JP2011151334A - Method of manufacturing solar cell module - Google Patents

Abstract

An object of the present invention is to stably provide a highly reliable solar cell module that can maintain a desired characteristic while maintaining a desired aesthetic property, in which a space between solar cell elements constituting a solar cell string can be made constant and alignment can be performed with high accuracy. The manufacturing method of the solar cell module which can be supplied in this way is provided.
A method of manufacturing a solar cell module in which a substrate, a first filler made of resin, and one or more solar cell strings formed by connecting a plurality of solar cell elements with a wiring material are stacked in this order. A step of disposing the solar cell element string on the first filler, and a step of heating the first filler to a temperature not lower than the melting point of the first filler and lower than a crosslinking point or lower than a thermosetting point. Cooling the laminated body in which the solar cell string is disposed on the first filler to a temperature lower than the melting point of the first filler; deforming the laminated body along the surface of the substrate; including.
[Selection] Figure 2

Description

  The present invention relates to a method for manufacturing a solar cell module formed by wiring a plurality of solar cell elements.

  A solar cell module is formed by laminating a plurality of semiconductor elements that can generate power independently, such as a single crystal silicon substrate or a polycrystalline silicon substrate, in series and / or in parallel. It is comprised in the state sealed with resin by such as.

  In the manufacturing process of such a solar cell module, for example, when one or more of the solar cell strings formed by connecting a plurality of solar cell elements are arranged on a resin sheet provided on a curved substrate, The arrangement of the solar cell elements constituting the battery string may deviate from a predetermined position.

  A solar cell module manufactured in a state where the positional deviation of the solar cell elements occurs causes problems such as a decrease in power generation efficiency due to contact between the solar cell elements.

  In order to suppress misalignment of the solar cell elements, a method of fixing the solar cell elements with an adhesive tape or the like in advance can be considered. In addition, a method has been proposed in which after bonding to a flat substrate with a translucent adhesive, the substrate is heated and deformed in accordance with a curved mold in a laminating step. (See Patent Document 1 below).

Japanese Patent Laid-Open No. 03-204979

  However, in the method of fixing between the solar cell elements with a tape with an adhesive material, without undergoing a complicated process such as determining the material and thickness of the tape with sufficient consideration of the type and manufacturing method of the solar cell element, The movement of the solar cell element cannot be effectively suppressed.

  Moreover, in the method of patent document 1, in the case of the heating and deformation | transformation of the resin sheet in a lamination process, a solar cell element may shift | deviate from a predetermined position according to a deformation | transformation of a resin sheet.

  Therefore, the present invention can make the interval between the solar cell elements constituting the solar cell string constant, and can perform alignment and the like with high accuracy, and has excellent aesthetics and can maintain desired characteristics, and has high reliability. An object of the present invention is to provide a method for manufacturing a solar cell module capable of stably supplying a module.

A method of manufacturing a solar cell module according to an aspect of the present invention includes a substrate, a first filler made of resin, and one or more solar cell strings formed by connecting a plurality of solar cell elements with a wiring material. A method for producing a solar cell module comprising a laminate in order,
Disposing the solar cell element string on the first filler;
Heating the first filler to a temperature above the melting point of the first filler and below the crosslinking point or below the thermosetting point;
Cooling the laminate in which the solar cell string is disposed on the first filler to a temperature below the melting point of the first filler;
Deforming the laminate along the surface of the substrate;
It is characterized by including.

Moreover, the manufacturing method of the solar cell module which concerns on one form of this invention is the 2nd filling which consists of a board | substrate, the 1st filler, the solar cell string which connects a some solar cell element with a wiring material, and resin. A method for producing a solar cell module comprising a laminate of materials in this order,
Disposing the solar cell element string on the second filler;
Heating the second filler to a temperature above the melting point of the second filler and below the cross-linking point or below the thermosetting point;
Cooling the laminate in which the solar cell string is disposed on the second filler to a temperature below the melting point of the second filler;
Deforming the laminate along the surface of the substrate;
It is characterized by including.

Furthermore, the manufacturing method of the solar cell module which concerns on one form of this invention consists of a board | substrate, the 1st filler which consists of resin, the solar cell string which connects a some solar cell element with a wiring material, and resin. A method for manufacturing a solar cell module comprising a second filler and a laminate in this order,
Disposing a solar cell element string between the first filler and the second filler;
Heating the first filler and the second filler at a temperature not lower than the higher melting point of these melting points and lower than the lower cross-linking point or the thermosetting point;
The laminated body in which the solar cell element string is disposed between the first filler and the second filler is cooled to less than the lower melting point of the first filler and the second filler. Process,
Deforming the laminate along the surface of the substrate;
It is characterized by including.

  According to the method for manufacturing a solar cell module according to one aspect of the present invention, the solar cell string can be a laminate that can move integrally with the first filler and / or the second filler. Thereby, in such a movement of the laminated body, the movement of the solar cell element is suppressed as much as possible, and a highly reliable solar cell module excellent in aesthetics and maintaining desired characteristics can be stably supplied. .

