JPH1126796A - Solar cell module, manufacture thereof, building material, constructing method thereof and generator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module which never forms voids between a filler and reinforcing board during manufacturing the module, by sealing a photovoltaic element with the filler and fixing them to the board. SOLUTION: A module has a photovoltaic element 2 sealed with a filler 3 on a reinforcing board 5 having a rough surface shape 6 formed by the plastic deformation of at least a part of at least one surface which mounts the photovoltaic element 2, and the filler 3 is charged between the rough surface shape 6 and the photosensors 3. The manufacturing material comprises laminating at least a thermoplastic resin sheet and the photovoltaic element 2 on the board 5 having the rough surface, degassing between the board 5 and the resin sheet and between the sheet and the photovoltaic element 2, heating them and mutually tightly fixing them.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, a method of manufacturing the same, a building material using the same, a method of constructing the same, and a power generator.

[0002]

2. Description of the Related Art Hitherto, a solar cell module using a reinforcing plate on the back side of the solar cell module has been known.
As an example, a versatile solar cell module having an aluminum frame material shown in FIG. 8 will be briefly described below.

FIG. 8 is a perspective view showing a conventional solar cell module, and FIG. 9 is a partially enlarged sectional view taken along a section BB 'of FIG.

[0004] The configuration of the solar cell module 1 of this embodiment will be described with reference to FIG. The solar cell module 1 of the present invention includes:
The photovoltaic element 2 is resin-sealed with a translucent resin 3. The translucent resin 3 serves as a filler for sealing the photovoltaic element and fixing it on the reinforcing plate. In this example, the solar cell module 1 has the light-transmitting surface protection film 4 on the outermost surface on the light-receiving surface side, and has a metal reinforcing plate as the reinforcing plate 105. 3 are bonded and laminated.

[0005] An aluminum frame 7 is provided on the side of the solar cell module 1. The solar cell module 1 can be fixed to a desired place using this aluminum frame. The electric output of the solar cell module 1 of this example is performed from the cable 10 led out from the terminal take-out box 8 fixed to the reinforcing plate 5 with the adhesive 19.

An example of a method for manufacturing a solar cell module by sealing and fixing will be briefly described below. First, the following are prepared as filling materials for manufacturing a solar cell module by sealing and fixing a photovoltaic element.

[0007] As a filler that covers the front and back surfaces of the photovoltaic element and serves to adhere the filler material on the outside thereof,
For example, two sheets of EVA resin (ethylene-vinyl acetate copolymer) formed into a sheet having a thickness of 450 μm are prepared for the front and back sides.
m is prepared. As a reinforcing plate provided on the back side of the solar cell module, for example, a thickness of 0.4 m
A galvalume steel plate (55% aluminum-zinc alloy plated steel plate) is prepared.

Here, for example, an amorphous silicon photovoltaic element is prepared as the photovoltaic element. This is obtained by forming an amorphous silicon semiconductor layer on a stainless steel substrate having a thickness of 125 μm.

The thus-prepared product is sealed and fixed by heating and pressing. FIG. 10 is a perspective view showing an example of a jig for sealing and fixing, and FIG. 11 is a diagram showing a process of placing a material for manufacturing a solar cell module on the jig. FIG. The jig 18 is made of an aluminum plate.
The above-mentioned photovoltaic element and a material to be a filler thereof are mounted thereon. In order to fulfill the function as a jig, a groove 19 is formed on the outside of the aluminum plate so as to surround a region where the photovoltaic element and the filler are placed.
The groove 19 is provided with an O-ring 20 made of a heat-resistant resin. Immediately inside the O-ring 20, a suction port 21 for providing a vacuum is provided, which connects to a tube 22, which further connects to a vacuum pump (not shown). The pipe 22 is provided with a valve 26.

The fabrication of a solar cell module using the jig is performed, for example, as follows. First, jig 1
A Teflon film 23 for mold release is spread on 8. This is to prevent the EVA resin as the filler from protruding and sticking to the jig. Next, the above prepared ones are stacked on the jig 18 as follows. That is, at the bottom, a 0.4 mm-thick galvalume steel plate (manufactured by Daido Steel Co., Ltd .: 55% aluminum / galvanized steel plate) as a reinforcing plate, and a 450 μm-thick sheet formed thereon as a filler. A laminate 24 in which an EVA resin, an amorphous silicon photovoltaic element, the same EVA resin, and a 50 μm-thick fluororesin film are sequentially stacked on top is placed on a Teflon film 23 for mold release. At this time, a fluororesin film larger than the sheet size of the EVA resin is used. This prevents the filler from protruding and sticking to other material members, as in the case where the Teflon film 23 for release is laid at the bottom. Finally, the silicon rubber 25 is placed on the stack. Thus, the stacking of the materials on the jig 18 is completed.

