JP3099202B2 - Method for manufacturing flexible lightweight solar cell module - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a solar cell module formed by laminating a connection body of a solar cell wafer with a synthetic resin sheet or the like, and particularly to a method for manufacturing a solar cell module having flexibility. In addition, a lightweight material can be obtained under heating and pressure using a laminating apparatus.

[0002]

2. Description of the Related Art A conventional solar cell module is manufactured by using a laminated apparatus (Japanese Patent Publication No. 1-49117) as described below and using a tempered glass on a surface side for receiving sunlight. A heavy thing such as about 6 kg as a whole is often used, and of course, because it has little flexibility, labor must be spent on handling it. In addition, a special auxiliary member or the like is required for the mounting, and the mounting work also requires considerable time and labor.

[0003] That is, various types of laminating apparatuses used for manufacturing the above-mentioned conventional solar cell modules are known . In the apparatus illustrated in FIG. 3 , an upper chamber a and a lower chamber b are connected to each other. Sandwich the diaphragm c between
The mounting plate d provided in the lower chamber b is made heat-exchangeable by the heating / cooling unit f provided in the lower space e, and the mounting plate d includes a solar cell wafer to be processed on the mounting plate d. The stacked body g of the processed sheet is placed.

Next, the cock h is opened and the inside of the upper chamber a is evacuated to a negative pressure by the vacuum pump i.
The stack g is heated by heating the mounting plate d.
Further, by making the lower chamber b a negative pressure by opening the cock j,
After air bubbles generated from the laminate g are discharged to the outside, the cock k
To open the upper chamber a to atmospheric pressure, thereby pressing the diaphragm c against the laminate g as shown in the figure. If the mounting plate d was cooled by heating and cooling unit f after a desired time, cock
The lower chamber b is set to the atmospheric pressure by opening the clamp 1, whereby the upper chamber a and the lower chamber b are separated, and the processed solar cell module is taken out.

On the other hand, in the laminating apparatus shown in FIG. 4, an electric heating element m is embedded in a diaphragm c instead of using a heating / cooling section f for heating a laminated body g. By doing so, heat conduction is performed when the diaphragm c is pressed, and further, in order to finally cool the laminated body g, the cock k is opened and the air is supplied above the air supply unit n by a compressor or a blower. Outside air is sent into the chamber a, and cocks l and j are opened into the lower chamber b to operate the vacuum pump i so that the outside air flows into the lower chamber b.

[0006] By using the laminating apparatus as described above,
Up to the solar cell module manufacturing method
The stacked body g mounted on the mounting plate d is as follows.
It is structured like this. That is, as shown in FIG.
What is directly mounted on the mounting plate d is the solar cell module.
This is a glass plate o that is a member, which is used in actual use.
Used as the top surface to receive sunlight etc.AndLamine
When processingIsThe thickness of the substrate is 2mm
Are used, and on the upper surface side
Ethylene vinyl with a thickness of about 800 μmRuacetate
(EVA) adhesive sealing material lower layer p, solar cell wafer q
Is formed of the same material as the connection body r connecting the
The upper layer of the adhesive sealing material s, and white fluororesin 2
The back material layer t having a thickness of about 00 μm is laminated.

[0007] The laminate g constructed as described above is
By operating the above-described laminating apparatus, pressure is applied while heating, whereby the wire r is embedded in the adhesive sealing material upper layer s and the adhesive sealing material lower layer p, and the laminate g
Are integrally laminated and fixed, and this is cooled to obtain a solar cell module.

[0008]

As described above, the conventional solar cell module is manufactured . Since the glass plate o is used, the heating efficiency due to heat conduction from the mounting plate d is poor, and the laminated body g In order to prevent the solar cell wafer or the like from being damaged when pressing, the adhesive sealing material upper layer s and the adhesive sealing material lower layer p are each formed to a thickness of about 800 μm to serve as a cushion material. Fulfilled
As a result, not only does the overall thickness of the product including the glass plate o become large, but also the weight becomes considerably large and undeformable. It cannot be used by sticking on curved surfaces such as cars and airplanes.

