KR20210027969A - Solar cell panel and method for manufacturing the same - Google Patents

Abstract

According to an embodiment of the present invention, provided is a solar cell panel which can improve productivity. The solar cell panel comprises: a solar cell; first and second cover members which are respectively positioned on one side and the other side of the solar cell, and at least one of which includes a glass substrate; and a sealing material enclosing and sealing the solar cell between the first cover member and the second cover member, wherein the sealing material includes a plurality of sealing parts having a plurality of gel contents different from each other in at least an edge portion of the first or second cover member.

Description

A solar panel and its manufacturing method TECHNICAL FIELD

The present invention relates to a solar panel and a method for manufacturing the same, and more particularly, to a solar panel having an improved structure and a method for manufacturing the same.

Since the solar cell needs to be exposed to the external environment for a long time, it is manufactured in the form of a solar cell panel including a solar cell, a sealing material, and a cover member by a packaging process for protecting the solar cell.

As such, a solar panel including various members is manufactured by a lamination process that applies heat and pressure, and a problem in which the solar cell or the cover member is broken or damaged in a part receiving a large load by the pressure applied during the lamination process may occur. Could. In addition, due to the pressure applied during the lamination process, the sealing material flows out from the edge portion of the solar panel, so that the thickness of the sealing material at the edge portion may be significantly thinner than that of other portions (eg, the central portion). Accordingly, since the sealing material does not have a certain thickness at the edge of the solar panel, it may be difficult to implement desired sealing properties. This problem may occur more seriously when the cover member includes a glass substrate, particularly when both cover members positioned on both sides include a glass substrate.

In order to prevent such a problem, in US Patent Publication No. 2014/0137940 (name of the invention: solar cell module and its manufacturing method) as a prior art, an additional sealing member having a predetermined shape is inserted between the cover members on both sides at the edge. How to do it has been disclosed. However, in order to insert an additional sealing member having a predetermined shape, the size and shape of the sealing material are precisely controlled during the lamination process to correspond to the shape of the additional sealing member, and when the additional sealing member is inserted, the sealing material and the additional sealing member are aligned. Must be precisely controlled. Accordingly, when the process is complicated and precise control is not performed, problems such as a water penetration path may occur or an additional sealing member is separated to the outside may occur.

US Patent Publication No. 2014/0137940 (Name of invention: solar cell module and manufacturing method thereof)

An object of the present invention is to provide a solar panel capable of improving productivity by improving the productivity of the solar panel and reducing the defect rate, and a method of manufacturing the same.

More specifically, the present invention provides a solar panel and a manufacturing method thereof in which the edge portion of the solar panel has a sufficient sealing distance in consideration of leakage of the sealing material that may occur at the edge portion of the solar panel during the lamination process. I want to provide.

In particular, the present invention provides a solar panel in which the first and second cover members each have a sufficient sealing distance at the edge of the solar panel used in a building-integrated structure composed of a glass substrate, a double-sided light-receiving structure, and manufacturing thereof I want to provide a way.

A solar panel according to an embodiment of the present invention includes a plurality of sealing portions in which a sealing material, a filler, a sealing material, or a sealing material surrounding and sealing the solar cell has different gel contents.

More specifically, the solar panel according to an embodiment of the present invention includes a solar cell, a first and a second cover member each positioned on one side and the other side of the solar cell, and at least one including a glass substrate, and the second cover member. It may include a sealing material surrounding and sealing the solar cell between the first cover member and the second cover member. In addition, the sealing material may include a plurality of sealing portions having different gel contents at at least an edge portion of the first or second cover member.

The plurality of sealing portions may include a base sealing portion and a curable sealing material positioned adjacent to at least one of the first and second cover members than the base sealing portion at least at an edge portion and having a gel content greater than that of the base sealing portion. It may include an additional sealing portion comprising a.

The additional sealing portion and the base sealing portion may contain 50 wt% or more of the same component.

The base sealing portion may include a polyolefin resin or an ethylene vinyl acetate resin, and the additional sealing portion may include a polyolefin resin or an ethylene vinyl acetate resin.

Each of the additional sealing portion and the base sealing portion may contain a silane coupling agent.

The base sealing portion may comprise a curable sealing material or a plastic sealing material having a lower degree of curing or a lower gel content than the additional sealing portion.

The additional sealing portion may contact one of the first cover member and the second cover member.

When viewed in a plan view, the additional sealing portion may be spaced apart from the solar cell so that it does not overlap with the solar cell.

A plurality of the additional sealing portions may be positioned adjacent to each of the plurality of corners of the solar panel.

The additional sealing portion may further include an intermediate sealing portion spaced apart from the edge of the solar panel and positioned in an intermediate region of a long or short edge of the solar panel.

A method of manufacturing a solar panel according to an embodiment of the present invention includes a lamination step and a lamination step, and a plurality of sealing parts having a sealing material, a filler, a sealing material, or a sealing material having different gel contents to surround and seal the solar cell Includes.

More specifically, in the laminating step of the method for manufacturing a solar panel according to an embodiment of the present invention, a solar cell, a sealing member to form a sealing material surrounding and sealing the solar cell, and the solar cell on the sealing member. A laminated structure may be formed by laminating first and second cover members, each of which is positioned on one side and the other side, and at least one of which includes a glass substrate. In the lamination step, heat and pressure may be applied to the laminate structure so that the solar cell, the sealing material, and the first and second cover members are integrated to form a solar panel. The sealing material may include a plurality of sealing portions having different gel contents at at least an edge portion of the first or second cover member.

In the laminating step, the sealing member includes a first sealing member positioned between the solar cell and the first cover member, a second sealing member positioned between the solar cell and the second cover member, and at least an edge portion In may include a support member positioned adjacent to the first or second cover member and formed of a curable sealing material having a gel content greater than that of the first or second sealing member. In the lamination step, the first and second sealing members constitute a base sealing portion, and the support member constitutes an additional sealing portion, thereby forming the integrated sealing material.

The support member may include 50 wt% or more of the same component as the first or second sealing member.

In the laminating step, the support member may be formed of a curable sealing material that is semi-cured or temporarily cured.

In the laminating step, the support member may have a gel content of 40% to 60%.

In the laminating step, the first or second sealing member may include a curable sealing material or a plastic sealing material having a lower curing degree or a lower gel content than the support member.

In the laminating step, the support member may be attached to the first or second cover member so as to be spaced apart from the edge of the first or second cover member and positioned in a fixed state.

In the laminating step, the width or diameter of the support member may be greater than a distance between the first cover member and the second cover member after the laminating step.

A method of manufacturing a solar panel according to an embodiment of the present invention includes a lamination step and a lamination step, and a sealing member, a sealing member, a filling member, or a sealing member surrounding and sealing the solar panel in the lamination step is And a support member composed of a curable sealing material that has been cured or provisionally cured. Here, the support member may be regarded as a kind of support, spacer, corner spacer, etc. for maintaining the thickness of the edge portion at a predetermined or more.

More specifically, in the laminating step of the method for manufacturing a solar panel according to an embodiment of the present invention, a solar cell, a sealing member to form a sealing material surrounding and sealing the solar cell, and the solar cell on the sealing member. A laminated structure may be formed by laminating first and second cover members, each of which is positioned on one side and the other side, and at least one of which includes a glass substrate. In the lamination step, heat and pressure may be applied to the laminate structure so that the solar cell, the sealing material, and the first and second cover members are integrated to form a solar panel. In the laminating step, the sealing member may include a support member positioned adjacent to the first or second cover member at least at an edge portion and formed of a semi-cured or pre-cured curable sealing material.

In the laminating step, the sealing member may further include a first sealing member positioned between the solar cell and the first cover member, and a second sealing member positioned between the solar cell and the second cover member. have. The support member may have a gel content of 40% to 60%.

