JP4534243B2 - Manufacturing method of solar cell module - Google Patents

Description

The present invention relates to a method for manufacturing a solar cell module, and in particular, reduces molding defects and process failures during the manufacture of the solar cell module, and further reduces the end of the solar cell module when the solar cell module is used outdoors for a long period of time. It is related with the manufacturing method of the solar cell module which can prevent that a part will peel.

  Conventional solar cell modules include those that cover the outermost surface on the light-receiving surface side with glass and those that cover with a translucent film. A solar cell module whose surface is covered with glass has an insulating sealing material and a moisture-resistant film in which an aluminum foil is sandwiched with a weather-resistant film on the non-light-receiving surface side. On the other hand, in a solar cell module in which the light-receiving surface side is covered with a translucent film, a method of adhering the translucent film and the solar cell with an insulating sealing material is generally adopted, and only the front and back surfaces are covered with a film. However, since the rigidity is insufficient, a back surface support material is provided on the back surface side.

  As the back support material, a metal plate such as a steel plate, an aluminum plate or a stainless steel plate, carbon fiber, FRP (glass fiber reinforced plastic), ceramic, glass or the like is used.

  The manufacturing method of such a solar cell module is as follows.

  9 to 11 are views showing a conventional method for manufacturing a solar cell module. In the first method, as shown in FIG. 9, a surface protective material 601 that is a constituent material of the solar cell module, an insulating sealing material 602, a solar cell or a solar cell group 603, an insulating sealing material 604, And the back support material 605 are laminated, and as shown in FIG. At this time, the environmental resistance of the solar cell module 600 after molding, in particular, water intrusion from the end of the solar cell module, and melting shrinkage of the insulating sealing materials 602 and 604 at the time of heating / compression molding of the solar cell module. In consideration of the above, the insulating sealing materials 602 and 604 are set to be larger than the dimensions of the back surface support material 605, and the insulating sealing materials 602 and 604 are molded so as to protrude from the back surface support material 605. .

  The protruding portion 606 of the insulating sealing material after molding invites the resin to adhere to other objects, becomes unsightly in shape, or interferes with the case where the frame is attached to the solar cell module 600. Therefore, as shown in FIG. 11, the entire circumference of the protruding portion 606 is cut and removed by a manual operation using a cutter. The integral molding is generally performed by a laminating apparatus having a thermocompression bonding section having a diaphragm on the upper side and a heater plate on the lower side. In order to prevent the molten insulating sealing material from adhering to the diaphragm and the heater plate, the release sheet 608 having a size larger than that of the constituent material of the solar cell module is arranged on the diaphragm surface and the heater plate surface, and integrated molding is performed. (See FIGS. 9 and 10).

  In order to prevent the remaining bubbles in the solar cell module due to the gas generated when the insulating sealing materials 602 and 604 are melted and the molding failure due to the remaining bubbles between the release sheet 608 and the molded product, the solar cell module A ventilation layer is formed on the outside of the member. Specifically, by using a fluororesin-impregnated glass cloth sheet that has been subjected to surface unevenness processing as the release sheet 608, a ventilation layer is formed on the outside of the solar cell module member (Japanese Patent Laid-Open No. 9-172192, JP-A-11-87743, JP-A-11-145504, JP-A-11-204811).

  In this method, as shown in FIG. 11, the insulating sealing materials 602 and 604 not only protrude from the surface (upper surface) of the back surface support material 605, but also the back surface support material via the surface uneven portion of the release sheet 608. Around the back surface (lower surface) of 605, it was bonded, and it was difficult to remove the wraparound portion 607 of the insulating sealing material by simply cutting with a cutter. In addition, the insulating sealing material wrap-around portion 607 that wraps around the back surface of the back surface support material 605 enters the gap between the back surface support material 605 and the release sheet 608 and is thus bonded. There are non-uniform portions with strong and weak adhesion. As a result, the part with weak adhesive strength was easily peeled off from the back surface support material 605. For this reason, the wrap-around portion 607 of the insulating sealing material that wraps around the back surface of the back surface support member 605 may cause the resin to adhere to other objects, become unnatural in shape, When it was attached to the frame, it was in the way, and it caused the conveyance failure and the processing defect at the time of bending.

