JPH1197731A - Solar cell module and method of manufacturing the same - Google Patents

Abstract

(57) [Problem] To provide a solar cell module capable of preventing the sealing frame member on the back surface from peeling off without changing the configuration of the solar cell module. A width b of a back frame portion 122B of a sealing frame member 12 is made wider than a width a of a front frame portion 122A. As a result, the back side of the solar cell panel 11 and the sealing frame member 12
The contact area with the solar cell panel 11
On the back side of the solar cell panel 11 and the sealing frame member 12
Adhesive strength is enhanced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module and a method of manufacturing the same, and more particularly, to a solar cell module in which a peripheral portion of a solar cell panel is sealed by reactive injection molding or the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, along with the worsening of global environmental problems and energy depletion problems due to increased consumption of fossil fuels, etc., panel-shaped solar cell modules have been installed on roofs of houses and the like, and clean solar cells have been installed. 2. Description of the Related Art A residential photovoltaic power generation system that directly extracts power from energy and supplies the power to a home has attracted attention.

By the way, this type of solar cell module 5
Represents a large number of solar cells 51, 5 as shown in FIG.
, And EVA (ethylene vinyl acetate) 52 as a filling adhesive, a glass substrate 53 and a back cover case 5
Are sandwiched between the EVA 52 and the glass substrate 53 and the back cover case 54 by thermocompression bonding to form a laminated structure, so that the solar cells 51, 51,.
And a back cover case 54 to provide high insulation. However, in the solar cell module 5, moisture penetrates from the peripheral end of the stacked structure, and the solar cells 51 are degraded.

Accordingly, for example, as disclosed in Japanese Patent Application No. Hei 8-22578, a sealing member is formed at the peripheral end of the solar cell module body by injection molding using a polymer composition. I do. Thereby, the peripheral end of the solar cell module main body can be reliably sealed, and the invasion of moisture can be prevented.

[0005]

However, the prior art described in the above publication has the following problems. That is, in the solar cell module, a resin film is used as the cover case 54 on the back side of the solar cell module. However, since the adhesive force between the resin film and the sealing member is weak, there is a problem that the sealing member on the back surface side of the solar cell module is easily peeled.

[0006] Further, when pressure is applied to the sealing member at the time of attachment to the roof, there is a problem that the sealing member on the back surface side of the solar cell module may be peeled off.

The present invention has been made in view of the above circumstances, and does not require a change in the configuration or the like of the solar cell module, and prevents the sealing frame member on the back surface from peeling off. It is intended to provide.

[0008]

Means for Solving the Problems To solve the above problems, the invention according to claim 1 has at least a front transparent protective plate, a photoelectric conversion layer constituting a solar cell, and a back cover material, and A solar cell panel formed by laminating the front transparent protective plate, the photoelectric conversion layer, and the back cover material in this order from the front side that receives sunlight, and a function of sealing a peripheral portion of the solar cell panel. A solar cell module comprising a polymer sealing frame member provided with the solar cell module, wherein the sealing frame member closes a periphery of a front side of the solar cell panel; It is characterized in that it comprises a back frame portion closing around the peripheral edge portion on the back surface side of the panel, and the back frame portion is set wider than the width of the front frame portion.

According to a second aspect of the present invention, there is provided the solar cell module according to the first aspect, wherein the back frame portion is set to be at least twice as wide as the width of the front frame portion. Features.

The invention according to claim 3 relates to a method for manufacturing the solar cell module according to claim 1 or 2,
A surface pattern having an inner surface shape substantially corresponding to the outer shape on the front surface side of the solar cell module, and a surface pattern for forming the surface frame portion around a peripheral portion on the front surface side of the solar cell panel, and a back surface of the solar cell module In the mold having an inner surface shape substantially corresponding to the outer shape of the side, and a mold configured by combining a back mold for forming the back frame portion around the periphery of the back surface side of the solar cell panel, After the solar cell panel is positioned and housed in a mode in which a cavity is formed around the periphery thereof, an organic composition is injected into the cavity and shaped and solidified, so that the sealing frame member is formed of the solar cell panel. It is characterized in that it is formed and mounted on the peripheral portion of the.

[0011]

According to the structure of the present invention, the width of the back frame portion of the sealing frame member is set wider than the width of the front frame portion. By increasing the contact area, the adhesive force of the sealing frame member can be enhanced. As a result, the sealing frame member can be prevented from peeling off on the back surface side of the solar cell module.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view schematically illustrating the configuration of a solar cell module according to an embodiment of the present invention, FIG. 2 is a cross-sectional view illustrating the configuration of a solar cell panel that is the main body of the solar cell module, and FIG. FIG. 4 is a cross-sectional view illustrating a schematic configuration of an injection molding apparatus for manufacturing a solar cell module, FIG. 4 is a cross-sectional view illustrating a cross-sectional shape of a mold used in the injection molding apparatus, and FIG. FIG. 6 is an explanatory diagram for explaining a process for manufacturing the used solar cell module, and FIG. 6 is an explanatory diagram for explaining a shape of a sealing frame member for sealing the solar cell module body.
As shown in FIG. 1, the solar cell module 1 was attached so as to surround a solar cell panel (solar cell module main body) 11 and a peripheral end of the solar cell panel 11.
For example, a sealing frame member 12 made of urethane resin is provided.

As shown in FIG. 2, the solar cell panel 11 includes a large number of single-crystal silicon solar cells (pn junction elements).
After wiring 111, 111,... In series / parallel, a transparent support substrate 112 such as a white plate reinforced glass having excellent light transmittance and impact strength so as to withstand outdoor exposure for a long time;
Packaging (sealing) in a layer configuration with a filler 113 such as EVA (ethylene vinyl acetate) having excellent moisture resistance and a metal sheet 114 coated on both sides with PVF (vinyl fluoride resin) having excellent insulating properties. It is formed.

The sealing frame member 12 is formed along the periphery of the solar cell module 1. On the upper surface and the lower surface of the sealing frame member 12, two pairs of convex portions 1 each having
Are formed in an annular shape over the entire circumference. The convex portions 121, 121,...
It is for waterproofing when installing.

The solar cell module 1 having the above structure is shown in FIG.
Is manufactured by the injection molding apparatus 2 shown in FIG. As shown in the figure, this injection molding apparatus 2 mixes two kinds of liquid agents in a predetermined portion of a mold 21 for integrally molding the sealing frame member 12 with the solar cell panel 11. A mixing head 22 for feeding to the mold 21 is connected, and a liquid material pressure feeding unit 23 for injecting the two types of liquid materials is provided in front of the mixing head 22.

The mold 21 is, as shown in FIG.
1 and a back mold 212. Table type 211 is
It is made of, for example, structural carbon steel for forming the substantially upper half of the sealing frame member 12, and the back mold 212 is for forming the substantially lower half of the sealing frame member 12. Table type 21
It is made of the same material as that of No. 1, that is, made of structural carbon steel. On the inner surface of the front mold 211, a convex portion 211A is provided.
2 has a convex portion 212 smaller than the convex portion 211A.
A is provided. The opening faces of the front mold 211 and the back mold 212 are used so as to be in contact with each other at their peripheral ends.

The mold 21 combined with the solar cell panel 11 housed therein has a cavity 213 for molding the sealing frame member 12 therein, and the solar cell panel 11 Are provided with a pair of substantially rectangular sandwiching surfaces 214 and 215 which sandwich the shutter from above and below.
The holding surface 214 is the lower surface of the convex portion 211A, and the holding surface 21
5 is the upper surface of the convex portion 212A. When the solar cell panel 11 is stored in the mold 21, the holding surface 214 is in close contact with the surface of the solar cell panel 11, and the holding surface 215 is in close contact with the back surface of the solar cell panel 11. Thereby, the solar cell panel 11 is positioned in the mold 21.

A gate 21a is provided at a predetermined portion of the front mold 211 to which the mixing head 22 is connected. Further, the surface mold 21 corresponding to the cavity 213 is formed.
1 and the back mold 212 have annular concave grooves 213a, 213a,.
Is provided.

The injection molding apparatus 2 uses such a mold 21. The mixing head 22 of the injection molding device 2
For example, a main agent 12a such as a polyol and a sub-agent (curing agent) 12b such as an isocyanate compound, which are raw materials of a urethane resin which is a material of the sealing frame member 12, respectively, flow out of the liquid agent pumping unit 23. Then, the mixture is mixed in the mixing head 22 and supplied from the gate 21 a to the cavity 213.

The urethane resin (polyurethane) of this example
Is a two-component mixed-curing type resin, which can be cured at room temperature by blending the above main agent 12a and main agent 12b. As the isocyanate compound, MDI (diphenylmethane-4,4′-diisocyanate), TD
I (tolylene diisocyanate) and the like, and polyols such as polyester and polyether are used.

The liquid agent pumping unit 23 is a device for pumping the main agent 12a and the main agent 12b to the mixing head 22, respectively. As shown in FIG. 3, a main agent storage tank 231 for storing the main agent 12a and a main agent 12b are provided. A main agent storage tank 232 to be stored, a main agent pumping pipe 233 serving as a path for sending the main agent 12a to the mixing head 22, and a main agent 12b
A main agent pumping tube 234 for pumping the main agent 12a, and a main agent pump 236 for pumping the main agent 12b are provided.

In order to manufacture the solar cell module 1 using the injection molding apparatus 2 having the above structure, first, as shown in FIG. The holding surface 214 of the front mold 211 of the mold 21 and the back mold 2
12 so as to be in contact with the holding surface 215. At this time, the lower surface of the front mold 211 and the upper surface of the back mold 212 are combined in a state where they are in contact at their respective peripheral ends. The mold 21 is clamped by a mold clamping mechanism (not shown) so as not to come off or shift due to the pressure at the time of injection.

Next, in the main agent storage tank 231 and the main agent storage tank 232 of the liquid agent pressure feeding unit 23, respectively, the main agent 1 is stored.
2a and the base material 12b are introduced. Then, as shown in FIG. 3B, the main agent pump 235 and the main agent pump 236 are simultaneously started via a control device (not shown), and the main agent 12a and the main agent 12b are simultaneously driven at a predetermined pressure, respectively. The pressure is fed to the mixing head 22. The main agent 12a and the main agent 12b sent to the mixing head 22 are mixed in the mixing head 22 and injected into the cavity 213 from the gate 21a.

The above-mentioned mixture enters all the fine parts of the cavity part 213, and as shown in FIG.
When the inside of the cavity portion 213 is completely filled, the main agent pumping tube 233 and the main agent pumping tube 23 of the liquid agent pumping unit 23 are provided.
The valve (not shown) attached to 4 is closed, and the main agent pump 235 and the main agent pump 236 are stopped. Since the mixture cures at room temperature as it is, the mold clamping mechanism is released and the mold 21 is disassembled without heat treatment, and the sealing frame member 12 is molded integrally with the solar cell panel 11. The battery module 1 can be taken out. In addition, heating can also be performed to shorten the curing time.

The sealing frame member 12 of the solar cell module 1 manufactured as described above has a frame-shaped front frame portion 12.
2A and a back frame portion 122B. As shown in FIG. 6, the width b of the back frame portion 122B on the back surface side of the solar cell panel 11 is wider than the width a of the front frame portion 122A on the front surface side of the solar cell panel 11.

Note that sunlight enters the area surrounded by the front frame portion 122A. As described above, the back frame portion 122
Since the width b of B is increased, the contact area between the sealing frame member 12 and the back surface of the solar cell panel 11 increases, and the adhesive strength between the sealing frame member 12 and the solar cell panel 11 can be enhanced. it can. This situation is shown in the following table.

[0027]

[Table 1]

As is apparent from this table, the width (width on the transparent plate side) a of the front frame portion 122A and the width (width on the back material side) b of the back frame portion 122B of the sealing frame member 12 are the same. Assuming that the adhesive force of the comparative example 100 is 100, the adhesive force is 110 to 125 when the width b of the back frame portion 122B is 1.5a, and the adhesive force is 120 when the width b of the back frame portion 122B is 2a. ~ 125. Further, when the width b of the back frame portion 122B is set to 2.5a, the adhesive strength becomes 130 to 170, and the adhesive strength is greatly enhanced.

In order to attach the solar cell module 1 manufactured in this manner to, for example, a roof unit 3 of a unit building, as shown in FIGS. 3, a mounting frame member 4 for fixing to the roof surface is used. In this example, as shown in FIG. 7, two solar cell modules 1, 1 are mounted on a roof surface. As shown in FIG. 8, the roof surfaces to which the solar cell modules 1 and 1 are attached have rafters 31 and 31,
A base plate 32 such as a structural plywood or a particle board is disposed on the upper surface of the..., And a waterproof sheet 33 such as asphalt roofing is laid on the base plate 32.

As shown in FIGS. 7 and 8, the mounting member includes an upper frame 41a and a lower frame 41b for supporting and fixing the two solar cell modules 1, 1, and two solar cells arranged side by side. An upper frame 42a, 42a and a lower frame 42b, 42b for supporting and fixing a peripheral end of the module 1, 1 in the flow direction, and a periphery in a direction orthogonal to the flow direction of the two solar cell modules 1, 1 arranged. Upper frames 43a, 4 supporting and fixing the ends
3a and lower frames 43b, 43b. Here, the lower frames 41b, 42b, 42b, 43b, 43b
Are fixed to the roof unit 3 side and support the lower side of the solar cell module 1, while the upper frames 41a, 42a, 42
a, 43a, and 43a press and fix the solar cell module 1 from above.

First, the lower frames 41b, 42b, 42b, 43
The b and 43b are placed on the waterproof sheet 33 of the roof unit 3 as shown in FIG. 7, and are fixed at predetermined positions by wood screws 4a, 4a,. As shown in FIG. 8, the wood screws 4a, 4a,... Are screwed down to the tree 31 that passes through the base plate 32, and the lower frames 41b, 42b, 42b, 43b, 43b.
Is firmly fixed. Next, the lower frames 41b, 42b, 42
b, 43b, the solar cell module 1, 1
Are mounted, and the upper frames 41a, 42a, 42a, 43a,
43a are respectively arranged.

Then, as shown in FIG.
b, ... are upper frames 41a, 42a, 42a, 43a, 43a.
And screwed into a female screw portion (not shown) provided at a location corresponding to the insertion hole of the lower frame 41b, 42b, 42b, 43b, 43b. Upper frames 41a, 42a, 42a, 43
a, 43a are fixed, and the solar cell modules 1, 1 are tightened from above and below to support and fix. At this time, the solar cell modules 1 and 1 have the convex portions 121 and 12
In order to have 1, ..., it can be securely and uniformly tightened.

According to the above configuration, the front mold 211 and the back mold 21
The solar cell panel 11 is housed in a mold obtained by combining the solar cell panel 2 and the curable mixed composition into a cavity 213 formed around the peripheral end of the solar cell panel 11 and solidified. Since the solar cell module 1 is manufactured by molding the curable mixed composition into all the fine concave portions of the cavity portion 213, and after the solidification molding, the solar cell panel 11 and the sealing frame member 12 are formed. When the curable mixed composition penetrates into the fine recessed portions and solidifies, the anchoring effect makes it difficult to separate the sealing frame member 12 from the solar cell panel 11.

Further, by mixing the main component 12a and the main component 12b with the mixing head 22, a two-part mixture-curing type composition is produced, and when the produced composition is poured into the cavity portion 213, the composition becomes , Curing without heating, there is no need to provide a heating device,
Since the time required for the heating step can be saved, the solar cell module 1 can be manufactured more efficiently.

Further, annular concave grooves 213a and 213 are formed in the front mold 211 and the back mold 212 corresponding to the cavity 213.
are provided, the molded sealing frame member 12 of the solar cell module 1 has convex portions 121, 121,... on the front surface and the back surface of the peripheral end portion. When tightening from the outside and fixing it, force is applied evenly,
In addition to being securely fixed, the adhesion between the solar cell panel 1 and the sealing frame member 12 can be enhanced.

On the back surface of the solar cell panel 11, the width b of the back frame portion 122 B of the sealing frame member 12 is set to the width of the front frame portion 1.
The solar cell panel 1 is wider than the width a of 22A.
1 to increase the contact area between the back surface and the sealing frame member 12,
The adhesive strength between the sealing frame member 12 and the solar cell panel 11 is enhanced. This can prevent the sealing frame member 12 from peeling off from the solar cell panel 11. As a result, even when pressure is applied to the sealing frame member 12 during construction, the sealing frame member 12 can be prevented from peeling off. And since the solar cell module 1 is kept waterproof,
Power generation performance during construction can be maintained forever.
Furthermore, since only the width of the back frame portion 122B of the sealing frame member 12 is increased, the injection molding device 2 and the mold 21 need not be changed drastically, and the sealing frame member 12 can be removed. Can be prevented.

Although the embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and the design may be changed without departing from the scope of the present invention. Is also included in the present invention. For example, in the above embodiment, a urethane resin is used as the two-pack type resin, but an epoxy resin may be used. Further, the two-liquid type may not be used. For example, a polyolefin-based composition such as polyethylene or polypropylene may be integrally formed by injection molding. In addition, for example, polycarbonate,
Polyamide, polyacetal, polyethylene terephthalate, chlorinated polyethylene, polystyrene, polyesteramide, polyphenylene sulfide, polyetherester, polyvinyl chloride, polymethacrylate,
Heat of polyacrylate, polymethyl methacrylate, fluororesin, sulfone resin, ethylene-vinyl acetate copolymer, vinyl chloride-vinylidene chloride copolymer, polyvinyl butyral, polyvinylidene fluoride, styrene-acryl copolymer, etc. A plastic may be used.

Further, a thermosetting plastic such as a urea resin, a melia resin, or a melamine / phenol resin may be used, a metal-containing plastic, a reinforced plastic compounded with glass fiber, or the like. Further, synthetic rubber such as EPDM (ethylene-propylene-diene-terpolymer) may be used. The metal used for the mold may be chromium molybdenum steel, carbon tool steel, or the like, in addition to the structural carbon steel. Furthermore, the solar cell incorporated in the solar cell module is not limited to a single-crystal silicon solar cell, but may be a polycrystalline silicon solar cell or an amorphous silicon solar cell.
A microcrystalline silicon solar cell, a compound semiconductor solar cell, or an organic semiconductor solar cell may be used.

In the above-described embodiment, a laminate of a transparent glass substrate, a filling adhesive such as an EVA film, a silicon solar cell, a filling adhesive such as an EVA film, and a back protective cover material such as a resin-coated metal sheet. Although the case of using a solar cell panel composed of is described, but is not limited thereto, a transparent glass substrate-a photoelectric conversion layer constituting a solar cell-laminated in the order of the back surface protective cover material, and,
A solar cell panel in which the photoelectric conversion layer is formed directly on the transparent glass substrate or the rear surface protective cover material as a substrate may be used.

As a molding means, in addition to injection molding, for example, a solar cell panel is installed upside down, and a two-part mixed-curing type composition is poured by gravity into a sink mold disposed on the upper surface thereof. It may be possible to use a casting method for solidification.

[0041]

As described above, according to the structure of the present invention, the width of the back frame portion of the sealing frame member is set wider than the width of the front frame portion. Thus, the contact area of the sealing frame member can be increased to enhance the adhesive force of the sealing frame member. As a result, the sealing frame member can be prevented from peeling off on the back surface side of the solar cell module.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view schematically showing a configuration of a solar cell module according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a configuration of the solar cell panel.

FIG. 3 is a cross-sectional view illustrating a schematic configuration of an injection molding apparatus for manufacturing the solar cell module.

FIG. 4 is a sectional view showing a sectional shape of a mold used in the injection molding apparatus.

FIG. 5 is a process explanatory view for explaining the production of a solar cell module using the injection molding apparatus.

FIG. 6 is an explanatory diagram for explaining a shape of a sealing frame member that seals the solar cell panel.

FIG. 7 is a plan view showing a state where the solar cell module is mounted on a roof surface.

8 is an enlarged sectional view taken along line AA of FIG. 7;

FIG. 9 is an explanatory diagram for explaining a conventional technique.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Solar cell module 11 Solar cell panel 12 Sealable frame member 121 Convex part 121A Front frame part 121B Back frame part

Claims (3)

[Claims] At least a front transparent protective plate, a photoelectric conversion layer constituting a solar cell, and a back cover material, and
A solar cell panel formed by stacking the front transparent protective plate, the photoelectric conversion layer, and the back cover material in this order from the front surface side that receives sunlight, and a function of sealing a peripheral portion of the solar cell panel. A solar cell module comprising a polymer sealing frame member provided, wherein the sealing frame member covers a periphery of a front side of the solar cell panel, A solar cell module, comprising: a back frame portion closing around a peripheral portion on the back surface side of the battery panel; and wherein the back frame portion is set wider than the width of the front frame portion. 2. The solar cell module according to claim 1, wherein the back frame portion is set to be at least twice as wide as the width of the front frame portion. 3. The method for manufacturing a solar cell module according to claim 1, wherein the solar cell module has an inner surface shape substantially corresponding to an outer shape on a front surface side of the solar cell module, A front mold for forming the front frame portion around a peripheral portion, and an inner surface shape substantially corresponding to an outer shape of the back surface side of the solar cell module; and the back surface around the back surface side peripheral portion of the solar cell panel. After the solar cell panel is positioned and housed in a form that forms a cavity around the periphery thereof in a mold configured by combining with a back mold for forming a frame portion, an organic A method of manufacturing a solar cell module, comprising: injecting and shaping and solidifying a composition to form and mount the sealing frame member on a peripheral portion of the solar cell panel.