According to this embodiment, an additional sealing portion having a relatively high gel content or hardening degree is included at least in the edge portion to maintain a uniform sealing distance between the edge portion of the solar panel and other portions (for example, the central portion). have. In particular, when the first and second cover members each have a building-integrated structure composed of a glass substrate, a double-sided light-receiving structure, etc., the problem of reducing the sealing distance at the edge of the solar panel could seriously occur. According to an example, this can be effectively prevented. Accordingly, peeling of the first or second cover member and the sealing material, which may occur due to a decrease in the sealing distance at the edge of the solar panel, damage that may occur when the first and second cover members come into contact with each other, deterioration of sealing properties, It is possible to fundamentally prevent problems such as damage or deterioration of properties of the solar cell adjacent to the edge, and the residual air bubbles inside the solar cell panel. Accordingly, it is possible to improve the reliability and productivity of the solar panel.

In addition, a solar panel having excellent properties can be manufactured by a simple process using a support member having a relatively high gel content or curing degree. Accordingly, the defective rate can be lowered and productivity can be improved.

1 is a perspective view schematically showing a solar panel according to an embodiment of the present invention.
FIG. 2 is a schematic cross-sectional view of a solar panel taken along line II-II of FIG. 1.
3 is a plan view schematically illustrating a first or second cover member, a solar cell, and an additional sealing part included in the solar panel shown in FIG. 1.
4 is a graph showing a sealing distance along a length direction in a solar panel according to an embodiment of the present invention.
5 is a graph showing a sealing distance along a length direction in a solar panel according to the prior art.
6 is a flowchart illustrating a method of manufacturing a solar panel according to an embodiment of the present invention.
7A to 7C are views schematically showing a method of manufacturing a solar panel according to an exemplary embodiment of the present invention.
8 is a partial plan view showing various planar shapes of a support member used in a method of manufacturing a solar panel according to an exemplary embodiment of the present invention, together with a first or second cover member and a solar cell.
9 is a plan view schematically showing a first or second cover member, a solar cell, and an additional sealing part included in a solar panel according to another embodiment of the present invention.
10 is a schematic cross-sectional view of a solar panel according to a modified example of the present invention.
11 is a schematic cross-sectional view of a solar panel according to another modification of the present invention.
12 is a schematic cross-sectional view of a solar panel according to another modification of the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, it goes without saying that the present invention is not limited to these embodiments and may be modified in various forms.

In the drawings, in order to clearly and briefly describe the present invention, illustration of parts irrelevant to the description is omitted, and the same reference numerals are used for identical or extremely similar parts throughout the specification. In addition, in the drawings, the thickness and width are enlarged or reduced in order to clarify the description. However, the thickness and width of the present invention are not limited to those shown in the drawings.

In addition, when a certain part "includes" another part throughout the specification, the other part is not excluded and other parts may be further included unless otherwise stated. Further, when a part such as a layer, film, region, plate, etc. is said to be "on" another part, this includes not only the case where the other part is "directly above", but also the case where the other part is located in the middle. When a part such as a layer, a film, a region, or a plate is "directly over" another part, it means that no other part is located in the middle.

Hereinafter, a solar panel according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. In the present specification, the expressions "first" or "second" are used for distinction from each other, and the present invention is not limited thereto.

1 is a perspective view schematically showing a solar panel according to an embodiment of the present invention, and FIG. 2 is a schematic cross-sectional view of the solar panel cut along line II-II of FIG. 1. 3 is a plan view schematically showing the first or second cover members 110 and 120, the solar cell 150, and the additional sealing portion 130b included in the solar panel shown in FIG. 1. In FIG. 1, the sealing material 130 is illustrated only schematically with the base sealing portion 130a mainly, and the additional sealing portion 130b of the sealing material 130 will be described in detail with reference to FIGS. 2 and 3.

1 to 3, the solar panel 100 according to the present embodiment includes a solar cell 150, and first and second cover members positioned on one side and the other side of the solar cell 150, respectively. 110 and 120, and a sealing material 130 that surrounds and seals the solar cell 150 between the first cover member 110 and the second cover member 120. Here, at least one of the first and second cover members 110 and 120 (in particular, each of the first and second cover members 110 and 120) may include a glass substrate. In addition, the sealing material 130 may include a plurality of sealing portions 130a and 130b having different gel contents at the edge portions of the first or second cover members 110 and 120 or the solar panel 100. This will be described in more detail.

In this embodiment, the solar cell 150 may include a photoelectric conversion unit that converts the solar cell into electrical energy, and an electrode that is electrically connected to the photoelectric conversion unit to collect and transmit current. For example, the solar cell 150 may be a solar cell generating electric energy from light in a wavelength range of at least 100 nm to 1400 nm (eg, 100 nm to 1200 nm). In this embodiment, as an example, the photoelectric conversion unit may be composed of a crystalline silicon substrate (eg, a silicon wafer), and a conductive type region including a dopant or a conductive type region formed on or on the crystalline silicon substrate. I can. As such, the solar cell 150 based on the crystalline silicon substrate having high crystallinity and low defects has excellent electrical characteristics.

Further, in the present embodiment, a plurality of solar cells 150 are provided while being spaced apart from each other, and a plurality of solar cells 150 may be electrically connected in series, parallel, or serially parallel by wiring units 142 and 145. As an example, a plurality of solar cells 150 may be connected in series by a wiring member 142 to form a solar cell string extending long along a first direction (y-axis direction in the drawing). In addition, a bus ribbon 145 extending in a second direction crossing the first direction (the x-axis direction in the drawing) may be provided at an end of the solar cell string. For example, the bus ribbon 145 may be connected to both ends of the wiring member 142 of the solar cell string. The bus ribbon 145 may connect adjacent solar cell strings in a second direction in series, parallel, or serially parallel, or connect the solar cell strings to a junction box that prevents reverse current flow.

Various structures and shapes capable of connecting the solar cells 150 such as ribbons and wires may be applied as the wiring material 142. Then, the structure of the solar cell 150, the number of wiring members 142, the location, and the like, the material, shape, and connection structure of the bus ribbon 145 may be variously modified. For example, two or more wiring members 142 may be provided based on one surface of the solar cell 150. In addition, although FIG. 2 discloses that the wiring member 142 has a structure that is connected from the front surface of one solar cell 150 to the rear surface of the other solar cell 150, the present invention is not limited thereto. Accordingly, since the solar cell 150 has a rear electrode structure, the wiring member 142 may connect electrodes located on the rear surfaces of the adjacent two solar cells 150. In addition, the solar cell 150 may have various structures such as a compound semiconductor solar cell, a silicon semiconductor solar cell, and a dye-sensitized solar cell. And it is also possible that only one solar cell 150 is provided. Other variations are possible.

The first cover member 110 is located on the sealing material 130 on one side (for example, the front) side of the solar cell 150 connected by the wiring parts 142 and 145 to constitute one side of the solar cell panel 100, and , The second cover member 120 is located on the sealing material 130 from the other surface (for example, the rear) side of the solar cell 150 connected by the wiring parts 142 and 145 to constitute the other surface of the solar panel 100 do. Each of the first cover member 110 and the second cover member 120 may be formed of an insulating material capable of protecting the solar cell 150 from external shock, moisture, and ultraviolet rays. In the present embodiment, each of the first cover member 110 and the second cover member 120 may be a glass substrate having excellent durability, insulating properties, moisture-proof properties, light transmittance, and the like. For example, the first cover member 110 and the second cover member 120 may be formed of tempered glass or semi-tempered glass, respectively. Then, since the glass substrates are located on both sides of the solar panel 100, it can have excellent transmittance at least on the entire surface, and can have high durability due to high strength, and excellent moisture resistance, UV resistance, insulation properties, etc. I can have it.

