JPH11307800A - Solar cell module, its manufacture and manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a solar cell module, having a desired shape at a low cost without developing deformation in a photovoltaic element, improve design property as a roof, enhance the productivity of the solar cell module integrated with a roof material, and realize low cost. SOLUTION: This manufacturing method has a manufacturing steps for forming a group of photovoltaic elements, a lamination step for insulating and sealing them to make a flat solar cell module 1201, and a step for forming the solar cell module into a desired shape, and the forming step is provided with a means for eliminating a deformation applied horizontally to the photovoltaic element.

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, a method and an apparatus for manufacturing the same, and more particularly to a roofing-integrated solar cell module having a photovoltaic element formed on a light-receiving surface of a roofing material, a method for manufacturing the same, and a method for manufacturing the same. It relates to a manufacturing device.

[0002]

2. Description of the Related Art As global environmental problems become more serious, solar energy has recently attracted much attention as clean energy that does not generate harmful by-products such as thermal power and nuclear power. Also, there is a demand for the effective use of solar energy as infinite energy that does not deplete resources on limited earth.

[0003] On the other hand, in the case of a disaster such as an earthquake, the existing one-piece energy system has a problem that the energy supply is cut off or it takes a long time to recover the energy supply. On the other hand, since solar energy can be used at any time as long as it is a sunny area, its utility as a distributed independent energy source is high.

[0004] These needs have promoted the development of solar cell modules for homes, and at present, systems for construction and operation of solar power generation systems have been established.

[0005] However, at present, the practical application of solar cells has been difficult, and the reason is that the cost is high. As a means for solving this problem, a roof material-integrated solar cell module has been developed. The roofing-material-integrated solar cell module has a photovoltaic element formed on the light-receiving surface of the roofing material.

For example, the roofing-integrated solar cell module proposed in JP-A-7-302924 can be provided at a very low cost. The reason is that it has excellent compatibility with a normal roof, so that roof construction can be performed in the same manner as in the past, and equipment such as a suspension required for construction can be used as it is.

[0007] That is, as compared with a method of once installing a roof and then mounting a gantry on the roof and installing a solar cell module, not only the cost is low but also the construction work is simple. Also in the manufacturing method, the flat solar cell module can be processed by a conventional roller former molding machine or the like, and no new equipment is required.

The roofing-integrated solar cell module described in Japanese Patent Application Laid-Open No. 7-302924 has a roofing type design, in which photovoltaic elements are arranged in a flat portion in the shape of a roofing material.

In the design of the roofing material, there are a corrugated type, a tile type, a flat type and the like in addition to the horizontal roofing type.

[0010] Japanese Patent Application Laid-Open No. 6-218439 describes a method of manufacturing a corrugated roofing material. This roofing material is a general metal panel that does not use a solar cell module. Regarding the formation of a corrugation, a plurality of corrugations are formed by sequentially pressing a long metal panel a plurality of times with a small press die in order to perform press processing at low equipment cost. The corrugation is a method of pressing once shallowly and then pressing it again to form deeply.
The corrugation is pressed twice.

[0011] According to this, no distortion occurs at the boundary between the pressed portions when partially pressed,
Multiple corrugations can be formed.

[0012] Japanese Patent Application Laid-Open No. Hei 8-222752,
Japanese Patent Publication No. -222753 and Japanese Patent Publication No. 6-5768 describe a corrugated solar cell module. In each case, the photovoltaic elements are arranged in a wave shape in order to improve the light use efficiency, and the manufacturing method is a procedure of attaching the photovoltaic elements to a corrugated steel plate or the like with an adhesive or the like.

[0013]

However, the conventional corrugated solar cell module cannot satisfy the low cost expected of a roofing-integrated solar cell module. This is because the photovoltaic element and the corrugated sheet need to be separately formed and then bonded later. This is because the number of production steps is large, production time such as bonding time is required, and production cost is increased.

However, if a conventional pressing process is applied to the solar cell module in order to manufacture a corrugated solar cell module at low cost, the photovoltaic element is distorted, cracks are generated, and the photoelectric conversion characteristics are increased. And there is a problem that the characteristics are deteriorated in outdoor use for a long period of time.

In view of the above problems, the present invention makes it possible to manufacture a photovoltaic module having a desired shape at low cost by using an existing molding machine without causing distortion in a photovoltaic element. To provide a solar cell module capable of improving the design as a roof, improving the productivity of a roof material-integrated solar cell module, and realizing low cost, and a method and apparatus for manufacturing the solar cell module. With the goal.

[0016]

The invention according to claims 1 to 12 relates to a method for manufacturing a solar cell module, and includes a mounting step of forming a photovoltaic element group, and an insulating sealing of the photovoltaic element group. A lamination step of forming a flat-plate-shaped solar cell module, and a step of molding the solar cell module into a desired shape. In the molding step, a distortion that suppresses parallel distortion applied to the photovoltaic element is suppressed. It is characterized in that reduction means is applied.

A thirteenth aspect of the present invention relates to a solar cell module obtained by the above manufacturing method.

The inventions of claims 14 to 25 relate to an apparatus for manufacturing a solar cell module provided with a molding apparatus for molding a solar cell module having a photovoltaic element into a desired shape. It is characterized in that it has a distortion reduction device for suppressing distortion in the parallel direction applied to the electromotive element.

As described above, the present invention relates to a novel solar cell module, a method of manufacturing the same, and a manufacturing apparatus thereof.
The configuration and operation of each invention will be further described below.

According to the present invention, a corrugated roof material integrated solar cell module is obtained by processing a flat solar cell module using a conventional roof material processing and forming machine. The difference from the horizontal roofing type roof material-integrated solar cell module described in JP-A-302924 is that processing is performed at a photovoltaic element. That is, a process in which the photovoltaic element is distorted is performed.

