JP5100571B2 - Manufacturing method of solar cell module - Google Patents

Description

  The present invention relates to a method for manufacturing a solar cell module including a translucent light-receiving surface side protective material.

  Solar cells are expected as new energy sources because they directly convert clean and inexhaustible sunlight into electricity. The output per solar cell is about several watts. Therefore, when using a solar cell as an electric power source (energy source) such as a house or a building, a solar cell module including a plurality of solar cells is used. Specifically, the plurality of solar cells are sealed with a sealing material between the light-transmitting light-receiving surface side protective material and the back surface side protective material.

  In the manufacturing process of such a solar cell module, a heating device for heating the sealing material is used. The heating device is a laminating device used in the laminating step and a curing device used in the curing step.

  Specifically, in the laminating process, a light-transmitting light-receiving surface side protective material, a first sealing material, a plurality of solar cells, a second sealing material, and a back surface-side protective material are sequentially disposed on the support portion of the laminating apparatus. At the same time, the first and second sealing materials are heated (see, for example, Patent Document 1). Thereby, hardening of the 1st and 2nd sealing material is started, and each members are temporarily bonded.

  Next, in the curing step, the light receiving surface side protective material is disposed downward on the support portion of the curing device, and the first and second sealing materials are further heated. Thereby, hardening of the 1st and 2nd sealing material advances, and each member is finally adhere | attached.

In the heating process such as the laminating process and the curing process, the light receiving surface side protective material is supported by the support portion.
JP 2004-193448 A

  However, in the above-described laminating process and curing process, there is a possibility that dirt such as a sealing material or dust remaining on the support portion may adhere to the surface of the light receiving surface side protective material. If dirt adheres to the surface of the light-receiving surface side protective material, the translucency of the light-receiving surface side protective material is reduced. Therefore, since it is necessary to remove dirt from the surface of the light receiving surface side protective material, there is a problem that productivity of the solar cell module is lowered.

  Further, when fine irregularities are formed on the surface of the light-receiving surface side protective material for the purpose of preventing reflection of incident light, it is difficult to remove the attached dirt.

  The present invention has been made in view of the above situation, and an object of the present invention is to provide a method for manufacturing a solar cell module capable of suppressing the adhesion of dirt to the light-receiving surface side protective material.

  In the method for manufacturing a solar cell module according to the feature of the present invention, a light-transmitting light-receiving surface side protective material, a first sealing material, a plurality of solar cells, a second sealing material, and a back surface side protective material are sequentially laminated. Step A for placing the laminated body formed on the support portion of the heating device, and Step B for heating the first sealing material and the second sealing material by the heating portion of the heating device. In the step A, the gist is to place the light-receiving surface side protective material on a protrusion provided on a surface of the support portion facing the light-receiving surface side protective material.

  According to the solar cell module according to the feature of the present invention, the light-receiving surface side protective material is placed on the protrusion. Therefore, the area where the support portion and the light receiving surface side protective material come into contact can be reduced. Therefore, it can suppress that the dirt of a support part adheres to the light-receiving surface side protective material.

  In the step A according to the feature of the present invention, the protruding portion may be disposed between the plurality of solar cells on a projection surface substantially parallel to the light receiving surface side protective material.

  In the feature of the present invention, the planar shape of the protrusion may be linear.

  In the feature of the present invention, the planar shape of the protrusion may be a dot shape.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the solar cell module which can suppress adhesion of the dirt to the light-receiving surface side protective material can be provided.

  Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic and ratios of dimensions and the like are different from actual ones. Accordingly, specific dimensions and the like should be determined in consideration of the following description. Moreover, it is a matter of course that portions having different dimensional relationships and ratios are included between the drawings.

[First Embodiment]
(Configuration of laminating equipment)
Below, the structure of the laminating apparatus which concerns on 1st Embodiment of this invention is demonstrated, referring drawings. FIG. 1 is a side view showing a configuration of a laminating apparatus 10 according to the first embodiment. The laminating apparatus 10 is a heating apparatus for laminating a laminate 100 described later in the manufacturing process of the solar cell module.

