JPH11303347A - Solar battery module and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery module ensuring waterproofness between abutting faces of frames constituting a frame body and heightening mass productivity. SOLUTION: Sealant 5 is stuck to an inclined face 21 and an extended face 22 of a short frame 11. A long frame 10 with an inclined face 14 and a vertical face 13 is fitted to a seal body 2 so as to make the inclined face 21 and extended face 22 abut the inclined face 14 and vertical face 13 of the long frame 10. A screw 4 is inserted from a through hole of the short frame 11, screwed into a thread-fastened piece of the long frame 10 and tightened.

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 having solar cells, and more particularly to a waterproof structure thereof.

[0002]

2. Description of the Related Art Conventionally, power solar cell modules having a plurality of solar cells have been widely used. Since a solar cell module for electric power is usually installed on a roof of a house, a wall surface of a building, or the like, sufficient waterproofness is required.

For example, Japanese Patent Application Laid-Open Nos. 62-122181 and 61-34752 propose a waterproof structure for a solar cell module. In the solar cell module described in the former publication, as shown in FIG. 19, a light receiving surface glass 63 is laminated on a surface of a pottant 62 having a solar cell 61 embedded therein, and a water-repellent back plate 64 is provided on the back surface of the pottant 62. Are stacked, and a moisture blocking material 65 is filled in a peripheral space between the light receiving surface glass 63 and the water repellent back plate 64.

[0004] Further, in the solar cell module described in the latter publication, as shown in FIG.
A panel 68 incorporating the solar cell 67 is sandwiched,
A butyl rubber 69 is interposed between the inner peripheral portions of the plate 66 to seal the peripheral portion of the panel 68, and the outside thereof is covered with a sealant 70.

[0005]

However, in order to install these solar cell modules on a roof or the like, it is necessary to attach a frame for supporting the solar cell modules to a peripheral edge of a panel or the like. Since the frame body is generally configured by combining a plurality of frames, a water-proof structure for preventing water from entering from abutting surfaces between the frames is required.

FIGS. 21 and 22 are views showing an example of the waterproof structure at the abutting surface between the frames. In this solar cell module, waterproofing is performed by applying a silicone resin 73 or the like to the butted portion between the frames 71 and 72 constituting the frame and the screwed portion.
In the figure, reference numeral 74 denotes a sealing body that seals the solar cell.

However, in the case of a solar cell module manufactured on the condition that it is installed on a roof or the like, in many cases, waterproofing only by applying a silicone resin or the like is not sufficient.
In addition, there is also a problem that it takes time and effort to apply a silicone resin or the like in manufacturing a solar cell module, and lacks mass productivity.

The present invention has been made in view of the above problems, and has as its object to provide a solar cell module that can reliably waterproof between abutting surfaces of frames constituting a frame and can enhance mass productivity. .

[0009]

Means for Solving the Problems The object of the present invention is to provide a solar cell module in which a frame for protecting the sealed body is attached to the periphery of the sealed body for sealing the solar cell. The body is composed of multiple frames,
A waterproof sealing material is interposed between the butting surfaces of the opposing frames. With this sealing material, it is possible to prevent infiltration of water or moisture into the sealing body from between the butting surfaces of the frames.

[0010] The sealing material is made of rubber, and is attached or baked to the abutting surface of the frame. In particular, operability is improved by baking the sealing material as compared with the case of sticking.

The butting surfaces of the frames are inclined surfaces so as to fit each other. Thus, the frames can be abutted against each other with an appropriate degree of adhesion, and the sealing material can be reliably brought into close contact with each frame.

The butting surface of the frame may be a composite surface composed of two or more types of surfaces including an inclined surface.
This makes it possible to eliminate the sharp portion on the tip side even on the inclined surface, so that it is safe for the operator to handle the frame.

The frames are combined by being tightened with screws, and a rubber washer is arranged between the screw head of the screws and the frame. With this washer,
Water between the screw and the frame can be prevented.

[0014]

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 2 is an external perspective view of the solar cell module according to one embodiment of the present invention.
In this solar cell module, a sealing body 2 sealing a solar cell 1 is formed, and a frame 3 for protecting the sealing body 2 is attached to a periphery of the sealing body 2. As shown in FIG. 1, the frame body 3 is formed by combining four frames by tightening them with screws 4, and a seal member 5 is interposed between abutting surfaces of the opposing frames.

As shown in FIG. 3, the sealing body 2 is formed by laminating a filler 7, a plurality of solar cells 1 and a weather-resistant backside protective film 8 on a translucent substrate 6 made of white plate reinforced glass or the like. It is formed by pressing and heating by a laminating method or the like. Each solar cell 1 is electrically connected in series or in parallel by an interconnector 9. The sealing body 2 is formed by forming a transparent electrode, a photoelectric conversion portion made of amorphous silicon, and a back electrode on a glass plate.
A so-called integrated sealing body sealed with a filler or the like may be used.

Referring to FIG. 2, the frame 3 is composed of a pair of opposed long frames 10 and a pair of opposed short frames 11 shorter than the long frames 10. The long frame 10 is formed by extruding a metal such as aluminum, and has a substantially rectangular parallelepiped main body 12 that is horizontally long as shown in FIG. The main body 12 has a hollow structure with both ends open, and a vertical surface 13 orthogonal to the longitudinal direction is formed at both ends, and an inclined surface 14 is integrally formed from the vertical surface 13. The inclined surface 14 is inclined at 45 ° with respect to the vertical surface 13. The composite surface composed of the vertical surface 13 and the inclined surface 14 serves as an abutting surface with the short frame 11.

At the upper part of the main body 12, there is formed a support portion 15 which is formed in a substantially U-shape when viewed from the side, and which sandwiches and supports the sealing body 2 along the longitudinal direction. Also, the main body 12
At the lower part, the mounting surface 1 extending from the bottom of the main body 12 is provided.
6 are formed. The mounting surface 16 is provided for installation on a roof or the like. The mounting surface 16 has a plurality of bolt through holes 17 for mounting the main body 12 on a roof or the like. A gutter 18 is formed on the outer side surface of the main body 12 along the longitudinal direction. On the inner wall surfaces at both ends of the main body 12, screwing pieces 19 are formed as mounting portions into which the screws 4 for fixing the short frame 11 to the long frame 10 are screwed. Note that the inclined surface 14 is formed not only by inclining the main body 12 but also inclining so as to be flush with the support portion 15 and the mounting surface portion 16.

The short frame 11 is, like the long frame 10,
As shown in FIG. 5, it has a substantially rectangular parallelepiped main body 20 formed by extrusion molding of a metal such as aluminum. The main body 20 has a hollow structure with both ends open, and an inclined surface 21 at 45 ° to the longitudinal direction is formed at both ends of the main body 20. An extension surface 22 extending parallel to the longitudinal direction is formed on the tip side of the inclined surface 21.
A vertical surface 23 perpendicular to the longitudinal direction is formed. The composite surface including the inclined surface 21 and the extension surface 22 is abutted on the vertical surface 13 and the inclined surface 14 of the long frame 10.

On the upper part of the main body 20, a long frame 1 is provided.
Similarly to the case of FIG. 0, the support portion 24 is formed in a substantially U-shape when viewed from the side, and the support portion 24 for sandwiching and supporting the sealing body 2 is formed. A gutter 25 is formed on the outer side surface of the main body 20 along the longitudinal direction. On the outer side surface of the main body 20, a through hole 26 is formed as a mounting portion into which the screw 4 for fixing the short frame 11 to the long frame 10 is inserted.

The sealing material 5 is made of a sheet-like butyl rubber, and is formed to have substantially the same size as the developed shape of the butted surface of the short frame 11 as shown in FIGS. And it is stuck on the extension surface 22 with an adhesive or the like. That is, the sealing material 5 includes a plate-shaped main body 31 and a substantially U-shaped support portion 32 formed on an upper portion of the main body 31 in a side view. The body 31 has two through holes 33 for the screws 4 for fixing the short frame 11 to the long frame 10. FIG. 6 shows a state before use, and FIG. 7 shows a state during use. That is, the seal member 5 is attached to the short frame 11 so that one end of the main body 31 and one end of the support portion 32 are bent.
When the sealing material 5 is attached to the other end of the short frame 11, the bending direction is reversed.

The sealing material 5 applied to the butting surface of the short frame 11 may be applied to the butting surface of the long frame 10. Further, the sealing material 5 may be fixed by baking after temporarily bonding rubber to the abutting surface of the short frame 11. As a result, it is possible to eliminate the time-consuming work of applying a silicone resin or the like which has conventionally been troublesome. In addition, since the work can be performed more easily than the case of using an adhesive, the mass productivity of the solar cell module can be increased.

FIG. 8 is a view showing a state before the long frame 10 and the short frame 11 are attached to the sealing body 2, and FIG.
FIG. 3 is a diagram when a long frame 10 is attached to a sealing body 2. As shown in FIG. 8, the long frame 10 is attached to the long side surface of the sealing body 2, and the sealing body 2 is fitted into the support portion 15 of the long frame 10 as shown in FIG. 9. The short frame 11 is attached to the short side surface of the sealing body 2, and the sealing body 2 is fitted into the support portion 24 of the short frame 11.

The inclined surface 21 of the short frame 11 is, as shown in FIG. 1, the inclined surface 14 of the long frame 10, and the extending surface 22 of the short frame 11 is the vertical surface 13 of the long frame 10.
Are respectively butted through the sealing material 5 so as to fit each other. In this case, the butting surfaces of the frames 10 and 11 are:
Since the inclined surfaces are formed so as to match each other, the frames 10 and 11 can be abutted against each other with an appropriate degree of adhesion. That is, when the short frame 11 is abutted against the long frame 10, if there is no inclined surface as shown in FIG. 22, the sealing material enters the inner surface of the long frame 71 while rubbing, and the sealing material is long on the surface parallel to the short frame 72. The frame 71 is pressed against the end face and compressed. However, no pressure is applied to the face orthogonal to the end face of the frame 71, and the frame 71 is peeled off or has low adhesion. However, as described above, when the inclined surfaces 14 and 21 abut against each other, there is no surface parallel to the direction in which the pressure is applied, and the frames 10 and 11 press against each other.
An appropriate degree of adhesion is obtained. Then, the sealing material 5 can be securely brought into close contact with the long frame 10, and it is possible to prevent water or moisture from entering.

The butting surface of the long frame 10 is a composite surface composed of two types of surfaces such as an inclined surface 14 and a vertical surface 13, and the butting surface of the short frame 11 is an extended surface having an inclined angle different from that of the inclined surface 21. By providing a composite surface composed of two types of surfaces, such as the surface 22, the sharp portion at the tip of the short frame 11 is eliminated, and the sharpness of the end can be reduced. Therefore, when assembling the frame 3, the worker is not injured at the tips of the frames 10 and 11, and handling safety can be improved.

Screw 4 for fixing frames 10 and 11 to each other
Is inserted into through holes 26 formed at both ends of the short frame 11 as shown in FIGS.
0 is screwed into the screwing piece 19 inside the main body 12. A rubber washer 36 is loosely fitted to the screw 4. Therefore, when the screw 4 is tightened, the washer 36 is interposed between the screw head 37 of the screw 4 and the short frame 11, and it is possible to prevent water or moisture from entering from the through hole 26. .

In FIG. 10, the screw head 37 of the screw 4 projects outward from the side surface of the short frame 11, but a recess is formed in the side surface of the short frame 11 so that the screw head 37 is May not be protruded.

Here, both ends of the short frame 11 are shown in FIG.
As shown in FIG. 3, an arc-shaped surface 40 and a straight surface 4 in plan view.
One composite surface may be used. Both ends of the long frame 10 are also combined surfaces of the arc-shaped surface 42 and the linear surface 43 in accordance with the combined surface of the short frame 11. Even in this case, the sharp portions at the tips of the frames 10 and 11 disappear, and the frame 1
0 and 11 can be handled safely.

Alternatively, as shown in FIG. 12, both ends of the short frame 11 may be formed as a composite surface of an inclined surface 44 and an extension surface 45 slightly inclined in the longitudinal direction of the short frame 11.
Both ends of the long frame 10 are also combined surfaces of the inclined surface 46 and the extension surface 47 having a slight inclination according to the combined surface of the short frame 11.

Further, as shown in FIG. 13, both ends of the short frame 11 may be a composite surface of the inclined surface 48 and the arc-shaped surface 49. Both ends of the long frame 10 are also short frames 1
A composite surface of the inclined surface 50 and the arc-shaped surface 51 is formed in accordance with the composite surface of (1). As described above, the structure of the butting surfaces of the frames 10 and 11 can be variously deformed in order to eliminate the sharp portions at the tips of the frames 10 and 11. Note that the gutters 18 and 25 are omitted in FIGS.

Further, as shown in FIG. 14, the shape of the sealing body 2 is not limited to the above-described substantially rectangular parallelepiped, but may be a substantially cylindrical shape having a small thickness. In this case, the frame 3 is formed by combining a plurality of bow-shaped frames 52, and the frame 52 is
They are butted by a so-called scarf joint, and a sealing material 53 is interposed between the butting surfaces. In the figure, 54
Are bolts for fixing the frame 52.

Next, a manufacturing procedure for manufacturing the above-described solar cell module will be described. First, the constituent members of the solar cell module are mounted on a mounting table or the like (not shown) of a manufacturing apparatus used for manufacturing the solar cell module. That is, as shown in FIG. 15, a white reinforced glass plate 6, a filler 7 made of a transparent resin, a plurality of solar cells 1, a filler 7, and a back surface protection film 8 are placed in this order.
Then, heating and pressurization are performed in a vacuum state by a lamination method or the like to form a sealing body 2 as shown in FIG. In addition, each filler 7 is integrated by being pressurized and heated,
It becomes one sealing material 7 that wraps around the solar cell 1.

Next, as shown in FIG. 16, a sealing material 55 made of butyl rubber is wound along the peripheral edge of the sealing body 2 formed in a plate shape, and attached with an adhesive or the like. And FIG.
As shown in FIG. 7, the support portion 15 of the long frame 10 is fitted to the long side surface of the sealing body 2 around which the sealing material 55 is wound. Thereafter, as shown in FIG. 18, the support portion 24 of the short frame 11 is fitted to the short side surface of the sealing body 2. Since the sealing material 55 is wound around the periphery of the sealing body 2, it is possible to prevent water, moisture, and the like from entering the sealing body 2 from between the frames 10 and 11.

Next, the short frame 11 is fixed to the long frame 10 by inserting and tightening the screws 4 from the through holes 26 formed on both side surfaces of the short frame 11. This allows
The frame body 3 is assembled, and a solar cell module that can be installed on a roof or the like is completed. Since a rubber washer 36 is loosely fitted to the screw 4, the washer 36 can prevent water, moisture, or the like from entering the through hole 26.

The present invention is not limited to the above embodiment, and many modifications and changes can be made to the above embodiment within the scope of the present invention. For example, the inclination angles of the inclined surfaces of the frames 10 and 11 are not limited to 45 °. Further, the sealing material 5 is not limited to butyl rubber, but may be fluoro rubber or the like.

[0035]

As described above, according to the present invention, the intrusion of water, moisture, or the like from between the butting surfaces of the frames is prevented by interposing the sealing material between the butting surfaces of the frames constituting the frame. And a highly reliable solar cell module can be provided.

Since the butting surfaces of the frames are inclined so that they match each other, the frames can be butted with an appropriate degree of adhesion, and the sealing material can be surely brought into close contact with each frame. The sealing effect increases.

Further, since the abutting surface of the frame is a composite surface composed of two or more types of surfaces, it is possible to eliminate a sharp portion on the tip end side when the surface is an inclined surface. Safety can be improved.

Further, the frames are combined by being tightened with screws, and a rubber washer is provided between the screw head of the screw and the frame. This washer prevents water penetration and moisture penetration through the screw. And the waterproofness of the solar cell module can be improved.

Further, by baking and applying the rubber of the sealing material to the abutting surface of the frame, the operation of attaching the sealing material can be eliminated, and the mass productivity of the solar cell module can be improved.

[Brief description of the drawings]

FIG. 1 is a view showing a frame of a solar cell module according to an embodiment of the present invention.

FIG. 2 is a perspective view of a solar cell module.

FIG. 3 is a sectional view of a sealing body.

FIG. 4 shows a long frame, (a) is a plan view, (b) is a front view, (c) is a bottom view, and (d) is a side view.

FIG. 5 shows a short frame, (a) is a plan view, (b) is a front view, (c) is a bottom view, and (d) is a side view.

FIG. 6 is a side view of a sealing material.

FIG. 7 is a perspective view of a sealing material.

FIG. 8 is a view before attaching each frame to a sealing body.

FIG. 9 is a cross-sectional view when a long frame is attached to a sealing body.

FIG. 10 is a sectional view when a screw is screwed into each frame.

FIG. 11 is a view showing a modification of the butting surface of each frame.

FIG. 12 is a view showing a modification of the butting surface of each frame.

FIG. 13 is a view showing a modification of the butting surface of each frame.

14 (a) is a plan view, and FIG. 14 (b) is a side view.

FIG. 15 is a diagram showing a manufacturing procedure of the solar cell module.

FIG. 16 is a diagram showing a procedure for manufacturing a solar cell module.

FIG. 17 is a diagram showing a manufacturing procedure of the solar cell module.

FIG. 18 is a diagram showing a manufacturing procedure of the solar cell module.

FIG. 19 is a sectional view showing a conventional solar cell module.

FIG. 20 is a sectional view showing another conventional solar cell module.

FIG. 21 is a view showing a waterproof structure of a conventional solar cell module.

FIG. 22 is a plan view of a conventional solar cell module.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Solar cell 2 Sealing body 3 Frame 4 Screw 5 Sealing material 10 Long frame 11 Short frame 14, 21 Inclined surface 15, 24 Supporting part 19 Screw piece 26 Through hole 36 Washer

Claims (7)

[Claims] 1. A solar cell module in which a frame for protecting the sealed body is attached to a peripheral edge of the sealed body for sealing the solar cell, wherein the frame is formed by combining a plurality of frames, A solar cell module comprising a waterproof sealing material interposed between abutting surfaces of opposed frames. 2. The solar cell module according to claim 1, wherein the abutting surfaces of the frame are inclined surfaces so as to fit each other. 3. The solar cell module according to claim 1, wherein the butted surfaces of the frame are a composite surface composed of two or more types of surfaces. 4. The solar cell module according to claim 1, wherein the sealing material is made of rubber, and is attached or baked to the abutting surface of the frame. 5. The frame according to claim 1, wherein the frames are combined by being tightened with screws, and a waterproof rubber washer is provided between the screw head of the screws and the frame. A solar cell module according to item 1. 6. The solar cell module according to claim 5, wherein the frame is provided with a support portion having a U-shaped cross section for supporting the sealing body and a mounting portion for mounting a screw. . 7. A sealed body is formed by sealing a solar cell with a sealing material, and when attaching a frame of a frame to a peripheral edge of the sealed body, the inclined butted surfaces of the frame are opposed to each other. A method for manufacturing a solar cell module, wherein a sealing material is sandwiched between abutting surfaces of the frames, and the frames are tightened with screws.