The above-mentioned Japanese Patent Application Laid-Open No. Hei 6-218439 describes the distortion applied to the metal panel. The distortion is a distortion that causes a problem in appearance. On the other hand, the distortion of the present invention is a distortion newly generated in a corrugated roof material-integrated solar cell module, and is not a distortion of a reinforcing material to be a roofing material, but is a resin sealed on the reinforcing material. This is the distortion of the photovoltaic element. The distortion of the photovoltaic element affects the electrical characteristics and reliability of the solar cell module even if the appearance is flat, for example.

A method of manufacturing a corrugated roof material integrated solar cell module will be described below.

FIG. 1 is a top view of a photovoltaic element group according to the present invention. In the method for manufacturing a roofing material-integrated solar cell module, first, a photovoltaic element group as shown in FIG. 1 is created. A plurality of photovoltaic elements 1
01 are connected in series by a connecting member 102, and a pair of positive and negative lead wiring members 103 are provided.
Each photovoltaic element 101 is provided with a bypass diode 104.

FIGS. 2A and 2B show a solar cell module before processing according to the present invention, wherein FIG. 2A is a top view thereof, and FIG.
Is a sectional view taken along the line aa ′. Next, a photovoltaic element group 202 is formed on a flat reinforcing material 201 as shown in FIG. 2. The method is to laminate a coating material 203 and a photovoltaic element group 202 on the reinforcing material 201. Then, the coating material 203 is melted by heating while vacuum defoaming, and then cooled.

FIGS. 3A and 3B show a solar cell module having an engaging portion according to the present invention, wherein FIG. 3A is a top view thereof, and FIG. 3B is a sectional view taken along line aa ′. An engaging portion 301 is formed in a part of the reinforcing material so that the solar cell module can be used as a roof material. The engaging portion is necessary for joining and fixing each other when the roofing material is laid, and also has a rain closing function for preventing rain from entering. The formation of the engaging portion 301 is the same as that of the conventional roofing material.
This is performed by a roller former molding machine, and the long side end of the module is processed in a U-shape.

FIG. 4 shows a corrugated solar cell module according to the present invention, wherein (a) is a perspective view thereof,
(B) is a sectional view taken along line aa ′. Finally, a corrugated roofing material-integrated solar cell module can be obtained by processing into a corrugated shape as shown in FIG. By making it corrugated, the design as a roofing material is enhanced. The corrugation is performed by pressing with a corrugated mold. The reason why the corrugating process is performed after the engaging portion 401 is formed first is that the roller former process performed before that may sometimes form only a planar shape, but by corrugating the engaging portion, This is because a corrugated shape can be maintained.

However, in the manufacturing process of such a corrugated roof material-integrated solar cell module, the photovoltaic element was distorted by press working and cracks were generated.

FIGS. 5A and 5B show a state in which a solar cell module having an engaging portion according to the present invention is formed into a corrugated shape by press working. FIG. 5A is a side view showing a state before pressing, and FIG. ) Is a side view showing the state after pressing,
(C) is a sectional view thereof.

Pressing is performed by sandwiching the solar cell module 503 from above and below with a pair of corrugated molds, an upper mold 501 and a lower mold 502. (B) is the upper mold 50
1 is the state where it has fallen to the bottom dead center. In this state, the height of the corrugation and the module length change depending on the distance (clearance) between the upper mold 501 and the lower mold 502.

FIG. 6 is an enlarged view of a corrugated portion of the solar cell module according to the present invention.
(A) is a sectional view in the direction parallel to the wave direction, and (b) is a sectional view taken along the line AB in the direction perpendicular to the wave direction.

A solar cell module in which a photovoltaic element 603 is sealed with a resin 605 on a reinforcing material 604 is formed in a wave shape.

Since the reinforcing member 604 is harder than the photovoltaic element 603 and the resin 605, it is considered that the processing neutral line when the corrugated shape is formed is near the center of the reinforcing member. For this reason, the photovoltaic element 603 of the corrugated peak 601 is located outside the processing neutral line by press working,
A strain is applied in the elongation direction.

In the portion 606 where the engaging portion is formed,
It is considered that the neutral line for processing shifts toward the center of the engagement portion. Therefore, it is considered that the distortion applied to the photovoltaic element in the vicinity is further increased. Although the distortion of the photovoltaic element can be reduced by increasing the R of the peak, the degree of freedom in design design is limited in consideration of the design of the corrugated solar cell module. Also, even if the peak portion R is too large, the distortion of the photovoltaic element near the engagement portion 606 becomes large for the above reason.

FIG. 16 is an explanatory diagram showing distortion measurement results in the process of studying the present invention.

Measurements were made on a corrugated roof-integrated solar cell module in which eight corrugations were formed. When viewed from the eaves side, the distortion of the photovoltaic element at the peak of each waveform when the first waveform from the right is R1, and subsequently R2, R3, R4, R5, R6, R7, and R8. And the result of observing the presence or absence of cracks by observing the surface of the photovoltaic element at that portion with an electron microscope. At this time, the clearance between the upper mold and the lower mold is 12 mm.
It is.

When a photovoltaic element is subjected to a strain exceeding a certain value, a crack is generated. This is the crack in the photovoltaic element. Cracks occur near the peak of the waveform. This strain is different from the strain at the boundary between the pressed portions described in Japanese Patent Application Laid-Open No. 6-218439. The photovoltaic element located on the reinforcing member is located outside the bending from the neutral line of the working. This is the distortion that is caused by having a distance in the direction.

Cracks in the photovoltaic element lower the photoelectric conversion characteristics, and may cause deterioration of the characteristics in long-term outdoor use.