  In the second method, in order to solve these problems, the outer peripheral size of the back surface support member 605 is set to be slightly larger than the outer peripheral size of the insulating sealing materials 602 and 604, and the insulating sealing is performed at the time of thermocompression molding. The material 602,604 is devised so that it does not protrude from the back surface support material 605 (refer to JP-A-11-145504 and JP-A-11-186575).

  In this method, it is possible to prevent the insulating sealing materials 602 and 604 from protruding from the extension of the back surface support material 605, but the end portions of the surface protecting material 601 and the end portions of the insulating sealing materials 602 and 604 are connected. It is difficult to align exactly. That is, in the solar cell module 600, the portions where the insulating sealing materials 602 and 604 protrude from the surface protective material 601 and the insulating sealing material do not exist, and the surface protective material 601 is not bonded. Even if resin filling is performed after molding, there is a problem in long-term reliability that peeling easily occurs from the end portions of the insulating sealing materials 602 and 604 or the surface protection material 601.

  In the third method, as a method for enhancing the long-term reliability of the end portion of the solar cell module, the outer peripheral size of the surface protective material 601 and the insulating sealing materials 602 and 604 is set larger than the back surface support material 605, and the surface The protective material 601 and the insulating sealing materials 602 and 604 are folded back on the back surface of the back surface support material 605. That is, the surface protective material 601 and the insulating sealing materials 602 and 604 are disposed on the side surfaces of the back surface support material 605, and the side surfaces of the back surface support material 605 are covered with the surface protection material 601 and the insulating sealing materials 602 and 604. (Refer to Japanese Patent Laid-Open No. 10-233521).

  In this method, although the end portion of the solar cell module 600 is covered with the surface protective material 601 and has long-term reliability, the surface protective material 601 and the insulating sealing materials 602 and 604 are used as the back surface support material. It was necessary to wrap around the back surface of 605 and perform thermocompression molding, and it was difficult to control the outer dimensions of the solar cell module 600 uniformly. In addition, molding defects such as wrinkles of the surface protection material 601 are likely to occur at the end of the solar cell module 600 and the back surface of the back surface support material 605, and the insulating sealing materials 602 and 604 are formed on the back surface of the back surface support material 605. There was a problem of protruding.

  That is, for example, in the conventional solar cell module manufacturing method as described in JP-A-9-172192 and JP-A-11-204811, a diaphragm, a heater plate, and the like disposed on the back surface side of the back surface support member 605 In order to prevent the insulating sealing materials 602 and 604 melted on the surface from adhering, a release sheet is disposed on the back surface of the back surface support material 605, but compared to release the gas generated during molding to the outside. Large irregularities were formed on the surface of the release sheet. Therefore, at the time of molding, the insulating sealing materials 602 and 604 wrap around the back surface of the back surface support material 605 through the unevenness on the surface of the release sheet.

  Further, in the conventional solar cell module manufacturing method as described in, for example, Japanese Patent Laid-Open No. 10-233521, not only the insulating sealing materials 602 and 604 but also the surface protection material 601 on the side surface of the back surface support material 605. Was also arranged. Therefore, it has been difficult to uniformly control the outer dimensions of the entire solar cell module. Further, not only the insulating sealing materials 602 and 604 but also the surface protection material 601 is disposed on the side surface of the back surface support material 605, so that the surface protection material 601 is wrinkled or the back surface support material 605. There is a possibility that the insulating sealing materials 602 and 604 may protrude from the back surface of the substrate.

JP-A-9-172192 Japanese Patent Application Laid-Open No. 11-87743 Japanese Patent Laid-Open No. 11-145504 JP-A-11-204811 JP-A-11-186575 Japanese Patent Laid-Open No. 10-233521

  The present invention has been made in view of the above problems, and provides a structure of a solar cell module and a low-cost manufacturing method of a solar cell module that have few molding defects and process defects during the manufacturing process and are excellent in long-term reliability. The purpose is to provide.

  Specifically, an object of the present invention is to provide a method for manufacturing a solar cell module capable of suppressing the insulating sealing material from entering the back surface of the back surface support material during molding.

