WO2018173216A1

WO2018173216A1 - Solar cell module and method for manufacturing solar cell module

Info

Publication number: WO2018173216A1
Application number: PCT/JP2017/011826
Authority: WO
Inventors: 高好松田
Original assignee: 三菱電機株式会社
Priority date: 2017-03-23
Filing date: 2017-03-23
Publication date: 2018-09-27
Also published as: JP6661051B2; JPWO2018173216A1; CN110419113A

Abstract

This solar cell module is provided with: a light-receiving surface-side protection member; a back surface-side protection member; solar cell strings in which a plurality of solar cells (3) are electrically connected in series by inter-cell tabs; lateral tabs for electrically connecting the plurality of solar cell strings in series; and output tabs for extracting output from the solar cell strings to the outside of the back surface-side protection member. The solar cell module is provided with: a sealing layer for holding the solar cell strings between the light-receiving surface-side protection member and the back surface-side protection member; an insulating sheet (72) for insulating the output tabs and the lateral tabs; a decorative sheet (74) that is disposed on the back surface side of the insulating sheet (72) to cover the outer peripheral side of the solar cell strings; a first intermediate sealing layer (71) that is disposed between the lateral tabs and the insulating sheet; and a second intermediate sealing layer (73) that is disposed between the insulating sheet and the decorative sheet (74).

Description

Solar cell module and method for manufacturing solar cell module

The present invention relates to a solar cell module in which solar cells are sealed between a light-receiving surface side protection member and a back surface side protection member, and a method for manufacturing the solar cell module.

Conventionally, one of the mounting structures of a solar cell module is one using an ethylene vinyl acetate (EVA) copolymer as a sealing material. Hereinafter, the ethylene vinyl acetate copolymer may be simply referred to as EVA.

At the time of manufacturing a solar cell module, as shown in Patent Document 1, a transparent surface member, a transparent surface sealing material, a solar battery cell constituting a photovoltaic element, a back surface sealing material, and a back surface member were laminated in this order. A laminated body is formed and a sealing process is performed in a laminating apparatus. EVA is used for the front surface sealing material and the back surface sealing material, and the solar cell module is sealed by melting and curing EVA by heating and pressurizing the laminate using a laminating apparatus. The front surface sealing material and the back surface sealing material are members necessary for ensuring insulation performance in addition to sealing performance.

Also, solar cell modules are often installed on the roofs of houses. Moreover, in a solar cell module, generally, a plurality of rectangular solar cells are arranged in a matrix in accordance with the shape of the installation surface of the solar cell module.

On the other hand, when the installation surface is trapezoidal or triangular, solar cells cannot be arranged in a matrix. For this reason, the shape of the solar cell module is also adapted to the installation surface, and the solar cells must be arranged in steps on the side corresponding to the trapezoidal or triangular hypotenuse of the installation surface. For this reason, in a solar cell module, it has a staircase shape that combines trapezoidal shapes near the hypotenuse, and a blank region in which solar cells are not arranged is formed.

On the other hand, as shown in Patent Document 2, it has been proposed to arrange triangular dummy cells in the blank area or to color the blank area in the same color as the solar battery cell. In order to color the blank area in the same color as the solar battery cell, a design sheet can be used. In general, such a design sheet is made of a resin such as polyethylene terephthalate (PET) so that the color can be clearly seen, and a pressure-treated resin sheet is formed so that there is no gap. used.

Japanese Patent No. 2915327 Japanese Patent No. 3410315

However, when the above design sheet is arranged with respect to Patent Document 1, the design sheet having no fluidity does not reach the surface of the design sheet in contact with the parts other than the sealant, and the surface of the design sheet does not reach the surface. Bubbles are generated on the surface, resulting in poor appearance due to the bubbles.

The present invention has been made in view of the above, and an object of the present invention is to obtain a solar cell module capable of suppressing deterioration in appearance quality due to generation of bubbles.

In order to solve the above-described problems and achieve the object, a solar cell module according to the present invention is provided on a light receiving surface side of a light receiving surface side protective member that is disposed on the light receiving surface side and has a light transmission property, and on the back surface side facing the light receiving surface. A rear surface side protective member disposed, a solar cell string in which a plurality of solar cells are electrically connected in series with inter-cell tabs, a lateral tab in which a plurality of solar cell strings are electrically connected in series, And an output tab for taking out the output from the solar cell string to the outside of the back surface side protection member. In addition, the solar cell module is made of resin, and is arranged between the output tab and the horizontal tab, and the output tab arranged to sandwich the solar cell string between the light receiving surface side protective member and the back surface side protective member. An insulating sheet that insulates the horizontal tab, a design sheet that is disposed on the back side of the insulating sheet and covers the outer peripheral side of the solar cell string, and a horizontal tab and the insulating sheet that are disposed between the horizontal tab and the insulating sheet. A first intermediate sealing layer that is in a non-contact state, and a second intermediate sealing layer that is disposed between the insulating sheet and the design sheet to bring the insulating sheet and the design sheet into a non-contact state. .

According to the present invention, there is an effect that a solar cell module capable of suppressing deterioration in appearance quality due to generation of bubbles can be obtained.

Sectional drawing which shows typically the structure of the arrangement | positioning area | region of the photovoltaic cell in the solar cell module concerning Embodiment 1 of this invention. The schematic diagram which saw through the solar cell module concerning Embodiment 1 of this invention from the back surface side. The schematic diagram which showed the electrical circuit-like connection structure of the solar cell module concerning Embodiment 1 of this invention. The schematic plan view which looked at the solar cell module concerning Embodiment 1 of this invention from the back surface side It is a conceptual diagram which shows the structure of the edge part periphery part of the solar cell string in the solar cell module concerning Embodiment 1 of this invention, and is a conceptual diagram which shows the structure of the area | region X in which the insulating sheet is arrange | positioned in FIG. It is a conceptual diagram which shows the structure of the edge part periphery of the solar cell string in the solar cell module concerning Embodiment 1 of this invention, and is a conceptual diagram which shows the structure of the area | region Y1 in which the insulating sheet is not arrange | positioned in FIG. The flowchart which shows the procedure of the manufacturing method of the solar cell module in Embodiment 1 of this invention. The conceptual diagram which shows typically the laminated structure of the periphery of the edge part of the design sheet | seat which is a peripheral part of S2 upper side tab of S1-S2 horizontal tab of the laminated body in the manufacturing method of the solar cell module in Embodiment 1 of this invention The conceptual diagram which shows typically the structure of the edge part periphery of the S4 upper tab of the horizontal tab between S4-S5 of the laminated body in the manufacturing method of the solar cell module in Embodiment 1 of this invention, and the periphery of the edge part of a design sheet | seat The enlarged view which shows typically the state before laminating | stacking a 1st intermediate | middle sealing layer sheet | seat and an insulating sheet in the lamination process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. In the lamination process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention, the enlarged plan view which shows typically the state by which the 1st intermediate | middle sealing layer sheet | seat and the insulating sheet were laminated | stacked. The top view of the insulating sheet laminated | stacked in the lamination | stacking process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. Sectional drawing of the insulating sheet laminated | stacked in the lamination | stacking process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. The enlarged plan view which shows typically the state by which the 2nd intermediate | middle sealing layer sheet | seat was laminated | stacked in the lamination process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. The enlarged plan view which shows typically the state by which the design sheet | seat was laminated | stacked in the lamination process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. The schematic diagram which saw through the laminated body in Example 2 from the back surface side Cross-sectional view of the principal part schematically showing the laminated structure around the end portion of the design sheet, which is the periphery of the S2 upper tab of the lateral tab between S1 and S2 of the laminated body in Example 2 Cross-sectional view of the principal part schematically showing the configuration around the end portion of the design sheet, which is the periphery of the S4 upper tab of the horizontal tab between S4-S5 of the laminate in Example 2 The conceptual diagram which shows typically the laminated structure of the periphery of the edge part of the design sheet | seat which is a periphery part of S2 upper side tab of S1-S2 horizontal tab of the laminated body in the comparative example 1 The conceptual diagram which shows typically the structure around the edge part of the S4 upper tab of the horizontal tab between S4-S5 of the laminated body in the comparative example 1, and the edge part periphery The conceptual diagram which shows typically the laminated structure of the periphery of the edge part of the design sheet | seat which is a peripheral part of S2 upper side tab of S1-S2 horizontal tab of the laminated body in the comparative example 2 The conceptual diagram which is a peripheral part of the S4 upper side tab of the horizontal tab between S4-S5 of the laminated body in the comparative example 2, and shows typically the structure around the edge part of the design sheet The conceptual diagram which shows typically the lamination | stacking structure of the periphery of the edge part of the design sheet | seat which is a peripheral part of S2 upper side tab of the horizontal tab between S1-S2 of the laminated body in the comparative example 3 The conceptual diagram which is a peripheral part of the S4 upper side tab of the horizontal tab between S4-S5 of the laminated body in the comparative example 3, and shows typically the structure around the edge part of the design sheet The figure which shows the evaluation result of the presence or absence of the bubble generation of the sample of an Example and a comparative example The schematic diagram which shows the bubble generation | occurrence | production area | region where the bubble generate | occur | produced which is the part which has not covered the 2nd intermediate sealing layer sheet in the sample of the comparative example 1. The schematic diagram which shows the bubble generation | occurrence | production area | region where the bubble generate | occur | produced which is the part which has not covered the 2nd intermediate sealing layer sheet in the sample of the comparative example 2. The schematic diagram which shows the bubble generation | occurrence | production area | region where the bubble generate | occur | produced which is the part which has not covered the 2nd intermediate sealing layer sheet in the sample of the comparative example 3.