  As shown in FIG. 1, the laminating apparatus 10 includes a lower housing 1, an upper housing 2, a first support portion 3, a heating portion 4, and a diaphragm 5.

  The lower housing 1 constitutes the lower part of the casing of the laminating apparatus 10. The lower housing 1 has a supply / exhaust mechanism, and the inside can be evacuated by exhaust. A first support 3 and a heating unit 4 are provided inside the lower housing 1.

  The upper housing 2 constitutes the upper part of the casing of the laminating apparatus 10. The upper housing 2 has a supply / exhaust mechanism, and the inside can be evacuated by exhaust. A diaphragm 5 is provided inside the upper housing 2.

  The first support part 3 supports each member constituting the stacked body 100. The first support unit 3 includes a support base 31, a release sheet 32, and a plurality of first protrusions 33.

  The support base 31 is disposed in the lower housing 1. As the support base 31, a metal plate such as iron, aluminum or copper, a plastic plate, or the like can be used.

  The release sheet 32 covers the upper surface of the support base 31. As shown in FIG. 1, the release sheet 32 forms a facing surface 3 </ b> S that faces the laminated body 100 (light receiving surface side protective material 101). As the release sheet 32, an embossed fluororesin sheet, a glass cloth sheet impregnated with a fluororesin, or the like can be used.

  The plurality of first protrusions 33 are regularly provided on the facing surface 3 </ b> S, that is, on the release sheet 32. The plurality of first protrusions 33 support the light receiving surface side protective material 101. The plurality of first protrusions 33 are made of a heat-resistant member, for example, metal, plastic, glass, or the like. The configuration of the plurality of first protrusions 33 will be described later.

  The heating unit 4 is, for example, a metal wire that generates heat when energized. The heating unit 4 is provided in the support base 31. The heating unit 4 heats the stacked body 100 through the release sheet 32 and the plurality of first protrusions 33 by heating the support base 31. Specifically, the heating unit 4 heats the first sealing material 102 and the second sealing material 104 constituting the stacked body 100 as described later.

  The diaphragm 5 forms the lower surface of the upper housing 2. The diaphragm 5 is inflated to the lower housing 1 side by bringing the inside of the lower housing 1 and the upper housing 2 into a vacuum state and then returning the inside of the upper housing 2 to atmospheric pressure. Thereby, the laminated body 100 is pressurized.

  Here, the structure of the laminated body 100 supported by the support stand 31 is demonstrated. The laminated body 100 is configured by sequentially laminating a light-receiving surface side protective material 101, a first sealing material 102, a solar cell group 103, a second sealing material 104, and a back surface side protective material 105.

  The light-receiving surface side protective material 101 protects the surface of the solar cell module. The light-receiving surface side protective material 101 is composed of a light-transmitting flat plate member. Specifically, glass, plastic, or the like can be used as the light-receiving surface side protective material 101. The light-receiving surface side protective material 101 may be subjected to antireflection processing for confining incident light inside. Specifically, fine irregularities and an antireflection film may be formed on the surface of the light-receiving surface side protective material 101.

  The first sealing material 102 and the second sealing material 104 seal the solar cell group 103 between the light receiving surface side protective material 101 and the back surface side protective material 105. As the 1st sealing material 102 and the 2nd sealing material 104, translucent resin, such as EVA, EEA, PVB, silicon | silicone, urethane, an acryl, an epoxy, can be used. Moreover, the 1st sealing material 102 and the 2nd sealing material 104 contain a crosslinking agent. Accordingly, the first sealing material 102 and the second sealing material 104 are heated to a temperature equal to or higher than a predetermined crosslinking temperature by the heating unit 4 to be softened and then crosslinked. Thereby, each structural member of the laminated body 100 is temporarily bonded.

  The solar cell group 103 includes a plurality of solar cells 103A and a wiring member 103B. The plurality of solar cells 103A are electrically connected to each other by the wiring member 103B.