Therefore, the present inventors have further conducted research and development and have obtained the following findings. That is, according to FIG. 16, it is understood that the distortion of the photovoltaic element located in the middle waveform is larger than the waveform of the end of the solar cell module. It can be inferred that this is because the peaks at the edges can disperse the distortion outward, but the peaks in the middle cannot escape the distortion. From these results, it can be expected that cracks in the photovoltaic element will be eliminated by forming all the ridges under the same conditions as the end ridges.

The present invention provides a corrugated roof-integrated solar cell module having the following features based on the above results, and a method and apparatus for manufacturing the same.

(1) The method of manufacturing a solar cell module is as follows:
The method includes a mounting step of creating a photovoltaic element group, a lamination step of insulating and sealing the photovoltaic element group to create a flat solar cell module, and a step of forming the solar cell module into a desired shape. In the molding process,
A distortion reducing means for suppressing a parallel distortion applied to the photovoltaic element is provided.

Accordingly, the distortion applied to the photovoltaic element can be reduced. In particular, cracking of the photovoltaic element occurs due to strain in the tensile direction, and cracking is prevented by means for reducing strain in the tensile direction.

(2) In the forming step, it is preferable to form the solar cell module in which the engaging portions are formed into a desired shape.

When used as a roofing-integrated solar cell module, an engaging portion is required. Since the distortion of the photovoltaic element near the engagement portion becomes large for the above reason,
In the molding process of the solar cell module in which the engaging portions are formed, a further effect by the distortion reducing means can be expected.

(3) The forming step is preferably performed by press working. This makes it possible to use the same pressing process that has been used in the manufacture of roofing materials. Therefore, it is possible to provide a method of manufacturing a roof-integrated solar cell module with low cost and high productivity without requiring new capital investment.

(4) The desired shape is preferably a wave shape, a triangle shape or a wedge shape. By molding the roof material-integrated solar cell module having such a shape, the design is enhanced.

(5) The reason why the strain in the parallel direction is defined as the strain in the tensile direction is that the photovoltaic element cracks particularly in the case of the corrugated roof material-integrated solar cell module particularly in the tensile direction. This is because cracks can be prevented by the strain reducing means in the tensile direction.

(6) Preferably, the distortion reducing means is a multi-stage press working for forming a desired shape in a plurality of times. Thereby, it is possible to prevent the concentration of strain that occurs when a desired shape is pressed once.

(7) In the multi-stage pressing, it is preferable to form the desired shape by repeating the pressing while sequentially transferring the solar cell modules. According to this method, a desired shape can be formed by using only one mold. In addition, since the mold can be easily changed, it is possible to efficiently process and mold various designs, and to provide a method of manufacturing a roof material-integrated solar cell module with high productivity.

(8) Alternatively, in the multi-stage press working, it is preferable to form a desired shape by sequentially operating a plurality of press dies without transporting the solar cell module. According to this method, dies having different shapes can be combined, and the range of designs can be expanded.

(9) Alternatively, in the multi-stage pressing, it is preferable to form a desired shape by roller pressing. According to the roller press working method, since the working speed is high, it is possible to provide a method for manufacturing a roof material-integrated solar cell module with high productivity.

(10) The photovoltaic element is preferably made of an amorphous semiconductor. Since an amorphous semiconductor has a large elastic region, a region where cracks do not occur due to strain is large. Therefore, the processing limit is widened, and it becomes possible to produce a roofing-integrated solar cell module with more design properties.

(11) In the photovoltaic element group, it is preferable that the photovoltaic element is sealed with resin on a reinforcing material. When the solar cell module is formed, the strain applied to the photovoltaic element increases for the above-described reason. Therefore, in the step of forming the solar cell module, the effect of the distortion reducing unit can be expected.

(12) The solar cell module is preferably formed as a roof material-integrated solar cell module. By using a solar cell module having a periodically formed unit shape as a roof material, the design of the roof material is further improved, and the roof design is improved. In addition, since it can be manufactured on a conventional production line as a roof material integrated type, the cost is low.

[0054]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of a solar cell module, a method of manufacturing the same, and a manufacturing apparatus according to the present invention will be described below in detail with reference to the accompanying drawings. However, the present invention is limited to this embodiment. Not something.

FIG. 7 shows a roof material-integrated solar cell module in which a desired shape of the present invention is formed.
Is a perspective view thereof, and (b) is a sectional view taken along the line aa ′.
In this case, the shape of each part is corrugated, but is not particularly limited, and may be anything other than corrugated, such as wedge.

In the structure of the roofing-integrated solar cell module, a photovoltaic element group 701 is formed on a reinforcing material 702 by insulating a back surface coating film 703 and a surface coating film 704, and a space between each material is provided. It is bonded with a filler 705.

The electricity generated by the photovoltaic element 701 is taken out of the solar cell module by a cable 706 or the like. A terminal box 707 is provided at a portion where the cable is attached for insulation protection and waterproofing.

The method of manufacturing the roofing-material-integrated solar cell module relates to a flat solar cell module using an existing processing and forming machine that has been conventionally used such as a roll former forming machine, a press machine, and a bender machine. After the formation of the joint portion, the joint portion is formed by pressing into a desired shape by means of a press working having a strain reducing means.

Hereinafter, each constituent material of the roof material-integrated solar cell module will be described.

(Roof material-integrated solar cell module) A roof material-integrated solar cell module is one in which a photovoltaic element is formed on the light-receiving surface side of the roof material, which is the exterior part of the roof, and is located above the existing roof. 2 shows a solar cell module that can be installed without a mount. Naturally, the design of the roofing material integrated solar cell module is the design of the roof.

