JP2016063125A - Solar cell module and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method or the like for a solar cell module adopting a laminate processing method which makes air bubbles unlikely to be residual.SOLUTION: The manufacturing method of the solar cell module including a laminate in which a plurality of members including solar cell elements are laminated and a terminal cover for covering a terminal of the laminate includes: disposing a first terminal cover member so as to protrude from an edge of a bottom face of a laminated body in which the plurality of members are stacked in a predetermined order; disposing a second terminal cover member so as to protrude from an edge of a top face of the laminated body to the outside of the laminated body and to confront the first terminal cover member outside of the laminated body; forming the laminate from the plurality of members by applying laminate processing to the first terminal cover member, the laminated body and the second terminal cover member; and simultaneously forming the terminal cover from the first terminal cover member and the second terminal cover member.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a solar cell module and a manufacturing method thereof.

  FIG. 1 is a cross-sectional view illustrating a general thin film solar cell module. In the thin film solar cell module 100 shown in FIG. 1, the laminated body 200 has a structure in which a planar member 210, a solar cell element 220, a sealing material 230, and a planar member 240 are sequentially laminated.

  For example, as illustrated in FIG. 2, the stacked body 200 is formed by disposing a solar cell element 220 and a sealing material 230 between opposing planar members 210 and 240 and bonding and integrating them by laminating. The laminated body 200 is provided with an end cover 300 that continuously covers all side surfaces of the laminated body 200 (see, for example, Patent Document 1).

  In manufacturing the end cover 300, a process of forming the end cover 300 is required in addition to the process of forming the laminated body 200, which is complicated. Therefore, a proposal of a method for simplifying these processes is required. As one of the solutions, for example, a method of simultaneously forming the end cover in the lamination process of the stacked body, which is a conventional process, can be considered.

  That is, as shown in FIG. 3, a laminated body 200 is formed by laminating a laminated body 400 in which a solar cell element 220 and a sealing material 230 are arranged between opposing planar members 210 and 240 by laminating. At this time, on the heater plate 960 of the laminating apparatus, the end covering member 310 is disposed between the peripheral portion of the planar member 210 and the peripheral portion of the planar member 240, and the laminate processing is performed in this state. In the example of FIG. 3, the stacking order of the members constituting the stacked body 400 is upside down with respect to the stacked body 200 illustrated in FIGS. 1 and 2.

JP 2011-231309 A

  However, when the lamination process is actually performed in the procedure as shown in FIG. 3, there may be a problem that bubbles remain in the laminated body 200 or between the laminated body 200 and the end cover 300. The cause is that the air exhausted from the laminated body 400 during the lamination process is blocked by the end cover member 310 and is not sufficiently exhausted.

  The end covering member 310 covers the periphery of the side surface of the stacked body 400. One end of the end covering member 310 is in contact with the planar member 210 and constitutes a part of a discharge path of air from the inside of the stacked body 400. The other end of the end covering member 310 is in contact with the planar member 240 and forms a part of another exhaust path.

  When exhaust is performed in this state, the air inside the stacked body 400 is exhausted along the path indicated by the solid and broken arrows in FIG. However, when the pressing process using the diaphragm 950 shown in FIG. 4 is started, the discharge path formed by the planar members 210 and 240 and the end covering member 310 is blocked by the pressing force P, and the air being discharged is blocked. It stays in the laminated body 400 or on the side surface of the laminated body 400.

  The staying air is not removed in the subsequent steps, and eventually remains as bubbles 390 in the laminate 200 or between the laminate 200 and the end cover 300. Note that FIG. 4 shows the state in which the bubbles 390 remain on the side surface of the stacked body 400, but the case where the bubbles 390 remain between the end covering member 310 and the planar members 210 and 240 or in the stacked body 400. There is also. The retained air can also cause misalignment of the end coating 300 during the lamination process.

  These problems can be solved if sufficient time is required for exhausting the air. However, since the tact time is increased, it is practically impossible to apply to the production line. Therefore, instead of this method, another method must be sought.

  Here, when the bubbles 390 remain in the end cover 300, the following problems occur. In the portion where the bubbles 390 remain, the end covering 300 and the laminated body 200 are not bonded to each other, so that the insulating function of this portion is lowered. In addition, the bubble 390 becomes a starting point of the peeling off of the end covering 300 and causes moisture to enter the final laminate 200. Any of these phenomena deteriorates the characteristics of the solar cell element 220. However, since the symptoms gradually progress over a long period of several months to several years, it is difficult to take measures after the characteristic deterioration is detected.

  That is, the remaining bubbles 390 cause a large influence on the long-term reliability of the solar cell module 100. Therefore, in order to simultaneously form the laminate 200 and the end cover 300, the laminating process in which the bubbles 390 do not remain is performed. It is essential to devise a method.

  This invention is made | formed in view of said point, and makes it a subject to provide the manufacturing method of a solar cell module etc. which used the laminating method which a bubble does not remain easily.

  The manufacturing method of this solar cell module is a manufacturing method of a solar cell module provided with the laminated body by which the several member containing a solar cell element was laminated | stacked, and the edge part coating | cover which covers the edge part of the said laminated body. The first end covering member is disposed so as to protrude from the peripheral edge of the lower surface of the stacked body in which the plurality of members are stacked in a predetermined order to the outside of the stacked body, and the upper surface of the stacked body A second end covering member is provided so as to protrude from the peripheral edge of the stacked body to the outside of the stacked body and to face the first end covering member on the outside of the stacked body. The first end covering member and the second end are simultaneously formed by laminating the portion covering member, the laminated body, and the second end covering member to form the laminated body from the plurality of members. It is a requirement to form the end cover from a part covering member.

  According to the disclosed technology, it is possible to provide a method for manufacturing a solar cell module using a laminating method in which bubbles do not easily remain.

It is sectional drawing which illustrates a general thin film solar cell module. It is a perspective view explaining the laminated body which comprises a general thin film solar cell module. It is sectional drawing (the 1) explaining the lamination process of a general thin film solar cell module. It is sectional drawing (the 2) explaining the lamination process of a general thin film solar cell module. It is a top view which illustrates the solar cell module which concerns on 1st Embodiment. It is sectional drawing which follows the AA line of FIG. It is sectional drawing which illustrates a laminating apparatus. It is sectional drawing (the 1) explaining the lamination process of the solar cell module which concerns on 1st Embodiment. It is sectional drawing (the 2) explaining the lamination process of the solar cell module which concerns on 1st Embodiment. It is sectional drawing (the 3) explaining the lamination process of the solar cell module which concerns on 1st Embodiment. It is sectional drawing (the 1) explaining the lamination process of the solar cell module which concerns on 2nd Embodiment. It is sectional drawing (the 2) explaining the lamination process of the solar cell module which concerns on 2nd Embodiment. It is sectional drawing explaining the 1st modification of FIG. It is sectional drawing explaining the 2nd modification of FIG. It is sectional drawing (the 1) explaining the lamination process of the solar cell module which concerns on 3rd Embodiment. It is sectional drawing (the 2) explaining the lamination process of the solar cell module which concerns on 3rd Embodiment. It is sectional drawing (the 1) explaining the lamination process of the solar cell module which concerns on 4th Embodiment. It is sectional drawing (the 2) explaining the lamination process of the solar cell module which concerns on 4th Embodiment. It is sectional drawing (the 1) explaining the lamination process of the solar cell module which concerns on 5th Embodiment. It is sectional drawing (the 2) explaining the lamination process of the solar cell module which concerns on 5th Embodiment. It is sectional drawing which illustrates the state which attached the flame | frame to the solar cell module shown in FIG.

  Hereinafter, embodiments for carrying out the invention will be described with reference to the drawings. In addition, in each drawing, the same code | symbol is attached | subjected to the same component and the overlapping description may be abbreviate | omitted.

<First Embodiment>
[Structure of Solar Cell Module According to First Embodiment]
First, the structure of the solar cell module according to the first embodiment will be described. FIG. 5 is a plan view illustrating the solar cell module according to the first embodiment. 6 is a cross-sectional view taken along line AA in FIG. For convenience, in FIG. 5, the end cover 30 is shown in a satin pattern.

  With reference to FIGS. 5 and 6, the solar cell module 10 includes a stacked body 20 and an end cover 30.

  The stacked body 20 has a structure in which a planar member 21, a solar cell element 22, a sealing material 23, and a planar member 24 are sequentially stacked. In the stacked body 20, the planar member 24 is a member that forms the surface of the solar cell module 10, and the planar member 21 is a member that forms the back surface of the solar cell module 10. The thickness of each of the planar members 21 and 24 can be, for example, about 1.0 to 3.0 mm.

  As the planar member 21, for example, high strain point glass can be used. As the planar member 24, for example, tempered glass can be used. However, the material of the planar members 21 and 24 can be appropriately selected from glass, resin, metal, etc. in consideration of the required rigidity, translucency, etc., whether it is plate-like or sheet-like It doesn't matter. Specific examples of appropriately selectable materials for the planar members 21 and 24 include borosilicate glass, low strain point glass, high strain point glass, tempered glass, resin, stainless steel, aluminum, or a composite material mainly composed of these. Can be mentioned. When a resin is selected as the material for the planar members 21 and 24, for example, film-like polyethylene terephthalate (PET), polyvinyl fluoride (PVF), polycarbonate, polyolefin, or the like can be used.

  The solar cell element 22 is formed in the central part on the planar member 21. As the solar cell element 22, for example, a CIS-based thin film solar cell element in which a plurality of thin films functioning as an electrode layer, a power generation layer, or the like is laminated can be used. However, the present invention is not limited to this, and as the solar cell element 22, other thin film solar cell elements (CIGS type, CZTS type, amorphous silicon type, etc.) may be used. Solar cell elements (silicon-based, compound-based, etc.) may be used.

  The sealing material 23 is softened by heating at the time of lamination, covers the entire surface of the solar cell element 22 and the entire surrounding side surface, and seals the solar cell element 22 between the planar member 21 and the planar member 24. An ethylene-vinyl acetate copolymer (hereinafter referred to as EVA), an olefin rubber, or the like can be used. EVA melts by heating and penetrates into surrounding members and gaps, and then cures by a crosslinking reaction to firmly bond the surrounding members. Note that a thermoplastic sealing material of butyl rubber or olefin rubber, or a sealing material such as silicone may be disposed between the peripheral portions of the opposing portions of the planar members 21 and 24. The thickness of the sealing material 23 can be set to, for example, about 0.2 to 1.0 mm.

  The end covering 30 is provided so as to cover the end of the stacked body 20. More specifically, the end cover 30 is provided so as to continuously cover the peripheral portion of one surface (light receiving surface), all the side surfaces, and the peripheral portion of the other surface (back surface) of the laminate 20. The purpose of providing the end cover 30 is to compensate for a decrease in the insulating function and moisture-proof ability of the side surface of the laminate 20. The end covering 30 improves the insulating function and moisture-proof ability of the stacked body 20 and ensures the long-term reliability of the solar cell module 10.

  The end covering 30 includes an end covering member 31 and an end covering member 32. The end covering member 31 is a flexible member that generates adhesiveness by heating during lamination and adheres to glass, resin, or metal, and includes an adhesive layer 311 and a moisture-proof layer 312. Similarly, the end covering member 32 is a flexible member that generates adhesiveness by heating during lamination and adheres to glass, resin, or metal, and has an adhesive layer 321 and a moisture-proof layer 322.

  As the adhesive layers 311 and 321, for example, an epoxy resin-based or acrylic resin-based thermosetting adhesive, a polyamide resin-based, a polyimide resin-based, or a polyisobutylene-based thermoplastic adhesive can be used. The moisture-proof layers 312 and 322 are flexible base materials and use, for example, a resin such as polyethylene terephthalate (PET), polyvinyl fluoride (PVF), polycarbonate, polyolefin, or a metal thin film or a composite material thereof. be able to.

  Further, a tie layer (primer layer) made of an adhesive material having adhesiveness to the adhesive layer 311 and the moisture-proof layer 312 may be provided. This is because the risk of the adhesive layer 311 peeling off from the moisture-proof layer 312 is reduced by having the tie layer. The same applies to the adhesive layer 321 and the moisture-proof layer 322.

  In addition, all the side surfaces of the laminated body 20 should just be coat | covered with at least one of the edge part covering members 31 and 32 extended from the peripheral part of the laminated body 20. FIG. In the example of FIG. 6, the entire side surface of the laminate 20 is covered with the end covering member 31. However, as shown in FIG. 18 described later, the entire side surface of the laminate 20 is both the end covering members 31 and 32. May be coated.

  Further, the peripheral edge portions of the end covering members 31 and 32 may protrude outward from the laminate 20 (substantially in the horizontal direction) and be bonded to each other. Alternatively, a terminal process such as cutting off an appropriate width may be applied to a portion where the end covering members 31 and 32 are bonded to each other and protrude from the laminated body 20 to the outside.

[Method for Manufacturing Solar Cell Module According to First Embodiment]
Next, the manufacturing method of the solar cell module according to the first embodiment will be described focusing on the laminating process. In addition, although the lamination process using a diaphragm is shown here, the means of laminating is not limited to this, but using a laminating process or the like by a hot plate press method in which a laminate is heated while being heated from both front and back surfaces in a vacuum. Also good. FIG. 7 is a cross-sectional view illustrating a laminating apparatus. 8-10 is sectional drawing explaining the lamination process of the solar cell module which concerns on 1st Embodiment.

  First, a laminating apparatus 90 shown in FIG. 7 is prepared. The laminating apparatus 90 has an openable / closable sealing structure including an upper chamber 91 and a lower chamber 92. The upper chamber 91 and the lower chamber 92 are provided with packings 93 and 94 at the opening. When the upper chamber 91 and the lower chamber 92 are closed, an airtight state in the laminating apparatus 90 is maintained by the packings 93 and 94. .

  Inside the upper chamber 91 is provided a heat-resistant rubber diaphragm 95 such as silicone rubber or fluorine rubber. The diaphragm 95 expands and contracts up and down according to the pressure difference between the upper chamber 91 and the lower chamber 92 in an airtight state in which the upper chamber 91 and the lower chamber 92 are overlapped.

  Inside the lower chamber 92 is provided a flat heater plate 96 for heating the stacked body 40 placed thereon. A vacuum exhaust system (not shown) is connected to the upper chamber 91 via an intake / exhaust pipe 97, and the vacuum exhaust system (not shown) depressurizes the upper chamber 91 or introduces air into the upper chamber 91. The pressure in the chamber 91 is adjusted. The lower chamber 92 has the same structure as the upper chamber 91, and the pressure in the lower chamber 92 is adjusted by an evacuation system (not shown).

  Next, as shown in FIG. 8, a planar member 21 on which the solar cell element 22 is formed is prepared by a known method. Then, the heater plate 96 of the laminating apparatus 90 shown in FIG. 7 is energized and kept in a heated state (for example, 140 ° C. to 170 ° C.). Then, with the upper chamber 91 opened, the end covering member 32 having the adhesive layer 321 and the moisture-proof layer 322, the stacked body 40, and the end coating having the adhesive layer 311 and the moisture-proof layer 312 on the heater plate 96. The members 31 are sequentially arranged. Thereafter, the upper chamber 91 and the lower chamber 92 are closed. Here, the laminated body 40 refers to the planar member 24, the sealing material 23, and the planar member 21 with the solar cell element 22 facing the sealing material 23 side, and each member is in a state before bonding. is there. If each member which comprises the laminated body 40 is adhere | attached, it will become the laminated body 20 shown in FIG.

  On the heater plate 96, the end covering member 32 is arranged so that the adhesive layer 321 faces the lower surface of the stacked body 40 and protrudes from the periphery of the lower surface of the stacked body 40 to the outside of the stacked body 40. To do. In other words, the end covering member 32 covers the entire circumference of the peripheral portion of the lower surface of the stacked body 40 and extends outward from the end of the planar member 24 by a predetermined length. The end covering member 32 is a typical example of the first end covering member according to the present invention.

  The end covering member 31 has the adhesive layer 311 facing the upper surface of the stacked body 40, protrudes from the peripheral edge of the upper surface of the stacked body 40 to the outside of the stacked body 40, and ends on the outside of the stacked body 40. It arrange | positions so that the part coating | coated member 32 may be opposed. In other words, the end covering member 31 covers the entire periphery of the peripheral portion of the upper surface of the stacked body 40 and extends outward from the end of the planar member 21 by a predetermined length. The end covering member 31 is a typical example of the second end covering member according to the present invention.

  The reason why such an arrangement is adopted is to have a structure in which the end face covering members 31 and 32 continuously cover the entire side surface and the peripheral edge of the laminated body 20 after the completion of the lamination. Therefore, the end covering member 31 does not need to have a shape that covers the entire top surface of the stacked body 40, and may have a shape that only covers the peripheral edge. The same applies to the end covering member 32. For example, the end covering members 31 and 32 can be formed into a frame shape or a tape shape (strip shape), and each side of the stacked body 40 can be covered in a cross-beam shape. At this time, the end covering member 31 and the end covering member 32 may be temporarily fixed to the stacked body 40 or the other end covering member by an adhesive tape or partial heating so that the positions of the end covering member 31 and the end covering member 32 do not shift. Good.

  In FIG. 8, the lower surface of the stacked body 40 corresponds to one surface (light receiving surface) of the stacked body 20 in FIGS. 5 and 6, and the upper surface of the stacked body 40 is the stacked body 20 in FIGS. 5 and 6. It corresponds to the other surface (back surface) of. The same applies to FIGS. 9 and 10.

  Next, as illustrated in FIG. 9, the laminating apparatus 90 performs laminating processing on the objects to be laminated (the end covering member 32, the stacked body 40 and the end covering member 31) illustrated in FIG. 8. Specifically, the insides of the upper chamber 91 and the lower chamber 92 are depressurized and maintained for a predetermined time (for example, 2 to 8 minutes). As the air is exhausted, the air inside the object to be laminated is discharged from the gap where the end covering member 31 and the end covering member 32 face each other along the path indicated by the solid arrow in FIG. The adhesive layers 311 and 321 of the stopper 23 and the end covering members 31 and 32 are softened.

  Next, air (for example, 0.3 to 1.0 atm) is introduced into the upper chamber 91 and maintained for a predetermined time (for example, 5 to 20 minutes). The air in the object to be laminated is discharged without stagnation, and the sealing material 23 fills between the planar member 21 and the planar member 24 by the pressing force P applied through the diaphragm 95, and the end covering member 31. And 32 easily follow the shape of the peripheral portion of the stacked body 40 due to its flexibility and continuously cover the peripheral portion of the stacked body 40 without a gap.

  When the time further elapses, as shown in FIG. 10, the laminate 20 is formed, and at the same time, the end cover 30 is formed from the end cover members 31 and 32. Specifically, the sealing material 23 is thermally cured and adhered to surrounding constituent members (the planar member 21, the solar cell element 22, and the planar member 24) to form the stacked body 20. Further, the end cover members 31 and 32 are also bonded to the upper and lower surfaces and the side surfaces of the laminate 20, and the portions facing each other are also bonded to form the end cover 30. Thereby, the solar cell module 10 is completed. Note that the end portions of the end portion covering members 31 and 32 that are bonded to each other and protrude outward from the laminate 20 may be left as they are, or subjected to terminal processing such as cutting off with leaving an appropriate width. Also good.

  As described above, according to the first embodiment, the end covering member 32 is disposed so as to protrude from the peripheral edge of the lower surface of the stacked body 40 to the outside of the stacked body 40, and the upper surface of the stacked body 40. The edge covering member 31 is disposed so as to protrude from the peripheral edge of the laminated body 40 to the outside of the laminated body 40 and to be opposed to the edge covering member 32 on the outside of the laminated body 40, and is laminated.

  Thereby, the air inside the to-be-laminated body 40 is discharged | emitted from the clearance gap formed between the edge part covering member 31 and the edge part covering member 32 at the time of lamination. For this reason, both can adhere, without air staying between the laminated body 40 and the edge part covering members 31 and 32, etc. FIG.

  That is, even if the laminated body 20 is formed from the laminated body 40 and the end covering 30 is formed from the end covering members 31 and 32, the laminated body 20 and the end covering 30 may be interposed between or in the laminated body 20. A structure in which bubbles do not remain can be realized. In other words, the laminate 20 and the end covering 30 can be formed simultaneously without leaving bubbles.

<Second Embodiment>
In 2nd Embodiment, the example which forms the edge part coating | cover 30 in the laminated body 40A in which the planar member 24 is larger than the planar member 21 is shown. In the second embodiment, description of the same components as those of the already described embodiments may be omitted.

  First, as shown in FIG. 11, a planar member 21 on which a solar cell element 22 is formed is prepared by a known method. Then, the heater plate 96 of the laminating apparatus 90 shown in FIG. 7 is energized and kept in a heated state (for example, 140 ° C. to 170 ° C.). Then, with the upper chamber 91 opened, the end covering member 32 having the adhesive layer 321 and the moisture-proof layer 322, the stacked body 40A (the planar member 24, the sealing material 23, the solar cell element) on the heater plate 96. The planar member 21 with the 22 facing the sealing material 23 side, the sealing material 50), and the end covering member 31 having the adhesive layer 311 and the moisture-proof layer 312 are sequentially arranged. Thereafter, the upper chamber 91 and the lower chamber 92 are closed.

  Then, similarly to FIG. 9, the laminate object 90 shown in FIG. 11 is laminated by the laminating apparatus 90 to complete the solar cell module 10 </ b> A shown in FIG. 12.

  In addition, in the solar cell module 10A, the material of the planar member 21 can be appropriately selected from the materials described above, and for example, high strain point glass can be used. The solar cell element 22 is, for example, a CIS-based thin film solar cell element disposed in the central portion of the planar member 21. The sealing material 23 is, for example, EVA, is approximately the same size as the solar cell element 22, and is disposed so as to cover the surface thereof. The material of the planar member 24 can be appropriately selected from the materials described above. For example, tempered glass can be used.

  Further, since the planar member 21 and the planar member 24 are different in size (the planar shape of the planar member 24 is larger than the planar shape of the planar member 21), the side surface shape of the stacked body 20A is stepped. . Here, in order to level the step and enhance the sealing effect, the planar member 21, the solar cell element 22, and the sealing are formed on the opposing portions of the peripheral portion of the planar member 21 and the peripheral portion of the planar member 24. A sealing material 50 covering the entire peripheral side surface of the material 23 is disposed. The side end surface of the sealing material 50 is an inclined surface.

  As shown in FIG. 13, the size of the sealing material 23 is made larger than that of the solar cell element 22 to cover the entire peripheral side surface in addition to the surface of the solar cell element 22, and the peripheral portion of the planar member 21 and the planar member. You may arrange | position the sealing material 50 which covers the whole surrounding side surface of the planar member 21 and the sealing material 23 in the part which the peripheral part of 24 opposes. Further, as shown in FIG. 14, the size of the sealing material 23 is made smaller than that of the solar cell element 22 to cover a part of the surface of the solar cell element 22, and the peripheral portion of the planar member 21 and the peripheral portion of the planar member 24. A sealing material 50 that covers the planar member 21, the sealing material 23, the entire peripheral side surface of the solar cell element 22, and the other surface of the solar cell element 22 may be disposed on the facing portion.

  That is, the sealing material 50 is disposed between the protruding surface of the planar member 24 and the side end surface of the planar member 21, thereby leveling the step between the two. Further, the sealing effect can be enhanced by arranging the sealing material 50 so as to surround the solar cell element 22 and the sealing material 23. As the sealing material 50, for example, a butyl rubber or olefin rubber thermoplastic sealing material, or a sealing material such as silicone can be used.

  Even in such a configuration, in the laminating process, the air inside the stacked body 40A is not exhausted from the gap between the end covering members 31 and 32 along the path indicated by the solid arrow in FIG. At the same time, the end covering members 31 and 32 easily follow the surface of a complicated shape as shown in FIG. 11 and cover the surface without a gap due to its flexibility. And the end cover 30 can be formed simultaneously.

<Third Embodiment>
In 3rd Embodiment, the example which forms the edge part coating | cover 30 in the laminated body 40B using the sheet-like planar member 21 is shown. Note that in the third embodiment, description of the same components as those of the already described embodiments may be omitted.

  First, as shown in FIG. 15, the heater plate 96 of the laminating apparatus 90 shown in FIG. 7 is energized and kept in a heated state (for example, 140 ° C. to 170 ° C.). Then, with the upper chamber 91 opened, the end covering member 32 having the adhesive layer 321 and the moisture-proof layer 322, the stacked body 40B (the planar member 24, the sealing material 52, the solar cell element) on the heater plate 96. 22, the sealing member 51, the planar member 21), and the end covering member 31 having the adhesive layer 311 and the moisture-proof layer 312 are sequentially arranged. Thereafter, the upper chamber 91 and the lower chamber 92 are closed.

  Then, similarly to FIG. 9, the laminating apparatus 90 laminates the object to be laminated shown in FIG. 15 to complete the solar cell module 10 </ b> B shown in FIG. 16.

  In the solar cell module 10B, the planar member 21 is a back sheet. For example, a metal layer or an adhesive layer is provided on a substrate such as polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF), or a fluororesin. A flexible sheet. The solar cell element 22 is, for example, a CIS-based thin film solar cell element formed on soda lime glass or high strain point glass, and is smaller than the planar members 21 and 24.

  The sealing materials 51 and 52 are EVA, for example, and seal the periphery of the solar cell element 22 after lamination. The material of the planar member 24 can be appropriately selected from the materials described above. For example, tempered glass can be used. The planar member 21, the planar member 24, and the sealing materials 51 and 52 are substantially the same size.

  Even in such a configuration, in the laminating process, the air inside the stacked body 40B is not exhausted from the gap between the end covering members 31 and 32 along the path indicated by the solid line arrow in FIG. At the same time, the end covering members 31 and 32 easily follow the surface of a complicated shape as shown in FIG. 15 and cover the surface without a gap due to its flexibility. And the end cover 30 can be formed simultaneously.

<Fourth embodiment>
In 4th Embodiment, the example which forms the edge part coating | cover 30 in the laminated body 40C which has flexibility is shown. Note that in the fourth embodiment, descriptions of the same components as those of the above-described embodiments may be omitted.

  First, as shown in FIG. 17, a planar member 24 having a solar cell element 22 formed at the center is prepared by a known method. The planar member 24 is obtained by providing an insulating layer 242 made of alumina or low-melting glass on a metal thin film substrate 241 such as a stainless thin film or an aluminum thin film.

  Then, the heater plate 96 of the laminating apparatus 90 shown in FIG. 7 is energized and kept in a heated state (for example, 140 ° C. to 170 ° C.). Then, with the upper chamber 91 opened, the end covering member 32 having the adhesive layer 321 and the moisture-proof layer 322, the stacked body 40C (the solar cell element 22 is directed to the sealing material 23 side) on the heater plate 96. The planar member 24, the sealing material 23, the planar member 21), and the end covering member 31 having the adhesive layer 311 and the moisture-proof layer 312 are sequentially arranged. Thereafter, the upper chamber 91 and the lower chamber 92 are closed.

  Then, similarly to FIG. 9, the laminating apparatus 90 performs laminating on the object to be laminated shown in FIG. 17, thereby completing the solar cell module 10 </ b> C shown in FIG. 18.

  In the solar cell module 10C, the material of the planar member 21 can be appropriately selected from the materials described above. For example, a flexible substrate having translucency such as a polycarbonate film or a thin glass plate is used. it can. The sealing material 23 is EVA, for example, and seals the periphery of the solar cell element 22 after lamination. Moreover, the planar member 21, the planar member 24, and the sealing material 23 are substantially the same size.

  Even in such a configuration, in the laminating process, the air inside the stacked body 40C is not discharged from the gap between the end covering members 31 and 32 along the path indicated by the solid line arrow in FIG. In addition, the end covering members 31 and 32 easily follow the surface of a complicated shape as shown in FIG. And the end cover 30 can be formed simultaneously.

<Fifth embodiment>
In the fifth embodiment, an example in which the end cover 30 is formed on the stacked body 40D having more layers or thicker than the first to fourth embodiments will be described. Note that in the fifth embodiment, description of the same components as those of the above-described embodiments may be omitted.

  First, as shown in FIG. 19, the heater plate 96 of the laminating apparatus 90 shown in FIG. 7 is energized and kept in a heated state (for example, 140 ° C. to 170 ° C.). Then, with the upper chamber 91 opened, the end covering member 32 having the adhesive layer 321 and the moisture-proof layer 322, the stacked body 40D (the planar member 24, the sealing material 52, the solar cell element) on the heater plate 96. 22, the sealing material 51, the planar member 21, the sealing material 50), and the end covering member 31 having the adhesive layer 311 and the moisture-proof layer 312 are sequentially disposed. Thereafter, the upper chamber 91 and the lower chamber 92 are closed.

  Note that, in the stacked body 40D, in addition to an increase in the amount of air to be discharged from the respective layers, the exhaust path length increases due to an increase in the overall thickness. That is, the exhaust conductance decreases and the discharge time must be increased. In this case, in order to perform efficient air discharge even in such a case, in the present embodiment, the position of the portion where the end covering members 31 and 32 are opposed to each other on the outer peripheral side surface of the stacked body 40D is the position of the stacked body 40D. It moves to the vicinity of the center in the thickness direction.

  In order to move the position of the portion where the end covering members 31 and 32 face each other to the vicinity of the central portion in the thickness direction of the stacked body 40D, it is only necessary to provide a step as shown in FIG. This is because the end covering members 31 and 32 are deformed by the pressing force P of the diaphragm 95 (not shown) during lamination, respectively, and have a shape as shown in FIG.

  Next, as in FIG. 9, the laminating apparatus 90 performs laminating on the object to be laminated shown in FIG. 19, thereby completing the solar cell module 10D shown in FIG.

  In the solar cell module 10D, the planar members 21 and 24 are approximately the same size, and the solar cell element 22 and the sealing materials 51 and 52 are approximately the same size. The solar cell element 22 and the sealing materials 51 and 52 are smaller than the planar members 21 and 24. A sealing material 50 that covers the entire peripheral side surfaces of the solar cell element 22 and the sealing materials 51 and 52 is disposed at a portion where the peripheral edge of the planar member 21 and the peripheral edge of the planar member 24 face each other. The side surface on the lower surface side of the stacked body 20 </ b> D is covered with the end covering member 32, and the side surface on the upper surface side of the stacked body 20 </ b> D is covered with the end covering member 31. Further, the solar cell element 22 is made smaller than the sealing materials 51 and 52, and the entire peripheral side surface of the solar cell element 22 is covered with the sealing materials 51 and 52, and the peripheral edge of the planar member 21 and the peripheral edge of the planar member 24. You may arrange | position the sealing material 50 which covers the whole surrounding side surface of the sealing materials 51 and 52 in the part which a part opposes.

  Even in such a configuration, in the laminating process, the air inside the stacked body 40D is not exhausted from the gap between the end covering members 31 and 32 along the path indicated by the solid line arrow in FIG. At the same time, the end covering members 31 and 32 easily follow the surface of a complicated shape as shown in FIG. 19 and cover the surface without a gap due to its flexibility, so that the stacked body 20D does not leave bubbles. And the end cover 30 can be formed simultaneously.

  Further, since the position of the portion where the end covering members 31 and 32 face each other is moved to the vicinity of the center in the thickness direction of the stacked body 40D on the outer peripheral side of the side surface of the stacked body 40D, the exhaust path length is made uniform and the exhaust An increase in conductance can be suppressed, and exhaust can be efficiently performed even in a multilayer stack or a thick stack.

<Sixth embodiment>
In 6th Embodiment, the example which attaches a flame | frame to a solar cell module is shown. Note that in the sixth embodiment, descriptions of the same components as in the already described embodiments may be omitted.

  FIG. 21 is obtained by attaching a frame 60 to the solar cell module 10A shown in FIG. The end cover 30 of the solar cell module 10 </ b> A is bent at a portion where the end cover members 31 and 32 overlap each other, and is inserted into the groove 60 x of the frame 60. The solar cell module 10 </ b> A and the frame 60 are bonded by a fixing member 70. The frame 60 is a frame member attached so as to surround the periphery of the end portion of the solar cell module 10A.

  Note that, in the end covering 30, the end portion 30e opposite to the side bonded to the stacked body 20A is subjected to a terminal treatment and cut off at a position appropriately separated from the end of the stacked body 20A. . For this reason, since the end covering 30 can be entirely accommodated in the frame 60, it does not interfere with the fixing member 70.

  Thus, while attaching the flame | frame 60 so that the edge part periphery of 10 A of solar cell modules may be enclosed, while being able to improve the intensity | strength of 10 A of solar cell modules, the light-receiving surface of the edge part of 10 A of solar cell modules, a side end surface, and a back surface And the periphery of the solar cell module 10A can be protected.

  The preferred embodiment has been described in detail above. However, the present invention is not limited to the above-described embodiment, and various modifications and replacements are made to the above-described embodiment without departing from the scope described in the claims. Can be added.

10, 10A, 10B, 10C, 10D Solar cell module 20, 20A, 20B, 20C, 20D Laminate 21, 24 Planar member 22 Solar cell element 23, 51, 52 Sealing material 30 End covering 30e End covering End portion 31, 32 End covering member 40, 40A, 40B, 40C, 40D Laminate 50 Sealing material 60 Frame 60x Groove portion 70 Fixing member 90 Laminating apparatus 91 Upper chamber 92 Lower chamber 93, 94 Packing 95 Diaphragm 96 Heater plate 97 Intake and exhaust pipe 241 Metal thin film substrate 242 Insulating layer 311, 321 Adhesive layer 312, 322 Moisture proof layer

Claims (10)

A manufacturing method of a solar cell module comprising: a laminated body in which a plurality of members including solar cell elements are laminated; and an end covering that covers an end of the laminated body,
The first end covering member is arranged so as to protrude from the peripheral portion of the lower surface of the stacked body in which the plurality of members are stacked in a predetermined order to the outside of the stacked body,
A second end covering member is disposed so as to protrude from the peripheral edge of the upper surface of the stacked body to the outside of the stacked body and to face the first end covering member outside the stacked body. ,
The first end covering member, the laminated body, and the second end covering member are laminated to form the laminate from the plurality of members, and at the same time, the first end covering member and The method of manufacturing a solar cell module, wherein the end cover is formed from the second end cover member.   2. The solar cell according to claim 1, wherein all side surfaces of the laminate are covered with at least one of the first end covering member and the second end covering member by laminating. Module manufacturing method.   By laminating, the side surface on the lower surface side of the laminate is covered with the first end covering member, and the side surface on the upper surface side of the laminate is covered with the second end covering member. The manufacturing method of the solar cell module of Claim 2. The plurality of members include a first planar member, a second planar member, and a sealing material in addition to the solar cell element.
From the first end covering member side, the first planar member, the sealing material, the solar cell element, and the second planar member are sequentially disposed on the second planar member. The method for manufacturing a solar cell module according to any one of claims 1 to 3, wherein laminating is performed in a state where the second end covering member is arranged. The peripheral portions of the first planar member and the second planar member protrude outward from the solar cell element and the sealing material,
Laminating is performed in a state in which a sealing material covering a peripheral side surface of the sealing material is disposed on a portion where the peripheral portion of the first planar member and the peripheral portion of the second planar member are opposed to each other. The manufacturing method of the solar cell module of Claim 4.   6. The method for manufacturing a solar cell module according to claim 5, wherein in addition to the sealing material, laminating is performed in a state where a sealing material covering a peripheral side surface of the solar cell element is disposed. Each of the first end covering member and the second end covering member is a flexible member in which an adhesive layer and a moisture-proof layer are laminated,
The first end covering member and the second end covering member are arranged with their respective adhesive layers facing the layered body side. Manufacturing method for solar cell module. A solar cell module comprising: a laminate in which a plurality of members including solar cell elements are laminated; and an end covering that covers an end of the laminate,
The end covering is
A first end covering member that covers a peripheral edge of one surface of the laminate;
A second end covering member that covers the peripheral edge of the other surface of the laminate,
All the side surfaces of the laminate are covered with at least one of the first end covering member and the second end covering member extending from the peripheral edge of the laminate. Solar cell module.   A side surface on one surface side of the laminate is covered with the first end covering member, and a side surface on the other surface side of the stacked body is covered with the second end covering member. The solar cell module according to claim 8.   10. The sun according to claim 8, wherein peripheral edges of the first end covering member and the second end covering member protrude outward from the stacked body and are bonded to each other. Battery module.

Images