Hereinafter, a solar cell module and a method for manufacturing the solar cell module according to an embodiment of the present invention will be described in detail based on the drawings. Note that the present invention is not limited to the embodiments.

Embodiment 1 FIG.
EMBODIMENT OF THE INVENTION Below, embodiment of the manufacturing method of the solar cell module and solar cell module concerning this invention is described in detail based on drawing. In addition, this invention is not limited to the following description, In the range which does not deviate from the summary of this invention, it can change suitably. In the drawings shown below, the scale of each member may be different from the actual scale for easy understanding. Similarly, the scale of each member may be different between the drawings. Further, even a plan view may be hatched to make the drawing easy to see. Further, even a cross-sectional view may not be hatched for easy viewing of the drawing.

FIG. 1 is a cross-sectional view schematically showing a configuration of a solar cell arrangement region in the solar cell module according to Embodiment 1 of the present invention. FIG. 2 is a schematic view of the solar cell module according to Embodiment 1 of the present invention seen through from the back side. FIG. 3 is a schematic diagram showing an electrical circuit connection configuration of the solar cell module according to Embodiment 1 of the present invention. FIG. 4 is a schematic plan view of the solar cell module according to Embodiment 1 of the present invention viewed from the back side. FIG. 5 is a conceptual diagram showing the configuration around the end of the solar cell string in the solar cell module according to Embodiment 1 of the present invention, and shows the configuration of the region X in which the insulating sheet 72 is arranged in FIG. It is a conceptual diagram. FIG. 6 is a conceptual diagram showing the configuration around the end of the solar cell string in the solar cell module according to Embodiment 1 of the present invention, and shows the configuration of the region Y1 in which the insulating sheet 72 is not arranged in FIG. It is a conceptual diagram.

5 and 6 mainly show the inclusion relationship, that is, the positional relationship, between the components in the surface direction of the solar cell module 50. 5 and FIG. 6, the thickness of the solar cell module is shown differently. However, the output tab 11, the S1-S2 horizontal tab 21 and the insulating sheet 72 have a thickness of 0.1 mm or less. Since it has thin thickness, it is set as the same thickness as the whole solar cell module because the thickness of the sealing layer in the solar cell module 50 changes with parts. Further, in FIGS. 5 and 6, the sealing layer region is hatched for easy understanding.

First, the configuration of the solar cell arrangement region in the solar cell module 50 according to the first embodiment will be described. As shown in FIG. 1, the solar cell module 50 according to the first embodiment includes a translucent substrate 1 that is a light-receiving surface side protective member disposed on the light-receiving surface A side, and a first substrate disposed on the light-receiving surface side. 1 is arranged on the back surface B side facing the light receiving surface A, the light receiving surface sealing layer 2 which is a sealing material, a plurality of solar cells 3 connected by the inter-cell tabs 4 and arranged on the same surface. A back surface sealing layer 5 that is a second sealing material and a back sheet 6 that is a back surface side covering film as a back surface side protective member disposed on the back surface side are sequentially laminated. The solar cell module 50 has a holding frame (not shown) for holding the periphery attached to the outer periphery, and a terminal box is bonded to the back surface of the solar cell module. In the solar cell module 50, sunlight enters from the surface side of the translucent substrate 1.

For the translucent substrate 1, a synthetic resin material such as a glass material or a polycarbonate resin is used. Sunlight enters the light receiving surface of the translucent substrate 1. Here, a translucent glass substrate is used as the translucent substrate 1, but a resin plate or the like may be used as long as it is a translucent material. The translucent substrate 1 is fixed to the outer surface of the light receiving surface sealing layer 2 located on the light receiving surface A side of the solar cell module 50.

For the light-receiving surface sealing layer 2, EVA, which is a resin having thermoplasticity and light transmittance, is used. In the first embodiment, EVA is used for the light-receiving surface sealing layer 2, but in addition to this, a thermosetting resin having translucency, such as polyethylene, polypropylene, polycarbonate, polyurethane resin, and polyolefin resin. Alternatively, the laminate can be used. Furthermore, it is effective to crosslink the sealing resin used for the light receiving surface sealing layer 2 in order to improve the weather resistance, strength, and adhesiveness. The adhesiveness of the light-receiving surface sealing layer 2 is required to be adhesive to the solar battery cell 3 in addition to the adhesiveness to the translucent substrate 1. As a crosslinking method, a method of generating radicals by heat is effective. Furthermore, it is preferable to add an ultraviolet absorber in order to improve light resistance. However, in order to improve the output of the solar cell module, it is preferable to reduce the amount of the ultraviolet absorber.

The same material as the light-receiving surface sealing layer 2 can be used for the back surface sealing layer 5. In addition, it is preferable that the back surface sealing layer 5 is white from a viewpoint of ensuring the design property and the electric power generation amount. The reason why the resin constituting the back surface sealing layer 5 is preferably white is that the sunlight that has entered the translucent substrate 1 and reached the back surface sealing layer 5 is reflected by the white resin and has an optical path length. This is because it re-enters the solar battery cell 3 without loss and contributes to power generation. The light-receiving surface sealing layer 2 and the back surface sealing layer 5 constitute a sealing layer that sandwiches the solar battery cell 3 between the translucent substrate 1 and the back sheet 6.

The back sheet 6 is fixed to the outer surface of the back surface sealing layer 5 located on the back surface B side facing the light receiving surface of the solar cell module 50, and has a function of protecting the solar cells 3 from moisture. . It is preferable that the back sheet 6 is a resin having high adhesiveness on the surface in contact with the back surface sealing layer 5. The outermost layer on the atmosphere side of the backsheet 6 is preferably a resin having high weather resistance such as polyethylene terephthalate (Poly Ethylene Teleflate: PET) or polyvinylidene phthalate (PVF: Poly Vinylidene Flate).

The solar battery cell 3 can be a solar battery cell such as a crystalline solar battery. Examples of crystalline solar cells include single crystal silicon solar cells and polycrystalline silicon solar cells.

As shown in FIGS. 2 and 3, a plurality of solar cells 3 are electrically connected by inter-cell tabs 4, so that a solar cell string S1 is formed from a solar cell string S1. And the solar cell array which is a photovoltaic cell group is comprised by arranging the solar cell string S5 from the solar cell string S1. Hereinafter, the solar cell string may be referred to as a string. In FIG. 2 and FIG. 3, two inter-cell tabs 4 for connecting the solar cells 3 are described, but the number of inter-cell tabs 4 for connecting the solar cells 3 may be three or more. The vertical direction is the same direction as the connecting direction of the solar cells 3 by the inter-cell tabs 4. The left-right direction is the same direction as the direction in which the strings S1 to S5 are arranged.

The string S1 in the first column from the left in FIG. 2 includes three solar cells 3, and the back electrode 3b of the upper solar cell 3 and the lower solar cell among the solar cells 3 in the string S1. And the inter-cell tab 4 that electrically connects the three light-receiving surface electrodes 3a.