Furthermore, the present invention makes it easy to uniformly control the outer dimensions of the entire solar cell module, and reduces the risk of wrinkles occurring on the surface protective material and the risk of the insulating sealing material protruding from the back surface side of the back surface support material. An object of the present invention is to provide a method for manufacturing a solar cell module that can be used.

According to the invention described in claim 1, a solar cell, an insulating sealing material for sealing the solar cell, and a surface side of the solar cell to protect the solar cell. In the method for manufacturing a solar cell module, comprising: a surface protective material to be disposed; and a back surface support material disposed on the back surface side of the solar cell to support the solar cell.
The insulating sealing material and the surface protective material are stacked so as to cover the entire surface of the back surface support material, and the wraparound is performed to prevent the insulating seal material from wrapping around the back surface of the back surface support material. A prevention member is disposed on the back surface of the back support member, a sheet having irregularities is further disposed on the back surface of the wraparound prevention member, and the insulating sealing material includes the wraparound prevention member and the sheet having the irregularities. In a state where it is less likely to wrap around between the back surface support material and the wraparound prevention member than between, the solar battery cell, the insulating sealing material, the surface protection material, and the back surface support material are thermocompression-bonded,
When the insulating sealing material melted at the time of thermocompression molding protrudes from the outer periphery of the back surface support material, the insulating sealing material that protrudes from the outer periphery of the back surface support material wraps around with the back surface support material. Without wrapping between the prevention member, wrapping between the wraparound prevention member and the sheet having the unevenness,
Next, a method for manufacturing a solar cell module is provided, wherein a portion of the surface protective material and the insulating sealing material that protrudes from the outer extension of the back surface support member is cut and removed.

  According to invention of Claim 2, the sum total of the uneven | corrugated depth of the surface of the said wraparound prevention member and the uneven | corrugated depth of the back surface of the said back surface support material is 0.2 mm or less, It is characterized by the above-mentioned. A method of manufacturing the described solar cell module is provided.

  According to invention of Claim 3, the said wraparound prevention member is arrange | positioned only on the edge area | region of the whole back surface of the said back surface support material, The solar cell module of Claim 1 or 2 characterized by the above-mentioned. A manufacturing method is provided.

  According to invention of Claim 4, the said wraparound prevention member is affixed on the back surface of the said back surface support material, and the part protruded from the extension of the said back surface support material among the said surface protection material and the said insulating sealing material. 3. The method for manufacturing a solar cell module according to claim 1 or 2, wherein the wraparound prevention member is peeled off after cutting and removing.

  According to invention of Claim 5, the said wraparound prevention member is affixed only on the edge area | region of the whole back surface of the said back surface support material, Manufacturing of the solar cell module of Claim 4 characterized by the above-mentioned. A method is provided.

  In the manufacturing method of the solar cell module according to claim 1 and 2, a wraparound prevention member for preventing the insulating sealing material from wrapping around the back surface of the back surface support material is disposed on the back surface of the back surface support material. Preferably, the sum of the uneven depth on the surface of the wraparound prevention member and the uneven depth on the back surface of the back support member is set to 0.2 mm or less. Therefore, it can suppress that an insulating sealing material wraps around the back surface of a back surface support material at the time of shaping | molding. More preferably, as the wraparound preventing member, a plastic sheet, a metal sheet, and a laminate structure obtained by subjecting the surface to a release property are used.

  Specifically, in the method for manufacturing a solar cell module according to claims 1 and 2, after molding, a portion of the surface protective material and the insulating sealing material that protrudes from the outer extension of the back surface support material may be cut and removed. Although necessary, molding defects due to remaining bubbles in the solar cell module due to gas generated when the insulating sealing material melts, and remaining bubbles between the release sheet and the back surface of the solar cell module, and back surface support It is possible to prevent the insulating sealing material from wrapping around the back surface of the material, and to reduce the process failure, frame attachment failure, conveyance failure and processing failure due to adhesion of the insulating sealing material to other materials. it can.

