JP2013219280A - Solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module in which its end-surface sealing material is suppressed from being partially pressed by a great force and is prevented from being parted or severed, when the end-surface sealing material is attached to the outer end surface of the peripheral edge of a solar cell module body.SOLUTION: A solar cell module comprises: a solar cell module body 10 comprising a light transmissive substrate, an encapsulation layer disposed on the substrate, a solar cell sealed with the encapsulation layer, and a back film; and an end-surface sealing material 30 in a band-shape, the sealing material 30 sealing an outer end surface 10C of the solar cell module body 10. A beveling treatment is applied to all the corners of a planar shape viewed from almost vertical direction of the substrate main surface, and/or to ridge edges formed with the substrate main surface and the substrate end surface. A parting or severance of the end-surface sealing material 30 can be prevented by the beveling treatment, when the end-surface sealing material 30 is being attached to the outer end surface 10C.

Description

  The present invention relates to a solar cell module, and more particularly to a solar cell module in which an end surface sealing material is attached to an outer peripheral end surface of a solar cell module main body.

  In recent years, as one means for generating and using clean energy, solar cells that convert sunlight into electric energy have been attracting attention and are becoming popular. In addition, solar cell modules are provided for residential use.

  The solar cell module is generally composed of a solar cell module main body and a frame body that supports it. The solar cell module body sequentially arranges the solar cells and the back film on the translucent substrate, and seals the solar cells with a sealing material filled between the translucent substrate and the back film. Is formed. A terminal box for taking out the output is provided on the back side of the solar cell module body. And a frame is fitted and attached to the outer periphery of this solar cell module main body.

  Further, when the frame body is fitted and attached to the outer peripheral edge of the solar cell module main body, it is desirable to provide an end face sealing material between the outer peripheral edge of the solar cell module main body and the frame body. For example, in Patent Document 1, a cushioning material is provided between the outer peripheral edge of the solar cell module main body and the frame body. Similarly, the end face sealing material is provided between the outer peripheral edge of the solar cell module main body and the frame body. When the frame is provided, it is possible to suppress an impact when the frame body directly contacts the outer peripheral edge of the solar cell module main body. Also, by providing the end face sealing material, the outer peripheral end face of the outer peripheral edge of the solar cell module body can be sealed with the end face sealing material, so that the waterproof performance of the solar cell module body is improved, and the inside of the solar cell module body It is also possible to prevent moisture (for example, water or water vapor) from entering.

JP 2003-229590 A

  However, when the end surface sealing material is attached to the outer peripheral end surface of the solar cell module body, the end surface sealing material is pressed against the outer peripheral end surface in a state where tension is applied. At this time, when the corner of the outer peripheral edge of the substrate of the solar cell module body (for example, the corner portion of the planar shape of the substrate or the ridge angle formed by the end surface and the main surface of the substrate) contacts the end surface sealing material, When the surface of the end surface sealing material is locally pressed with a relatively large pressure, a tear may occur in the end surface sealing material or the end surface sealing material may be cut off. In addition, although patent document 1 is disclosing providing a shock absorbing material between the outer periphery of a solar cell module main body and a frame, about the content of the process, it does not disclose specifically, Furthermore, It does not mention the above-mentioned problems.

  The present invention has been made in view of such a situation, and when the end surface sealing material is attached to the outer peripheral end surface of the outer peripheral edge of the solar cell module body, the end surface sealing material is locally pressed with a large pressure. It aims at providing the solar cell module which can suppress that and can prevent the tearing or fracture | rupture of an end surface sealing material.

  To achieve the above object, the present invention provides a solar cell comprising a light-transmitting substrate, a sealing layer provided on the substrate, a solar battery cell sealed by the sealing layer, and a back film. In a solar cell module comprising a battery module main body and a band-shaped end surface sealing material that seals an outer peripheral end surface of the solar cell module main body, all the planar shapes of the main surface of the substrate viewed from a substantially normal direction When the chamfering process is performed on the corner portion of the substrate and / or the ridge angle formed by the main surface of the substrate and the end surface of the substrate, and the end surface sealing material is attached to the outer peripheral end surface by the chamfering process, the end surface sealing is performed. The tearing or cutting of the material can be prevented.

  According to the said structure, when an end surface sealing material is attached to the outer peripheral end surface of the outer periphery of a solar cell module main body by chamfering all the corner | angular parts and / or ridge angles of a board | substrate, a corner | angular part and / or a ridge angle are attached. The chamfered surface formed on the end surface suppresses the end surface sealing material from being locally pressed with a large pressure, and prevents the end surface sealing material from being cleaved or cut.

  The said structure WHEREIN: R chamfering process may be given to all the said corner | angular parts. With this configuration, a smoothly curved R chamfered surface can be formed at each corner. Therefore, when the end face sealing material is attached to the outer peripheral end face of the outer peripheral edge of the solar cell module main body, the R chamfered surface comes into contact with the end face sealing material in a wider area, so that the R chamfered surface covers the surface of the end face sealing material. The pressing pressure is also reduced. Therefore, when the end surface sealing material is attached to the outer peripheral end surface, it is possible to suppress the end surface sealing material from being locally pressed with a large pressure by the R chamfered surface formed at the corner portion.

  Alternatively, in the above configuration, C corner chamfering processing is performed on all the corners, and a portion including a side having a predetermined length from the apex of each corner is removed from the all corners by the C chamfering processing. The predetermined length at each corner may be not less than 2.0 mm and not more than 1/4 of the shorter side of the two sides forming the corner. With this configuration, it is possible to form a C-chamfered surface having a relatively large area at each corner. Therefore, when the end surface sealing material is attached to the outer peripheral end surface of the outer peripheral edge of the solar cell module body, the C chamfered surface formed at the corner portion comes into contact with the end surface sealing material in a relatively wide area. The pressure which presses the surface of an end surface sealing material also becomes small. Therefore, when the end surface sealing material is attached to the outer peripheral end surface, it is possible to suppress the end surface sealing material from being locally pressed with a large pressure by the C chamfered surface formed at the corner portion. Furthermore, the solar cell of the solar cell module is sealed by setting the predetermined length at each corner to be equal to or less than 1/4 of the shorter side of the two sides forming the corner. It can prevent that the area | region to do becomes too small. Therefore, it is possible to prevent the conversion efficiency of the solar cell module from being greatly affected.