The present invention has been made in view of the above-mentioned conventional problems. As a constituent member of a laminated body to be heated and pressed by a laminating apparatus, a flat plate made of an aluminum plate or the like and a cushion placed thereon are newly provided. The solar cell wafer is damaged even if the thickness of the adhesive sealing material upper layer and the adhesive sealing material lower layer is reduced due to the provision of the cushioning material layer by adding the material layer and the release material layer to be stacked further in place. so never be, and release material the said flat plate and cushioning material layer or the like via the I want to peeling, is possible not to use as a product, if not a glass plate thinner lightweight flexible It is an object of the present invention to be able to efficiently produce a solar cell module which is highly efficient and can be used by being attached to a curved surface of an automobile roof.

[0010]

Since the present invention SUMMARY OF] is to achieve the above object, in the inside heating chamber of the laminator, sequentially flat on its table, cushion material layer by Echirenbini Le acetate, etc., fluororesins separation material layer by an equal, backsheet layer by a white fluororesins, Echirenbini Ruasete
G , lower layer of adhesive sealing material by polyvinyl butyral, etc.
A solar cell connection body that connects the required number of solar cell wafers,
By laminating the adhesive sealing material upper layer of the same material as the adhesive sealing material lower layer, and the light-transmitting material layer of a fluororesin material or the like, a laminate of a sheet to be processed including a solar cell connection body is formed. By applying pressure while heating with the above-described laminating apparatus, the connection body of the solar cell is embedded in the above-mentioned adhesive sealing material upper layer and the adhesive sealing material lower layer, and the laminated body is integrally laminated and fixed. An object of the present invention is to provide a method for manufacturing a flexible lightweight solar cell module characterized by the above.

[0011]

The laminated body of the sheet to be processed including the connection body of the solar cell is subjected to pressure under heating by using a flat plate such as an iron plate or an aluminum plate placed on the mounting plate in the laminating apparatus as a lower substrate. since a is uniform laminate <br/> Nate processing RinikuAtsu by the the pressing guarantee, since the cushion material layer is disposed thereon, the buffering action is exhibited even when subjected to pressing Therefore, there is no problem that the solar cell wafer or the like is damaged, so that the upper and lower layers of the adhesive sealing material can be formed sufficiently thin, and the product can be finished thin.

Further, the solar cell module is used only in the upper layer portion obtained by peeling from the release material layer, and the lower layer portion such as a flat plate, a cushion material layer and a release material layer is not used. Thus, a flexible and lightweight solar cell module can be obtained, and a solar cell module that can be freely attached to a curved surface or the like and used can be manufactured .

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to FIG. 1. In the above-described laminating apparatus 1, a laminate 2 is placed on a placing table 3 in a heating and pressurizing chamber 1a, and this is placed under heating conditions. It becomes a pressurizing there, the laminate 2 of the heavy loading following如Ku
I'm sorry .

In the conventional example, a glass plate is used as a substrate for lamination. However, in the present invention, a flat plate 4 made of an iron plate, an aluminum plate, or the like is separately laid on the lowermost layer instead of a constituent member of the solar cell module. A relatively thick cushion material layer 5 of EVA or the like having a thickness of about 600 μm is laminated thereon, and a relatively thick release material layer 6 of a fluororesin or the like is further placed thereon. a back sheet layer 7 which was 50μm thick about by white fluororesin or the like, a cushion material layer 5 described above to order not glued, or, after the processing by the laminating apparatus 1, from time to time the separation material layer 6 Also, the upper solar cell module is made detachable .

The properties required for the backing material layer 7 include (1) an electric breakdown voltage of 2000 V DC or more, (2) extremely low water vapor permeability, and (3) long-term reliability. It is excellent, and (3) it is flexible, but the above-mentioned white fluororesin sufficiently satisfies such properties.

Next, on the upper side of the back material layer 7, the conventional 80
EVA, PV thinned to about 200 μm thick compared to 0 μm
B between the adhesive sealing material lower layer 8a of B and the adhesive sealing material upper layer 8b of the same material and the same thickness, and the required number of solar cell wafers 9a are connected to each other.
In a sandwich state, a light-transmitting material layer 10 made of a fluororesin or the like that transmits sunlight or the like is stacked on the upper surface of the adhesive sealing material upper layer 8b with a thickness of about 50 μm.

