WO2012102320A1 - Module de piles solaires et son procédé de fabrication - Google Patents

Module de piles solaires et son procédé de fabrication Download PDF

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Publication number
WO2012102320A1
WO2012102320A1 PCT/JP2012/051598 JP2012051598W WO2012102320A1 WO 2012102320 A1 WO2012102320 A1 WO 2012102320A1 JP 2012051598 W JP2012051598 W JP 2012051598W WO 2012102320 A1 WO2012102320 A1 WO 2012102320A1
Authority
WO
WIPO (PCT)
Prior art keywords
filler
surface protection
wiring
solar cell
back surface
Prior art date
Application number
PCT/JP2012/051598
Other languages
English (en)
Japanese (ja)
Inventor
俊行 佐久間
直人 今田
祐 石黒
幸弘 吉嶺
齋田　敦
Original Assignee
三洋電機株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 三洋電機株式会社 filed Critical 三洋電機株式会社
Publication of WO2012102320A1 publication Critical patent/WO2012102320A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10293—Edge features, e.g. inserts or holes
    • B32B17/10302—Edge sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10743—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing acrylate (co)polymers or salts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to a solar cell module and a method for manufacturing the solar cell module.
  • the solar cell module has a structure in which a filler is disposed between the translucent member and the back surface protective film, and a plurality of solar cells are sealed in the filler.
  • the plurality of solar cells are connected in series or in parallel by a wiring member.
  • a plurality of solar cells arranged in one direction are electrically connected by a wiring member to constitute a solar cell string.
  • a plurality of solar cell strings are arranged in another direction orthogonal to one direction, and the wiring members positioned at the ends between the adjacent strings are electrically connected by the jumper wiring.
  • the crossover wiring is also used as an output wiring for taking out the generated power from all the solar cell strings. Therefore, a part of the crossover wiring collects the power generation output from the wiring member, routes it to the external output of the solar cell module, and is soldered to a conductor that is electrically connected to the external output unit.
  • Patent Document 1 a translucent member, a filler sheet, a plurality of solar cell strings, a filler sheet, and a back surface protective film are laminated in this order, and this laminate is manufactured by heating and pressing with a laminating apparatus. A solar cell module is described.
  • the back surface protective film may bend to the translucent member side and be damaged by coming into contact with the end of the crossover wiring. For this reason, there exists a possibility of reducing the manufacture yield of a solar cell module.
  • the present invention provides a solar cell module that suppresses damage to the back surface protection form and improves the manufacturing yield.
  • a solar cell module includes a surface protection member, a back surface protection film, a plurality of solar cells disposed between the surface protection member and the back surface protection film, and the surface protection member. And the back surface protective film, a filler for sealing the plurality of solar cells, a wiring member for electrically connecting the plurality of solar cells to each other, and a bridge electrically connected to the wiring member
  • the wiring is made of an insulating material that is interposed between the front surface protective member and the back surface protective film in the vicinity of the transition wiring and is harder than the filler or having a lower melt flow rate at a temperature equal to or higher than the softening point of the filler.
  • An end face sealing member is made of an insulating material that is interposed between the front surface protective member and the back surface protective film in the vicinity of the transition wiring and is harder than the filler or having a lower melt flow rate at a temperature equal to or higher than the softening point of the filler.
  • a solar cell module in another aspect of the present invention, includes a surface protection member, a back surface protection film, a plurality of solar cells disposed between the surface protection member and the back surface protection film, and the surface protection member. And a back surface protective film between the first filler for sealing the plurality of solar cells, a wiring member for electrically connecting the plurality of solar cells to each other, and electrically connected to the wiring member.
  • a transition wire and a second filler disposed at least at a part of the position where the transition wire is disposed, and having a melt flow rate smaller than that of the first filler, and the second filler is Further, the wiring has a thickness such that the wiring is separated from the back surface protective film across the interval between the transition wire and the back surface protective film.
  • a method for manufacturing a solar cell module includes wiring a plurality of solar cells by a wiring member and a crossover wiring, and a first filler sheet, the plurality of solar cells on a surface protection member, A first filler sheet, a second filler sheet disposed in at least a part of the place where the crossover wiring is disposed and having a melt flow rate lower than that of the first filler sheet, and a back surface protective film are laminated in this order. Then, a laminate is formed, the laminate is heated and pressed, and the softened filler is filled around the plurality of solar cells.
  • a solar cell module in another aspect of the present invention, includes a surface protection member, a back surface protection film, a plurality of solar cells disposed between the surface protection member and the back surface protection film, and the surface protection member. And the back surface protective film, a filler for sealing the plurality of solar cells, a wiring member for electrically connecting the plurality of solar cells to each other, and a bridge electrically connected to the wiring member Wiring, and the thickness of the portion located between the surface protection member and the back surface protective film at the end of the solar cell module on the side where at least the crossover wiring is arranged is greater than the thickness of the central portion. Largely formed.
  • a solar cell module is configured by wiring a plurality of solar cells by a wiring member and a crossover wiring, and on a surface protection member, a filler sheet, the plurality of solar cells, the filler sheet, and the bridge
  • the filler sheet placed at the place where the wiring is placed, the back surface protective film on the top is laminated in this order to form a laminate, the laminate is heated and pressed, and at least the transition wire is arranged
  • a thickness of the filler positioned between the surface protection member on the side and the back surface protection film is formed to be larger than a thickness of the filler in a central portion, and between the surface protection member and the back surface protection film
  • the plurality of solar cells are sealed with the filler.