  Furthermore, the said structure WHEREIN: 2.0 mm or more and 3.0 mm or less may be sufficient as the said predetermined length. By setting the predetermined length to 2.0 mm or more, a C-chamfered surface having a relatively large area can be formed at each corner. Therefore, when the end surface sealing material is attached to the outer peripheral end surface, it is possible to suppress the end surface sealing material from being locally pressed with a large pressure by the C chamfered surface formed at the corner portion. Furthermore, it can prevent that the area | region which seals the photovoltaic cell of a photovoltaic module becomes too small by making predetermined length into 3.0 mm or less.

  In the above configuration, an R chamfering process is performed on the ridge angle, the radius of the R chamfering process is half or more of the thickness of the substrate, and the center of the R chamfering process is in the thickness direction of the substrate. In a cross section, the thickness of the substrate may be on an imaginary line that is halved. Alternatively, in the above configuration, an R chamfering process is performed on the ridge angle, and the radius of the R chamfering process is smaller than half of the thickness of the substrate, and the center of the R chamfering process is in the thickness direction of the substrate. In cross section, the radius is approximately the same distance as the radius from the substrate end surface in the normal direction of the substrate end surface, and forms the ridge angle with the substrate end surface, and the radius in the normal direction of the main surface from the main surface of the substrate. They may be located at substantially the same distance.

  With these configurations, it is possible to form an R chamfered surface having a gentle curved surface at the ridge angle. Therefore, when the end face sealing material is attached to the outer peripheral end face of the outer peripheral edge of the solar cell module body, the end face sealing material is prevented from being locally pressed with a large pressure by the R chamfered surface formed at the ridge angle. be able to.

  In the above configuration, the R chamfering process may be performed only on one of the first ridge angle and the second ridge angle formed by both the main surfaces of the substrate and the substrate end surface. According to this configuration, since it is only necessary to perform the R chamfering process on only one of the two ridge angles, the number of manufacturing steps of the solar cell module is larger than when the R chamfering process is performed on both of the two ridge angles. Less.

  Alternatively, in the above configuration, R chamfering processing with different radii may be performed on the first ridge angle and the second ridge angle formed by both main surfaces of the substrate and the substrate end surface.

  According to the present invention, when the end surface sealing material is attached to the outer peripheral end surface of the outer peripheral edge of the solar cell module body, the end surface sealing material is suppressed from being locally pressed with a large pressure, and the end surface sealing material It is possible to provide a solar cell module that can prevent cleavage and breakage.

It is a perspective view which shows the structure of a solar cell module. It is local sectional drawing of the outer periphery of a solar cell module. It is a perspective view for demonstrating the process of attaching an end surface sealing material to the outer peripheral end surface of a solar cell module main body. It is a top view for demonstrating the state which attached the end surface sealing material to the outer peripheral end surface of a solar cell module main body. It is the top view which looked at the board | substrate of the photovoltaic module main body which concerns on a 1st comparative example from the substantially normal line direction of the main surface. It is an expansion perspective view of the corner | angular part vicinity of the board | substrate which concerns on a 1st comparative example. It is local sectional drawing of the outer periphery of the board | substrate of the photovoltaic module module main body which concerns on a 2nd comparative example. It is the top view which looked at the board | substrate of the photovoltaic module module body which concerns on 1st Example from the substantially normal line direction of the main surface. It is an expansion perspective view of the corner | angular part vicinity of the board | substrate which concerns on 1st Example. It is the top view which looked at the board | substrate of the photovoltaic module main body which concerns on 2nd Example from the substantially normal line direction of the main surface. It is an expansion perspective view of the corner | angular part vicinity of the board | substrate which concerns on 2nd Example. It is local sectional drawing of the outer periphery of the board | substrate of the photovoltaic module main body which concerns on 3rd Example. It is local sectional drawing of the outer periphery of the board | substrate which concerns on the modification of 3rd Example. It is local sectional drawing of the outer periphery of the board | substrate which concerns on the other modification of 3rd Example. It is local sectional drawing of the outer periphery of the board | substrate of the photovoltaic module main body which concerns on 4th Example. It is local sectional drawing of the outer periphery of the board | substrate which concerns on the modification of 4th Example. It is local sectional drawing of the outer periphery of the board | substrate which concerns on the other modification of 4th Example.

Embodiments of the present invention will be described below with reference to the drawings.
<Configuration of solar cell module>

  First, the configuration of the solar cell module 1 will be described. FIG. 1 is a perspective view showing a configuration of a solar cell module. FIG. 2 is a local cross-sectional view of the outer peripheral edge of the solar cell module. As shown in FIGS. 1 and 2, the solar cell module 1 includes a solar cell module main body 10, a frame body 20, and an end surface sealing material 30.

  The solar cell module body 10 includes a light-transmitting substrate 11, a sealing resin layer 12 (sealing layer), a solar cell 13, a back film 14, a terminal box 15, and a cable 16. Consists of.

  The substrate 11 is a transparent plate-like body, and for example, plate-like glass is used. The thickness of the substrate 11 is not particularly limited. The substrate 11 is chamfered (see FIGS. 5A to 14). The chamfering process will be described in detail later.

  On the substrate 11, a sealing resin layer 12, a solar battery cell 13 sealed with the sealing resin layer 12, and a back film 14 provided on the sealing resin layer 12 are disposed. .

  The sealing resin layer 12 is a transparent filler that fills the space between the substrate 11 and the back film 14. The first sealing resin layer 12 a and the second sealing resin layer that are sealed with the solar battery cell 13 interposed therebetween. 12b. In the present embodiment, EVA (ethylene vinyl acetate copolymer resin) is used for the first sealing resin layer 12a and the second sealing resin layer 12b. However, the present invention is not limited to this. The first sealing resin layer 12a and the second sealing resin layer 12b may use other materials (for example, a polyolefin resin or other transparent resin material).

  Although the solar cell 13 is not specifically limited, For example, the compound semiconductor solar cell using materials, such as GaAs type | system | group, Cu-In-Se type | system | group (CIS), Cu-In-Ga-Se type | system | group (CIGS), and CdTe type | system | group. A cell, a crystalline or thin film silicon solar cell, a dye-sensitized solar cell, or the like can be used. The solar battery cell 13 may be one solar battery cell or a plurality of electrically connected solar battery cells.

  The terminal box 15 is an output interface for taking out the output of the solar cell module body 10 and outputting it to the outside through the cable 16. The terminal box 15 is attached to the back surface 10a of the solar cell module body 10 (that is, the surface opposite to the light receiving surface 10b of the solar cell module body 10).

  The frame body 20 is a frame-like member that is fitted and attached to the outer peripheral edge of the solar cell module body 10 via the end surface sealing material 30. The frame 20 is formed, for example using aluminum, so that the cross-sectional shape becomes a frame shape by extrusion.

  The end surface sealing material 30 is a band-shaped sealing member having a width of 25 mm, for example. The end surface sealing material 30 is attached to the outer peripheral end face 10c of the outer peripheral edge of the solar cell module main body 10 along all the outer peripheral edges of the solar cell module main body 10, and the outer peripheral edge of the solar cell module main body 10 and the frame body. 20 is provided. In the present embodiment, EPT SEALER (registered trademark) is used for the end surface sealing material 30, but the present invention is not limited to this, and the end surface sealing material 30 is made of other flexible foam or elastic resin such as butyl rubber. A material or the like may be used.

  In addition, after the end surface sealing material 30 is attached to the outer peripheral end surface 10 c of the outer peripheral edge of the solar cell module main body 10, when the frame body 20 is fitted into the outer peripheral edge of the solar cell module main body 10, the solar cell module main body 10. The outer peripheral edge of the solar cell module 10 and the frame 20 are deformed so that the cross-sectional shape in the width direction becomes a U-shape, and the area in the vicinity of the outer peripheral edge on the back surface 10a side of the solar cell module body 10 and The region and the outer peripheral end face 10c are covered.

  Further, an adhesive layer is provided on the surface of the end surface sealing material 30 on the side in contact with the outer peripheral edge of the solar cell module body 10. With this adhesive layer, the end surface sealing material 30 is bonded to the outer peripheral edge of the solar cell module body 10, and the region near the outer peripheral edge of the back surface 10a of the solar cell module body 10, the region near the outer peripheral edge of the light receiving surface 10b, The outer peripheral end face 10c is covered and sealed. The end surface sealing material 30 only needs to seal at least the outer peripheral end surface 10c (particularly, the end surface of the outer peripheral edge of the sealing resin layer 12 exposed to the outside of the solar cell module body 10). If it carries out like this, the end surface sealing material 30 will prevent the penetration | invasion of the water | moisture content (for example, water and water vapor | steam) into the inside (especially sealing resin layer 12) of the solar cell module main body 10, and inside the frame 20 It is possible to prevent moisture from entering from the light receiving surface 10b side of the solar cell module body 10 to the back surface 10a side.

The solar cell module 1 is often placed in an environment exposed to direct sunlight or wind and rain. Therefore, when the end surface sealing material 30 protrudes from the frame 20, the end surface sealing material 30 may be locally exposed to sunlight or the like so that deterioration of the end surface sealing material 30 may be locally accelerated. As a result, a problem may occur in the weather resistance of the solar cell module 1. Moreover, when the end surface sealing material 30 protrudes from the frame body 20, it does not look good and is visually unfavorable as a stain on the appearance. Therefore, in this embodiment, as shown in FIGS. 1 and 2, the end surface sealing member 30 is provided so as not to protrude from the frame body 20. By so doing, the end face sealing material 30 is not directly exposed to direct sunlight or wind and rain, and therefore, local deterioration of the end face sealing material 30 can be prevented from being accelerated. Therefore, the weather resistance of the solar cell module 1 can be easily maintained, and the appearance of the solar cell module 1 can be improved.
<Method for manufacturing solar cell module>

  Next, the manufacturing process of the solar cell module 1 will be described.

  First, the first sealing resin layer 12a, the solar battery cell 13, the second sealing resin layer 12b, and the back film 14 are sequentially stacked on the substrate 11 and then subjected to a heating / pressurizing process. The substrate 11 and the solar battery cell 13 are bonded by the first sealing resin layer 12a, and the solar battery cell 13 and the back film 14 are bonded by the second sealing resin layer 12b. At this time, the solar battery cell 13 is further sealed by adhesion of the first sealing resin layer 12a and the second sealing resin layer 12b. In this way, the solar cell module main body 10 can be obtained. As another example of the solar cell module body 10, for example, when a thin-film silicon solar cell is used as the solar cell 13, the sealing resin layer 12 is only the first sealing resin layer 12b. This is because the solar battery cell 13 is directly formed on the substrate 11.

  A band-shaped end surface sealing material 30 is attached to the outer peripheral end surface 10 c of the outer peripheral edge of the obtained solar cell module body 10. FIG. 3 is a perspective view for explaining a process of attaching an end face sealing material to the outer peripheral end face of the solar cell module main body. As shown in FIG. 3, the solar cell module body 10 is attached to a mounting base (not shown) in a state where the substantially normal direction of the light receiving surface 10 b of the solar cell module body 10 is directed vertically downward. At this time, the outer peripheral end surface 10c of the solar cell module body 10 is substantially parallel to the vertical direction. And after adhering one end of the strip | belt-shaped end surface sealing material 30 to the outer peripheral end surface 10c, the end surface sealing material 30 is attached to the outer peripheral end surface 10c along all the outer periphery of the solar cell module main body 10. FIG. At this time, the end surface sealing material 30 is attached with a predetermined tension (for example, 2.5 to 3.0 N · m) being applied, with a substantially normal direction z passing through a substantially central portion of the light receiving surface 10b as a center. It is done.

  FIG. 4 is a top view for explaining a state in which an end surface sealing material is attached to the outer peripheral end surface of the solar cell module main body. As shown in FIG. 4, a strip-shaped end surface sealing material 30 is attached to the outer peripheral end surface 10 c along all the outer peripheral edges of the solar cell module body 10, and one end in the length direction of the attached end surface sealing material 30 and The other end overlaps with a predetermined length n. In other words, after the end surface sealing material 30 is attached to the outer peripheral end surface 10c by one turn, the end surface sealing material 30 is overlapped with a predetermined length n on one end of the end surface sealing material 30 that is first bonded to the outer peripheral end surface 10c. In this embodiment, this length n is set to 10 to 30 mm. Thus, if the attached end surface sealing material 30 is set so as to overlap the length n, the tolerance of the size of the solar cell module body 10 can be absorbed.

  Moreover, when attaching the end surface sealing material 30 to the outer peripheral end surface 10c, the solar cell module main body 10 may be in a fixed state, or a light receiving surface with a substantially normal direction z passing through a substantially central portion of the light receiving surface 10b as a rotation axis. You may rotate in the surface substantially parallel to 10b.

  Further, the band-shaped end surface sealing material 30 may be attached to the outer peripheral end surface 10c in a state substantially parallel to the outer peripheral end surface 10c (inclination angle θ = 0 °), but with respect to the outer peripheral end surface 10c of the solar cell module body 10. When the end surface sealing material 30 is attached to the outer peripheral end surface 10c in a substantially parallel state, the end surface sealing material 30 may bend vertically downward by its own weight. In this case, the end surface sealing material 30 is bonded to the outer peripheral end surface 10 c at a position away from a preset position on the outer peripheral edge of the solar cell module body 10. Therefore, when the frame body is fitted and attached to the solar cell module main body 10, the end surface sealing material 30 protrudes from the frame body, or the end surface sealing material 30 cannot cover the outer peripheral end surface 10c. Will occur.

  Therefore, it is desirable that the belt-shaped end surface sealing material 30 is attached to the outer peripheral end surface 10c in a state where the belt-shaped end surface sealing material 30 is inclined in the substantially normal direction z of the light receiving surface 10b (tilt angle θ> 0 °). By attaching to the outer peripheral end surface 10c while being inclined in the substantially normal direction z, it is possible to prevent the end surface sealing material 30 attached to the outer peripheral end surface 10c from being bent due to its own weight. Therefore, it is possible to prevent the occurrence of poor attachment as described above.

After the end face sealing material 30 is attached to the outer peripheral end face 10c, the terminal box 15 and the cable 16 are attached on the back film 14, and the frame body 20 is attached to the outer peripheral edge of the solar cell module body 10 via the end face sealing material 30. Is attached.
<Chamfering treatment applied to the substrate>

  The substrate 11 of the solar cell module main body 10 includes all the corners 111 of the planar shape of the substrate 11 viewed from a substantially normal direction of the main surface of the substrate 11 and / or the main surface of the substrate 11 and the substrate 11. A chamfering process (C chamfering process, R chamfering process, etc.) is performed on a ridge angle 115 formed by an end surface of the outer peripheral edge (hereinafter referred to as a substrate end surface 112).

Below, the chamfering process performed to the board | substrate 11 is demonstrated in detail with reference to a comparative example and an Example. First, in order to facilitate understanding of the present invention, a comparative example will be described.
(First comparative example)

  In the first comparative example, the C chamfering process was performed on all the corners 111 of the planar shape of the substrate 11 as viewed from the substantially normal direction of the main surface of the substrate 11. FIG. 5A is a plan view of the substrate of the solar electric module main body according to the first comparative example as viewed from the direction of the normal to the main surface. FIG. 5B is an enlarged perspective view of the vicinity of the corner of the substrate according to the first comparative example. 5A and 5B, the dotted line indicates the shape of the corner 111 before the chamfering process. As shown in FIGS. 5A and 5B, in the first comparative example, from all corners 111 of the planar shape of the substrate 11 viewed from the substantially normal direction of the main surface of the substrate 11, from the apex thereof by C chamfering processing. C chamfered surfaces 113 were formed on all corners 111 by removing a portion including a side having a length Lc = 0.5 to 1.8 mm. The substrate end surface 112 including the C chamfered surface 113 was subjected to a thread chamfering process. As the yarn surface treatment, for example, a 0.3 mm C chamfering process or an R chamfering process having a radius of about 0.3 mm was performed on the substrate 11 having a thickness t = 3.2 mm.

However, in the first comparative example, the area of the C chamfered surface 113 formed by the C chamfering process is relatively small. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10 c of the outer peripheral edge of the solar cell module body 10, the surface of the end surface sealing material 30 is locally pressed with a relatively large pressure by the C chamfered surface 113 of the substrate 11. Is done. Therefore, a tear may occur in the end surface sealing material 30 or the end surface sealing material 30 may be cut off.
(Second comparative example)

  In the second comparative example, the chamfering process was performed on the ridge angle 115 of the substrate 11. FIG. 6 is a local cross-sectional view of the outer peripheral edge of the substrate of the photovoltaic module module body according to the second comparative example. In FIG. 6, a dotted line indicates the shape of the ridge angle 115 before the chamfering process. As shown in FIG. 6, in the second comparative example, for example, two ridge angles 115a and 115b of a substrate 11 having a thickness t = 3.2 mm are provided with a radius rc (for example, rc = greater than half the thickness t of the substrate 11). R chamfering surfaces 116a and 116b were formed by performing an R chamfering process of 2.0 mm). Further, the center of the R chamfering process applied to one ridge angle 115a is the other of the other than the phantom one-dot chain line Tc-Tc indicating the position where the thickness t of the substrate 11 becomes half in the cross section in the thickness direction of the substrate 11. It is in a position ca close to the ridge angle 115b side. The center of the R chamfering process applied to the other ridge angle 115b is at a position cb that is closer to the one ridge angle 115a side than the alternate long and short dash line Tc-Tc.

  However, in the second comparative example, since the R chamfered surfaces 116 a and 116 b formed at the ridge angles 115 a and 115 b are in contact with each other at the substrate end surface 112, a sharp point is formed on the substrate end surface 112. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10 c of the outer peripheral edge of the solar cell module body 10, the surface of the end surface sealing material 30 is locally pressed with a relatively large pressure by the sharp end of the substrate end surface 112. The Therefore, a tear may occur in the end surface sealing material 30 or the end surface sealing material 30 may be cut off.

  The present invention has been made to solve such a problem, and the end surface sealing material is formed on the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module main body 10 by the chamfering treatment applied to the corner portion 111 and the ridge angle 115 of the substrate 11. When 30 is attached, tearing or cutting of the end face sealing material 30 can be prevented. In addition, conditions, such as a specific shape and dimension of this chamfering process, are a method of attaching the end surface sealing material 30 to the outer peripheral end surface 11c of the solar cell module body 10 (end surface). In consideration of the tension and the inclination angle θ of the sealing material 30, it can be obtained, for example, experimentally or by simulation.

Below, the example of the present invention is described in order.
(First embodiment)

  In the first example, the R chamfering process was performed on all corner portions 111 of the planar shape of the substrate 11 as viewed from the direction of the substantially normal line of the main surface of the substrate 11. FIG. 7A is a plan view of the substrate of the solar electric module main body according to the first embodiment when viewed from a direction substantially normal to the main surface. FIG. 7B is an enlarged perspective view of the vicinity of the corner portion of the substrate according to the first embodiment. 7A and 7B, the dotted line indicates the shape of the corner 111 before the chamfering process. As shown in FIGS. 7A and 7B, in the first embodiment, an R chamfered surface 114 is formed by subjecting all corners 111 of the substrate 11 to an R chamfering process with a radius R1 of 2.0 to 3.0 mm, for example. Formed. The substrate end surface 112 including the R chamfered surface 114 was subjected to a thread chamfering process. As the yarn surface treatment, for example, a C chamfering process of about 0.3 mm was performed on the substrate 11 having a thickness t = 3.2 mm, but an R chamfering process having a radius of about 0.3 mm was performed. May be.

In this way, by performing the R chamfering process on all the corners 111 of the substrate 11, the gently curved R chamfering surface 114 can be formed on each corner 111. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module body 10, the R chamfered surface 114 contacts the end surface sealing material 30 in a wider area, so that the R chamfered surface 114 is the end surface. The pressure for pressing the surface of the sealing material 30 is also reduced. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c, the end surface sealing material 30 is suppressed from being locally pressed by a large pressure by the R chamfered surface 114 formed in the corner portion 111, and the end surface It is possible to prevent the sealing material 30 from being cleaved or broken.
(Second embodiment)

  In the second example, all corners 111 of the planar shape of the substrate 11 viewed from the substantially normal direction of the main surface of the substrate 11 were subjected to C-chamfering processing having a size larger than that of the comparative example. FIG. 8A is a plan view of the substrate of the solar electric module main body according to the second embodiment when viewed from the direction of the substantially normal line of the main surface. FIG. 8B is an enlarged perspective view of the vicinity of the corner of the substrate according to the second embodiment. 8A and 8B, the dotted line indicates the shape of the corner 111 before the chamfering process. As shown in FIGS. 8A and 8B, in the second embodiment, for example, a predetermined length L1 = 2.0 to 3 from the apex of each corner 111 from all corners 111 of the substrate 11 by C chamfering processing. By removing a portion including a side of 0.0 mm, a C chamfered surface 113 having a larger area than that of the first comparative example was formed. The substrate end surface 112 including the C chamfered surface 113 was subjected to a thread chamfering process. As this yarn surface treatment, for example, a C chamfering process of about 0.3 mm was performed on the substrate 11 having a thickness of 3.2 mm, but an R chamfering process having a radius of about 0.3 mm was performed. Also good.

  In this way, a large chamfering process (for example, the dimension L1 is 2.0 mm or more) is performed on all the corners 111 of the substrate 11 to form the chamfering surface 113 having a relatively large area on each corner 111. can do. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module body 10, the C chamfered surface 113 formed in the corner portion 111 contacts the end surface sealing material 30 with a relatively wide area. Therefore, the pressure with which the C chamfered surface 113 presses the surface of the end surface sealing material 30 is also reduced. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c, the end surface sealing material 30 is suppressed from being locally pressed by a large pressure by the C chamfered surface 113 formed in the corner portion 111, and the end surface It is possible to prevent the sealing material 30 from being cleaved or broken.

In the second embodiment, the C-chamfering dimension L1 at each corner 111 is exemplified as 2.0 mm or more and 3.0 mm or less, but the dimension L1 is not limited to this numerical range. For example, the dimension L1 at each corner 111 may be equal to or less than ¼ of the shorter side of the two sides forming the corner 111. If it carries out like this, it can prevent that the area | region which seals the photovoltaic cell of a solar cell module becomes small too much. Therefore, it is possible to prevent the conversion efficiency of the solar cell module from being greatly affected.
(Third embodiment)

  In the third embodiment, both of the two ridge angles 115 formed by both main surfaces of the substrate 11 and the substrate end surface 112 were subjected to R chamfering processing with substantially the same radius and center position. FIG. 9 is a local cross-sectional view of the outer peripheral edge of the substrate of the photovoltaic module body according to the third embodiment. In FIG. 9, the dotted line shows the shape of the ridge angle 115 before the R chamfering process.

  As shown in FIG. 9, in the third embodiment, both of the two ridge angles 115a and 115b were subjected to an R chamfering process with a radius r1 that is at least half the thickness t of the substrate 11 (r1 ≧ t / 2). For example, for the substrate 11 having a thickness t = 3.2 mm, the radius c1 of the R chamfering process is set to 4.0 mm. Furthermore, the center of the R chamfering process applied to both the two ridge angles 115a and 115b is a virtual alternate long and short dash line T1-T1 indicating a position where the thickness t of the substrate 11 is halved in the cross section in the thickness direction of the substrate 11. It is in the upper position C1. Others are the same as the first embodiment and the second embodiment.

In this way, an R chamfered surface 116 having a gently curved surface in the thickness direction of the substrate 11 can be formed on the entire substrate end surface 112. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10 c of the outer peripheral edge of the solar cell module body 10, the gently curved R chamfered surface 116 can be brought into contact with the end surface sealing material 30. Therefore, the R chamfered surface 116 formed on the entire substrate end surface 112 suppresses the end surface sealing material 30 from being locally pressed with a large pressure, and prevents the end surface sealing material 30 from being cleaved or broken. Can do.
(Modification of the third embodiment)

  In the third embodiment described above, the R chamfering process with substantially the same radius is performed on the two ridge angles 115a and 115b, but the R chamfering process with different radii may be performed on each of the ridge angles 115a and 115b. FIG. 10 is a local sectional view of the outer peripheral edge of the substrate according to a modification of the third embodiment. In FIG. 10, a dotted line indicates the shape of the ridge angle 115 before the R chamfering process.

As shown in FIG. 10, in the modification of the third embodiment, an R chamfered surface 116a is formed by applying an R chamfering process with a radius r1a to one ridge angle 115a. Further, an R chamfering process with a radius r1b was performed on the other ridge angle 115b to form an R chamfering surface 116b. Further, the radii r1a and r1b were set to be more than half of the thickness t of the substrate 11 (r1a, r1b ≧ t / 2). Here, in FIG. 10, the radius r1a is smaller than the radius r1b. However, the present invention is not limited to this, and the radius r1a may be larger than the radius r1b. Furthermore, the center of the R chamfering process applied to the ridge angle 115a is a position C1a on a virtual one-dot chain line T1-T1 indicating a position where the thickness t of the substrate 11 is halved in the cross section in the thickness direction of the substrate 11. . Similarly, the center of the R chamfering process applied to the ridge angle 115b is set to a position C1b on the virtual one-dot chain line T1-T1. Others are the same as the third embodiment. By so doing, no sharp pointed tip is formed between each of the R chamfered surfaces 116a and 116b, thereby preventing the occurrence of the problem as in the second comparative example.
(Other variations of the third embodiment)

  In the third embodiment described above, the R chamfering process is performed on both of the two ridge angles 115a and 115b, but the R chamfering process may be performed only on one of the ridge angles. FIG. 11 is a local sectional view of the outer peripheral edge of the substrate according to another modification of the third embodiment. In FIG. 11, the dotted line shows the shape of the ridge angle 115a before the R chamfering process. Further, the upper side (surface including the ridge angle 115a) of the substrate 11 is the back surface 10a side, and the lower side (surface including the ridge angle 116a) of the substrate 11 is the light receiving surface 10b side.

  As shown in FIG. 11, in another modification of the third embodiment, of the two ridge angles 115a (first ridge angle) and ridge angle 115b (second ridge angle) formed by both main surfaces of the substrate 11 and the substrate end surface 112. Only one of the ridge angles 115a was subjected to an R chamfering process with a radius r1 that is half or more of the thickness t of the substrate 11 (r1 ≧ t / 2). In this way, an R-chamfered surface 116a having a gently curved surface in the thickness direction of the substrate 11 was formed only at the ridge angle 115a on the back surface 10a side. The center of the R chamfering process applied to the ridge angle 115a is located at a position C1 on a virtual one-dot chain line T1-T1 indicating the position where the thickness t of the substrate 11 is halved in the cross section in the thickness direction of the substrate 11. . Others are the same as the third embodiment.

  In this way, since it is only necessary to perform the R chamfering process on only one of the two ridge angles 115, the solar cell module 1 can be compared with the case of performing the R chamfering process on both of the two ridge angles 115 a and 115 b. The number of manufacturing processes is reduced.

  It should be noted that the substantially normal direction of the light receiving surface 10b of the solar cell module body 10 is directed vertically downward, and the end surface sealing material 30 is inclined in the substantially normal direction of the light receiving surface 10b (for example, an inclination angle θ> 0 ° in FIG. 3). When the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module main body 10 in the state of (1), first, the ridge angle 115a on the back surface 10a side of the solar cell module main body 10 is the end surface sealing material 30. Abut. At this time, in particular, since the ridge angle 115a locally presses the end surface sealing material 30 with a large pressure, a tear may occur in the end surface sealing material 30 or the end surface sealing material 30 may be cut. In such a case, first, the end surface sealing material 30 may be attached to the outer peripheral end surface 10c after the end surface sealing material 30 is brought into contact with the gently curved R chamfered surface 116a. By so doing, the end surface sealing material 30 is prevented from being locally pressed by a large pressure by the gently curved R chamfered surface 116a, so that the end surface sealing material 30 can be more efficiently cleaved and broken. Can be prevented.

  Moreover, the outer periphery of the outer periphery of the solar cell module main body 10 in the state which turned the substantially normal line direction of the back surface 10a of the solar cell module body 10 vertically downward, and inclined the end surface sealing material 30 in the substantially normal direction of the back surface 10a. When the end surface sealing material 30 is attached to the end surface 10c, the same R chamfering process may be performed only on the ridge angle 115b on the light receiving surface 10b side. First, after the end surface sealing material 30 is brought into contact with the gently curved R chamfered surface 116b, the end surface sealing material 30 may be attached to the outer peripheral end surface 10c. In this way, the end surface sealing material 30 is prevented from being locally pressed by a large pressure by the gently curved R chamfered surface 116b, so that the end surface sealing material 30 can be more efficiently cleaved and broken. Can be prevented.

  In the other modified example of the third embodiment described above, the case where the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the solar cell module body 10 while being inclined is described. Another modification of the third embodiment may also be applied when the end surface sealing material 30 is attached without being inclined (for example, with the inclination angle θ = 0 ° in FIG. 3).

Moreover, in the above-mentioned 3rd Example and those modifications, although the R chamfering process was performed to the ridge angle 115 of the board | substrate end surface 112, it may replace with R chamfering process and may perform a C chamfering process.
(Fourth embodiment)

  In the fourth embodiment, both of the two ridge angles 115 of the substrate 11 were subjected to R chamfering processing with substantially the same radius. FIG. 12 is a local cross-sectional view of the outer peripheral edge of the substrate of the solar electric module body according to the fourth embodiment. In FIG. 12, the dotted line indicates the shape of the ridge angle 115 before the R chamfering process.

  As shown in FIG. 12, in the fourth embodiment, both of the two ridge angles 115a and 115b were subjected to an R chamfering process with a radius r2 smaller than half the thickness t of the substrate 11 (r2 <t / 2). . For example, for a substrate 11 having a thickness t = 3.2 mm, the radius c2 of the R chamfering process is set to 1.2 mm. It should be noted that the radius c2 of the R chamfering process applied to each ridge angle 115a and 115b is not necessarily exactly the same because a slight error actually occurs in each R chamfering process. Therefore, the radius r2 of the R chamfering process applied to each ridge angle 115a and 115b may be substantially the same.

  Further, the center of the R chamfering process applied to the ridge angle 115 a is separated from the substrate end surface 112 in the normal direction in the cross section in the thickness direction of the substrate 11 by a distance substantially the same as the radius r 2, and the ridge angle 115 a together with the substrate end surface 112. It is at a position C2a that is substantially the same distance as the radius r2 in the normal direction from the main surface of the substrate 11 to be formed. This position C2a is closer to the ridge angle 115a side than a virtual one-dot chain line T2-T2 indicating a position at which the thickness t of the substrate 11 is halved in the cross section in the thickness direction of the substrate 11. The center of the R chamfering process applied to the ridge angle 115b is at the same position C2b. This position C2b is also closer to the ridge angle 115b side than the virtual one-dot chain line T2-T2 in the cross section in the thickness direction of the substrate 11. Others are the same as the first embodiment and the second embodiment.

By doing so, it is possible to form the R chamfered surfaces 116 a and 116 b having gentle curved surfaces in the thickness direction of the substrate 11 at the two ridge angles 115 a and 115 b. Therefore, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module body 10, the end surface sealing material 30 abuts the substrate end surface 112 including the gently curved R chamfered surfaces 116a and 116b. Can be touched. Therefore, since it can suppress that the end surface sealing material 30 is pressed locally with a big pressure, the tearing and the fracture | rupture of the end surface sealing material 30 can be prevented.
(Modification of the fourth embodiment)

  In the fourth embodiment described above, the same R chamfering process is performed on both the two ridge angles 115a and 115b. However, the two ridge angles 115a and 115b may be subjected to R chamfering processes having different radii. FIG. 13 is a local sectional view of the outer periphery of the substrate according to a modification of the fourth embodiment. In FIG. 13, a dotted line indicates the shape of the ridge angle 115 before the R chamfering process. The upper side of the substrate 11 is the back surface 10a side, and the lower side of the substrate 11 is the light receiving surface 10b side.

  As shown in FIG. 13, in the modification of the fourth embodiment, one ridge angle 115a (first ridge angle) on the back surface 10a side is subjected to an R chamfering process with a radius r2a, and the other ridge angle 115b (first ridge angle on the light receiving surface 10b side). R chamfering treatment with a radius r2b was performed at (2 ridge angles). The radii r2a and r2b are smaller than half the thickness t of the substrate 11 (r2a, r2b <t / 2). In FIG. 13, the radius r2a is larger than the radius r2b. However, the present invention is not limited to this, and the radius r2a may be smaller than the radius r2b.

Further, the center of the R chamfering process applied to the ridge angle 115a is substantially the same distance as the radius r2a in the normal direction from the substrate end surface 112 in the cross section in the thickness direction of the substrate 11, and the ridge angle 115a is set together with the substrate end surface 112. It is at a position C2a that is substantially the same distance as the radius r2a in the normal direction from the main surface (back surface 10a) of the substrate 11 to be formed. This position C2a is closer to the ridge angle 115a side than a virtual one-dot chain line T2-T2 indicating a position at which the thickness t of the substrate 11 is halved in the cross section in the thickness direction of the substrate 11. Further, the center of the R chamfering process applied to the ridge angle 115b is separated from the substrate end surface 112 in the normal direction in the cross section in the thickness direction of the substrate 11 by a distance substantially the same as the radius r2b, and the ridge angle 115b is set together with the substrate end surface 112. It is at a position C2b that is substantially the same distance as the radius r2b in the normal direction from the main surface (light receiving surface 10b) of the substrate 11 to be formed. This position C2b is also closer to the ridge angle 115b side than the virtual one-dot chain line T2-T2 in the cross section in the thickness direction of the substrate 11. Others are the same as the fourth embodiment. By so doing, no sharp pointed tip is formed between each of the R chamfered surfaces 116a and 116b, thereby preventing the occurrence of the problem as in the second comparative example.
(Other variations of the fourth embodiment)

  In the fourth embodiment described above, the R chamfering process is performed on both of the two ridge angles 115a and 115b. However, the R chamfering process may be performed only on one of the ridge angles. FIG. 14 is a local sectional view of the outer peripheral edge of the substrate according to another modification of the fourth embodiment. In FIG. 14, a dotted line indicates the shape of the ridge angle 115 before the R chamfering process. The upper side of the substrate 11 is the back surface 10a side, and the lower side of the substrate 11 is the light receiving surface 10b side.

  As shown in FIG. 14, in another modification of the fourth embodiment, the thickness of the substrate 11 is only at one ridge angle 115a of the two ridge angles 115a (first ridge angle) and ridge angle 115b (second ridge angle). An R chamfering process with a radius r2 smaller than half of t was performed (r2 <t / 2). In this way, an R-chamfered surface 116a having a gently curved surface in the thickness direction of the substrate 11 was formed only at the ridge angle 115a on the back surface 10a side. Note that the center of the R chamfering process applied to the ridge angle 115a is substantially the same distance as the radius r2 from the substrate end surface 112 in the normal direction in the cross section in the thickness direction of the substrate 11, and the ridge angle 115a together with the substrate end surface 112 is the same. It is at a position C2a that is substantially the same distance as the radius r2 in the normal direction from the main surface of the substrate 11 to be formed. Others are the same as the fourth embodiment.

  In this way, since it is only necessary to perform the R chamfering process on only one of the two ridge angles 115, the solar cell module 1 can be compared with the case of performing the R chamfering process on both of the two ridge angles 115 a and 115 b. The number of manufacturing processes is reduced.

