Solar cell module

Abstract

This solar cell module comprises a first protection layer, a solar cell unit, a support member, and a filler. The first protection layer has a first surface and a second surface on the reverse side from the first surface. The solar cell unit includes a plurality of solar cell elements that are positioned opposite the second surface of the first protection layer. The support member is positioned adjacent to the solar cell unit. The support member includes an inner portion positioned opposite the second surface of the first protection layer, and an outer portion positioned extending outward from the inner portion. The filler is positioned in contact with the second surface of the first protection layer, and covering the inner portion and the solar cell unit. The thickness of the filler between the solar cell unit and the support member is greater than the thickness of the filler between two of the plurality of solar cell elements that are adjacent to each other.

Description

Cross - reference to related applications

[0001] This application claims the priority of Japanese Application No. 2022 - 075028 (filed on April 28, 2022), and the entire disclosure of the said application is incorporated herein by reference for that purpose.

Technical Field

[0002] This disclosure relates to a solar cell module.

Background Art

[0003] A solar cell module in which a plurality of solar cell elements arranged in a plane and electrically connected are located between a front - surface protective layer and a back - surface protective layer is known (see, for example, the description of Patent Document 1). In this solar cell module, the plurality of solar cell elements are covered with a filler mainly composed of ethylene - vinyl acetate copolymer (EVA).

Prior - art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

[0005] A solar cell module is disclosed.

[0006] In one embodiment, the solar cell module includes a first protective layer, a solar cell section, a support member, and a filling material. The first protective layer has a first surface and a second surface opposite to the first surface. The solar cell section includes a plurality of solar cell elements positioned to face the second surface of the first protective layer. The support member is positioned adjacent to the solar cell section. The support member includes an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion. The filling material is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell section. The thickness of the filling material between the solar cell section and the support member is greater than the thickness of the filling material between two adjacent solar cell elements among the plurality of solar cell elements.

[0007] Also, in one embodiment, the solar cell module includes a first protective layer, a solar cell section, a support member, and a filling material. The first protective layer has a first surface and a second surface opposite to the first surface. The solar cell section is positioned to face the second surface of the first protective layer. The support member is positioned adjacent to the solar cell section. The support member includes an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion. The filling material is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell section. The thickness of the filling material increases as it goes from the solar cell section toward the support member.

Brief Description of the Drawings

[0008]

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Embodiments for Carrying Out the Invention

[0009] The inventor has created a technology for improving the flexibility and strength of the solar cell module. Regarding this, the first to seventh embodiments will be described below with reference to the drawings.

[0010] In the drawings, parts having the same or similar configurations and functions are denoted by the same reference numerals, and redundant descriptions are omitted in the following description. The drawings are schematically shown. In FIGS. 1 to 17(b), a right-handed XYZ coordinate system is attached. In this XYZ coordinate system, the short side direction of the front surface 10f of the solar cell panel 10 is the +X direction, the long side direction of the front surface 10f is the +Y direction, and the normal direction of the front surface 10f perpendicular to both the +X direction and the +Y direction is the +Z direction.

[0011] <1-1. Solar Cell Module> The solar cell module 100 according to the first embodiment will be described with reference to FIGS. 1 to 3(b).

[0012] As shown in FIGS. 1 and 2, the solar cell module 100 includes, for example, a solar cell panel 10. The solar cell panel 10 has, for example, a light-receiving surface (also referred to as the front surface) 10f on which light mainly enters, and a back surface 10b located on the opposite side of the front surface 10f. In the first embodiment, the front surface 10f is in a state facing the +Z direction. The back surface 10b is in a state facing the -Z direction. The +Z direction is set, for example, as the direction facing the sun at noon. In the example of FIG. 1, the front surface 10f has a rectangular shape, for example, a rectangular shape as an example of a rectangular shape.

[0013] The solar cell module 100 may further include a terminal box (not shown) for taking out the electric power generated in the solar cell panel 10 to the outside.

[0014] As shown in FIGS. 1 and 2, the solar cell panel 10 includes, for example, a front surface protection layer 1, a back surface protection layer 2, a solar cell portion 3, a filling material 4, and a support member 5.

[0015] <1-1-1. Front Surface Protection Layer> The front surface protection layer 1 has, for example, a first surface 1f and a second surface 1s (see FIG. 2). In the first embodiment, the first surface 1f is, for example, in a state of constituting the front surface 10f of the solar cell panel 10. That is, the front surface protection layer 1 has a rectangular shape, for example, a rectangular shape as an example of a rectangular shape. In the examples of FIGS. 1 and 2, the first surface 1f is in a state of being exposed to the space outside the solar cell module 100 (also referred to as the external space) 200. Further, the second surface 1s is the surface on the opposite side of the first surface 1f.

[0016] The front surface protection layer 1 has, for example, translucency. Specifically, the front surface protection layer 1 has, for example, translucency with respect to light having a specific range of wavelengths. The specific range of wavelengths includes, for example, the wavelengths of light that the solar cell portion 3 can photoelectrically convert. If the wavelengths of sunlight with high irradiation intensity are included in the specific range of wavelengths, the photoelectric conversion efficiency of the solar cell module 100 can be improved.

[0017] For the material of the surface protective layer 1, for example, a resin having weather resistance is applied. In other words, for the surface protective layer 1, for example, a layer composed of a resin having weather resistance is applied. Here, weather resistance means, for example, a property that is less likely to cause deterioration such as deformation, discoloration, and degradation when used outdoors. By applying a resin to the material of the surface protective layer 1, the surface protective layer 1 reduces, for example, the intrusion of water such as water droplets from the external space 200 of the solar cell module 100 toward the solar cell unit 3, and has a property (also referred to as moisture permeability and waterproofness) that moisture easily passes from the filler 4 toward the external space 200. Here, the resin having weather resistance includes, for example, fluorine-based resins. Fluorine-based resins include, for example, fluorinated ethylene propylene copolymer (Fluorinated Ethylene Propylene: FEP), ethylene tetrafluoroethylene copolymer (Ethylene Tetrafluoroethylene: ETFE), and ethylene chlorotrifluoroethylene copolymer (Ethylene Chlorotrifluoroethylene: ECTFE). Here, for example, the surface protective layer 1 may be composed of two or more resins having weather resistance. In this case, the fluorine-based resin applied to the surface protective layer 1 may be, for example, two or more types of resins. Therefore, for example, an aspect in which the fluorine-based resin applied to the surface protective layer 1 contains at least one of FEP, ETFE, and ECTFE is conceivable.

[0018] The thickness of the surface protective layer 1 is, for example, set to about 0.05 millimeters (mm) to 0.5 mm. Thus, since the surface protective layer 1 is composed of a resin having moisture permeability and a relatively low density and its thickness is thin, the surface protective layer 1 is light. Therefore, for example, compared with a structure in which glass having a large density and a thickness of about 1 mm or more is adopted instead of the surface protective layer 1, the solar cell module 100 can be lightened, and the solar cell module 100 can be thinned.

[0019] In addition, as the material of the surface protection layer 1, resins such as acrylic resin and polycarbonate can be applied instead of or together with the fluorine-based resin. When acrylic resin and polycarbonate are applied, the thickness of the resin is, for example, about 0.03 mm to 0.6 mm. The surface protection layer 1 may be composed of a plurality of types of resins laminated.

[0020] <1-1-2. Solar cell part> The solar cell part 3 is located, for example, between the surface protection layer 1 and the back surface protection layer 2. In other words, the solar cell part 3 is in a state of facing the surface protection layer 1 in the Z direction and is also in a state of facing the back surface protection layer 2 in the Z direction. As shown in FIGS. 1 and 2, the solar cell part 3 has, for example, a plurality of solar cell elements 31. The plurality of solar cell elements 31 are located between the second surface 1s of the surface protection layer 1 and the back surface protection layer 2. In the first embodiment, the plurality of solar cell elements 31 are in a two-dimensionally arranged state. In the examples of FIGS. 1 and 2, the plurality of solar cell elements 31 are arranged in a planar manner so as to be located along the second surface 1s of the surface protection layer 1. Note that the plurality of solar cell elements 31 may be arranged in one dimension.

[0021] The solar cell unit 3 further includes, for example, a plurality of first wiring members 32, a second wiring member 33, and a third wiring member 34. The solar cell unit 3 includes, for example, a plurality (here, two) of solar cell strings 30. The plurality of solar cell strings 30 are, for example, arranged in the X direction. Each of the plurality of solar cell strings 30 includes, for example, a plurality (here, five) of solar cell elements 31 and a plurality of first wiring members 32. In each solar cell string 30, the plurality of solar cell elements 31 are, for example, arranged in the Y direction. The plurality of first wiring members 32 are, for example, in a state of electrically connecting two adjacent solar cell elements 31 among the plurality of solar cell elements 31. The second wiring member 33 is in a state of electrically connecting two adjacent solar cell strings 30 among the plurality of solar cell strings 30. In the examples of FIGS. 1 and 2, the two third wiring members 34 are each connected to two solar cell strings 30. The third wiring member 34 connected to the solar cell string 30 located at the most -X direction end and the third wiring member 34 connected to the solar cell string 30 located at the most +X direction end are drawn out to the outside of the solar cell panel 10.

[0022] Each of the plurality of solar cell elements 31 can convert light energy into electrical energy. Each of the plurality of solar cell elements 31 has a surface (also referred to as the first element surface) 31f located on the front (front) side and a surface (also referred to as the second element surface) 31s on the opposite side of this first element surface 31f. In the example of FIG. 2, the first element surface 31f is in a state of facing the +Z direction, and the second element surface 31s is in a state of facing the -Z direction. In this case, for example, the first element surface 31f mainly serves as a surface (also referred to as a light-receiving surface) where light is incident, and the second element surface 31s mainly serves as a surface (also referred to as a non-light-receiving surface) where light is not incident.

[0023] In the first embodiment, as shown in FIGS. 3(a) and 3(b), each of the plurality of solar cell elements 31 includes a semiconductor substrate 310, a first output extraction electrode 311, a first current collection electrode 312, a second output extraction electrode 313, and a second current collection electrode 314.

[0024] For the semiconductor substrate 310, for example, a crystalline semiconductor such as crystalline silicon, an amorphous semiconductor such as amorphous silicon, or a compound semiconductor using four elements of copper, indium, gallium, and selenium or two elements of cadmium and tellurium is applied. Here, it is assumed that crystalline silicon is applied to the semiconductor substrate 310. In this case, the semiconductor substrate 310 mainly has a region having a first conductivity type (also referred to as a first conductivity type region) and a region having a second conductivity type opposite to the first conductivity type (also referred to as a second conductivity type region). The first conductivity type region is located, for example, on the second element surface 31s side in the -Z direction of the semiconductor substrate 310. The second conductivity type region is located, for example, in the surface layer portion on the first element surface 31f side in the +Z direction of the semiconductor substrate 310. Here, for example, when the first conductivity type is p-type, the second conductivity type is n-type. Also, for example, when the first conductivity type is n-type, the second conductivity type is p-type. Thereby, the semiconductor substrate 310 has a pn junction portion located at the interface between the first conductivity type region and the second conductivity type region. The thickness of the semiconductor substrate 310 is, for example, about 0.15 mm to 0.5 mm.

[0025] The first output extraction electrode 311 and the first current collecting electrode 312 are located, for example, on the surface of the semiconductor substrate 310 on the side of the first element surface 31f. For example, a bus bar electrode is applied to the first output extraction electrode 311. For example, a finger electrode is applied to the first current collecting electrode 312. In the example of FIG. 3(a), five substantially parallel first output extraction electrodes 311 are located on the side of the first element surface 31f of the semiconductor substrate 310, and a large number of substantially parallel first current collecting electrodes 312 are located so as to be substantially orthogonal to the five first output extraction electrodes 311. In the example of FIG. 3(a), each of the first output extraction electrodes 311 has an elongated shape that is long in the Y direction, and each of the first current collecting electrodes 312 has a linear shape that is long in the X direction. Further, in the region above the second conductivity type region of the semiconductor substrate 310 where the first output extraction electrode 311 and the first current collecting electrode 312 are not formed, an insulating film such as an antireflection film 315 made of, for example, silicon nitride may be located. Here, for example, when the main component of the first output extraction electrode 311 is silver, the first output extraction electrode 311 can be formed by baking after a silver paste is applied in a desired shape by screen printing or the like. The main component means the component having the largest (highest) ratio (also referred to as the content ratio) among the contained components. As the silver paste, for example, a metal paste containing metal powder containing silver as the main component, an organic vehicle, and glass frit is applied. For example, when the main component of the first current collecting electrode 312 is silver, the first current collecting electrode 312 can be formed by baking after a silver paste is applied in a desired shape by screen printing or the like, similar to the first output extraction electrode 311. The first output extraction electrode 311 and the first current collecting electrode 312 may be formed in separate processes from each other, or may be formed in the same process.

[0026] The second output extraction electrode 313 and the second current collecting electrode 314 are located, for example, on the surface of the semiconductor substrate 310 on the side of the second element surface 31s. For example, a bus bar electrode is applied to the second output extraction electrode 313. In the example of Fig. 3(b), five rows of second output extraction electrodes 313 that are substantially parallel to each other along the +Y direction are located on the second element surface 31s side of the semiconductor substrate 310. The second current collecting electrode 314 is located on substantially the entire area of the region where the second output extraction electrode 313 is not formed, excluding the portion where the second output extraction electrode 313 and the second current collecting electrode 314 are mutually connected by overlapping on the second element surface 31s side of the semiconductor substrate 310. Each of the five rows of second output extraction electrodes 313 includes, for example, four electrodes arranged in a row. Further, for example, a thin film of an oxide or nitride such as aluminum oxide may exist as a passivation film in a desired pattern between the first conductivity type region of the semiconductor substrate 310 and the second output extraction electrode 313 and the second current collecting electrode 314. Here, for example, when the main component of the second output extraction electrode 313 is silver, similar to the first output extraction electrode 311, the second output extraction electrode 313 can be formed by baking after a silver paste is applied in a desired shape by screen printing or the like. For example, when the main component of the second current collecting electrode 314 is aluminum, the second current collecting electrode 314 can be formed by baking after an aluminum paste is applied in a desired shape by screen printing or the like. As the aluminum paste, for example, a metal paste containing metal powder containing aluminum as the main component, an organic vehicle, and glass frit is applied.

[0027] The first wiring member 32 is, for example, in a state of electrically connecting the first output extraction electrode 311 of one solar cell element 31 and the second output extraction electrode 313 of another solar cell element 31 adjacent to this one solar cell element 31. In the examples of FIGS. 3(a) and 3(b), the outer edges of the plurality of first wiring members 32 attached to each of the solar cell elements 31 are virtually drawn with a two-dot chain line. In the examples from FIG. 1 to FIG. 3(b), the first wiring member 32 has an elongated shape that is long in the Y direction. Here, the first wiring member 32 is, for example, in a state of being joined to the first output extraction electrode 311 and the second output extraction electrode 313. Specifically, for example, there is a portion (also referred to as the first joining portion) 321 that is located between the first wiring member 32 and the first output extraction electrode 311 and joins the first wiring member 32 and the first output extraction electrode 311. For this reason, for example, the first wiring member 32 is in a state of being joined to the first output extraction electrode 311 of one solar cell element 31 via the first joining portion 321. Also, for example, there is a portion (also referred to as the second joining portion) 322 that is located between the first wiring member 32 and the second output extraction electrode 313 and joins the first wiring member 32 and the second output extraction electrode 313. For this reason, for example, the first wiring member 32 is in a state of being joined to the second output extraction electrode 313 of another solar cell element 31 adjacent to one solar cell element 31 via the second joining portion 322. A metal body having linear or strip-like conductivity, for example, is applied to the first wiring member 32. For the materials of the first joining portion 321 and the second joining portion 322, for example, a low-melting-point alloy such as solder or a low-melting-point single metal is applied. More specifically, for example, a copper foil having a thickness of about 0.1 mm to 0.2 mm and a width of about 1 mm to 2 mm is applied to the first wiring member 32, and the entire surface of this first wiring member 32 is covered with solder. The first wiring member 32 is, for example, in a state of being electrically connected to the first output extraction electrode 311 and the second output extraction electrode 313 by soldering. In this case, for example, the solder located between the first wiring member 32 and the first output extraction electrode 311 constitutes the first joining portion 321. Also, for example, the solder located between the first wiring member 32 and the second output extraction electrode 313 constitutes the second joining portion 322.

[0028] <1-1-3. Filling Material> The filling material 4 is in a state of covering the solar cell portion 3 between the front surface protection layer 1 and the back surface protection layer 2. In other words, the filling material 4 is in a state of covering a plurality of solar cell elements 31 between the front surface protection layer 1 and the back surface protection layer 2. From another perspective, the filling material 4 is in a state of being filled while covering the solar cell portion 3 in, for example, the region (also referred to as the gap region) 10g between the front surface protection layer 1 and the back surface protection layer 2.

[0029] The filling material 4 has a first surface 4f located on the front (front) surface and a second surface 4s located on the side opposite to the first surface 4f. The first surface 4f of the filling material 4 is in contact with the second surface 1s of the front surface protection layer 1, and the second surface 4s of the filling material 4 is in contact with the back surface protection layer 2.

[0030] In the first embodiment, the filling material 4 includes, for example, a filling material (also referred to as the first filling material) 41 located on the front surface 10f side and a filling material (also referred to as the second filling material) 42 located on the back surface 10b side. The first filling material 41 is, for example, in a state of constituting the first surface 4f and is in a state of covering the entire surface on the front surface protection layer 1 side of the solar cell portion 3. In other words, the first filling material 41 is in a state of covering a plurality of solar cell elements 31 between the front surface protection layer 1 and the plurality of solar cell elements 31. The second filling material 42 is, for example, in a state of constituting the second surface 4s and is in a state of covering the entire surface on the back surface protection layer 2 side of the solar cell portion 3. In other words, the second filling material 42 is in a state of covering a plurality of solar cell elements 31 between the back surface protection layer 2 and the plurality of solar cell elements 31. Therefore, in the first embodiment, the solar cell portion 3 is, for example, surrounded so as to be sandwiched between the first filling material 41 and the second filling material 42. Thereby, for example, the posture of the solar cell portion 3 can be maintained by the filling material 4.

[0031] Also, the filler 4 has, for example, translucency. Here, the filler 4 has, for example, translucency with respect to light having a wavelength within the above-described specific range. Here, for example, if at least the first filler 41 among the first filler 41 and the second filler 42 that constitute the filler 4 has translucency, the incident light from the front surface 10f side can reach the solar cell unit 3.

[0032] For the material of the first filler 41, for example, polyvinyl acetals such as ethylene vinyl acetate copolymer (EVA) and polyvinyl butyral (PVB), and acid-modified resins are applied. Here, for example, if a relatively inexpensive EVA is applied to the material of the first filler 41, the performance of protecting a plurality of solar cell elements 31 can be easily realized. As the acid-modified resin, for example, a modified polyolefin resin that can be formed by graft modification with an acid such as a resin such as polyolefin is applied. As the acid that can be used for the graft modification of the acid-modified resin, for example, acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, maleic anhydride, hymic anhydride, itaconic anhydride, and citraconic anhydride are applied. For the material of the second filler 42, for example, the same as the first filler 41, polyvinyl acetals such as EVA and PVB, and acid-modified resins are applied. The first filler 41 and the second filler 42 may be composed of, for example, two or more kinds of materials.

[0033] The second filler 42 may contain, for example, a pigment. For example, when a white pigment is contained, the light transmitted through the solar cell unit 3 can be reflected by the second filler 42 and made to enter the solar cell unit 3 again. Thereby, the power generation efficiency of the solar cell module 100 can be improved.

[0034] Note that the filler 4 may not have the second filler 42 and may have only the first filler 41. In this case, the first filler 41 covers the solar cell unit 3 between the front surface protective layer 1 and the back surface protective layer 2.

[0035] <1-1-4. Back Surface Protective Layer> The back surface protective layer 2 is, for example, in a state of constituting the back surface 10b of the solar cell panel 10. The back surface protective layer 2 is, for example, in a state of facing the second surface 1s of the front surface protective layer 1. The back surface protective layer 2 is in contact with the filling material 4 on the side opposite to the front surface protective layer 1 with respect to the filling material 4. The back surface protective layer 2 is positioned in a state of facing the inner part 51 of the solar cell part 3 and the support member 5 in the Z direction. The inner part 51 is, as will be described later, the part on the solar cell part 3 side with respect to the outer part 52 of the support member 5 in the X direction.

[0036] The back surface protective layer 2 can, for example, protect the solar cell part 3 from the back surface 10b side. For example, a backsheet constituting the back surface 10b is applied to the back surface protective layer 2. The thickness of the backsheet is, for example, about 0.15 mm to 0.5 mm. For example, a resin is applied to the material of the backsheet. The same material as that of the front surface protective layer 1 can be applied to the resin. The back surface protective layer 2 has the same or a similar shape as the front surface protective layer 1 when viewed in a plan view from the back surface 10b side. For example, when viewed in a plan view from the back surface 10b side, a configuration in which both the front surface protective layer 1 and the back surface protective layer 2 have a rectangular outer shape is assumed.

[0037] <1-1-5. Support member> The support member 5 is a member for improving the rigidity of the solar cell panel 10 and has, for example, a higher rigidity than the rigidity of all of the front surface protective layer 1, the back surface protective layer 2, and the filling material 4. For example, a metal can be applied to the material of the support member 5, and as a more specific example, aluminum or stainless steel can be applied.

[0038] When viewed in a plan view toward the main surface of the surface protection layer 1, the support member 5 is positioned adjacent to the solar cell portion 3 with a space therebetween. In other words, when viewed in a state where the line of sight is along the Z direction, the support member 5 is positioned adjacent to the solar cell portion 3 with a space therebetween. Hereinafter, viewing in a state where the line of sight is along the Z direction is also simply referred to as a plan view. The support member 5 includes an inner portion 51 and an outer portion 52, and the inner portion 51 is positioned in a state of being covered by the filling material 4 between the surface protection layer 1 and the back surface protection layer 2. In other words, the inner portion 51 is in a state of facing the surface protection layer 1 in the Z direction, and is also in a state of facing the back surface protection layer 2 in the Z direction, and is in a state of being covered by the filling material 4.

[0039] The outer portion 52 extends from the inner portion 51 to the side opposite to the solar cell portion 3 (that is, the outer side), and for example, is in a state of not being covered by the filling material 4. In the examples of FIGS. 1 and 2, the outer portion 52 extends from the inner portion 51 to the outside of the surface protection layer 1 and the back surface protection layer 2 in a plan view. That is, the outer portion 52 is not in a state of facing the surface protection layer 1 in the Z direction, and is also not in a state of facing the back surface protection layer 2 in the Z direction. The inner portion 51 of the support member 5 is positioned on the solar cell portion 3 side (that is, the inner side) with respect to the outer portion 52 of the support member 5 in a plan view.

[0040] In the examples of FIGS. 1 and 2, the support member 5 has a plate-like shape and has a rectangular shape in a plan view. In the example of FIG. 2, the ZX cross-section of the support member 5 also has a rectangular shape. The corners of the support member 5 may be chamfered as appropriate. The longitudinal direction (here, the Y direction) of the support member 5 is along, for example, one side of the surface protection layer 1. Further, the longitudinal direction of the support member 5 is along, for example, the arrangement direction (here, the Y direction) of a plurality of solar cell elements 31 included in one solar cell string 30. That is, the longitudinal direction of the support member 5 is along, for example, the longitudinal direction (here, the Y direction) of the first wiring member 32.

[0041] In the examples of FIGS. 1 and 2, the solar cell panel 10 includes two support members 5. The two support members 5 are respectively positioned along both sides on both sides in the X direction of the surface protection layer 1. Here, the two sides located on both sides in the X direction refer to one side extending along the Y direction at the -X direction end of the surface protection layer 1 and one side extending along the Y direction at the +X direction end. That is, one support member 5 is located at the -X direction end of the surface protection layer 1 and has a rectangular shape with the longitudinal direction being the Y direction, and the other support member 5 is located at the +X direction end of the surface protection layer 1 and has a rectangular shape with the longitudinal direction being the Y direction. The length of the support member 5 in the longitudinal direction (here the Y direction) is, for example, substantially equal to the length of the surface protection layer 1. The width of the support member 5 in the short side direction (here the X direction) is set to, for example, several tens of mm or more. The width of the inner portion 51 of the support member 5 is set to, for example, about 20% or more and 80% or less of the width of the support member 5. Thereby, the support member 5 can be integrated with the filler 4 with a relatively high adhesive strength. The thickness of the support member 5 is larger than the thickness of the solar cell portion 3 and is set to, for example, about 1 mm to 5 mm.

[0042] The outer portion 52 of the support member 5 is attached to an attachment target member such as an external building material. For example, attachment holes (not shown) may be formed in the outer portion 52. The attachment holes penetrate the outer portion 52 in the Z direction. By passing an attachment bolt through the attachment holes and screwing it into the attachment target member, the solar cell panel 10 can be attached to the attachment target member. In the examples of FIGS. 1 and 2, since the two support members 5 are respectively located on both sides of the solar cell panel 10, the two support members 5 on both sides of the solar cell panel 10 can be fixed to the attachment target member. For this reason, the solar cell panel 10 can be more firmly attached to the attachment target member. It can also be said that the support member 5 is an attachment member.

[0043] In the example of FIG. 1, the rigid support member 5 is not mainly located on both sides of the solar cell panel 10 in the Y direction. That is, the support member 5 is not substantially located at the end of the solar cell panel 10 in the +Y direction and extending along the X direction, nor is it substantially located at the end of the solar cell panel 10 in the -Y direction and extending along the X direction. Therefore, as shown in FIG. 6, when an external force F1 is applied to the support member 5, the solar cell panel 10 can bend in an arc shape when viewed in the direction along the Y direction. In other words, the solar cell panel 10 can bend in an arc shape when viewed with the line of sight along the Y direction. For example, the solar cell panel 10 can bend to a state along an arc with a radius of about several hundred mm (for example, 500 mm). According to this, it is easy to attach the solar cell panel 10 to a curved mounting target member.

[0044] <1-1-6. Thickness of the filler 4> As shown in FIG. 2, the thickness of the filler 4 is small in the solar cell portion 3 and large between the solar cell portion 3 and the support member 5. Here, the thickness W1 and the thickness W3 are introduced. The thickness W1 is the thickness (maximum value) of the filler 4 between the solar cell portion 3 and the support member 5. The thickness W3 is the thickness (maximum value) of the filler 4 between two adjacent solar cell elements 31 among the plurality of solar cell elements 31 belonging to the solar cell portion 3. As shown in FIG. 2, the thickness W1 is, for example, larger than the thickness W3. The difference between the thickness W1 and the thickness W3 may be, for example, 0.1 mm or more, 0.5 mm or more, or 1 mm or more.

[0045] Focusing on the distance between the front surface protective layer 1 and the back surface protective layer 2, the distance between the front surface protective layer 1 and the back surface protective layer 2 is small in the solar cell portion 3 and large between the solar cell portion 3 and the support member 5. In other words, the distance (maximum value) between the front surface protective layer 1 and the back surface protective layer 2 between the solar cell portion 3 and the support member 5 is larger than the distance (maximum value) between the front surface protective layer 1 and the back surface protective layer 2 in the solar cell portion 3.

[0046] Here, an example of the thickness distribution of the portion 4a between the solar cell portion 3 and the support member 5 in the filler 4 will be described. The portion 4a referred to here is the portion of the filler 4 that is located between the solar cell portion 3 and the support member 5 and is located in a continuous state from the front surface protective layer 1 to the back surface protective layer 2. In the example of FIG. 2, the thickness W1 of the portion 4a at the end on the support member 5 side is greater than the thickness W2 of the portion 4a at the end on the solar cell portion 3 side. The difference between the thickness W1 and the thickness W2 may be, for example, 0.1 mm or more, 0.5 mm or more, or 1 mm or more.

[0047] As shown in FIG. 2, the thickness of the portion 4a of the filler 4 gradually increases as it goes from the solar cell portion 3 toward the support member 5 along the X direction in at least a part of the region R1 between the support member 5 and the solar cell portion 3. That is, the thickness of the portion 4a of the filler 4 monotonically increases as it goes from the solar cell portion 3 toward the support member 5 along the X direction in the region R1. More specifically, as the position in the X direction approaches the support member 5 from the solar cell portion 3, the thickness of the portion 4a of the filler 4 at that position gradually increases. In short, the thickness of the portion 4a gradually increases as it goes outward along the X direction in the region R1. The amount of increase in thickness over the entire region R1 may be, for example, 0.1 mm or more, 0.5 mm or more, or 1 mm or more. The shape of the portion 4a of the filler 4 is, for example, uniform in the Y direction.

[0048] Note that in the example of FIG. 2, although the first surface 4f and the second surface 4s of the filler 4 have a shape that is line-symmetric with respect to the XY plane, the drawing is only schematically shown and is not necessarily limited to this.

[0049] <1-2. Characteristics of the solar cell module> According to this embodiment, the inner portion 51 of the rigid support member 5 is covered by the filling material 4 between the front surface protective layer 1 and the back surface protective layer 2. Therefore, the rigidity of the solar cell panel 10 can be improved. In the example of FIG. 1, since the support member 5 is located at the X-direction end of the solar cell panel 10 across both ends in the Y direction of the solar cell panel 10, the rigidity in the Y direction can be particularly improved.

[0050] On the other hand, the support member 5 is not substantially located on both sides of the solar cell panel 10 in the Y direction. That is, the support member 5 is not substantially located at the end portion in the +Y direction of the solar cell panel 10 extending along the X direction, nor is it substantially located at the end portion in the -Y direction of the solar cell panel 10 extending along the X direction. Therefore, when viewed in a state where the line of sight is along the Y direction, the solar cell panel 10 can be bent in an arc shape (see FIG. 6). In such a bent state, a relatively large stress is generated in the portion between the support member 5 and the solar cell portion 3 of the solar cell panel 10. More specifically, a large stress is generated in the portion near the inner end face 5a of the support member 5 of the solar cell panel 10. Here, the inner end face 5a refers to the end face of the support member 5 on the solar cell portion 3 side.

[0051] In this embodiment, the thickness of the filling material 4 is large between the support member 5 and the solar cell portion 3 and small in the solar cell portion 3. In other words, the thickness W1 is larger than the thickness W3. Therefore, the strength of the solar cell panel 10 can be improved between the support member 5 and the solar cell portion 3. Therefore, the solar cell panel 10 can appropriately cope with the stress caused by bending. Further, since the filling material 4 is thin in the solar cell portion 3, the flexibility of the solar cell panel 10 can be improved. That is, the flexibility and strength of the solar cell panel 10 can be made compatible. Also, compared with a structure in which the thickness W3 is increased to about the same level as the thickness W1, the volume of the filling material 4 can be reduced, so the material cost of the filling material 4 can also be reduced.

[0052] As shown in FIG. 2, if the thickness W1 of the portion 4a of the filler 4 is greater than the thickness W2, the strength of the solar cell panel 10 can be improved in the vicinity of the inner end face 5a of the support member 5. Therefore, the solar cell panel 10 can appropriately cope with the stress caused by bending. Further, in the region R1, if the thickness of the portion 4a gradually increases from the solar cell portion 3 toward the support member 5, the stress in the portion 4a can be effectively dispersed.

[0053] <1-3. First specific example of manufacturing the solar cell module according to the first embodiment> Next, an example of a method for manufacturing the solar cell module 100 will be described with reference to FIGS. 4(a) to 4(c).

[0054] First, the surface protection layer 1 is prepared. Here, for example, as the surface protection layer 1, a resin film having rectangular front and back surfaces and weather resistance is prepared. As the resin having weather resistance, for example, a fluorine-based resin is adopted. As the fluorine-based resin, for example, FEP, ETFE, or ECTFE is adopted. Here, for example, a treatment for activating the surface, such as corona treatment or plasma treatment, is performed on the second surface 1s, which is one side of the surface protection layer 1. Thereby, the adhesion between the surface protection layer 1 and the filler 4 in the subsequent lamination treatment can be improved.

[0055] Next, for example, as shown in FIGS. 4(b) and 4(c), the surface protection layer 1, the sheet 41s, the sheet 41t, the solar cell portion 3, the support member 5, the sheet 42s, the sheet 42t, and the back surface protection layer 2 are laminated to form a laminate 10s.

[0056] In the laminate 10s, the solar cell unit 3 is positioned between two support members 5, which are arranged at intervals in the X direction. Also, at this time, wiring for drawing out from the solar cell unit 3 to the outside of the solar cell panel 10 and connecting to a terminal box or the like is appropriately positioned. For example, a plurality of solar cell elements 31 of the solar cell unit 3 are interconnected by a first wiring member 32 and a second wiring member 33. Also, a third wiring member 34 is connected to the solar cell unit 3.

[0057] The sheets 41s and 41t are sheets made of a resin (such as EVA) that forms the first filler 41. The sheet 41s is positioned between the surface protective layer 1 and the solar cell unit 3 and between the surface protective layer 1 and the support member 5. That is, the sheet 41s is positioned above the surface protective layer 1, and the solar cell unit 3 and the support member 5 are positioned above the sheet 41s. The sheet 41s has a rectangular shape, which is an example of a rectangular shape in plan view.

[0058] In plan view, the sheet 41t is positioned above the sheet 41s between the support member 5 and the solar cell unit 3. In the examples of FIGS. 4(b) and 4(c), since two support members 5 are positioned, two sheets 41t are positioned. Each sheet 41t has a long shape that is long in the Y direction, for example, in plan view. In the examples of FIGS. 4(b) and 4(c), the width of each sheet 41t is narrower than the interval between the support member 5 and the solar cell unit 3. That is, in the examples of FIGS. 4(b) and 4(c), the sheet 41t is positioned in a state where it does not face both the support member 5 and the solar cell unit 3 in the Z direction.

[0059] The sheets 42s and 42t are sheets made of a resin (such as EVA) that forms the second filler 42. The sheets 42s and 42t may contain a pigment. The sheet 42s is positioned between the back surface protective layer 2 and the solar cell unit 3 and between the back surface protective layer 2 and the support member 5. That is, the sheet 42s is positioned in a state where both of its ends face the support member 5 respectively. The sheet 42s has a rectangular shape, which is an example of a rectangular shape in plan view.

[0060] In a plan view, the sheet 42t is positioned above the sheet 42s between the support member 5 and the solar cell unit 3. In the examples of FIGS. 4(b) and 4(c), since two support members 5 are positioned, two sheets 42t are positioned. Each sheet 42t has, for example, an elongated shape that is long in the Y direction in a plan view. In the examples of FIGS. 4(b) and 4(c), the width of each sheet 42t is narrower than the interval between the support member 5 and the solar cell unit 3. That is, in the examples of FIGS. 4(b) and 4(c), the sheet 42t is positioned in a state of not facing both the support member 5 and the solar cell unit 3 in the Z direction.

[0061] The back surface protective layer 2 is positioned above the sheet 42s and the sheet 42t.

[0062] As described above, in the laminate 10s, the sheet 41t and the sheet 42t are positioned between the support member 5 and the solar cell unit 3 in a plan view. For this reason, the total thickness of the sheets between the support member 5 and the solar cell unit 3 becomes larger by the amount of the sheet 41t and the sheet 42t than the total thickness of the sheets in the region facing the solar cell unit 3.

[0063] In addition, in the example of FIG. 4(c), although the sheet 42s and the back surface protective layer 2 are shown in a flat plate shape, when they have flexibility or softness, the central portion thereof can be bent toward the surface protective layer 1 side.

[0064] Next, for example, a laminating process is performed on the laminate 10s. Here, for example, the laminate 10s is integrated using a laminating device (laminator). For example, in the laminator, the laminate 10s is placed on a heater plate in a chamber, and the laminate 10s is heated from about 100 degrees Celsius (100°C) to about 200 degrees Celsius (200°C) while reducing the pressure in the chamber from 50 pascals (Pa) to about 150 Pa. At this time, the sheets 41s, 41t, 42s, and 42t become in a state where they can flow to some extent due to heating. In this state, in the chamber, the laminate 10s is integrated by pressing the laminate 10s in the Z direction with a pressing body such as a diaphragm sheet.

[0065] In this lamination process, as described above, the sheets 41t and 42t are positioned on the laminate 10s. That is, between the support member 5 and the solar cell portion 3, the total thickness of the sheets increases. For this reason, between the support member 5 and the solar cell portion 3, the thickness of the filler 4 can be more easily increased.

[0066] Also, if the sheets 41t and 42t are positioned, voids caused by the difference in thickness between the support member 5 and the solar cell element 31 can be reduced between the support member 5 and the solar cell portion 3 in the laminate 10s. As a result, the pressing body of the laminator can press the laminate 10s with sufficient pressure also between the support member 5 and the solar cell portion 3. In other words, the non-uniformity of the pressure distribution caused by the difference in thickness between the support member 5 and the solar cell element 31 can be reduced. Therefore, the melted sheet is pressed with sufficient pressure against the front surface protective layer 1, the support member 5, the solar cell portion 3, and the back surface protective layer 2 also between the support member 5 and the solar cell portion 3. As a result, the filler 4 can be adhered to these with higher adhesive strength.

[0067] Note that in the above example, in the lamination process, although the sheet 42t is positioned on the sheet 42s, it may be positioned between the sheet 42s and the sheet 41t. Also, although the sheet 41t is positioned on the sheet 41s, it may be positioned between the sheet 41s and the front surface protective layer 1. Also, between each of the solar cell portion 3 and the support member 5, a plurality of sheets 41t may be laminated in the Z direction, or a plurality of sheets 42t may be laminated in the Z direction. Also, only one of the sheets 41t and 42t may be positioned.

[0068] In addition, in the above example, although the sheets 41s and 41t are separate sheets from each other, they may be integrated. That is, it is sufficient that the thickness of the sheet in the region between the support member 5 and the solar cell portion 3 is larger than the thickness of the sheet in the region facing the solar cell portion 3. The same applies to the sheets 42s and 42t.

[0069] After the lamination process, a terminal box or the like may be appropriately attached to the solar cell panel 10. At this time, for example, the wiring drawn out from the solar cell portion 3 to the outside of the solar cell panel 10 is appropriately connected to the terminals in the terminal box. Thereby, the solar cell module 100 is assembled.

[0070] In the above example, the solar cell panel 10 including the support member 5 is integrated by the lamination process. Therefore, compared with a structure in which an external frame (not shown) is attached to the solar cell panel 10 with screws or the like instead of the support member 5, the assembly of the solar cell panel 10 is easy.

[0071] <1-4. Second specific example of manufacturing the solar cell module according to the first embodiment> As shown in FIGS. 5(a) and 5(b), in the lamination process, the sheets 41t and 42t may not be positioned on the laminate 10s. In this case, as shown in FIG. 5(b), the pressing surface 400s of the pressing body 400 of the laminator may have a stepped shape. The pressing surface 400s is a surface that contacts the laminate 10s and presses the laminate 10s.

[0072] In the example of FIG. 5(b), the pressing body 400 includes a diaphragm sheet 410, a first release sheet 420, and a second release sheet 421. As the material of the diaphragm sheet 410, for example, an elastic member such as silicon rubber that is easily elastically deformed is applied. The diaphragm sheet 410 is wider than the laminate 10s in plan view and is positioned in a state of facing the entire laminate 10s.

[0073] The first release sheet 420 is a sheet having releasability. The first release sheet 420 is obtained, for example, by forming a release film such as a silicon coating on the surface of a sheet-like base material. The first release sheet 420 is located on the laminate 10s side with respect to the diaphragm sheet 410. The first release sheet 420 is positioned in a state of being overlapped with the diaphragm sheet 410. The first release sheet 420 is wider than the laminate 10s in plan view and is positioned in a state of facing the entire laminate 10s.

[0074] The second release sheet 421 is a sheet having releasability. The second release sheet 421 is obtained, for example, by forming a release film such as a silicon coating on the surface of a sheet-like base material. The second release sheet 421 is located on the laminate 10s side with respect to the first release sheet 420. The second release sheet 421 is positioned in a state of being overlapped with the first release sheet 420.

[0075] The second release sheet 421 has, for example, an elongated shape that is long in the Y direction in plan view. The width of the second release sheet 421 in the X direction is narrower than the interval between the two support members 5 and is equal to or greater than the width of the solar cell portion 3. The second release sheet 421 is in a state of facing the laminate 10s in the Z direction between the two support members 5 and is not in a state of facing the support members 5 in the Z direction. Also, the second release sheet 421 is in a state of facing the entire solar cell portion 3 in the Z direction. The length of the second release sheet 421 in the Y direction is, for example, equal to or greater than the length of the laminate 10s in the Y direction.

[0076] The thickness of such a pressing body 400 is small in the region facing the support member 5 in the Z direction and large in the region facing the solar cell unit 3 in the Z-axis direction. For this reason, the pressing surface 400s, which is the surface of the pressing body 400 on the laminate 10s side, has steps on both sides of the second release sheet 421, and the portion of the pressing surface 400s corresponding to the second release sheet 421 protrudes toward the laminate 10s side by the thickness of the second release sheet 421. In other words, the pressing surface 400s has a first region 401s facing the support member 5 and a second region 402s located on the laminate 10s side of the first region 401s and corresponding to the solar cell unit 3, and the step between the first region 401s and the second region 402s is located between the support member 5 and the solar cell unit 3 in the X direction. The pressing surface 400s of such a pressing body 400 has a stepped shape corresponding to the thickness distribution of the filling material 4 illustrated in FIG. 2.

[0077] In the laminating process, initially, the pressing body 400 presses the back surface protective layer 2 in the second region (that is, the second release sheet 421) facing the solar cell unit 3, and then presses the back surface protective layer 2 in the first region on the support member 5 side. For this reason, the melted sheet easily flows toward the support member 5 side and flows into the space between the support member 5 and the solar cell unit 3. Therefore, the thickness of the filling material 4 between the support member 5 and the solar cell unit 3 can be easily increased.

[0078] Further, since the melted sheet flows into the space between the support member 5 and the solar cell unit 3, the volume of the sheet between the support member 5 and the solar cell unit 3 increases, and the pressing body 400 can press the laminate 10s with a more uniform pressure distribution. As a result, also between the support member 5 and the solar cell unit 3, the filling material 4 can adhere with higher adhesive strength to the surface protective layer 1, the support member 5, the solar cell unit 3, and the back surface protective layer 2.

[0079] <1-5. Summary of the First Embodiment> In the solar cell module 100 according to the first embodiment, for example, the thickness W1 of the filler 4 between the support member 5 and the solar cell unit 3 is larger than the thickness W3 of the filler 4 between the solar cell elements 31. Therefore, the strength of the solar cell panel 10 can be increased between the support member 5 and the solar cell unit 3. As a result, the solar cell panel 10 can withstand the stress applied to the portion between the support member 5 and the solar cell unit 3 due to the deflection caused by the external force F1. Further, since the thickness W3 is small, the flexibility of the solar cell panel 10 can be improved.

[0080] <1-6. Array number of solar cell elements> In the example of FIG. 1, the array number of the solar cell elements 31 in the X direction is 2, which is an even number. In other words, the array number of the solar cell elements 31 in the direction orthogonal to the longitudinal direction of the support member 5 is an even number. Further, the widths of the respective solar cell elements 31 in the X direction are substantially equal to each other. Therefore, no solar cell element 31 exists at the center of the solar cell panel 10 in the X direction. That is, the center of the solar cell panel 10 corresponds to the portion between the solar cell elements 31.

[0081] By the way, when the solar cell panel 10 is deflected by the external force F1 (see also FIG. 6), a relatively large stress is also applied to the center of the solar cell panel 10 in the X direction. Further, even when a load such as snow accumulation is applied to the solar cell panel 10 in a state where the support member 5 is attached to the attachment target member, the solar cell panel 10 can be deflected in an arc shape when viewed in the Y direction. Even in such a case, a relatively large stress is applied to the center of the solar cell panel 10 in the X direction.

[0082] In the example of FIG. 1, no solar cell element 31 exists at the center of the solar cell panel 10. Therefore, even when the external force F1 or a load such as snow accumulation is applied to the solar cell panel 10 and the solar cell panel 10 is deflected, the stress applied to each solar cell element 31 is relatively small. Therefore, it is possible to reduce the possibility of problems such as performance degradation of the solar cell element 31 due to stress.

[0083] <2. Other embodiments> The present disclosure is not limited to the above-described first embodiment, and various modifications and improvements can be made without departing from the gist of the present disclosure.

[0084] <2-1. Second Embodiment> <2-1-1. Solar Cell Module> In the above-described first embodiment, for example, as shown in FIGS. 7 and 8, a portion (corresponding to the first portion) 4b between the support member 5 and the surface protection layer 1 in the filler 4 may have the following thickness distribution (corresponding to a predetermined first thickness distribution). The first thickness distribution is a thickness distribution in which the thickness W4 at the end of the portion 4b on the solar cell portion 3 side is larger than the thickness W5 at the end of the portion 4b on the outer portion 52 side. The difference between the thickness W4 and the thickness W5 may be, for example, 0.01 mm or more, 0.05 mm or more, or 0.1 mm or more.

[0085] As shown in FIGS. 7 and 8, the thickness of the portion 4b of the filler 4 may gradually decrease from the inner end face 5a toward the outer end face 5b at least in the region R2 among the regions facing the support member 5 in the Z direction. Here, the outer end face 5b refers to the end face of the support member 5 on the side opposite to the solar cell portion 3 in the X direction. It can also be said that the thickness of the portion 4b may monotonically decrease from the inner end face 5a toward the outer end face 5b in the region R2. The amount of thickness reduction in the entire region R2 may be, for example, 0.01 mm or more, 0.05 mm or more, or 0.1 mm or more.

[0086] In the examples of FIGS. 7 and 8, the thickness of the portion 4a of the filler 4 gradually increases from the solar cell portion 3 toward the support member 5, and the thickness of the portion 4b of the filler 4 gradually decreases from the inner end face 5a toward the outer end face 5b. For this reason, the first surface 4f of the filler 4 has a convex shape that bulges in the +Z direction in the vicinity of the inner end face 5a of the support member 5. Specifically, the first surface 4f bulges, for example, in a smooth mountain shape. The shapes of the portion 4a and the portion 4b of the filler 4 are, for example, uniform in the Y direction.

[0087] As shown in FIGS. 7 and 8, a portion 4c (corresponding to the second portion) between the support member 5 and the back surface protection layer 2 in the filling material 4 may also have a thickness distribution (corresponding to the second thickness distribution) described below. The second thickness distribution is a thickness distribution in which the thickness W6 at the end of the portion 4c on the solar cell portion 3 side is greater than the thickness W7 at the end of the outer portion 52 side of the portion 4c. The difference between the thickness W6 and the thickness W7 may be, for example, 0.01 mm or more, 0.05 mm or more, or 0.1 mm or more.

[0088] As shown in FIGS. 7 and 8, the thickness of the portion 4c of the filling material 4 may gradually decrease from the inner end face 5a toward the outer end face 5b at least in the region R3 among the regions facing the support member 5 in the Z direction. In other words, the thickness of the portion 4c may monotonically decrease from the inner end face 5a toward the outer end face 5b in the region R3. The amount of thickness reduction in the entire region R3 may be, for example, 0.01 mm or more, 0.05 mm or more, or 0.1 mm or more. Further, in the examples of FIGS. 7 and 8, the second surface 4s of the filling material 4 has a convex shape that bulges in the -Z direction in the vicinity of the inner end face 5a of the support member 5. Specifically, the second surface 4s bulges in a smooth mountain shape, for example. The shape of the portion 4c of the filling material 4 is uniform in the Y direction, for example.

[0089] Here, an explanation will be given focusing on the interval between the front surface protection layer 1 and the back surface protection layer 2. That is, the interval between the front surface protection layer 1 and the back surface protection layer 2 at the position of the inner end face 5a of the support member 5 is wider than the interval between the front surface protection layer 1 and the back surface protection layer 2 at the X-direction end of the front surface protection layer 1 or the X-direction end of the back surface protection layer 2. The interval between the front surface protection layer 1 and the back surface protection layer 2 is maximum in the vicinity of the inner end face 5a of the support member 5.

[0090] Next, an explanation will be given focusing on the thickness of the structure composed of the filler 4 and the support member 5. That is, the thickness of the structure at the position of the inner end face 5a of the support member 5 is larger than the thickness of the structure at the X-direction end of the surface protection layer 1 or the X-direction end of the back surface protection layer 2. The thickness of the structure is maximum in the vicinity of the inner end face 5a of the support member 5.

[0091] <2-1-2. Characteristics of solar cell module> According to the second embodiment, the thickness W4 of the portion 4b of the filler 4 is larger than the thickness W5. For this reason, the thickness of the solar cell panel 10 in the vicinity of the inner end face 5a of the support member 5 can be further increased, and the strength of the solar cell panel 10 in the vicinity of the inner end face 5a can be further improved. Therefore, even if the external force F1 is increased and the solar cell panel 10 is bent more greatly, the solar cell panel 10 can withstand the stress. Also, since the thickness W5 of the filler 4 is smaller than the thickness W4, the material cost of the filler 4 can be reduced as compared with a structure in which the thickness W5 of the filler 4 is increased to the same level as the thickness W4.

[0092] In the examples of FIGS. 7 and 8, the thickness W6 of the portion 4c of the filler 4 is larger than the thickness W7. For this reason, the thickness of the solar cell panel 10 in the vicinity of the inner end face 5a of the support member 5 can be further increased, and the strength of the solar cell panel 10 in the vicinity of the inner end face 5a can be further improved. Therefore, even if the external force F1 is increased and the solar cell panel 10 is bent more greatly, the solar cell panel 10 can withstand the stress. Also, since the thickness W7 of the filler 4 is smaller than the thickness W6, the material cost of the filler 4 can be reduced as compared with a structure in which the thickness W7 of the filler 4 is increased to the same level as the thickness W6.

[0093] Note that in the examples of FIGS. 7 and 8, although the first surface 4f and the second surface 4s of the filler 4 have shapes that are line-symmetric with respect to the XY plane, the drawings are only schematically shown and are not necessarily limited to this.

[0094] Further, for example, the thickness of either the portion 4b or the portion 4c of the filler 4 may be uniform. That is, either the portion 4b or the portion 4c may have a flat plate shape with a uniform thickness. This is because if either the portion 4b or the portion 4c has the above-described thickness distribution, the strength of the solar cell panel 10 can be improved in the vicinity of the inner end face 5a.

[0095] <2-1-3. First specific example of the manufacturing method of the solar cell module according to the second embodiment> An example of the lamination process in the manufacturing method of the solar cell module 100 according to the second embodiment will be described with reference to FIGS. 9(a) and 9(b).

[0096] For example, as shown in FIGS. 9(a) and 9(b), a laminate 10s is formed by laminating the surface protective layer 1, the sheet 41s, the sheet 41u, the solar cell part 3, the support member 5, the sheet 42s, the sheet 42u, and the back surface protective layer 2. That is, compared with the first specific example of the first embodiment, the sheets 41u and 42u are used instead of the sheets 41t and 42t, respectively.

[0097] The sheet 41u is a sheet made of a resin (such as EVA) that is part of the first filler 41. The sheet 41u is located, for example, on the sheet 41s. In the examples of FIGS. 9(a) and 9(b), since two support members 5 are located, two sheets 41u are located. Each sheet 41u has a long shape that is long in the Y direction, for example, in plan view. The sheet 41u is located in a region straddling the inner end face 5a of the support member 5 in the X direction. That is, the outer portion of the sheet 41u in the X direction is located between the surface protective layer 1 and the support member 5, and the inner portion of the sheet 41u in the X direction is located inside the inner end face 5a of the support member 5. The inner portion of this sheet 41u is located, for example, in a state where it does not face the solar cell part 3 in the Z direction. Also, the outer end of the sheet 41u in the X direction is located inside, for example, the end of the surface protective layer 1 and the end of the sheet 41s in the X direction.

[0098] The sheet 42u is a sheet made of resin (such as EVA) that forms part of the second filler 42. The sheet 42u is located, for example, on top of the sheet 42s. In the examples of FIGS. 9(a) and 9(b), since two support members 5 are located, two sheets 42u are located. Each sheet 42u has, in plan view, a long and narrow shape that is long, for example, in the Y direction. The sheet 42u is located in a region straddling the inner end face 5a of the support member 5 in the X direction. That is, the outer portion of the sheet 42u in the X direction is located between the back surface protective layer 2 and the support member 5, and the inner portion of the sheet 42u in the X direction is located inside the inner end face 5a of the support member 5. The inner portion of this sheet 42u is located, for example, in a state where it does not face the solar cell portion 3 in the Z direction. Also, the outer end of the sheet 42u in the X direction is located inside, for example, the end of the back surface protective layer 2 and the end of the sheet 42s in the X direction.

[0099] Next, for example, a lamination process is performed on the laminate 10s. Here, for example, a laminating device (laminator) is used to integrate the laminate 10s. Thereby, the solar cell panel 10 shown in FIGS. 7 and 8 can be manufactured.

[0100] In the laminate 10s, the sheet 41u is located in a state straddling the inner end face 5a of the support member 5. For this reason, the thickness W4 of the portion 4b of the filler 4 can be more easily increased. Also, in plan view, since the outer end of the sheet 41u is located inside the end of the surface protective layer 1 and the end of the sheet 41s, the thickness W5 of the portion 4b can be more easily reduced to be lower than the thickness W4.

[0101] In the laminate 10s, the sheet 42u is located in a state straddling the inner end face 5a of the support member 5. For this reason, the thickness W6 of the portion 4c of the filler 4 can be more easily increased. Also, in plan view, since the outer end of the sheet 42u is located inside the end of the back surface protective layer 2 and the end of the sheet 41s, the thickness W7 of the portion 4c can be more easily reduced to be lower than the thickness W6.

[0102] <2-1-4. Second Specific Example of the Manufacturing Method of the Solar Cell Module According to the Second Embodiment> As shown in FIGS. 10(a) and 10(b), in the lamination process, the sheets 41u and 42u may not be positioned on the laminate 10s. In this case, as shown in FIG. 10(b), the pressing surface 400s of the pressing body 400 may have a stepped shape. In the example of FIG. 10(b), the pressing body 400 further includes a third release sheet 422 as compared with the pressing body 400 of FIG. 5(b).

[0103] The third release sheet 422 is a sheet having releasability. The third release sheet 422 can be obtained, for example, by forming a release film such as a silicon coating on the surface of a sheet-like base material. The third release sheet 422 is positioned on the laminate 10s side with respect to the first release sheet 420. The third release sheet 422 is positioned in a state of being overlapped with the first release sheet 420.

[0104] In the example of FIG. 10(b), since two support members 5 are positioned on the laminate 10s, two third release sheets 422 are positioned. The third release sheet 422 has, for example, an elongated shape that is long in the Y direction and is positioned in a state of facing the X-direction end of the back surface protective layer 2 in the Z direction. The inner end 422a of the third release sheet 422 on the second release sheet 421 side is positioned between the end of the back surface protective layer 2 and the inner end face 5a of the support member 5 in the X direction. The outer end 422b of the third release sheet 422 on the side opposite to the second release sheet 421 is positioned outside the end of the back surface protective layer 2 in the X direction.

[0105] The thickness of such a pressing body 400 is small in a region that faces the vicinity of the inner end face 5a of the support member 5 in the Z direction. For this reason, the pressing surface 400s of the pressing body 400 has a concave shape that is recessed in a region that faces the vicinity of the inner end face 5a of the support member 5 in the Z direction. More specifically, the pressing surface 400s has a first region 401s that faces the inner end face 5a of the support member 5, a second region 402s that is located closer to the laminate 10s side than the first region 401s and faces the solar cell portion 3, and a third region 403s that is located closer to the laminate 10s side than the first region 401s and faces the end portion of the back surface protective layer 2. The pressing surface 400s of such a pressing body 400 has a stepped shape according to the thickness distribution of the filler 4 illustrated in FIGS. 7 and 8.

[0106] Such a pressing body 400 presses regions at both ends in the X direction and a region facing the solar cell portion 3 of the back surface protective layer 2 in the laminating process, and then presses the back surface protective layer 2 in a region near the inner end face 5a of the support member 5. For this reason, the melted sheet flows from both sides in the X direction to the vicinity of each inner end face 5a. As a result, in the vicinity of the inner end face 5a of the support member 5, the thickness of the filler 4 can be easily increased.

[0107] Note that, in the laminator, the support surface of a support body (not shown) that supports the front surface protective layer 1 may have the same stepped shape as the pressing surface 400s of the pressing body 400. That is, the support body may include the first release sheet 420, the second release sheet 421, and the third release sheet 422 of the pressing body 400 in a state where the top and bottom are reversed.

[0108] <2-2. Third Embodiment> <2-2-1. Solar Cell Module> In the above-described first embodiment and the second embodiment, as shown in FIG. 11, the end 2a in the X direction of the back surface protective layer 2 may be located on the solar cell unit 3 side with respect to the end 1a in the X direction of the front surface protective layer 1. The end 1a can be said to be the end of the front surface protective layer 1 on the support member 5 side, and the end 2a can be said to be the end of the back surface protective layer 2 on the support member 5 side. More specifically, the end 2a in the -X direction of the back surface protective layer 2 is located on the solar cell unit 3 side with respect to the end 1a in the -X direction of the front surface protective layer 1, and the end 2a in the +X direction of the back surface protective layer 2 may be located on the solar cell unit 3 side with respect to the end 1a in the +X direction of the front surface protective layer 1. In other words, the width of the back surface protective layer 2 in the X direction may be smaller than the width of the front surface protective layer 1 in the X direction. Also, as shown in FIG. 11, the end 42a of the filling material 4 on the back surface protective layer 2 side and the outer portion 52 side may be located on the solar cell unit 3 side with respect to the end 41a of the filling material 4 on the front surface protective layer 1 side and the outer portion 52 side. Specifically, the end 42a in the -X direction and the -Z direction of the filling material 4 may be located on the solar cell unit 3 side with respect to the end 41a in the -X direction and the +Z direction of the filling material 4, and the end 42a in the +X direction and the -Z direction of the filling material 4 may be located on the solar cell unit 3 side with respect to the end 41a in the +X direction and the +Z direction of the filling material 4.

[0109] As a more specific example, as shown in FIG. 11, the back surface protective layer 2 may be located avoiding the regions facing the respective support members 5 in the Z direction, and the filling material 4 may be in the -Z direction (i.e., on the side opposite to the front surface protective layer 1) with respect to each support member 5 and may be located avoiding the regions facing the respective support members 5 in the Z direction. That is, in the -Z direction with respect to the support member 5 and in the region facing the support member 5 in the Z direction, the filling material 4 and the back surface protective layer 2 may not be located.

[0110] In such a structure, the entire -Z direction surface of the support member 5 is exposed to the outside of the solar cell module 100. In the example of FIG. 11, the mounting target member 300 to which the support member 5 in the +X direction is fixed and the fastening member 301 for fixing them are shown by phantom lines. In the example of FIG. 11, the mounting target member 300 faces the support member 5 in the Z direction and is in contact with the support member 5. The fastening member 301 is, for example, a bolt that penetrates the support member 5 in the Z direction. The support member 5 can be pressed and fixed to the mounting target member 300 by the fastening member 301. Although not shown in FIG. 11, the support member 5 in the -X direction can also be attached to the mounting target member, for example, in the same manner as the support member 5 in the +X direction.

[0111] In the example of FIG. 11, the filler 4 and the back surface protective layer 2 are not located between the mounting target member 300 and the support member 5. Therefore, even if the thicknesses of the filler 4 and the back surface protective layer 2 vary due to various factors such as thermal expansion, thermal contraction, and aging deterioration of the filler 4 and the back surface protective layer 2, the distance between the support member 5 and the mounting target member 300 does not vary. Accordingly, loosening of the fastening member 301 due to variations in the thicknesses of the filler 4 and the back surface protective layer 2 can be suppressed, and the solar cell module 100 can be fixed to the mounting target member 300 more firmly with higher reliability.

[0112] Also, since the opposing area between the support member 5 and the mounting target member 300 can be increased, the support member 5 can be fixed more firmly to the mounting target member 300. Conversely, even if the width of the support member 5 in the X direction is narrowed, the opposing area between the support member 5 and the mounting target member 300 can be ensured, so that the solar cell module 100 can be miniaturized.

[0113] In the example of FIG. 11, a part of the filler 4 is located between the surface protection layer 1 and each support member 5. Therefore, even if water such as rainwater reaches the front surface 10f of the solar cell panel 10 from the external space 200, it is difficult for the water to enter between the surface protection layer 1 and each support member 5. On the other hand, since rainwater hardly reaches the back surface 10b of the solar cell panel 10, there is little water entering between the back surface protection layer 2 and each support member 5 in the first place. For this reason, the solar cell portion 3 can also be appropriately protected from water.

[0114] <2-2-2. Manufacturing method of solar cell module according to the third embodiment> Next, an example of the lamination process in the manufacturing method of the solar cell module 100 according to the third embodiment will be described with reference to FIGS. 12(a) and 12(b).

[0115] For example, as shown in FIGS. 12(a) and 12(b), a laminate 10s is formed by laminating the surface protection layer 1, the sheet 41s, the sheet 41t, the solar cell portion 3, the support member 5, the sheet 42s, the sheet 42t, and the back surface protection layer 2. As shown in FIGS. 12(a) and 12(b), in the laminate 10s according to the third embodiment, the sheet 42s that is the element of the filler 4 is not located between the support member 5 and the back surface protection layer 2. That is, the width of the sheet 42s in the X direction is smaller than the width of the sheet 41s in the X direction, and more specifically, smaller than the interval between the two support members 5. Also, the width of the sheet 42s is wider than the width of the solar cell portion 3 in the X direction. This sheet 42s is positioned so as to face the solar cell portion 3 in the Z direction and not to face the support member 5 in the Z direction.

[0116] Also, as shown in FIGS. 12(a) and 12(b), the width of the back surface protection layer 2 in the X direction is narrower than the width of the surface protection layer 1 in the X direction. The width of the back surface protection layer 2 in the X direction may be, for example, the same as the interval between the two support members 5, or may be narrower than the interval. Also, in another example described later, the width of the back surface protection layer 2 in the X direction may be made wider than the interval between the support members 5 and narrower than the width of the surface protection layer 1 in the X direction.

[0117] Next, for example, a lamination process is performed on the laminate 10s. Here, for example, using a laminating device (laminator), the laminate 10s is integrated. Thereby, the solar cell panel 10 shown in FIG. 11 can be manufactured.

[0118] In the examples of FIGS. 12(a) and 12(b), although the sheets 41t and 42t are positioned, for example, as shown in FIGS. 5(a) and 5(b), the sheets 41t and 42t may not be positioned. Even in this case, the width of the sheet 42s is set to the width shown in FIGS. 12(a) and 12(b).

[0119] <2-2-3. Another Example of the Third Embodiment> In the example of FIG. 11, the filler 4 and the back surface protective layer 2 do not entirely cover the regions facing the respective support members 5 in the -Z direction with respect to the respective support members 5. However, it is not necessarily limited to this. A part of the back surface protective layer 2 and the filler 4 may be located in this region. In the example of FIG. 11, a state where a part of the filler 4 and a part of the back surface protective layer 2 are located in this region on the support member 5 side in the -X direction is shown by a two-dot chain line. Even in this case, in a plan view, the -X direction end 2a of the back surface protective layer 2 is located on the solar cell unit 3 side with respect to the -X direction end 1a of the front surface protective layer 1, and the end 42a of the filler 4 on the back surface protective layer 2 side and the outer portion 52 side is located on the solar cell unit 3 side with respect to the end 41a of the filler 4 on the front surface protective layer 1 side and the outer portion 52 side. Although not shown in FIG. 11, also on the support member 5 side in the +X direction, a part of the filler 4 and a part of the back surface protective layer 2 may be located in this region.

[0120] Even with such a structure, it is possible to improve the area of the exposed portion of each support member 5 on the back surface protective layer 2 side. Therefore, the facing area between the support member 5 and the member to be attached can be improved, and the solar cell module 100 can be more firmly fixed to the member to be attached. Alternatively, even if the width of the support member 5 in the X direction in the solar cell module 100 is narrowed, the facing area between the support member 5 and the member to be attached can be ensured, so that the solar cell module 100 can be miniaturized.

[0121] <2-3. Fourth Embodiment> In the first to third embodiments described above, as shown in FIGS. 13(a) and 13(b), a plurality of support members 5 may be positioned at intervals in the Y direction. In the example of FIG. 13(a), on each of the two sides in the X direction of the solar cell panel 10, four support members 5 are positioned in an array in the Y direction. That is, the four support members 5 are at the -X direction end of the solar cell panel 10 and at the end extending along the Y direction, and are arranged at intervals in the Y direction. Another four support members 5 are at the +X direction end of the solar cell panel 10 and at the end extending along the Y direction, and are arranged at intervals in the Y direction. In the example of FIG. 13(a), the four support members 5 on one side of the solar cell panel 10 are positioned in a state of facing the four support members 5 on the other side of the solar cell panel 10 in the X direction. That is, eight support members 5 are arranged in a matrix of four rows and two columns.

[0122] Referring to FIG. 13(b), the thickness of the portion (corresponding to the third portion) 4d of the filling material 4 between two adjacent support members 5 in the Y direction will be described. The portion 4d may have the following thickness distribution (corresponding to the third thickness distribution). The third thickness distribution is a thickness distribution in which the thickness W8 of the portion 4d at one end of two adjacent support members 5 is greater than the thickness W9 of the portion 4d at the central position between the two support members 5. The difference between the thickness W8 and the thickness W9 may be, for example, 0.1 mm or more, 0.5 mm or more, or 1 mm or more.

[0123] In the example of FIG. 13(b), the portion 4d of the filler 4 has a thickness distribution in which the thickness gradually decreases toward the center between the two adjacent support members 5 in at least a part of the region R4 in the Y direction.

[0124] According to the fourth embodiment, since the plurality of support members 5 are arranged at intervals in the Y direction, the solar cell panel 10 can be bent in an arc shape when viewed with the line of sight along the X direction. In this bent state, larger stress is generated in the solar cell panel 10 in the vicinity of the end faces 5c on both sides in the Y direction of each support member 5. Here, the end faces 5c on both sides in the Y direction include the end face 5c of the support member 5 located on one side in the Y direction and intersecting the Y direction, and the end face 5c of the support member 5 located on the other side in the Y direction and intersecting the Y direction.

[0125] As shown in FIG. 13(b), the thickness of the portion 4d of the filler 4 is large on the side of the support member 5 and small at the center between the support members 5. Therefore, the strength of the solar cell panel 10 can be improved in the vicinity of the end face 5c of the support member 5. Accordingly, the solar cell panel 10 can cope with the stress caused by the above-described bending. Further, since the filler 4 is thin at the center between the support members 5, the flexibility of the solar cell panel 10 can also be improved. Also, the material cost of the filler 4 can be reduced as compared with a structure in which the thickness W9 is increased to the same level as the thickness W8.

[0126] Such a thickness distribution of the portion 4d of the filler 4 can be easily realized, for example, by newly positioning a resin sheet that is the base of the filler 4 only at the end portions between the support members 5 in a lamination process. Alternatively, for example, in a lamination process, the thickness distribution of the portion 4d can be realized by forming a stepped shape corresponding to the thickness distribution of the portion 4d on the pressing surface 400s of the pressing body 400.

[0127] Also, similar to the second embodiment, the first surface 4f of the filler 4 may have a convex shape that bulges in the +Z direction in the vicinity of the end face 5c of the support member 5, and the second surface 4s of the filler 4 may have a convex shape that bulges in the -Z direction in the vicinity of the end face 5c of the support member 5.

[0128] <2-4. Fifth Embodiment> In the first to fourth embodiments described above, as shown in FIG. 14, the support member 5 may be located only on one side of a rectangular solar cell panel 10. In other words, the support member 5 may be located only on one side of the front surface protection layer 1 and the back surface protection layer 2 having a rectangular shape. In the example of FIG. 14, the support member 5 is located only on one side in the -X direction of the solar cell panel 10. Even with this structure, the rigidity of the solar cell panel 10 can be improved compared to a structure without the support member 5. Further, this solar cell panel 10 is integrated by a lamination process. Therefore, the assembly of the solar cell panel 10 is easy.

[0129] Also, since the support member 5 is not located on three sides of the solar cell panel 10, the solar cell panel 10 is more likely to bend in more directions. That is, the flexibility of the solar cell panel 10 can be improved.

[0130] <2-5. Sixth Embodiment> In the first to fifth embodiments described above, for example, as shown in FIGS. 15(a) and 15(b), the solar cell module 100 may further include a reinforcing fiber member 60. The reinforcing fiber member 60 includes, for example, fiber members such as aramid fibers such as Kevlar (registered trademark) and carbon fibers, and is positioned in a state of being covered by the filler 4 between the front surface protective layer 1 and the back surface protective layer 2. For example, the entire reinforcing fiber member 60 is covered by the filler 4. In the example of FIG. 15(a), the reinforcing fiber member 60 is positioned along the sides of the solar cell panel 10 where the support member 5 is not located. In the example of FIG. 15(a), since the two support members 5 are respectively positioned on the sides (corresponding to the first side) on both sides of the solar cell panel 10 in the X direction, the two reinforcing fiber members 60 are respectively positioned on the sides (corresponding to the second side) on both sides of the solar cell panel 10 in the Y direction. Here, the sides on both sides in the X direction refer to one side located at the -X direction end of the solar cell panel 10 and extending in the Y direction, and one side located at the +X direction end of the solar cell panel 10 and extending in the Y direction, and the sides on both sides in the Y direction refer to one side located at the -Y direction end of the solar cell panel 10 and extending in the X direction, and one side located at the +Y direction end of the solar cell panel 10 and extending in the X direction. The reinforcing fiber member 60 has an elongated shape that is long in the X direction and is positioned in a state of not overlapping the solar cell portion 3 in plan view. That is, the reinforcing fiber member 60 is positioned in a state of not facing the solar cell portion 3 in the Z direction.

[0131] The length of the reinforcing fiber member 60 in the longitudinal direction (that is, the length in the X direction) may be, for example, 1 / 2 or more of the width of the solar cell panel 10 in the X direction, 2 / 3 or more, or 3 / 4 or more. Both ends of the reinforcing fiber member 60 in the X direction may respectively abut against the support member 5.

[0132] While the reinforcing fiber member 60 is easily deformable, it has high strength. Therefore, the reinforcing fiber member 60 can improve the strength of the solar cell panel 10 without reducing its flexibility. In the example of Fig. 15(a), since the reinforcing fiber member 60 is located at the side of the solar cell panel 10 where the support member 5 is not located, the reinforcing fiber member 60 can improve the strength of the low-strength portion. For this reason, the support member 5 and the reinforcing fiber member 60 can overall increase the strength in the peripheral region of the solar cell panel 10.

[0133] <2-6. Seventh Embodiment> In the above-described first to sixth embodiments, for example, as shown in Figs. 16(a) to 17(b), the solar cell unit 3 may be changed to a solar cell unit 3B having a plurality of thin-film solar cell regions 31B each including a thin-film semiconductor and a transparent electrode. The thin-film semiconductor includes, for example, a silicon-based, compound-based, or other type of semiconductor. For the silicon-based thin-film semiconductor, for example, a semiconductor using amorphous silicon or thin-film polycrystalline silicon is applicable. For the compound-based thin-film semiconductor, for example, a compound semiconductor having a chalcopyrite structure such as a CIS semiconductor or a CIGS semiconductor, a compound semiconductor having a perovskite structure, a compound semiconductor having a kesterite structure, or a cadmium telluride (CdTe) semiconductor is applicable. The CIS semiconductor is a compound semiconductor containing copper (Cu), indium (In), and selenium (Se). The CIGS semiconductor is a compound semiconductor containing Cu, In, gallium (Ga), and Se. Here, an example will be described in which a plurality of thin-film solar cell regions 31B are located on the substrate 6.

[0134] As shown in FIGS. 16(a) to 17(b), the solar cell section 3B includes a substrate 6 and a plurality of solar cell regions 31B that are arranged side by side on the substrate 6 in a planar manner. Here, being arranged side by side in a planar manner means that each of the plurality of solar cell regions 31B is located along a virtual or actual plane and the plurality of solar cell regions 31B are arranged side by side. In the examples of FIGS. 17(a) and 17(b), the plurality of solar cell regions 31B are arranged along the surface of the substrate 6 on the substrate 6. For the substrate 6, for example, a transparent glass substrate having a thickness of about 0.5 mm to 2 mm is applied. Here, for example, assume a case where the solar cell section 3B includes N (N is a natural number of 2 or more) solar cell regions 31B. In this case, for example, if the N solar cell regions 31B are electrically connected in series, the larger the numerical value N, the larger the output voltage of the solar cell section 3B can be. FIGS. 17(a) and 17(b) show an example in which a plurality (here, 7) of solar cell regions 31B are arranged along the +Y direction. Here, for example, each of the solar cell regions 31B has an elongated shape having a longitudinal direction along the +X direction. In this case, for example, if the width of the solar cell region 31B in the +Y direction is about several millimeters (mm) to 1 centimeter (cm), several tens to several hundreds of solar cell regions 31B can be arranged in the solar cell section 3B.

[0135] Each of the plurality of solar cell regions 31B has, for example, a first electrode layer 8a, a semiconductor layer 8b, and a second electrode layer 8c as shown in FIG. 17(b). Further, in the solar cell section 3B, for example, as shown in FIG. 17(b), a connection section 9 and a transparent section 7 are present between adjacent solar cell regions 31B. Here, for example, if the second electrode layer 8c is a layer having higher light transmittance for light of a specific wavelength range than the semiconductor layer 8b (also referred to as a light-transmissive electrode layer), incident light can pass through the second electrode layer 8c in each solar cell region 31B. Thereby, for example, the incident light that has passed through the surface protective layer 1 can pass through the second electrode layer 8c and be irradiated onto the semiconductor layer 8b. At this time, for example, the incident light can be absorbed by the semiconductor layer 8b. Here, for example, when the back surface protective layer 2 is made of a material having the same light transmittance as the surface protective layer 1, if the first electrode layer 8a is a layer having higher light transmittance for light of a specific wavelength range than the semiconductor layer 8b (light-transmissive electrode layer), the incident light that has passed through the back surface protective layer 2 can pass through the first electrode layer 8a and be irradiated onto the semiconductor layer 8b.

[0136] The first electrode layer 8a is located, for example, on the surface of the substrate 6 facing the +Z direction. The first electrode layer 8a is an electrode (also referred to as the first electrode) that can collect charges generated by photoelectric conversion in response to light irradiation in the semiconductor layer 8b. If a transparent conductive oxide (TCO: Transparent Conductive Oxide) having light transmittance for light of a specific wavelength range is applied to the material of the first electrode layer 8a, for example, light of a specific wavelength range can pass through the back surface protective layer 2 and the first electrode layer 8a and be incident on the semiconductor layer 8b. TCO includes, for example, indium tin oxide (ITO: Indium Tin Oxide), fluorine-doped tin oxide (FTO: Fluorine-doped tin oxide), or zinc oxide (ZnO). When zinc oxide is used as the TCO, the TCO may contain aluminum (Al), boron (B), or gallium (Ga) as necessary. In the example of FIG. 17(b), seven first electrode layers 8a are in a state of being arranged planar along the +Y direction on the substrate 6. Here, the first electrode layer 8a of the m-th solar cell region 31Bm (m is a natural number from 1 to 6) and the portion of the first electrode layer 8a of the (m + 1)-th solar cell region 31B(m + 1) that extends toward the m-th solar cell region 31Bm are arranged with a gap (also referred to as the first gap) G1 therebetween. For example, the first electrode layer 8a of the first solar cell region 31B1 and the portion of the first electrode layer 8a of the second solar cell region 31B2 that extends toward the first solar cell region 31B1 are arranged with the first gap G1 therebetween. Each first gap G1 has a longitudinal direction along the +X direction. Here, in each first gap G1, a first groove portion P1 having the surface of the substrate 6 as the bottom surface exists.

[0137] The semiconductor layer 8b is positioned between the first electrode layer 8a and the second electrode layer 8c. Here, the semiconductor layer 8b of the m-th solar cell region 31Bm extends until it reaches the end of the portion where the first electrode layer 8a of the adjacent (m + 1)-th solar cell region 31B(m + 1) extends in the -Y direction. For example, the semiconductor layer 8b of the first solar cell region 31B1 is positioned in a state where it extends until it reaches the end of the portion where the first electrode layer 8a of the adjacent second solar cell region 31B2 extends in the -Y direction. The semiconductor layer 8b is composed of, for example, the thin film semiconductor described above.

[0138] The second electrode layer 8c is located on the semiconductor layer 8b. The second electrode layer 8c is an electrode (also referred to as the second electrode) that can collect charges generated by photoelectric conversion in response to light irradiation in the semiconductor layer 8b. As the material of the second electrode layer 8c, for example, similar to the material of the first electrode layer 8a, a transparent conductive oxide (TCO) having light transmittance for light with a specific wavelength range or the like can be adopted. In the example of FIG. 17(b), seven second electrode layers 8c are in a state of being arranged side by side in the +Y direction. Here, a portion of the second electrode layer 8c of the m-th solar cell region 31Bm extending toward the (m + 1)-th solar cell region 31B(m + 1) and the second electrode layer 8c of the (m + 1)-th solar cell region 31B(m + 1) are arranged with a gap (also referred to as the second gap) G2 therebetween. For example, a portion of the second electrode layer 8c of the first solar cell region 31B1 extending in the +Y direction and the second electrode layer 8c of the second solar cell region 31B2 are arranged with a gap (the second gap) G2 therebetween. Each second gap G2 has a longitudinal direction along the +X direction. Here, in each second gap G2, there is a third groove portion P3 having the first electrode layer 8a as the bottom surface. Also, here, for example, between the m-th solar cell region 31Bm and the (m + 1)-th solar cell region 31B(m + 1) adjacent in the +Y direction, the second gap G2 exists at a position shifted in the +Y direction from the first gap G1. Therefore, for example, the inter-cell region 31ga between the m-th solar cell region 31Bm and the (m + 1)-th solar cell region 31B(m + 1) adjacent in the +Y direction is located from the -Y direction edge of the first gap G1 to the +Y direction edge of the second gap G2.

[0139] The connection part 9 is in a state of electrically connecting two adjacent solar cell regions 31B among the plurality of solar cell regions 31B in series. In the example of Fig. 17(b), the m-th connection part 9m is located in a state of penetrating between the semiconductor layer 8b and the transparent part 7. This m-th connection part 9m is in a state of electrically connecting the m-th solar cell region 31Bm and the (m + 1)-th solar cell region 31B(m + 1). For example, the first connection part 91 is in a state of electrically connecting the first solar cell region 31B1 and the second solar cell region 31B2. More specifically, the m-th connection part 9m is in a state of electrically connecting the second electrode layer 8c of the m-th solar cell region 31Bm and the first electrode layer 8a of the (m + 1)-th solar cell region 31B(m + 1). For example, the first connection part 91 is in a state of electrically connecting the second electrode layer 8c of the first solar cell region 31B1 and the first electrode layer 8a of the second solar cell region 31B2. Thereby, the plurality of solar cell regions 31B are in a state of being electrically connected in series. Further, the connection part 9 exists in a second groove part (not shown) having, as both side surfaces, the end surface of the semiconductor layer 8b facing the +Y direction and the end surface of the transparent part 7 facing the -Y direction, and having, as the bottom surface, the surface of the first electrode layer 8a facing the -Z direction. Each second groove part has a longitudinal direction along the +X direction. And the connection part 9 is in a state of filling the second groove part.

[0140] The transparent portion 7 has a higher light transmittance for light with a wavelength in a specific range than the semiconductor layer 8b. The transparent portion 7 can be formed, for example, by locally heating a part of the semiconductor layer having a perovskite structure. Here, the m-th transparent portion 7m is located between the m-th connection portion 9m of the m-th solar cell region 31Bm and the (m + 1)-th solar cell region 31B(m + 1). For example, the first transparent portion 71 is located between the first connection portion 91 of the first solar cell region 31B1 and the second solar cell region 31B2. In the example of FIG. 17(b), the m-th transparent portion 7m is located between the m-th connection portion 9m of the m-th solar cell region 31Bm and the third groove portion P3 existing between the m-th solar cell region 31Bm and the (m + 1)-th solar cell region 31B(m + 1). For example, the first transparent portion 71 is located between the first connection portion 91 of the first solar cell region 31B1 and the third groove portion P3 existing between the first solar cell region 31B1 and the second solar cell region 31B2. The transparent portion 7 may be composed of, for example, a non-transparent semiconductor layer, or may be the same as the semiconductor layer 8b.

[0141] In the first solar cell region 31B1, the first electrode layer 8a has a portion (also referred to as the first extending portion) 8ae that extends in the -Y direction more than the semiconductor layer 8b and the second electrode layer 8c. In the seventh solar cell region 31B7, the semiconductor layer 8b and the second electrode layer 8c extend in the +Y direction more than the first electrode layer 8a, and the second electrode layer 8c has a portion (also referred to as the second extending portion) 8ce that extends in the +Y direction more than the semiconductor layer 8b. On the first extending portion 8ae, a wiring member (also referred to as the first output wiring member) 32a for output of the first polarity is in a state of being electrically connected. Here, the first output wiring member 32a is, for example, in a state of being joined to the first extending portion 8ae that is a part of the electrode of the first solar cell region 31B1. Specifically, for example, there is a portion (also referred to as the third joining portion) 321B that is located between the first output wiring member 32a and the first extending portion 8ae and is in a state of joining the first output wiring member 32a and the first extending portion 8ae. In the example of FIG. 17(a), the first output wiring member 32a is located along the end side in the -Y direction of the first solar cell region 31B1. On the second extending portion 8ce, a wiring member (also referred to as the second output wiring member) 32b for output of the second polarity is in a state of being electrically connected. Here, the second output wiring member 32b is, for example, in a state of being joined to the second extending portion 8ce that is a part of the electrode of the seventh solar cell region 31B7. Specifically, for example, there is a portion (also referred to as the fourth joining portion) 322B that is located between the second output wiring member 32b and the second extending portion 8ce and is in a state of joining the second output wiring member 32b and the second extending portion 8ce. In the example of FIG. 17(a), the second output wiring member 32b is located along the end side in the +Y direction of the seventh solar cell region 31B7.

[0142] For the first output wiring member 32a and the second output wiring member 32b, for example, linear or strip-shaped conductive metal bodies are respectively applied. For the materials of the third joint portion 321B and the fourth joint portion 322B, for example, low-melting-point alloys such as solder or single metals with low melting points are applied. More specifically, for example, copper foils having a thickness of about 0.1 mm to 0.2 mm and a width of about 1 mm to 2 mm are respectively applied to the first output wiring member 32a and the second output wiring member 32b, and the entire surfaces of these first output wiring member 32a and second output wiring member 32b are in a state of being coated with solder. The first output wiring member 32a is, for example, electrically connected to the first extending portion 8ae by soldering. Also, the second output wiring member 32b is, for example, electrically connected to the second extending portion 8ce by soldering. In this case, for example, the solder located between the first output wiring member 32a and the first extending portion 8ae constitutes the third joint portion 321B. Also, for example, the solder located between the second output wiring member 32b and the second extending portion 8ce constitutes the fourth joint portion 322B. Hereinafter, the third joint portion 321B and the fourth joint portion 322B will also be abbreviated as "joint portion" as appropriate. Also, here, for example, if the first polarity is the negative electrode, the second polarity is the positive electrode. For example, if the first polarity is the positive electrode, the second polarity is the negative electrode. And each of the first output wiring member 32a and the second output wiring member 32b is, for example, in a state of being drawn out to the outside through a through hole or the like that penetrates the back surface protective layer 2.

[0143] Here, for example, the substrate 6 in the solar cell portion 3B may be the back surface protective layer 2. Also, in the above example, although the plurality of solar cell regions 31B are arranged along the Y direction, it is not necessarily limited to this. The arrangement direction of the plurality of solar cell regions 31B may be the X direction and can be changed as appropriate.

[0144] <3. Others> In the first to seventh embodiments described above, for example, the back surface protective layer 2 may be omitted. In this structure, since the free acid (for example, acetic acid) generated in the filler 4 desorbs from the filler 4 in a gaseous state toward the -Z direction, defects in the solar cell unit 3 due to the free acid can be reduced.

[0145] In the first to seventh embodiments described above, the two support members 5 may be respectively positioned on both sides of the solar cell panel 10 in the Y direction instead of both sides in the X direction. When viewed in a state where the line of sight is along the X direction, the solar cell panel 10 can be bent. In this case, the number of arrays of the solar cell elements 31 in the Y direction may be even. According to this, the central portion of the solar cell panel 10 in the Y direction corresponds to the portion between the solar cell elements 31. Therefore, compared with the structure where the number of arrays is odd, the stress generated in the solar cell elements 31 can be reduced.

[0146] Also, in the third to sixth embodiments described above, the thickness W1 of the filler 4 does not necessarily have to be larger than the thickness W2 and the thickness W3. This is because the effects brought about in each of the third to sixth embodiments do not necessarily assume the thickness distribution of the filler 4.

[0147] As described above, the solar cell module has been described in detail. However, the above description is illustrative in all aspects, and this disclosure is not limited thereto. Also, the various examples described above can be applied in combination as long as they do not contradict each other. And it is understood that countless examples not illustrated can be assumed without departing from the scope of this disclosure.

[0148] The present disclosure includes the following content.

[0149] In one embodiment, (1) the solar cell module includes a first protective layer having a first surface and a second surface opposite to the first surface, a solar cell portion including a plurality of solar cell elements positioned to face the second surface of the first protective layer, a support member positioned adjacent to the solar cell portion and including an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion, and a filling material that is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell portion, and the thickness between the solar cell portion and the support member is greater than the thickness between two adjacent solar cell elements among the plurality of solar cell elements.

[0150] (2) In the solar cell module of (1) above, the number of arrangements of the plurality of solar cell elements is an even number.

[0151] (3) The solar cell module includes a first protective layer having a first surface and a second surface opposite to the first surface, a solar cell portion positioned to face the second surface of the first protective layer, a support member positioned adjacent to the solar cell portion and including an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion, and a filling material that is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell portion, and the thickness of the filling material increases from the solar cell portion toward the support member.

[0152] (4) In any one of the solar cell modules of (1) to (3) above, among the filling material, a first portion between the inner portion of the support member and the first protective layer has a predetermined first thickness distribution, and in the predetermined first thickness distribution, the thickness at the end of the first portion on the solar cell portion side is greater than the thickness at the end of the first portion on the outer portion side.

[0153] (5) Any one of the solar cell modules of (1) to (4) above further includes a second protective layer that is in contact with the filling material on the side opposite to the first protective layer with respect to the filling material and is located in a state of facing the solar cell unit.

[0154] (6) In the solar cell module of (5) above, the second protective layer is located in a state of also facing the inner part of the support member, and a second part of the filling material between the inner part of the support member and the second protective layer has a predetermined second thickness distribution. In the second thickness distribution, the thickness at the end of the second part on the solar cell unit side is greater than the thickness at the end of the second part on the outer part side.

[0155] (7) In the solar cell module of (5) or (6) above, the end of the filling material on the second protective layer side and the outer part side is located on the solar cell unit side with respect to the end of the first protective layer side and the outer part side.

[0156] (8) In the solar cell module of (7) above, the end of the second protective layer on the support member side is located on the solar cell unit side with respect to the end of the first protective layer on the support member side.

[0157] (9) In the solar cell module of (7) or (8) above, the filling material and the second protective layer are located avoiding the region facing the support member on the side opposite to the first protective layer with respect to the support member.

[0158] (10) In any one of the solar cell modules of (1) to (9) above, the first protective layer has a rectangular shape, and the plurality of support members are located at intervals along one side of the first protective layer.

[0159] (11) In the solar cell module of the above (10), a third portion which is part of the filling material is located between two adjacent support members among the plurality of support members, the third portion has a predetermined third thickness distribution, and in the third thickness distribution, the thickness of the third portion at the end on one side of the two support members is larger than the thickness of the third portion at the central position between the two support members.

[0160] (12) In the solar cell module of any one of the above (1) to (11), the first protective layer has a rectangular shape, and the support member is located on only one side of the first protective layer.

[0161] (13) In the solar cell module of any one of the above (1) to (12), it further includes a carbon fiber member, the first protective layer has a rectangular shape, the support member is located on the first side of the first protective layer, and the carbon fiber member is located on the second side of the first protective layer where the support member is not located and is covered by the filling material.

Explanation of Reference Numerals

[0162] 1 Surface protective layer 1a End of the surface protective layer 1 on the side of the support member 5 1f First surface 1s Second surface 2 Back surface protective layer 2a End of the back surface protective layer 2 on the side of the support member 5 3, 3B Solar cell portion 31 Solar cell element 4 Filling material 4a Portion 4b First portion (portion) 4c Second portion (portion) 4d Third portion (portion) 41a End of the filling material 4 on the surface protective layer 1 side and the outer portion 52 side 42a End of the filling material 4 on the back surface protective layer 2 side and the outer portion 52 side 5 Support member 60 Reinforcing fiber member 100 Solar cell module

Claims

1. A solar cell module, comprising: a first protective layer having a first surface and a second surface opposite to the first surface; a solar cell unit including a plurality of solar cell elements positioned to face the second surface of the first protective layer; a support member positioned adjacent to the solar cell unit; a filler wherein the support member includes an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion; the filler is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell unit; a solar cell module, wherein a thickness of the filler between the solar cell unit and the support member is greater than a thickness of the filler between two adjacent solar cell elements among the plurality of solar cell elements.

2. The solar cell module according to claim 1, wherein the number of arrays of the plurality of solar cell elements is an even number.

3. A solar cell module, comprising: a first protective layer having a first surface and a second surface opposite to the first surface; a solar cell unit positioned to face the second surface of the first protective layer; a support member positioned adjacent to the solar cell unit; a filler wherein the support member includes an inner portion positioned to face the second surface of the first protective layer and an outer portion extending outward from the inner portion; the filler is in contact with the second surface of the first protective layer and covers the inner portion and the solar cell unit; a solar cell module, wherein a thickness of the filler increases from the solar cell unit toward the support member.

4. The solar cell module according to any one of claims 1 to 3, wherein a first portion of the filler between the inner portion of the support member and the first protective layer has a predetermined first thickness distribution, and in the predetermined first thickness distribution, a thickness at an end of the first portion on the solar cell unit side is greater than a thickness at an end of the first portion on the outer portion side.

5. The solar cell module according to any one of claims 1 to 3, A solar cell module further comprising a second protective layer that is in contact with the filler and is positioned in a state of facing the solar cell portion on the side opposite to the first protective layer with respect to the filler.

6. The solar cell module according to claim 5, wherein the second protective layer is positioned in a state of also facing the inner portion of the support member, a second portion of the filler, between the inner portion of the support member and the second protective layer, has a predetermined second thickness distribution, and in the second thickness distribution, the thickness at the end of the second portion on the solar cell portion side is greater than the thickness at the end of the second portion on the outer portion side, a solar cell module.

7. The solar cell module according to claim 5, wherein the end of the filler on the second protective layer side and on the outer portion side is positioned on the solar cell portion side with respect to the end of the filler on the first protective layer side and on the outer portion side, a solar cell module.

8. The solar cell module according to claim 7, wherein the end of the second protective layer on the support member side is positioned on the solar cell portion side with respect to the end of the first protective layer on the support member side, a solar cell module.

9. The solar cell module according to claim 7, wherein the filler and the second protective layer are positioned avoiding a region facing the support member on the side opposite to the first protective layer with respect to the support member, a solar cell module.

10. The solar cell module according to any one of claims 1 to 3, wherein the first protective layer has a rectangular shape, and a plurality of the support members are positioned side by side at intervals along one side of the first protective layer, a solar cell module.

11. The solar cell module according to claim 10, wherein a third portion, which is a part of the filler, is positioned between two adjacent support members among the plurality of support members, the third portion has a predetermined third thickness distribution, and in the third thickness distribution, the thickness at the end of the third portion on one side of the two support members is greater than the thickness at the central position between the two support members of the third portion, a solar cell module.

12. The solar cell module according to any one of claims 1 to 3, wherein the first protective layer has a rectangular shape, and the support member is positioned only on one side of the first protective layer, a solar cell module.

13. A solar cell module according to any one of claims 1 to 3, further comprising a reinforcing fiber member, wherein the first protective layer has a rectangular shape, the support member is located on a first side of the first protective layer, and the reinforcing fiber member is located in a state of being covered with the filling material on a second side of the first protective layer where the support member is not located.

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