  • a solar cell module is configured by wiring a plurality of solar cells by a wiring member and a crossover wiring, and on the surface protection member, a filler sheet, the plurality of solar cells, the filler sheet, and the uppermost part.
  • the back surface protective film is laminated in this order to form a laminated body, and the laminated body is pressed in a state where the laminating temperature of the portion where the crossover wiring is located is heated higher than the other portions, and at least the crossover wiring
  • the thickness of the filler positioned between the surface protection member on the side where the metal is disposed and the back surface protection film is formed to be larger than the thickness of the filler at the central portion, and the surface protection member and the back surface protection
  • the plurality of solar cells are sealed with the filler between the film.
  • a solar cell module is configured by wiring a plurality of solar cells by a wiring member and a crossover wiring, and on the surface protection member, a filler sheet, the plurality of solar cells, the filler sheet, and the uppermost part.
  • the back surface protective film is laminated in this order to form a laminated body, the laminated body is heated, and after the passage of a predetermined time after the start of crimping of a portion other than the portion where the transition wiring is located, the transition wiring is positioned.
  • the pressure of the portion to be pressed is started, the laminate is pressed, and the thickness of the filler located between at least the front surface protection member and the back surface protection film on the side where the crossover wiring is arranged is determined as a central portion.
  • the plurality of solar cells are sealed with the filler between the surface protective member and the back surface protective film.
  • a method for manufacturing a solar cell module includes: wiring a plurality of solar cells by a wiring member and a crossover wiring; and a filler sheet, the plurality of solar cells, and a filler sheet on a surface protection member. Then, a back surface protective film is laminated on the uppermost portion in this order to form a laminated body, and the laminated body is heated, and the crimping strength of the portion other than the portion where the jumper wiring is located is higher than the crimping strength of the portion where the jumper wire is located.
  • the crossover wiring can be prevented from coming into contact with the back surface protective film.
  • FIG. 2 is an enlarged cross-sectional view of a main part of the solar cell module according to the first embodiment, taken along line AA in FIG.
  • FIG. 3 is an enlarged cross-sectional view of a main part of a solar cell module according to a second embodiment, taken along line AA in FIG.
  • FIG. 5 is an enlarged cross-sectional view of a main part of a solar cell module according to a third embodiment, taken along line AA in FIG. FIG.
  • FIG. 6 is an enlarged cross-sectional view of a main part of a solar cell module according to a fourth embodiment, taken along line AA in FIG.
  • FIG. 7 is an enlarged cross-sectional view of a main part of a solar cell module according to a fifth embodiment, taken along line AA in FIG.
  • FIG. 10 is an enlarged cross-sectional view of a main part of a solar cell module according to a sixth embodiment, taken along line AA in FIG. It is a principal part expanded sectional view of the solar cell module which concerns on the 7th Embodiment of this invention. It is the top view seen from the back surface side of the solar cell module centering on the crossover wiring part of the solar cell module which concerns on the 7th Embodiment of this invention.
  • FIGS. 1 to 3 A schematic configuration of the solar cell module 10 according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 3.
  • the solar cell module 10 is formed in a substantially rectangular shape in plan view.
  • the solar cell module 10 includes a solar cell 11, a surface protection member 12, a back surface protection film 13, and fillers 14a and 14b.
  • the solar cell module 10 is configured by sealing a plurality of solar cells 11 between the surface protection member 12 and the back surface protection film 13. Electrodes are formed on the light receiving surface and the back surface of the solar cell 11.
  • the plurality of solar cells 11 are connected to each other by the wiring member 16.
  • the plurality of solar cells 11 connected in series by the wiring member 16 constitutes a string 110 that is a unit. These strings 110 and 110 are connected by a crossover wiring 20. A part of the crossover wiring 20 is used as an output wiring for outputting electricity to the outside.
  • the solar cell 11 is made of a crystalline semiconductor composed of, for example, single crystal silicon or polycrystalline silicon having a thickness of about 0.15 mm, and has a substantially square shape with one side being 100 mm, but is not limited thereto. Other solar cells may be used.
  • the solar cell 11 has, for example, an n-type region and a p-type region.
  • a junction for forming an electric field for carrier separation is formed at the interface between the n-type region and the p-type region.
  • the wiring member 16 is connected to an electrode formed on the light receiving surface of the solar cell 11 and an electrode formed on the back surface of another solar cell 11 adjacent to the solar cell 11. Thereby, the adjacent solar cells 11 are electrically connected.
  • the wiring member 16 includes a thin plate-like copper foil and solder plated on the surface of the copper foil.
  • the solder plated on the surface of the wiring member 16 is melted and connected to the electrode of the solar cell 11.
  • the connection between the solar cell 11 and the wiring member 16 can be performed using a resin adhesive in addition to the connection using solder.
  • the resin adhesive is preferably cured at a temperature lower than the melting point of the eutectic solder, that is, about 200 ° C. or lower.
  • a resin adhesive film having anisotropy is used as the resin adhesive.
  • the conductive adhesive film includes at least a resin adhesive component and conductive particles dispersed therein.
  • a resin adhesive component in which conductive particles are dispersed is provided on a base film made of polyimide or the like.
  • the resin adhesive component is composed of a composition containing a thermosetting resin.
  • an epoxy resin, a phenoxy resin, an acrylic resin, a polyimide resin, a polyamide resin, or a polycarbonate resin can be used.
  • These thermosetting resins are used singly or in combination of two or more, and one or more thermosetting resins selected from the group consisting of epoxy resins, phenoxy resins and acrylic resins are preferable.