The string S2 in the second column from the left in FIG. 2 includes four solar cells 3, and the back electrode 3b of the lower solar cell 3 and the upper solar cell among the upper and lower solar cells 3 in the string S2. And an inter-cell tab 4 that electrically connects the light-receiving surface electrode 3a of the battery cell 3. The string S1 and the string S2 are arranged so that the positions of the lowermost solar cells 3 are aligned. The string S1 and the string S2 are electrically connected by a lateral tab 21 between S1 and S2 on the lower side of the lowermost solar cell 3.

The string S3 in the third column from the left in FIG. 2 includes five solar cells 3, and the back electrode 3b of the upper solar cell 3 and the lower solar cell among the upper and lower solar cells 3 in the string S3. And an inter-cell tab 4 that electrically connects the light-receiving surface electrode 3a of the battery cell 3. The string S1, the string S2, and the string S3 are arranged so that the positions of the lowermost solar cells 3 are aligned. The string S2 and the string S3 are electrically connected by the horizontal tab 22 between S2 and S3 on the upper side of the uppermost solar cell 3.

The string S2 and the string S3 are different in height by one solar cell 3 on the upper side. Therefore, in order to electrically connect the solar cells 3 at different heights, the S2-S3 horizontal tab 22 is an inter-cell tab connected to the uppermost solar cell 3 of the string S3. 4, an S3 upper tab 22 a electrically connected to the S 4, an S2 upper tab 22 b electrically connected to the inter-cell tab 4 connected to the uppermost solar cell 3 of the string S 2, an S3 upper tab and an S2 upper tab Are connected to the left side of the uppermost solar cell 3 of the string S3, that is, the S2-S3 connection tab 22c on the string S2 side. The S3 upper tab 22a is electrically connected to the inter-cell tab 4 on the upper side of the uppermost solar cell 3 of the string S3. The S2 upper tab 22b is electrically connected to the inter-cell tab 4 on the upper side of the uppermost solar cell 3 of the string S2.

The string S4 in the fourth column from the left in FIG. 2 includes six solar cells 3, and the back electrode 3b of the lower solar cell 3 and the upper solar cell among the upper and lower solar cells 3 in the string S4. And a cell-to-cell tab 4 that connects the light-receiving surface electrode 3a of the battery cell 3. The string S3 and the string S4 are arranged so that the positions of the lowermost solar cells 3 are aligned. The string S3 and the string S4 are electrically connected by the horizontal tab 23 between S3 and S4 on the lower side of the lowermost solar cell 3.

The string S5 in the fifth column from the left in FIG. 2 includes seven solar cells 3, and the back electrode 3b of the upper solar cell 3 and the lower solar cell among the upper and lower solar cells 3 in the string S5. And a cell-to-cell tab 4 that connects the light-receiving surface electrode 3a of the battery cell 3. The string S4 and the string S5 are arranged so that the positions of the lowermost solar cells 3 are aligned. The string S4 and the string S5 are connected by the horizontal tab 24 between S4 and S5 on the upper side of the uppermost solar cell 3.

The string S4 and the string S5 are different in height by one solar cell 3 on the upper side. Therefore, in order to electrically connect the solar cells 3 at different heights, the S4-S5 horizontal tab 24 is an inter-cell tab connected to the uppermost solar cell 3 of the string S5. S5 upper tab 24a electrically connected to S4, S4 upper tab 24b electrically connected to the inter-cell tab 4 connected to the uppermost solar cell 3 of string S4, S5 upper tab 24a and S4 upper side And an S4-S5 connection tab 24c for connecting the tab 24b on the left side of the uppermost solar cell 3 of the string S5. The S5 upper tab 24a is electrically connected to the inter-cell tab 4 on the upper side of the uppermost solar cell 3 of the string S5. The S4 upper tab 24b is electrically connected to the inter-cell tab 4 on the upper side of the uppermost solar cell 3 of the string S4.

Also, as shown in FIGS. 2 and 3, the output is taken out from the uppermost solar cell 3 of the string S1 in the first column from the left in the drawing to the outside of the back sheet 6, that is, outside the solar cell module 50. Output tab 11 is taken out of the solar cell module. Since the take-out position is taken out together with a take-out tab 31 described later, the take-out position is near the back side of the uppermost solar cell 3 of the string S2. Therefore, the output tab 11 is wired from the upper side of the uppermost solar cell 3 of the string S1 to the vicinity of the back side of the uppermost solar cell 3 of the string S2. The back sheet 6 at the take-out position is provided with a take-out hole 6a.

From the S2 upper tab 22b, an extraction tab 31 for connection to a bypass diode 41 described later is extracted to the outside of the solar cell module. The take-out position is near the back side of the uppermost solar cell 3 of the string S2, and the take-out hole 6a is provided in the back sheet 6 at the take-out position.

The negative terminal box 51 is adhered to the back surface of the back sheet 6 so as to cover the take-out hole 6 a of the back sheet 6 between the output tab 11 and the take-out tab 31. Inside the negative terminal box 51, the bypass diode 41 is connected between the output tab 11 and the extraction tab 31 so that the direction from the output tab 11 to the extraction tab 31 is the forward direction. A negative output cable 52 is connected to the outside of the negative terminal box 51 from a connection point between the output tab 11 and the bypass diode 41.

In the figure, the output tab 12 for taking out the output is taken out from the solar cell module 50 from the lowest stage of the string S5 in the fifth column from the left. Since the take-out position is taken out together with take-out

tabs

32 and 33 to be described later, the take-out position is in the vicinity of the back side of the lowermost solar cell 3 of the string S4. Accordingly, the output tab 12 is wired from the lower side of the lowermost solar cell 3 of the string S5 to the vicinity of the back side of the lowermost solar cell 3 of the string S4. The back sheet 6 at the take-out position is provided with a take-out hole 6b.

The take-out tab 33 for connecting to the

bypass diodes

42 and 43 is taken out of the solar cell module 50 from the S3-S4 horizontal tab 23 that connects the string S3 and the string S4 at the lowermost stage. The take-out position is a take-out hole 6b provided in the back sheet 6 near the back side of the lowermost solar cell 3 of the string S4.

The take-out tab 32 for connecting to the bypass diode 42 is taken out of the solar cell module 50 from the S1-S2 horizontal tab 21 that connects the string S1 and the string S2 at the lowermost stage. The take-out position is a take-out hole 6b provided in the back sheet 6 near the back side of the lowermost solar cell 3 of the string S4.

The positive terminal box 53 is adhered to the back surface of the back sheet 6 so as to cover the extraction hole 6b of the back sheet 6 from which the output tab 12, the extraction tab 32, and the extraction tab 33 are extracted. Inside the positive terminal box 53, the bypass diode 41 is connected between the output tab 11 and the extraction tab 31 so that the direction from the output tab 11 to the extraction tab is the forward direction. A positive output cable 54 is connected to the outside of the positive terminal box 53 from a connection point between the output tab 12 and the bypass diode 43.

Next, the configuration around the end of the solar cell string in the solar cell module 50 will be described. In FIG. 5, the configuration around the end portion of the design sheet 74 is the periphery of the end portion of the uppermost solar cell 3 of the string S2, that is, the periphery portion of the S2 upper tab 22b of the horizontal tab 21 between S1 and S2. It shows. In FIG. 6, the configuration around the end portion of the design sheet 74 is the periphery of the end portion of the uppermost solar cell 3 of the string S4, that is, the periphery portion of the S4 upper tab 24b of the horizontal tab 24 between S4-S5. It shows.

At the periphery of the S2 upper tab 22b, as shown in FIG. 5, on the light-transmitting substrate 1, the light receiving surface sealing layer 2, the S2 upper tab 22b of the S1-S2 lateral tab 21, and the first intermediate The sealing layer 71, the insulating sheet 72, the second intermediate sealing layer 73, the output tab 11, the design sheet 74, the back surface sealing layer 5, and the back sheet 6 are laminated. Depending on the position, there is a region where any of the above-described components does not exist. Said structural member is provided along the surface parallel to the in-plane direction of the translucent board | substrate 1. FIG.

Moreover, in the peripheral part of S4 upper side tab 24b, as shown in FIG. 6, on the translucent board | substrate 1, the light-receiving surface sealing layer 2, the tab 4 between cells, the design sheet 74, and the back surface sealing layer 5 are provided. And the back sheet 6 are laminated. 5 and FIG. 6, the solar cell modules are shown with different thicknesses. However, the output tab 11, the S1-S2 horizontal tab 21 and the insulating sheet 72 have a thickness of 0.1 mm or less. Since it has thin thickness, it is set as the same thickness as the whole solar cell module because the thickness of the sealing layer in a solar cell module changes with parts.

