Method for manufacturing solar cell module and manufacturing apparatus for solar cell module

Abstract

To provide a manufacturing method of a solar cell module that can form a desired three-dimensional shape, including non-developable surfaces such as hemispherical surfaces and saddle-shaped surfaces, while also enabling improved productivity.SOLUTION: A manufacturing method of a solar cell module 1 includes a sealing step in which a plurality of solar cells 2 arranged in a matrix are covered with a first thermoplastic resin 3a and heated and pressurized to form a solar cell substrate 5 having a sealing layer 3 made of the first thermoplastic resin 3a, a primary molding step in which a reinforcing layer 6 made of reinforcing fibers 7 and a second thermoplastic resin 6a, the solar cell substrate 5, and a protective layer 4 made of a third thermoplastic resin 4a are laminated in that order and heated and pressurized to form an intermediate body 8 in which the reinforcing layer 6, the solar cell substrate 5, and the protective layer 4 are integrated into one structure, and a secondary molding step in which the reinforcing layer 6 in the intermediate body 8 is heated and pressurized to fit a mold, thereby forming the intermediate body 8 into a three-dimensional shape that fits the mold.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a solar cell module and an apparatus for manufacturing a solar cell module.

Background Art

[0002] Conventionally, various efforts have been made to make it possible to apply a solar cell module to a curved surface shape.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Non-Patent Documents

[0004]

Non-Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Moving bodies such as automobiles have bodies composed of a wide variety of curved surface shapes. However, the conventional technology has limited applicable curved surface shapes and has been difficult to apply to non-developable surfaces such as hemispherical surfaces and saddle-shaped surfaces. For this reason, there has been a problem that it is difficult to attach solar cell modules over a wide range while maintaining the design and functionality of the body. In addition, an improvement in productivity is desired to increase the mounting rate of solar cell modules on moving bodies such as automobiles.

Means for Solving the Problems

[0006] The present invention has been made in view of the above circumstances, and an object thereof is to provide a method for manufacturing a solar cell module that can be formed into a desired three-dimensional shape including non-developable surfaces such as a hemispherical surface and a saddle-shaped surface, and that can improve productivity, and a manufacturing apparatus for a solar cell module suitable for the manufacturing method.

[0007] As one embodiment, the above problems are solved by the solution means disclosed below.

[0008] The method for manufacturing a solar cell module according to the present invention includes a sealing step of covering a plurality of matrix-arranged solar cell cells with a first thermoplastic resin and heating and pressing to form a solar cell substrate having a sealing layer made of the first thermoplastic resin; a primary molding step of laminating a reinforcing layer made of a reinforcing fiber and a second thermoplastic resin, the solar cell substrate, and a protective layer made of a third thermoplastic resin in this order and heating and pressing to form an intermediate body in which the reinforcing layer, the solar cell substrate, and the protective layer have an integral structure; and a secondary molding step of heating and pressing the reinforcing layer in the intermediate body to conform to a mold to form the intermediate body into a three-dimensional shape conforming to the mold.

[0009] According to this configuration, a flat intermediate body that can be mass-produced by primary molding can be produced, and by secondary molding, it can be formed into a desired three-dimensional shape including non-developable surfaces such as a hemispherical surface and a saddle-shaped surface, and productivity can be improved.

[0010] The manufacturing apparatus for a solar cell module according to the present invention includes a vacuum laminator that forms a solar cell substrate having a sealing layer made of the first thermoplastic resin by covering a plurality of matrix-arranged solar cells with the first thermoplastic resin and heating and pressing them, a primary molding machine that stacks a reinforcing layer made of a reinforcing fiber and a second thermoplastic resin, the solar cell substrate, and a protective layer made of a third thermoplastic resin in this order and heats and presses them to form an intermediate body in which the reinforcing layer, the solar cell substrate, and the protective layer have an integrated structure, and a secondary molding machine that heats and presses the reinforcing layer in the intermediate body to conform to a mold to form the intermediate body into a three-dimensional shape conforming to the mold.

[0011] According to this configuration, a flat intermediate body that can be mass-produced by a primary molding machine can be produced, and a desired three-dimensional shape including a non-developable surface such as a hemispherical surface or a saddle-shaped surface can be formed by a secondary molding machine, and productivity can be improved.

Effects of the Invention

[0012] According to the present invention, a desired three-dimensional shape including a non-developable surface such as a hemispherical surface or a saddle-shaped surface can be formed, and productivity can be improved. Moreover, by separating the processes into primary molding and secondary molding, cracking of the solar cells can be prevented, and the yield and the manufacturing quality can be improved.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0014] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a schematic perspective view showing an example of the solar cell module 1 according to the present embodiment. The solar cell module 1 includes a solar cell substrate 5 having a plurality of solar cells 2 arranged in a matrix and a sealing layer 3 covering the surface of the solar cell 2, a protective layer 4 covering the surface of the solar cell substrate 5, and a reinforcing layer 6 supporting the solar cell substrate 5 from below. The sealing layer 3 is made of a first thermoplastic resin 3a. The reinforcing layer 6 is made of a composite material of reinforcing fibers 7 laminated in the thickness direction and a second thermoplastic resin 6a. And the protective layer 4 is made of a third thermoplastic resin 4a. In all the drawings for explaining the embodiments, members having the same function may be denoted by the same reference numerals, and repeated explanations may be omitted.

[0015] FIG. 2A is a schematic cross-sectional view showing an example of the intermediate body 8 according to the present embodiment. FIG. 2B is a schematic cross-sectional view showing a state in which the primary-formed intermediate body 8 is secondary-formed in accordance with the mold 21. The intermediate body 8 is a structure in which the protective layer 4 is disposed on the surface, the reinforcing layer 6 is disposed on the back surface, and the solar cell substrate 5 is sandwiched between the protective layer 4 and the reinforcing layer 6.

[0016] The solar cell 2 is selected, as an example, from single-crystalline silicon, polycrystalline silicon, amorphous silicon, organic solar cells, perovskite solar cells, and other known solar cells. When the solar cell 2 is a perovskite solar cell, a gas barrier film or a gas barrier layer is added above and below the sealing layer in the sealing step.

[0017] The first thermoplastic resin 3a constituting the sealing layer 3 is selected, as an example, from ethylene vinyl acetate (EVA), polyamide-based thermoplastic elastomers (TPA), and other known thermoplastic elastomers. The first thermoplastic resin 3a is made of a transparent or translucent material.

[0018] The second thermoplastic resin 6a that constitutes the reinforcing layer 6 is selected, for example, from acrylic, polyethylene (PE), polypropylene (PP), and other known thermoplastic resins. The reinforcing fibers 7 that constitute the reinforcing layer 6 are selected, for example, from glass fibers, aramid fibers, carbon fibers, hemp, and other known reinforcing fibers.

[0019] The third thermoplastic resin 4a that constitutes the protective layer 4 is selected, for example, from acrylic, polycarbonate (PC), tetrafluoroethylene-ethylene copolymer (ETFE), thermoplastic polyamide, thermoplastic polyimide, thermoplastic epoxy, and other known thermoplastic resins. The third thermoplastic resin 4a is made of a transparent or translucent material.

[0020] The reinforcing layer 6 is formed, for example, by alternately laminating the reinforcing fibers 7 of a sheet-like fabric and a plurality of sheet-like second thermoplastic resins 6a and then heating and pressing them. For example, the thickness of each of the reinforcing fibers 7 is 5 μm to 1000 μm. For example, the thickness of each of the reinforcing fibers 7 is 50 μm to 500 μm. For example, the number of laminated layers of the reinforcing fibers 7 is 1 to 100 layers. For example, the number of laminated layers of the reinforcing fibers 7 is 2 to 20 layers. For example, the thickness of each of the second thermoplastic resins 6a is 5 μm to 1000 μm. For example, the thickness of each of the second thermoplastic resins 6a is 50 μm to 500 μm. For example, the number of laminated layers of the second thermoplastic resins 6a is 1 to 100 layers. For example, the number of laminated layers of the second thermoplastic resins 6a is 2 to 20 layers.

[0021] The reinforcing layer 6 is configured, as an example, by alternately laminating a sheet-like reinforcing fiber 7 and a powdery second thermoplastic resin 6a, and then heating and pressing them. As an example, the thickness of each reinforcing fiber 7 is 5 μm to 1000 μm. As an example, the thickness of each reinforcing fiber 7 is 50 μm to 500 μm. As an example, the number of laminated layers of the reinforcing fiber 7 is 5 to 100 layers. As an example, the number of laminated layers of the reinforcing fiber 7 is 5 to 20 layers. The reinforcing layer 6 is configured, as an example, by laminating a prepreg in which a sheet-like reinforcing fiber 7 is impregnated with a second thermoplastic resin 6a, and then heating and pressing them. The reinforcing layer 6 is configured, as an example, by laminating a semi-prepreg in which a second thermoplastic resin 6a is adhered to a sheet-like reinforcing fiber 7, and then heating and pressing them.

[0022] The hand lay-up molding method can be applied to the reinforcing layer 6. As an example, a sheet-like reinforcing fiber 7 is impregnated with a liquid second thermoplastic resin 6a, or impregnated with a monomer or oligomer which is a precursor of the second thermoplastic resin 6a, and then laminated, heated and pressed to form the reinforcing layer 6. The RTM (Resin Transfer Molding) molding method can be applied to the reinforcing layer 6. As an example, a sheet-like reinforcing fiber 7 is laminated and arranged in a mold, and after the mold is closed, a liquid second thermoplastic resin 6a is injected, or a monomer or oligomer which is a precursor of the second thermoplastic resin 6a is injected, and then heated and pressed to form the reinforcing layer 6. In addition to the above configuration, a frame-like reinforcing fiber can be provided on the lowermost layer for further reinforcement. Also, in addition to the above configuration, a reinforcing member made of carbon fiber or the like can be partially provided on the lowermost layer for further reinforcement.

[0023] FIG. 3A is a schematic perspective view showing an example of the vacuum laminator 11 according to the present embodiment. FIG. 3B is a schematic perspective view showing an example of the autoclave 12 according to the present embodiment. As an example, the above-mentioned primary molding machine is an autoclave 12 or a known hot press machine or a known thermocompression bonding device. As an example, the above-mentioned secondary molding machine is an autoclave 12. Note that the present invention is not limited to the above configuration.

[0024] Subsequently, a method for manufacturing the solar cell module 1 according to the present invention will be described below.

[0025] FIG. 4 is a schematic flowchart showing an example of the manufacturing procedure of the solar cell module 1 according to the present embodiment. The solar cell module 1 is manufactured in the order of a sealing step S1, a primary molding step S2, and a secondary molding step S3.

[0026] In the sealing step S1, for example, a vacuum laminator 11 is used. In the sealing step S1, a plurality of matrix-arranged solar cells 2 are covered with a first thermoplastic resin 3a and heated and pressed to form a solar cell substrate 5 having a sealing layer 3 made of the first thermoplastic resin 3a. After the sealing step S1, the primary molding step S2 follows.

[0027] In the primary molding step S2, for example, an autoclave 12 is used. In the primary molding step S2, a reinforcing layer 6 made of a reinforcing fiber 7 and a second thermoplastic resin 6a, the solar cell substrate 5, and a protective layer 4 made of a third thermoplastic resin 4a are laminated in this order and heated and pressed to form an intermediate body 8 in which the reinforcing layer 6, the solar cell substrate 5, and the protective layer 4 have an integrated structure. Since the intermediate body 8 is flat, storage costs and transportation costs can be suppressed. After the primary molding step S2, the secondary molding step S3 follows.

[0028] In the secondary molding step S3, for example, an autoclave 12 is used. In the secondary molding step S3, inside the autoclave 12, the back surface of the intermediate body 8 is heated and pressed in accordance with a mold 21 made of a curved glass to be formed into a three-dimensional shape, thereby forming the solar cell module 1.

[0029] Here, the heating temperature in the secondary molding step S3 is set to a temperature equal to or higher than the heating temperature in the primary molding step S2. The pressing force in the secondary molding step S3 is set to a pressure equal to or higher than the pressing force in the primary molding step S2. Further, the heating temperature in the secondary molding step S3 is set to a temperature equal to or lower than the heat-resistant temperature of the first thermoplastic resin 3a.

[0030] According to this embodiment, a solar cell module 1 that can be formed into a desired three-dimensional shape including non-developable surfaces such as a hemispherical surface and a saddle-shaped surface and that can improve productivity can be manufactured. And, as will be described later, the method of performing primary molding in advance and forming into a desired shape by secondary molding has the merit that the solar cell 2 is less likely to break than the method of conforming to the desired shape by one-time molding.

[0031] Subsequently, examples and comparative examples of the solar cell module 1 according to the present invention will be described below.

[0032] [Examples] The solar cell module 1 of the example includes a solar cell 2 made of single-crystalline silicon, a sealing layer 3 that seals the matrix-arranged solar cells 2 with ethylene vinyl acetate (EVA), a protective layer 4 made of a tetrafluoroethylene-ethylene copolymer (ETFE), and a reinforcing layer 6 made of a composite material of a reinforcing fiber 7 made of a glass fabric laminated in the thickness direction and acrylic as a second thermoplastic resin 6a. The size of the solar cell 2 is 3 inches, and 16 solar cells 2 are arranged.

[0033] As described above, in the sealing step S1, a solar cell substrate 5 having a sealing layer 3 made of the first thermoplastic resin 3a is formed by covering the matrix-arranged plurality of solar cells 2 with the first thermoplastic resin 3a and heating and pressing. And, in the primary molding step S2, a reinforcing layer 6 made of a reinforcing fiber 7 and a second thermoplastic resin 6a, a solar cell substrate 5, and a protective layer 4 made of a third thermoplastic resin 4a are laminated in this order and heated and pressed to form an intermediate body 8 in which the reinforcing layer 6, the solar cell substrate 5, and the protective layer 4 are integrated. And, in the secondary molding step S3, the back surface of the intermediate body 8 is heated and pressed in accordance with a predetermined mold to be formed into a three-dimensional shape, thereby forming the solar cell module 1.

[0034] The solar cell module 1 of the example has a curvature radius of 1000 mm. It was confirmed that none of the 16 solar cells 2 were cracked and operated normally.

[0035] [Comparative Examples] The constituent materials of the comparative example are the same as those of the example. However, without separating the molding steps, the reinforcing layer 6 composed of the reinforcing fiber 7 and the second thermoplastic resin 6a, the solar cell substrate 5, and the protective layer 4 composed of the third thermoplastic resin 4a were laminated in this order, and then the back surface of the reinforcing layer 6 was heated and pressed according to a predetermined mold to form a three-dimensional shape. As a result, half of the 16 solar cells 2 were cracked.

[0036] From the results of the above-described examples and comparative examples, it is presumed that by mutually restraining the constituent materials with a certain restraining force in the primary molding, cracking of the solar cell 2 due to strain could be prevented. On the other hand, from the results of the comparative example, when a shape is given to a non-developable surface in a state where the constituent materials are not mutually restrained, wrinkles are likely to occur in the constituent materials, particularly the reinforcing fiber 7, and it is presumed that the solar cell 2 cracked due to the strain caused by the wrinkles. That is, from the above-described prototype results, it was confirmed that by separating the process into the primary molding and the secondary molding, cracking of the solar cell 2 can be prevented, and the yield and the manufacturing quality can be improved.

[0037] The above-described example is an application example to the hemispherical mold 21, but is not limited to this example, and the present invention can be applied to known non-developable surfaces such as a saddle-shaped surface. Also, it is possible to use a part of the body of a moving object such as an automobile as a mold. The size of the solar cell 2 can be increased to 6 inches or more. Also, the size of the solar cell 2 can be reduced to 2 inches or less. The above-described example showed that the radius of curvature of the solar cell module 1 can be 1000 mm or more, but depending on the application, the radius of curvature of the solar cell module 1 may be less than 1000 mm. In this case, a known hot press machine or a known thermocompression bonding device can be applied to the secondary molding step S3. The present invention is not limited to the above-described examples, and various modifications can be made without departing from the scope of the present invention.

Explanation of reference numerals

[0038] 1 Solar cell module 2 Solar cell 3 Sealing layer, 3a First thermoplastic resin 4 Protective layer, 4a Third thermoplastic resin 5 Solar cell substrate 6 Reinforcing layer, 6a Second thermoplastic resin 7 Reinforcing fiber 8 Intermediate 11 Vacuum laminator 12 Autoclave

Claims

1. A sealing step of covering a plurality of matrix-arranged solar cell cells with a first thermoplastic resin and heating and pressing to obtain a solar cell substrate having a sealing layer made of the first thermoplastic resin; A primary molding step of laminating a reinforcing layer made of a reinforcing fiber and a second thermoplastic resin, the solar cell substrate, and a protective layer made of a third thermoplastic resin in this order and heating and pressing to obtain an intermediate body in which the reinforcing layer, the solar cell substrate, and the protective layer have an integrated structure; A secondary molding step of heating and pressing the reinforcing layer in the intermediate body in accordance with a mold to form the intermediate body into a three-dimensional shape conforming to the mold. A method for manufacturing a solar cell module, characterized by the above.

2. In the secondary molding step, the reinforcing fiber formed in a sheet shape and laminated in the thickness direction and the second thermoplastic resin in the reinforcing layer are adhered to each other, the second thermoplastic resin and the first thermoplastic resin are adhered to each other, and the first thermoplastic resin and the third thermoplastic resin are adhered to each other. The method for manufacturing a solar cell module according to Claim 1, characterized by the above.

3. The secondary molding step is carried out by heating and pressing with an autoclave. The method for manufacturing a solar cell module according to Claim 1 or 2, characterized by the above.

4. A vacuum laminator for covering a plurality of matrix-arranged solar cell cells with a first thermoplastic resin and heating and pressing to obtain a solar cell substrate having a sealing layer made of the first thermoplastic resin; A primary molding machine for laminating a reinforcing layer made of a reinforcing fiber and a second thermoplastic resin, the solar cell substrate, and a protective layer made of a third thermoplastic resin in this order and heating and pressing to obtain an intermediate body in which the reinforcing layer, the solar cell substrate, and the protective layer have an integrated structure; A secondary molding machine for heating and pressing the reinforcing layer in the intermediate body in accordance with a mold to form the intermediate body into a three-dimensional shape conforming to the mold. A manufacturing apparatus for a solar cell module, characterized by the above.

5. The primary molding machine is an autoclave or a hot press machine, and the secondary molding machine is an autoclave. The manufacturing apparatus for a solar cell module according to Claim 4, characterized by the above.

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