It is a disassembled perspective schematic diagram explaining the example of the structure of the solar cell module which concerns on one form of this invention. Each of (a) and (b) is a schematic perspective view for explaining an example of a structure and a manufacturing method of a laminated body constituting a solar cell module. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. It is a disassembled perspective schematic diagram explaining the example of the structure of a laminated body which comprises a solar cell module, and a manufacturing method. It is a plane schematic diagram explaining the mounting position of the solar cell string in a conveying apparatus. It is a disassembled perspective schematic diagram explaining the projection part formed in the filler which comprises a laminated body. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. Each of (a) to (c) is a schematic cross-sectional view illustrating an example of a structure and a manufacturing method of a solar cell module according to one embodiment of the present invention. It is a perspective schematic diagram explaining the example of the structure and manufacturing method of the solar cell module which concerns on one form of this invention. It is a perspective schematic diagram explaining the example of the structure and manufacturing method of the solar cell module which concerns on one form of this invention. It is a cross-sectional schematic diagram explaining the relationship between a general solar cell string and wiring material. Each of (a) and (b) is a schematic cross-sectional view illustrating a protrusion formed on a filler constituting a laminate according to an embodiment of the present invention. It is an exploded perspective schematic diagram explaining the projection part formed in the filler which constitutes the layered product concerning one form of the present invention. It is a perspective schematic diagram explaining the projection part formed in the filler which comprises the laminated body which concerns on one form of this invention.

  Hereinafter, the form of the manufacturing method of the solar cell module which concerns on one form of this invention is demonstrated, referring drawings.

<Embodiment 1>
As shown in FIG. 1, the solar cell module 20 forms a solar cell matrix by connecting a plurality of solar cell elements 2 in series and / or in parallel using a wiring material 10 or the like, and a desired voltage value and current value. Is to be obtained. The solar cell module 20 includes a substrate 21, a light receiving surface side filler 22 that is a first filler made of resin, one or more solar cell strings formed by connecting a plurality of solar cell elements with a wiring member 10, Are stacked in this order.

  For example, each of the solar cell strings 4a to 4c includes a plurality of solar cell elements 2 arranged in a line, and each of the solar cell strings 4a to 4c may be configured by connecting the solar cell elements 2 in series. it can.

  For example, the solar cell strings 4a to 4c are arranged on a flat plate that is rectangular and flat in a plan view, or on a translucent substrate 21 having a main surface that is square and curved in a plan view. Thus, the solar cell module 20 is obtained. That is, the light-receiving surface side filler 22 that is the first filler made of resin and the back surface side filler 23 that is the second filler made of resin are stacked with the solar cell strings 4a to 4c sandwiched therebetween, and the back side filler 23 The back sheet 24 excellent in weather resistance, water resistance and voltage resistance is disposed on the substrate, and a member made of a resin is crosslinked by heating with a laminator to obtain a solar cell module 20.

  Here, the solar cell element 2 can electrically connect the solar cell elements 2, and any solar cell element 2 may be used as long as it is disposed on the substrate with a filler, and various materials can be used for the power generation region of the solar cell element. Can be applied. For the sake of simplicity, the present embodiment and other embodiments will be described by taking an example in which polycrystalline silicon is mainly used as the material of the power generation region of the solar cell element.

  The wiring member 10 is a conducting wire for extracting the generated power of the solar cell element 2, and can be soldered to each of the + electrode and the − electrode of the solar cell element 2. By soldering the solar cell elements 2 in series or in parallel with the wiring member 10, the solar cell elements 2 are connected to form a single solar cell string. Whether each of the solar cell strings connected in this way is connected in series or in parallel is determined by soldering between adjacent solar cell elements between the + electrode and the − electrode via the wiring member 10. (Series connection), -determined by soldering between poles (parallel connection). For the wiring member 10, a ribbon-like copper foil having a width of about 1 to 3 mm and a thickness of about 0.1 to 0.8 mm is solder-plated or solder-coated.

  A portion corresponding to the end of the solar cell strings 4a to 4c in the wiring member 10 is soldered in series or in parallel with a wiring member (not shown) to form a solar cell string, and is conveyed and placed in this state.

In the present embodiment, each of the solar cell strings 4a to 4c is configured such that three solar cell elements 2 are connected. Although a solar cell module configured by nine solar cell elements in total is schematically illustrated, the number of solar cell elements and the electrical output of the solar cell module can be freely determined. For example, in a solar cell module used for a power solar cell array using a polycrystalline solar cell, a solar cell module in which 48 to 56 solar cell elements are connected is manufactured. The solar cell module has a size of about 1.4 m ² , for example.

  The light-receiving surface-side filler 22 is, for example, an ethylene-vinyl acetate copolymer (hereinafter abbreviated as EVA) (melting point: 50 to 100 ° C., cross-linking point: 110 to 130 ° C. can be used), or polyvinyl butyral (hereinafter referred to as the following). Abbreviated as PVB) (melting point: 50 to 100 ° C., thermosetting point: 110 to 130 ° C. can be used) and the like, and a sheet shape having a thickness of about 0.4 to 1 mm by a T-die and an extruder The one formed into the above is used. Hereinafter, the case where EVA is used as the light receiving surface side filler 22 will be described as an example.

  As shown in FIG. 2A, the solar cell string is transported onto the light receiving surface side filler 22 by an adsorption-type transport device or the like, and after being placed by suction release, the solar cell string is moved to the light receiving surface side filler. The light-receiving surface side filler 22 can be adhered (or adhered) to the solar cell element 2 by heating to a temperature range of, for example, 60 ° C. to 90 ° C. that is equal to or higher than the melting point of 22 and less than the crosslinking point or less than the thermosetting point. . As this heating means, a method of directly heating the solar cell element 2 with a soldering iron or a heater, an indirect heating method such as spraying heat like hot air, or a back electromotive force on a solar cell string described later. A method of applying heat to heat the solar cell element itself is suitable.

  As shown in FIG.2 (b), as a manufacturing apparatus for manufacturing the said laminated body, the heater apparatus by which multiple rod-shaped heaters 40 are arrange | positioned, for example is used. The heater 40 is heated and lowered onto the solar cell element 2, and the solar cell element 2 is heated to 90 ° C. to melt the light receiving surface side filler 22 and adhere to the solar cell element 2. At this time, if the heater 40 slightly presses the solar cell element 2 against the light receiving surface side filler 22, the adhesion between the solar cell element 2 and the light receiving surface side filler 22 is improved and heat conduction is also good. Is called.

  The heating time at this time varies depending on the area and thickness of the solar cell element 2, but according to experiments by the present inventors, about 5 to 7 seconds is suitable for a 156 mm square polycrystalline silicon solar cell element. Met. In the case where the thickness of the solar cell element 2 is as thin as 0.16 to 0.18 mm, the main heating is performed for about 10 seconds after the heater 40 is lowered onto the solar cell element 2 in the preheated state. Further, there was little thermal shock to the solar cell element 2, and cracking was difficult to occur.

  After the heating to the solar cell element 2 and the light receiving surface side filler 22 is completed, the heater 40 is raised to cool the solar cell element 2 and the light receiving surface side filler 22 to below the melting point. This cooling may be naturally cooled or forcedly cooled by an air cooling fan or the like.

  In this way, since the solar cell element 2 is integrated with the light receiving surface side filler 22, the solar cell string moves together when the light receiving surface side filler 22 is moved during transportation, and each solar cell element 2 is The position is fixed to the light receiving surface side filler 22 with high accuracy. Thereby, the shift | offset | difference of arrangement | positioning of a solar cell string and the solar cell element 2 is suppressed.

  Therefore, in addition to suction conveyance, a conveyance method with some vibration and impact using a roller or a conveyor can be used, and the degree of freedom of the conveyance means of the manufacturing apparatus is increased. At this time, the area where the light receiving surface side filler 22 and the solar cell element 2 adhere (or adhere) does not necessarily need to be equal to the area of the solar cell element 2. For example, it may be limited to a range of about 2 to 4 cm near the center of the solar cell element, as long as the solar cell element 2 can secure an adhesive force that does not drop off from the light receiving surface side filler 22.

  The laminated body of the solar cell element 2 and the light receiving surface side filler 22 is placed on a substrate 21 having a flat plate shape or a curved surface. At this time, the temperature of the light-receiving surface-side filler 22 is lower than the melting point of the resin constituting it. Here, the substrate 21 is a substrate made of glass or polycarbonate resin. In the case of a glass plate, white plate glass, tempered glass, double tempered glass, heat ray reflective glass, or the like is used. For example, white plate tempered glass having a thickness of about 3 mm to 5 mm is used. On the other hand, when a substrate made of a synthetic resin such as polycarbonate resin is used, a substrate having a thickness of about 5 mm is used.

  And the back surface side filler 23 and the back surface sheet 24 of the same material as the light receiving surface side filler 22 are placed on the laminate, and in this laminated state, heating and pressurization are performed under reduced pressure by a laminating apparatus. Thereby, the light receiving surface side filler 22 and the back surface side filler 23 are softened and fused to be integrated with other members. The back surface side filler 23 may be made of a material different from that of the light receiving surface side filler 22.

  Thus, by placing the laminate of the solar cell element 2 and the light receiving surface side filler 22 on the substrate 21, even if the light receiving surface side filler 22 is deformed by thermal expansion during initial heating, Since the battery string and the solar cell element 2 suppress it by the tension of the wiring material 10 and keep the position until the light receiving surface side filler 22 is melted, the solar cell string and the solar cell element 2 are heated by the light receiving surface side filler 22. It can suppress that a position moves according to expansion | swelling.

  Further, the force to move the solar cell string due to the thermal expansion of the back surface side filler 23 is not affected by the fact that the solar cell element 2 is fixed to the light receiving surface side filler 22. Furthermore, when the temperature is raised to 110 to 130 degrees above the crosslinking point, the crosslinking agent contained in the light-receiving surface side filler and the back surface side filler reacts, and once cured, the filler softens even if heated again. It becomes difficult to do.

  Note that EVA and PVB used for the back-side filler 24 may be transparent, or may be colored white or the like by containing titanium oxide or a pigment according to the surrounding installation environment where the solar cell module is installed.

  As described above, at least one substrate 21, a first filler made of resin (light receiving surface side filler 22 in this embodiment), and a plurality of solar cell elements 2 are connected by the wiring member 10. A solar cell module 20 including the solar cell strings stacked in this order is completed.

  According to this embodiment, the step of disposing the solar cell element string on the first filler, and the step of heating the first filler to a temperature not lower than the melting point of the first filler and lower than the cross-linking point or lower than the thermosetting point. And a step of cooling the laminated body in which the solar cell string is arranged on the first filler to a temperature lower than the melting point of the first filler, and a step of deforming the laminated body along the surface of the substrate. It is possible to provide a solar cell module manufacturing method and manufacturing apparatus with a high degree of freedom in which the battery string can be easily aligned, is not easily displaced during transport, and a transport method such as a conveyor that could not be used conventionally can also be used.

<Embodiment 2>
Next, an embodiment in which the solar cell string is arranged on a substrate having a particularly curved surface will be described in detail. In addition, about the process and description which overlap with Embodiment 1, it abbreviate | omits.

