JP6624388B2 - Solar cell module and method for manufacturing solar cell module - Google Patents

Description

  The present invention relates to a solar cell module and a method for manufacturing a solar cell module.

  The solar cell module has a plurality of solar cells. The plurality of solar cells are resin-sealed between the first protection member and the second protection member to form a solar cell panel. The solar cell panel is fitted and fixed in a metal frame (for example, see Patent Document 1).

International Publication No. WO 2012/128342

  The thickness of the solar cell panel may vary depending on manufacturing conditions and the like. When a solar cell panel is fitted and fixed to a metal frame using an elastic body such as a rubber packing, a variation in the thickness of the panel may affect the fixing strength.

  The present invention has been made in view of such a situation, and an object thereof is to reduce the influence on fixing strength when a solar cell panel is fitted into a metal frame by using an elastic body, and improve the reliability of the solar cell. To provide modules.

  In order to solve the above problem, a solar cell module according to an embodiment of the present invention includes a first protective substrate, a first sealing layer, a plurality of solar cells, a second sealing layer, which are sequentially stacked. A second protection substrate. The side surface of the first protection substrate is covered with a protection member. The second protection substrate has a larger thickness in the stacking direction than the first protection substrate, has a larger outer circumference than the first protection substrate, and has a stacked region overlapping the first protection substrate in the stacking direction and an outer portion of the stacked region. And an outer peripheral region.

  Another embodiment of the present invention is a method for manufacturing a solar cell module. In this method, a first protection substrate, a first sealing material, a plurality of solar cells, a second sealing material, and a second protection substrate are placed between a first jig and a second jig from the first jig. Arranging the laminated body sequentially laminated in the direction toward the second jig, arranging an auxiliary jig on the outer periphery of the laminated body, sandwiching the laminated body between the first jig and the second jig, and heating Crimping. The second protection substrate has a larger thickness in the stacking direction than the first protection substrate, has a larger outer circumference than the first protection substrate, and has a stacked region overlapping the first protection substrate in the stacking direction and an outer portion of the stacked region. And an outer peripheral region. The auxiliary jig includes a first portion disposed between the first jig and the outer peripheral region of the second protection substrate, and the height of the first portion in the stacking direction is equal to that of the first protection substrate and the solar cell. It is larger than the sum of the thicknesses and smaller than the sum of the thicknesses of the first protective substrate, the first sealing material, and the second sealing material.

  According to the present invention, a solar cell module with improved reliability can be provided.

It is sectional drawing which shows the structure of the solar cell module which concerns on Embodiment. It is a top view which shows the structure of the solar cell panel which concerns on Embodiment. It is a figure which shows the manufacturing process of a solar cell module typically. It is a figure which shows the manufacturing process of a solar cell module typically. It is a figure which shows typically the effect which the solar cell module which concerns on Embodiment produces.

  Before describing the present invention in detail, an overview will be given. An embodiment of the present invention is a solar cell module. A solar cell module has a plurality of solar cells, and adjacent solar cells are connected by a connecting member called a tab wiring. The solar cell connected by the tab wiring is resin-sealed between the first protection substrate and the second protection substrate to form a solar cell panel.

  The thickness of the solar cell panel may vary depending on manufacturing conditions and the like. For example, due to in-plane variation of the pressing force when the laminate is laminated to form a panel, the position of the laminate on a hot plate, the positional relationship with other laminates arranged around, etc., the sealing material. In some cases, the thickness of the panel may vary. In addition, when a template glass having antiglare properties is used as a protective substrate, the glass has undulations in the template glass manufacturing process and the air-cooling tempering process, so that the convex portions or concave portions of the glass plates used on both sides of the panel are used. May occur randomly, and the thickness of the panel may vary. When the thickness of the panel varies, the fixing strength of the panel to the frame may be affected when the solar cell panel is fitted into the metal frame using an elastic body such as rubber packing.

  Therefore, in the present embodiment, a second protection substrate having an area larger than that of the first protection substrate is employed, and the second protection substrate is provided outside the stacked region where the first protection substrate and the second protection substrate overlap in the stacking direction. Is provided. Further, the thickness of the second protection substrate is made larger than that of the first protection substrate, and the outer peripheral region of the second protection substrate is fitted into the frame so that the solar cell panel is fixed. Even when the thickness of the entire panel from the first protection substrate to the second protection substrate varies due to manufacturing conditions or the like, the variation in the thickness of the entire panel compared to the variation in the thickness of the entire panel causes 2 Variation in the thickness of the protective substrate is relatively small. As a result, by fitting only the second protection substrate into the frame, it is possible to reduce the influence on the fixing strength due to the variation in thickness as compared with the case where the entire panel is fitted into the frame. In addition, by ensuring the fixing strength of the panel to the metal frame, it is possible to increase the reliability of the solar cell module particularly against a positive load.

  Hereinafter, embodiments for implementing the present invention will be described in detail with reference to the drawings. In the description of the drawings, the same elements will be denoted by the same reference symbols, without redundant description.

  FIG. 1 is a cross-sectional view illustrating the structure of solar cell module 100 according to the embodiment. FIG. 2 is a top view showing the structure of the solar cell panel 60. The solar cell module 100 includes a solar cell panel 60 and a frame 62. The solar cell panel 60 includes a plurality of solar cells 10, a tab wiring 20 for connecting adjacent solar cells 10 to each other, a first protection substrate 30, a second protection substrate 32, and a first sealing layer 34. , A second sealing layer 36.

  The solar cell 10 is a layer that absorbs incident light and generates photovoltaic power, and has a substrate made of a semiconductor material such as crystalline silicon, gallium arsenide (GaAs), or indium phosphide (InP). Although the structure of the solar cell 10 is not particularly limited, the present embodiment has a heterojunction between an n-type single-crystal silicon substrate and amorphous silicon. The solar cell 10 includes, for example, an i-type amorphous silicon layer, a p-type amorphous silicon layer doped with boron (B) or the like, or a transparent material such as indium oxide on the light-receiving surface side of an n-type single-crystal silicon substrate. They are laminated in the order of a transparent conductive layer made of a photoconductive oxide. Further, an i-type amorphous silicon layer, an n-type amorphous silicon layer doped with phosphorus (P) or the like, and a transparent conductive layer are stacked in this order on the rear surface side of the substrate.

  The solar battery cell 10 has a light receiving surface 12 which is one of the cell surfaces, and a back surface 14 which is one of the cell surfaces and faces the light receiving surface 12. Here, the light receiving surface 12 refers to a main surface of the solar cell 10 on which sunlight is mainly incident, and is a surface on which most of the light incident on the solar cell 10 is incident. A light receiving surface electrode is formed on the light receiving surface 12, and a back surface electrode is formed on the back surface 14.

  The tab wiring 20 is an elongated metal foil, for example, a copper foil coated with silver, tin, solder, or the like, or an aluminum foil. The tab wiring 20 electrically and mechanically connects the adjacent solar cells 10. One end of the tab wiring 20 is electrically connected to a light receiving surface electrode formed on one light receiving surface 12 of the adjacent solar cell 10. The other end of the tab wiring 20 is electrically connected to a back electrode formed on the other back surface 14 of the adjacent solar cell 10. The tab wiring 20 is bent in an inter-cell region between the adjacent solar cells 10 so that each of the light receiving surface 12 and the back surface 14 of the adjacent solar cell 10 is arranged in the same plane. .

The first protection substrate 30 and the second protection substrate 32 are exterior members that protect the plurality of solar cells 10 from the external environment, and are, for example, glass substrates. The first protection substrate 30 is provided on the light receiving surface 12 side, and transmits light in a wavelength band that the solar cell 10 absorbs for power generation. The second protection substrate 32 is provided on the back surface 14 side. The second protection substrate 32 is preferably thicker in the stacking direction than the first protection substrate 30 and has a thickness of 1.1 times or more the first protection substrate 30. By the thickness of the first protective substrate 30 t ₁ and providing a difference in thickness t ₂ of the second protective substrate 32, as the entire module when both of the thickness of the sum of (t 1 _{+ t 2)} to a constant Can be increased in strength. Since the strength of the glass is generally proportional to the square of the thickness, if the sum of the thicknesses is constant, the sum of the strengths of the two glasses is minimum when the thicknesses of the two are equal (t ₁ = t ₂ ). It is because it becomes.

  The first protection member 35 is provided on the side surface 30 a of the first protection substrate 30. The first protection member 35 is provided along the outer periphery of the first protection substrate 30, and is provided along each of the four sides of the rectangular first protection substrate 30. The first protection member 35 has a role of protecting the first protection substrate 30 from an impact applied to the side surface 30a of the first protection substrate 30. The first protection member 35 is formed of a resin material, and is preferably formed of a thermosetting resin such as ethylene-vinyl acetate copolymer (EVA) or polyimide. The first protection member 35 may be made of a polyethylene-based or polypropylene-based thermoplastic resin. The first protective member 35 may be made of the same material as at least one of a first sealing layer 34 and a second sealing layer 36 described later, and is integrated with the first sealing layer 34 and the second sealing layer 36. May be formed.

  The second protection substrate 32 has a larger outer circumference than the first protection substrate 30 and has a main surface having an area larger than that of the first protection substrate 30. As a result, the second protection substrate 32 includes a stacked region C1 overlapping the first protection substrate 30 in the stacking direction, and an outer peripheral region C2 outside the stacked region C1. The outer peripheral region C2 is provided over the entire periphery of the second protection substrate 32, and the outer peripheral region C2 is provided along each of the four sides of the rectangular second protection substrate 32. In the modified example, the outer peripheral area C2 may be provided only on three or two of the four sides of the second protection substrate 32. The outer peripheral area C2 of the second protection substrate 32 is fitted into the recess 64 of the frame 62 via a second protection member 66 such as a rubber frame.

In order to increase the fixing strength of the solar cell panel 60 to the frame 62, the width (contact width) Wb in the in-plane direction where the second protection substrate 32 and the second protection member 66 are in contact with each other is set to the thickness t ₂ of the second protection substrate 32. It is preferably larger. By increasing the contact width Wb between the second protection substrate 32 and the second protection member 66, the frictional force between the second protection substrate 32 and the second protection member 66 is increased, and the solar cell panel 60 is deformed so as to bend. It is possible to prevent the frame 62 from coming off the concave portion 64. In order to secure a contact width Wb sufficient for fixing the solar cell panel 60, the width Wa in which the outer peripheral region C2 is provided (the width Wa in the direction in which the stacked region C1 and the outer peripheral region C2 are adjacent) is also set to the second protective substrate 32. it is preferable greater than the thickness t _2. This is because the width Wa of the outer peripheral region C2 is substantially the same as the contact width Wb between the second protection substrate 32 and the second protection member 66, or is larger than the contact width Wb as illustrated. The width Wa of the outer peripheral region C2 is made larger than the thickness t ₂ of the second protective substrate 32, to ensure sufficient contact width Wb for fixing the solar cell panel 60, the fixing strength of the solar cell panel 60 with respect to the frame 62 Can be enhanced.

  The first sealing layer 34 and the second sealing layer 36 are sealing resin layers, and prevent penetration of moisture into the solar cell 10 and improve the strength of the entire solar cell module 100. The first sealing layer 34 is provided between the solar cell 10 and the first protection substrate 30, that is, on the light receiving surface 12 side. The second sealing layer 36 is provided between the solar cell 10 and the second protection substrate 32, that is, on the back surface 14 side. The first sealing layer 34 is a thermoplastic resin, for example, a polyethylene-based or polypropylene-based resin. The second sealing layer 36 is a thermosetting resin, for example, an ethylene-vinyl acetate copolymer (EVA), a polyimide-based resin containing a polyimide or a cross-linking material, or a polypropylene-based resin. The materials of the first sealing layer 34 and the second sealing layer 36 are not limited to these, and in a modified example, both the first sealing layer 34 and the second sealing layer 36 may be made of a thermoplastic resin. Then, both the first sealing layer 34 and the second sealing layer 36 may be made of a thermosetting resin.

  In the present embodiment, a resin having a lower melting point than the first sealing layer 34 is selected for the second sealing layer 36. That is, the resin material of the first sealing layer 34 has a relatively high melting point, and the resin material of the second sealing layer 36 has a relatively low melting point. For example, the melting point of the resin material is at least when the average molecular weight of the polymer constituting the resin is large, when the ratio of the branched structure (weight or density) is high, and when the localized site exists in the main chain of the polymer. In either case, the melting point will be high. Therefore, by using a resin having at least one of these resin characteristics different, it is possible to make the melting points of the first sealing layer 34 and the second sealing layer 36 different. The melting point of the resin material may be made different by utilizing characteristics different from the above-mentioned resin characteristics.

  The frame 62 is provided along the outer periphery of the solar cell panel 60, and is formed in a rectangular frame shape corresponding to the four sides of the rectangular second protection substrate 32. The frame 62 is formed of a metal material such as aluminum, iron, and stainless steel, or a resin material. The frame 62 has a concave portion 64 for receiving the outer peripheral area C2 of the second protective substrate 32. A second protection member 66 made of an elastic body such as a rubber frame is provided in the recess 64. The second protection member 66 has a role of filling the gap between the second protection substrate 32 and the concave portion 64 to increase the fixing strength and protecting the side surface 32 a of the second protection substrate 32.

  FIG. 3 is a diagram schematically illustrating a manufacturing process of the solar cell module 100. In this figure, the direction of the solar cell 10 is turned upside down from that in FIG. A plurality of solar cells 10 are connected by tab wires 20 to form a cell string 18. Next, the first sealing material 54 and the first protection substrate 30 are arranged on the light receiving surface 12 side of the cell string 18, and the second sealing material 56 and the second protection substrate 32 are arranged on the back surface 14 side. Subsequently, the first jig 40 and the first jig 40 are vertically arranged so as to sandwich the stacked body including the first protection substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protection substrate 32. The second jig 42 is arranged and the laminate is heated while applying pressure. At this time, the first jig 40 is on the heating side, and the second jig 42 is on the pressing side. The first sealing material 54 and the second sealing material 56 are fused by heat and pressure bonding to form the first sealing layer 34 and the second sealing layer 36, and the solar cell panel 60 is completed. When a thermosetting resin is used for at least one of the first sealing material 54 and the second sealing material 56, the thermosetting resin is placed in a resin curing furnace after the thermocompression bonding. May be completely cured.

  In the above-mentioned heat compression bonding step, the first jig 40 is arranged so as to contact the first protection substrate 30, and the second jig 42 is arranged so as to contact the second protection substrate 32. The first jig 40 has a heating device 44 such as a heater. The heating device 44 heats the first protection substrate 30. The heat generated by the heating device 44 is transmitted in the order of the first protection substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protection substrate 32. In the present embodiment, the first sealing material 54 and the second sealing material 56 are heated by heating from the first protection substrate 30 having a small thickness, compared with the case of heating from the second protection substrate 32 having a large thickness. Heat can be easily transmitted to In addition, by using a resin material having a low melting point for the second sealing material 56 that is less likely to be heated as compared with the first sealing material 54, the first sealing material 54 and the second sealing material 56 can be almost at the same timing. It can be softened and fused. This makes it possible to complete the thermocompression bonding step in a shorter time, thereby suppressing an increase in manufacturing cost.

  In the above-mentioned thermocompression bonding step, the outer periphery of the laminated body 50 in which the first protective substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protective substrate 32 are sequentially laminated is auxiliary auxiliary treatment. The tool 70 is arranged. The auxiliary jig 70 positions the second protection substrate 32 having a larger area than the first protection substrate 30, and places the first protection substrate 30, the first sealing material 54, and the cell string in the lamination region C1 of the second protection substrate 32. 18 and the second sealing material 56 are arranged. The auxiliary jig 70 includes a first portion 71 disposed in the outer peripheral region C2 of the second protection substrate 32, and a second portion 72 disposed outside the outer peripheral region C2 of the second protection substrate 32.

The first portion 71 is arranged close to the first protection substrate 30 so as to surround the outer periphery of the first protection substrate 30. The first portion 71 is disposed so as to face each other across the first protective substrate 30 has a broad interval w ₃₁ than the width w ₁ of the first protective substrate 30. Interval _{w 31} of the first portion 71 is smaller than the width _{w 2} of the second protective substrate 32. Thereby, the upper surface 71a of the first portion 71 can contact the outer peripheral area C2 of the second protection substrate 32 to support the second protection substrate 32. Width w ₃₂ of the upper surface 71a of the first portion 71 is preferably wider than the width of the same level or outer peripheral region C2 of the outer peripheral region C2. The height h ₁ of the first portion 71 is larger than the sum of the thicknesses of the first protection substrate 30 and the solar cell 10, and the height h ₁ of the first protection substrate 30, the first sealing material 54, and the second sealing material 56 It is preferably smaller than the sum of the thicknesses. Thereby, it is possible to support the second protection substrate 32 so as not to damage the solar cell 10 at the time of heat compression, and to prevent a gap or a bubble from being generated between the first protection substrate 30 and the second protection substrate 32 after the pressure bonding. .

The second portion 72 is arranged close to the second protection substrate 32 so as to surround the outer periphery of the second protection substrate 32. The second portion 72 is positioned adjacent to the outer side of the first portion 71, is the disposed so as to face each other across the second protective substrate 32 in the wide interval w ₄ than the width w ₂ of the second protective substrate 32 . Thereby, the displacement of the first protection substrate 30 and the second protection substrate 32 in the in-plane direction can be suppressed. The height _{h 2} of the second portion 72 has a height _h greater than ₁ of the first portion 71, smaller than the sum of the height _{h 1} of the thickness _{t 2} the first portion 71 of the second protective substrate 32 Is preferred. In other words, the height _{h 3} of the step between the upper surface 72a of the upper surface 71a and the second portion 72 of the first portion 71 is smaller than the thickness _{t 2} of the second protective substrate 32 is desired. Thereby, pressure can be reliably applied to the second protection substrate 32 during the thermocompression bonding.

  In the illustrated example, the first portion 71 and the second portion 72 are integral, but in a modified example, the first portion 71 and the second portion 72 may be separate. The auxiliary jig 70 may be disposed along each of the four sides of the rectangular first protection substrate 30 and the second protection substrate 32, or may be disposed along two or three of the four sides. Good. For example, while the auxiliary jig 70 is disposed along two opposing long sides of the first protection substrate 30 and the second protection substrate 32, the auxiliary jig 70 does not need to be disposed along the two opposing short sides. Good.

FIG. 4 is a diagram schematically showing a manufacturing process of the solar cell module 100, and shows a structure of the solar cell panel 60 which is heat-pressed. As illustrated, the first portion 71 of the auxiliary jig 70 is disposed between the first jig 40 and the second protection substrate 32 in the outer peripheral area C2 of the second protection substrate 32, I support. Thus, the first protective substrate 30, the same height h ₁ and the first part 71 as the sum of the thickness of the first sealing layer 34 and the second sealing layer 36 can be secured. Further, since the first portion 71 and the height difference h ₃ of the second portion 72 is smaller than the thickness t ₂ of the second protective substrate 32, the laminate between the first jig 40 of the second jig 42 The solar cell panel 60 can be formed by reliably heating and pressing the 50.

  In addition, the first protection member 35 is formed on the side surface 30a of the first protection substrate 30 by using the sealing material that protrudes outside the lamination region C1 during the thermocompression bonding. The first protection member 35 is formed using a gap between the first protection substrate 30 and the auxiliary jig 70. The first protection member 35 can be formed, for example, by using a part of the first sealing material 54 that has been softened at the time of thermocompression bonding. When a resin material that is difficult to soften is used as the material of the first sealing material 54, a part of the second sealing material 56 having a lower melting point than the first sealing material 54 is softened and the first protection member 35 is formed. May be formed. When a thermosetting resin is used for at least one of the first sealing material 54 and the second sealing material 56, the first protection member 35 can be formed of the thermosetting resin. By forming the first protection member 35 with a thermosetting resin, the strength of the first protection member 35 at a high temperature can be increased as compared with the case where a thermoplastic resin is used.

Next, the effects of the solar cell module 100 will be described.
FIG. 5 is a diagram schematically illustrating the effect of the solar cell module 100 according to the embodiment. The solar cell module 100 is installed such that the first protection substrate 30 is vertically above and the second protection substrate 32 is vertically below. The solar cell module 100 may be installed so that the first protection substrate 30 is orthogonal to the vertical direction, or may be installed diagonally so that the first protection substrate 30 intersects the vertical direction. When the solar cell module 100 is placed in a place where there is snowfall with the first protection substrate 30 being set vertically upward, snow is deposited on the first protection substrate 30 and the right side as shown by the arrow A from above the first protection substrate 30. Load is applied.

  When a positive load is applied, bending occurs such that the center of the solar cell module 100 is directed downward. A compressive stress is applied to the first protection substrate 30 as indicated by an arrow B, and a tensile stress is applied to the second protection substrate 32 as indicated by an arrow C. In the solar cell module 100, since the first protection substrate 30 is thin and the second protection substrate 32 is thick, the neutral plane F of the stress is located at a position close to the second protection substrate 32. Here, the neutral plane F refers to a place where no compressive stress or tensile stress is applied when the solar cell panel 60 bends. The range closer to the first protection substrate 30 than the neutral plane F is a compression region D where a compressive stress is applied, and the range closer to the second protection substrate 32 than the neutral plane F is a tensile region E where a tensile stress is applied. is there. Since the neutral plane F of the stress is located closer to the second protective substrate 32 than the solar cell 10 as shown in the figure, the solar cell 10 included in the compression region D is subjected to compressive stress. Become. The crystalline semiconductor material constituting the solar cell 10 has a characteristic that it is weak against tensile stress but strong against compressive stress. According to the present embodiment, by increasing the thickness of the second protective substrate 32, it is possible to prevent the solar cell 10 from generating tensile stress even when a positive load is applied to the solar cell module 100. Thereby, damage to the solar cell 10 can be prevented, and the reliability of the solar cell module 100 can be improved.

  According to the present embodiment, since the first protective substrate 30 having a small thickness is provided on the light receiving surface 12 side of the solar cell 10, the amount of attenuation of incident light caused by the first protective substrate 30 can be reduced. This is because, even if the glass substrate is transparent to the incident light, the transmittance of the incident light may decrease when the glass substrate is thick. Therefore, according to the present embodiment, more light can be incident on the solar cell 10 and the power generation efficiency of the solar cell module 100 can be increased.

  When the thickness of the first protection substrate 30 is reduced, the first protection substrate 30 may be easily warped depending on an external environment at the time of installation. For example, in summer or the like where the intensity of sunlight is high, the solar cell 10 absorbs high-intensity incident light and becomes high temperature, and the temperature of the first protection substrate 30 also increases. Since the first protection substrate 30 has a small heat capacity, the temperature of the first protection substrate 30 tends to be higher than that of the second protection substrate 32. As a result, the first protection substrate 30 has a larger thermal expansion than the second protection substrate 32, and the solar cell panel 60 warps so that the outer surface (light receiving surface) of the first protection substrate 30 becomes convex. It will be. Then, a tensile stress may be applied to the solar battery cell 10 and the solar battery cell 10 may be damaged.

  On the other hand, in the present embodiment, a thermoplastic resin is used as first sealing layer 34 between first protection substrate 30 and solar cell 10. Therefore, even when the first protective substrate 30 is warped due to a rise in the temperature of the solar cell module 100, the stress caused by the warp of the first protective substrate 30 due to the softening of the thermoplastic first sealing layer 34. Can be alleviated by the first sealing layer 34. Thereby, strong tensile stress is not generated in the solar cell 10, and damage to the solar cell 10 can be prevented.

  According to the present embodiment, the first sealing layer 34 on the light receiving surface 12 side is made of a thermoplastic resin, while the second sealing layer 36 on the back surface 14 is made of a thermosetting resin. 100 reliability can be increased. If both the first sealing layer 34 and the second sealing layer 36 are made of thermoplastic resin, the entire sealing layer is softened when the temperature of the solar cell panel 60 becomes high, and the arrangement of the cell strings 18 is shifted. This may cause damage to the solar cell 10. According to the present embodiment, by disposing at least one sealing layer of a thermosetting resin, displacement of the cell string 18 at a high temperature is prevented, and the solar cell 10 is damaged due to the displacement of the cell string 18. Can be prevented.

  According to the present embodiment, damage to the first protection substrate 30 can be suppressed by forming the first protection member 35 on the side surface 30a of the first protection substrate 30. In particular, by using a thermosetting resin as the first protection member 35, the strength of the first protection member 35 can be further increased.

  According to the present embodiment, by heating the first protection substrate 30 having a small thickness at the time of manufacturing the solar cell panel 60, the time required for the thermocompression bonding step can be reduced, and the manufacturing cost of the solar cell panel 60 can be reduced. Can be. In addition, by using the auxiliary jig 70 that supports the second protection substrate 32 having a size different from that of the first protection substrate 30, it is possible to prevent the second protection substrate 32 from being warped in the thermocompression bonding step. In particular, it is possible to prevent the outer peripheral region C2 of the second protective substrate 32 from being warped so as to be deformed toward the first protective substrate 30, and to improve the uniformity of the thickness of the solar cell panel 60 after the heat compression. By increasing the uniformity of the thickness of the solar cell panel 60, attachment to the frame 62 is facilitated, and a positional shift between the concave portion 64 of the frame 62 and the side surface 32a of the second protective substrate 32 can be prevented. Thereby, the fixing strength of the solar cell panel 60 to the frame 62 can be secured, and the reliability of the solar cell module 100 can be improved.

One embodiment of the present embodiment is a solar cell module (100). The solar cell module (100)
A first protection substrate (30), a first sealing layer (34), a plurality of solar cells (10), a second sealing layer (36), and a second protection substrate (32) that are sequentially stacked. With
The side surface (30a) of the first protection substrate (30) is covered with a protection member (35),
The second protective substrate (32) has a greater thickness in the stacking direction than the first protective substrate (30), has a larger outer circumference than the first protective substrate (30), and has a first protective substrate (30) in the stacking direction. ) And an outer peripheral region (C2) outside the laminated region (C1).

  The protection member (35) may include the same material as at least one of the first sealing layer (34) and the second sealing layer (36).

The width (w) of the outer peripheral region (C2) in the direction in which the laminated region (C1) and the outer peripheral region (C2) are adjacent to each other is the thickness (t ₂ ) of the second protective substrate (32). It may be larger than.

The first protection substrate (30) is arranged on the light receiving surface side of the plurality of solar cells (10),
The second protection substrate (32) may be arranged on the back side of the plurality of solar cells (10).

  The second sealing layer (36) may have a lower melting point than the first sealing layer (34).

  The first sealing layer (34) may be a thermoplastic resin, and the second sealing layer (36) may be a thermosetting resin.

  The first protection substrate (30) may be installed so as to be vertically upward.

Another aspect of the present embodiment is a method for manufacturing solar cell module (100). This method
A first protection substrate (30), a first sealing material (54), a plurality of solar cells (10), a second sealing material between a first jig (40) and a second jig (42). (56) and a stacked body (50) in which the second protective substrate (32) is sequentially stacked in a direction from the first jig (40) to the second jig (42);
Placing an auxiliary jig (70) on the outer periphery of the laminate (50), sandwiching the laminate (50) between the first jig (40) and the second jig (42), and heat-pressing; With
The second protective substrate (32) has a greater thickness in the stacking direction than the first protective substrate (30), has a larger outer circumference than the first protective substrate (30), and has a first protective substrate (30) in the stacking direction. ) And an outer peripheral region (C2) outside the laminated region (C1),
The auxiliary jig (70) includes a first portion (71) disposed between the first jig (40) and the outer peripheral area (C2) of the second protection substrate (32), and the first portion (71). ) In the stacking direction (h ₁ ) is larger than the sum of the thicknesses of the first protective substrate (30) and the solar cell (10), and the first protective substrate (30) and the first sealing material ( 54) and the thickness of the second sealing material (56).

Auxiliary jig (70) further includes a second portion (72) which is arranged outside the second protective substrate (32), the stacking direction of the height of the second portion (72) _{(h 2)} is, It is larger than the height (h ₁ ) of the first portion (71) and smaller than the sum of the height (h ₁ ) of the first portion (71) and the thickness (t ₂ ) of the second protection substrate (32). You may.

  The thermocompression bonding means that at least one of the first sealing material (54) and the second sealing material (56) protrudes outside the lamination area (C1) and the side surface (30a) of the first protection substrate (30). May be coated.

  The first jig (40) includes a heating device (44), and the laminate (50) may be heated from the first protection substrate (30) side.

  As described above, the present invention has been described with reference to the above-described embodiments. However, the present invention is not limited to the above-described embodiments, and may be obtained by appropriately combining or replacing the configurations of the embodiments. It is included in the present invention.

  C1: stacked region, C2: outer peripheral region, 10: solar cell, 12: light receiving surface, 14: back surface, 30: first protective substrate, 30a: side surface, 32: second protective substrate, 34: first sealing layer , 36: second sealing layer, 40: first jig, 42: second jig, 44: heating device, 50: laminated body, 54: first sealing material, 56: second sealing material, 60 ... Solar cell panel, 70 ... Auxiliary jig, 71 ... First part, 72 ... Second part, 100 ... Solar cell module.

Claims (10)

A first protection substrate, a first sealing layer, a plurality of solar cells, a second sealing layer, and a second protection substrate that are sequentially stacked;
The side surface of the first protection substrate is covered with a protection member,
The second protection substrate has a thickness in the stacking direction larger than the first protection substrate, has a larger outer periphery than the first protection substrate, and has a stacked region overlapping the first protection substrate in the stacking direction. look including an outer peripheral region than said deposition area,
The solar cell module according to claim 1, wherein the second sealing layer has a lower melting point than the first sealing layer .   The solar cell module according to claim 1, wherein the protection member includes the same material as at least one of the first sealing layer and the second sealing layer.   The solar cell according to claim 1, wherein a width of the outer peripheral region of the second protective substrate in a direction in which the stacked region and the outer peripheral region are adjacent to each other is larger than a thickness of the second protective substrate. module. The first protection substrate is disposed on a light receiving surface side of the plurality of solar cells,
4. The solar cell module according to claim 1, wherein the second protection substrate is disposed on a back side of the plurality of solar cells. 5. The solar cell according to any one of claims 1 to 4 , wherein the first sealing layer is a thermoplastic resin, and the second sealing layer is a thermosetting resin. module. The solar cell module according to any one of claims 1 to 5 , wherein the first protection substrate is installed so as to be vertically upper. A first protection substrate, a first sealing material, a plurality of solar cells, a second sealing material, and a second protection substrate are provided between the first jig and the second jig from the first jig to the second jig. Arranging the laminated body sequentially laminated in the direction toward the jig,
Arranging an auxiliary jig on the outer periphery of the laminate, sandwiching the laminate between the first jig and the second jig, and heat-pressing the laminate.
The second protection substrate has a thickness in the stacking direction larger than the first protection substrate, has a larger outer periphery than the first protection substrate, and has a stacked region overlapping the first protection substrate in the stacking direction. An outer peripheral region outside the laminated region,
The auxiliary jig includes a first portion disposed between the first jig and the outer peripheral region of the second protection substrate, and the height of the first portion in the stacking direction is the first portion. A solar cell characterized by being larger than the sum of the thicknesses of the protection substrate and the solar cell, and smaller than the sum of the thicknesses of the first protection substrate, the first sealing material and the second sealing material. Module manufacturing method. The auxiliary jig further includes a second portion disposed outside the second protection substrate, wherein a height of the second portion in the stacking direction is greater than a height of the first portion, and The method for manufacturing a solar cell module according to claim 7 , wherein the height is smaller than the sum of the height of one portion and the thickness of the second protection substrate. The thermocompression bonding may include at least one of the first sealing material and the second sealing material protruding outside the lamination region to cover a side surface of the first protection substrate. method of manufacturing a solar cell module according to claim 7 or 8. The method according to any one of claims 7 to 9 , wherein the first jig includes a heating device, and the stacked body is heated from a first protection substrate side. .

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