  In the manufacturing method of the solar cell module according to claim 3, the wraparound prevention member is disposed only on the edge region of the entire back surface of the back surface support member. Therefore, the wraparound prevention member can be saved and the manufacturing cost of the solar cell module can be reduced as compared with the case where the wraparound prevention member is disposed on the entire back surface of the back surface support member.

  In the manufacturing method of the solar cell module according to claim 4, the wraparound prevention member is attached to the back surface of the back surface support material. Therefore, it is possible to reduce the possibility that the wraparound preventing member is displaced during molding, compared to the case where the wraparound preventing member is not attached to the back surface of the back surface support material.

  In the manufacturing method of the solar cell module according to claim 5, the wraparound prevention member is attached only on the edge region of the entire back surface of the back surface support member. Therefore, the wraparound preventing member can be saved and the manufacturing cost of the solar cell module can be reduced as compared with the case where the wraparound preventing member is attached to the entire back surface of the back surface support member.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

1 and 2 are cross-sectional views schematically showing an example of a molded body before and after thermocompression molding in the method for manufacturing a solar cell module according to the invention related to the present invention. In FIGS. 1 and 2, 101 is a surface protective material, 102 and 104 are insulating sealing materials, 105 is a protruding portion of the insulating sealing material, 103 is a solar cell, 106 is a back surface support material, and 107 is insulating. The wraparound prevention members for preventing the sealing materials 102 and 104 from wrapping around the back surface of the back surface support member 106 are shown.

In the method for manufacturing a solar cell module according to the invention related to the present invention , as shown in FIG. 1, a wraparound prevention member 107 is laminated on the back surface of the back surface support member 106 and thermocompression-bonded. Thereby, as shown in FIG. 2, the insulating sealing materials 102 and 104 are molded without wrapping around the back surface of the back surface support material 106. Next, the surface protection material 101 and the protruding portion 105 of the insulating sealing material are cut and removed around the back surface support material 106. That is, the portion of the surface protective material 101 and the insulating sealing material that protrudes from the outer extension of the back surface support member 106 is cut and removed. As a result, the solar cell module shown in FIG. 3 or 4 is obtained.

Figure 3 is a first cross-sectional view schematically showing the embodiment, the cross section schematically showing a second embodiment of the solar cell module of FIG. 4 invention relating to the present invention the solar cell module of the invention relating to the present invention FIG. In FIG. 4, 201 is a surface protective material, 202 and 204 are insulating sealing materials, 203 is a solar battery cell, 206 is a back surface support material, and 205 is a back surface support material 205 for covering the side surface of the back surface support material 206. The insulating sealing material arrange | positioned on the side is shown, respectively.

As shown in FIG. 3, in the first embodiment the solar cell module of the invention relating to the present invention, the side surface of the back supporting member 106 is allowed to expose. On the other hand, as shown in FIG. 4, the solar cell module of the second embodiment of the invention relating to the present invention, on the side of the back supporting member 206 is disposed an insulating sealing material 205, the surface protective member 201 is disposed It has not been. That is, the side surface of the back support member 206 is covered only with the insulating sealing material 205. By switching the cutting removal position of the protruding portion 105 of the insulating sealing material of the solar cell module after integral molding as shown in FIG. 2, the solar cell of the first aspect of the invention relating to the present invention shown in FIG. 3 producing modules or, alternatively, can be switched easily or for manufacturing the solar cell module of the second embodiment of the invention relating to the present invention shown in FIG.

  Hereinafter, the surface protective material, the insulating sealing material, the solar battery cell, the back surface support material, and the wraparound prevention member used in the solar cell module of the present invention will be described in detail.

The surface protective material 4 01, 5 01 used in a solar cell module of the present invention, polyethylene tetrafluoroethylene (ETFE), poly 3-ethylene fluoride, or the like can be used fluororesin films like polyvinyl fluoride. The bonding surface of the insulating sealing member 4 02, 5 02, it is desirable that the insulating sealing material 4 02, 5 02 previously subjected to a surface treatment such as corona discharge treatment for easy adhesion.