The first intermediate sealing layer 71 includes a first overlapping region where the S2 upper tab 22b of the S1-S2 horizontal tab 21 and the insulating sheet 72 overlap in the surface direction of the insulating sheet 72, and includes S1- It is disposed between the S2 upper tab 22b of the inter-S2 horizontal tab 21 and the insulating sheet 72. The same material as that of the light-receiving surface sealing layer 2 can be used for the first intermediate sealing layer 71.

The insulating sheet 72 is sandwiched and fixed between the first intermediate sealing layer 71 and the second intermediate sealing layer 73 inside the solar cell module 50. The insulating sheet 72 is disposed between the output tab 11 and the S2 upper tab 22b of the S1-S2 horizontal tab 21 to insulate between the output tab 11 and the S2 upper tab 22b of the S1-S2 horizontal tab 21. It has a function to improve. Further, the insulating sheet 72 is disposed between the output tab 11 and the solar battery cell 3 and has a function of improving the insulation between the output tab 11 and the solar battery cell 3. The entire surface of the insulating sheet 72 on the light receiving surface side is in close contact with the first intermediate sealing layer 71. The entire surface of the insulating sheet 72 on the back side is in close contact with the second intermediate sealing layer 73.

It is preferable that the insulating sheet 72 is a resin having high adhesiveness on the surface in contact with the first intermediate sealing layer 71 and the second intermediate sealing layer 73. Further, the insulating sheet 72 is preferably a resin having high adhesion to the back surface sealing layer 5 on the surface in contact with the back surface sealing layer 5. As the insulating sheet 72, an insulating resin sheet such as a PET sheet or polyvinylidene phthalate can be used.

The second intermediate sealing layer 73 includes a second overlapping region in which the output tab 11 and the insulating sheet 72 overlap the design sheet 74 in the surface direction of the insulating sheet 72, and includes the output tab 11 and the insulating sheet. 72 and the design sheet 74. The same material as that of the light-receiving surface sealing layer 2 can be used for the second intermediate sealing layer 73.

The design sheet 74 is disposed on the back side of the insulating sheet 72 and is fixed inside the solar cell module 50, and covers the outer peripheral side of the solar cell 3 to enhance the design of the solar cell module 50. The design sheet 74 is not disposed on the upper part of the solar battery cell 3. As shown in FIG. 5, the design sheet 74 is sandwiched and fixed between the second intermediate sealing layer 73 and the back surface sealing layer 5 at the periphery of the S2 upper tab 22b. The output tab 11 is in contact with part of the light receiving surface side of the design sheet 74. Moreover, the design sheet 74 is sandwiched and fixed between the light-receiving surface sealing layer 2 and the back surface sealing layer 5 in the peripheral portion of the S4 upper tab 24b as shown in FIG. Further, the S4 upper tab 24b is in contact with a part of the light receiving surface side of the design sheet 74.

The design sheet 74 preferably has high adhesion to the second intermediate sealing layer 73 on the surface in contact with the second intermediate sealing layer 73. Moreover, it is preferable that the design sheet 74 has high adhesiveness on the surface in contact with the light-receiving surface sealing layer 2 and the back surface sealing layer 5. The design sheet 74 has a structure in which fibers are folded, such as a non-woven fabric having a large specific surface area, in order to improve adhesion between the second intermediate sealing layer 73, the light-receiving surface sealing layer 2 and the back surface sealing layer 5. Is preferred. The material of the nonwoven fabric is preferably a resin having high weather resistance such as PET or PVF. In the first embodiment, a nonwoven fabric sheet is used for the design sheet 74. In this Embodiment 1, the adhesiveness with the 2nd intermediate | middle sealing layer 73, the light-receiving surface sealing layer 2, and the back surface sealing layer 5 is improved by using the nonwoven fabric sheet which consists of PET for the design sheet 74. Yes. In addition, as the design sheet 74, a sheet made of a solid material of PET having no space inside, that is, having no space inside may be used.

In the solar cell module 50, as shown in FIG. 2, a trapezoidal shape having one side as a hypotenuse is formed by increasing the number of solar cells 3 connected in series for each row of strings. Since the solar battery cell 3 forms a square flat plate shape, the edge on the oblique side of the solar battery cell group is stepped. Therefore, a sawtooth-shaped blank region having a shape in which a plurality of triangles are connected while overlapping the top and the top is formed between the solar cell group and the hypotenuse. And the design sheet 74 of the same color tone as the photovoltaic cell 3 is arrange | positioned in this area | region so that the whole area | region may be covered. The outer peripheral edge of the solar cell module 50 is covered over the entire periphery by a frame (not shown).

As described above, in the solar cell module 50 having such a configuration, the design sheet 74 having the same color tone as that of the solar cell 3 is disposed in a blank area other than the solar cell 3 being disposed. By arranging the design sheet 74 and the solar battery cell 3 having the same color tone as that of the solar battery cell 3, the solar battery module 50 does not have an uncomfortable appearance and is excellent in design.

Moreover, in the solar cell module 50, if the blank area has an area formed between the frame and the solar battery cell 3, it is possible to improve the appearance aesthetics by arranging the design sheet 74. Obtainable.

Next, a method for manufacturing the solar cell module 50 will be described. FIG. 7 is a flowchart showing the procedure of the method for manufacturing the solar cell module according to Embodiment 1 of the present invention. The light-receiving surface sealing layer sheet 2 s is a sheet made of a material constituting the light-receiving surface sealing layer 2 described above. The first intermediate sealing layer sheet 71s is a sheet made of the material constituting the first intermediate sealing layer 71 described above. The second intermediate sealing layer sheet 73s is a sheet made of a material constituting the second intermediate sealing layer 73 described above. The back surface sealing layer sheet 5 s is a sheet made of a material constituting the back surface sealing layer 5 described above.

FIG. 8 is a peripheral portion of the S2 upper tab of the lateral tab between S1 and S2 of the laminate in the method for manufacturing the solar cell module according to Embodiment 1 of the present invention, and schematically shows a laminate configuration around the end portion of the design sheet. It is a conceptual diagram shown in FIG. That is, FIG. 8 shows a cross-sectional view of the main part of the portion corresponding to the region X in FIG. FIG. 9 is a peripheral portion of the S4 upper tab of the S4-S5 horizontal tab of the laminate in the method for manufacturing the solar cell module according to Embodiment 1 of the present invention, and schematically shows the configuration around the end portion of the design sheet. FIG. That is, FIG. 9 shows a cross-sectional view of the main part of the portion corresponding to the region Y1 in FIG. FIGS. 8 and 9 mainly show the inclusion relationship, that is, the positional relationship, of the components in the surface direction of the solar cell module 50. The laminated structure in the periphery of the S2 upper tab of the horizontal tab between S1 and S2 of the laminated body is the structure shown in FIG. Further, the laminated structure in the periphery of the S4 upper tab of the horizontal tab between S4 and S5 of the laminated body is as shown in FIG.

The manufacturing method of the solar cell module 50 according to the first embodiment includes a translucent substrate 1, a light receiving surface sealing layer sheet 2s that is a first sealing layer sheet, a solar cell string, and a first intermediate. A sealing layer sheet 71s, an insulating sheet 72, a second intermediate sealing layer sheet 73s, a design sheet 74, a back sealing layer sheet 5s which is a second sealing layer sheet, and a back sheet 6. A laminating process for sequentially laminating layers to form a laminated body, and a sealing process for heating and pressurizing the laminated body by a laminating process to seal the solar cells 3 between the translucent substrate 1 and the back sheet 6; ,including.