  The back surface side protective material 105 is a member that protects the back surface of the solar cell module. As the back surface side protective material 105, a resin film such as PET (Polyethylene Terephthalate), a laminated film having a structure in which an Al foil is sandwiched between resin films, or the like can be used.

(Configuration of the first protrusion)
Below, the structure of the some 1st projection part 33 which concerns on 1st Embodiment is demonstrated, referring drawings. FIG. 2 is a plan view of the first support portion 3 as viewed from the facing surface 3S side. FIG. 3 is a projection surface view that is substantially parallel to the light-receiving surface side protective material 101. In FIG. 3, only the release sheet 32, the plurality of first protrusions 33, and the plurality of solar cells 103A are illustrated.

  As shown in FIG. 2, the plurality of first protrusions 33 are provided in a dot shape on the release sheet 32 in plan view. Specifically, four rows of first protrusions 33 are provided along the first direction. Each row includes five first protrusions 33. The first protrusions 33 are regularly provided at substantially equal intervals in the first direction and the second direction.

  Here, the cross section of each first protrusion 33 has a trapezoidal shape (see FIG. 1). Therefore, the upper surface 33S of each first protrusion 33 is formed in a planar shape. The light-receiving surface side protective material 101 is placed on the upper surface 33S. That is, each first protrusion 33 has a placement surface on which the light-receiving surface side protective material 101 is placed.

  As shown in FIG. 3, each first protrusion 33 does not overlap with each solar cell 103 </ b> A on a projection surface substantially parallel to the light-receiving surface side protective material 101. That is, each 1st projection part 33 is arrange | positioned according to the position of each solar cell 103A, and each 1st projection part 33 is arrange | positioned between each solar cell 103A and the outer side of each solar cell 103A.

(Lamination process)
Next, the lamination process by the laminating apparatus 10 will be described.

  First, the light-receiving surface side protective material 101 is placed on the first support portion 3 of the laminating apparatus 10. Specifically, the light receiving surface side protection member 101 is placed on the upper surface (mounting surface) 33 </ b> S of each first protrusion 33.

  Next, the first sealing material 102, the solar cell group 103, the second sealing material 104, and the back surface side protection material 105 are sequentially laminated on the light receiving surface side protection material 101. Thereby, the laminated body 100 is formed. At this time, the positions of the light receiving surface side protection member 101 and the solar cell group 103 are finely adjusted so that the first protrusions 33 are positioned between the solar cells 103A.

  Next, after the inside of the lower housing 1 and the upper housing 2 are evacuated, the atmospheric pressure in the upper housing 2 is returned to atmospheric pressure. Thereby, the diaphragm 5 is pressed against the laminate 100.

  At this time, the first sealing member 102 and the second sealing member 104 are heated by heating the first support portion 3 with the heating portion 4. Thereby, the members constituting the laminated body 100 are temporarily bonded to each other.

(Configuration of cure device)
Hereinafter, the configuration of the curing apparatus according to the first embodiment of the present invention will be described with reference to the drawings. FIG. 4 is a side view showing the configuration of the curing device 60 according to the first embodiment. The curing device 60 is a heating device for curing the stacked body 100 in the manufacturing process of the solar cell module.

  As shown in FIG. 4, the curing device 60 includes a housing 6 and a plurality of second support portions 7. Moreover, the curing device 60 includes a heating unit (not shown) that circulates warm air inside the curing device 60.

  The housing 6 is a furnace having a function of circulating hot air inside. The laminated body 100 carried into the housing 6 is heated by warm air. Specifically, when the first sealing material 102 and the second sealing material 104 are heated to a predetermined crosslinking temperature or higher, the crosslinking of the first sealing material 102 and the second sealing material 104 is promoted. . As a result, the constituent members of the laminate 100 are bonded together.