As the insulating sealing material 4 02, 4 04, 5 02, 5 04, transparent resin such as ethylene vinyl acetate copolymer (EVA) resin, butyral resin, silicon resin, epoxy resin, fluorinated polyimide resin is used. can do. It is also possible to perform crosslinking by adding a crosslinking agent to the insulating sealing material 4 02, 4 04, 5 02, 5 04. Moreover, in order to suppress photodegradation, it is desirable to contain an ultraviolet absorber. The insulating sealing material 4 04 5 04 does not necessarily need to be transparent, it may be used those colored. As the solar cell 4 03, 5 03 of the light-receiving surface side surface protector 4 01 disposed on the (upper side), 5 01 and an insulating sealing material 4 02, 5 02, the laminated film which is previously laminated adhesive sheet May be used.

The solar cell 4 03, 5 03, not particularly limited, a semiconductor pn junction or a single crystal material, pin junction non-single-crystal material, or a semiconductor junction such as a Schottky junction is used. As the semiconductor material, a silicon system or a compound system is used. A solar cell having bendability is preferable, and an amorphous silicon (a-Si) semiconductor or a compound semiconductor formed on a stainless steel substrate or a film substrate is particularly preferable.

As the back support members 4 0 5 and 5 0 5 , a metal plate such as a steel plate, an aluminum plate or a stainless steel (SUS) plate, a plastic plate, an FRP plate, or the like can be used. When the back surface support materials 4 0 5 , 5 0 5 are conductive materials, an insulating film may be provided between the back surface support materials 4 0 5 , 5 0 5 and the solar cells 4 03, 5 03. . Insulating films are used to maintain electrical insulation of the solar cell 4 03, 5 03. As a material suitably used, a plastic film such as nylon or polyethylene terephthalate (PET) can be used.

As the wraparound prevention member 4 0 6,506, there are a reusable member and a non-reusable member. As reusable materials, there can be used woven fabrics, nonwoven fabrics, plastics, metals, and laminated structure sheets thereof impregnated or coated with a fluororesin or silicone resin in order to impart releasability. As a material for the woven fabric or the nonwoven fabric, glass, aramid, polyester, or the like, or a metal material such as aluminum or stainless steel may be used. The surface of the wraparound prevention member 4 0 6 506 that contacts the back surface of the back support material 4 0 5 , 5 0 5 has a concavo-convex depth of 0.2 mm or less in order to prevent molding defects during thermocompression molding. It is desirable that Also, preventing member 4 0 6,506 wraparound need not necessarily cover the entire backside of the back support 4 0 5, 5 0 5, the edges of the entire back surface of the back supporting member 4 0 5, 5 0 5 It is only necessary to cover the partial area. That is, a frame-like member obtained by removing the central portion of the back surface supporting members 4 0 5 and 5 0 5 or a member having an opening such as punching metal may be used as the wraparound prevention member 4 0 6 or 506 .

  On the other hand, as a material that is not reused, it is possible to use a sheet made of the above-mentioned material with an adhesive applied to one side, but an adhesive is applied to one side of an inexpensive plastic film such as nylon, polyester, or polyethylene. The one given is preferable.

Examples will be described below. The Example mentioned later is related with the manufacturing method of the solar cell module which used the a-Si photovoltaic cell produced on the film substrate, and was produced using the steel plate as a back surface support material.

FIG. 5: is sectional drawing which shows typically an example of the to-be-molded body before the thermocompression molding of the manufacturing method of the solar cell module of the invention relevant to this invention . First, ETFE having a thickness of 0.05 mm is used as the surface protective material 301, which is unwound from a roll-shaped film, and is larger than the insulating sealing materials 302 and 304, the film substrate solar cell 303, and the back surface support material 305. Cut. Next, as an insulating sealing material 302 on the front surface side, a 0.4 mm thick EVA film is unwound from the roll-shaped film, smaller than the surface protective material 301, and smaller than the film substrate solar cell 303 and the back surface support material 305. It is cut into a large size and placed on the surface protective material 301. The light receiving surface of the film substrate a-Si solar battery cell 303 is disposed adjacent to the insulating sealing material 302. As the insulating sealing material 304 on the back surface side, 0.4 mm thick EVA is unwound from the roll-shaped film, cut into the same size as the insulating sealing material 302 on the front surface side, and disposed on the solar battery cell 303. A fluorine-coated galvanium steel plate having a thickness of 0.8 mm was used as the back support member 305, and was placed on the insulating sealing material 304 on the back side. The size of the back surface support member 305 was larger than the film substrate solar cell 303 and smaller than the insulating sealing materials 302 and 304.