  As shown in FIG. 3A, the laminate 1a is obtained by heat-sealing the light-receiving surface side of the solar cell element string 4 to the light-receiving surface-side filler 22 as described in the first embodiment. The substrate 21 has a shape in which two main sides in a cross section are curved in an arc shape.

  Here, the laminated body 1a may be lowered onto the substrate 21 as it is and may be faced from the end of the laminated body 1a. Further, as shown in FIG. 3B, the laminated body 1a may be bent and brought into contact with the curved surface of the substrate 21.

  A specific operation example will be described. First, both ends of two sides facing each other in plan view of the light receiving surface side filler 22 of the laminate 1a are lifted by an arm portion (not shown) of the manufacturing apparatus. Next, by narrowing the interval between the arm portions having these two sides, the central portion of the laminated body 1a is curved below the end portion. When the curvature of the substrate 21 becomes greater than or equal to the curvature of the substrate 21, the movement of the arm portion is stopped and the laminate 1 a is moved onto the substrate 21.

  And the arm part of a manufacturing apparatus is dropped and the laminated body 1a is made to face the board | substrate 21. FIG. Then, after adjusting the arrangement position of the solar cell string 4 of the laminated body 1a with respect to the board | substrate 21 by moving the light-receiving surface side filler 22, the position of the solar cell string 4 is performed by performing the process of canceling | releasing support of the said arm part. The alignment can be performed with high accuracy.

  This facilitates the alignment or repositioning of the solar cell string 4 that has been difficult to automate, and causes the solar cell element to crack or crack due to the movement of the solar cell element for repositioning or the like. Generation can be suppressed.

  In addition, the operation | movement which bends a laminated body may be after the movement on the board | substrate 21, and a support point may be 2 or more sides or multiple places. Further, the alignment of the solar cell string 4 may be before or after the descent, and the laminated body may be raised rather than lowered, and the order in the process is not limited to the above example. Absent.

  Since the solar cell element 4 is fixed to the light receiving surface side filler 22, the solar cell string 4 is not displaced even if it is bent. Further, as shown in FIG. 3 (c), when it is placed on the substrate 21, the laminated body 1a can be easily aligned with the substrate 21, and the solar cell string is not displaced. In addition, even after being placed, the solar cell elements (solar cell strings 4a and 4c in the figure) located on the slope are suppressed from sliding down, and even if vibration or impact such as transfer is applied in this state, the solar cell It is possible to suppress the displacement of the strings. Finally, the back side filler 23 and the back sheet (not shown) are stacked and conveyed to the laminating step. The same effect can be obtained even if the substrate has a mortar shape in which the four sides are curved, and the shape is not particularly limited.

  As described above, also in the present embodiment, as in the first embodiment, at least the substrate 21, the first filler made of resin (light receiving surface side filler 22 in the present embodiment), and one or more solar cell strings 4. And a solar cell module including those stacked in this order is completed. Also in this embodiment, the step of disposing the solar cell element string 4 in the first filler, and the step of heating the first filler to a temperature not lower than the melting point of the first filler and lower than the crosslinking point or the thermosetting point. And a step of cooling the laminated body in which the solar cell string 4 is disposed on the first filler to a temperature lower than the melting point of the first filler, and a step of deforming the laminated body 1a along the surface of the substrate 21. .

  Conventionally, after the solar cell string is transported onto the substrate by the suction transport device, the suction is cut as it is, and it is allowed to fall freely, or an elevating mechanism is provided so that the central portion of the suction transport device is lowered below the end. However, it was a cause of misalignment and complicated equipment. According to this embodiment, when it is going to arrange | position a solar cell string on a curved-surface-shaped board | substrate, what is necessary is just to hold | maintain the edge part of a 1st filler and to curve a center part. In addition, since the solar cell string can be repositioned in this embodiment, it is easy to improve the arrangement accuracy of the solar cell string, and it is possible to easily provide a solar cell module with a good appearance and high reliability.

<Embodiment 3>
Still another embodiment will be described. The laminated body 1b shown to Fig.4 (a)-(c) heat-fuses the back surface side of the solar cell element 2 to the back surface side filler 23 which consists of resin which is a 2nd filler. Here, the back surface side filler 23 is heated to a temperature equal to or higher than the melting point of the resin used therein and lower than the crosslinking point or lower than the thermosetting point to produce the laminate 1b. Moreover, the light-receiving surface side filler 22 is previously laminated on the substrate 21, and the laminated body 1b is preferably placed thereon. The conveyance, bending deformation, alignment, and the like by the manufacturing apparatus of the laminated body 1b can be performed by the same operations as those in the first and second embodiments. In addition, in order to take out an output from the solar cell string 4, for example, a cut may be made in the back surface side filler 23, and the output may be taken out from the portion via an output line (for example, copper foil).

  FIG. 6 shows the process of transporting the laminate 1 in the transport apparatus according to this embodiment, and FIG. 7 shows the process of aligning the solar cell string (correcting the mounting position) by the transport apparatus. It is.

  The transport device 41 is a device that transports and places the stacked body 1 that moves between the position of the process of manufacturing the stacked body 1 and the position of the laminating process. For example, the rail 41c which moves between these processes, the adsorption | suction arm 41a which lifts the laminated body 1, and the clamping arm 41b are comprised. The rail 41c itself may be extended to a position where the next step is performed. Alternatively, the length of the rail 41c may be only a length necessary for lifting the laminated body, and the movement between processes may be performed by a moving device that suspends the rail 41c.

  The suction arm 41a and the sandwiching arm 41b are configured such that the rail 1c can be moved in the long side direction, and the arm extends and contracts in the vertical direction with respect to the stacked body 1. For example, in FIG. 2, since the laminated body 1 is flat in that state, the conveying device 41 descends and approaches the laminated body 1 to lift the end of the laminated body 1, and extends the suction arm 41 a. The suction part at the tip is brought into contact with the laminate 1.

  Next, the air in the suction portion of the suction arm 41a is removed to suck the stacked body 1, and the suction arm 41a or the entire conveying device 41 is raised to lift the stacked body 1. At this time, if the adsorption portion of the adsorption arm is to lift the entire laminated body 1, a large number (for example, the same number as the number of solar cell elements) may be arranged, and only the end of the laminated body is lifted. In this case, the number may be small, such as 2 to 4, and the configuration of the device may be adapted to the lifting method.

  Next, the lifted back side filler 23 of the laminated body 1 is gripped by the clamping portion (claw portion in the figure) of the clamping arm 41b, and the suction arm 41a and the clamping arm 41b are rail 41c as indicated by the white arrows in the figure. Move the tops closer together.

  By doing in this way, the center part of the laminated body 1 hangs down with dead weight, and it can be set as the curvature state equivalent to the curvature degree of the board | substrate 21. FIG. In this state, the substrate 21 and the light receiving surface side filler 22 are transported to a process place where they are laminated. At this time, the shift of the arrangement position of the solar cell strings of the laminated body 1 is suppressed as much as possible, and stable bending work and transport work can be performed.

  After transporting onto the substrate 21, the transport device 41 descends again, and the laminate 1 is placed on the substrate 21. Here, if there is no problem in the mounting position of the solar cell string of the laminated body 1, the clamping of the clamping arm 41b is released as it is, and the adsorption of the adsorption arm 41a is also released. However, for example, as shown in FIG. 7, when the positions of the end marker 29 and the solar cell string 4 that specify the placement position of the solar cell string provided on the substrate 21 are shifted, the adsorption arm 41a and The back surface side filler 23 of the laminated body 1 is moved up and down, right and left with respect to the surface of the substrate 21 by the sandwiching arm 41b, and the positions of the end marker 29 and the solar cell string 4 are aligned.

  In the example of FIG. 7, the solar cell string 4 is inclined to the right side in the figure, and therefore, the solar cell string 4 may be rotated to the left side in the figure and aligned with the end marker 29. Also in this case, even if the back surface side filler 23 is moved, the arrangement of the solar cell strings 4 between the solar cell elements does not shift. In addition, it is possible to suppress such a problem that the arrangement interval between the solar cell elements of the solar cell string 4 is narrowed or widened during the alignment with the end marker 29. And after aligning arrangement | positioning of the edge marker 29 and the solar cell string 4, the laminated body 1 is released | separated and the conveying apparatus 41 is raised.

  In this example, the gripping portion is formed by lifting the end with the suction arm so that the sandwiching arm can easily grip the laminate, but the present invention is not limited to this. For example, only the suction by the suction arm or the gripping by the holding arm may be performed.

  As described above, in the manufacturing method of the present embodiment, the substrate 21, the first filler, the solar cell string 4, and the second filler (back surface side filler 23) made of resin in this order. A solar cell module comprising the stacked ones is completed. In particular, in the manufacturing method of the present embodiment, the step of disposing the solar cell element string 4 on the second filler, the melting point of the resin constituting the second filler, and less than the crosslinking point or less than the thermosetting point. A step of heating to a temperature, a step of cooling the laminated body 1b in which the solar cell string 4 is arranged on the second filler to a temperature lower than the melting point of the second filler, and the deformation of the laminated body 1 along the surface of the substrate 21 And a step of causing.

  Thereby, when the back surface side filler 23 and the solar cell element 2 which are 2nd fillers are heat-seal | fused, the output line of a solar cell element can be passed through the back surface side filler 23, Therefore The board | substrate 21 The wiring drawing work after placing on the board can be easily performed. Further, if the output line of the laminated body 1b is passed through the back sheet in advance and the back sheet and the laminated body 1b are placed together on the substrate 21, the post-process can be further facilitated. Furthermore, since the lamination of the substrate 21 and the light receiving surface side filler 22 can be performed as a pre-process, the tact time of the manufacturing apparatus can be shortened.

<Embodiment 4>
Still another embodiment will be described. A laminated body 1c shown in FIGS. 5A to 5C is formed by laminating a light-receiving surface side filler 22 made of resin, a solar cell string 4 and a back side filler 23 made of resin, and then, on both fillers, Each surface of the battery element 2 is heat-sealed. About the conveyance by the manufacturing apparatus of the laminated body 1c, a curve, alignment, etc., the operation | work similar to Embodiment 1-3 mentioned above is possible, and the same effect can be anticipated.

  In the process of the present embodiment, heating by the soldering iron or hot air is not used for raising the temperature of the solar cell element 2 as in the first to third embodiments. Instead, a back electromotive force is applied to the output line from the solar cell string 4 to cause the solar cell element 2 itself to generate heat.

  Specifically, a DC power source (an AC power source is also acceptable) is prepared outside. Then, the positive electrode of the power source is connected to the positive electrode of the solar cell string 4, the negative electrode of the power source is connected to the negative electrode of the solar cell string 4, and a voltage higher than the open circuit voltage is applied to the solar cell element to apply the back electromotive force. To do. The power of the counter electromotive force varies depending on the type of solar cell element and the number of strings in series and / or the number of parallel strings. For example, in a solar cell string in which nine 156 mm square polycrystalline solar cell elements are arranged in series, when the melting point of the light receiving surface side filler and the back surface side filler is 70 ° C., an applied voltage of 245 V and a current of 20 A are applied as counter electromotive forces. Good. As a result, the temperature is equal to or higher than the higher melting point of the resin constituting the light-receiving surface side filler 22 and the back surface side filler 23, and the lower one is below the crosslinking point or below the thermosetting point. Heat is generated at ˜80 ° C., and these fillers can be melted. According to the inventor's experiment, even if the solar cell element is exposed to light at this time, almost no change is observed in the amount of heat generation, and no problem occurs in the process.

  Thereby, heat can be raised to the end of the solar cell element on average rather than a melting method in which heat conduction is performed from a locally high temperature as in the case of a soldering iron or a heater. For this reason, it is possible to avoid a problem that a part of the temperature rises too much and the cross-linking agent reacts before reaching the melting point to the end. Moreover, since temperature management is easy, there are few apparatuses required for temperature control of a manufacturing apparatus. Furthermore, since only the solar cell element rises in temperature, it does not overheat or melt even unnecessary fillers such as hot air. For example, if the manufacturing apparatus controls the heat generation so that only the surface of the filler melts, the position of the solar cell string does not shift due to the thermal expansion of the filler, and the solar cell element and the filler melt. You can wear.

  Furthermore, in the present embodiment, the manufacturing apparatus only needs to be provided with a power supply for power supply, and the device configuration is simple, and overheating control and management can be facilitated.

  In addition, since the cooling process of the light-receiving surface side filler 22 and the back surface side filler 23 and the process of deforming the laminated body 1c along the surface of the substrate 21 are the same as those in the first to third embodiments, the description thereof is omitted.

  In the manufacturing method of the present embodiment, a substrate, a first filler made of resin, a solar cell string in which a plurality of solar cell elements are connected by a wiring material, and a second filler made of resin are arranged in this order. It is a manufacturing method of the solar cell module containing what was laminated | stacked by. In particular, the step of arranging the solar cell element string between the first filler and the second filler, and the first filler and the second filler are more than the higher melting point of these melting points. And a step of heating at a temperature lower than the lower cross-linking point or lower than the thermosetting point, and a laminate in which a solar cell element string is disposed between the first filler and the second filler. A step of cooling below the lower melting point of the filler and the second filler, and a step of deforming the laminate along the surface of the substrate.

  Thereby, it becomes possible to provide the solar cell module in which the positional deviation of the solar cell element is more reliably suppressed than in the first to third embodiments. Specifically, the light-receiving surface side filler made of EVA on a substrate 21 (total size: 1000 mm × 500 mm × 70 mm) made of borosilicate glass having a radius of curvature in the long side direction of 1600 mm and a radius of curvature in the short side direction of 1900 mm. Solar cell string 4 sandwiched between backside fillers 23 made of 22 and EVA (36 series of 6 parallel strings of 6 series-connected 150 mm × 75 mm × 0.2 mm polycrystalline silicon type solar cell elements (6 In the example in which the solar cell element matrix) in a row × 6 columns) was disposed and the lamination process was performed, the deviation of the solar cell string between the solar cell elements and the substrate 21 was within 1.5 mm at the maximum.

  On the other hand, in an example in which a flat substrate is bonded with an epoxy-based translucent adhesive and then subjected to a laminating process using a mold having a curved surface similar to the above substrate, the substrate is curved in accordance with the curvature of the substrate. The distance between the solar cell elements was clogged, pushed by the connection conductor and the wiring conductor connecting the solar cell elements, the mounting position shifted, and cell cracking occurred.

<Embodiment 5>
Still another embodiment will be described. Although not particularly illustrated, the substrate 21 may be curved in a complicated shape in which, for example, peaks and valleys are continued in a wave shape. Even in this case, the solar cell string can be easily aligned and repositioned by the same method as in the first to fourth embodiments.

  Thereby, even in the manufacture of a solar cell module having a complicated shape, the solar cell element is hardly cracked and cracked, and the solar cell string is prevented from being placed before the laminating process.

<Embodiment 6>
Still another embodiment will be described. Although not particularly illustrated, the step of forming a laminate may be performed by laminating the light receiving surface side filler and the back surface side filler on the solar cell string.

  In this way, for example, the light receiving surface side filler may be laminated on the solar cell string, so that the solar cell element is electrically wired to form the solar cell string, and then the process proceeds to the laminating step without moving the solar cell string. be able to.

  Thereby, conveyance of a solar cell string is abbreviate | omitted, the process time can be shortened, the vibration and impact accompanying a movement to a solar cell element can be eliminated, and the damage of a solar cell element can be reduced. In addition, since the solar cell element is held down by the weight of the light receiving surface side filler or the back surface side filler, it is possible to obtain a function of extending and correcting the warpage of the solar cell element, and in what direction the warpage of the solar cell element is. Can also suppress the occurrence of cracks.

<Embodiment 7>
Still another embodiment will be described. When the light-receiving surface side filler and / or the back surface side filler made of resin is fused to the solar cell element, if air remains in the resin, air will escape from the resin even if evacuation is performed in the lamination process. Therefore, it is necessary to manage so that no air remains in the fusion process.

  Therefore, as shown in FIG. 8, it is preferable to provide a linear protrusion 12 at the fused portion of the light receiving surface side filler 22 or the back surface side filler (not shown) so that air can escape.

