JP3571531B2 - Solar cell module and method of manufacturing the same - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a solar cell module having solar cells, and more particularly to a waterproof structure thereof.
[0002]
[Prior art]
BACKGROUND ART Conventionally, a power solar cell module having a plurality of solar cells has been widely used. Since a solar cell module for electric power is usually installed on a roof of a house, a wall surface of a building, or the like, sufficient waterproofness is required.
[0003]
For example, JP-A-62-122181 and JP-A-61-34752 propose a waterproof structure for a solar cell module. In the solar cell module described in the former publication, as shown in FIG. 19, a light receiving surface glass 63 is laminated on a surface of a pottant 62 having a solar cell 61 embedded therein, and a water-repellent back plate 64 is provided on the back surface of the pottant 62. Are laminated, and a moisture blocking material 65 is filled in a peripheral space between the light receiving surface glass 63 and the water repellent back plate 64.
[0004]
Further, in the solar cell module described in the latter publication, as shown in FIG. 20, a panel 68 incorporating a solar cell 67 is sandwiched between two plate members 66, and between the inner peripheral portions of the plate members 66. The periphery of the panel 68 is sealed with a butyl rubber 69 interposed therebetween, and the outside thereof is covered with a sealant 70.
[0005]
[Problems to be solved by the invention]
However, in order to install these solar cell modules on a roof or the like, it is necessary to attach a frame for supporting the module to a peripheral edge of a panel or the like. Since the frame body is generally configured by combining a plurality of frames, a water-proof structure for preventing water from entering from abutting surfaces between the frames is required.
[0006]
FIGS. 21 and 22 are diagrams illustrating an example of the waterproof structure at the abutting surface between the frames. In this solar cell module, waterproofing is performed by applying a silicone resin 73 or the like to the butted portion between the frames 71 and 72 constituting the frame and the screwed portion. In addition, in the figure, 74 is a sealing body which sealed the solar cell.
[0007]
However, in a solar cell module manufactured on the condition that it is installed on a roof or the like, in many cases, waterproofing only by applying a silicone resin or the like is not sufficient. In addition, there is a problem that it takes time and effort to apply a silicone resin or the like in manufacturing a solar cell module, and lacks mass productivity.
[0008]
In view of the above problems, an object of the present invention is to provide a solar cell module that can reliably perform waterproofing between abutting surfaces of frames that form a frame and that can enhance mass productivity.
[0009]
[Means for Solving the Problems]
Means for Solving the Problems According to the present invention, in a solar battery module in which a frame for protecting the sealed body is attached to the periphery of the sealed body for sealing the solar cell, the frame is formed by combining a plurality of frames. A waterproof sealing material is interposed between the butting surfaces of the opposing frames. With this sealing material, it is possible to prevent infiltration of water or moisture into the sealing body from between the butting surfaces of the frames.
[0010]
The seal material is made of rubber, and is attached or baked on the abutting surface of the frame. In particular, the workability is improved by baking the sealing material, as compared with the case of sticking.
[0011]
The butting surfaces of the frames are inclined to fit each other. Thus, the frames can be abutted with an appropriate degree of adhesion, and the sealing material can be reliably brought into close contact with each frame.
[0012]
Further, the butting surface of the frame may be a composite surface including two or more types of surfaces including an inclined surface. This makes it possible to eliminate a sharp portion on the tip end side even on an inclined surface, so that it is safe for an operator to handle the frame.
[0013]
The frames are combined by being fastened by screws, and a rubber washer is arranged between the screw head of the screws and the frame. With this washer, it is possible to prevent water from entering between the screw and the frame.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. FIG. 2 is an external perspective view of the solar cell module according to one embodiment of the present invention. In this solar cell module, a sealing body 2 sealing a solar cell 1 is formed, and a frame 3 for protecting the sealing body 2 is attached to a periphery of the sealing body 2. As shown in FIG. 1, the frame body 3 is formed by combining four frames by tightening them with screws 4, and a sealing material 5 is interposed between the butting surfaces of the opposing frames.
