JP2016171295A - Solar cell module, manufacturing method of the same, and rework method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module capable of improving weather resistance and a rework process yield and preventing damage of a solar cell cause by an external force.SOLUTION: The solar cell module used for improving reliability of a moisture resistance test and a rework yield includes a substrate layer, a first encapsulating layer, at least one solar cell, a second encapsulating layer, a buffer layer and a back plane. In a rework process, it is possible to reduce damage of the solar cell caused by an external force and improve a yield of the rework process.SELECTED DRAWING: Figure 3

Description

Cross-reference of related application and priority claim

  This application claims the benefit based on the Taiwan application of No. 104107989 for which it applied on March 12, 2015, The content is taken in into this specification as a reference.

  The present invention relates to a solar cell module, and more particularly, to a solar cell module package structure, a module structure manufacturing method, and a rework method.

  FIG. 1 is a plan view of a conventional solar cell module 11. In general, since the front surface of the solar cell module 11 is a light receiving surface for receiving daytime sunlight exposure, the uppermost layer portion of the front surface is combined with the transparent glass substrate 12. The arrangement of the plurality of solar cells 13 positioned below the glass substrate 12 is visible through the glass substrate 12. Further, in the solar cell module 11, only one solar cell may be arranged in order to satisfy customer demands and product requirements. The plurality of solar cells 13 are electrically connected to each other and arranged in a plurality of rows. Each of the plurality of solar cells 13 is connected by a ribbon (not shown). The plurality of solar cells 13 performs photoelectric conversion by sunlight entering the solar cell module 11 through the glass substrate 12, that is, converts the sunlight into electric power used in daily life. Usually, module frames 14 and 15 are included around the solar cell module 11. As shown in FIG. 1, two shorter module frames 14 and two longer module frames 15 are arranged around the solar cell module 11 in order to fix and protect the solar cell module 11.

  FIG. 2 is a cross-sectional view taken along line A-A ′ of the solar cell module 11 of FIG. 1. The solar cell module 11 is usually composed of a plurality of components. As shown in FIG. 2, the glass layer 12, a sealing material 25 made of ethylene vinyl acetate (EVA), a plurality of solar cells 13, and ethylene vinyl acetate. A sealing material 26 made of (EVA) and a backplane 24 are sequentially included. The back plane 24 is a non-light receiving surface located on the back surface of the solar cell module 11. The backplane 24 protects the plurality of solar cells 13 in order to avoid damage due to external force. In addition, since the backplane 24 can reflect sunlight entering the solar cell module 11, the backplane 24 further performs a photoelectric reaction with the plurality of solar cells 13, thereby improving the photoelectric conversion efficiency of the solar cell module 11. The excellent solar cell backplane 24 has high insulation, water resistance, high pressure resistance, and a function of preventing deterioration in addition to the above functions.

  EVA sealing materials 25 and 26 for bonding are included between the glass layer 12 and the plurality of solar cells 13 and between the backplane 24 and the plurality of solar cells 13. The sealing materials 25 and 26 also have impact resistance, high transmittance, and insulation protection function. After the laminated structure is pressure-bonded at a high temperature, the solar cell module 11 is completed. In the step of pressure bonding at a high temperature, since the processing temperature is about 140 to 170 ° C., the sealing materials 25 and 26 are in a molten state, and after the cooling is completed, the two sealing materials 25 and 26 are composed of a plurality of suns. The battery 13 is cross-linked and fixed so as to be fixed. Further, the completed solar cell module 11 needs to be subjected to many tests, such as a thermal cycle test, a moisture resistance test, and a mechanical load test. The moisture resistance test is used to test the weather resistance of the solar cell module 11. The solar cell module 11 is placed in a test environment of 85 ° C. and a relative humidity of 85%, and the module is kept at a high temperature and high humidity for a long time. Test moisture resistance and sealing reliability. In general standards, the test time is 1000 hours. The test results show that the solar cell module 11 exhibits better weather resistance when the attenuation of the overall power of the solar cell module 11 decreases. With the development of solar energy technology, various manufacturers are developing new products that emphasize the excellent properties and weather resistance of materials. Some manufacturers declare that they can pass more than 3,000 hours of moisture testing and emphasize the differentiation of other products. The EVA sealing material of the prior art does not meet the needs of the industry, after the moisture resistance test of 3,000 hours or more, the attenuation of the overall power of the solar cell module is 5% or more. When the EVA encapsulant is exposed to an atmosphere with water, it hydrolyzes to generate acid radicals, thereby reducing the output of the solar cell module.

  Therefore, the selection of the sealing material and the solar cell module certification test are closely related. As technology evolves, the industry chooses polyolefin materials instead of traditional EVA materials. The main reason is that after a moisture resistance test of 3,000 hours or more than 6,000 hours, the total power attenuation of the solar cell module using polyolefin as a sealing material is less than 5%, meeting the needs of the industry. Yes. In addition, since the sealing material made of polyolefin does not hydrolyze to generate acid radicals, the solar cell is not damaged. In addition to the moisture resistance test, the solar cell module requires tests such as defects in appearance, electrical connection, and whether air bubbles are present in the sealing material. The solar cell module determined to be low quality is reworked. In the rework process, the solar cell module is heated, the back plate is removed, and the parts are replaced. However, since the bonding between the solar cell module and the back plate is too tight, when removing the back plate, the solar cell is damaged and rework cannot be completed. When polyolefin is used as the sealing material, compared with EVA, when removing the back plate, the solar cell is more damaged and the rework yield is lower.

  Therefore, in order to solve such a conventional problem, the present applicant develops and proposes a solar cell module, a manufacturing method thereof, and a rework method through results of repeated experiments and researches.

  The present invention proposes a solar cell module in order to improve the weather resistance of the solar cell module and the yield of the rework process. The solar cell module of the present invention includes a substrate, a first sealing material, at least one solar cell, a second sealing material, a cushioning material, and a backplane. A first interface that is located between a plane and the second sealing material and is joined to the second sealing material, and a second interface that is joined to the backplane. The first interface and the second interface form a fracture surface between the at least one solar cell and the second sealing material when the back plate is removed, so that the at least one solar cell by an external force is formed. Avoid damage.

  In view of the prior art, the present invention provides a solar cell module. The solar cell module includes a substrate, a backplane parallel to the substrate, at least one solar cell positioned between the substrate and the backplane, and between the substrate and the at least one solar cell. A first sealing material positioned; a second sealing material positioned between the backplane and the at least one solar cell; and a cushioning material positioned between the backplane and the second sealing material. And including.

  In the solar cell module, the substrate is a glass substrate.

  In the solar cell module, the at least one solar cell has a bonding interface bonded to the second sealing material, the buffer material includes a first interface bonded to the second sealing material, and the back. A second interface joined to the plane, and the adhesive force of the bonding interface is greater than the adhesive force of the first interface or the second interface.

  In the solar cell module, the adhesive force of the first interface or the second interface is 25 n / cm or more.

  In the solar cell module, the first sealing material or the second sealing material is selected from a polyolefin, an ionomer-based material, or a combination thereof.

  In the solar cell module, the buffer material is selected from ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), silicone, or a combination thereof.

  In the solar cell module, the second sealing material has a thickness of 150 to 300 μm.

  In the solar cell module, the buffer material has a thickness of 150 to 300 μm.

  In order to achieve the above object, a method for manufacturing a solar cell module is submitted. The method for manufacturing the solar cell module includes a step of installing a substrate, a step of installing a backplane parallel to the substrate, and the substrate between the substrate and the backplane so as to form a laminated structure. , First sealing material, at least one solar cell, second sealing material, buffer material and the backplane in this order, the first sealing material, the at least one solar cell, and the second sealing material. And a step of installing the buffer material, and a step of pressing the laminated structure so as to form a solar cell module.

  In order to achieve the above object, a method for reworking a solar cell module is submitted. The method for reworking the solar cell module includes a step of preparing a solar cell module including a substrate, a first sealing material, at least one solar cell, a second sealing material, a buffer material, and a backplane, A step of removing a backplane, a step of removing at least a part of the buffer material, a step of removing at least a part of the second sealing material, and a removal of the at least a part of the second sealing material. So as to form a laminated structure, a step of installing another second sealing material at the place where the at least part of the buffer material is removed, a step of installing another buffer material, A step of installing another backplane at a place where the at least a part of the backplane has been removed, and a step of pressing the laminated structure so as to complete rework of the solar cell module. .

  In the rework method of the solar cell module, another step of removing the at least part of the second sealing material and another second sealing material at the place where the at least part of the second sealing material is removed. Between the step of installing, the step of removing the at least one solar cell, and the step of installing another at least one solar cell at the place where the at least one solar cell has been removed are included.

  The present invention improves the weather resistance of the solar cell module and the yield of the rework process by submitting the solar cell module, and avoids damage of the solar cell due to external force.

It is a top view of the conventional solar cell module. It is sectional drawing of the conventional solar cell module. It is sectional drawing of embodiment of the solar cell module of this invention. It is a flowchart which shows the manufacturing method of the solar cell module which concerns on embodiment of this invention. It is a flowchart which shows the rework method of the solar cell module which concerns on embodiment of this invention.

  As described below, the present invention will be described in detail based on examples. However, the present invention is merely illustrative, and the scope of the present invention is not limited to these embodiments. The scope of the present invention is described in the scope of the claims, and includes all modifications within the meaning and scope equivalent to the scope of the claims.

  FIG. 3 is a cross-sectional view of an embodiment of the solar cell module of the present invention, and is the same cross-sectional view of the solar cell module as in FIG. 2, but the laminated structure is different. The solar cell module 31 of the present invention includes a single layer substrate 32 and a single layer backplane 34, and includes a plurality of solar cells 33 between the substrate 32 and the backplane 34. In order to be able to combine the substrate 32, the backplane 34, and the solar cell 33, a first sealing material 35 is filled between the substrate 32 and at least one solar cell 33. Correspondingly, a second sealing material 36 is filled between the backplane 34 and at least one solar cell 33. The first sealing material 35 and the second sealing material 36 in a high temperature environment are in a molten state, and can be brought into close contact with the elements such as the substrate 32, the backplane 34, and the solar cell 33 after crosslinking and curing. In order to improve the yield of the solar cell module rework process, a buffer material 37 is filled between the backplane 34 and the second sealing material 36. As shown in FIG. 3, a substrate 32, a first sealing material 35, a plurality of solar cells 33, a second sealing material 36, a buffer material 37 and a backplane 34 are installed in this order to form a laminated structure. The laminated structure is pressed at a high temperature of 140 to 170 ° C. to form the solar cell module 31. In this embodiment, a plurality of solar cells 33 are exemplified, but the number of solar cells is not limited to this, and it is sufficient if there is at least one solar cell 33.

  In this embodiment, the board | substrate 32 is a glass substrate which can permeate | transmit sunlight, and usually consists of glass, it is not limited to this, What is necessary is just to have a function which can permeate | transmit light to a board | substrate. A preferred transparent substrate has a high strength and a low light reflection function. The back plate 34 has a multilayer structure made of a composite material, and includes at least one polyethylene terephthalate (abbreviated as PET) layer (not shown) and at least one fluorinated layer (not shown). It is not limited. The back plate 34 has functions such as corrosion prevention, moisture proofing, and weather resistance in order to protect the back surface of the solar cell module 31. The plurality of solar cells 33 are mainly silicon cells, and can be generally divided into single crystal silicon cells and polycrystalline silicon cells. The difference between the two types of batteries is that there is a clear difference in appearance in addition to the photoelectric conversion efficiency, but the application of the batteries is not limited. The first sealing material 35, the second sealing material 36, and the buffer material 37 have a high transmittance in addition to the function of bringing the elements such as the substrate 32, the backplane 34, and the solar cell 33 into close contact with each other. Do not block reactions with multiple solar cells. Normally, the first sealing material 35, the second sealing material 36, and the buffer material 37 require a transmittance of 92% or more, but are not limited thereto. The material of the first sealing material 35 or the second sealing material 36 can be selected from polyolefins, ionomer materials, or combinations thereof. In the present embodiment, polyolefin is preferable, but it is not limited to these materials. The material of the cushioning material 37 can be selected from ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), silicone, or a combination thereof. The solar cell module 31 according to this embodiment includes a substrate 32, a first sealing material 35 made of polyolefin, at least one solar cell 33, a second sealing material 36 made of polyolefin, and a buffer material made of EVA. 37, the back plane 34, and the structure laminated in this order, but is not limited to this.

  In the present embodiment, there is a bonding interface 381 that is bonded between the plurality of solar cells 33 and the second sealing material 36, and there is a bonding between the second sealing material 36 and the buffer material 37. There is a first interface 382 that is connected, and there is a second interface 383 that is bonded between the backplane 34 and the cushioning material 37. When the back plate 34 is removed in the rework process of the solar cell module, the removed stress acts on the bonding interface 381, the first interface 382, and the second interface 383. If the bonding interface 381 is broken by stress, the solar cell 33 may be damaged. However, based on a general physical phenomenon, the bonding force at the interface is relatively weak, which causes breakage. . In this embodiment, the adhesive force of the bonding interface 381 is larger than the adhesive force of the first interface 382 or the second interface 383, and when the back plate 34 is removed, the first interface 382 or the second interface 383 is more than the bonding interface 381. Breakage occurs, and damage to the plurality of solar cells 33 due to external force is avoided. Further, in order to comply with the industry module test standard, the adhesive force of the first interface 382 or the second interface 383 is 25 n / cm or more, but is not limited to this embodiment.

  In the present embodiment, the thickness h1 of the first sealing material 35 is 400 to 500 μm, the thickness h2 of the second sealing material 36 is 150 to 300 μm, and the thickness h3 of the buffer material 37 is 150-300 μm. If the thickness of the sealing material is too thick, the sealing cost of the module becomes high and it takes too much production time. If the thickness of the sealing material is too thin, the module has insufficient shock absorption capacity and cannot pass the mechanical load test. In the present embodiment, the thickness of the sealing material is set so as to provide an appropriate mechanical load capacity for the solar cell module, but is not limited to this embodiment.

  In this embodiment, the weather resistance of the polyolefin material is superior to EVA as compared with the preferable sealing material polyolefin and the preferable buffer material EVA, so that the results of the moisture resistance test can be improved. In the rework process of the solar cell module, the adhesive force between the backplane and the EVA cushioning material is smaller than the adhesive force between the cushioning material and the polyolefin encapsulant that adheres to the cushioning material. Easy to remove. Therefore, the weather resistance of the module and the yield of the rework process can be improved at the same time, which has application value in actual products. Polyolefin can effectively prevent water vapor from being absorbed and acid radicals from being generated to damage the solar cell. Therefore, a decrease in the output of the solar cell can be avoided, and the actual application has a special effect.

  In conclusion, the present invention has the effect of improving the reliability of the moisture resistance test and the yield of rework. In the rework process, the damage of at least one solar cell due to external force can be avoided and the yield of the rework process can be improved. it can.

  FIG. 4 is a flowchart showing a method for manufacturing the solar cell module 31 according to the embodiment of the present invention. The manufacturing method of the solar cell module 31 includes at least one of a step S1 of installing the substrate 32, a step S2 of installing the first sealing material 35 on the substrate 32 such that the first sealing material 35 covers the substrate 32. Step S3 of installing at least one solar cell 33 so that one solar cell 33 covers the first sealing material 35, and second sealing so that the second sealing material 36 covers at least one solar cell 33. Step S4 for installing the stop material 36, Step S5 for installing the buffer material 37 so that the buffer material 37 covers the second sealing material 36, and the backplane 34 so that the backplane 34 covers the buffer material 37. And a step S7 in which a laminated structure formed by laminating these elements is pressed at a high temperature of 140 to 170 ° C., crosslinked and cured to form the solar cell module 31. The 1st sealing material 35, the 2nd sealing material 36, and the buffering material 37 may be a sheet | seat or a fluid, and can perform sheet | seat lamination | stacking or a fluid coating. If the 1st sealing material 35, the 2nd sealing material 36, and the buffering material 37 are a sheet | seat or solid, you may change the order of said process S1-S6. In other words, as long as the solar cell module 31 shown in FIG. 3 can be formed regardless of the order of the steps S1 to S6, other steps may be added in addition to the steps S1 to S6. For example, first, the substrate 32 is installed in step S1, and then the backplane 34 parallel to the substrate 32 is installed in step S6. Thus, the substrate 32 and the backplane 34 are formed so as to form a stacked structure. Steps S2 to S5 are performed between the substrate 32, the first sealing material 35, the at least one solar cell 33, the second sealing material 36, the buffer material 37, and the back regardless of the order of the steps S2 to S5. The laminated structure may be installed in the order of the plane 34, but is not limited to this embodiment.

  FIG. 5 is a flowchart showing a rework method of the solar cell module 31 according to the embodiment of the present invention. The rework method of the solar cell module 31 is a step of preparing the solar cell module 31 including the substrate 32, the first sealing material 35, at least one solar cell 33, the second sealing material 36, the buffer material 37, and the backplane 34. R1, a step R2 for removing at least a portion of the backplane 34, a step R3 for removing at least a portion of the cushioning material 37, a step R4 for removing at least a portion of the second sealing material 36, A step R5 of installing another second sealing material at a location where some of the second sealing material 36 has been removed, and another cushioning material at a location where the at least some of the cushioning material 37 has been removed. A step R6 of installing, a step R7 of installing another backplane at a location where the at least part of the backplane 34 is removed so as to form a laminated structure, and a solar cell module 31 To complete the work, including a step R8 mutually pressing said laminated structure at 140 to 170 ° C.. Steps R2 to R4 may be performed simultaneously or not sequentially. For example, the steps R2 and R3 may be performed simultaneously, the steps R3 and R4 may be performed simultaneously, and the steps R2 to R4 may be performed simultaneously, but are not limited thereto. The second sealing material and the buffer material may be a sheet or a fluid, and may be a sheet lamination or a fluid coating as an installation step. If said 2nd sealing material and said buffer material are a sheet | seat or solid, said process R5-R7 may be performed simultaneously and does not need to be performed sequentially. For example, the steps R5 and R6 may be performed at the same time, the steps R6 and R7 may be performed at the same time, and the steps R5 to R7 may be performed at the same time, but are not limited thereto. When it is necessary to replace at least one solar cell 33 in the present embodiment, a step of removing at least one solar cell 33 (not shown) between step R4 and step R5, and at least one solar cell And a step (not shown) of installing at least one other solar cell at the place where the battery 33 is removed.

  From the above description, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the technical idea of the present invention. Therefore, the technical scope of the present invention is not limited to the contents described in the detailed description of the specification, but must be defined by the claims.

11, 31 Solar cell module 12 Glass substrate 13, 33 Solar cell 14, 15 Module frame 24, 34 Backplane 25, 26 Sealing material 32 Substrate 35 First sealing material 36 Second sealing material 37 Buffer material 381 Bonding interface 382 First interface 383 Second interface h1, h2, h3 thickness

Claims (11)

A substrate,
A backplane parallel to the substrate;
At least one solar cell located between the substrate and the backplane;
A first encapsulant located between the substrate and the at least one solar cell;
A second encapsulant located between the backplane and the at least one solar cell;
The solar cell module characterized by including the buffer material located between the said back plane and said 2nd sealing material.   The solar cell module according to claim 1, wherein the substrate is a glass substrate. The at least one solar cell has a bonding interface bonded to the second sealing material,
The cushioning material has a first interface bonded to the second sealing material and a second interface bonded to the backplane,
The solar cell module according to claim 1, wherein an adhesive force of the bonding interface is larger than an adhesive force of the first interface or the second interface.   The solar cell module according to claim 3, wherein the adhesive force of the first interface or the second interface is 25 n / cm or more.   2. The solar cell module according to claim 1, wherein the first sealing material or the second sealing material is selected from a polyolefin, an ionomer-based material, or a combination thereof.   The solar cell module according to claim 1, wherein the buffer material is selected from ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), silicone, or a combination thereof.   The solar cell module according to claim 1, wherein the second sealing material has a thickness of 150 to 300 μm.   2. The solar cell module according to claim 1, wherein a thickness of the buffer material is 150 to 300 μm. A step of installing a substrate;
Installing a backplane parallel to the substrate;
Between the substrate and the backplane, in order of the substrate, the first sealing material, at least one solar cell, the second sealing material, the buffer material, and the backplane so as to form a laminated structure Installing a first sealing material, the at least one solar cell, the second sealing material, and the buffer material;
And a step of pressing the laminated structure so as to form a solar cell module. Preparing a solar cell module including a substrate, a first sealing material, at least one solar cell, a second sealing material, a buffer material and a backplane;
Removing at least a portion of the backplane;
Removing at least a portion of the cushioning material;
Removing at least a portion of the second sealing material;
A step of installing another second sealing material at a location where the at least part of the second sealing material is removed;
Installing another cushioning material at a location where the at least part of the cushioning material is removed;
Installing another backplane at a location where the at least part of the backplane is removed so as to form a laminated structure;
A step of pressing the laminated structure so as to complete the rework of the solar cell module, and a method for reworking the solar cell module.   Between the step of removing the at least part of the second sealing material and the step of installing another second sealing material at the place where the at least part of the second sealing material is removed, The method of claim 10, comprising: removing the at least one solar cell; and installing another at least one solar cell at a location where the at least one solar cell has been removed. Rework method of solar cell module.

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