  In the example of FIG. 8, the protrusion 12 has a cross-shaped line. However, the protrusion 12 may be formed in two parallel lines so that the protrusion 12 can be removed in a direction parallel to the line. An air passage may be formed only in a part so that the pressing force is concentrated on a part of the solar cell element and the crack is not generated. Also, three or more linear protrusions may be provided to increase the adhesion area with the solar cell element so that the solar cell element does not fall off. The shape, quantity, arrangement, etc. of the line are appropriately set according to the purpose. You may change it.

  The protrusions 12 may be formed by molding, for example, when a filler such as EVA is manufactured, or may be integrated by attaching a linear protrusion separately to the filler. According to the inventor's experiment, air is likely to remain even if the height of the protrusion 12 is too high. For example, when EVA resin having a thickness of 1 mm is used as the filler, a height of 0.3 mm to 1 mm is preferable. Results were obtained.

<Eighth embodiment>
Still another embodiment will be described. The solar cell string may be arranged on a substrate having a shape in which two main sides in a square when viewed from above are curved in an arc shape by using the laminate of Embodiment 3 (FIG. 4) described above.

  As shown in FIG. 9A, the laminate 1b is obtained by heat-sealing the back side of the solar cell element string 4 to the back side filler 23 as described in the first embodiment. The mounting table 42 is formed by molding a mounting portion in a circular arc shape with a resin or metal in accordance with the curved surface of the substrate 21, and has heat resistance capable of performing a laminating process while the solar cell module is mounted.

  As shown in FIG. 9B, when the back sheet 24 is laid on the mounting table 42 and the laminated body 1b is mounted thereon, the central portion of the laminated body 1b is supported first, and then the mounting table 42 The back side of the laminate 1b is supported along the curve.

  Next, as shown in FIG. 9C, the light receiving surface side filler 22 and the substrate 21 are sequentially laminated on the laminated body 1b.

  According to this method, the solar cell string 4 is only required to be fixed with a fusion strength that does not slip off from the back-side filler 23, and the time and energy required for heating can be reduced by reducing the fusion area. .

  Moreover, the apparatus which curves a laminated body as shown in FIG. 6 can be simplified. The alignment of the stacked body 1b with respect to the substrate 21 can also be performed by moving the substrate 21 side or moving the entire mounting table 42. As a result, the solar cell string 4 is prevented from moving as much as possible, the stress is reduced, and the occurrence of cell cracking, cracking, and soldering peeling of the wiring material in the process can be suppressed.

<Ninth Embodiment>
Still another embodiment will be described. The solar cell string may be arranged on a substrate having a curved surface in which two main sides in a cross-section are curved in a circular arc shape using the laminate of Embodiment 2 (FIG. 3) described above.

  As shown to Fig.10 (a), the laminated body 1a heat-fuses the light-receiving surface side of the solar cell element string 4 to the light-receiving surface side filler 22. As shown in FIG. 10 (b), this is placed on the placing table 42 in which the back sheet 24 and the back side filler 23 are laminated in this order.

  According to the present embodiment, as in the eighth embodiment, the central portion of the stacked body 1b is first supported, and then the back surface side of the stacked body 1b is supported along the curved surface of the mounting table 42. And as shown in FIG.10 (c), the board | substrate 21 is laminated | stacked on these.

  According to this method, the process of laminating on the laminate 1a can be minimized. For this reason, the stress to the solar cell string 4 can be reduced, and the occurrence of cell cracking, cracking, and soldering peeling of the wiring material in the process can be suppressed.

<Embodiment 10>
Still another embodiment will be described. Using the laminate of Embodiment 4 (FIG. 5) described above, the solar cell string is placed on a substrate having a curved surface in which two main sides are curved in an arc shape with a solar cell string sandwiched between them. It is good also as a battery module.

  As shown to Fig.11 (a), the laminated body 1c heat-fuses the light-receiving surface side filler 22, the solar cell element string 4, and the back surface side filler 23. As shown in FIG. First, the back side substrate 27 is placed on the placing table 42. The back side substrate 27 may be the same as the substrate 21 or may be made of a different material. Next, the laminated body 1c is mounted on the back surface side substrate 27 of the mounting table 42 as shown in FIG.

  According to this method, the position of the stacked body 1c with respect to the back surface side substrate 27 is first corrected, and then the alignment with the substrate 21 can be performed. Accordingly, by applying a pressing force to all the stacks by the weight of the substrate 21, the stacks are difficult to shift, so that it is possible to suppress the position shift of the stacks due to vibration accompanying the movement.

<Embodiment 11>
Still another embodiment will be described. The solar cell string and the light receiving surface side filler (or the back surface side filler) may be fused with the third resin.

  For example, as shown in FIG. 12, the solar cell string 4 is placed on the back surface side filler 23, and the third resin 25 melted using the resin injector 43 is dropped onto the wiring material 10. Then, the wiring member 10 and the back surface side filler 23 are fused. Here, the third resin 25 is preferably a resin having the same composition as that of the light receiving surface side filler and the back surface side filler. For example, when the back surface side filler 23 is an EVA resin, the third resin is PVB. It is also possible to use resins having different compositions.