The solar panel 100 according to the present embodiment may be individually installed and used in a building, a site, etc., or a building-integrated structure applied to an exterior material or exterior wall (eg, vertical wall, roof surface, windows, etc.) of a building. You can have it. When the solar panel 100 is individually installed and used, the first and second cover members 110 and 120 are each composed of a glass substrate, and the solar cell 150 is a double-sided light-receiving structure (bi-facial structure) If it has, it is possible to use all of the light incident on both sides, thereby contributing to the improvement of the output of the solar panel 100. When the solar panel 100 has a building-integrated structure, if the first and second cover members 110 and 120 are each formed of a glass substrate, it can function stably as an exterior material or a part of an exterior wall of a building. In this embodiment, the glass substrate used as the first cover member 110 or the second cover member 120 may be transparent or translucent, or may have a certain image, color, texture, feel, and the like.

However, the present invention is not limited thereto. Accordingly, the first cover member 110 or the second cover member 120 may include various materials other than those described above, or may have various forms such as sheets and films.

A sealing material 130 surrounding and sealing the solar cell 150 is positioned between the first cover member 110 and the second cover member 120. The sealing material 130 prevents moisture and oxygen from flowing into the solar panel 100 and chemically couples the elements of the solar panel 100. The sealing material 130 may be formed of an insulating material having light-transmitting properties and adhesive properties. As an example, the sealing material 130 may include an ethylene vinyl acetate (EVA) resin, a polyvinyl butyral resin, a silicon resin, an ester resin, an olefin resin (for example, a polyolefin resin).

In the present embodiment, the sealing material 130 includes a plurality of sealing portions 130a and 130b having different gel contents to form a solar cell 150 between the first cover member 110 and the second cover member 120. It can be enclosed and sealed. In particular, a plurality of sealing portions 130a and 130b having different gel contents may be included in at least an edge portion of the first or second cover members 110 and 120 or the solar panel 100.

More specifically, the sealing material 130 is positioned adjacent to at least one of the first and/or second cover members 110 and 120 than the base sealing portion 130a at the base sealing portion 130a and at least the edge portion. And it may include an additional sealing portion (130b) including a curable sealing material having a gel content greater than the base sealing portion (130a). Here, the base sealing portion 130a and the additional sealing portion 130b may be positioned together at least at the edge portions of the first and/or second cover members 110 and 120.

For example, in the present embodiment, the base sealing portion 130a is a sealing portion that occupies most of the sealing material 130 (more specifically, 50% or more, for example, 90% or more volume), and the solar cell 150 as a whole is Can be positioned while wrapping. The base sealing portion 130a is located on the front surface of the solar cell 150 connected by the wiring portions 142 and 145 and positioned between the first cover member 110 and the solar cell 150 ( 131a) and a second sealing portion 132a positioned between the second cover member 120 and the solar cell 150 and positioned on the rear surface of the solar cell 150 connected by the wiring member 142 .

The additional sealing portion 130b is used to prevent the sealing distance between the first cover member 110 and the second cover member 120 from becoming smaller at the edge portion than the other portion (eg, the center portion) in the lamination process. It may be a portion formed by remaining at least a support member (reference numeral 130d in FIG. 7A, hereinafter the same) inserted at the edge portion of the first and/or second cover members 110 and 120. Here, the support member 130d may be viewed as a kind of support, spacer, corner spacer, or the like for maintaining the thickness of the edge portion at a predetermined or more.

Here, the materials of the base sealing portion 130a and the additional sealing portion 130b may be the same or different from each other. In this case, the base sealing portion 130a and the additional sealing portion 130b may include a sealing material having the same or similar material, the same or similar properties, and the like to improve adhesive properties.

For example, the base sealing portion 130a and the additional sealing portion 130b may contain 50 wt% or more of the same component. That is, the main components of the base sealing portion 130a and the additional sealing portion 130b are the same, so that a component corresponding to at least 50wt% of the base sealing portion 130a is the same as a part or all of the additional sealing component 130b, or A component corresponding to at least 50 wt% of the additional sealing portion 130b may be the same as a part or all of the base sealing portion 130a.

For example, the base sealing portion 130a includes a polyolefin resin (polyolefin-based sealing material) or an ethylene vinyl acetate resin (ethylene vinyl acetate-based sealing material), and the additional sealing portion 130b includes a polyolefin resin or an ethylene vinyl acetate resin. Can include. Polyolefin or ethylene vinyl acetate resin has excellent adhesion to each other and excellent adhesion to glass substrates. In addition, since both polyolefin resin and ethylene vinyl acetate resin have ethylene as a basic component and have similar properties, properties such as a coefficient of thermal expansion are similar. For reference, even if the gel contents of the base sealing part 130a and the additional sealing part 130b are different from each other, the difference in properties such as a coefficient of thermal expansion according to the gel content is not large.

As described above, when the base sealing portion 130a and the additional sealing portion 130b contain the same main component, even when the base sealing portion 130a and the additional sealing portion 130b contain the same material or some different materials, adhesion between them is excellent and the characteristic difference is not large. Accordingly, the base sealing portion 130a and the additional sealing portion 130b can be stably bonded to the first and second cover members 110 and 120, and the solar cell 150 can be stably sealed. have.

On the other hand, unlike the present embodiment, when a material other than a sealing material is used as the support member, the adhesive strength between each other is not excellent, the difference in characteristics of each other is large, or the sealing property of the solar panel 100 is deteriorated. Can occur. For example, when a metal support is used as a support member, adhesion with other sealing parts may not be good, and the sealing material 1300 protruding to the outside of the first or second cover members 110 and 120 is cut out and removed. In addition, when a metal support is used as a support member, it may be difficult to secure enough insulation distance if the metal support is used as a support member, and it may escape to the outside and peel off after bonding due to a difference in thermal expansion coefficient. In addition, problems such as damage or impact may occur in the first or second cover members 110 and 120 formed of a glass substrate.

Even when a sealing material is used as the support member (or the additional sealing part 130b), if the main components of the base sealing part 130a and the additional sealing part 130b are different from each other, the adhesion is not excellent or the coefficient of thermal expansion is different from each other. The adhesion may not be excellent. For example, polycarbonate (PC) resin and ethylene vinyl acetate resin, or polycarbonate resin and polyether ether ketone (PEEK) resin do not have excellent adhesion between each other, so when used together, the boundary portion may not adhere well. Then, a moisture penetration path may be created, and thus sealing properties may not be excellent.

Accordingly, the present embodiment includes an additional sealing portion 130b formed using the same or similar material as the base sealing portion 130a, the support member 130d having the same or similar properties, and the base sealing portion 130a And the additional sealing portion 130b may have the same or similar coefficient of thermal expansion and have excellent adhesion.

Alternatively, the base sealing portion 130a and the additional sealing portion 130b may each be formed of a sealing material including a silane coupling agent. Since the silane coupling agent is a material having excellent adhesion to the glass substrate, when the base sealing portion 130a and the additional sealing portion 130b each contain a silane coupling agent, the first and/or second cover members ( 110, 120) and excellent adhesion properties.

However, the present invention is not limited thereto, and the additional sealing portion 130b may be formed of a sealing material or resin having a main chain different from the base sealing portion 130a. For example, the additional sealing portion 130b may include a benzene ring and may be made of a polyethylene terephthalate (PET) resin having a melting point of 200° C. or higher. Polyethylene terephthalate resin may have excellent processability, chemical resistance, adhesion, and the like. The additional sealing portion 130b may include various other materials.