  • the conductive particles include metal particles such as gold particles, silver particles, copper particles, and nickel particles, or conductive or insulating core particles such as gold plating particles, copper plating particles, and nickel plating particles. Conductive particles formed by coating with a conductive layer such as a layer are used.
  • the surface protection member 12 is disposed on the light receiving surface side of the filler 14 a and protects the surface of the solar cell module 10.
  • glass having translucency and water shielding properties, translucent plastic, or the like can be used as the surface protection member 12.
  • the back surface protective film 13 is disposed on the back surface side of the filler 14b and protects the back surface of the solar cell module 10.
  • a resin film such as PET (Polyethylene Terephthalate), a laminated film having a structure in which an Al (aluminum) foil is sandwiched between resin films, or the like can be used.
  • Fillers 14 a and 14 b seal the solar cell 11 between the front surface protection member 12 and the back surface protection film 13.
  • EVA ethylene / vinyl acetate copolymer resin
  • polyolefins such as polyethylene and polypropylene, cyclic polyethylene, ionomers, polyacrylic acid polymers, and copolymers obtained by polymerizing a plurality of these can be used.
  • at least the filler 14a disposed between the surface protection member 12 and the solar cell 11 has translucency.
  • an end face sealing material 17 is disposed near the crossover wiring 20 as will be described later.
  • a surface protection member 12, an end surface sealing material 17 disposed on the surface protection member 12 in the vicinity of the crossover wiring 20, a front surface side filler resin sheet 14a, a plurality of solar cell strings, a back surface side filler resin sheet 14b, And the back surface protective film 13 are laminated in this order, and the laminated body is heated and pressurized by a laminating apparatus to soften the resin sheet for the filler while maintaining a predetermined interval at the place where the end face sealing material 17 is arranged. . Then, the air bubbles inside are expelled, and the softening filling resin is uniformly filled around the solar cell 11, so that the solar cell 11 is sealed between the surface protection member 12 and the back surface protection film 13.
  • the back surface protective film 13 is provided with an opening 13 a for taking out the output wiring 20.
  • a terminal box (not shown) is attached using an adhesive such as silicone resin so as to cover the opening 13a of the back surface protective film 13.
  • the output crossover wiring 20 taken out from the opening 13a is connected to a terminal in a terminal box (not shown) and led out to the outside.
  • the terminal block of the terminal box is provided with four terminals, to which the corresponding output transition wirings 20 1 to 20 4 are connected.
  • a backflow prevention diode is connected between the terminals of the terminal box.
  • the interconnectors 20 1-20 4 for these output, an insulating member 20a is attached to insulate the transition wirings 20 for other output.
  • FIGS. 1 and 2 six strings are connected in series. Output transition wirings 20 1 leftmost string is pulled out from the opening 13a. Second and third string from the left are connected by the output connecting wire 20 2, interconnectors 20 2 for the output is withdrawn from the opening 13a.
  • rightmost output interconnectors 20 4 strings is pulled from the opening 13a.
  • the second from the right and third strings are connected by the output connecting wire 20 3, the output line 20 3 is pulled out from the opening 13a.
  • the solar cell module is configured by being drawn out from the opening 13a of the back surface protective film 13 as the output wirings 20 1 to 20 4 from the six strings, and connected to predetermined terminals of the terminal box. .
  • An Al (aluminum) frame (not shown) can be attached to the outer periphery of the solar cell module 10 having the above configuration.
  • the wiring member 16 located at the end of each solar cell string is connected to the crossover wiring 20 that connects the solar cell strings.
  • the crossover wiring 20 is also used as an output wiring for taking out the power generation output from all the solar cell strings.
  • the output transition wiring 20 taken out to the outside is connected to the terminal of a terminal box (not shown) for the electrical output from the solar cell 11.
  • the crossover wiring 20 is usually a copper foil having a thickness of about 0.1 mm to 0.3 mm and a width of 4 to 6 mm, and its entire surface is solder-coated, cut to a predetermined length, and soldered to the wiring member 16. Yes.
  • the fillers 14a and 14b flow, the back surface protection film 13 bends to the surface protection film 12 side, and the solar cell module 10 ends.
  • the thickness of the fillers 14a and 14b is reduced.
  • angular part of the crossover wiring 20 located in the edge part side of the solar cell module 10 may penetrate the filler 14b on the back surface side, and may reach the back surface protective film 13 side.
  • the end portions of the crossover wires 20 located at the four corners of the solar cell module 10 are in contact with the back surface protective film 13.
  • the ends of the solar cell module 10 where the crossover wires 20 are arranged are filled at a temperature higher than the softening point of the fillers 14a and 14b.
  • An end face sealing material 17 made of an insulating material harder than the materials 14a and 14b or an insulating material having a low melt flow rate (MFR) is interposed. That is, the end face seal of such a size that the distance between the front surface protection member 12 and the rear surface protection film 13 is maintained at a predetermined distance during and after the lamination so that the end of the crossover wiring 20 does not contact the back surface protection film 13. Stop material 17 is interposed.
  • the outflow of the fillers 14a and 14b is suppressed, and the wiring member 16 is reliably sealed by the fillers 14a and 14b. Thereby, since insulation is maintained even if the distance between the end face of the surface protection member 12 and the crossover wiring 20 is reduced, the surface protection member 12 can be reduced, and module efficiency can be improved.
  • the shape of the end surface portion of the solar cell module 10 can be maintained, and it can be applied to a building material integrated solar cell module with a high yield.