(Photovoltaic element) As a photovoltaic element,
There is no particular limitation, for example, a single-crystal silicon photovoltaic element,
Non-single-crystal photovoltaic elements, specifically, polycrystalline silicon photovoltaic elements, amorphous silicon photovoltaic elements, copper indium selenide photovoltaic elements, compound semiconductor photovoltaic elements, and the like, but preferably An amorphous silicon photovoltaic element formed on a flexible stainless steel substrate is employed.

(Series Member) The series member is for electrically connecting the photovoltaic elements to each other, and is not particularly limited as long as it is a conductive material.

As the material of the series member, for example, copper,
Silver, aluminum, nickel, tin, tin-plated copper foil and the like can be mentioned, and preferably, copper having flexibility is adopted.

(Bypass Diode) The bypass diode is an electric bypass circuit when the photovoltaic element is partially shaded, and is provided for each photovoltaic element.
The type, performance, size, and shape of the diode vary depending on the size of the photovoltaic element, the current used, the connection form, and the like, but are not particularly limited. In consideration of the thinness of the solar cell module, it is preferable that the shape is as small as possible and the thickness is small. Specifically, a chip diode, a flat diode, and the like are given.

(Lead Wiring Member) The lead wiring member is a wiring for extracting electricity from the photovoltaic element to the outside of the solar cell module, and is wired to the terminal position of the solar cell module.

The wiring member is not particularly limited as long as it is conductive. For example, a flexible material such as copper, silver, aluminum, tin, and tin-plated copper is preferable.

(Group of Photovoltaic Elements) The group of photovoltaic elements is formed by electrically connecting a plurality of photovoltaic elements provided with bypass diodes to each other by a series member, and electrically connecting the solar cell module to the outside. The lead wiring member is provided up to the terminal position for taking out the lead wire. The number of series and parallel numbers of photovoltaic elements are set as required.

(Surface-Coated Film) The surface-coated film needs to protect the surface and ensure insulation, and is required to have insulation, light-transmitting properties, weather resistance, and low adhesion of dirt.

As a material of the surface coating film, there is a fluororesin film such as polyethylene tetrafluoroethylene, polytrifluoroethylene and polyvinyl fluoride. Usually, since the fluororesin film has poor adhesiveness, the back surface is subjected to corona treatment or plasma treatment.

(Back Coating Film) The back coating film needs to ensure insulation between the photovoltaic element and the reinforcing material, and is required to have insulation.

Examples of the material of the back cover film include nylon and polyethylene terephthalate. Further, the back cover film may be an integral type coated on a reinforcing material.

(Reinforcing Material) The reinforcing material is required to maintain the strength of the solar cell module and to have weather resistance, load resistance and workability. Similar to a conventional metal roof, it is possible to use a strong steel sheet and a non-ferrous metal having excellent corrosion resistance.

Steel sheets include surface-treated and coated steel sheets, alloys containing other elements, and special steels, as well as composite steel sheets bonded with a heat insulating material. Generally, hot-dip galvanized steel sheets are used. , Galfan, galvalume steel sheet, hot-dip aluminized steel sheet, copper-plated steel sheet, PVC coated steel sheet,
Fluororesin steel sheets, stainless steel sheets, vibration-damping steel sheets, heat-insulated galvanized steel sheets, weather-resistant steel sheets, the above-mentioned painted steel sheets, etc. are used.As non-ferrous metals, copper sheets, aluminum alloy sheets, zinc alloy sheets,
A lead plate, a titanium plate, the above-mentioned painted color plate and the like are used.

In the present embodiment, metal is used as a reinforcing material. However, the present invention is not limited to this. Needless to say, the present invention is applied to ceramics and plastics which have been widely used for roofs. It is possible.

(Filler) The filler has a role of bonding the above-mentioned materials, and is required to have adhesiveness, flexibility, translucency and weather resistance.

As the material of the filler, for example, EVA
(Vinyl acetate-ethylene copolymer), butyral resin,
Use a resin such as silicone resin or epoxy resin. In addition, the filler may be impregnated with glass fiber to increase the scratch resistance of the solar cell module, or may absorb ultraviolet rays to improve the weather resistance of the filler or to protect the semiconductor layer below the filler. In many cases, an absorbent, a light stabilizer, an antioxidant and the like are added to the filler.

(Cable line) The cable line is for taking out electricity from the photovoltaic element and connecting the solar cell modules to each other or to external wiring, and is soldered to a lead wiring member wired to the terminal position. Become. What is composed of a cable and a connector can be easily connected. The cable is insulated and coated on a core wire, which is a conductor such as soft copper, and is further protected and protected from the outside.

As the insulating covering material, for example, vinyl chloride, chloroprene, cross-linked polyethylene, natural rubber, ethylene propylene, silicone resin, fluororesin, inorganic insulating material and the like are used.

As the protective covering material, for example, vinyl chloride, chloroprene, polyethylene, polyurethane, silicone resin, fluororesin, metal and the like are used.

There are two types of connectors, a positive electrode and a negative electrode, which can be connected to each other. For this housing portion, for example, polyethylene, polycarbonate, polybutylene terephthalate, or the like is used.

(Terminal Box) The terminal box is provided at the terminal position, protects the cable line taken out from the lead wiring member of the solar cell element from mechanical external force, and at the same time, removes the cable line from the relics such as water and dust. It has the role of protecting the junction of the electromotive element. Therefore, a material having excellent heat resistance, water resistance, electrical insulation and aging properties is required. Further, a material having good adhesiveness with the filler is preferably used.

In consideration of the above-mentioned factors, the terminal member is preferably made of plastic.
Flame-retardant plastics and ceramics are preferred.