At this time, in the present embodiment, the support member 130d used during the lamination process and constituting the additional sealing portion 130b after the lamination process may include a curable sealing material, but may be made of a semi-cured or temporary cured sealing material. This will be described in more detail later. Accordingly, the additional sealing portion 130b formed by the lamination process may have a gel content higher than that of the base sealing portion 130a.

In this embodiment, when the base sealing portion 130a is made of a curable sealing material, the base sealing portion 130a and the additional sealing portion 130b are made of the same curable sealing material, but the degree of curing of the additional sealing portion 130b or The gel content may be greater than the hardening degree or the gel content of the base sealing portion 130a. When the base sealing portion 130a is made of a plastic sealing material, the additional sealing portion 130b made of a curable sealing material may have a gel content higher than that of the base sealing portion 130a.

For example, the additional sealing portion 130b may have a degree of cure or a gel content of 50% or more (eg, 60 to 95%, for example, 80% to 95%). This is because if the degree of cure or gel content is 50% or more, the required sealing properties can be maintained depending on the material. Here, the degree of curing or the gel content of the additional sealing portion 130b may be 60% or more so as to stably have desired sealing properties. For example, the degree of curing or gel content of the additional sealing portion 130b may be 80% or more so as to maximize the effect of the additional sealing portion 130b, but the present invention is not limited thereto. In addition, in order to cure the additional sealing portion 130b so that the degree of curing or the gel content exceeds 95%, the process time of the lamination process is increased, or the solar cell 150 constituting the solar panel 100 during the lamination process. Since a characteristic change or the like may occur, the degree of curing or the gel content of the additional sealing portion 130b may be 95% or less. However, the present invention is not limited thereto, and the gel content of the additional sealing portion 130b may exceed 95%.

When the base sealing part 130a is provided with a curable sealing material, the hardening degree or the gel content of the base sealing part 130a is smaller than that of the additional sealing part 130b, for example, the hardening degree of the base sealing part 130a or The gel content may be 50% or more (eg, 60 to 95%, for example, 70% to 90%). This is because if the degree of cure or gel content is 50% or more, the required sealing properties can be maintained depending on the material. Here, the degree of curing or the gel content of the base sealing portion 130a may be 60% or more so as to stably have desired sealing properties. For example, the hardening degree or gel content of the base sealing portion 130a may be 70% or more so as to maximize the sealing characteristics by the base sealing portion 130a, but the present invention is not limited thereto. In addition, in order to cure the base sealing portion 130a such that the degree of curing or the gel content exceeds 90%, the process time of the lamination process is increased, or the solar cell 150 constituting the solar panel 100 during the lamination process. Since a change in properties or the like may occur, the degree of curing or the gel content of the base sealing portion 130a may be 90% or less. However, the present invention is not limited thereto, and the gel content of the base sealing portion 130a may exceed 90%.

As another example, when the base sealing portion 130a is made of a plastic sealing material, the gel content may be 0%.

The curing degree or gel content of the base sealing portion 130a, and the gel content or curing degree of the additional sealing portion 130b are not limited to the above-described values. Accordingly, the material, thickness, etc. of the base sealing portion 130a and the additional sealing portion 130b may be variously changed according to process conditions in the lamination process. In addition, when the base sealing portion 130a is formed of a curable sealing material and the time of the lamination process is prolonged, the curing degree or the gel content of the base sealing portion 130a and the additional sealing portion 130b may be substantially the same.

Whether the base sealing portion 130a and the additional sealing portion 130b are composed of a curable sealing material or a plastic sealing material can be determined by various methods. For example, a curable sealing material has a curing agent (eg, an amine-based curing agent), whereas a plastic sealing material does not have a curing agent. Accordingly, plastic sealing whether the base sealing portion 130a and the additional sealing portion 130b are made of a curable sealing material by determining whether the curing agent is present by various analysis methods, for example, Fourier infrared spectroscopy (FT-IR), etc. It can be determined whether it is composed of a substance. Alternatively, since the plastic sealing material has a gel content of 0%, the gel content is analyzed and judged as a plastic sealing material if the gel content is 0, and if the gel content is measured as a value other than 0%, it will be judged as a curable sealing material. I can.

The gel content of the base sealing portion 130a and the additional sealing portion 130b can be determined by various known methods. For example, the gel content can be determined by a general gel content test. In the gel content test, a substance for which the gel content is to be measured is added to a solvent such as toluene, xylene, etc., and then boiled at a certain temperature and for a certain time, and then the unreacted and dried residual weight is measured. I can. Alternatively, the gel content may be determined by differential scanning calorimetry (DSC).

When the additional sealing portion 130b is formed by using the support member 130d made of a semi-cured sealing material as in the present embodiment, it is possible to prevent or minimize the thickness decrease at the edge portion in the lamination process. The support member 130d made of a semi-cured or temporary cured sealing material has excellent adhesion to the glass substrate constituting the first and/or second cover members 110 and 120, and does not easily leak out during the lamination process. This is because it can be located stably. This will be described in detail later in the manufacturing method of the solar panel 100.

In this way, when the sealing distance between the first cover member 110 and the second cover member 120 or the thickness of the sealing material 130 is sufficiently secured at the edge portion by the support member 130d or the additional sealing portion 130b , It is possible to prevent bubbles from remaining inside the solar panel 100. On the other hand, when the sealing distance between the first cover member 110 and the second cover member 120 or the thickness of the sealing material 130 at the edge portion is greatly reduced, as in the prior art, bubbles are difficult to leak to the outside. A lot of air bubbles are trapped and remain between the edge of the solar cell 150 located and the first or second cover member 110, 120, and between the solar cell 150 and the bus ribbon 145 positioned at the edge. do. If the air bubbles remain in this way, the yield of the solar panel 100 may be lowered because it corresponds to a defect in the appearance of the solar panel 100. In addition, moisture permeates through the bubbles, or adhesion between the sealing member (reference numeral 130e in Fig. 7A, hereinafter the same) or the sealing portions 130a, 130b or the sealing member 130e or the sealing portions 130a, 130b by the bubbles And the adhesion between the first or second cover members 110 and 120 may be reduced. Accordingly, the sealing properties may be deteriorated, and thus the reliability of the solar panel 100 may be deteriorated. This problem caused by bubbles is difficult to solve easily even by applying various methods, structures, etc. when the sealing distance between the first cover member 110 and the second cover member 120 is decreased at the edge portion.

In the present embodiment, the first and second cover members 110 and the second cover are prevented from bending of the glass substrates of the first and second cover members 110 and 120 at the edges by the support member 130d. Since the sealing distance between the members 120 or the thickness of the sealing material 130 can be sufficiently secured, air bubbles can be effectively discharged to the outside during the lamination process so as not to remain inside the solar panel 100.

On the other hand, even when the support member 130d is made of a sealing material, if it is made of a sealing material in an uncured state, during the lamination process, the support member 130d is discharged to the outside together with the sealing material constituting the base sealing part 130a. Even if) was inserted, it was difficult to maintain the thickness of the edge portion at a level similar to that of other portions. Accordingly, it was difficult to solve a problem that may occur due to a decrease in the thickness of the sealing material 130 at the edge portion, and a problem caused by air bubbles. In order to prevent this, when the support member 130d having a very large thickness is used, problems such as a step or a portion where the sealing material 130 is not filled may occur.

In this embodiment, a semi-cured or temporary-hardened sealing material is used as the support member 130d to form the base sealing portion 130a, and the remaining portion can be recycled as the support member 130d, thereby reducing material cost. can do.