  Further, the place where the third resin 25 is fused to the back surface side filler 23 may be the solar cell string 4 as shown in FIG. 13 in addition to the wiring material 10. The position of the entire solar cell string 4 can be fixed if it is fixed to a part of the string 4 (for example, only two places at both ends), and the heat stress is reduced by minimizing the heating of the solar cell element, It is possible to suppress the occurrence of cell cracking, cracking, and soldering peeling of the wiring material. In particular, as shown in FIG. 12, if the wiring material 10 is fixed, the solar cell element of the solar cell string 4 can be made free. Thereby, a solar cell element is not directly dragged by the thermal expansion of the back surface side filler during the laminating step, and cell cracks and cracks are particularly difficult to occur.

<Twelfth embodiment>
Still another embodiment will be described. A protrusion may be provided on a portion to be fused with the solar cell string 4 on either the light receiving surface side filler or the back surface side filler.

  FIG. 14 shows a state in which the solar cell string 4 is placed on the back side filler 23 having no general protrusion. The wiring member 10 connecting the solar cell elements is greatly bent to connect the negative electrode on the front surface side and the positive electrode on the back surface side of the solar cell element. This bent portion is likely to cause disconnection due to thermal expansion / contraction of the solar cell module.

  In this embodiment, as shown to Fig.15 (a), the projection part 26 is provided on the back surface side filler 23, and the solar cell string 4 is made to melt | fuse at this part. Thus, the solar cell element can be inclined by the height of the protrusion 26, and the bending (or bending) angle of the wiring member 10 can be reduced. And generation | occurrence | production of defects, such as soldering peeling of a wiring material and an electrode, can be suppressed and a highly reliable solar cell module can be provided. In addition, since the volume for melting the resin is small in the thermal fusion process, the time required for fusion can be shortened, and the process time can be shortened.

  Further, as shown in FIG. 15B, the protrusions 26 are increased to provide a protrusion 26a as a fusion part, or a protrusion 26b as a stopper that prevents the solar cell string 4 from shifting at the time of fusion. The workability during the fusing process may be improved.

<Embodiment 13>
Still another embodiment will be described. As shown in FIG. 16, the shape of the protrusion 26 of the back surface side filler (or the light receiving surface side filler) is, for example, L-shaped and T-shaped so that the solar cell element of the solar cell string 4 enters and is fixed. You may make it combine a shape.

  According to this method, as shown by the arrows in the figure, the wiring material 10 provided in the solar cell string 4 can be placed on the protrusions 26 and can be fixed by performing heat fusion at this portion. Thereby, the alignment of the solar cell string 4 with respect to the back surface side filler 23 can be automatically performed, and the solar cell string 4 is not easily displaced due to an impact or the like during movement, and the fusion should have a minimum strength. Therefore, the fusion time can be shortened.

<Embodiment 14>
Still another embodiment will be described. As shown in FIG. 17, the protrusions 26 of the back surface side filler 23 (or the light receiving surface side filler) may be arranged so as to guide the end side surface of the solar cell string 4. In this case, the protrusions 26 may be generated on the back surface side filler 23 in advance, or may be arranged and fused after the solar cell string 4 is placed.

  According to this method, the end surface of the solar cell element of the solar cell string 4 and the protrusion 26 are fusion-fixed. Thereby, the pressing stress to the solar cell element becomes the most resistant side surface direction, and cell cracks and cracks due to the fixing of the solar cell string 4 hardly occur.

DESCRIPTION OF SYMBOLS 1, 1a-1c: Laminated body 2: Solar cell element 4, 4a-4c: Solar cell string 10: Wiring material 12: Protrusion 20: Solar cell module 21: Substrate 22: Light-receiving surface side filler 23: Back surface side filler 24: back sheet 25: third resin 26: protrusion 27: back substrate 29: end marker 40: heater 41: transport device 41a: suction arm 41b: clamping arm 41c: body rail 42: mounting table 43: resin Injector

Claims (4)

A method for manufacturing a solar cell module, comprising a substrate, a first filler made of resin, and one or more solar cell strings formed by connecting a plurality of solar cell elements with a wiring material in this order. Because
Disposing the solar cell element string on the first filler;
Heating the first filler to a temperature above the melting point of the first filler and below the crosslinking point or below the thermosetting point;
Cooling the laminate in which the solar cell string is disposed on the first filler to a temperature below the melting point of the first filler;
Deforming the laminate along the surface of the substrate;
The manufacturing method of the solar cell module characterized by including. A solar cell module comprising a substrate, a first filler, a solar cell string formed by connecting a plurality of solar cell elements with a wiring material, and a second filler made of resin in this order. A manufacturing method of
Disposing the solar cell element string on the second filler;
Heating the second filler to a temperature above the melting point of the second filler and below the cross-linking point or below the thermosetting point;
Cooling the laminate in which the solar cell string is disposed on the second filler to a temperature below the melting point of the second filler;
Deforming the laminate along the surface of the substrate;
The manufacturing method of the solar cell module characterized by including. It includes a substrate, a first filler made of resin, a solar cell string formed by connecting a plurality of solar cell elements with a wiring material, and a second filler made of resin in this order. A method for manufacturing a solar cell module, comprising:
Disposing a solar cell element string between the first filler and the second filler;
Heating the first filler and the second filler at a temperature not lower than the higher melting point of these melting points and lower than the lower cross-linking point or the thermosetting point;
The laminated body in which the solar cell element string is disposed between the first filler and the second filler is cooled to less than the lower melting point of the first filler and the second filler. Process,
Deforming the laminate along the surface of the substrate;
The manufacturing method of the solar cell module characterized by including.   The method for manufacturing a solar cell module according to claim 1, wherein the substrate has a curved surface.

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