As the plastic, for example, Noryl,
Examples include engineering plastics such as polycarbonate, polyamide, polyacetal, modified PPO, polyester, polyarylate, unsaturated polyester, phenolic resin, and epoxy resin, which have excellent strength, impact resistance, heat resistance, hardness, and aging resistance. ABS resin, P
Thermoplastics such as P and PVC can also be used.

Next, a method for manufacturing a roof material-integrated solar cell module will be described.

(Mounting Step) The mounting step is a step of electrically connecting a plurality of photovoltaic elements in series and in parallel, forming a bypass diode and a terminal extraction portion, and forming a photovoltaic element group. .

The electrical connection may be formed by any connection method such as, for example, soldering, laser welding, ultrasonic welding and the like.

(Lamination Step) The lamination step is a step in which the photovoltaic element group is insulated and sealed to produce a flat solar cell module.

A method of laminating necessary constituent materials and heating them while pressing them in a vacuum may be used. There are various other methods, and any method may be used.

(Step of Forming Engaging Part) The step of forming the engaging part is a step of forming an engaging part in order to have a function as a roofing material. This is performed using a former molding machine, a bender machine, a press machine, or the like. Although it depends on the shape of the engaging portion, it is preferable to use a press or a roller former which does not require a long processing time.

(Step of Forming Desired Shape) The desired shape is a shape formed to enhance the design property as a roofing-integrated solar cell module.
There are various shapes such as a wedge.

(Distortion Reduction Means) This is means for reducing the distortion applied to the photovoltaic element in the step of forming the solar cell module into a desired shape, and reduces the distortion applied to the photovoltaic element in the parallel direction. . In particular, by reducing the strain in the tensile direction, it is possible to prevent the photovoltaic element from cracking.

The reduction means is not particularly limited. For example, when performing a press working to obtain a desired shape, not all the shapes are pressed at once, but a plurality of partial presses. Is preferred.

For example, when distortion occurs in the tensile direction,
There is also included a method of forming a wrinkle in the reinforcing material of the portion of the solar cell module in advance to reduce the distortion at the time of tensile deformation.

In addition, a plurality of corrugated shapes are press-formed at a time. The press is performed by a method in which a single corrugated mold is pressed while moving each other in a direction to reduce the distance, or a roller forming process. This includes a method of applying a lubricant in order to improve the slip between the roller or the bender mold and the solar cell module to be processed in the bender processing.

(Multi-stage pressing) This is an example of a means for reducing distortion in the step of forming a desired shape on a solar cell module. Instead of pressing all shapes at once, partial pressing may be performed several times. The way to do it.

More specifically, a method of repeating pressing while sequentially transporting the solar cell module, a method of fixing the solar cell module, preparing a plurality of press dies, and partially pressing sequentially, There is a method of continuously pressing with a roller press. However, it is not particularly limited to the above method.

Further, an apparatus for manufacturing a roof material-integrated solar cell module will be described.

(Manufacturing Apparatus for Solar Cell Module) The manufacturing apparatus for a solar cell module includes a forming apparatus for forming a solar cell module having a photovoltaic element into a desired shape. There is a distortion reduction device for suppressing such distortion in the parallel direction, particularly in the tensile direction.

(Forming Apparatus) The forming apparatus is used in the above-mentioned forming step of a desired shape, and is a device for forming a solar cell module having an engaging portion formed therein into a desired shape. However, the present invention is not limited to this.

The desired shape is, as described above, a shape formed to enhance the design as a roofing-integrated solar cell module, and has various shapes such as a corrugated shape, a triangular shape, and a wedge shape. .

(Distortion Reduction Apparatus) The distortion reduction apparatus is an apparatus for applying the above-described distortion reduction means to a photovoltaic element.
A multi-stage press machine or the like that forms the desired shape in a plurality of times is employed.

As a multi-stage press machine, by repeatedly performing press working while sequentially transporting a solar cell module, a device for forming a desired shape or a plurality of press dies can be formed without transporting the solar cell module. A device that forms a desired shape by sequentially operating the device or a device that forms a desired shape by performing a roller press process may be used.

[0103]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings, but the present invention is not limited to these embodiments.

(Example 1) This example is a method for manufacturing a solar cell module with a corrugated roofing material, in which an engaging portion is formed on a flat solar cell module by roller former processing, and pressing is performed. Is used to form a corrugation.

In the press working in the first embodiment, as a means for reducing the distortion generated in the photovoltaic element, a multi-step press working in which the press is repeated while the solar cell module is transported is adopted.

First, a mounting process for forming a photovoltaic element group will be described.

FIGS. 8A and 8B show a photovoltaic element group in Example 1, wherein FIG. 8A is a top view thereof, and FIG.
FIG. 3 is a sectional view taken along line a ′.

In FIG. 8, the photovoltaic element 801 has
An amorphous silicon-based semiconductor 803 is formed on a stainless steel substrate 802 having a thickness of 25 μm, and the stainless steel substrate 802 is on the negative electrode side and the semiconductor 803 is on the positive electrode side.

Correspondingly, a positive electrode tab 804 is formed on the front side of the photovoltaic element 801 and a negative electrode tab 805 is formed on the rear side. A copper foil having a thickness of 100 μm is used for the tab. The positive electrode tab 804 collects electricity generated in the semiconductor region by the current collecting electrode 806, and the negative electrode tab 805 collects electricity generated on the stainless steel substrate 802 on the back surface.

Positive electrode tab 80 between adjacent photovoltaic elements
4 and the negative electrode tab 805 are electrically connected by the connecting member 807, whereby a plurality of photovoltaic elements 801 are assembled in series. 100 as the connection member 807
A μm copper foil is used, and is attached by soldering. Also, a gap 808 between the photovoltaic elements 801
Is 2 mm, and the output is increased as a solar cell module by arranging it at high density.