Here, the additional sealing portion 130b may be positioned adjacent to the first or second cover members 110 and 120 than the base sealing portion 130a. That is, when the additional sealing portion 130b is positioned between the solar cell 150 and the first cover member 110, the additional sealing portion 130b is more than the first and/or second sealing portions 131a, 132a. 1 It may be located adjacent to the cover member 110. Alternatively, when the additional sealing portion 130b is positioned between the solar cell 150 and the second cover member 120, the additional sealing portion 130b is more than the first and/or second sealing portions 131a, 132a. 2 It may be located adjacent to the cover member 120.

For example, the additional sealing portion 130b may contact one of the first and second cover members 110 and 120. This is because during the lamination process, the support member 130d, which will constitute the additional sealing portion 130b, is placed on the first or second cover members 110 and 120 in a temporarily fixed state. This will be described in more detail later in the manufacturing method of the solar panel 100.

In this embodiment, the additional sealing portion 130b is adjacent to the first additional sealing portion 131b and the second cover member 120 positioned adjacent to (for example, in contact with) the first cover member 110 (for example, , Contact) may include a second additional sealing portion (132b) positioned. In this case, the base sealing portion 130a may be positioned between the first additional sealing portion 131b and the second additional sealing portion 132b. For example, in this case, the base sealing portion 130a located between the first additional sealing portion 131b and the second additional sealing portion 132b may contact the first and second additional sealing portions 131b and 132b. have. 2 illustrates that the first and second sealing portions 131a and 131b are positioned together between the first additional sealing portion 131b and the second additional sealing portion 132b, but the present invention is not limited thereto. Accordingly, at least one of the first and second sealing portions 131a and 131b is positioned between the first additional sealing portion 131b and the second additional sealing portion 132b, so that the first and second additional sealing portions 131b, 132b) is sufficient to contact each.

In this way, the base sealing portion 130a is positioned between the first additional sealing portion 131b and the second additional sealing portion 132b, so that the plurality of sealing portions 130a, 130b constituting the sealing material 130 during the lamination process It is possible to improve adhesion properties. However, the present invention is not limited thereto. A modified example thereof will be described in detail later with reference to FIGS. 10 to 12.

In the present embodiment, a plurality of additional sealing portions 130b or support members 130d are provided based on one side of the solar cell 150 to provide a constant distance between the first cover member 110 and the second cover member 120. It can be stably supported by thickness. For example, in a plan view, a plurality of additional sealing portions 130b may be provided so as to be adjacent to a plurality of corners of the solar panel 100, respectively. Since the edges of the opposite sides are effectively supported by the additional sealing portion 130b or the support member 130d located adjacent to the corner, the first cover member 110 and the second cover member 120 are bent or at the edge portion. It can effectively support the narrowing between them. In the present invention, the additional sealing portion 130b or the support member 130d may have a shape extending along the edge of the solar panel 100, but according to this, the material cost increases and the outflow path of the air bubbles is blocked. May occur. That is, in the present embodiment, the additional sealing portion 130b or the supporting member 130d is partially located at the corner corresponding portion, thereby reducing material cost and effectively securing a bubble outflow path.

The additional sealing portion 130b may be located spaced apart from the solar cell 150 so as not to overlap with the solar cell 150 when viewed in a plan view. On the other hand, if the additional sealing portion 130b is positioned so as to overlap the solar cell 150, problems such as damage to the solar cell 150 and unwanted change in characteristics may occur by applying pressure to the solar cell 150. However, the present invention is not limited thereto, and a part of the additional sealing portion 130b may be positioned to overlap the solar cell 150.

In addition, the additional sealing portion 130b may be positioned so as not to protrude to the outside of the first or second cover members 110 and 120. This may be because the support member 130d forming the additional sealing portion 130b is positioned inside the first or second cover members 110 and 120 in the manufacturing process. It will be described in detail in the manufacturing method of. Alternatively, if the additional sealing portion 130b protrudes to the outside of the first or second cover member 110 or 120 after the lamination process, it protrudes to the outside of the first or second cover member 110 or 120 by a trimming process. When the sealed material 130 or the additional sealing portion 130b is cut and removed, the additional sealing portion 130b may not protrude to the outside of the first or second cover members 110 and 120.

Since the additional sealing part 130b is located only at the edge of the solar panel 100 where the solar cell 150 is not located, the area where the additional sealing part 130b is not located is less than the area where the additional sealing part 130b is located. This can be bigger. That is, the ratio of the area where the additional sealing portion 130b is located to the total area of the sealing material 130 may be less than 50% (eg, 20% or less, for example, 10% or less). Accordingly, it is possible to reduce the material cost of the sealing material 130 by reducing the area of the additional sealing portion 130b. However, the present invention is not limited thereto.

In FIG. 3, each of the additional sealing portions 130b is shown to have a rectangular shape. This is only illustrated as an example, and the additional sealing portion 130b may have various shapes such as a circular shape, a rounded shape, a polygonal shape, or a shape in which a portion thereof is formed or a shape in which a portion thereof is combined, an irregular shape, and the like. When the plurality of additional sealing portions 130b are provided, at least two of the plurality of additional sealing portions 130b may have different shapes. For example, since the additional sealing portion 130b is formed by pressing the support member 130d used in the lamination process by the pressure provided in the lamination process, the additional sealing portion 130b may have more various shapes.

For example, the thickness of the additional sealing portion 130b may be greater than a distance (eg, a minimum distance) between the solar cell 150 and the first or second cover members 110 and 120. Accordingly, it is possible to sufficiently secure a sealing distance between the first cover member 110 and the second cover member 120 or the thickness of the sealing material 130 at the edge portion. However, the present invention is not limited thereto, and the thickness of the additional sealing portion 130b is equal to the distance (for example, the minimum distance) between the solar cell 150 and the first or second cover members 110 and 120 It can be smaller than that.

However, the present invention is not limited thereto. Therefore, the sealing material 130, the base sealing portion 130a, and the additional sealing portion 130b include various materials other than the above description, have various properties, have various thicknesses, or have various shapes. I can.

For clear understanding, in FIGS. 2 and 3, a plurality of sealing parts 130a and 130b are shown to have a certain boundary, but in fact, a plurality of sealing parts 130a and 130b are integrated by a lamination process or the like to form one phase. ), and may not have such a boundary. The additional sealing part 130b has the same or similar color as the first and/or second sealing parts 131a, 132a, and is integrated with the base sealing part 130a to exist as a single phase. It may not be possible to distinguish it with the naked eye, etc.). Accordingly, the solar panel 100 may have an excellent appearance. However, the present invention is not limited thereto, and the additional sealing portion 130b may have a color different from that of the first and/or second sealing portions 131a and 132a.

According to the present embodiment, the additional sealing portion 130b having a relatively high gel content or curing degree is included at least in the edge portion, and sealing in a portion different from the edge portion (for example, the central portion) of the solar panel 100 The distance can be kept uniform. As an example, as illustrated in FIG. 4, substantially the same sealing distance (eg, a difference of within 10%) may be provided in the entire area of the solar panel 100. In particular, when the first and second cover members 110 and 120 each have a building-integrated structure composed of a glass substrate, a double-sided light-receiving structure, etc., there is a problem that the sealing distance at the edge of the solar panel 100 is reduced. This could have occurred seriously, but this can be effectively prevented according to the present embodiment. Accordingly, peeling of the first or second cover members 110 and 120 and the sealing material 130, which may occur due to a decrease in the sealing distance at the edge of the solar panel 100, and the first and second cover members 110 It is possible to fundamentally prevent problems such as damage that may occur when the, 120) come into contact with each other, deterioration of sealing characteristics, damage or deterioration of characteristics of the solar cell 150 adjacent to the edge, and the remaining air bubbles in the solar panel 100. . And it is possible to improve the fastening force with the frame fastened to the edge of the solar panel 100. Accordingly, reliability and productivity of the solar panel 100 may be improved. In particular, the first and second cover members 110 and 120 may have excellent effects in a building-integrated structure consisting of a glass substrate, a double-sided light-receiving structure, and in particular, in a building-integrated structure using a relatively thick glass substrate. It can have a better effect.

On the other hand, unlike in the present embodiment, in the prior art, which does not include an additional sealing portion having a relatively high gel content or hardening degree, the sealing portion constituting the sealing material at the edge portion is largely leaked to the outside, so that the first cover member and the second cover member The sealing distance between them may become too close. Accordingly, as shown in FIG. 5, the sealing distance at the edge portion of the solar panel can be rapidly reduced to close to zero. Then, the first or second cover member may be peeled off from the sealing material due to the restoring force of the first or second cover member, or the first cover member and the second cover member may be damaged by contacting each other. In addition, pressure is applied to the solar cell located adjacent to the edge, so that problems such as damage to the solar cell and deterioration of characteristics may occur. In addition, bubbles may remain inside the solar panel, thereby increasing the defect rate. In addition, since the thickness of the edge portion of the solar panel is insufficient, the fastening force of the frame fastened to the edge portion of the solar panel may not be excellent. This problem may appear more in a building-integrated structure in which the first and second cover members are composed of a glass substrate, a double-sided light-receiving structure, and in particular, may seriously occur in a building-integrated structure using a relatively thick glass substrate. .

Hereinafter, a method of manufacturing the solar panel 100 according to an embodiment of the present invention will be described in detail.

6 is a flowchart showing a method of manufacturing the solar panel 100 according to an embodiment of the present invention, and FIGS. 7A to 7C schematically illustrate a method of manufacturing the solar panel 100 according to an exemplary embodiment of the present invention. It is a drawing shown.

Referring to FIG. 6, a method of manufacturing the solar panel 100 according to the present embodiment includes a lamination step S10 and a lamination step S20.

First, as shown in Figure 7a, in the lamination step (S10), the solar cell 150 on the work table 200 of the lamination device, and sealing to form a sealing material 130 surrounding and sealing the solar cell 150 A laminated structure by stacking the member 130e and the first and second cover members 110 and 120 each positioned on one side and the other side of the solar cell 150 on the sealing member 130e, and at least one including a glass substrate (100a) is formed. Here, the solar cell 150 may be in the form of a plurality of solar cells 150 to which the wiring units 142 and 145 are connected. 7A and 7B, for clear understanding, the first cover member 110 provided with the first support member 131d, the first sealing member 131c, the solar cell 150, the second sealing member 132c, In addition, although the second cover members 120 provided with the second support members 132d are shown to be spaced apart from each other, in reality, they may be positioned in contact with each other.

In this embodiment, the sealing member 130e is a base sealing member 130c forming a base sealing portion 130a, which is a basic sealing portion surrounding the solar cell 150, that is, the first and second sealing members 131c, In addition to 132c), it further includes a support member (supporting sealing member) 130d for preventing thickness reduction or the like at the edge portion. Accordingly, as described above, the sealing material 130 is provided with an additional sealing portion 130b at least at the edge, which will be described in more detail.

In the lamination step (S10), the sealing member 130d includes a first sealing member 131c positioned between the solar cell 150 and the first cover member 110, and the solar cell 150 and the second cover member ( It may include a second sealing member (132c) positioned between the 120), and a support member (130d) made of a curable sealing material having a gel content greater than that of the first or second sealing members (131c, 132c). Here, the support member 130d may be positioned closer to the first or second cover members 110 and 120 than the first or second sealing members 131c and 132c at least at the edge.

The first or second sealing members 131c and 132c may be formed of various sealing materials capable of constituting the base sealing portion 130a by the lamination step S20.

For example, the first or second sealing members 131c and 132c may be formed of a curable sealing material or a plastic sealing material. When the first or second sealing members 131c and 132c are made of a curable sealing material, the curing degree or the gel content of the curable sealing material constituting the first or second sealing members 131c and 132c is determined by the supporting member 130d. ) It may be lower than the curing degree or gel content of the curable sealing material constituting. That is, the first or second sealing members 131c and 132c are not cured or less cured than the support member 130d, so that the degree of curing or the gel content of the first or second sealing members 131c and 132c is zero or zero. It is larger and lower than the hardening degree or gel content of the support member 130d. As another example, when the first or second sealing members 131c and 132c are made of a plastic sealing material, the gel content is 0, and thus the gel content is lower than that of the support member 130d.

In addition, the first or second sealing members 131c and 132c may include various sealing materials, for example, polyolefin resin or ethylene vinyl acetate resin having excellent adhesion including a silane coupling agent.

In this embodiment, the support member 130d may be made of a curable sealing material that is semi-cured or temporarily cured. The support member 130d made of the curable sealing material semi-cured or provisionally cured as described above is partially cured and has excellent adhesion to a substrate such as a glass substrate, and when heat is provided again in the lamination step (S20), As it is cured, it has a higher curing degree or gel content than the first or second sealing members 131c and 132c, so that the outflow of the sealing material constituting the support member 130d causes the first or second sealing members 131c and 132c. It can be less than the outflow of the constituent sealing material. Accordingly, it is possible to effectively prevent a decrease in the sealing distance at the edge of the solar panel 100.

For example, the support member 130d may have a gel content of 20% to 70% (more specifically, 40% to 60%). If the gel content of the support member 130d is less than 20%, the effect of maintaining the thickness by the support member 130d may not be sufficient. When the gel content of the support member 130d exceeds 70%, the time for a process of semi-curing or pre-curing the support member 130d may increase. In addition, the light transmittance of the support member 130d or the curable sealing material constituting the same may increase as the gel content increases at a gel content of 50% or less, and may be saturated at a gel content of about 50%. In consideration of this, when the support member 130d is used with a gel content of 40% or more, the light transmittance may be prevented from deteriorating. The strength of the supporting member 130d or the curable sealing material constituting the same increases as the gel content increases at a gel content of 60% or less, and is saturated at a gel content of about 60%, and the strength increases at a gel content exceeding 60%. Does not increase. In addition, when the gel content of the support member 130d is 40% or more, the support member 130d may have a relatively high strength, so that leakage to the outside due to the pressure applied during the lamination process may be minimized. In addition, the gel content of the support member 130d may be 60% or less, thereby minimizing the process time of the semi-curing or pre-curing process for forming the semi-cured or pre-cured support member 130d. However, the present invention is not limited thereto, and the value of the gel content of the support member 130d may be variously modified.

In this case, the support member 130d and the first or second sealing members 131c and 132c may contain 50 wt% or more of the same component. For example, the support member 130d may include polyolefin resin or ethylene vinyl acetate resin. As described above, when the first or second sealing members 131c and 132c and the support member 130d are made of the same or similar material, the first and second cover members 110 and the second cover members 110 and 110 have excellent adhesive strength and do not have a large difference in characteristics. It is bonded to them between 120) and sealing the solar cell 150 may be excellent. However, the present invention is not limited thereto, and the support member 130d may be formed of a sealing material or resin having a main chain different from the first or second sealing members 131c and 132c. For example, the support member 130d may include a benzene ring and may be formed of a polyethylene terephthalate resin having a melting point of 200° C. or higher. The support member 130d may include various other materials.

In this embodiment, the support member 130d may include a first support member 131d and a second support member 132d. At this time, the first support member 131d is positioned closer to the inner surface of the first cover member 110 than the first and/or second sealing members 131c and 132c, and the second support member 132d is the first and/or second sealing members 131c and 132c. / Or may be positioned closer to the inner surface of the second cover member 120 than the second sealing member (131c, 132c). As described above, by providing the first and second support members 131d and 132d together, it is possible to effectively solve problems such as thickness reduction and remaining air bubbles that may occur at the edge of the solar panel 100.

For example, in the stacking step (S10), the first support member 131d is attached to the first cover member 110 to be fixed in contact, and the second cover member 120 is an inner surface of the second cover member 120 It may be attached to and fixed in contact. As described above, since the support member 130d is in a semi-cured or pre-cured state and has excellent adhesion to the glass substrate, it is temporarily fixed by attaching to the first or second cover members 110 and 120 in the lamination step (S10). When positioned in the state, the manufacturing process can be simplified and the support member 130d can be stably positioned at a desired position. In addition, it is possible to prevent problems such as the outflow of the support member 130d to the outside due to pressure or the like in the lamination step S20. However, the present invention is not limited thereto, and various modifications may be made such that the support member 130d is located in a state separated from or spaced apart from the first or second cover members 110 and 120 in the stacking step S10.

And in the stacking step (S10), the support member (130d) may be positioned so as not to protrude to the outside of the first or second cover member (110, 120), for example, the first or second cover member (110, 120). ) It can be positioned (for example, attached or temporarily fixed) spaced apart from the edge of a certain distance. For example, a separation distance D between the support member 130d and the edges of the first or second cover members 110 and 120 may be 1 mm or more. When positioned in this state, it is possible to effectively prevent the support member 130d from escaping to the outside during the lamination step (S20) or the trimming step. However, the present invention is not limited thereto, and the separation distance D1 between the support member 130d and the first or second cover members 110 and 120 in the stacking step S10 may be variously changed.

The support member 130d may be spaced apart from the solar cell 150 and the wiring portions 142 and 145 so as not to overlap the solar cell 150 when viewed in a plan view. Accordingly, it is possible to prevent the occurrence of problems such as damage to the solar cell 150 and unwanted change in properties by undesirably applying pressure to the solar cell 150 by the support member 130d. However, the present invention is not limited thereto, and at least a part of the support member 130d may be positioned to overlap the solar cell 150.

A plurality of such support members 130d may be provided on one side of the solar cell 150 to uniformly support the first cover member 110 and the second cover member 120. For example, the support member 130d may be provided in plural so as to be adjacent to the corners of the first or second cover members 110 and 120 or the solar panel 100, respectively. The support member 130d may have various planar shapes. For example, as shown in (a) to (i) of Fig. 8, a rounded shape such as a circle or a semicircle, a polygon such as a triangle, a square (for example, a rectangle, a square, a rhombus, etc.), or these It may have various shapes, such as a shape that constitutes a part of or a combination of some of them, an irregular shape. For example, when the support member 130d is circular, the effect of the support member 130d may be excellent, but the present invention is not limited thereto. Accordingly, the planar shape of the supporting member 130d suitable for the shape and structure of the solar cell 150 and the arrangement of the wiring portions 142 and 145 may be variously modified.

In addition, the support member 130d may have various sizes. For example, the width (eg, long width) or diameter of the support member 130d is the gap between the first cover member 110 and the second cover member 120 after the lamination step S20 (that is, the sealing distance). Can be greater than ). Alternatively, the width (eg, long width) or diameter L of the support member 130d may be 3 mm or more (eg, 5 mm or more). With this size, the effect of the support member 130d can be sufficiently implemented. However, the present invention is not limited thereto, and various modifications are possible.

The thickness of the support member 130d may be smaller than the sum of the thicknesses of the first sealing member 131c and the second sealing member 132c. As a result, the distance between the first sealing member 131c and the second sealing member 132c at the edge portion is greatly increased by the support member 130d, so that an undesired step is created and a portion where the sealing material is not filled occurs. It can prevent problems from occurring. However, the present invention is not limited thereto, and the thickness of the support member 130d may be greater than the sum of the thicknesses of the first sealing member 131c and the second sealing member 132c.

For example, the thickness of the support member 130d may be greater than the thickness of the first or second sealing members 131c and 132c. Accordingly, the sealing distance between the first cover member 110 and the second cover member 120 or the thickness of the sealing material 130 can be sufficiently secured at the edge of the solar panel 100 after the lamination step (S20). have. However, the present invention is not limited thereto, and the thickness of the support member 130d may be equal to or smaller than the thickness of the first or second sealing members 131c and 132c.

In this embodiment, since the support member 130d is located only at the edge of the solar panel 100 where the solar cell 150 is not located, the support member 130d is not located more than the area where the support member 130d is located. The area may be larger. That is, the ratio of the total area of the support member 130d to the total area of the sealing member 130e may be less than 50% (eg, 20% or less, for example, 10% or less). Accordingly, it is possible to reduce the material cost of the sealing member 130e by reducing the area of the support member 130d. However, the present invention is not limited thereto.

Subsequently, as shown in FIGS. 7B and 7C, heat and pressure are applied to the stacked structure 100a in the lamination step S20 to provide the solar cell 150, the sealing material 130, the first and second cover members 110, The solar panel 100 is formed by integrating 120). In the lamination step S20, for example, air pressure may be used as the pressure. Accordingly, the lamination process can be performed without applying a large pressure to the solar cell 150 or the like.

More specifically, as shown in FIG. 7B, the sealing member 130e is melted and cured at a high temperature in the lamination step S20, and the sealing material 130 formed by compressing by pressure is formed with the first cover member 110. The solar cell 150 may be enclosed and sealed while completely filling the space between the second cover member 120. In this case, the first and second sealing members 131c and 132c and the support member 130d may be integrated to form the sealing material 130. That is, the first and second sealing members 131c and 132c may constitute the base sealing portion 130a of the sealing material 130, and the support member 130d may constitute the additional sealing portion 130b. As a result, the solar panel 100 as shown in FIG. 7C is manufactured.

Here, the additional sealing portion 130b may have a higher degree of curing or a gel content than the base sealing portion 130a. This is because the manufacturing process is controlled so that the time of the manufacturing process is not too long. However, the present invention is not limited thereto, and the hardening degree or gel content of the additional sealing part 130b may be made equal to the hardening degree or gel content of the base sealing part 130a by increasing the process time of the lamination step (S20). have.

In this embodiment, the additional sealing portion 130b may be positioned to correspond to the portion where the supporting member 130d is located, and the supporting member 130d is pressed by the pressure in the lamination step S20 and the additional sealing portion ( As 130b) can be configured, the area of the additional sealing portion 130b may be larger than the area of the support member 130d. However, the present invention is not limited thereto, and the area of the additional sealing portion 130b may be equal to or smaller than the area of the support member 130d.

In this embodiment, the solar panel 100 having excellent properties may be manufactured by a simple process using the support member 130d having a relatively high gel content or hardening degree. Accordingly, the defective rate can be lowered and productivity can be improved.

Hereinafter, a solar panel according to another embodiment of the present invention and a method of manufacturing the same will be described in detail. Detailed descriptions of parts that are the same or extremely similar to those of the above description will be omitted, and only different parts will be described in detail. In addition, a combination of the above-described embodiment or a modified example thereof and the following embodiment or modified examples thereof also falls within the scope of the present invention.

9 is a plan view schematically showing a first or second cover member, a solar cell, and an additional sealing part included in a solar panel according to another embodiment of the present invention.

Referring to FIG. 9, in this embodiment, the additional sealing portion 130b is spaced apart from the edge sealing portion 134a adjacent to the edge of the solar panel 100 and the solar panel 100, and is spaced apart from the edge of the solar panel 100. An intermediate sealing portion 134b positioned adjacent to the long side or short side edge of the 100 may be further included. According to this, even when a scene or a short edge of the solar panel 100 is lengthened, the sealing distance or the sealing material 130 can have a sufficient thickness along the entire edge of the solar panel 100. This solar panel 100 is by the same method as the above-described manufacturing method, but in the lamination step (reference numeral S10 in FIG. 6A, hereinafter the same), the support member (reference numeral 130d in FIG. 7A, hereinafter the same) is placed in the above-described position. It can be manufactured by positioning to correspond.