First, in step S101, solar cells 3 are formed. Next, in step S <b> 102, the inter-cell tab 4 is fixed to the solar cell 3, whereby the plurality of solar cells 3 are connected by the inter-cell tab 4 to form the string S. Subsequently, in the stacking process of step S103, a stacked body is formed. The laminated body is formed by sequentially laminating the light-receiving surface sealing layer sheet 2s and the string S on the translucent substrate 1 made of a translucent glass substrate. Furthermore, the first intermediate sealing layer sheet 71s for the purpose of filling the sealing material and suppressing the generation of bubbles in the portion in contact with the insulating sheet 72, the insulating sheet 72 for the purpose of insulation, the filling of the sealing material and the insulating sheet 72 and the second intermediate sealing layer sheet 73 s for the purpose of suppressing the generation of bubbles in the portion in contact with the design sheet 74, the design sheet 74 for the purpose of improving the design property, the back surface sealing layer sheet 5 s, and the back sheet 6. A laminated body is formed by sequentially laminating on the string S.

In step S104, a depressurization process is performed to depressurize the inside of a laminating apparatus (not shown) into which the laminate obtained in step S103 is carried. Next, in the sealing process of Step S105, the batch heat treatment process is performed to heat and press the stacked body in the melt pressurizing process, and then the stacked body is cooled, so that the solar cells 3 are sealed. A solar cell module 50 is formed. The periphery of the solar cell module 50 is fixed with a frame, and the negative terminal box 51 and the positive terminal box 53 are attached.

Next, the stacking process at the periphery of the S2 upper tab and the output tab in step S103 will be described. 10 to 15, the stacking method in the periphery of the uppermost solar cell 3, S2 upper tab and output tab of the string S2 in the stacking step in the manufacturing method of the solar cell module according to Embodiment 1 of the present invention. Indicates.

FIG. 10 is an enlarged view schematically showing a state before the first intermediate sealing layer sheet and the insulating sheet are stacked in the stacking step of the method for manufacturing the solar cell module according to the first embodiment of the present invention. is there. After laminating the light-receiving surface sealing layer sheet 2s and the string S on the translucent substrate 1, four cells are formed on the upper side of the solar cell 3 from the back electrode 3b of the solar cell 3 as shown in FIG. The intermediate tab 4 is connected to the S2 upper tab 22b of the S2-S3 horizontal tab 22 outside the upper side of the solar battery cell 3. An extraction tab 31 for connection to the bypass diode 41 is connected to the S2 upper tab 22b of the horizontal tab 22 between S2 and S3, and is drawn out near the back surface of the uppermost solar cell 3 of the string S2.

Further, as shown in FIG. 10, an output tab 11 is wired from the upper side lateral tab of the uppermost solar cell 3 of the string S1 along the outer left side of the uppermost solar cell 3 of the string S2. The The output tab 11 is above the S2 upper tab 22b of the horizontal tab 22 and overlaps with the S2 upper tab 22b of the horizontal tab 22 in the plane of the solar cell 3, and the back surface of the uppermost solar cell 3 of the string S2. Pulled out nearby.

FIG. 11 is an enlarged plan view schematically illustrating a state in which the first intermediate sealing layer sheet and the insulating sheet are stacked in the stacking step of the method for manufacturing the solar cell module according to the first embodiment of the present invention. . FIG. 12 is a top view of the insulating sheets stacked in the stacking step of the method for manufacturing the solar cell module according to Embodiment 1 of the present invention. FIG. 13: is sectional drawing of the insulating sheet laminated | stacked in the lamination process of the manufacturing method of the solar cell module concerning Embodiment 1 of this invention. In FIG. 11, the position of the take-out hole 6a provided in the back sheet 6 is indicated by a broken line.

The insulating sheet 72 is sandwiched between the S2 upper tab 22b of the horizontal tab 22 and the output tab 11, and insulates the S2 upper tab 22b of the horizontal tab 22 from the output tab 11. Further, the insulating sheet 72 is provided with a notch 61 at a position corresponding to the connection position between the S2 upper tab 22b of the horizontal tab 22 and the extraction tab 31, and the extraction tab 31 extends from the notch 61 to the back surface of the insulating sheet 72. Pulled out to the side. The insulating sheet 72 is sandwiched between the output tab 11 and the extraction tab 31 and the back surface of the uppermost solar cell 3 of the string S2, and the output tab 11, the extraction tab 31 and the uppermost solar cell of the string S2. Insulates the battery cell 3.

The insulating sheet 72 has a rectangular outer shape, the left side is located on the left side of the left end of the S2 upper tab 22b, the right side is located on the right side of the extraction tab 31, and the upper side is located above the upper end of the output tab 11. Thus, the lower side is configured to have a size lower than the take-out hole 6 a provided in the back sheet 6.

A first intermediate sealing layer sheet 71s having the same size as the insulating sheet 72 is laminated in advance on the surface of the insulating sheet 72 that is disposed on the light receiving surface side. The insulating sheet 72 and the first intermediate sealing layer sheet 71 s are provided with a cut 61 for sandwiching the extraction tab 31.

FIG. 14 is an enlarged plan view schematically showing a state in which the second intermediate sealing layer sheet is laminated in the laminating step of the method for manufacturing the solar cell module according to the first embodiment of the present invention. The second intermediate sealing layer sheet 73 s is sandwiched between the output tab 11 and the insulating sheet 72. The second intermediate sealing layer sheet 73s is disposed outside the uppermost solar cell 3 of the string S2 so as to cover a portion wider than the insulating sheet 72.

FIG. 15 is an enlarged plan view schematically showing a state in which the design sheets are stacked in the stacking step of the manufacturing method of the solar cell module according to Embodiment 1 of the present invention. The design sheet 74 is laminated in the tooth-shaped blank area between the solar cell group and the hypotenuse so as not to overlap the uppermost solar cell 3 of the string S2.

When the design sheet 74 made of non-woven fabric and the insulating sheet 72 made of PET are in contact with each other, only EVA of the back surface sealing layer sheet 5s does not penetrate part of the EVA into the surface of the design sheet 74 made of non-woven fabric. For this reason, bubbles remain on the surface of the design sheet 74, and bubbles are confirmed when the solar cell module 50 is viewed from the translucent substrate 1 side. That is, when EVA does not penetrate to the surface of the design sheet 74, bubbles are generated between the design sheet 74 and the insulating sheet 72 after the laminating process, that is, on the surface of the design sheet 74 and the surface of the insulating sheet 72. Bubbles may be generated and the appearance quality may be degraded. Further, due to aging deterioration, bubbles remaining in the nonwoven fabric of the design sheet 74 and bubbles generated from EVA may accumulate on the surface of the design sheet 74 and cause deterioration in appearance quality. That is, an aged deterioration portion in which the adhesion between the sealing material EVA and the design sheet 74 is reduced due to the aged deterioration. In this case, the escape place of the gas generated inside the solar cell module concentrates on the aged deterioration portion, and the appearance defect due to bubbles occurs.

On the other hand, in the area where the insulating sheet 72 is not disposed, represented by the area Y1 in FIG. 2, the inter-cell tab 4, the output tab 11, and the S2-S3 horizontal tab are provided on the design sheet 74 on the light-transmitting substrate 1 side. 22 and S4-S5 horizontal tabs 24 exist, and a design sheet 74 made of a nonwoven fabric and EVA of the back surface sealing layer 5 exist in this order on the back sheet 6 side of the tabs. In this case, since the tab does not transmit light, there is no problem in the appearance quality of the solar cell module 50 when the solar cell module 50 is viewed from the translucent substrate 1 side. Moreover, since a part of EVA of the back surface sealing layer 5 penetrates into the design sheet 74 made of a nonwoven fabric and is joined to the tab, there are problems of adhesion and adhesion between the EVA of the sealing material and the design sheet 74. There is no. In addition, since the tab is harder and has a smaller width than other insulating sheets or the like, the pressure of the press is likely to be applied during lamination, and EVA is likely to penetrate from between the nonwoven fabrics.

Therefore, in the method for manufacturing the solar cell module according to Embodiment 1, in order to fill EVA between the design sheet 74 made of non-woven fabric and the insulating sheet 72 made of PET, the second intermediate sealing layer sheet 73s is used. The second intermediate sealing layer 73 is formed using the second intermediate sealing layer 73. Thereby, in the solar cell module 50, EVA surely penetrates to the surface of the design sheet 74 and suppresses deterioration of the appearance quality due to generation of bubbles on the surface of the design sheet 74 and the surface of the insulating sheet 72 after the lamination process. it can. Further, in the solar cell module 50, it is possible to suppress deterioration in the appearance quality due to the bubbles remaining in the nonwoven fabric of the design sheet 74 and the bubbles generated from the EVA collecting on the surface of the design sheet 74 due to deterioration over time.