  The second support part 7 supports the stacked body 100. Specifically, since the laminated body 100 is disposed with the light receiving surface side protective material 101 facing downward, the second support portion 7 supports the light receiving surface side protective material 101. In the present embodiment, as illustrated in FIG. 4, the stacked body 100 is supported by the two second support portions 7. Each second support portion 7 includes a support rod 71 and a plurality of second protrusions 72.

  The support rod 71 is, for example, a metal rod coated with silicone resin. As shown in FIG. 4, the support bar 71 forms a facing surface 7 </ b> S that faces the light-receiving surface side protective material 101.

  The plurality of second protrusions 72 are regularly provided on the facing surface 7 </ b> S, that is, on the support rod 71. The plurality of second protrusions 72 support the light receiving surface side protection member 101. The plurality of second protrusions 72 are made of a heat-resistant member, for example, metal, plastic, glass, or the like.

(Configuration of the second protrusion)
Below, the structure of the several 2nd projection part 72 which concerns on 1st Embodiment is demonstrated, referring drawings. FIG. 5 is a plan view of the second support portion 7 as viewed from the facing surface 7S side. FIG. 6 is a projection surface view that is substantially parallel to the light-receiving surface side protective material 101. In FIG. 6, only the support rod 71, the plurality of second protrusions 72, and the plurality of solar cells 103A are illustrated.

  As shown in FIG. 5, the plurality of second protrusions 72 are provided in a dot shape on the support rod 71 in plan view. Specifically, four second protrusions 72 are provided along the longitudinal direction of the support bar 71. The second protrusions 72 are regularly provided at substantially equal intervals in the longitudinal direction.

  Here, the cross section of each second protrusion 72 has a trapezoidal shape (see FIG. 4). Therefore, the upper surface 72S of each second protrusion 72 is formed in a planar shape. The light-receiving surface side protective material 101 is placed on the upper surface 72S. That is, each 2nd projection part 72 has a mounting surface in which the light-receiving surface side protective material 101 is mounted.

  As shown in FIG. 6, each second protrusion 72 does not overlap with each solar cell 103 </ b> A on the projection surface substantially parallel to the light-receiving surface side protective material 101. That is, each 2nd projection part 72 is arrange | positioned according to the position of each solar cell 103A, and each 2nd projection part 72 is arrange | positioned between each solar cell 103A and the outer side of each solar cell 103A.

(Cure process)
Next, a curing process by the curing device 60 will be described.

  First, the laminated body 100 temporarily bonded in the laminating step is placed on the two second support portions 7. Specifically, the light-receiving surface side protective material 101 is placed on the upper surface (mounting surface) 72S of each second protrusion 72.

  Next, the laminated body 100 is heated for a predetermined time by circulating hot air inside the curing device 60. As a result, the first sealing material 102 and the second sealing material 104 are cured, and the members constituting the stacked body 100 are permanently bonded to each other. Thereby, a solar cell module is formed.

  In addition, a metal frame and a terminal box can be attached to such a solar cell module.

(Function and effect)
In the method for manufacturing the solar cell module according to the present embodiment, the light-receiving surface side protective material 101 is placed on the first protrusion 33 provided on the facing surface 3S of the first support portion 3 in the laminating process of the stacked body 100. To do.

  As described above, the light-receiving surface side protection member 101 is placed on the first protrusion 33. Therefore, compared with the case where the light receiving surface side protective material 101 is directly placed on the release sheet 32, the area where the first support portion 3 and the light receiving surface side protective material 101 are in contact can be reduced. Therefore, in the laminating process, it is possible to suppress the dirt of the first support portion 3 from adhering to the light receiving surface side protective material 101. As a result, it is possible to suppress a decrease in translucency of the light-receiving surface side protective material 101 and a decrease in productivity of the solar cell module. In addition, when fine unevenness | corrugation etc. are formed in the light-receiving surface side protective material surface, since removal of dirt is difficult, it is especially effective.

  In the laminating step, the first protrusion 33 is disposed between the plurality of solar cells 103 </ b> A on a projection surface substantially parallel to the light-receiving surface side protective material 101. Therefore, it is possible to further suppress dirt from adhering to the portion of the light-receiving surface side protective material 101 that transmits the light toward each solar cell 103A.

  In the method for manufacturing the solar cell module according to the present embodiment, the light-receiving surface side protective material 101 is placed on the second protrusion 72 provided on the facing surface 7S of the second support portion 7 in the curing process of the stacked body 100. Place.

  Therefore, it is possible to suppress the dirt on the second support portion 7 from adhering to the light receiving surface side protective material 101 in the curing step. As a result, it is possible to further suppress a decrease in translucency of the light-receiving surface side protective material 101 and a decrease in productivity of the solar cell module.

  In the curing step, the second protrusion 72 is disposed between the plurality of solar cells 103 </ b> A on the projection surface substantially parallel to the light-receiving surface side protective material 101. Therefore, the translucency fall in the part which permeate | transmits the light which goes to each solar cell 103A among the light-receiving surface side protective materials 101 can be suppressed more.

[Second Embodiment]
Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. In the following, differences from the first embodiment will be mainly described. Specifically, each of the first protrusion and the second protrusion is formed in a linear shape in plan view.

(Configuration of the first protrusion)
Below, the structure of the several 1st projection part 33 which the 1st support part 3 which concerns on 2nd Embodiment has is demonstrated, referring drawings. FIG. 7 is a plan view of the first support portion 3 as viewed from the facing surface 3S side. FIG. 8 is a projection surface view that is substantially parallel to the light-receiving surface side protective material 101.

  As shown in FIG. 7, the plurality of first protrusions 33 are linearly provided on the release sheet 32 in plan view. Specifically, the two first protrusions 33 are provided along the first direction, and the five first protrusions 33 are provided at substantially equal intervals along the second direction.

  Here, the cross section of each first protrusion 33 has a trapezoidal shape. Therefore, the upper surface 33S of each first protrusion 33 is formed in a planar shape. The light-receiving surface side protective material 101 is placed on the upper surface 33S.

  As shown in FIG. 8, each first protrusion 33 does not overlap with each solar cell 103 </ b> A on a projection surface substantially parallel to the light-receiving surface side protective material 101. That is, each 1st projection part 33 is arrange | positioned according to the dimension of each solar cell 103A, and is arrange | positioned along between the solar cells 103A and the outer edge of each solar cell 103A.

(Configuration of the second protrusion)
Below, the structure of the 2nd projection part 72 which concerns on 2nd Embodiment is demonstrated, referring drawings. FIG. 9 is a plan view of the second support portion 7 as viewed from the facing surface 7S side. FIG. 10 is a projection surface view that is substantially parallel to the light-receiving surface side protective material 101.

  As shown in FIG. 9, the second protrusion 72 is linearly provided on the support bar 71 along the longitudinal direction of the support bar 71.

  Here, the cross section of the second protrusion 72 has a trapezoidal shape. Accordingly, the upper surface 72S of the second protrusion 72 is formed in a planar shape. The light-receiving surface side protective material 101 is placed on the upper surface 72S.

  As shown in FIG. 10, the second protrusion 72 does not overlap each solar cell 103 </ b> A on the projection surface substantially parallel to the light receiving surface side protection material 101. That is, the 2nd protrusion part 72 is arrange | positioned according to the dimension of each solar cell 103A, and is arrange | positioned between each solar cell 103A.

(Lamination process and curing process)
In the present embodiment, similarly to the first embodiment, in the laminating process, the light-receiving surface side protective material 101 is placed on the first protrusion 33 provided on the facing surface 3S of the first support 3. In the curing step, the light receiving surface side protective material 101 is placed on the second protrusion 72 provided on the facing surface 7S of the second support portion 7. Therefore, it is possible to suppress the dirt from adhering to the light receiving surface side protective material 101.

(Other embodiments)
Although the present invention has been described with reference to the above-described embodiments and modifications thereof, it should not be understood that the descriptions and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples and operational techniques will be apparent to those skilled in the art.

  For example, in the above embodiment, the first protrusion 33 is formed on the release sheet 32, but the first protrusion 33 may be integrally formed with the release sheet 32. In this case, the first protrusion 33 forms part of the facing surface 3S.

  In the above embodiment, the second protrusion 72 is formed on the support bar 71, but the second protrusion 72 may be integrally formed with the support bar 71. In this case, the second protrusion 72 forms part of the facing surface 7S.

  In the above embodiment, the first support unit 3 includes the release sheet 32, but the first support unit 3 may not include the release sheet 32. In this case, the first protrusion 33 may be integrally formed with the support base 31. The first protrusion 33 and the support base 31 form a facing surface 3S.

  In the above embodiment, the upper surface 33S of the first protrusion 33 is the mounting surface on which the light-receiving surface side protective material 101 is mounted. However, the present invention is not limited to this. The first protrusion 33 may not have the upper surface 33S.

  Moreover, in the said embodiment, although the upper surface 72S of the 2nd projection part 72 was a mounting surface in which the light-receiving surface side protective material 101 is mounted, it is not restricted to this. The second protrusion 72 may not have the upper surface 72S.

  As described above, the present invention naturally includes various embodiments not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

It is a side view which shows the structure of the laminating apparatus 10 which concerns on 1st Embodiment of this invention. It is the top view which looked at the 1st support part 3 concerning a 1st embodiment of the present invention from the counter surface 3S side. It is a projection surface figure substantially parallel to the light-receiving surface side protective material 101 which concerns on 1st Embodiment of this invention. It is a side view which shows the structure of the curing apparatus 60 which concerns on 1st Embodiment of this invention. It is the top view which looked at the 2nd support part 7 concerning a 1st embodiment of the present invention from the counter surface 7S side. It is a projection surface figure substantially parallel to the light-receiving surface side protective material 101 which concerns on 1st Embodiment of this invention. It is the top view which looked at the 1st support part 3 concerning a 2nd embodiment of the present invention from the counter surface 3S side. It is a projection surface figure substantially parallel to the light-receiving surface side protective material 101 which concerns on 2nd Embodiment of this invention. It is the top view which looked at the 2nd support part 7 concerning a 2nd embodiment of the present invention from the counter surface 7S side. It is a projection surface figure substantially parallel to the light-receiving surface side protective material 101 which concerns on 2nd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Lower housing 2 ... Upper housing 3 ... 1st support part 3S ... Opposite surface 4 ... Heating part 5 ... Diaphragm 6 ... Housing 7 ... 2nd support part 7S ... Opposite surface 10 ... Laminating apparatus 31 ... Support stand 32 ... Separation Mold sheet 33 ... first protrusion 33S ... upper surface 60 ... curing device 71 ... support rod 72 ... second protrusion 72S ... upper surface 100 ... laminated body 101 ... light-receiving surface side protective material 102 ... first sealing material 103 ... solar cell Group 103A ... Solar cell 103B ... Wiring material 104 ... Second sealing material 105 ... Back side protection material

Claims (3)

A laminated body formed by sequentially laminating a light-transmitting light-receiving surface-side protective material, a first sealing material, a plurality of solar cells, a second sealing material, and a back-side protective material is placed on the support portion of the heating device. Step A to be placed on
Step B for heating the first sealing material and the second sealing material by a heating unit of the heating device,
Step A includes
Prior SL-receiving surface side protection member substantially parallel to the projection plane, the projection portion to be positioned between the plurality of solar cells are provided on the opposing surface that faces the light receiving surface side protection member of the serial support portion A method for manufacturing a solar cell module, comprising placing the light-receiving surface side protective material on a protrusion. The method for manufacturing a solar cell module according to claim 1 , wherein a planar shape of the protrusion is linear. The method for manufacturing a solar cell module according to claim 1 , wherein a planar shape of the protruding portion is a point shape.

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