JP3564889B2 - Roll type manufacturing method and manufacturing apparatus for solar cell module - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for manufacturing a roll-type solar cell module for sealing a flexible solar cell unit between two long sealing films.
[0002]
[Prior art]
A solar cell module in which a solar cell unit in which a photoelectric conversion element is formed on a flexible base film is sealed between two long sealing films has high mass productivity and low cost, and is easy to construct. However, it is flexible and can be installed on curved surfaces, so it has high design. 6A and 6B show a part of one example of the solar cell module, FIG. 6A is a plan view, and FIG. 6B is a cross-sectional view along XX in FIG. In the solar cell unit 1u, a solar cell element including an electrode layer 1a, a photoelectric conversion layer 1p, and an electrode layer 1b is formed on one flexible base film 1s. Usually, a plurality of solar cell elements are connected, but for simplicity, they are provided as one element. The electrodes for power extraction are the electrodes 1e at both ends of the solar cell unit. In this example, the extraction electrode is on the opposite side (back surface) of the film from the solar cell element, and the effective area of the solar cell element is large. It is also possible to use a solar cell unit in which an electrode for taking out power is on the surface on the solar cell element side. In order to extract higher voltage or electric power, the solar cell module M connects a large number of the solar cell units by the main wiring 2 and the auxiliary wiring 3, and sandwiches and seals the long sealing films 41 and 42 to increase weather resistance. It is a thing. Further, protective films 51 and 52 are provided to prevent moisture from entering the solar cell element, to block ultraviolet rays from entering the solar cell element, and to prevent damage during installation work. In some cases, no protective film is used.
[0003]
In such a flexible and long solar cell module manufacturing method, the components of the solar cell module are supplied in a state of being wound on a roll, and supply and connection of a wiring member, adhesion of a sealing film and a protective film, A roll-to-roll system in which sealing and the like are continuously performed and the solar cell module is wound around a roll at the end, or a stepping roll system in which these are temporarily stopped are adopted. Hereinafter, these are collectively referred to as a roll system.
[0004]
As a sealing film, an ethylene vinyl acetate (hereinafter, abbreviated to EVA) film having good thermal adhesiveness and high weather resistance is widely used. EVA is a thermoplastic and hot-melt adhesive resin, and its thermophysical properties are as follows. The softening temperature is 60-80 ° C. Between 60 and 150 ° C., the viscosity gradually increases but does not change significantly. If a cross-linking agent is added to EVA, a cross-linking reaction occurs at 120 ° C. or higher, and the EVA is thermally stabilized. On the other hand, in the fusing property of EVA, under a constant pressure, the fusing force increases with an increase in temperature and with time. Therefore, when performing thermocompression bonding and cross-linking continuously, 60 to 120 ° C. is suitable as the thermocompression bonding condition of EVA. Suitable crosslinking conditions are 140 to 150 ° C. and 10 to 15 minutes in order to sufficiently promote gelation of EVA.
[0005]
In the roll method, it is necessary to feed the EVA film wound on the roll at a constant speed while controlling the tension so as not to cause deflection or dimensional change. As one method therefor, there is known a method in which an EVA film is temporarily fixed to a support film having releasability (or small adhesiveness) and transported only during a manufacturing process (hereinafter, referred to as a support transport method). As a result, the generation of wrinkles and bubbles during the compression bonding between the EVA film or the EVA film and the protective film can be considerably suppressed.
[0006]
FIG. 7 is a schematic view of a conventional supporting and transporting type solar cell module manufacturing apparatus. The first sealing film 41 and the first support film 61 sent out from the rolls 41i and 61i, respectively, are thermocompression-bonded by the rolls 10 to form the base film 81 (Step 1). The main wiring 2 sent from the roll 2i is supplied to the first sealing film 41 (Step 2), and the solar cell unit 1u is supplied in a single-wafer manner and arranged at a predetermined position (Step 3). Further, the auxiliary wiring 3 is supplied and arranged at a predetermined position (step 4). Then, the second sealing film 42 and the base film 82 of the second support film 62 (by the same process as the process 1) which are respectively sent from the rolls 42i and the rolls 62i are covered, and are thermocompression-bonded by the rolls 13. (Step 5). Each of the stacked films is degassed and heated in the heating device 14 to be sealed (step 5). After the roll 15, the first and second support films 61 and 62 are peeled off and wound on rolls 61e and 62e, respectively. The remaining solar cell module M is wound up by a roll Me (Step 7), and the manufacturing process ends.
[0007]
In some cases, the support film is also used by the protective film, and in this case, the protective film is not peeled off. Steps 2 to 4 may be performed in a different order.
[0008]
[Problems to be solved by the invention]
However, since EVA has the above-mentioned physical properties, in the support transport method, the surfaces of the releasable support film and the sealing film that are not in contact with each other are adhered to the pressure rolls or transport rolls of the manufacturing apparatus. Or sticking to a sealing film to be supplied next time, and there has been a problem that conveyance becomes unstable. In particular, when the sealing film is extremely smooth, the adhesiveness is high and transport failure is likely to occur. Even if the sealing film is previously provided with irregularities by embossing or matting to prevent this, the irregularities are crushed during thermocompression bonding with the support film, and the same problem occurs in the subsequent steps.
[0009]
An object of the present invention is to provide a roll-type solar cell module in which a sealing film or a supporting film does not adhere to a roll or a sealing film supplied next, and the transport of these films is performed smoothly and stably. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus.
[0010]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, a plurality of solar cell units each having a photoelectric conversion element formed on a flexible base film, and two wiring members for connecting the units, are provided with two long heat-adhesive members. In order to manufacture a solar cell module that is sandwiched and sealed between insulating sealing films, a base film obtained by thermally bonding the sealing film and the releasable supporting film is transported by a roll, In the method for manufacturing a solar cell module for supplying, bonding, and sealing, the surface of the sealing film is subjected to uneven processing during thermal bonding between the sealing film and the releasable support film, and the supply of the member is performed . Adhesion and sealing will be performed.
[0011]
The concavo-convex processing on the sealing film is performed by continuously pressing the concavities and convexities of the mold member while pressing or heating and pressing a mold member with a releasable surface subjected to concavo-convex processing on the sealing film. It is good to transfer to the surface.
The mold member is preferably a roll or a film.
The unevenness of the mold member is preferably formed by embossing, matting or chemical etching.
[0012]
The sealing film is preferably made of ethylene vinyl acetate. The mold member film is preferably a fluorine-based resin coating film, a silicone-based resin coating film, a surface-treated polyethylene-based resin film, a polyolefin-based resin film, a metal foil, or paper.
In addition, a plurality of solar cell units each having a photoelectric conversion element formed on a flexible base film, together with wiring members for connecting the units, are formed into two long heat-bonding and insulating sealing films. In order to manufacture a solar cell module that is sandwiched and sealed, the supply, adhesion, and sealing of the members are performed while a base film in which the sealing film and the releasable support film are thermally bonded is transported by a roll. In the method of manufacturing a solar cell module to be performed, a means for subjecting the surface of the sealing film to irregularity processing at a heat bonding portion between the sealing film and the releasable support film is provided.
[0013]
The means for performing the unevenness processing on the surface of the sealing film includes a releasable mold member film having an unevenness formed on the surface, a supply roll for the mold member film, and heat for sandwiching the mold member film and the base film. It is preferable that the mold member film be formed of a pressing roll and that the uneven surface of the mold member film face the sealing film.
The means for applying the unevenness to the surface of the sealing film includes a thermocompression bonding roll that sandwiches the sealing base film, and at least a roll of the thermocompression bonding roll facing the sealing film has a surface provided with an unevenness. It is good to be a member roll.