  • the end face sealing material 17 can reduce the outflow of the fillers 14a and 14b, it is possible to reduce the trimming process for removing the filler that protrudes to the periphery in the subsequent process, and to reduce the manufacturing cost.
  • the inside of the module can be deaerated during lamination, and the solar cell module can be manufactured with high yield.
  • the fillers 14a and 14b, the end surface sealing material 17 and the adhesive layer 18 may satisfy the following relationship.
  • the end surface sealing member 17 may be selected from an insulating material that is harder than the fillers 14a and 14b or has a lower melt flow rate at a temperature equal to or higher than the softening point of the fillers 14a and 14b. That is, when the fillers 14a and 14b are selected, the material of the end surface sealing member 17 that can be used can be selected.
  • the adhesive layer 18 may be selected from materials that cure at a lower temperature than the softening points of the fillers 14a and 14b.
  • Table 1 illustrates the fillers 14a and 14b. Note that the fillers 14a and 14b may be selected from the materials shown in Table 1. A combination of the materials shown in Table 1 can also be used as the filler.
  • EVA is an ethylene / vinyl acetate copolymer resin
  • HDPE is a high-density polyethylene resin
  • LDPE is a low-density polyethylene resin.
  • the end surface sealing member 17 may be selected from an insulating material harder than the selected fillers 14a and 14b or an insulating material having a low melt flow rate. .
  • the following are insulating materials whose hardness at the high temperature (40 degrees to 180 degrees) which is the softening point temperature of the filler is harder than that of the filler.
  • Glass epoxy resin which is a material obtained by impregnating a substrate such as glass cloth, glass fiber, or glass paper with an epoxy resin, a phenol resin, a methacryl resin, a silicone resin, an acrylic resin, or a urethane resin
  • the melt flow rate of this glass epoxy resin is zero.
  • Epoxy resin, phenol resin, methacryl resin, silicone resin, acrylic resin or urethane resin, and the melt flow rate of these resins is 0.02 to 53.
  • Polyamide resin the melt flow rate of this resin is 10-80.
  • Polyolefin resin having a high melting point represented by polypropylene resin, and the melt flow rate of this resin is 5 to 60.
  • Polycarbonate resin the melt flow rate of this resin is 2-30.
  • melt flow rate of polyethylene and this resin is 0.03 to 50.
  • Elastomers such as butyl rubber, butadiene rubber and styrene / butadiene rubber, and the melt flow rate of this resin is 5 to 60.
  • the insulating resin that cures at a temperature lower than the softening point temperature of the filler that can be used as the adhesive layer 18 is shown in Table 2.
  • an epoxy resin may be used as the adhesive layer 18 and a glass epoxy resin may be used as the end surface sealing member 17.
  • the fillers 14 a and 14 b are softened between the surface protection member 12 and the back surface protection film 13 at the end of the solar cell module 10 on which the crossover wiring 20 is arranged.
  • An end face sealing material 17 is provided through an adhesive layer 18 that cures at a lower temperature than the point.
  • the adhesive layer 18 is provided on each of the surface protection member 12 and the back surface protection film 13 side.
  • the fillers 14a and 14b flow, but since the end surface sealing material 17 made of an insulating material harder than the fillers 14a and 14b or an insulating material having a low melt flow rate is interposed, It is possible to prevent the back surface protection film 13 from being curved toward the surface protection member 12, and to prevent the crossover wiring 20 from penetrating the filler 14 b and coming into contact with the back surface protection film 13.
  • the end surface sealing material 17 is provided between the surface protection member 12 and the back surface protection film 13 of the edge part of the solar cell module 10 by which the crossover wiring 20 is distribute
  • the end surface sealing material 17 is configured to be bonded by the fillers 14a and 14b.
  • the end surface sealing material 17 is provided with an engaging portion 17 a that engages with the surface protection member 12.
  • the engaging portion 17a is engaged with the surface protection member 12, and the end surface sealing material 17 is temporarily fixed to the surface protection member 12 until the lamination is completed.
  • the end surface sealing material 17 is bonded by the fillers 14 a and 14 b and fixed between the front surface protection member 12 and the rear surface protection film 13.
  • the end surface sealing material 17 can be fixed with higher accuracy by fixing the end surface sealing material 17 to the surface protection member 12 and then setting and laminating.
  • the end surface sealing material 17 is provided between the surface protection member 12 and the back surface protection film 13 of the edge part of the solar cell module 10 by which the crossover wiring 20 is distribute
  • the end surface sealing material 17 is configured to be bonded by an adhesive 18 and fillers 14a and 14b.
  • the end surface sealing material 17 is provided with an engaging portion 17 a that engages with the surface protection member 12.
  • the engaging portion 17 a is engaged with the surface protection member 12, and the surface protection member 12 and the end surface sealing material 17 are adhered by the adhesive layer 18 at the start of lamination.
  • the end surface sealing material 17 is bonded by the fillers 14 a and 14 b and the adhesive 18, and is fixed between the surface protection member 12 and the back surface protection film 13.
  • the end surface sealing material 17 is provided between the surface protection member 12 and the back surface protection film 13 of the edge part of the solar cell module 10 by which the crossover wiring 20 is distribute
  • the end surface sealing material 17 is configured to be bonded by an adhesive 18 and fillers 14a and 14b.
  • the end surface sealing material 17 is provided with an engaging portion 17 a that engages with the surface protection member 12.
  • An adhesive layer 18 is provided on the bottom and side surfaces of the engaging portion 17a.
  • the engaging portion 17 a is engaged with the surface protection member 12, and the surface protection member 12 and the end surface sealing material 17 are adhered by the adhesive layer 18 at the start of lamination.