That is, in the manufacturing method of the solar cell module according to the first embodiment, in order to prevent the design sheet 74 made of PET and the insulating sheet 72 made of PET from coming into contact with each other in the region X, the purpose is to suppress bubbles. A second intermediate sealing layer 73 made of EVA is provided on the surface of the design sheet 74 made of nonwoven fabric. Thereby, the design sheet 74 and the insulating sheet 72 are brought into a non-contact state, and the generation of bubbles between the design sheet 74 and the insulating sheet 72 can be suppressed. And by providing the 2nd intermediate | middle sealing layer 73, while being able to infiltrate the space | gap of the nonwoven fabric of the design sheet 74, since the specific surface area of the design sheet 74 is large, between the design sheet 74 and EVA Adhesion can be improved, and generation of bubbles on the surface of the design sheet 74 made of a nonwoven fabric can be suppressed.

Even when a design sheet 74a made of a solid PET sheet that is not a non-woven fabric is used, the second intermediate sealing layer 73 made of EVA for the purpose of suppressing air bubbles is provided on the surface of the design sheet 74a, thereby providing a region. In X, the contact between the design sheet 74a made of PET and the insulating sheet 72 made of PET is prevented. Thereby, generation | occurrence | production of the bubble between the design sheet 74a which consists of PET, and the insulating sheet 72 which consists of PET can be suppressed.

In addition, when using a design sheet 74a made of a solid PET sheet that is not a non-woven fabric, in order to prevent the inter-cell tab 4 and the design sheet 74a from coming into contact with each other in the region Y2, A third intermediate sealing layer sheet 75s made of EVA is inserted into a surface facing a design sheet 74a made of a solid PET sheet that is not a non-woven fabric. Thereby, the inter-cell tab 4 and the design sheet 74a made of a solid PET sheet that is not a non-woven fabric are brought into a non-contact state, and the inter-cell tab 4 and the design sheet 74a made of a solid PET sheet that is not a non-woven cloth It is possible to suppress the generation of bubbles in between.

Therefore, the manufacturing method of the solar cell module 50 according to the first embodiment described above is performed on the design sheet 74 and the insulating sheet 72 that are visible from the translucent substrate 1 side after the lamination process and after use over a long period of time. Generation of bubbles can be suppressed. Thereby, in the manufacturing method of the solar cell module 50 of Embodiment 1, there is no generation | occurrence | production of the bubble at the time of production, and there is also no generation | occurrence | production of an air bubble in the outdoor installation after shipment. A solar cell module 50 capable of suppressing deterioration in the appearance quality due to deterioration is obtained.

In addition, when laminating a non-woven fabric, if the non-woven fabric has low rigidity, there is a possibility that an appearance defect may occur due to the generation of wrinkles. Therefore, the non-woven fabric may be folded in double.

When using a non-woven fabric folded twice, if the size of the folded portion is the same, the end of the folded non-woven fabric may be displaced, resulting in poor appearance. For this reason, it is preferable that the nonwoven fabric to be folded is not symmetrical with respect to the center of the folded portion, and that one dimension is made larger or smaller.

Next, a method for manufacturing the solar cell module 50 according to the first embodiment will be described based on specific examples.

Hereinafter, the laminated structure in the vicinity of the output tab 11 and the extraction tab 31 according to the first embodiment will be described in detail.

Example 1
In Example 1, a sample of the solar cell module was produced according to the method for manufacturing the solar cell module 50 of Embodiment 1 described above. The main process was performed as follows. A white plate glass having an outer dimension of 1700 mm × 1000 mm and a thickness of 3.2 mm was prepared as the translucent substrate 1.

As an overall lamination process of the solar cell module 50, an EVA resin sheet is prepared as a light-receiving surface sealing layer sheet 2s for forming the light-receiving surface sealing layer 2 in contact with the translucent substrate 1, and a solar cell is formed thereon. A string in which the cells 3 were connected in series with the inter-cell tab 4, the back surface sealing layer sheet 5 s and the back sheet 6 were laminated to form a laminate.

Further, in the region X in FIG. 2, that is, the peripheral portion of the S2 upper tab 22b of the horizontal tab between S1 and S2, and around the end portion of the design sheet 74, the constituent portions were laminated as follows. In order to secure insulation between the output tab 11 and the output tab 31 for taking out the output and the solar battery cell 3 which are soldered to the string, the first outer dimensions are 100 mm × 100 mm and the thickness is 0.04 mm. The EVA sheet as the intermediate sealing layer sheet 71 s, the PET sheet as the insulating sheet 72 having an outer dimension of 100 mm × 100 mm and a thickness of 0.05 mm, the output tab 11, the extraction tab 31, and the solar battery cell 3. Inserted in between.

Then, the EVA sheet, which is the second intermediate sealing layer sheet 73 s having an outer dimension of 120 mm × 120 mm and a thickness of 0.4 mm, which is larger than the PET sheet that is the insulating sheet 72, and the PET sheet of the insulating sheet 72 is left and right And it laminated | stacked so that it might not protrude above the uppermost photovoltaic cell 3 of string S2. Furthermore, a non-woven fabric sheet made of PET, which is a design sheet 74 for ensuring design properties, a back surface sealing layer sheet 5s and a back sheet 6 were laminated thereon. That is, in Example 1, as shown in FIG. 8, the second intermediate sealing layer sheet 73 s includes the entire region where the insulating sheet 72 and the design sheet 74 face each other.

Further, in the region Y1 in FIG. 2, that is, the peripheral portion of the S4 upper tab 24b of the S4-S5 horizontal tab 24, around the end portion of the design sheet 74, on the EVA resin sheet of the light-receiving surface sealing layer sheet 2s, The inter-cell tab 4, the nonwoven fabric sheet made of PET as the design sheet 74, the back surface sealing layer sheet 5s, and the back sheet 6 were laminated in this order.

Therefore, outside the solar cell 3 corresponding to the region Y1, there is a portion where the inter-cell tab 4 for electrically connecting the solar cell 3 and the nonwoven fabric sheet made of PET which is the insulating sheet 72 are in contact.

And the lamination process was performed with respect to the formed body produced as mentioned above, and the sample of the solar cell module of Example 1 was obtained. The laminating conditions were as follows: evacuation was performed at 160 ° C. for 5 minutes, the pressing time was 5 minutes, and the pressing pressure was 50 kPa or 100 kPa.

(Example 2)
FIG. 16 is a schematic view of the laminate in Example 2 seen through from the back side. FIG. 17 is a cross-sectional view of a principal part schematically showing a laminated structure around the end portion of the design sheet, which is the peripheral portion of the S2 upper tab of the lateral tab between S1 and S2 of the laminated body in Example 2. That is, FIG. 17 shows a cross-sectional view of the main part of the portion corresponding to the region X in FIG. FIG. 18 is a cross-sectional view of a principal part schematically showing a configuration around the end portion of the design sheet, which is the periphery of the S4 upper tab of the S4-S5 horizontal tab of the laminate in Example 2. That is, FIG. 18 shows a cross-sectional view of the main part of the portion corresponding to the region Y2 in FIG.

In Example 2, a design sheet 74a made of a solid PET sheet that is not a non-woven fabric was used in place of the design sheet 74 made of a non-woven fabric sheet made of PET. Further, outside the solar cell 3 corresponding to the region Y2, as shown in FIG. 18, the surface on which the inter-cell tab 4 and the design sheet 74a made of a solid PET sheet that is not a nonwoven fabric face is made of EVA. A third intermediate sealing layer sheet 75s was inserted. Thereby, after the lamination process, a third intermediate sealing layer made of EVA is formed between the inter-cell tab 4 and the design sheet 74a, and the inter-cell tab 4 and the design sheet 74a are not in contact with each other. A sample of the solar cell module of Example 2 was obtained. That is, in Example 2, the second intermediate sealing layer sheet 73s includes the entire region where the insulating sheet 72 and the design sheet 74a face each other.

(Example 3)
In Example 3, an EVA sheet, which is the first intermediate sealing layer sheet 71s having the same size as the insulating sheet 72, is preliminarily bonded and integrated on one surface of the PET sheet, which is the insulating sheet 72. Except that, a solar cell module sample of Example 3 was obtained in the same manner as Example 1. That is, in Example 3, the second intermediate sealing layer sheet 73s includes the entire region where the insulating sheet 72 and the design sheet 74 face each other.