The photovoltaic element group has two (terminals 809 and 810) terminal extraction portions for extracting the output. The positions of the terminal extracting portions 809 and 810 are determined according to the design of the module.

The terminal extraction portion 809 on the positive electrode side is wired by a lead wiring member 811 from the positive electrode tab 804 of the photovoltaic element 801 at the positive terminal. The terminal extraction portion 810 on the negative electrode side is connected to the negative electrode tab 8 of the photovoltaic element 801 at the negative terminal.
From 05, wiring is performed by the lead wiring member 812.

The lead wiring member 812 has a thickness of 40 μm.
A soft copper foil having a width of 20 mm and a width of 20 mm is used, and the lead wiring member 811 on the positive electrode side is insulated from the stainless steel substrate 802 by an insulating double-sided tape 813 and adhered thereto.

Since the terminal take-out portions 809 and 810 are used to solder cables and the like later, the lead wiring member 81
Immediately below 1, 812, a glass woven fabric tape is provided as a heat-resistant tape 814.

The bypass diode 815 is connected to the positive and negative tabs and will be described in detail below.

FIGS. 9A and 9B show a bypass diode provided in the photovoltaic element according to the first embodiment, wherein FIG. 9A is a top view and FIG. 9B is a sectional view taken along the line aa ′.

A bypass diode 902 is mounted on the negative electrode tab 903 of each photovoltaic element 901. The bypass diode 902 includes a 1.
A 5 mm square flat diode chip is used.
Positive electrode tab 904 and negative electrode tab 903 of photovoltaic element 901
, An insulating tape 905 is provided on the negative electrode tab 903, and a bypass diode 9 is provided thereon.
02 is arranged. The ribbon has a concave shape on one side, and is connected to the positive electrode tab 904 by turning the ribbon from the back to the front.

The connection is performed by soldering, and a soft copper foil having a thickness of 0.1 mm is used for the ribbon. The mounting position of the bypass diode 902 is arranged at a fixed position with respect to the photovoltaic element 901.

Next, a lamination process for resin-sealing the photovoltaic element group will be described.

FIG. 10 shows a flat solar cell module after lamination in Example 1.
(A) is the top view, (b) is the aa 'line sectional drawing.

The surface coating film 1003 has a thickness of 50
μm non-stretched ETFE (ethylene-tetrafluoroethylene copolymer: “Tefzel” manufactured by DuPont)
Is a 50 μm thick P
ET (polyethylene terephthalate) is used.
With these, the photovoltaic element group 1002 is insulated and sealed, and is bonded to the reinforcing member 1005 with a filler.

As the reinforcing material 1005, a galvalume steel plate having a thickness of 0.4 mm ("Abrasion Color GL" manufactured by Daido Steel Co., Ltd.)
And filling material 1 at the interface of each material
As 006, EVA (ethylene vinyl acetate) was used, and the photovoltaic element group 1002 and the surface coating film 10 were used.
03 is 460 μm, between the photovoltaic element group 1002 and the back coating film 1004 is 230 μm, and between the back coating film 1004 and the reinforcing material 1005 is 230 μm.
Filled with thickness.

The lamination method is as follows.
Filler 1006, back coating film 1004, photovoltaic element group 1002, filler 1006, surface coating film 1
003 are sequentially stacked, heated at 160 ° C. for 50 minutes in a vacuum, and then cooled.

Next, a description will be given of a step of forming an engaging portion in a flat solar cell module.

FIGS. 11A and 11B show a roller former processing step in the first embodiment, wherein FIG. 11A is a perspective view showing the appearance thereof, and FIG. 11B is a side view showing the processing state.

By sending the solar cell module 1101 by the plurality of rollers 1102, an engaging portion is formed. The engaging portions have a U-shape, which is for fitting each other as a roof material.

Next, the step of forming the solar cell module having the engaging portions into a corrugated shape will be described.

FIG. 12 is a schematic view showing a press working step in the first embodiment. In the pressing process of the first embodiment, as a means for reducing distortion generated in the photovoltaic element,
A multi-stage press machine that repeats pressing while transporting the solar cell module is employed.

In this multi-stage press machine, the solar cell module 1201 having the engaging portion formed thereon is
It is conveyed by 202 and is formed into a corrugated shape by a press machine 1203. The press 1203 is a corrugated upper mold 12
04 and the lower mold 1205 are moved up and down, respectively, and press working is performed so as to sandwich the solar cell module 1201.

FIG. 13 is a perspective view of a corrugated roof material-integrated solar cell module according to the first embodiment. Finally, in order to extract electricity from the corrugated solar cell module, the photovoltaic element group 1301 and the cable 1302 are soldered at terminal positions, and the terminal box 1 is protected for its protection.
Attach 303 to obtain a corrugated roof material integrated solar cell module.

The roof material-integrated solar cell module obtained in Example 1 has a corrugated shape with high designability.
No cracks occurred.

Example 2 This example is a method of manufacturing a solar cell module with a corrugated roofing material, in which an engaging portion is formed on a flat solar cell module by roller former processing, and pressing is performed. Is used to form a corrugation.

In the press working described in the second embodiment, a multi-step press working in which a solar cell module is fixed and pressing is repeated with a plurality of dies is employed as means for reducing distortion applied to the photovoltaic element. .

The only difference from the other embodiments is the step of forming the solar cell module having the engaging portions into a corrugated form. The press working for forming the corrugated form of the second embodiment will be described below. .

FIG. 14 is a schematic view showing a press working step in the second embodiment. In the pressing step of the second embodiment, as a means for reducing distortion generated in the photovoltaic element,
A multi-stage press working machine that fixes the solar cell module and repeats pressing with a plurality of dies is employed.

In this multi-stage press working machine, the solar cell module 1401 having an engaging portion is connected to the lower die 14 of the press machine.
02, and a plurality of upper dies 1403 are sequentially operated to form a corrugation.

The roof material-integrated solar cell module obtained in Example 2 has a corrugated shape with high designability.
No cracks occurred.

Embodiment 3 This embodiment is a method of manufacturing a corrugated roof material integrated solar cell module, in which an engaging portion is formed on a flat solar cell module by roller former processing, and pressing is performed. Is used to form a corrugation.

In the press working in the third embodiment, as a means for reducing the distortion generated in the photovoltaic element, a multi-stage press working in which pressing is continuously repeated by a roller press is employed.

The only difference from the other embodiments is the step of shaping the solar cell module having the engaging portions formed into a corrugated form. The press working for forming the corrugated form of the third embodiment will be described below. .

FIG. 15 is a schematic view showing a press working step in the third embodiment. In the press working process of the third embodiment, a multi-stage press working machine that repeats pressing continuously with a roller press is used as a means for reducing distortion applied to the photovoltaic element.

This multi-stage press machine continuously presses the solar cell module 1501 having the engaging portion in such a manner as to sandwich two roller molds 1502,
It forms a wavy shape.

The roof material-integrated solar cell module obtained in Example 3 has a corrugated shape with high designability.
No cracks occurred.

[0144]

As described above, according to the present invention,
Since the photovoltaic element has a strain reducing means for suppressing distortion in the tensile direction generated in the photovoltaic element during processing of the solar cell module, it is possible to prevent the photovoltaic element from cracking. A physical solar cell module can be obtained.

Further, since the photovoltaic element can be prevented from cracking, the solar cell module can be formed into a desired shape such as a corrugated shape, and a roof material-integrated solar cell having extremely high designability can be obtained. You can get a module.

Further, in the step of forming the solar cell module, the photovoltaic element can be prevented from cracking, so that it is processed by using an existing press forming machine which has been conventionally used for forming roofing materials. Because you can
It is possible to obtain a low-cost roofing-material-integrated solar cell module without requiring new capital investment.

[Brief description of the drawings]

FIG. 1 is a top view of a photovoltaic element group according to the present invention.

FIGS. 2A and 2B show a solar cell module before processing in the present invention, wherein FIG. 2A is a top view thereof, and FIG.
FIG. 3 is a sectional view taken along line a ′.

3A and 3B show a solar cell module having an engaging portion according to the present invention, wherein FIG. 3A is a top view thereof, and FIG. 3B is a sectional view taken along line aa ′.

FIGS. 4A and 4B show a corrugated solar cell module according to the present invention, wherein FIG. 4A is a perspective view thereof, and FIG. 4B is a sectional view taken along line aa ′.

FIGS. 5A and 5B show a state in which a solar cell module having an engaging portion according to the present invention is formed into a corrugated shape by press working; FIG. 5A is a side view showing a state before pressing;
(B) is a side view showing a state after pressing, and (c) is a sectional view thereof.

6A and 6B are enlarged views of a wave portion of a solar cell module having a wave shape according to the present invention, wherein FIG. 6A is a cross-sectional view in a direction parallel to the wave direction, and FIG. It is a B sectional view.

7A and 7B show a roof material-integrated solar cell module having a desired shape according to the present invention, wherein FIG. 7A is a perspective view thereof, and FIG. 7B is a sectional view taken along line aa ′.

FIGS. 8A and 8B show a photovoltaic element group in Example 1, wherein FIG. 8A is a top view thereof and FIG.

FIGS. 9A and 9B show a bypass diode provided in the photovoltaic element according to the first embodiment, and FIG.
(B) is a sectional view taken along line aa ′.

FIGS. 10A and 10B show a flat solar cell module after lamination in Example 1, wherein FIG. 10A is a top view thereof and FIG. 10B is a sectional view taken along line aa ′.

11A and 11B show a roller former processing step in Example 1, and FIG. 11A is a perspective view showing the appearance thereof.
(B) is a side view showing the processing situation.

FIG. 12 is a schematic view showing a press working step in the first embodiment.

13 is a perspective view of a corrugated roof material-integrated solar cell module in Example 1. FIG.

FIG. 14 is a schematic view showing a press working step in Embodiment 2.

FIG. 15 is a schematic view showing a press working step in Embodiment 3.

FIG. 16 is an explanatory diagram showing a distortion measurement result in a study process of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 101 Photovoltaic element 102 Connection member 103 Lead wiring member 104 Bypass diode 201 Reinforcement material 202 Photovoltaic element group 203 Coating material 301 Engagement part 401 Engagement part 501 Upper mold 502 Lower mold 503 Solar cell module 601 Wave-shaped mountain Part 603 Photovoltaic element 604 Reinforcement material 605 Resin 606 Part where engagement part is formed 701 Photovoltaic element group 702 Reinforcement 703 Back coating film 704 Surface coating film 705 Filler 706 Cable 707 Terminal box 801 Photovoltaic element 802 Stainless steel substrate 803 Amorphous silicon-based semiconductor 804 Positive tab 805 Negative tab 806 Current collecting electrode 807 Connection member 808 Gap between photovoltaic elements 809 Positive terminal extraction section 810 Negative terminal extraction section 811 Positive lead lead member 812 Negative side lead wiring member 813 Insulated double-sided tape 814 Heat resistant tape 815 Bypass diode 901 Photovoltaic element 902 Bypass diode 903 Negative tab 904 Positive tab 905 Insulating tape 1002 Photovoltaic element group 1003 Surface coating film 1004 Back coating film 1005 Reinforcement Material 1006 Filler 1101 Solar cell module 1102 Roller 1201 Solar cell module 1202 Belt conveyor 1203 Press machine 1204 Upper mold 1205 Lower mold 1301 Photovoltaic element group 1302 Cable 1303 Terminal box 1401 Solar cell module 1402 Lower mold 1403 Upper mold 1501 Solar cell Module 1502 roller type

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] June 29, 1998

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0073

[Correction method] Change

[Correction contents]

The steel sheet includes a surface-treated, coated steel sheet, an alloy containing other elements, a special steel, and a composite steel sheet bonded with a heat insulating material. Generally, a hot-dip galvanized steel sheet is used. , Hot-dip zinc-5% aluminum alloy plated steel sheet
Yodokou, registered trademark: Yodogalfan), molten zinc
-55% aluminum alloy plated steel sheet (Nippon Steel Corporation and
Made by Daido Steel Co., Ltd., registered trademark: Galvalume Steel
Sheet) , hot-dip aluminum plated steel sheet, copper plated steel sheet, vinyl chloride coated steel sheet, fluororesin steel sheet, stainless steel sheet,
Damping steel sheets, heat-insulated galvanized steel sheets, weather-resistant steel sheets, the above-mentioned painted steel sheets, etc. are used. As the non-ferrous metals, copper sheets, aluminum alloy sheets, zinc alloy sheets, lead sheets, titanium sheets, and the above-mentioned painted color sheets are used .

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0122

[Correction method] Change

[Correction contents]

As the reinforcing material 1005, a 0.4 mm-thick galvalume steel plate ( registered trademark: "Abrasion Color GL" manufactured by Daido Steel Co., Ltd.) is used, and as the filler 1006 filling the interface between the above-mentioned materials, EVA is used. (Ethylene vinyl acetate), the distance between the photovoltaic element group 1002 and the surface coating film 1003 was 460 μm, and the photovoltaic element group 1
230 μm between 002 and back coating film 1004
m, the space between the back cover film 1004 and the reinforcing material 1005 is filled with a thickness of 230 μm.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Meiji Takabayashi 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc.

Claims (25)

[Claims] 1. A mounting step for forming a photovoltaic element group, a lamination step for forming a flat solar cell module by insulating and sealing the photovoltaic element group, and forming the solar cell module into a desired shape. And a distortion reducing means for suppressing a distortion in the parallel direction applied to the photovoltaic element in the molding step. 2. The method for manufacturing a solar cell module according to claim 1, wherein in the forming step, the solar cell module on which the engaging portion is formed is formed into a desired shape. 3. The method for manufacturing a solar cell module according to claim 1, wherein the forming step is performed by press working. 4. The method for manufacturing a solar cell module according to claim 1, wherein the desired shape is a wave shape, a triangle shape, or a wedge shape. 5. The method according to claim 1, wherein the strain in the parallel direction is a strain in a tensile direction. 6. The method for manufacturing a solar cell module according to claim 1, wherein the distortion reducing means is a multi-stage press working for forming a desired shape in a plurality of times. 7. The method for manufacturing a solar cell module according to claim 6, wherein in the multi-stage pressing, a desired shape is formed by repeating the pressing while sequentially transporting the solar cell module. 8. The multi-stage press working includes forming a desired shape by sequentially operating a plurality of press dies without transporting a solar cell module.
3. The method for manufacturing a solar cell module according to item 1. 9. The method for manufacturing a solar cell module according to claim 6, wherein the multi-stage pressing is performed by roller pressing to form a desired shape. 10. The method for manufacturing a solar cell module according to claim 1, wherein the photovoltaic element is made of an amorphous semiconductor. 11. The method for manufacturing a solar cell module according to claim 1, wherein the group of photovoltaic elements is sealed on a reinforcing material with a resin. 12. The method of manufacturing a solar cell module according to claim 1, wherein the solar cell module is formed as a roof material-integrated solar cell module. 13. A solar cell module manufactured by the method according to claim 1. Description: 14. A manufacturing apparatus for a solar cell module including a forming apparatus for forming a solar cell module having a photovoltaic element into a desired shape, wherein the forming apparatus removes parallel distortion applied to the photovoltaic element. An apparatus for manufacturing a solar cell module, comprising: a distortion reducing device for suppressing the distortion. 15. The manufacturing apparatus for a solar cell module according to claim 14, wherein the forming apparatus forms the solar cell module having the engaging portion formed therein into a desired shape. 16. The solar cell module manufacturing apparatus according to claim 14, wherein the forming apparatus is a press working machine. 17. The solar cell module manufacturing apparatus according to claim 14, wherein the desired shape is a wave shape, a triangle shape, or a wedge shape. 18. The solar cell module manufacturing apparatus according to claim 14, wherein the strain in the parallel direction is a strain in a tensile direction. 19. The apparatus for manufacturing a solar cell module according to claim 14, wherein the distortion reducing unit is a multi-stage press working machine that forms a desired shape in a plurality of times. . 20. The multi-stage press working machine according to claim 19, wherein the press working is repeated while sequentially transferring the solar cell modules to form a desired shape.
The manufacturing apparatus of a solar cell module according to item 1. 21. The multi-stage press machine according to claim 19, wherein a desired shape is formed by sequentially operating a plurality of press dies without transporting the solar cell module. Manufacturing equipment for solar cell modules. 22. The solar cell module manufacturing apparatus according to claim 19, wherein the multi-stage press machine performs a roller press process to form a desired shape. 23. The apparatus for manufacturing a solar cell module according to claim 14, wherein the photovoltaic element is made of an amorphous semiconductor. 24. The apparatus for manufacturing a solar cell module according to claim 14, wherein the photovoltaic element group is sealed on a reinforcing material with a resin. 25. The apparatus for manufacturing a solar cell module according to claim 14, wherein the apparatus is formed as a roof material-integrated solar cell module.