  • the end surface sealing material 17 is bonded by the fillers 14 a and 14 b and the adhesive 18, and is fixed between the surface protection member 12 and the back surface protection film 13.
  • the end surface sealing material 17 is provided between the surface protection member 12 and the back surface protection film 13 of the edge part of the solar cell module 10 by which the crossover wiring 20 is distribute
  • the end surface sealing material 17 is configured to be bonded by an adhesive 18 and fillers 14a and 14b.
  • the end surface sealing material 17 is provided with an engaging portion 17 a that engages with the surface protection member 12.
  • An adhesive layer 18 is provided on the bottom and side surfaces of the engaging portion 17a.
  • the engaging portion 17 a is engaged with the surface protection member 12, and the surface protection member 12 and the end surface sealing material 17 are adhered by the adhesive layer 18 at the start of lamination.
  • the end surface sealing material 17 is bonded by the fillers 14 a and 14 b and the adhesive 18, and is fixed between the surface protection member 12 and the back surface protection film 13.
  • FIG. 10 A schematic configuration of a solar cell module 10 according to a seventh embodiment of the present invention will be described with reference to FIG.
  • the surface protection member 12 is disposed on the light receiving surface side of the first filler 14 a and protects the surface of the solar cell module 10.
  • the back surface protective film 13 is disposed on the back surface side of the second filler 14b and protects the back surface of the solar cell module 10.
  • a second filler 14c having a melt flow rate smaller than that of the first fillers 14a and 14b is disposed between the crossover wiring 20 and the back surface protective film 13.
  • Fillers 14a, 14b, and 14c seal the solar cell 11 between the front surface protective member 12 and the back surface protective film 13.
  • the filler 14a disposed between the surface protection member 12 and the solar cell 11 has translucency.
  • the filler 14c and the fillers 14a and 14b arranged at least at a part of the end of the solar cell module 10 in the vicinity of the crossover wiring 20 are selected in consideration of the relationship between the respective material melt flow rates.
  • the fillers 14a, 14b and 14c are selected from ethylene / vinyl acetate copolymer (EVA), polyolefin, cyclic polyethylene, ionomer, polyacrylic acid polymer, or a copolymer obtained by polymerizing a plurality of these, and the filler 14a 14b and the filler 14c are selected such that the filler 14c has a lower melt flow rate than the fillers 14a and 14b at a temperature equal to or higher than the softening point of the filler, for example, 150 ° C.
  • EVA ethylene / vinyl acetate copolymer
  • first filler (first filler sheet) 14a made of a resin sheet on the front side, a plurality of solar cell strings, a filler made of a resin sheet on the back side (first filler sheet) 14b, the 2nd filler (2nd filler sheet) 14c which consists of a resin sheet distribute
  • each filler made of a resin sheet is softened.
  • a material having a lower melt flow rate is selected as the second filler 14c than the first fillers 14a and 14b.
  • the fluidity of the second filler 14c is smaller than that of the first fillers 14a and 14b, so that the distance between the back surface protective film 13 and the crossover wiring 20 is secured at the softening temperature of the resin. A certain cell is expelled and the softening filling resin is uniformly filled around the solar cell 11, and the solar cell 11 is sealed between the front surface protection member 12 and the back surface protection film 13.
  • a temperature higher than the softening point of the first fillers 14a and 14b for example, 150 ° C. or higher.
  • a second filler 14c made of an insulating material having a lower melt flow rate than the first fillers 14a and 14b is interposed. That is, the gap between the back film 13 and the crossover wiring 20 is maintained at a predetermined interval during and after lamination so that the end of the crossover wiring 20 and the like do not come into contact with the back surface protection film 13.
  • the melt flow rate is at the softening point of the first fillers 14 a and 14 b between the back film 13 at the end of the solar cell module 10 on which the crossover wiring 20 is arranged and the crossover wiring 20.
  • a second filler 14c made of a small insulating material is interposed.
  • the second filler 14c made of an insulating material harder than the first fillers 14a and 14b or an insulating material having a lower melt flow rate is interposed. Therefore, the second filler 14c does not flow much.
  • the back surface protection film 13 curves to the surface protection member 12 side, and it can prevent that the crossover wiring 20 penetrates the 2nd filler 14c, and contacts with the back surface protection film 13.
  • first fillers 14a and 14b and the second filler 14c may satisfy the following relationship.
  • the second filler 14c is selected from an insulating material having a lower melt flow rate than the first fillers 14a and 14b at a temperature equal to or higher than the softening point of the first fillers 14a and 14b, for example, 150 degrees or higher. Good. That is, when the first fillers 14a and 14b are selected, a usable material for the second filler 14c can be selected.
  • Table 3 illustrates the first fillers 14a and 14b and the second filler 14c. Note that the fillers 14a, 14b, and 14c may be selected from the materials shown in Table 3. A combination of the materials shown in Table 3 can also be used as the filler.
  • EVA is an ethylene / vinyl acetate copolymer resin.
  • the first fillers 14a and 14b are selected from the resins exemplified in Table 3, and the second filler 14c may be selected from an insulating material having a lower melt flow rate than the selected fillers 14a and 14b.
  • the first fillers 14a and 14b EVA or polyolefin polymer used as the first fillers 14a and 14b
  • EVA or polyolefin polymer used in the cyclic polyethylene, ionomer, polyacrylic acid polymer as the second filler 14c. Therefore, a material having a low melt flow rate may be selected. These materials have good adhesion to EVA or polyolefin polymer, and the interface between the two is closely integrated to suppress moisture permeation from the interface.
  • FIG. 12 is a schematic diagram showing an example of a laminating apparatus for manufacturing a solar cell module.
  • the solar cell 11 is sealed between the front surface protection member 12 and the back surface protection film 13 by the fillers 14a, 14b, and 14c.
  • a laminating apparatus as shown in FIG. 12 is used.
  • the laminating apparatus includes an upper chamber 101 having an inflatable diaphragm 102 and a lower chamber 105 having a support 107 incorporating a heater for heating the laminate to be laminated.
  • a vacuum pump 104 outside the chamber is connected so that the diaphragm sheet 102 inside the upper chamber 101 and the inner region surrounded by the upper chamber 101 can be depressurized.
  • the upper chamber 101 and the lower chamber 105 are openable and closable.
  • the lower chamber 105 is connected to a vacuum pump 110 for depressurizing the inside of the lower chamber 105, and a support body 107 disposed almost in the center of the lower chamber 105 is made of a metal member such as aluminum or stainless steel. Is disposed in an insulating state with respect to the support 107.
  • FIGS. 12 With reference to the laminating apparatus shown in FIG. 12, a method of laminating with the filler 14c disposed in the crossover wiring 20 portion and securing the space between the back surface protective film 13 and the crossover wiring 20 is shown in FIGS. This will be described with reference to FIG.
  • the laminating process first, placing the laminated body 10 1 to be laminated on a support 107 in the lower chamber 105.
  • Laminate 10 1, the surface protective member 12, such as EVA on its first filling material made of a resin sheet (first filler sheet) 14a, the wiring member 16, a plurality of which were wired by interconnectors 20
  • the first filling material (first filling material sheet) 14b made of a resin sheet such as the solar cell 11 or EVA, and the second filling made of a resin sheet at a position where at least the crossover wiring 20 for connecting the strings is arranged.
  • the material (second filler sheet) 14c and the back surface protective film 13 are laminated on the top.
  • the second filler 14c is selected from an insulating material having a lower melt flow rate than the first fillers 14a and 14b.
  • the second filler 14c is selected from cyclic polyethylene and ionomer polyacrylic acid polymer.
  • the second filler 14c is a material having a lower melt flow rate than the EVA or polyolefin polymer used.
  • EVA or polyolefin-based polymer may be used as the second filler 14c, and a resin having a higher melt flow rate than the resin of the second filler 14c may be used as the first fillers 14a and 14b. .
  • the laminated body 101 described above is set on the support 107 with the surface protection member 12 side down, the upper and lower chambers 101 and 105 are closed, and the upper chamber vacuum region and the lower chamber vacuum region are set by the vacuum pumps 104 and 110.
  • the pressure is reduced to about 66 to 133 Pa.
  • the lower chamber vacuum region 105 is also returned to atmospheric pressure, the upper chamber 101 and the lower chamber 105 are opened, and the solar cell module 10 is taken out.
  • the second filling sheet 14c having a low melt flow rate is disposed at the position where the crossover wiring 20 is disposed, and then laminated. As shown in FIG. 9, the second filler 14 c located at the end of the solar cell module 10 on which the crossover wiring 20 is arranged does not flow so much, and the corner of the crossover wiring 20 and the back surface protective film 13 A sufficient interval can be maintained, and the back surface protective film 13 is suppressed from being damaged.
  • the second filler 14 c is arranged on the first filler 14 b where the crossover wiring 20 is located.
  • the first filler 14b is disposed at least in the vicinity of the crossover wiring 20 that connects the strings 30.
  • the second filler 14c is disposed so as to be in contact with the filler 14b.
  • Other configurations are the same as those of the seventh embodiment.
  • the laminated body of the eighth embodiment having such a configuration is laminated in the same manner as described above.
  • the second filler 14c has a melt flow rate smaller than that of the first fillers 14a and 14b, so the second filler 14c does not flow so much, and the corners of the transition wiring 20 and the back surface protective film It is possible to maintain a sufficient distance between the back surface protective film 13 and the back surface protective film 13 from being damaged.
  • FIG. 10 A schematic configuration of a solar cell module 10 according to a ninth embodiment of the present invention will be described with reference to FIG.
  • the surface protection member 12 is disposed on the light receiving surface side of the filler 14 and protects the surface of the solar cell module 10.
  • the back surface protective film 13 is disposed on the back surface side of the filler 14 and protects the back surface of the solar cell module 10.
  • the filler 14 seals the solar cell 11 between the front surface protective member 12 and the back surface protective film 13.
  • the filler 14 include EVA (ethylene / vinyl acetate copolymer resin), polyolefins such as polyethylene and polypropylene, cyclic polyethylene, ionomers, polyacrylic acid polymers, copolymers obtained by polymerizing a plurality of these, polydimethylsiloxane, and the like. Silicone-based resins can be used.
  • a filler having translucency is used as the filler 14 disposed at least between the surface protection member 12 and the solar cell 11.
  • the surface protective member 12, the front surface side filler resin sheet, the plurality of solar cell strings 30, the back surface side filler resin sheet, and the back surface protective film 13 are laminated in this order.
  • the resin sheet for fillers is softened by heating and pressurizing this laminated body with a laminating apparatus. Then, the air bubbles inside are expelled, and the softening filling resin is uniformly filled around the solar cell 11, so that the solar cell 11 is sealed between the surface protection member 12 and the back surface protection film 13.
  • the solar cell module 10 As shown in FIG. 15, the solar cell module 10 according to the ninth embodiment of the present invention varies in the size of the thickness of the filler 14 filled between the surface protection member 12 and the back surface protection film 13 depending on the part. It is laminated so that.
  • sealing member 14 1 is located in the solar cell module 10 ends including at least interconnectors 20 is larger than the center of the sealing member 14 2 of the thickness of the site.
  • the filler 14 flows in the vicinity of the end portions of the surface protection member 12 and the back surface protection film 13 during the laminating process described above, and the back surface protection film 13 protects the surface.
  • the thickness of the filler 14 at the end of the solar cell module 10 is reduced by bending toward the film 12 side.
  • angular part of the crossover wiring 20 located in the edge part side of the solar cell module 10 may penetrate the filler 14b on the back surface side, and may reach the back surface protective film 13 side.
  • the end portions of the crossover wires 20 located at the four corners of the solar cell module 10 are in contact with the back surface protective film 13.
  • at least one part of the crossover wiring 20 contacts the back surface protection member 13 in this way there exists a possibility that the reliability of a solar cell module may be reduced, and there exists a possibility that a yield may fall for this reason.
  • the filler 14 1 located at the end of the side of the solar cell module 10 over wires 20 are disposed, the central site filler 14 It is formed larger than the thickness of 2 .
  • the additional filler interconnectors 20 parts The thickness of the filler depending on the part is controlled by, for example, arranging or changing the conditions at the time of laminating and controlling the curing of the filler.
  • a method of increasing the thickness of the filler 14 1 located at the end of the solar cell module 10 over wires 20 are disposed.
  • Lamination process first, placing the laminated body 10 1 to be laminated on a support 107 in the lower chamber 105.
  • the first filler 14b made of a sheet, the filler 14d made of an additional resin sheet at a position where the crossover wiring 20 connecting at least the string 20 is disposed, and the back surface protective film 13 are laminated on the uppermost part. Yes.
  • the upper and lower chambers 101, 105 are closed, and the upper chamber vacuum region and the lower chamber vacuum region are reduced to about 66 to 133 Pa by the vacuum pumps 104, 110.
  • the lower chamber vacuum region 105 is also returned to atmospheric pressure, the upper chamber 101 and the lower chamber 105 are opened, and the solar cell module 10 is taken out.
  • sealing member 14 1 located at the end may be larger than the filler 14 2 of the thickness of the central portion.
  • a filler 14 1 interconnectors 20 are located at the end of the solar cell module 10 on the side which is arranged, by formed larger than the filler 14 2 of the thickness of the central portion, the corners of the interconnectors 20 and the back A sufficient distance from the protective film 13 can be maintained, and the crossover wiring 20 can be prevented from coming into contact with the back surface protective film 13.
  • the laminating temperature of the part where the crossover wiring 20 is located is made higher than that of the other part. That is, the temperature of the heaters 107a and 107b built in the support 107 is changed to increase the laminating temperature of the portion where the crossover wiring 20 is located.
  • the heaters 107a at both ends are controlled so that the laminating temperature of the portion where the crossover wiring 20 is located is 130 ° C. to 180 ° C.
  • the central portion heater 107b is controlled so that the central portion temperature becomes 100 ° C. to 130 ° C.
  • a surface protection member 102 is placed on a support 107 in the lower chamber 105, and a plurality of fillers (filler sheet) 14 a made of a resin sheet such as EVA, a wiring member 16, and a transition wiring 20 are wired thereon.
  • the laminated body which consists of the solar cell 11, the filler 14b which consists of resin sheets, such as EVA, and the back surface protective film 13 is put on the uppermost part.
  • the upper chamber vacuum region and the lower chamber vacuum region 11 are decompressed to about 66 to 133 Pa by the vacuum pumps 104 and 110.
  • the temperature of the laminated body is heated by the support body 107 in which the temperature is distributed, and the temperature rise is started. In this state, maintain for 4 to 5 minutes.
  • the fillers 14a and 14b such as EVA are softened, but when the temperature is high, the curing starts first. For this reason, the hardening of the filler at the position of the crossover wiring 20 starts first.
  • the diaphragm sheet 102 is expanded by gradually returning the upper chamber vacuum region to atmospheric pressure, and the laminate is heated and pressed between the diaphragm sheet 102 and the support 107 of the upper chamber 101. This state is maintained for about 4 to 5 minutes to expel air bubbles inside the laminate, and the softened fillers 14a and 14b are uniformly filled around the solar cell 11.
  • the thickness of the portion where the hardening has started at the time of heating and pressing does not start hardening. Thickness will increase from the location.
  • the vacuum region of the lower chamber 105 is also returned to atmospheric pressure, the upper chamber 101 and the lower chamber 101 are opened, and the solar cell module 10 is taken out.
  • filler 14 1 located at the end of the solar cell module 10 on the side where the transition wirings 20 are disposed are it can be larger than the center of the sealing member 14 2 of the thickness of the site.
  • a filler 14 1 interconnectors 20 are located at the end of the side solar cell module 10 which is arranged, by larger than the filler 14 2 of the thickness of the other portions, the corner portions of the interconnectors 20 and the back surface protection A sufficient distance between the film 13 and the film 13 can be maintained, and the crossover wiring 20 is prevented from coming into contact with the back surface protective film 13.
  • the thickness of the filler 14 is changed depending on the location so as to change the time for starting the crimping between the center and both ends.
  • the laminator device is configured such that a crimping member 121 for crimping the crossover wiring 20 portion and a crimping member 120 for crimping other portions are operated separately.