Example 4
In Example 4, the EVA sheet as the first intermediate sealing layer sheet 71 s is bonded in advance to one surface of the PET sheet that is the insulating sheet 72, and the same as the insulating sheet 72 on the other surface of the PET sheet that is the insulating sheet 72. A sample of the solar cell module of Example 4 was prepared in the same manner as in Example 1 except that the EVA sheet as the second intermediate sealing layer sheet 73s having a size was previously bonded and integrated. Obtained. That is, in Example 4, the second intermediate sealing layer sheet 73s includes the entire region where the insulating sheet 72 and the design sheet 74 face each other. In Example 4, the EVA sheet that is the first intermediate sealing layer sheet 71 s, the EVA sheet that is the second intermediate sealing layer sheet 73 s, and the insulating sheet 72 that are previously bonded and integrated are used. Since the arrangement shown in FIG. 14 cannot be performed, the EVA sheet as the second intermediate sealing layer sheet 73s is arranged on the insulating sheet 72 in FIG.

(Comparative Example 1)
FIG. 19 is a conceptual diagram schematically showing a layered configuration around the end portion of the design sheet, which is the peripheral portion of the S2 upper tab of the lateral tab between S1 and S2 of the laminate in Comparative Example 1. That is, FIG. 19 shows a conceptual diagram corresponding to FIG. FIG. 20 is a conceptual diagram schematically showing the configuration around the end portion of the design sheet, which is the peripheral portion of the S4 upper tab of the S4-S5 horizontal tab of the laminate in Comparative Example 1. That is, FIG. 20 shows a conceptual diagram corresponding to FIG.

In Comparative Example 1, in the region X in FIG. 2, the EVA sheet that is the second intermediate sealing layer sheet 73 s that is larger than the PET sheet that is the insulating sheet 72 is smaller than the PET sheet that is the insulating sheet 72, The second intermediate sealing layer sheet 73 s having an outer shape of 50 mm × 20 mm and a thickness of 0.4 mm is so arranged that the PET sheet of the insulating sheet 72 protrudes from the left and right sides and above the uppermost solar cell 3 of the string S2. Laminated. Except for this, a solar cell module sample of Comparative Example 1 was obtained in the same manner as Example 1. That is, in Comparative Example 1, as shown in FIG. 19, the second intermediate sealing layer sheet 73s does not include the entire region where the insulating sheet 72 and the design sheet 74 face each other.

(Comparative Example 2)
FIG. 21 is a conceptual diagram schematically showing a stacking configuration around the end portion of the design sheet, which is the periphery of the S2 upper tab of the horizontal tab between S1 and S2 of the laminate in Comparative Example 2. That is, FIG. 21 shows a conceptual diagram corresponding to FIG. FIG. 22 is a conceptual diagram schematically showing the configuration around the end portion of the design sheet, which is the peripheral portion of the S4 upper tab of the S4-S5 horizontal tab of the laminate in Comparative Example 2. That is, FIG. 22 shows a conceptual diagram corresponding to FIG.

In Comparative Example 2, a sample of the solar cell module of Comparative Example 2 was obtained in the same manner as in Example 1 except that the EVA sheet as the second intermediate sealing layer sheet 73s was not provided in the region X in FIG. It was. That is, in Comparative Example 2, as shown in FIG. 21, the second intermediate sealing layer sheet 73s does not exist in all the regions where the insulating sheet 72 and the design sheet 74 face each other.

(Comparative Example 3)
FIG. 23 is a conceptual diagram schematically showing a stacking configuration around the end portion of the design sheet, which is the periphery of the S2 upper tab of the S1-S2 horizontal tab of the laminate in Comparative Example 3. That is, FIG. 23 shows a conceptual diagram corresponding to FIG. 17 of the second embodiment. FIG. 24 is a conceptual diagram schematically showing the configuration around the end portion of the design sheet, which is the periphery of the S4 upper tab of the S4-S5 horizontal tab of the laminate in Comparative Example 3. That is, FIG. 24 shows a conceptual diagram corresponding to FIG. 18 of the second embodiment.

In the third comparative example, outside the solar cell 3 corresponding to the region Y2 in FIG. 16, the inter-cell tab 4 and the design sheet 74a made of a solid PET sheet that is not non-woven fabric face the third sheet made of EVA. A solar cell module sample of Comparative Example 3 was obtained in the same manner as Example 2 except that the intermediate sealing layer sheet 75s was not inserted. That is, in Comparative Example 3, the inter-cell tab 4 and the design sheet 74a made of a solid PET sheet that is not a non-woven fabric are not formed with the third intermediate sealing layer 75 made of EVA in the sample of Example 2. A sample of a solar cell module having a structure in contact with each other was obtained. Therefore, in Comparative Example 3, the second intermediate sealing layer sheet 73s includes the entire region where the insulating sheet 72 and the design sheet 74a face each other.

Thereafter, a sample of Example 1 to Example 4 and Comparative Example 1 to Comparative Example 3 was subjected to a 100 hr high temperature and high humidity (Damp-Heat: DH) test to determine whether or not bubbles were generated in an outdoor environment. A confirmation test was conducted. Then, after the laminating process and after the DH test, the sample was visually confirmed from the translucent substrate 1 side, and the presence or absence of bubbles was evaluated. The result is shown in FIG. FIG. 25 is a diagram showing the evaluation results of the presence or absence of bubble generation in the samples of the example and the comparative example.

FIG. 26 is a schematic diagram showing a bubble generation region α in which bubbles are generated in the sample of Comparative Example 1 that is not covered with the second intermediate sealing layer sheet 73s. FIG. 27 is a schematic diagram showing a bubble generation region α where bubbles are generated in the sample of Comparative Example 2 that is not covered with the second intermediate sealing layer sheet 73s. FIG. 28 is a schematic diagram showing a bubble generation region α in which bubbles are generated in the sample of Comparative Example 3, which is a portion not covered with the second intermediate sealing layer sheet 73s. 26 to 28 show a state in which a sample solar cell module is seen through from the back side.

As shown in FIG. 25, in the samples of Examples 1, 2, 3, and 4, neither the generation of bubbles nor poor appearance was confirmed either after the two types of lamination treatment or after the DH test.

However, since the sample of Example 2 uses more parts for the solar cell module than the sample of Example 1 and is expensive in terms of workability and cost, the sample of Example 1 is preferable.

On the other hand, in the samples of Comparative Example 1 and Comparative Example 2, in the confirmation after the two laminating processes, the region X is not covered with the second intermediate sealing layer sheet 73s made of EVA for the purpose of suppressing bubbles. As a result, bubbles were generated on the surface of the design sheet 74 made of non-woven fabric, resulting in poor appearance. That is, in the samples of Comparative Example 1 and Comparative Example 2, a portion of the design sheet 74 that is not filled with EVA as a sealing material is generated, and a portion that is not filled with EVA in the solar cell module is generated. It was confirmed that However, in the samples of Comparative Example 1 and Comparative Example 2, expansion of bubbles was not confirmed after the DH test. However, the occurrence of bubbles both after the laminating process and after the DH test is a problem in terms of appearance.

In the sample of Comparative Example 3, no bubbles were observed in the confirmation after the two lamination processes. However, the sample of Comparative Example 3 is not solid between the inter-cell tab 4 and the non-woven fabric, which is not covered with the second intermediate sealing layer sheet 73s made of EVA for the purpose of suppressing bubbles in the region Y2 after the DH test. Bubbles were generated from the contact portion with the design sheet 74a made of a PET sheet, and the appearance was poor.

Accordingly, in the region X, the second intermediate sealing layer 73 made of EVA for the purpose of suppressing air bubbles is provided on the surface of the design sheet 74 made of nonwoven fabric, so that the design sheet 74 made of PET and the PET are made of PET. It can be said that generation of bubbles between the design sheet 74 made of PET and the insulation sheet 72 made of PET can be suppressed by preventing the insulation sheet 72 from coming into contact. And by providing the 2nd intermediate | middle sealing layer 73, while being able to infiltrate the space | gap of the nonwoven fabric of the design sheet 74, since the specific surface area of the design sheet 74 is large, between the design sheet 74 and EVA Adhesion can be enhanced, and the generation of bubbles on the surface of the design sheet 74 made of a nonwoven fabric can be suppressed.