  Further, the outer peripheral edge of the solar cell module body 10 with the end surface sealing material 30 tilted in the substantially normal direction of the light receiving surface 10b with the substantially normal direction of the light receiving surface 10b of the solar cell module body 10 directed vertically downward. When the end surface sealing material 30 is attached to the outer peripheral end surface 10c, the end surface sealing material 30 is first brought into contact with the gently curved R-chamfered surface 116a, and then the end surface sealing material 30 is attached to the outer peripheral end surface 10c. That's fine. By so doing, the end surface sealing material 30 is prevented from being locally pressed by a large pressure by the gently curved R chamfered surface 116a, so that the end surface sealing material 30 can be more efficiently cleaved and broken. Can be prevented.

  Moreover, the outer periphery of the outer periphery of the solar cell module main body 10 in the state which turned the substantially normal line direction of the back surface 10a of the solar cell module body 10 vertically downward, and inclined the end surface sealing material 30 in the substantially normal direction of the back surface 10a. When the end surface sealing material 30 is attached to the end surface 10c, the same R chamfering process may be performed only on the ridge angle 115b on the light receiving surface 10b side. Even if it does in this way, the above effects can be obtained similarly.

  In addition, in the other modification of 4th Embodiment, although the case where it attached to the outer peripheral end surface 10c of the solar cell module main body 10 in the state which inclined the end surface sealing material 30 was demonstrated, it is attached to the outer peripheral end surface 10c of the solar cell module main body 10. Another modification of the fourth embodiment may also be applied when the end surface sealing material 30 is attached without being inclined (for example, with the inclination angle θ = 0 ° in FIG. 3).

  Moreover, in the above-mentioned 4th Example and those modifications, although the R chamfering process was performed to the ridge angle 115 of the board | substrate end surface 112, it may replace with an R chamfering process and a C chamfering process may be performed.

  In the solar cell module 1 of the above-described embodiment, the light-transmitting substrate 11, the sealing layer (sealing resin layer 12) provided on the substrate 11, and the solar cell sealed by the sealing layer. A solar cell module main body 10 having cells 13 and a band-shaped end surface sealing material 30 for sealing the outer peripheral end surface 111 of the solar cell module main body 10, and the end surface sealing material 30 on the outer peripheral end surface 10 c. In the solar cell module 1 to which the main surface of the substrate 11 is attached, all corner portions 111 of the planar shape viewed from a substantially normal direction of the main surface of the substrate 11 and / or the main surface of the substrate 11 and the substrate end surface 112 are formed. When chamfering processing (for example, C chamfering processing or R chamfering processing) is performed on the ridge angle 115 and the end surface sealing material 30 is attached to the outer peripheral end surface 10c by this chamfering processing, It is possible to prevent the cutting.

  As described above, when the end surface sealing material 30 is attached to the outer peripheral end surface 10c of the outer peripheral edge of the solar cell module body 10 by performing the chamfering process on all the corner portions 111 and / or the ridge angles 115 of the substrate 11, the corner portion The chamfered surface (for example, the C chamfered surface 113 and the R chamfered surfaces 114 and 116) formed at the ridge angle 115 and / or the ridge angle 115 suppresses the end surface sealing material 30 from being locally pressed with a large pressure, thereby sealing the end surface. It is possible to prevent tearing and cutting of the stopper.

  The present invention has been described based on the embodiments. This embodiment is an exemplification, and it is understood by those skilled in the art that various modifications can be made to each component and combination of processes, and are within the scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Solar cell module 10 Solar cell module main body 10a Back surface 10b Light-receiving surface 10c Outer peripheral end surface 11 Substrate 111 Corner | angular part 112 Substrate end surface 113 C chamfered surface 114, 116 R chamfered surface 115 Edge angle 12 Sealing resin layer (sealing layer)
12a 1st sealing resin layer 12b 2nd sealing resin layer 13 Solar cell 14 Back film 15 Terminal box 16 Cable 20 Frame 30 End face sealing material

Claims (8)

A solar cell module body having a light-transmitting substrate, a sealing layer provided on the substrate, a solar cell sealed by the sealing layer, and a back film; and In a solar cell module comprising a band-shaped end surface sealing material that seals the outer peripheral end surface,
All corners of the planar shape seen from the substantially normal direction of the main surface of the substrate, and / or ridge angle formed by the main surface of the substrate and the substrate end surface, chamfering is performed,
The solar cell module, wherein when the end surface sealing material is attached to the outer peripheral end surface by the chamfering process, the end surface sealing material can be prevented from being cleaved or cut.   The solar cell module according to claim 1, wherein an R chamfering process is performed on all the corners. C corner chamfering is applied to all the corners,
From all the corners, the C chamfering process removes a part including a side having a predetermined length from the apex of each corner,
The predetermined length at each corner is not less than 2.0 mm and not more than 1/4 of the shorter one of the two sides forming the corner. Item 2. The solar cell module according to Item 1.   The solar cell module according to claim 3, wherein the predetermined length is 2.0 mm or more and 3.0 mm or less. R chamfering treatment is applied to the ridge angle,
The radius of the R chamfering process is more than half of the thickness of the substrate,
5. The sun according to claim 1, wherein the center of the R chamfering process is on an imaginary line in which the thickness of the substrate is halved in a cross section in the thickness direction of the substrate. Battery module. R chamfering treatment is applied to the ridge angle,
The radius of the R chamfering process is smaller than half of the thickness of the substrate,
The center of the R chamfering process is the substrate that is substantially the same distance as the radius from the substrate end surface in the normal direction of the substrate end surface, and forms the ridge angle with the substrate end surface in the cross section in the thickness direction of the substrate. The solar cell module according to any one of claims 1 to 4, wherein the solar cell module is located at a position that is substantially the same distance as the radius in the normal direction of the main surface from the main surface.   7. The sun according to claim 5, wherein an R chamfering process is performed only on one of the first ridge angle and the second ridge angle formed by both main surfaces of the substrate and the substrate end surface. Battery module.   7. The solar cell module according to claim 5, wherein R chamfering processing with different radii is performed on a first ridge angle and a second ridge angle formed by both main surfaces of the substrate and a substrate end surface.

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