[0014]
It is preferable that the surface of the roll that comes into contact with the sealing film is made of a fluorine-based resin and has a releasability from the sealing film.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is a schematic view showing a roll-type manufacturing method of a supporting and transporting method of a solar cell module according to an embodiment of the present invention. Except that the conventional process 1 is a new process 1 according to the present invention, it is the same as the conventional roll-type manufacturing method of the supporting and transporting method. Therefore, only the new process 1 that replaces the conventional process 1 will be described.
[0016]
In the new step 1, after the first sealing film 41 and the first support film 61 are supplied, the unevenness processing means 100 on the newly provided first sealing film 41 is used to form the sealing film 41. At least the surface on the side where the solar cell unit 1u is arranged (the side opposite to the surface facing the first support film 61) is an uneven surface. Similarly, at least the surface of the second sealing film 42 that faces the solar cell unit 1 u is also made to be an uneven surface by the unevenness adding means 100.
[0017]
A protective film can also be used as a support film.
First, the unevenness adding means according to the present invention is characterized in that, when the unevenness surface of the mold film which has been subjected to the unevenness processing in advance is opposed to the sealing film and thermocompression-bonded by a thermocompression roll sandwiching both films, the unevenness is simultaneously performed. The transfer is, secondly, the transfer of unevenness by passing between at least two pressure-bonding rolls whose surfaces of the thermocompression-bonding roll facing the sealing film have been subjected to unevenness processing.
[0018]
A support film having irregularities on the surface on the sealing film side may be used.
Embossing, matting, or chemical etching can be applied to the unevenness of the support film and the pressure roll. Alternatively, the concavities and convexities may be separately transferred to a support film or a protective film by a roll whose surface is separately concavo-convex processed.
[0019]
The thermocompression bonding condition between the support film and the sealing film is set to 120 ° C. or less in the case of EVA so that the crosslinking agent in the sealing film is not consumed.
2A and 2B are cross-sectional views of the base film after a new process 1 according to the present invention taken along the line AA in FIG. 1, wherein FIG. 2A shows a case where the first support film has a smooth surface, and FIG. This is the case of an uneven surface. Reference F is an uneven surface.
[0020]
As described above, there are two types of uneven transfer methods, and different transfer methods may be applied to two sealing films.
The releasable support film and mold film have an appropriate adhesiveness and releasability with respect to the sealing film, and have no adhesiveness with respect to a pressure-bonding or thermocompression-bonding roll. It is preferable to use a film of a material having high moldability), and the following films can be used. Fluorine resin coating film, silicone resin coating film, surface-treated polyethylene resin film, polyolefin resin film, metal foil or paper.
[0021]
The protective film is used to prevent moisture from entering the solar cell element, block ultraviolet rays, protect the solar cell module from external forces during storage, transportation, and construction, prevent contamination of the light incident surface, and prevent electric shock during construction. From the viewpoint, a fluorine-based resin film such as polyvinyl fluoride (PVF), tetrafluoroethylene perfluoroalkylvinyl ether copolymer resin (PFA), a fluorine-based resin, silicone, a polyethylene-based resin or a polyolefin coated with SiO ₂ It is preferable to use a resin film.
[0022]
The new step 1 can be performed independently of the subsequent steps. In this case, the base film is once wound up by a roll and used as a supply roll in the next step.
Example 1
FIG. 3 is a schematic cross-sectional view of a roll-type manufacturing apparatus for supporting and transporting a solar cell module according to the present invention. Starting with the supply of the first sealing film, the first release support film, the supply of the solar cell unit, the wiring material, the second sealing film, the supply of the second release support film, and the sealing. The basic mode from the stopping step to the winding of the solar cell module is the same as that of the conventional roll-type manufacturing apparatus of the supporting and transporting method, and the description thereof will be omitted, and only the points related to the invention will be described.
[0023]
Between the roll 10 to which the first sealing film 41 and the first support film 61 are thermocompression-bonded, a releasable first mold film 71 is newly fed, and the film configuration is the first support film 61. , The first sealing film 41 and the first mold film 71. The surface of the first mold film 71 facing the sealing film 41 is subjected to unevenness processing. The first mold film 71 is fed from a roll 71i, is thermocompression-bonded by a roll 10, is peeled immediately after passing, and is wound up by a roll 71e. When thermocompression bonding is performed, the irregularities of the first mold film 71 are transferred to the first sealing film 41.
[0024]
Similarly, when supplying the second sealing film 42, the irregularities are transferred to the second sealing film 42 by using the second mold film 72 having the same irregularities as the first mold film 71. The second mold film 72 is sent out from a roll 72i and wound up on a roll 72e.
The mold film may be connected to both ends in the transport direction to form an endless film, and the rolls 71i, 71e, etc. are replaced with a tension adjusting roll or a transport roll.
[0025]
Since the sealing film 41 does not directly contact the roll 10 due to the presence of the first mold film 71, the sealing film 41 does not adhere to the roll 101. In addition, since the sealing film 41 has the transferred irregularities, the subsequent mounting of the solar cell unit and the wiring material does not cause bubbles to occur therebetween, and does not adhere to the subsequent rolls 11 and 12, Stable transport is now possible.
[0026]
Further, since the concave and convex surfaces of the first sealing film 41 and the second sealing film 42 face each other, the space between the two films is continuous, and the gas generated from the film or the gas remaining between the two films remains. The air that had flowed through this space could easily escape from the end of the sealing film to the outside, and degassing by decompression was performed quickly.
Example 2
FIG. 4 is a schematic cross-sectional view illustrating a roll-type manufacturing method of a solar cell module according to another embodiment of the present invention. In this example, instead of the mold film, a thermocompression roll 101 having a surface made of a releasable fluororesin and further having irregularities on the surface was used as the mold member. When the first sealing film 41 and the first supporting film 61 pass between the thermocompression bonding rolls 101, the surface irregularities of the thermocompression bonding roll 101 are transferred to the first sealing film 41 simultaneously with the thermocompression bonding. .
[0027]
The operation is the same as that of the first embodiment, and the same effect is obtained.
Example 3
FIG. 5 is a schematic sectional view showing a roll-type manufacturing method of a solar cell module according to another embodiment of the present invention. In this example, the protective film 52 was used as the second support film of the releasing property in Example 1. In this case, since the protective film is a constituent material of the solar cell module, the step of removing the mold film is unnecessary.
[0028]
The same effect as in Example 1 was obtained.
In addition to the above, different concavity and convexity adding means may be applied to the two sealing films, and the effect is the same as that of the first embodiment.
[0029]
【The invention's effect】
According to the present invention, a plurality of solar cell units each having a photoelectric conversion element formed on a flexible base film and two long heat-adhesive and insulating members together with a wiring member connecting the units are provided. In order to manufacture a solar cell module that is sandwiched and sealed in a sealing film, the supply and bonding of the members are performed while a base film in which the sealing film and the release support film are thermally bonded is transported by a roll. In the method for manufacturing a solar cell module for performing sealing and sealing, after performing unevenness processing on the surface of the sealing film, the supply, adhesion, and sealing of the member were performed. Due to the irregularities, no air bubbles will be generated between the solar cell unit and the wiring material after mounting, and there will be no sticking to the subsequent transport or thermocompression roll. , Will be able to stable conveyance, process monitoring, etc. is not required. In addition, since the concave and convex surfaces of the two sealing films face each other, the space between the two films is continuous, and the gas generated from the films or the air remaining between the films easily passes through this space. As a result, it was possible to diverge from the end of the sealing film to the outside, and degassing by decompression was performed quickly. Therefore, there is no variation in the sealing of the solar cell module, and the reliability is improved.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a roll-type manufacturing method of a supporting and transporting method of a solar cell module according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the base film after a new process 1 according to the present invention taken along the line AA in FIG. (A) when the first support film has a smooth surface, and (b) when the first support film has an uneven surface. [FIG. 3] The roll of the solar cell module according to the present invention for supporting and transporting it. FIG. 4 is a schematic cross-sectional view showing a roll-type manufacturing method for a solar cell module according to another embodiment of the present invention. FIG. 5 is a schematic cross-sectional view showing a solar cell module according to another embodiment of the present invention. FIG. 6 shows a part of an example of a solar cell module, in which (a) is a plan view, (b) is a XX cross-sectional view in (a), and FIG. Schematic diagram of the manufacturing method of the solar cell module of the transport method [ Description of the issue]