Moreover, in the area | region Y2, when using the design sheet 74a which consists of a solid PET sheet which is not a nonwoven fabric, the inter-cell tab 4 and the design sheet 74a which consists of a solid PET sheet which is not a nonwoven fabric face each other. By inserting the third intermediate sealing layer sheet 75s made of EVA, the contact between the inter-cell tab 4 and the design sheet 74a is prevented, and bubbles between the inter-cell tab 4 and the design sheet 74a are prevented. It can be said that generation can be suppressed.

Therefore, if it is a manufacturing method of Example 1, 2, 3, 4, there is no generation | occurrence | production of the bubble at the time of production, and there is no generation | occurrence | production of an air bubble in the outdoor installation after shipment. It can be said that a solar cell module capable of suppressing deterioration in appearance quality due to aging is obtained.

The configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.

The solar cell module 50 shown in the above embodiment has a trapezoidal shape in which one side of the outer shape becomes a hypotenuse by changing the number of series-connected solar cells 3 electrically connected in series for each string. This is useful when the design sheet 74 is disposed between the holding frame attached to the oblique side and the solar battery cell 3. Even if the solar cell module 50 is a solar cell module having a trapezoidal shape by providing 74 on the design sheet, there is an effect that the design property is not impaired.

Moreover, the solar cell module 50 shown in the above embodiment is configured such that one side of the outer shape becomes a hypotenuse by changing the number of series connection of the solar cells 3 electrically connected in series for each string. The solar cell module having a trapezoidal shape is useful for a solar cell module configured by arranging strings in odd rows. The solar cell module 50 is configured by arranging the strings in odd rows to constitute the solar cell module, thereby disposing the negative terminal box 51 on one end side in the connection direction of the solar cells 3 in the string and the negative electrode on the other end side. The side output cable 52 can be arranged, and there is an effect that electrical connection between the solar cell modules arranged adjacent to each other becomes easy. In this case, it is only necessary that the negative electrode side terminal box 51 and the negative electrode side output cable 52 be arranged at a certain distance in the connecting direction of the solar cells 3 in the string. Moreover, it is necessary to arrange a terminal box on the hypotenuse side of the trapezoidal shape of the solar cell module by making the number of strings arranged odd. Even in this case, even if the solar cell module 50 arranges the terminal box on the oblique side provided with the design sheet 74, there is an effect that generation of bubbles can be suppressed.

Moreover, the solar cell module 50 shown in the above embodiment is configured such that one side of the outer shape becomes a hypotenuse by changing the number of series connection of the solar cells 3 electrically connected in series for each string. The solar cell module having a trapezoidal shape is useful for a solar cell module including an output tab and an extraction tab on the oblique side. For example, when the above-described string S1 is shaded and sunlight does not enter and the string S1 does not generate power, a take-out tab is required on the hypotenuse side in order to bypass the string S1. In this case, the string S1 cannot be bypassed with the extraction tabs arranged only on the other side of the string in the connecting direction of the solar cells 3 but not on the oblique side. By taking out the extraction tab from the hypotenuse side, there is an effect that the string S1 can be bypassed when the string S1 connected to the output tab on the hypotenuse side becomes shaded. That is, referring to FIG. 3, the string S <b> 1 cannot be bypassed with the extraction tabs arranged only on the lower side in the trapezoidal shape in the drawing. The solar cell module 50 has an effect that the string S1 that is shaded by the string S1 connected to the output tab on the hypotenuse side can be bypassed by taking out the extraction tab 31 from the hypotenuse side.

Moreover, the solar cell module 50 shown in the above embodiment is configured such that one side of the outer shape becomes a hypotenuse by changing the number of series connection of the solar cells 3 electrically connected in series for each string. The solar cell module having a trapezoidal shape is useful for a solar cell module in which an output tab and an extraction tab are taken out to the same terminal box on the oblique side. In order to bypass the string S1 connected to the output tab on the hypotenuse side, it is necessary to take out the output tab and the extraction tab on the hypotenuse side in the same terminal box. Here, in order to reduce the size of the terminal box, it is necessary to wire the output tab to the vicinity of the extraction tab, and there are places where the output tab overlaps with the horizontal tab, so insulation between the output tab and the horizontal tab is necessary become. The solar cell module 50 has an effect that the terminal box can be miniaturized because the take-out position of the output tab on the oblique side and the take-out tab can be brought close by the insulating sheet.

1 translucent substrate, 2 light-receiving surface sealing layer, 2s light-receiving surface sealing layer sheet, 3 solar cell, 3a light-receiving surface electrode, 3b back surface electrode, 4 cell-to-cell tab, 5 back surface sealing layer, 5s back surface sealing Layer sheet, 6 back sheet, 6a, 6b take-out hole, 11, 12 output tab, 21 S1-S2 horizontal tab, 22 S2-S3 horizontal tab, 22a S3 upper tab, 22b S2 upper tab, 22c S2-S3 connection Tab, 23 S3-S4 horizontal tab, 24 S4-S5 horizontal tab, 24a S5 upper tab, 24b S4 upper tab, 24c S4-S5 connection tab, 31, 32, 33 extraction tab, 41, 42, 43 bypass diode , 50 solar cell module, 51 negative terminal box, 52 negative output cable, 53 positive terminal box, 54 positive terminal Cable, 71 first intermediate sealing layer, 71s first intermediate sealing layer sheet, 72 insulating sheet, 73 second intermediate sealing layer, 73s second intermediate sealing layer sheet, 74 design sheet, 75s first 3 intermediate sealing layer sheet, α bubble generation region.

Claims

A light-receiving surface-side protective member that is disposed on the light-receiving surface side and has light transmittance;
A back side protective member disposed on the back side facing the light receiving surface;
A solar cell string in which a plurality of solar cells are electrically connected in series with inter-cell tabs;
A lateral tab for electrically connecting a plurality of the solar cell strings in series;
An output tab for taking out the output from the solar cell string to the outside of the back surface side protection member;
A sealing layer made of resin and sandwiching the solar cell string between the light-receiving surface side protection member and the back surface side protection member;
An insulating sheet disposed between the output tab and the lateral tab to insulate the output tab and the lateral tab;
A design sheet disposed on the back side of the insulating sheet and covering the outer peripheral side of the solar cell string;
A first intermediate sealing layer disposed between the lateral tab and the insulating sheet to bring the lateral tab and the insulating sheet into a non-contact state;
A second intermediate sealing layer disposed between the insulating sheet and the design sheet to bring the insulating sheet and the design sheet into a non-contact state;
A solar cell module comprising:
The design sheet is a nonwoven fabric;
The solar cell module according to claim 1.
The design sheet is made of a solid material,
Comprising a third intermediate sealing layer disposed between the inter-cell tab and the design sheet to bring the inter-cell tab and the design sheet into a non-contact state;
The solar cell module according to claim 1.
A light receiving surface side protective member having light transmittance, a first sealing layer sheet, and a solar cell string in which a plurality of solar cells are electrically connected in series with inter-cell tabs are electrically connected with lateral tabs. The solar cell array, the first intermediate sealing layer sheet, the insulating sheet, the second intermediate sealing layer sheet, the design sheet, the second sealing layer sheet, the back surface side protection member, Laminating step of sequentially laminating layers to form a laminate,
A sealing step of heating and pressurizing the laminate to seal the solar cell string between the light-receiving surface side protection member and the back surface side protection member;
Including
The first intermediate sealing layer sheet is disposed between the lateral tab and the insulating sheet;
The second intermediate sealing layer sheet is disposed between the insulating sheet and the design sheet;
The manufacturing method of the solar cell module characterized by these.
The design sheet is a nonwoven fabric;
The manufacturing method of the solar cell module of Claim 4 characterized by these.
The design sheet is made of a solid material,
In the lamination step, a third intermediate sealing layer is disposed between the inter-cell tab and the design sheet,
The manufacturing method of the solar cell module of Claim 4 characterized by these.
Using a sheet in which the first intermediate sealing layer sheet is bonded and integrated on one surface of the insulating sheet;
The method for manufacturing a solar cell module according to any one of claims 4 to 6, wherein:
Using the sheet in which the first intermediate sealing layer sheet is bonded to one surface of the insulating sheet and the second intermediate sealing layer sheet is bonded and integrated to the other surface of the insulating sheet;
The method for manufacturing a solar cell module according to any one of claims 4 to 6, wherein: