JPS58137265A - Method for manufacturing solar cell module - Google Patents

Abstract

PURPOSE:To arrange a photovoltaic element simply and accurately by bonding and fixing the element onto a transparent thermoplastic resin sheet through heat seal and enclosing the sheet into predetermined synthetic resin. CONSTITUTION:The transparent thermoplastic resin sheet 2 is set up onto a cover glass plate 1, and the photovoltaic elements 3 connected by lead wires 9 are disposed at accurate positions on the sheet so that light-receiving surfaces are directed to a glass surface. The temperature of the elements 3 is elevated by using a soldering iron 6, and one parts of the light-receiving surfaces are heat-sealed to the resin sheet 2. A thermoplastic resin sheet 2 and a synthetic sheet 5 are set up on the side reverse to the light-receiving surfaces of the elements 3, and pressed and heated. Accordingly, the photovoltaic elements 3 can simply be positioned accurately, and defective characteristics due to the movement of the elements can be removed completely.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a solar cell module.

Conventionally, solar cells have been mainly used as an independent power source for remote areas. Therefore, the output of solar cells was mostly in the tens of watts, and the output of most modules was less than ten watts.

However, recently, as the cost of solar cells has decreased, the range of applications has expanded significantly, and high-output solar cell systems have been constructed. Accordingly, the module output increases year by year, and 40 to 60 W solar cell modules are now the mainstay of products. These large modules are composed of 60 or more photovoltaic elements, and regularly arranging the elements such as strips requires
What are the important elemental technologies for module configuration? ing.

In order to prevent element movement, a spacer as shown in Figure 1-4 has been considered, and although some are on the verge of being put into practical use, the high cost of creating spacers leaves most workers unskilled. The reality is that it is being ignored. In FIG. 1, 1 is a cover glass plate, 2 is a transparent resin, 3 is a photovoltaic element, and 6 is a back cover plate.

In particular, during the process of integrating photovoltaic elements with transparent resin for filling, element movement occurs, resulting in contact and overlapping between elements, resulting in cracks in the elements and short-circuits between the elements, resulting in characteristics of the solar cell module. Defects occur frequently, and a method to solve them has been desired.

The present invention was made to solve these problems, and more specifically, by increasing the surface temperature of the photovoltaic element, the above element is made into a transparent thermoplastic resin sheet. This provides a method for thermally fusing and easily arranging elements accurately.

The invention will now be explained with reference to the illustrated embodiments.

A transparent thermoplastic resin sheet 2 cut to the same size as the glass plate, such as a sheet of polyvinyl butyral resin (PVB), vinyl acetate-ethylene copolymer resin (EVA), etc., is placed on the cover glass plate 1 shown in Figure 2. A photovoltaic element 3 connected in series or in series and parallel with a 1"'"-wire is placed thereon at an accurate position so that the light-receiving surface faces the glass surface. The temperature of the photovoltaic element 3 is raised using a soldering iron 6 from the opposite side 8 from the light-receiving surface 7 of the arranged photovoltaic element 3, and a part of the light-receiving surface is placed on a transparent thermoplastic resin sheet on the glass plate 1. 2. Heat fused. At this time, it is most desirable that the temperature of the light receiving surface of the element 3 be within the range of 100°C≦T≦120″C.5o″C≦T≦100°C
Although it is possible to heat-seal the element 3 to the thermoplastic resin sheet 2 in the temperature range of , it is not preferable in terms of work efficiency because heat-sealing takes time.

Note that when measured in a temperature range of 50"C or less, the thermoplastic resin sheet 2 and the element 3 are not thermally bonded, and it is impossible to fix the position of the element 3. Furthermore, the temperature of the light-receiving surface of the element 3 is 12
Heat fusion in the temperature range of 0°C<T≦200'C can be done in a short time, but on the other hand, the thermoplastic resin sheet 2 will change color slightly and the light transmittance will decrease. It is no longer preferable to perform heat fusion.

If heat fusion is performed in a temperature range where the temperature of the light-receiving surface of the element 3 exceeds 200''C, it is not preferable because the thermoplastic resin sheet 2 will undergo a thermal decomposition reaction.

For the above reasons, when fixing the element 3 and the thermoplastic resin sheet 2 by heat fusion, the temperature of the light-receiving surface of the element 3 is 6o''C≦
The temperature range is T≦200°C, and 1.00°C≦T≦
Most preferred is a temperature range of 12o'C. Note that 9 in FIG. 2 is a lead wire that connects the elements 5 in series.

After fixing the photovoltaic element 3 to the thermoplastic resin sheet 2 by heat-sealing 10, as shown in FIG. A resin sheet 2 and a synthetic resin sheet 6 cut to the same size as the thermoplastic resin sheet 2, such as a sheet 6 made of vinyl chloride or tetra, are sequentially placed on the resin sheet 2. The synthetic resin sheet 61, thermoplastic resin sheet 2, and photovoltaic power element 3 thus formed can be encapsulated.

The solar cell module according to the present invention formed by the above method has the following features: (1) Since the photovoltaic element is thermally fused to the thermoplastic resin sheet using a soldering iron or the like, the photovoltaic element can be formed very easily. It is now possible to fix it in a precise position.

(It) Element movement of photovoltaic force is completely eliminated, and defects in characteristics of the solar cell module due to contact between elements, overlapping of elements, etc. are completely eliminated.

@) Peeling of the lead wire from the element surface due to element movement has been completely eliminated.

(Foundation) It has become possible to fix the position of photovoltaic elements at a much lower cost than when using spacers, etc.0 (v) Other materials such as spacers and tape can be used to fix photovoltaic elements. It is no longer necessary to encapsulate the fixing member in resin, and there is no need to worry about deterioration or decomposition of the fixing member.

It has significant advantages such as

As explained above, according to the present invention, characteristic defects caused by element movement can be completely eliminated, and excellent solar cells with extremely few characteristic defects can be manufactured.

4. Explanation of the drawings Figure 1 is an exploded view showing a conventional solar cell module using spacers, Figure 2 is a side view of the thermal fusing process of solar cell elements using non-nandagote, and Figure 3 is an exploded view of a conventional solar cell module using spacers. 1 shows a completed sectional view of a solar cell module according to the invention.

2...Transparent is on thermoplastic resin sheet, 3@...
・Φ Solar cell element, 10...Fusion surface.

Claims (3)

[Claims] (1) A method for manufacturing a solar cell module, which comprises adhering and fixing a photovoltaic element to a transparent thermoplastic resin sheet by heat fusion, and then encapsulating it in a predetermined synthetic resin. (2) The method for manufacturing a solar cell module according to claim 1, wherein the thermoplastic resin sheet is made of polyvinyl butyral or vinyl acetate-ethylene copolymer. (3) The surface temperature of the photovoltaic element is 60°C≦T≦2
2. The method of manufacturing a solar cell module according to claim 1, wherein the photovoltaic element is thermocompression bonded to the thermoplastic resin sheet while maintaining the temperature in the range of 0.000°C.