1s Base film 1a First electrode 1b Second electrode 1p Photoelectric conversion layer 1e Back electrode 1u Solar cell unit 2 Main wiring 3 Auxiliary wiring 41 First sealing film 42 Second sealing film 51 First protective film 52 second protective film 61 first support film 62 second support film 8 base film 71 first mold film 72 second mold film 2i delivery roll 41i delivery roll 52i delivery roll 61i delivery roll 62i delivery roll 71i delivery Roll 72i Send-out roll 61e Take-up roll 62e Take-up roll 71e Take-up roll 72e Take-up roll M Solar cell module Me Take-up roll 10 Thermocompression roll 11 Thermocompression roll 12 Thermocompression roll 13 Thermocompression roll 14 Thermocompression roll 15 Roll 01 uneven surface roll 16 linking reaction device 100 uneven application device F uneven surface

Claims (10)

A plurality of solar cell units each having a photoelectric conversion element formed on a flexible base film, together with a wiring member for connecting the units, are sandwiched between two long heat-bonding and insulating sealing films. In order to manufacture a stopped solar cell module, the supply, adhesion and sealing of the members are performed while a base film in which the sealing film and the releasable support film are thermally bonded is transported by a roll. In the method for manufacturing a battery module, the surface of the sealing film is subjected to unevenness processing during thermal bonding between the sealing film and the releasable support film, and supply, adhesion, and sealing of the member are performed. Roll-type manufacturing method for a solar cell module. The concavo-convex processing on the sealing film is performed by continuously pressing the concavities and convexities of the mold member on the sealing film while pressing or heating and pressing the releasable mold member subjected to the concavo-convex processing on the surface. The method according to claim 1, wherein the transfer is performed on a surface. The method according to claim 2, wherein the mold member is a roll or a film. 4. The method of manufacturing a solar cell module according to claim 2, wherein the unevenness of the mold member is formed by embossing, matting, or chemical etching. 5. 5. The method according to claim 1, wherein the sealing film is made of ethylene vinyl acetate. 3. The mold member film according to claim 2, wherein the mold member film is a fluorine resin coating film, a silicone resin coating film, a surface-treated polyethylene resin film, a polyolefin resin film, a metal foil or paper. Roll type manufacturing method for solar cell module. A plurality of solar cell units each having a photoelectric conversion element formed on a flexible base film, together with a wiring member for connecting the units, are sandwiched between two long heat-bonding and insulating sealing films. In order to manufacture a stopped solar cell module, the supply, adhesion and sealing of the members are performed while a base film in which the sealing film and the releasable support film are thermally bonded is transported by a roll. In a method for manufacturing a battery module, a roll-type solar cell module characterized by having means for performing unevenness processing on the surface of the sealing film in a heat bonding portion between the sealing film and the releasable support film. manufacturing device. The means for performing the unevenness processing on the surface of the sealing film includes a mold member film having a releasable shape whose surface has been unevenly processed, a supply roll for the mold member film, and heat for sandwiching the mold member film and the base film. The roll-type manufacturing apparatus for a solar cell module according to claim 7, comprising a pressing roll, wherein the uneven surface of the mold member film faces the sealing film. The means for performing the unevenness processing on the surface of the sealing film includes a thermocompression bonding roll that sandwiches the sealing base film, and at least a roll facing the sealing film of the thermocompression bonding roll is a mold having an unevenness formed on the surface. The roll-type manufacturing apparatus for a solar cell module according to claim 7, which is a member roll. The roll of the solar cell module according to claim 7, wherein a surface of the roll that contacts the sealing film is made of a fluorine-based resin, and has a release property with respect to the sealing film. Type manufacturing equipment.

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