is demonstrated.

  FIG. 4 shows a method of manufacturing the solar cell module 1 according to the embodiment of the present invention. The cutting edge portion 32 curved in a convex shape when there is a misalignment between the first protective substrate 4 and the second protective substrate 5. It is principal part sectional drawing which shows an effect | action with a principal part cross section.

  The end surface 4c of the first protective substrate 4 and the end surface 5c of the second protective substrate 5 are usually at the same position in plan view. However, the end face 4c and the end face 5c are arranged in the same arrangement due to an alignment error of the second protective board 5 with respect to the first protective board 4 or a dimensional tolerance when the first protective board 4 and the second protective board 5 are formed. It may not be possible. That is, the positions of the end surface 4c and the end surface 5c may not match in the direction perpendicular to the plane of the first protective substrate 4 and the second protective substrate 5.

  In the present embodiment, since the blade edge portion 32 is formed as a curved convex shape, the blade edge curved at both the outer peripheral edge 4 t of the first protective substrate 4 and the outer peripheral edge 5 t of the second protective substrate 5 facing each other. The blade member 30 can be run in a state where the portion 32 is aligned. Therefore, even when the end surface 4c of the first protective substrate 4 and the end surface 5c of the second protective substrate 5 are misaligned due to dimensional tolerances or the like, the protruding sealing resin 6rr is surely removed, and the outer shape defect due to the resin residue is eliminated. Occurrence can be prevented.

  In addition, it is set as the structure which adjusts the position of the blade edge | tip part 32 (blade member 30) according to the condition of the position shift between the 1st protective substrate 4 and the 2nd protective substrate 5 (refer FIG. 6). Moreover, in this Embodiment, several things from which the curved state (for example, the magnitude | size of radius (phi) (refer FIG. 5B)) of the blade edge | tip part 32 differ are prepared, the situation of position shift, the resin sealing part 6 ( Depending on the thickness Tr of the protruding sealing resin 6rr), it can be used by appropriately replacing it.

  Moreover, it is preferable that the length Lc between both ends of the blade edge portion 32 is formed larger than the thickness Tr of the resin sealing portion 6. That is, in order to dispose the blade edge portion 32 across the first protective substrate 4 (outer peripheral end 4t) and the second protective substrate 5 (outer peripheral end 5t), the length Lc is preferably larger than the thickness Tr.

  That is, the length Lc between both ends of the blade edge portion 32 is preferably larger than the thickness Tr of the resin sealing portion 6. Therefore, with this configuration, the blade edge portion 32 can be brought into contact with the outer peripheral ends (the outer peripheral end 4t and the outer peripheral end 5t) of both the first protective substrate 4 and the second protective substrate 5, and the resin sealing portion The sealing resin 6rr protruding from 6 can be more reliably removed.

  As described above, the method for manufacturing solar cell module 1 according to the present embodiment includes solar cell 2 having first surface 2f and second surface 2s, and first protection disposed to face first surface 2f. A substrate 4, a second protective substrate 5 disposed to face the second surface 2 s, and a resin sealing portion 6 that seals the solar cells 2 between the first protective substrate 4 and the second protective substrate 5. It is a manufacturing method of the solar cell module 1 provided with.

  In the method for manufacturing the solar cell module 1 according to the present embodiment, the solar battery cell 2 positioned between the first protective substrate 4 and the second protective substrate 5 is sealed with a sealing resin 6r, and the resin sealing portion 6 is used. And a protruding resin removing step of removing the sealing resin 6rr protruding from between the first protective substrate 4 and the second protective substrate 5 in the resin sealing step, and in the protruding resin removing step Then, the blade member 30 having the blade portion 32 curved in a convex shape is caused to travel along the outer peripheral end 4 t of the first protective substrate 4 and the outer peripheral end 5 t of the second protective substrate 5.

  Therefore, the manufacturing method of the solar cell module 1 according to the present embodiment includes a cutting edge that is curved in a convex manner on both the outer peripheral edge 4t of the first protective substrate 4 and the outer peripheral edge 5t of the second protective substrate 5 that face each other. Since the blade member 30 having the portion 32 travels along the end member 4, even when the end surface 4 c of the first protective substrate 4 and the end surface 5 c of the second protective substrate 5 are misaligned due to dimensional tolerances (see FIG. 4), The protruding sealing resin 6rr can be surely cut out so as not to cause a resin residue, thereby preventing the appearance defect due to the resin residue.

  With reference to FIG. 5A thru | or FIG. 5D, the structure of the blade member 30 (blade edge part 32) which removes sealing resin 6rr when manufacturing the solar cell module 1 which concerns on this Embodiment is demonstrated.

  FIG. 5A is a perspective view showing an outline of a blade member 30 (blade edge portion 32) applied to the method for manufacturing solar cell module 1 according to the embodiment of the present invention.

  FIG. 5B is a side view illustrating a state in which the blade tip portion 32 of the blade member 30 illustrated in FIG. 5A is viewed from the side surface.

  5C is a cross-sectional view showing a cross-sectional state of the bending portion 33 and the blade edge portion 32 at the arrow CC in FIG. 5B.

  FIG. 5D is a front view of the substrate portion 31 of the blade member 30 shown in FIG. 5A as viewed from the front.

  The blade member 30 according to the present embodiment has a length direction DL along the stacking direction of the first protective substrate 4 and the second protective substrate 5, a width direction DW intersecting the length direction DL, and a plate thickness direction DT. A substrate portion 31 and a cutting edge portion 32 formed in an intermediate region of the substrate portion 31 in the length direction DL are provided. Moreover, it is preferable that the blade edge | tip part 32 formed in the blade member 30 is curving convexly.

  Therefore, even when the first protective substrate 4 and the second protective substrate 5 of the solar cell module 1 are misaligned due to, for example, a dimensional tolerance, the blade member 30 is provided with the first protective substrate 4 (outer peripheral end 4t) and the second protective substrate 4. Since the cutting edge portion 32 can be brought into contact (contact) with the protective substrate 5 (outer peripheral end 5t), the protruding sealing resin 6rr can be surely cut off. The cutting edge portion 32 is cut so as to contact the sealing resin 6rr and contact the first protective substrate 4 and the second protective substrate 5. Further, the cutting position (removal position) is adjusted as appropriate.

  Furthermore, the blade member 30 according to the present embodiment is configured so that the substrate portion 31 is positioned in the plate thickness direction DT in an intermediate region of the substrate portion 31 (a region sandwiched between two substrate portions 31 arranged vertically in FIG. 5D). It is preferable that the curved portion 33 curved in a convex shape toward one side is provided, and the blade edge portion 32 is formed at an end along the length direction DL of the curved portion 33. With this configuration, the blade member 30 can cut off the sealing resin 6r protruding from between the first protective substrate 4 and the second protective substrate 5 with high accuracy.

  The curved portion 33 is formed by processing one sheet metal, for example. The bending portion 33 is formed by bending one sheet metal in a semicircular cylindrical shape toward one side in the plate thickness direction DT in an intermediate region in the length direction DL. In other words, the axis (the center of the circle constituting the semicircle corresponding to the cylinder) that is the center of the cylinder is parallel to the width direction DW, and the bending portion 33 has a half of the cylinder vertically divided and extends in the width direction DW. The both ends of the vertical division continue to the substrate part 31. That is, on both sides of the bending portion 33, the plate-like substrate portions 31 are disposed with respect to the bending portion 33. The radius φ of the semicircle (semi-cylinder) is set to an appropriate size according to the thickness Tr of the resin sealing portion 6.

  Further, the end face (thickness Tc) along the length direction DL appears as it is in the original sheet metal state on the substrate part 31 and the curved part 33. Therefore, the end along the length direction DL of the curved portion 33 is the end of the substrate portion 31 (curved portion 33) in the width direction Dw where the plate thickness (thickness Tc) of the substrate portion 31 appears as it is.

  The dimensions of the blade member 30 are about 100 mm to 150 mm in the length direction DL and about 15 mm to 40 mm in the width direction DW, and the thickness Tc in the plate thickness direction DT takes into account the strength and accuracy of the sheet metal (blade edge portion 32). About 1 mm.

  In addition, the board | substrate part 31 becomes a to-be-held part (refer FIG. 6) when hold | maintaining the blade member 30 from the outside. The substrate part 31 may be plate-shaped (for example, rectangular) so that it can be held from the outside. Further, since there is no direct influence on the removal operation (cutting operation) itself of the sealing resin 6rr, it is only necessary to ensure an appropriate strength, and various shapes other than a rectangular shape can be applied. Moreover, the board | substrate part 31 becomes an area | region which demarcates the curved part 33 (blade edge part 32). Therefore, it is sufficient if the shape and strength are sufficient to form the curved portion 33 in the intermediate region of the substrate portion 31.

  As described above, the blade member 30 according to the present embodiment includes the solar cell 2 having the first surface 2f and the second surface 2s, the first protective substrate 4 disposed to face the first surface 2f, The second protective substrate 5 disposed to face the second surface 2s, and the resin sealing portion 6 that seals the solar cells 2 with the sealing resin 6r between the first protective substrate 4 and the second protective substrate 5. The sealing resin 6rr that protrudes from the resin sealing portion 6 of the solar cell module 1 including the above is cut off.

  The blade member 30 shown in FIG. 5A to FIG. 5D described above has a cutting edge portion 32 that is curved three-dimensionally (semi-cylindrical) in an intermediate region of the flat plate-like substrate portion 31. As a modification to this, unlike the blade edge portion 32 formed on the three-dimensional curved portion 33, a blade member 30b (FIG. 5E) having a blade edge portion 32b curved in a plane can be used. Hereinafter, the blade member 30b which is a modification of the blade member 30 is demonstrated with reference to FIG. 5E and FIG. 5F. In addition, about the matter which overlaps with the blade member 30, description may be abbreviate | omitted suitably.

  FIG. 5E is a plan view showing a planar state of the blade member 30b (blade edge portion 32b) applied to the method for manufacturing the solar cell module 1 according to the embodiment of the present invention.

  FIG. 5F is a cross-sectional view showing a cross-sectional state of the blade member 30b (blade edge portion 32b) at the arrow FF in FIG. 5E.

  The blade member 30b according to the present modification has a length direction DL along the stacking direction of the first protective substrate 4 and the second protective substrate 5, a width direction DW intersecting the length direction DL, and a board thickness direction DT. Part 31b, and a blade edge part 32b formed in the intermediate region of the substrate part 31b in the length direction DL. Moreover, the blade edge | tip part 32 formed in the blade member 30 is curving in convex shape.

  Therefore, the blade member 30b according to the present invention has the first protective substrate 4 (the outer peripheral end 4t) even when the first protective substrate 4 and the second protective substrate 5 of the solar cell module 1 are misaligned due to, for example, dimensional tolerance. ) And the second protective substrate 5 (outer peripheral end 5t), the cutting edge portion 32b can be aligned (contacted), so that the protruding sealing resin 6rr can be surely cut off.

  Further, the blade member 30b includes a curved portion 34 that is curved in a convex shape by projecting the substrate portion 31b to one side in the width direction DW in an intermediate region of the substrate portion 31b, and the blade tip portion 32b is provided at the end of the curved portion 34. Is formed. With this configuration, the blade member 30b according to the present modification can cut off the sealing resin 6rr protruding from between the first protective substrate 4 and the second protective substrate 5 with high accuracy, like the blade member 30.

  Further, the length Lc between both ends of the blade edge portion 32 b is preferably larger than the thickness Tr of the resin sealing portion 6, like the blade edge portion 32 of the blade member 30. The blade edge portion 32 b can have an appropriate radius φ, like the blade edge portion 32 of the blade member 30.

  Note that the blade member is not limited to the shape described above, and may have other shapes. For example, it is good also as a form which makes the whole disk shape and has a blade edge | tip part in the periphery. In the case of a disk shape, it is possible to extend the life of the blade by changing the use range in the circumferential direction according to the use frequency.

  The blade member 30 (three-dimensional blade) has been described above with reference to FIGS. 5A to 5D, and the blade member 30 b (flat blade) has been described with reference to FIGS. 5E and 5F. Moreover, although the blade member 30 is described as a single blade (see FIG. 5C) and the blade member 30b is described as a double blade (see FIG. 5E), the sealing resin 6rr protruding from both the blade member 30 and the blade member 30b can be removed. What is necessary is just to have either a single blade or a double blade.

  With reference to FIG. 6, the manufacturing apparatus (manufacturing apparatus which manufactures the solar cell module 1) which makes the blade member 30 (blade edge part 32) drive when manufacturing the solar cell module 1 which concerns on this Embodiment is demonstrated. Below, although the blade member 30 is demonstrated, it is the same also about the blade member 30b.