  • a surface protection member 102 is placed on a support 107 in the lower chamber 105, and a plurality of fillers (filler sheet) 14 a made of a resin sheet such as EVA, a wiring member 16, and a transition wiring 20 are wired thereon.
  • seat) 14b which consists of resin sheets, such as the solar cell 11 and EVA, and the uppermost part is installed.
  • the upper chamber vacuum region and the lower chamber vacuum region are reduced to about 66 to 133 Pa by the vacuum pumps 104 and 110.
  • the temperature of the laminate is started by heating the laminate with the support 107.
  • the temperature of the laminated body reaches 130 to 180 ° C., and is maintained in this state for 4 to 5 minutes to soften the fillers 14a and 14b.
  • the vicinity of the center is crimped for 2 to 3 minutes by the crimping member 120 at the center.
  • the whole is crimped by the crimping members 121 at both ends and the crimping member 120 at the center.
  • This state is maintained for about 4 to 5 minutes to expel air bubbles inside the laminate, and the softened fillers 14a and 14b are uniformly filled around the solar cell 11.
  • filler 14 1 located at the end of the solar cell module 10 over wires 20 are disposed, the other parts filler 14
  • the thickness can be larger than 2 .
  • a filler 14 1 interconnectors 20 are located at the end of the solar cell module 10 on the side which is arranged, by formed larger than the filler 14 2 of the thickness of the central portion, the corners of the interconnectors 20 and the back A sufficient distance from the protective film 13 can be maintained, and the crossover wiring 20 can be prevented from coming into contact with the back surface protective film 13.
  • the thickness of the filler 14 is changed depending on the location so as to change the pressure-bonding strength between the center and both ends.
  • the laminator device is configured such that the crimping member 121 for crimping the crossover wiring portion 20 and the crimping member 120 for crimping other portions are driven separately.
  • the surface protection member 12 is placed on the support 107 in the lower chamber 105, and a plurality of solar cells on which wiring is performed by a filler (filling sheet) 14 a made of a resin sheet such as EVA, the wiring member 16, and the transition wiring 20.
  • a filler (filler sheet) 14 b made of a resin sheet such as EVA, and a laminate in which the back surface protective film 13 is placed on the uppermost part are installed.
  • the upper chamber vacuum region and the lower chamber vacuum region are reduced to about 66 to 133 Pa by the vacuum pumps 104 and 110.
  • the temperature of the laminate is started by heating the laminate with the support 107.
  • the temperature of the laminated body 8 reaches 130 to 180 ° C., and this state is maintained for 4 to 5 minutes.
  • the crimping strength of the crimping member 120 near the center is increased by the crimping member 120 near the center, and the crimping strength is weaker than that of the central portion by the crimping members 121 at both ends, and the crimping is performed for 4 to 5 minutes.
  • a filler 14 1 interconnectors 20 are located at the end of the solar cell module 10 on the side which is arranged, by formed larger than the filler 14 2 of the thickness of the central portion, the corners of the interconnectors 20 and the back A sufficient distance from the protective film 13 can be maintained, and the crossover wiring 20 can be prevented from coming into contact with the back surface protective film 13.

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  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
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  • Photovoltaic Devices (AREA)

Abstract

La présente invention concerne un module de piles solaires dans lequel un dommage causé à un film protecteur de surface arrière est supprimé, ainsi que l'occurrence d'un dommage. Ce module de piles solaires (10) comprend : un élément protecteur de surface avant (12) ; un film protecteur de surface arrière (13) ; une pluralité de piles solaires (11) installées entre l'élément protecteur de surface avant (12) et le film protecteur de surface arrière (13) et reliées électriquement par des éléments de câblage (16) ; des charges (14a, 14b) permettant de sceller les piles solaires (11) entre l'élément protecteur de surface avant (12) et le film protecteur de surface arrière (13) ; et un câblage de transition (20) électriquement connecté aux éléments de câblage (16). Un élément de scellement de surface d'extrémité (17) est interposé entre le film protecteur de surface arrière (13) et l'élément protecteur de surface avant (12) au moins au voisinage du câblage de transition (20), l'élément de scellement comprenant un matériau isolant présentant un débit plus faible à l'état fondu, ou un matériau isolant présentant une plus grande dureté, qu'une charge à une température supérieure ou égale au point de ramollissement de la charge.
PCT/JP2012/051598 2011-01-28 2012-01-26 Module de piles solaires et son procédé de fabrication WO2012102320A1 (fr)

Applications Claiming Priority (6)

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JP2011-016602 2011-01-28
JP2011016602 2011-01-28
JP2011-033706 2011-02-18
JP2011033706 2011-02-18
JP2011-037608 2011-02-23
JP2011037608 2011-02-23

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WO2014030225A1 (fr) * 2012-08-22 2014-02-27 三洋電機株式会社 Module de cellule solaire et son procédé de fabrication
JP2015002318A (ja) * 2013-06-18 2015-01-05 三菱電機株式会社 太陽電池モジュール及びその製造方法
JP2017073466A (ja) * 2015-10-07 2017-04-13 トヨタ自動車株式会社 車載用太陽電池モジュール
JP2019102503A (ja) * 2017-11-28 2019-06-24 藤森工業株式会社 カバーレイフィルムおよびそれを用いた電子機器
CN113841258A (zh) * 2019-06-05 2021-12-24 松下知识产权经营株式会社 太阳能电池模块

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CN113841258A (zh) * 2019-06-05 2021-12-24 松下知识产权经营株式会社 太阳能电池模块

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