[0015]
As shown in FIG. 3, the sealing body 2 is formed by laminating a filler 7, a plurality of solar cells 1, and a weather-resistant backside protective film 8 on a translucent substrate 6 made of a white plate reinforced glass or the like. It is formed by pressurizing and heating by the like. Each solar cell 1 is electrically connected in series or in parallel by an interconnector 9. Note that the sealing body 2 may be a so-called integrated sealing body in which a transparent electrode, a photoelectric conversion portion made of amorphous silicon, and a back electrode are formed and formed on a glass plate and sealed with a filler or the like. .
[0016]
According to FIG. 2, the frame 3 includes a pair of opposed long frames 10 and a pair of opposed short frames 11 shorter than the long frame 10. The long frame 10 is formed by extruding a metal such as aluminum, and has a substantially rectangular parallelepiped main body 12 formed in a horizontally long shape as shown in FIG. The main body 12 has a hollow structure with both ends open, and a vertical surface 13 orthogonal to the longitudinal direction is formed at both ends, and an inclined surface 14 is integrally formed from the vertical surface 13. The inclined surface 14 is inclined at 45 ° with respect to the vertical surface 13. The composite surface composed of the vertical surface 13 and the inclined surface 14 serves as an abutting surface with the short frame 11.
[0017]
At the upper part of the main body 12, a support portion 15 formed to have a substantially U-shape in a side view and for holding and supporting the sealing body 2 along the longitudinal direction is formed. At the lower part of the main body 12, a mounting surface portion 16 extending from the bottom surface of the main body 12 is formed. The mounting surface portion 16 is provided for installation on a roof or the like. The mounting surface portion 16 has a plurality of through holes 17 for bolts for mounting the main body 12 on the roof or the like. A gutter 18 is formed on the outer side surface of the main body 12 along the longitudinal direction. On the inner wall surfaces at both ends of the main body 12, screwing pieces 19 are formed as mounting portions into which the screws 4 for fixing the short frame 11 to the long frame 10 are screwed. The inclined surface 14 is formed not only by inclining the main body 12 but also inclining so as to be flush with the support portion 15 and the mounting surface portion 16.
[0018]
Like the long frame 10, the short frame 11 is formed by extruding a metal such as aluminum, and as shown in FIG. 5, has a substantially rectangular parallelepiped main body 20 formed horizontally. The main body 20 has a hollow structure with both ends open, and inclined surfaces 21 at 45 ° to the longitudinal direction are formed at both ends of the main body 20. An extension surface 22 extending parallel to the longitudinal direction is formed on the tip side of the inclined surface 21, and a vertical surface 23 orthogonal to the longitudinal direction is further formed. The composite surface composed of the inclined surface 21 and the extension surface 22 abuts on the vertical surface 13 and the inclined surface 14 of the long frame 10.
[0019]
Further, as in the case of the long frame 10, a support portion 24 is formed on the upper part of the main body 20 in a substantially U-shape when viewed from the side, and sandwiches and supports the sealing body 2. A gutter 25 is formed on the outer side surface of the main body 20 along the longitudinal direction. On the outer side surface of the main body 20, a through hole 26 is formed as a mounting portion into which the screw 4 for fixing the short frame 11 to the long frame 10 is inserted.
[0020]
The sealing material 5 is made of a sheet-like butyl rubber, and is formed in substantially the same size as the developed shape of the butted surface of the short frame 11 as shown in FIGS. It is attached to the surface 22 with an adhesive or the like. That is, the sealing member 5 includes a plate-shaped main body 31 and a substantially U-shaped support portion 32 formed on an upper portion of the main body 31 in a side view. The body 31 has two through holes 33 for the screws 4 for fixing the short frame 11 to the long frame 10. 6 shows a state before use, and FIG. 7 shows a state during use. That is, the seal material 5 is attached to the short frame 11 so that one end of the main body 31 and one end of the support portion 32 are bent. When the sealing material 5 is attached to the other end of the short frame 11, the bending direction is reversed.
[0021]
Note that the sealing material 5 attached to the butting surface of the short frame 11 may be attached to the butting surface on the long frame 10 side. Moreover, the sealing material 5 may be fixed by baking after temporarily bonding rubber to the abutting surface of the short frame 11. As a result, it is possible to eliminate the time-consuming work of applying a silicone resin or the like which has conventionally been troublesome. Further, since the operation can be performed more easily than the case of using an adhesive, the mass productivity of the solar cell module can be improved.
[0022]
FIG. 8 is a diagram before the long frame 10 and the short frame 11 are attached to the sealing body 2, and FIG. 9 is a diagram when the long frame 10 is attached to the sealing body 2. As shown in FIG. 8, the long frame 10 is attached to the long side surface of the sealing body 2, and the sealing body 2 is fitted into the support portion 15 of the long frame 10 as shown in FIG. The short frame 11 is attached to the short side surface of the sealing body 2, and the sealing body 2 is fitted into the support portion 24 of the short frame 11.
[0023]
As shown in FIG. 1, the inclined surface 21 of the short frame 11 is sealed with the inclined surface 14 of the long frame 10, and the extended surface 22 of the short frame 11 is fitted with the vertical surface 13 of the long frame 10. Butted through the material 5. In this case, the abutting surfaces of the frames 10, 11 are inclined surfaces so as to fit each other, so that the frames 10, 11 can abut each other with an appropriate degree of adhesion. That is, when the short frame 11 is abutted against the long frame 10, if there is no inclined surface as shown in FIG. 22, the sealing material enters the inner surface of the long frame 71 while rubbing, and the sealing material is long on the surface parallel to the short frame 72. The frame 71 is pressed against the end face and compressed. However, no pressure is applied to the face orthogonal to the end face, and the frame 71 is peeled off or has a low degree of adhesion. However, as described above, when the inclined surfaces 14 and 21 abut each other, there is no surface parallel to the direction in which the pressure is applied, and the frames 10 and 11 press against each other, so that an appropriate degree of adhesion can be obtained. . Then, the sealing material 5 can be securely brought into close contact with the long frame 10, and it is possible to prevent water or moisture from entering.
[0024]
The butting surface of the long frame 10 is a composite surface composed of two types of surfaces such as an inclined surface 14 and a vertical surface 13, and the butting surface of the short frame 11 is an extending surface 22 having a different inclination angle from the inclined surface 21. By providing a composite surface including two types of surfaces, the sharp portion at the tip of the short frame 11 is eliminated, and the sharpness of the end can be reduced. Therefore, when assembling the frame 3, the worker is not injured at the tips of the frames 10 and 11, and handling safety can be improved.
[0025]
The screws 4 for fixing the frames 10, 11 are inserted into through holes 26 formed at both ends of the short frame 11 as shown in FIGS. Is screwed into. A rubber washer 36 is loosely fitted to the screw 4. Therefore, when the screw 4 is tightened, the washer 36 is interposed between the screw head 37 of the screw 4 and the short frame 11, and it is possible to prevent water and moisture from entering from the through hole 26. .
[0026]
In FIG. 10, the screw head 37 of the screw 4 projects outward from the side surface of the short frame 11. However, a recess is formed in the side surface of the short frame 11 so that the screw head 37 does not project from the side surface of the short frame 11. You may do so.
[0027]
Here, both ends of the short frame 11 may be formed as a composite surface of an arc-shaped surface 40 and a linear surface 41 in plan view, as shown in FIG. Both ends of the long frame 10 are also combined surfaces of the arc-shaped surface 42 and the straight surface 43 according to the combined surface of the short frame 11. Even in this case, the sharp portions at the tips of the frames 10, 11 are eliminated, and the frames 10, 11 can be handled safely.
[0028]
Alternatively, as shown in FIG. 12, both ends of the short frame 11 may be a composite surface of the inclined surface 44 and the extension surface 45 slightly inclined in the longitudinal direction of the short frame 11. Both ends of the long frame 10 are also combined surfaces of the inclined surface 46 and the extension surface 47 having a slight inclination according to the combined surface of the short frame 11.
[0029]
Further, as shown in FIG. 13, both ends of the short frame 11 may be formed as a composite surface of the inclined surface 48 and the arc-shaped surface 49. Both ends of the long frame 10 are also combined surfaces of the inclined surface 50 and the arc-shaped surface 51 according to the combined surface of the short frame 11. As described above, the structure of the butting surfaces of the frames 10 and 11 can be variously modified in order to eliminate the sharp portions at the tips of the frames 10 and 11. Note that the gutters 18 and 25 are omitted in FIGS.
[0030]
Further, as shown in FIG. 14, the shape of the sealing body 2 is not limited to the above-described substantially rectangular parallelepiped, but may be a substantially cylindrical shape having a small thickness. In this case, the frame 3 is formed by combining a plurality of bow-shaped frames 52, the frames 52 are butted by a so-called scarf joint, and a sealing material 53 is interposed between the butted surfaces. In the figure, reference numeral 54 denotes a bolt for fixing the frame 52.
[0031]
Next, a manufacturing procedure for manufacturing the above-described solar cell module will be described. First, the constituent members of the solar cell module are mounted on a mounting table or the like (not shown) of a manufacturing apparatus used for manufacturing the solar cell module. That is, as shown in FIG. 15, a white reinforced glass plate 6, a filler 7 made of a transparent resin, a plurality of solar cells 1, a filler 7, and a back surface protection film 8 are placed in this order. Then, heating and pressurization are performed in a vacuum state by a laminating method or the like to form a sealing body 2 as shown in FIG. Each of the fillers 7 is integrated by being pressurized and heated to form one sealing material 7 that wraps around the solar cell 1.
[0032]
Next, as shown in FIG. 16, a sealing material 55 made of butyl rubber is wound along the periphery of the plate-shaped sealing body 2, and is attached with an adhesive or the like. Then, as shown in FIG. 17, the support portion 15 of the long frame 10 is fitted to the long side surface of the sealing body 2 around which the sealing material 55 is wound. Thereafter, as shown in FIG. 18, the support portion 24 of the short frame 11 is fitted to the short side surface of the sealing body 2. Since the sealing material 55 is wound around the periphery of the sealing body 2, it is possible to prevent water, moisture, or the like from entering the sealing body 2 from between the frames 10 and 11.
[0033]
Next, the short frame 11 is fixed to the long frame 10 by inserting and tightening the screws 4 from the through holes 26 formed on both side surfaces of the short frame 11. Thus, the frame 3 is assembled, and a solar cell module that can be installed on a roof or the like is completed. Since a rubber washer 36 is loosely fitted to the screw 4, the washer 36 can prevent water, moisture, and the like from entering the through hole 26.
[0034]
The present invention is not limited to the above embodiment, and many modifications and changes can be made to the above embodiment within the scope of the present invention. For example, the inclination angles of the inclined surfaces of the frames 10 and 11 are not limited to 45 °. Further, the sealing material 5 is not limited to butyl rubber, but may be fluorine rubber or the like.
[0035]
【The invention's effect】
As described above, according to the present invention, it is possible to prevent intrusion of water or moisture from between the butting surfaces of the frames by interposing the sealing material between the butting surfaces of the frames constituting the frame, A highly reliable solar cell module can be provided.
[0036]
The abutment surfaces of the frames are inclined so that they fit each other, so that the frames can be abutted with an appropriate degree of adhesion, and the sealing material can be securely adhered to each frame, and the sealing effect can be improved. Increase.
[0037]
In addition, since the abutting surface of the frame is a composite surface composed of two or more types of surfaces, it is possible to eliminate a sharp portion on the tip side when the surface is an inclined surface, thereby ensuring safety when an operator handles the frame. Can be improved.
[0038]
In addition, the frames are combined by being screwed together, and a rubber washer is placed between the screw head of the screw and the frame.This washer can prevent water penetration and moisture penetration through the screw. It is possible to increase the waterproofness of the solar cell module.
[0039]
Furthermore, by baking and applying the rubber of the sealing material to the abutting surfaces of the frame, the operation of attaching the sealing material can be eliminated, so that the mass productivity of the solar cell module can be improved.
[Brief description of the drawings]
FIG. 1 is a view showing a frame of a solar cell module according to an embodiment of the present invention; FIG. 2 is a perspective view of the solar cell module; FIG. 3 is a cross-sectional view of a sealing body; FIG. (A) is a plan view, (b) is a front view, (c) is a bottom view, (d) is a side view. FIG. 5 shows a short frame, (a) is a plan view, (b) is a front view, (C) is a bottom view, (d) is a side view. [FIG. 6] A side view of a sealing material. [FIG. 7] A perspective view of a sealing material. [FIG. 8] A view before attaching each frame to a sealing body. FIG. 10 is a cross-sectional view when a long frame is attached to a sealing body. FIG. 10 is a cross-sectional view when a screw is screwed into each frame. FIG. 11 is a view showing a modified example of a butt surface of each frame. FIG. 13 is a diagram showing a modified example of the butting surface of the frame. FIG. 13 is a diagram showing a modified example of the butting surface of each frame. FIG. 14 is a diagram showing a modified example of the frame body. FIG. 15 is a plan view, and FIG. 15B is a side view. FIG. 15 is a view showing a procedure for manufacturing a solar cell module. FIG. 16 is a view showing a procedure for manufacturing a solar cell module. FIG. 18 is a view showing a manufacturing procedure of a solar cell module. FIG. 19 is a sectional view showing a conventional solar cell module. FIG. 20 is a sectional view showing another conventional solar cell module. FIG. FIG. 22 shows a waterproof structure. FIG. 22 is a plan view of a conventional solar cell module.
DESCRIPTION OF SYMBOLS 1 Solar cell 2 Sealing body 3 Frame body 4 Screw 5 Sealing material 10 Long frame 11 Short frame 14, 21 Inclined surface 15, 24 Supporting part 19 Screwing piece 26 Through hole 36 Washer

Claims (7)

In a solar cell module in which a frame for protecting the sealing body is attached to a periphery of a sealing body that seals the solar cell, the frame is formed by combining a plurality of frames, and abutting of opposing frames. A solar cell module, wherein a waterproof sealing material is interposed between the surfaces, and the butted surface of the frame is a composite surface composed of an arc-shaped surface and a linear surface. In a solar cell module in which a frame for protecting the sealing body is attached to a periphery of a sealing body that seals the solar cell, the frame is formed by combining a plurality of frames, and abutting of opposing frames. A solar cell module, wherein a waterproof sealing material is interposed between the surfaces, and the abutting surface of the frame is a composite surface including an inclined surface and an extended surface slightly inclined in the longitudinal direction. In a solar cell module in which a frame for protecting the sealing body is attached to a periphery of a sealing body that seals the solar cell, the frame is formed by combining a plurality of frames, and abutting of opposing frames. A solar cell module, wherein a waterproof sealing material is interposed between the surfaces, and the abutting surface of the frame is a composite surface including an inclined surface and an arc-shaped surface. The solar cell module according to any one of claims 1 to 3, wherein the sealing material is made of rubber, and is attached or baked on the abutting surface of the frame. The solar cell according to any one of claims 1 to 4, wherein the frames are combined by being screwed together, and a rubber washer for waterproofing is provided between the screw head of the screw and the frame. module. The solar cell module according to claim 5, wherein the frame is provided with a support portion having a U-shaped cross section for supporting the sealing body and a mounting portion for mounting a screw. A solar cell is sealed with a sealing material to form a sealing body, and when a frame of a frame is attached to a periphery of the sealing body, the frame includes an arc-shaped surface and a linear surface of the frame. Abutting surfaces, which are any one of a composite surface, a composite surface composed of an inclined surface and an extended surface slightly inclined in the longitudinal direction, and a composite surface composed of an inclined surface and an arc-shaped surface, are opposed to each other. A method of manufacturing a solar cell module, comprising sandwiching a waterproof sealing material between butting surfaces of the frames, and tightening the frames with screws.

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