In this state, a vacuum pump (not shown) is operated to open the valve 26. Then, Silicon Rubber 2
5 is in close contact with the O-ring 20 so that the silicone rubber 25 and O
A sealed space is formed between the ring 20 and the aluminum plate of the jig 18, and a vacuum is formed therein. Thereby, the reinforcing plate, the filler, the photovoltaic element, the filler, and the translucent surface protection film are uniformly pressed to the jig 18 by the atmospheric pressure via the silicon rubber 25.

The jig in such a state is put into the heating furnace while the vacuum pump is operated, that is, while maintaining the vacuum state. The temperature in the heating furnace is maintained at a temperature exceeding the melting point of the filler. In the heating furnace, after the filling material has exceeded the melting point and softened, and after the time for completing the chemical change for exhibiting sufficient adhesive force has elapsed, the jig kept in the above vacuum state from the heating furnace Take out. After cooling this to room temperature, stop the operation of the vacuum pump,
The vacuum is released by removing the silicon rubber 25. Thus, a solar cell module can be obtained.

[0013]

The solar cell module is manufactured in this way. When the above materials are stacked and then evacuated, a galvalume steel plate as a reinforcing plate and an EVA resin as a filler are used. However, there is a problem that the air between them cannot be completely sucked by the vacuum pump.

That is, as shown in FIG. 12, a portion between the EVA resin 3 as the filler and the galvalume steel plate 105 as the reinforcing plate is in contact with another portion while the air 27 is taken in. There is. This often occurs, for example, when the EVA resin absorbs moisture and the surface of the reinforcing plate is very smooth. Once in such a state, no matter how much the vacuum pump is used, the air 27 in this portion cannot be sucked, and the solar cell module is sealed and fixed as it is. as a result,
A bubble reservoir where the EVA resin and the reinforcing plate do not adhere to each other is generated.

On the other hand, there is an increasing number of cases where a solar cell module having a large area is required due to market demand, but this problem becomes more remarkable when a large-sized and large-area solar cell module is manufactured. . As the size and area of the solar cell module increase, the distance from the center to the end of the solar cell module increases. Therefore, the resistance at the time of bleeding air is greatly increased. Until now, even a solar cell module which did not have the problem of the occurrence of the above-mentioned bubble pool portion has been experiencing this problem when it was simply attempted to increase the size in response to market demands.

If the bubble reservoir is large,
The appearance is significantly impaired, and it cannot be shipped as a product, which causes a reduction in the production yield rate, and as a result, raises the production cost.

On the other hand, the air bubble reservoir is small and
In the case where it is behind the photovoltaic element, for example, there is a problem that it cannot be found by visual inspection before product shipment. The fact that it cannot be found by the appearance inspection means that there is no problem in the appearance in the initial state. However, while the solar cell module has been used for a long period of time, the air in the small bubble reservoir repeats expansion and contraction, and may grow into a large bubble reservoir. Then, there is a problem in appearance. Also, during the growth process, a phenomenon such as dew condensation may occur in the bubble reservoir, and water may be retained. In that case, there is a problem that the moisture may penetrate into the photovoltaic element and reduce the electrical performance of the photovoltaic element.

[0018]

According to the present invention, there is provided a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, and at least a part of a surface of the reinforcing plate on the side of the photovoltaic element. A solar cell module characterized by having an uneven shape formed by plastic deformation, and filling the space between the uneven shape and the photovoltaic element with the filler.

Further, the present invention provides a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, and at least a part of a surface of the reinforcing plate on the photovoltaic element side has an uneven shape. Having a width of the convex portion of the concavo-convex shape and a distance between centers of adjacent convex portions of 0.1 mm or more and 50 mm or more.
The present invention provides a solar cell module, wherein the height of the protrusion is 0.1 mm or more and 10 mm or less.

Further, the present invention provides a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, wherein at least a part of the surface of the reinforcing plate on the photovoltaic element side has a linear shape. A solar cell module having an uneven shape, wherein a space between the uneven shape and the photovoltaic element is filled with the filler.

Further, according to the present invention, at least a sheet member made of a thermoplastic resin and a photovoltaic element are laminated on a reinforcing plate having irregularities on the surface, and a sheet member made of the thermoplastic resin is provided between the reinforcing plate and the sheet member made of the thermoplastic resin. A method for manufacturing a solar cell module, characterized in that a sheet member made of a thermoplastic resin and the photovoltaic element are heated while being degassed and adhered and fixed to each other.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of a solar cell module 1 according to the present invention will be described with reference to FIG. The solar cell module 1 of the present invention is obtained by sealing the photovoltaic element 2 with a translucent resin 3. Translucent resin 3
Serves as a filler for sealing the photovoltaic element and fixing it on the reinforcing plate, and a thermoplastic sheet member can be used. In this example, a light-transmitting surface protection film 4 is provided on the outermost surface on the light-receiving surface side, and a reinforcing plate 5 is provided on the back surface, and they are bonded by the light-transmitting resin (filler) 3 respectively. It is sealed.

A frame 7 is provided on the side of the solar cell module 1 and can be fixed to a desired place using the frame 7. The electric output of the solar cell module of this example is performed from a cable 10 led out from a terminal extraction box 8. The terminal take-out box 8 is fixed to the reinforcing plate 5 with an adhesive 9.

An irregular shape 6 is formed on the surface of the reinforcing plate 5. FIG. 2 shows an example of the concavo-convex shape, in which a plurality of convex regions are formed on the photovoltaic element side of the reinforcing plate 5. FIG. 3 is a partially enlarged cross-sectional view taken along the line AA 'of FIG. In the figure, a is the width of the projection, b is the height of the projection, and c is the distance between the centers of the adjacent projections. Such a concavo-convex shape can be formed, for example, by causing plastic deformation. When the reinforcing plate is made of metal, it can be formed by press molding. In the case of a plastic plate, it can also be formed by curing using a mold having an uneven shape.

Since the reinforcing plate 5 is formed with an uneven shape, a bubble pool is formed between the filler 3 and the reinforcing plate 5 so as to adhere to each other when the photovoltaic element is sealed and manufactured. Can be prevented. The reason for this is that when the reinforcing plate has an uneven shape, it is difficult to hold air bubbles when the reinforcing plate and the filler sheet are brought into close contact with each other, and air is easily released along the uneven shape. This allows
The yield in manufacturing a solar cell module can be significantly improved. Further, there is no possibility that the electric performance of the photovoltaic element is reduced due to the bubbles, and the reliability is greatly improved.

Further, compared with the case where the reinforcing plate has a smooth surface,
By having the uneven shape, the contact area with the filler increases, which leads to an increase in the adhesive force. Thereby, the possibility that the reinforcing plate and the filler are peeled off is very small, and the long-term reliability is improved.

Further, the surface of the back surface of the solar cell module can be increased by providing the reinforcing plate with the uneven shape on the surface opposite to the photovoltaic element. Thereby, the heat radiation efficiency of the solar cell module can be increased. In particular, when a solar cell module is installed as shown in FIG. 13 (c) to be described later and air passing through a separated surface of the module is used as a heat energy source, a high heat radiation efficiency of the module is a great advantage. .

The width of the protrusions of the reinforcing plate (FIG. 3A) and the distance between the centers of adjacent protrusions (FIG. 3C) are 0.1 mm.
It is preferably not less than 50 mm and not more than 1 mm
More preferably, it is 0 mm or less. Further, the height of the protrusion (b in FIG. 3) is preferably 0.1 mm or more and 10 mm or less, and more preferably 0.5 mm or more and 5 mm or less. If the unevenness is larger than this range, there is a possibility that air may not easily escape. If the irregularities are smaller than this range, the heat radiation efficiency may be reduced.

Finally, the terminal box 8 for electrical output and the cable 10 are attached to the solar cell module manufactured as described above. Briefly, it is as follows. A hole 11 as shown in FIG. 2 is previously formed in a portion of the reinforcing plate 5 corresponding to the terminal take-out portion. Also,
At the time of sealing, the terminal portion is previously exposed outside from the hole 11. The terminal portion of the photovoltaic element 2 is soldered to the cable 10 using the hole 11 to perform electric output. At this time, the terminal take-out box 8 is attached for the purpose of protecting and waterproofing the terminal take-out portion. The terminal take-out box 8 and the reinforcing plate 5 are bonded with, for example, a silicone adhesive 9. At this time, waterproofness between the reinforcing plate and the terminal take-out box is also ensured at the same time. The reinforcing plate has an uneven shape in the area of the bonding portion of the terminal take-out box, and the silicone-based adhesive absorbs the uneven shape and securely adheres.

FIG. 4 shows an example of a reinforcing plate having no uneven shape in the bonding area of the terminal take-out box. As a result, the following operational effects can be expected, and the electrical reliability of the solar cell module is also improved. Since there is no need to absorb and bond the uneven shape, various members can be selected as the members to be bonded. Even if pulling the cable connected to the terminal take-out box and applying a force to peel the terminal take-out box, there is no unevenness on the adhesive surface, and stress concentration of peeling force occurs at the protrusions etc. There is no peeling strength of terminal box.

The method of sealing the photovoltaic element with the filler and fixing it to the reinforcing plate can be the same as the method of manufacturing the above-mentioned conventional example. In addition, it is preferable to cut off the filler 3 and the translucent surface protection film 4 which have protruded from the reinforcing plate 5.

By employing this manufacturing method, it is possible to easily increase the size of the apparatus while using an apparatus having a simple configuration as the manufacturing apparatus. When the device can be easily enlarged in this way, the solar cell module that can be manufactured can also be easily increased in size and area,
We can respond to various requests. That is, the problem of bleeding air between members caused by the increase in size and area of the solar cell module can be solved by using the means of the present invention.

Each component will be described below.

(Reinforcing Plate 5) The reinforcing plate used on the back side of the solar cell module of the present invention is not particularly limited except that at least a part of the surface on the side of the photovoltaic element has an uneven shape. . However, the shape of the reinforcing plate is preferably a plate-like material, and examples of the material include carbon fiber, FRP (glass fiber reinforced plastic), ceramic, glass, and the like. Particularly preferably, a metal plate is used. Things.

The use of a metal plate has the following advantages. It is easy to form irregularities. For example, it can be easily formed by pressing with a mold having a desired uneven shape. Since it has flexibility, it is possible to obtain a solar cell module that can be fixed to a curved portion. By bending or perforating the side portions, the solar cell module can be fixed by using the portions. By folding, it can be made into a solar cell integrated building material.

At this time, it is preferable that the metal material is excellent in weather resistance, corrosion resistance, and bending workability.
For example, a galvanized steel sheet, a steel sheet further having a weather-resistant substance such as a fluororesin or vinyl chloride thereon, a stainless steel sheet, and the like can be given.

FIG. 13 shows an example of a shape obtained by processing a reinforcing plate as a roof material. FIG. 13A is a schematic perspective view of a roof material in which the ridge-side locking portion 31 and the eave-side locking portion 32 are assembled together.
FIG. 13B shows a fixing member 34 fixed on a field board 33.
FIG. 13 (c) is a schematic perspective view showing a part of a roof material into which a locking portion 35 is inserted, and FIG. 13 (c) shows a locking portion 36 between adjacent roof materials.
It is a typical perspective view which shows a part of roof material which locks with the cap 37. A photovoltaic element 30 is provided on the light receiving surface of each roofing material. In the roofing material shown in FIG. 13A, first, the eave-side locking portion 32 of the first roofing material is fixed to the baseboard with a fixing member such as a hook, and a similar second locking portion is attached to the ridge-side locking portion 31. The roof material of the second roofing material is combined with the eave-side locking portion 3 of the second roofing material.
The work of fixing 2 with a slinger is repeatedly performed.

(Unevenness Formed on Reinforcement Plate 6) The unevenness formed on the reinforcement plate of the solar cell module of the present invention is not particularly limited. However, it is preferable that the concavo-convex shape is formed up to the end of the reinforcing plate. Thereby,
Without closing the path through which the air passes, it is possible to create a structure in which air bubbles are less likely to be formed.

The uneven shape may be the shape shown in FIGS. 2 and 3, but is more preferably a linear uneven shape as shown in FIG. With the linear uneven shape, when air is removed between the members, the direction of the removal can be made to conform to the intention of the creator. For example, when a solar cell module is manufactured using an elongated rectangular reinforcing plate, bleeding air in the short side direction has a shorter distance for bleeding air and lower resistance. Therefore, by forming the linear unevenness substantially parallel to the short side direction of the reinforcing plate, the air passes in parallel along the unevenness as a path and the deaeration is further improved.

Further, since the extending directions of the linear irregularities are uniform, the linear irregularities function as reinforcing ribs, and the linear irregularities are bent in a direction perpendicular to the extending direction of the linear irregularities. The bending rigidity with respect to the force to be applied is improved, and the strength of the entire solar cell module is improved. As a result, a frame material or the like is conventionally provided on the side of the solar cell module in order to assist the bending rigidity of the solar cell module. However, this is not necessary in the direction parallel to the direction in which the unevenness extends, thereby reducing costs. be able to.

FIG. 6 is an example of another uneven shape. In FIG. 6, a range 17 indicated by a dotted line is a portion where the photovoltaic element 2 is arranged, and there is no uneven shape 6 in this range, and the uneven shape 6 is formed in a region outside the range.

FIG. 7 is a sectional view of a member constituting a solar cell module having a reinforcing plate having the shape of FIG. 6 before sealing.
In FIG. 7, a sheet member 28 made of a fiber material is used.
Is disposed between the reinforcing plate 15 and the filler 3 so as to cover the arrangement area of the photovoltaic element 2 and the uneven portion on the outside thereof.

Thus, the uneven shape does not affect the photovoltaic element. For example, even if a photovoltaic element having no flexibility such as a crystalline silicon photovoltaic element is used,
There is no accident such as cracking when pressed at atmospheric pressure. Also, in a photovoltaic element having flexibility, such as an amorphous silicon photovoltaic element formed on a stainless steel substrate, the uneven shape of the reinforcing plate may have an appearance that reflects the photovoltaic element. Depending on the person, it is considered unfavorable in design and may be disliked, but according to the present embodiment, it is possible to obtain a beautiful solar cell module even in the design without having a pattern of irregularities visible. .

On the other hand, since there is no uneven shape on the back side of the photovoltaic element, the structure is inferior in air bleeding. However, the function of the sheet member 28 made of a fiber material allows the air bleeding. Ease has been improved. Seat member 2
Numeral 8 is provided between the reinforcing plate 15 and the filler 3 to prevent the reinforcing plate 15 and the filler 3 from contacting each other and to provide a gap between the fibrous materials as a passage through which air passes. is there. It is desirable that the fibrous sheet member 28 does not reach the end of the reinforcing plate 15. When the fibrous sheet member 28 reaches the end of the reinforcing plate 15, the end can serve as a moisture entry path, and the photovoltaic element 2
May reduce the reliability of the At the end portion where the sheet member 28 is not provided, the concave-convex shape 6 of the reinforcing plate 15 ensures air bleeding.

(Photovoltaic Element 2) The photovoltaic element 2 in the solar cell module of the present invention is not particularly limited. Examples include crystalline silicon photovoltaic devices, polycrystalline silicon photovoltaic devices, microcrystalline silicon photovoltaic devices, amorphous silicon photovoltaic devices, copper indium selenide photovoltaic devices, compound semiconductor photovoltaic devices, etc. Is mentioned. Preferably, it is a photovoltaic element having flexibility, and particularly preferably, an amorphous silicon photovoltaic element formed on a stainless steel substrate. By using a photovoltaic element having flexibility, in the manufacturing process as described above, even if the photovoltaic element is placed on the uneven shape of the reinforcing plate and pressed against the atmospheric pressure. No cracking accidents occur.

By using an amorphous silicon photovoltaic element formed on a stainless steel substrate as a flexible photovoltaic element, for example, compared to a photovoltaic element having a film substrate, Since it has rigidity, it is easy to form a gap between the filler and the filler, a passage for air when bleeding air between members is secured, and deaeration is further improved.

(Filler 3) The filler 3 protects the element from a severe external environment such as temperature change, humidity, impact and the like, and secures adhesion between the surface film and / or reinforcing material and the element. As a material, an ethylene-vinyl acetate copolymer (EV
A), ethylene-methyl acrylate copolymer (EM
A), ethylene-ethyl acrylate copolymer (EE
A), polyolefin resins such as butyral resin, urethane resins, silicone resins and the like. Among them, EVA is suitably used for solar cells. E
In the case of VA, crosslinking is generally performed with an organic peroxide.

In order to ensure insulation between the photovoltaic element 2 and the reinforcing plate 5, an insulating film may be provided by laminating with a filler. Examples of the material include nylon, polyethylene terephthalate, and polycarbonate. By using a material in which the above-mentioned fillers, for example, EVA and EEA, etc. are integrally laminated on both sides of the insulating film,
The step of disposing the filler on the back surface can be simplified.

(Sheet member 2 made of fiber material)
8) As a sheet member made of a fibrous material, which is disposed on a portion of the reinforcing plate having no unevenness to assist degassing, a glass fiber nonwoven fabric, a glass fiber woven fabric, or the like can be exemplified. Since the cost of the glass fiber nonwoven fabric is lower and when a thermoplastic resin is used as the filler, the space between the glass fibers can be easily filled with the thermoplastic resin,
More preferred.

The fiber material may be provided between the photovoltaic element 2 and the surface protection film 4 in some cases. Thereby, the scratch resistance is improved, and the photovoltaic element can be sufficiently protected from the external environment with a small amount of resin.

(Surface Protective Film 4) The surface film ensures long-term reliability of the solar cell module in outdoor exposure. Examples of the material include a fluorine resin and an acrylic resin. Among them, fluororesins are preferably used because of their excellent weather resistance and stain resistance. Specific examples include a polyvinylidene fluoride resin, a polyvinyl fluoride resin, and an ethylene-tetrafluoroethylene-ethylene copolymer. Polyvinylidene fluoride resin is excellent in terms of weather resistance, but ethylene tetrafluoride-ethylene copolymer is excellent in terms of compatibility between weather resistance and mechanical strength and transparency. In order to improve the adhesiveness with the filler 103, it is desirable to perform a treatment such as a corona treatment, a plasma treatment, an ozone treatment, a UV irradiation, an electron beam irradiation, a flame treatment, etc. on the surface of the surface film which is in contact with the filler.

The solar cell according to the present invention and the power converter can be combined to form a power generator. The power converter may have a function of cooperating with commercial power.

[0053]

EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited to these examples.

Example 1 A solar cell module shown in FIG. 1 was manufactured. However, as the reinforcing plate 5, a reinforcing plate having no uneven shape was used in the region 12 where the terminal take-out box as shown in FIG. 4 was bonded. The dimensions of the concavo-convex shape in FIG. 3 were such that the width a of the protrusion was 7 mm, the height b of the protrusion was 1.5 mm, and the distance c between centers of adjacent protrusions was 7 mm. The formation of the irregularities was performed by roll pressing with a pair of rollers each having irregularities on the surface.

Here, the photovoltaic element 2 has a thickness of 125 μm.
Silicon photovoltaic device with amorphous silicon semiconductor layer formed on stainless steel substrate, filler 3
Is EVA resin (ethylene-vinyl acetate copolymer) with a thickness of 4
Two sheets of a 50 μm sheet were used on the front and back of the photovoltaic element, and the light-transmitting surface protection film 4 had a thickness of 50 μm.
μm fluororesin film, reinforcement plate 5 0.4 mm thick
Was used.

The reinforcing plate 1 on which the irregularities 6 are formed in advance
In 3, the area 12 to which the terminal take-out box was adhered was formed into a smooth surface by using the press mold when press-forming to form a hole 11 for taking out the terminal. As a result, a thickness of 0.5 m is used for bonding the terminal take-out box.
m of the structural double-sided adhesive tape could be used. The double-sided adhesive tape does not require drying and curing time as compared with the silicone adhesive used in the embodiment. Therefore, in the production process, there is no need for a place to store the solar cell module for drying and curing, which is very convenient.

The fabrication of the solar cell module was performed in the same manner as in the prior art. A Teflon film 23 for release is placed on the jig 18 shown in FIGS. 10 and 11, on which a reinforcing plate 5 is provided at the bottom, a sheet-like filler 3 is provided thereon, a photovoltaic element 2, The laminated body 24 that was sequentially stacked with the sheet-like filler 3 and the surface protection film 4 was placed. Further, the silicon rubber 25 was covered, and a vacuum pump (not shown) was operated in this state, and the valve 26 was opened. As a result, the silicon rubber 25 comes into close contact with the O-ring 20, and a sealed space is formed between the silicon rubber 25, the O-ring 20, and the aluminum plate of the jig 18. Was. Thus, the reinforcing plate, the filler, the photovoltaic element, the filler, and the translucent surface protection film were uniformly pressed to the jig 18 via the silicon rubber 25 by the atmospheric pressure. By using a reinforcing plate having an uneven shape, smooth degassing is performed, and thus no air bubbles remain between the reinforcing plate and the filler.

The jig in such a state was put into a heating furnace while operating the vacuum pump and maintaining the vacuum state. The temperature in the heating furnace is maintained at a temperature exceeding the melting point of the filler. In the heating furnace, the filler becomes softer than the melting point, and after the time for completing the chemical change for exhibiting a sufficient adhesive force has passed, the heating furnace is used to remove the jig held in the above vacuum state. I took it out. After cooling to room temperature, the operation of the vacuum pump was stopped, and the silicon rubber 25 was removed to release the vacuum.
Thus, a solar cell module was obtained.

(Example 2) The solar cell module of this example was manufactured in the same manner as in Example 1 except that a reinforcing plate having a linear uneven shape was used as shown in FIG. The linear concavo-convex shape shown in FIG. 5 is such that a portion 16 protruding toward the photovoltaic element has a width of 7 mm, a height of 2 mm, and an interval of 10 mm. At this time, since the convex portion 16 functions as a reinforcing rib, the bending rigidity in the direction perpendicular to the extension direction of the convex portion 16 is increased, and the strength of the entire solar cell module is extremely low. Improved.

Embodiment 3 In the solar cell module of this embodiment, as shown in FIGS. 6 and 7, the portion 17 of the reinforcing plate 15 where the photovoltaic elements are arranged is provided with no irregularities. And a sheet member 28 made of a fibrous material was disposed in the same manner as in Example 1. As the sheet member 28 made of a fiber material, a nonwoven fabric made of glass fiber was used. This nonwoven fabric is a glass fiber with a wire diameter of 10 μm,
It was manufactured to have a basis weight of 20 g / m ² and a thickness of 100 μm. As a result, bubbles could be prevented from remaining, and the appearance of the completed solar cell module could be made favorable.

[0061]

As described above, according to the present invention,
When a photovoltaic element is sealed with a filler and fixed on a reinforcing plate to produce a solar cell module, no air bubbles are formed between the filler and the reinforcing plate. Productivity could be improved without producing a good product. In addition, there is no possibility of causing a decrease in electric performance, and the reliability has been greatly improved. Further, the heat radiation efficiency could be improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a solar cell module according to the present invention.

FIG. 2 is an example of a reinforcing plate used in the solar cell module of the present invention.

FIG. 3 is a partially enlarged cross-sectional view of an example of a reinforcing plate used in the solar cell module of the present invention.

FIG. 4 is a plan view showing a reinforcing plate used in Embodiment 1 of the solar cell module of the present invention.

FIG. 5 is a plan view showing a reinforcing plate used in Embodiment 2 of the solar cell module of the present invention.

FIG. 6 is a plan view showing a reinforcing plate used in Embodiment 3 of the solar cell module of the present invention.

FIG. 7 is a partially enlarged cross-sectional view showing a state in which components are stacked to produce a solar cell module according to a third embodiment of the present invention.

FIG. 8 is a perspective view showing a conventional solar cell module.

FIG. 9 is a sectional view showing a conventional solar cell module.

FIG. 10 is a perspective view showing a jig used for sealing the solar cell module with a resin.

FIG. 11 shows a diagram for sealing a solar cell module with resin.
Sectional drawing which shows the place where the filling material was piled up on the jig.

FIG. 12 is a cross-sectional view showing a state where air bubbles are formed between a reinforcing plate and a filler.

FIG. 13 shows an example of a building material of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 solar cell module 2 photovoltaic element 3 filler 4 surface protection film 5, 13, 14, 15, 105 reinforcing plate 6 uneven shape 7 frame 8 terminal extraction box 9 adhesive 10 cable 11 terminal extraction hole 12 terminal extraction Box bonding area 28 Sheet member made of fiber material

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Ayako Shiozuka 3-30-2 Shimomaruko, Ota-ku, Tokyo Within Canon Inc. (72) Inventor Toshihiko Mimura 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside the corporation

Claims (43)

[Claims] 1. In a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, at least a part of a surface of the reinforcing plate on the photovoltaic element side is formed by plastic deformation. A solar cell module having an uneven shape, wherein a space between the uneven shape and the photovoltaic element is filled with the filler. 2. The solar cell module according to claim 1, wherein a sheet member made of a thermoplastic resin is used as the filler. 3. The solar cell module according to claim 1, wherein the uneven shape is a linear unevenness. 4. The solar cell module according to claim 1, wherein the photovoltaic element has flexibility. 5. The solar cell module according to claim 4, wherein the photovoltaic element having flexibility is an amorphous silicon photovoltaic element formed on a stainless steel substrate. 6. The solar cell module according to claim 1, wherein at least a part of the concavo-convex shape reaches an end of the reinforcing plate. 7. The solar cell module according to claim 1, wherein the non-light-receiving surface side of the reinforcing plate has no irregularities at least in a region corresponding to a bonding portion of the terminal take-out box. 8. The solar cell module according to claim 1, wherein a portion of the reinforcing plate where the photovoltaic elements are arranged has no irregularities. 9. A sheet member made of a fibrous material is disposed in contact with a portion of the reinforcing plate having no unevenness, and overlaps a part of the portion having the unevenness. 8. The solar cell module according to 8. 10. The solar cell module according to claim 1, further comprising an insulating member between the reinforcing plate and the photovoltaic element. 11. A thermoplastic resin sheet member and a photovoltaic element are laminated at least on a reinforcing plate having irregularities on its surface, and the thermoplastic resin sheet member and the reinforcing resin sheet are interposed between the reinforcing plate and the thermoplastic resin sheet member. A method for manufacturing a solar cell module, characterized in that a resin sheet member and a photovoltaic element are heated while being degassed and adhered and fixed to each other. 12. The method for manufacturing a solar cell module according to claim 11, wherein the uneven shape is a linear unevenness. 13. The method according to claim 11, wherein the photovoltaic element has flexibility. 14. The method according to claim 13, wherein the flexible photovoltaic device is an amorphous silicon photovoltaic device formed on a stainless steel substrate. 15. The method for manufacturing a solar cell module according to claim 11, wherein at least a part of the concave-convex shape reaches an end of the reinforcing plate. 16. The method for manufacturing a solar cell module according to claim 11, wherein the non-light-receiving surface side of the reinforcing plate has no irregularities at least in a region corresponding to a bonding portion of the terminal take-out box. 17. The method for manufacturing a solar cell module according to claim 11, wherein a portion of the reinforcing plate where the photovoltaic elements are arranged has no irregularities. 18. A reinforcing plate, wherein a sheet member made of a fiber material is disposed in contact with a portion having no unevenness, and overlaps a part of the portion having the unevenness. 18. The method for manufacturing a solar cell module according to item 17. 19. A method according to claim 19, wherein when a hole for taking out a terminal is punched out of the reinforcing plate by a press molding machine, a region corresponding to a bonding portion of the terminal take-out box is formed to be smooth by the punching die. A method for manufacturing a solar cell module according to claim 15. 20. The method according to claim 11, further comprising an insulating member between the reinforcing plate and the photovoltaic element. 21. In a building material in which a photovoltaic element is sealed on a reinforcing plate with a filler, at least a part of the surface of the reinforcing plate on the side of the photovoltaic element has an uneven shape. And a space between the photovoltaic element and the photovoltaic element. 22. A method of constructing a building material according to claim 21, wherein the building material according to claim 21 is fixed on a field board by a fixing member, and the adjacent building materials are fixed to each other. 23. A thermoplastic resin sheet member and a photovoltaic element are laminated at least on a reinforcing plate having irregularities on the surface, and the thermoplastic resin sheet member is formed between the reinforcing plate and the thermoplastic resin sheet member. A method for producing a building material, wherein a resin sheet member and a photovoltaic element are heated while being degassed and closely adhered to each other. 24. A power generator comprising: the solar cell module according to claim 1; and a power converter connected to the solar cell module. 25. In a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, at least a part of a surface of the reinforcing plate on the side of the photovoltaic element has an uneven shape, The gap between the concave and convex shape and the photovoltaic element is filled with the filler, and the width of the convex portion of the concave and convex shape and the center-to-center distance between adjacent convex portions are 0.1 mm or more.
mm or less, and the height of the convex portion is 0.1 mm or more and 10 mm
A solar cell module characterized by the following. 26. The solar cell module according to claim 25, wherein a sheet member made of a thermoplastic resin is used as the filler. 27. The solar cell module according to claim 25, wherein the uneven shape is a linear unevenness. 28. The solar cell module according to claim 25, wherein the photovoltaic element has flexibility. 29. The solar cell module according to claim 28, wherein the flexible photovoltaic element is an amorphous silicon photovoltaic element formed on a stainless steel substrate. 30. The solar cell module according to claim 25, wherein at least a part of the concave-convex shape reaches an end of the reinforcing plate. 31. The solar cell module according to claim 25, wherein the non-light-receiving surface side of the reinforcing plate has no irregularities at least in a region corresponding to a bonding portion of the terminal take-out box. 32. The solar cell module according to claim 25, wherein a portion of the reinforcing plate where the photovoltaic elements are arranged has no irregularities. 33. A sheet member made of a fibrous material is arranged in contact with a portion of the reinforcing plate having no unevenness, and overlaps a part of the portion having the unevenness. 32. The solar cell module according to 32. 34. The solar cell module according to claim 25, further comprising an insulating member between the reinforcing plate and the photovoltaic element. 35. In a solar cell module in which a photovoltaic element is sealed on a reinforcing plate with a filler, at least a part of a surface of the reinforcing plate on the side of the photovoltaic element has a linear uneven shape. A solar cell module, comprising: a space between the uneven shape and the photovoltaic element is filled with the filler. 36. The solar cell module according to claim 35, wherein a sheet member made of a thermoplastic resin is used as the filler. 37. The solar cell module according to claim 35, wherein the photovoltaic element has flexibility. 38. The solar cell module according to claim 37, wherein the photovoltaic element having flexibility is an amorphous silicon photovoltaic element formed on a stainless steel substrate. 39. The solar cell module according to claim 35, wherein at least a part of the concave-convex shape reaches the end of the reinforcing plate. 40. The solar cell module according to claim 35, wherein the non-light-receiving surface side of the reinforcing plate has no irregularities at least in a region corresponding to a bonding portion of the terminal take-out box. 41. The solar cell module according to claim 35, wherein a portion of the reinforcing plate where the photovoltaic element is arranged has no uneven shape. 42. A sheet member made of a fibrous material is disposed in contact with a portion of the reinforcing plate having no irregularities, and overlaps a part of the irregularities. 42. The solar cell module according to 41. 43. The solar cell module according to claim 35, further comprising an insulating member between the reinforcing plate and the photovoltaic element.