  A plurality of fluororesin-impregnated glass cloth sheets having different surface unevenness depths are provided on the back surface side (upper side in FIG. 5) of the constituent material of the solar cell module thus laminated as the wraparound prevention member 306. It is arranged so as to cover the entire rear surface of the constituent material, and is formed by vacuum thermocompression bonding at a temperature of 140 ° C. to 150 ° C. for 15 minutes to 25 minutes, thereby integrally molding and crosslinking of the insulating sealing materials 302 and 304 Went.

  The glass cloth sheet as the wraparound prevention member 306 is peeled off from the integrally molded solar cell module, and the insulating sealing materials 302 and 304 and the surface protection material 301 protruding from the back surface support material 305 are removed from the back surface using a cutter. It cut and removed along the outer peripheral part (outward extension) of the support material 305.

  Table 1 shows a state in which the insulating sealing material wraps around the back surface of the back surface support material in the solar cell module produced by the above manufacturing method. As shown in Table 1, when the surface unevenness depth of the wraparound prevention member disposed on the back surface of the back surface support material is 0.2 mm or less, the molten insulating sealing material wraps around the back surface of the back surface support material. There wasn't. When the surface unevenness depth is 0.3 mm or more, the melted insulating sealing material enters between the wraparound prevention member and the back surface support material, that is, the back surface of the back surface support material, to the back surface of the back surface support material. Adhesion was confirmed. In any case, there was no molding defect due to a gas reservoir caused by the gas released when the insulating sealing material was melted.

FIG. 6 is a cross-sectional view schematically showing an example of a molded body before thermocompression molding in the method for manufacturing a solar cell module according to Example 1 of the present invention . First, 0.05 mm-thick ETFE is used as the surface protective material 401, which is unwound from a roll-shaped film, and is larger than the insulating sealing materials 402 and 404, the film substrate solar cell 403, and the back surface support material 405. Cut. Next, as the insulating sealing material 402 on the front surface side, a 0.4 mm thick EVA film is unwound from the roll-shaped film, smaller than the surface protective material 401, and smaller than the film substrate solar cell 403 and the back surface support material 405. It is cut into a large size and placed on the surface protective material 401. The light receiving surface of the film substrate a-Si solar battery cell 403 is disposed adjacent to the insulating sealing material 402. As the insulating sealing material 404 on the back surface side, 0.4 mm thick EVA is unwound from the roll film, cut into the same size as the insulating sealing material 402 on the front surface side, and disposed on the solar battery cell 403. A fluorine-coated galvanium steel sheet having a thickness of 0.8 mm was used as the back surface support member 405 and was disposed on the insulating sealing material 404 on the back surface side. The size of the back surface support member 405 was larger than the film substrate solar cell 403 and smaller than the insulating sealing materials 402 and 404.

  A stainless steel material with a thickness of 0.1 mm coated with a fluororesin is used as a back-around prevention member 406 on the back surface side (upper side in FIG. 6) of the constituent material of the solar cell module laminated and disposed in this manner. It arrange | positions so that the whole back surface may be covered, and also arrange | positions the fluororesin impregnation glass cloth sheet 407 whose surface uneven | corrugated depth is 0.3 mm on it so that the whole back surface of the constituent material of a solar cell module may be covered, and vacuum heating The integrated molding and the cross-linking of the insulating sealing materials 402 and 404 were performed by vacuum heating and pressure bonding at a temperature of 140 ° C. to 150 ° C. for 15 to 25 minutes by a pressure bonding method.

  From the integrally molded solar cell module, the stainless steel material covered with the fluororesin-impregnated glass cloth sheet 407 and the fluororesin as the wraparound prevention member 406 is removed, and the insulating sealing protruding from the back surface support material 405 using a cutter The materials 402 and 404 and the surface protection material 401 were cut and removed along the outer peripheral portion (extended) of the back surface support material 405.

  In this case, the insulating sealing material wraps around and adheres to the end on the back side (upper side in FIG. 6) of the stainless steel coated with the fluororesin as the wraparound prevention member 406. The stop material did not wrap around the back surface of the back surface support material 405. Further, there was no molding failure due to gas accumulation caused by the gas released when the insulating sealing material was melted. The insulating sealing material attached to the stainless steel coated with the fluororesin as the wraparound prevention member 406 could be easily removed, and the stainless steel coated with the fluorinated resin as the wraparound prevention member 406 could be reused. .

FIG. 7: is sectional drawing which shows typically an example of the to-be-molded body before the thermocompression molding of the manufacturing method of the solar cell module of Example 2 of this invention . FIG. 8 is a plan view schematically showing the relationship between the back support member and the wraparound prevention member of FIG. First, ETFE having a thickness of 0.05 mm is used as the surface protective material 501, which is unwound from a roll-shaped film, and is larger in size than the insulating sealing materials 502 and 504, the film substrate solar cell 503, and the back surface support material 505. Cut. Next, as the insulating sealing material 502 on the front surface side, a 0.4 mm thick EVA film is unwound from the roll-shaped film and is smaller than the surface protective material 501, and is smaller than the film substrate solar cell 503 and the back surface support material 505. It is cut into a large size and placed on the surface protective material 501. The light receiving surface of the film substrate a-Si solar battery cell 503 is disposed adjacent to the insulating sealing material 502. As the insulating sealing material 504 on the back surface side, 0.4 mm thick EVA is unwound from the roll film, cut into the same size as the insulating sealing material 502 on the front surface side, and disposed on the solar battery cell 503. A fluorine-coated galvanium steel sheet having a thickness of 0.8 mm was used as the back surface support member 505 and was disposed on the insulating sealing material 504 on the back surface side. The size of the back support member 505 was larger than the film substrate solar battery cell 503 and smaller than the insulating sealing materials 502 and 504.

  In this way, on the back side (upper side in FIG. 7) of the constituent material of the solar cell module arranged in a stacked manner, an adhesive material is provided on one side of the polyester film as a wraparound prevention member 506, thickness 0.15 mm, width 10 mm The polyester pressure-sensitive adhesive tape is affixed to the edge region of the entire back surface of the back surface support member 505, and a fluororesin-impregnated glass cloth sheet 507 having a surface unevenness depth of 0.3 mm is further formed thereon. It is arranged so as to cover the entire back surface of the material, and by vacuum thermocompression bonding, it is subjected to vacuum thermocompression bonding at a temperature of 140 ° C. to 150 ° C. for 15 minutes to 25 minutes, so that integral molding and crosslinking of the insulating sealing materials 502 and 504 are performed. went.

  The fluororesin-impregnated glass cloth sheet 507 is removed from the integrally molded solar cell module, and the insulating sealing materials 502 and 504 and the surface protection material 501 protruding from the back surface support material 505 are removed from the back surface support material 505 by using a cutter. The polyester pressure-sensitive adhesive tape as the wraparound prevention member 506 was removed by cutting along the outer peripheral portion (extended).

In this case, although the rear surface of a polyester adhesive tape as prevention member 5 06 wraparound (upper surface in FIG. 7) was adhered wraps around the insulating sealing member, hands polyester adhesive tape as prevention member 5 06 sneak It was possible to remove easily by peeling off, and the molten insulating sealing material did not wrap around the back surface of the back surface support member 505. Further, there was no molding failure due to gas accumulation caused by the gas released when the insulating sealing material was melted.

A solar cell obtained by cutting and removing the insulating sealing material and the surface protective material protruding from the back surface support member along the outer peripheral portion (extended) of the back surface support material from the solar cell module integrally molded by the method of FIG. For each of the module and the solar cell module cut and removed 1 mm outside from the outer peripheral portion (outward extension) of the back surface support member, the end of the solar cell module is subjected to 90 ° uneven bending, and the end of the solar cell module Adhesion reliability was evaluated by a temperature and humidity cycle test (100 cycles) of −40 ° C. × 1 hour and 85 ° C. × 85% RH × 4 hours.

  In a solar cell module that is cut and removed along the outer periphery (extended) of the back surface support member and the side surface of the back surface support material is exposed, the solar cell module does not peel off, but is insulated from the back surface support material. The sealing material was turned up. On the other hand, in the solar cell module cut and removed 1 mm outside from the outer peripheral portion (extended) of the back surface support material, the insulating sealing material was not turned up from the back surface support material.

It is sectional drawing which shows typically an example of the to-be-molded body before and behind thermocompression molding in the manufacturing method of the solar cell module of the invention relevant to this invention. It is sectional drawing which shows typically an example of the to-be-molded body before and behind thermocompression molding in the manufacturing method of the solar cell module of the invention relevant to this invention. The first embodiment of the solar cell module of the invention relating to the present invention is a cross-sectional view schematically showing. The second embodiment of the solar cell module of the invention relating to the present invention is a cross-sectional view schematically showing. It is sectional drawing which shows typically an example of the to-be-molded body before the thermocompression molding of the manufacturing method of the solar cell module of the invention relevant to this invention . It is sectional drawing which shows typically an example of the to-be-molded body before the thermocompression molding of the manufacturing method of the solar cell module of Example 1 of this invention . It is sectional drawing which shows typically an example of the to-be-molded body before the thermocompression molding of the manufacturing method of the solar cell module of Example 2 of this invention . It is a top view which shows typically the relationship between the back surface support material of FIG. 7, and a wraparound prevention member. It is the figure which showed the manufacturing method of the conventional solar cell module. It is the figure which showed the manufacturing method of the conventional solar cell module. It is the figure which showed the manufacturing method of the conventional solar cell module.

DESCRIPTION OF SYMBOLS 101 Surface protective material 102,104 Insulating sealing material 103 Solar cell 106 Back surface support material 107 Anti-wraparound member

Claims (5)

A solar battery cell, an insulating sealing material for sealing the solar battery cell, a surface protective material disposed on the surface side of the solar battery cell to protect the solar battery cell, and the solar battery In the method for manufacturing a solar cell module comprising a back surface support material disposed on the back surface side of the solar cell to support the cell,
The insulating sealing material and the surface protective material are stacked so as to cover the entire surface of the back surface support material, and the wraparound is performed to prevent the insulating seal material from wrapping around the back surface of the back surface support material. A prevention member is disposed on the back surface of the back support member, a sheet having irregularities is further disposed on the back surface of the wraparound prevention member, and the insulating sealing material includes the wraparound prevention member and the sheet having the irregularities. In a state where it is less likely to wrap around between the back surface support material and the wraparound prevention member than between, the solar battery cell, the insulating sealing material, the surface protection material, and the back surface support material are thermocompression-bonded,
When the insulating sealing material melted at the time of thermocompression molding protrudes from the outer periphery of the back surface support material, the insulating sealing material that protrudes from the outer periphery of the back surface support material wraps around with the back surface support material. Without wrapping between the prevention member, wrapping between the wraparound prevention member and the sheet having the unevenness,
Next, the method of manufacturing a solar cell module, comprising cutting and removing a portion of the surface protective material and the insulating sealing material that protrudes from the outer extension of the back surface support material.   2. The method of manufacturing a solar cell module according to claim 1, wherein the sum of the unevenness depth of the surface of the wraparound prevention member and the unevenness depth of the back surface of the back surface support member is 0.2 mm or less.   The method for manufacturing a solar cell module according to claim 1, wherein the wraparound prevention member is disposed only on an edge region of the entire back surface of the back surface support member.   The wraparound prevention member is attached to the back surface of the back surface support member, and the wraparound prevention member is removed after cutting and removing the portion of the surface protection material and the insulating sealing material that protrudes from the outer extension of the back surface support material. The method for producing a solar cell module according to claim 1 or 2, wherein the method is peeled off.   The method for manufacturing a solar cell module according to claim 4, wherein the wraparound preventing member is attached only on an edge region of the entire back surface of the back surface support member.

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