  FIG. 6 is a schematic configuration diagram conceptually showing a schematic configuration of a manufacturing apparatus 40 for manufacturing the solar cell module 1 applied when the method for manufacturing the solar cell module 1 according to the embodiment of the present invention is executed. .

  The manufacturing apparatus 40 according to the present embodiment has a blade member 30 having a mounting table 41 on which the solar cell module 1 that has been subjected to the vacuum laminating process is mounted, and a blade edge portion 32 that cuts off the sealing resin 6rr protruding from the solar cell module 1. (See FIG. 2H), a blade holding portion 42 that holds the blade member 30 so that the blade member 30 travels along the first protective substrate 4 (outer peripheral end 4t) and the second protective substrate 5 (outer peripheral end 5t). , An elastic pressing portion 45 for finely adjusting the position of the blade member 30 (blade edge portion 32), a traveling mechanism portion 43 for causing the blade holding portion 42 to travel along the side of the solar cell module 1, and a blade by controlling the traveling mechanism portion 43. A travel control unit 44 that controls the travel of the member 30 is provided.

  The elastic pressing portion 45 is constituted by, for example, a coil spring, and exerts an elastic force in a direction in which the blade member 30 (the blade edge portion 32) is pressed against the solar cell module 1, so that the position of the blade edge portion 32 is finely adjusted, and the solar cell. The blade edge portion 32 (blade member 30) is brought into contact with the first protective substrate 4 (outer peripheral end 4t) and the second protective substrate 5 (outer peripheral end 5t) along the module 1. Since the contact state is buffered by the elastic force of the coil spring, it is possible to buffer the processing force (cutting force against the protruding sealing resin 6rr) exerted on the solar cell module 1 by the cutting edge portion 32. it can.

  That is, the manufacturing apparatus 40 that manufactures the solar cell module 1 according to the present embodiment includes the solar cells 2 having the first surface 2f and the second surface 2s, and the first arranged to face the first surface 2f. The solar cell 2 is sealed with a sealing resin 6r between the protective substrate 4, the second protective substrate 5 disposed opposite to the second surface 2s, and the first protective substrate 4 and the second protective substrate 5. It is a manufacturing apparatus which manufactures the solar cell module 1 provided with the resin sealing part 6. FIG.

  In addition, the manufacturing apparatus 40 according to the present embodiment includes a blade holding part 42 that holds the blade member 30 (substrate part 31) that cuts off the sealing resin 6rr that protrudes from the resin sealing part 6, and the traveling of the blade holding part 42. The blade holding unit 42 includes an elastic pressing unit 45 that moves the blade member 30 along the first protective substrate 4 and the second protective substrate 5.

  Therefore, the manufacturing apparatus 40 that manufactures the solar cell module 1 according to the present embodiment removes the sealing resin 6rr protruding from the resin sealing portion 6 formed between the first protective substrate 4 and the second protective substrate 5. It can be reliably removed with high productivity.

DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Solar cell 2f 1st surface 2s 2nd surface 4 1st protective substrate 4c End surface 4f End part 4s Outer surface 4t Outer peripheral end 5 Second protective substrate 5c End surface 5f End portion 5s Outer surface 5t Outer end 6 Resin Sealing part 6f First sealing resin film 6r Sealing resin 6rr Overhanging sealing resin 6s Second sealing resin film 6t End part 8 Masking tape 9 Resin stopper film 20 Laminating table 21 Laminator base 30, 30b Blade member 31 , 31b Substrate part 32, 32b Cutting edge part 33, 34 Bending part 40 Manufacturing device 41 Mounting table 42 Blade holding part 43 Traveling mechanism part 44 Traveling control part 45 Elastic pressing part Lc Length Rc Traveling direction Rf Central part Rt End part Rtc Angle Part ST Stopper Tr Thickness

Claims (13)

A photovoltaic cell having a first surface and a second surface; a first protective substrate disposed opposite to the first surface; a second protective substrate disposed opposite to the second surface; A method for manufacturing a solar cell module comprising a resin sealing portion that seals the solar cell between one protective substrate and the second protective substrate,
A resin sealing step of forming the resin sealing portion by sealing the solar cell located between the first protective substrate and the second protective substrate with a sealing resin;
A protruding resin removing step of removing the sealing resin protruding from between the first protective substrate and the second protective substrate in the resin sealing step,
In the protruding resin removing step, a blade member having a convexly curved cutting edge is caused to travel along the outer peripheral end of the first protective substrate and the outer peripheral end of the second protective substrate. Manufacturing method. It is a manufacturing method of the solar cell module according to claim 1,
The length between the both ends of the said blade edge | tip part is larger than the thickness of the said resin sealing part. The manufacturing method of the solar cell module characterized by the above-mentioned. It is a manufacturing method of the solar cell module according to claim 1 or 2,
A method for manufacturing a solar cell module, comprising: a tape attaching step of attaching a masking tape to each end face of the first protective substrate and the second protective substrate before the resin sealing step. It is a manufacturing method of the solar cell module according to any one of claims 1 to 3,
The method for manufacturing a solar cell module, wherein, in the protruding resin removal step, the blade member is caused to travel in a direction from a central portion to an end portion of each side of the first protective substrate and the second protective substrate. It is a manufacturing method of the solar cell module according to any one of claims 1 to 4,
In the resin sealing step, a first protective substrate disposing step of disposing the first protective substrate, and a first sealing resin film formed of the sealing resin being disposed so as to overlap the first protective substrate. A sealing resin film disposing step, a cell disposing step of disposing the solar battery cell on the first sealing resin film, and a second sealing resin film formed of the sealing resin on the solar cell. A solar cell module comprising: a second sealing resin film arranging step of arranging the second protective substrate; and a second protective substrate arranging step of arranging the second protective substrate on the second sealing resin film. Production method. It is a manufacturing method of the solar cell module according to any one of claims 1 to 5,
In the resin sealing step, before forming the resin sealing portion, the sealing is performed between the end portion of the outer surface of the first protective substrate and the end portion of the outer surface of the second protective substrate. A method for producing a solar cell module, comprising disposing a resin stopper film covering the resin. It is a manufacturing method of the solar cell module according to any one of claims 1 to 6,
The method of manufacturing a solar cell module, wherein the resin sealing step is performed by applying pressure to the sealing resin through the first protective substrate and the second protective substrate under a heated state. . It is a manufacturing method of the solar cell module according to any one of claims 1 to 7,
The first protective substrate is white plate glass, the second protective substrate is blue plate glass, and the light receiving surface of the solar cell is located on the white plate glass side. Method. A solar cell module manufactured by the method for manufacturing a solar cell module according to any one of claims 1 to 8,
The solar cell module, wherein the resin sealing portion has a concave end toward the inside. A photovoltaic cell having a first surface and a second surface; a first protective substrate disposed opposite to the first surface; a second protective substrate disposed opposite to the second surface; A manufacturing apparatus for manufacturing a solar cell module including a resin sealing portion that seals the solar cell with a sealing resin between one protective substrate and the second protective substrate,
A blade holding portion that holds a blade member that cuts off the sealing resin protruding from the resin sealing portion;
A travel control unit for controlling the travel of the blade holding unit,
The said blade holding | maintenance part is provided with the elastic press part which makes the said blade member go along with the said 1st protective substrate and the said 2nd protective substrate. The manufacturing apparatus which manufactures the solar cell module characterized by these. A photovoltaic cell having a first surface and a second surface; a first protective substrate disposed opposite to the first surface; a second protective substrate disposed opposite to the second surface; The sealing resin protruding from the resin sealing portion of a solar cell module including a resin sealing portion that seals the solar battery cell with a sealing resin between the first protective substrate and the second protective substrate. A blade member,
A substrate portion having a length direction along a stacking direction of the first protection substrate and the second protection substrate, a width direction intersecting the length direction, and a plate thickness direction; and an intermediate portion of the substrate portion in the length direction A cutting edge portion formed in the region,
The blade member is curved in a convex shape. The blade member according to claim 11,
A curved portion that is curved in a convex shape toward one of the plate thickness directions in the intermediate region;
The blade member is formed at an end along the length direction of the curved portion. The blade member according to claim 11,
A curved portion that is curved in a convex shape by projecting the substrate portion in one of the width directions in the intermediate region;
The blade edge part is formed at an end of the curved part.

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