For example, the additional sealing portions 130b may be regularly positioned at regular intervals. In FIG. 9, it is exemplified that the middle sealing portion 134b is located at both the short side edge and the long side edge and is provided in a larger number at the long side edge. However, the present invention is not limited thereto, and various modifications are possible. For example, the middle sealing portions 134b may be located at both the short side edge and the long side edge, and may be provided in a larger number at the short side edge or the same number at the long side and the short side edge. Alternatively, the intermediate sealing portion 134b may be positioned only at one of the short side edge and the long side edge, for example, it may be positioned at the long side edge.

For reference, unlike the present embodiment, if the additional sealing portion 130b is continuously positioned so as to correspond to the entire edge of the long side or the short side, the material cost may increase, and rather, air bubbles, etc. may be prevented from leaking to the outside. have. However, the present invention is not limited thereto, and the additional sealing portion 130b may have a shape extending along a long side or an edge. Other variations are possible.

10 is a schematic cross-sectional view of a solar panel according to a modified example of the present invention.

Referring to FIG. 10, in this modified example, the additional sealing portion 130b includes only the first additional sealing portion 131b adjacent to (for example, contacting) the first cover member 110, and the second additional sealing portion It may not have (132b). Accordingly, the first or second sealing portions 131a and 132b may be adjacent to (for example, contact) the second cover member 120. This solar panel 100 is provided with only the first support member (reference numeral 131d in FIG. 7A, hereinafter the same) in the lamination step (S10) and the second support member (FIG. 7A) by the same method as the above-described manufacturing method. It can be manufactured by not having the reference numeral 132 (the same hereinafter).

In another variation, as shown in FIG. 11, the additional sealing portion 130b includes only the second additional sealing portion 132b adjacent (for example, in contact with) the second cover member 120, and the first The additional sealing portion 131b may not be provided. Accordingly, the first or second sealing portions 131a and 132b may be adjacent to (for example, contact) the first cover member 110. The solar panel 100 may be manufactured by the same method as the above-described manufacturing method, but with only the second support member 132d and not the first support member 131d in the lamination step (S10). have.

In another variation, as shown in FIG. 12, the additional sealing portion 130b is provided with first and second additional sealing portions 131b, 132b, but the first and second additional sealing portions 131b, 132b In this plane, they can be located in different positions. The solar panel 100 is manufactured by the same method as the above-described manufacturing method, but by placing the first support member 131d and the second support member 132d at different positions in the lamination step (S10). I can.

Accordingly, it is possible to reduce the material cost by minimizing the number of support members (130d).

Features, structures, effects, and the like according to the above are included in at least one embodiment of the present invention, and are not necessarily limited to only one embodiment. Furthermore, the features, structures, effects, and the like illustrated in each embodiment may be combined or modified for other embodiments by a person having ordinary knowledge in the field to which the embodiments belong. Therefore, contents related to such combinations and modifications should be construed as being included in the scope of the present invention.

100: solar panel
110: first cover member
120: second cover member
130: sealing material
130a: base sealing part
130b: additional sealing part
130c: base sealing member
130d: support member
130e: sealing member

Claims (20)

Solar cells;
First and second cover members respectively positioned on one side and the other side of the solar cell, at least one including a glass substrate; And
A sealing material surrounding and sealing the solar cell between the first cover member and the second cover member
Including,
The sealing material includes a plurality of sealing portions having different gel contents in at least an edge portion of the first or second cover member. The method of claim 1,
The plurality of sealing portions may include a base sealing portion and a curable sealing material positioned adjacent to at least one of the first and second cover members than the base sealing portion at at least an edge portion and having a gel content greater than that of the base sealing portion. Solar panel comprising an additional sealing portion comprising a. The method of claim 2,
The additional sealing portion and the base sealing portion contain 50 wt% or more of the same component. The method of claim 3,
The base sealing portion contains a polyolefin resin or an ethylene vinyl acetate resin,
The solar cell panel wherein the additional sealing portion comprises a polyolefin resin or an ethylene vinyl acetate resin. The method of claim 2,
A solar panel in which the additional sealing portion and the base sealing portion each contain a silane coupling agent. The method of claim 2,
The solar panel in which the base sealing portion includes a curable sealing material or a plastic sealing material having a lower curing degree or a lower gel content than the additional sealing portion. The method of claim 2,
The solar panel in which the additional sealing portion contacts one of the first cover member and the second cover member. The method of claim 2,
A solar panel positioned spaced apart from the solar cell so that the additional sealing portion does not overlap the solar cell when viewed in plan view. The method of claim 2,
A solar panel having a plurality of the additional sealing portions positioned adjacent to each of the plurality of corners of the solar panel. The method of claim 9,
The solar panel further comprises an intermediate sealing portion spaced apart from the edge of the solar panel and positioned in an intermediate region of a long or short edge of the solar panel. First and second cover members each comprising a solar cell, a sealing member to form a sealing material surrounding and sealing the solar cell, and each of which is positioned on one side and the other side of the solar cell above the sealing member, and at least one includes a glass substrate A lamination step of laminating the layers to form a laminated structure; And
Lamination step of applying heat and pressure to the stacked structure so that the solar cell, the sealing material, and the first and second cover members are integrated to form a solar panel
Including,
The sealing material includes a plurality of sealing portions having different gel contents at at least an edge portion of the first or second cover member. The method of claim 11,
In the laminating step, the sealing member includes a first sealing member positioned between the solar cell and the first cover member, a second sealing member positioned between the solar cell and the second cover member, and at least an edge portion A support member positioned adjacent to the first or second cover member and formed of a curable sealing material having a gel content greater than that of the first or second sealing member,
In the lamination step, the first and second sealing members constitute a base sealing portion and the support member constitutes an additional sealing portion to form the integrated sealing material. The method of claim 11,
The support member is a method of manufacturing a solar panel comprising 50 wt% or more of the same component as the first or second sealing member. The method of claim 11,
A method of manufacturing a solar panel in which the support member is made of a curable sealing material that is semi-cured or temporarily cured in the laminating step. The method of claim 14,
In the laminating step, the method of manufacturing a solar panel in which the support member has a gel content of 40% to 60%. The method of claim 14,
In the laminating step, the first or second sealing member includes a curable sealing material having a lower curing degree or a lower gel content than the supporting member, or a plastic sealing material. The method of claim 11,
In the laminating step, the support member is attached to the first or second cover member so as to be spaced apart from the edge of the first or second cover member, and is positioned in a fixed state. The method of claim 11,
A method of manufacturing a solar panel in which the width or diameter of the support member in the laminating step is greater than the distance between the first cover member and the second cover member after the laminating step. First and second cover members each comprising a solar cell, a sealing member to form a sealing material surrounding and sealing the solar cell, and each of which is positioned on one side and the other side of the solar cell above the sealing member, and at least one includes a glass substrate A lamination step of laminating the layers to form a laminated structure; And
Lamination step of applying heat and pressure to the stacked structure so that the solar cell, the sealing material, and the first and second cover members are integrated to form a solar panel
Including,
In the laminating step, the sealing member is positioned adjacent to the first or second cover member at least at an edge portion and includes a support member made of a curable sealing material that has been semi-cured or pre-cured. The method of claim 19,
In the laminating step, the sealing member further includes a first sealing member positioned between the solar cell and the first cover member, and a second sealing member positioned between the solar cell and the second cover member,
A method of manufacturing a solar panel in which the support member has a gel content of 40% to 60%.

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