Here, the properties required for the above-mentioned light-transmitting material layer 10 are as follows: (1) 90% at a wavelength of 400 to 1100 mm.
%, Excellent weather resistance over a long period of time, (3) dust is difficult to adhere,
(4) Extremely low water vapor permeability, (5) Good electrical insulation resistance, (6) Stiffness as a structural support, etc. It is glass. However, when this is used as a component of a solar cell module, it is desirable to use a fluororesin that also has flexibility since the module itself cannot have flexibility.

The laminate 2 obtained by stacking as described above is pressed on the mounting table 3 of the laminating apparatus 1 under heating conditions in the same manner as in the above-mentioned conventional example, so that the above-mentioned adhesive sealing is performed. When the material upper layer 8b and the adhesive sealing material lower layer 8a bury the connection body 9 of the solar cell, the adhesive sealing material filling layer 8 as shown in FIG. 2 is finally formed. Here, the properties required as the above-mentioned filling material are (1) that the transmittance of sunlight is high, (2) that there is no change in physical properties such as a decrease in light transmittance even when left outdoors for a long time, (3) High electrical insulation and does not corrode other materials. (4) Damage to the solar cell wafer due to a sudden change in outside air conditions, and no cracking or interface peeling. Examples of those having a silicone resin, polyurethane, EVA, PVB and the like,
EVA is considered to be good in terms of cost. In FIG.
Reference numeral 11 denotes a curved surface in a car or the like.

[0019]

Since the present invention can be carried out as described above, the laminating process is stabilized by using a flat plate, and a uniform thick product can be obtained. Without damaging the wafer etc.
In addition, since the upper and lower layers of the adhesive sealing material can be made thin, the thickness of the entire product can be reduced.

Further, since the separation material layer are interposed in place, the solar cell module in use, a flat plate and cushions
It can be peeled from the lower side member by the material layer , and the peeled material is lightweight because it does not use a glass plate etc., and it has flexibility, and it can be easily applied to curved surfaces of automobiles etc. It can be used by sticking.

The conventional solar cell module has a capacity of about 6000 g in comparison with a conventional product having a capacity of about 6000 g, and can be manufactured in about 500 g to reduce the weight by about 1/10. It was also confirmed that the solar cell wafer could be stuck on a surface having a curvature of about 500 mm without damage to the solar cell wafer.

[Brief description of the drawings]

FIG. 1 is a vertical cross-sectional front view showing a laminated body placed in a laminating apparatus for manufacturing a flexible lightweight solar cell module according to the present invention.

FIG. 2 is a vertical sectional front view of a solar cell module separated from a product obtained by heating and pressing the laminate of FIG. 1;

FIG. 3 is a longitudinal sectional front view showing an example of a laminating apparatus.

FIG. 4 is a longitudinal sectional front view showing another example of the laminating apparatus.

FIG. 5 is a vertical sectional front view of the laminate shown in FIGS. 3 and 4;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Laminating apparatus 1a Heating and pressurizing chamber 2 Laminated body 3 Mounting table 4 Flat plate 5 Cushion material layer 6 Release material layer 7 Back material layer 8a Adhesive sealing material lower layer 8b Adhesive sealing material upper layer 9 Solar cell connection body 9a Solar cell wafer 10 Translucent material layer

Continuation of the front page (56) References JP-A-61-47259 (JP, A) JP-A-63-147375 (JP, A) JP-A-58-56369 (JP, A) Real opening 60-90848 (JP, A) , U) (58) Field surveyed (Int.Cl. ⁷ , DB name) H01L 31/04-31/078

Claims (1)

(57) [Claims] 1. A be within heating chamber of the laminator, sequentially flat on its table, cushion material layer by Echirenbini Le acetate, etc., the separation material layer with fluorine resin or the like, backsheet layer by a white fluororesins, Echirenbini Ruasete
G , lower layer of adhesive sealing material by polyvinyl butyral, etc.
A solar cell connection body that connects the required number of solar cell wafers,
By laminating the adhesive sealing material upper layer of the same material as the adhesive sealing material lower layer, and the light-transmitting material layer of a fluororesin material or the like, a laminate of a sheet to be processed including a solar cell connection body is formed. By applying pressure while heating with the above-described laminating apparatus, the connection body of the solar cell is embedded in the above-mentioned adhesive sealing material upper layer and the adhesive sealing material lower layer, and the laminated body is integrally laminated and fixed. A method for manufacturing a flexible lightweight solar cell module, comprising: