Solar cell module and production method therefor
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- KANEKA CORP
- Filing Date
- 2025-11-28
- Publication Date
- 2026-06-25
Smart Images
Figure JP2025041495_25062026_PF_FP_ABST
Abstract
Description
Solar cell module and method for manufacturing the same Cross-reference to related applications
[0001] This application claims priority based on Japanese Patent Application No. 2024-221942, and the description thereof is incorporated herein by reference.
[0002] The present invention relates to a solar cell module formed by encapsulating a plurality of solar cells and a method for manufacturing the same.
[0003] For the purpose of improving the power generation efficiency of a solar cell module, there is a tendency to increase the size of the solar cells in the module and the module size. As a result, since the current value increases, the strip-shaped extraction wiring (see, for example, Patent Document 1) for extracting the generated current to the outside of the solar cell module becomes longer, and the stress applied to the extraction wiring increases. In response to this, in a module structure provided with a plurality of solar cells cut into a small area to suppress the current value, an extraction wiring with a smaller thickness can be used as the current value becomes smaller.
[0004] Japanese Patent Application Laid-Open No. 2022-102585
[0005] As shown in FIG. 4, in the solar cell module 10, a terminal box 16 for connecting an external electric wire is often arranged at the extraction portion of the extraction wiring 15. The inside of the terminal box 16 may be filled with a resin 17. When the extraction portion of the extraction wiring 15 is curved, due to the strip shape of the extraction wiring 15, there may be insufficient intrusion of the resin injected at the inner position of the curved portion 151, resulting in the generation of air bubbles 18. When the resin 17 solidifies while containing the air bubbles 18, after the solar cell module is installed and operation is started, the air bubbles 18 expand and contract under the influence of temperature changes at the installation location, and a force may be applied to the extraction wiring 15. In this case, the risk of disconnection of the extraction wiring 15 increases.
[0006] An object of the present invention is to provide a solar cell module and a method for manufacturing the same in which the extraction wiring is less likely to be disconnected, particularly after the installation of a completed solar cell module.
[0007] The solar cell module of the present invention is a solar cell module in which a plurality of solar cells are sandwiched between an opposing light-receiving protective plate and a back protective plate via a sealing material containing a plastic resin, wherein the back protective plate has a wiring outlet hole that penetrates in the thickness direction, and a plurality of strip-shaped outlet wirings for taking out current to the outside of the solar cell module are connected to the plurality of solar cells, and the outlet wirings are taken out to the outside of the solar cell module through the wiring outlet hole, and the portion of each of the plurality of outlet wirings that passes through the wiring outlet hole to the outside of the back protective plate includes a curved region that is curved in the thickness direction, the sealing material fills the space of the wiring outlet hole and also protrudes to the outside of the wiring outlet hole to form a protruding portion, and the curved region of each of the plurality of outlet wirings is enclosed in the sealing material inside the wiring outlet hole and at the protruding portion.
[0008] Furthermore, a resin different from the sealing material may be placed in contact with the protruding portion.
[0009] Furthermore, a terminal box is provided on the back side of the rear protective plate so as to cover the wiring outlet hole, and the plurality of outlet wires with different polarities are passed through the wiring outlet hole, and the protruding portion ensures an insulating distance between the plurality of outlet wires with different polarities, and the inside of the terminal box may not be provided with any configuration to ensure the insulating distance.
[0010] The present invention provides a method for manufacturing a solar cell module in which a plurality of solar cells are sandwiched between opposing light-receiving protective plates and back protective plates via a sealing material containing a plastic resin, the back protective plate having wiring exit holes penetrating in the thickness direction, the sealing material being formed by heating and integrating a light-receiving sealing material and a back sealing material, the plurality of solar cells being connected to a plurality of strip-shaped exit wirings for extracting current to the outside of the solar cell module, the exit wirings being extracted to the outside of the solar cell module through the wiring exit holes, the light-receiving protective plate and the light-receiving sealing material being superimposed, and the back protective plate and the back sealing material being superimposed, and the plurality A pre-assembly is formed by placing the light-receiving sealing material and the back sealing material opposite each other, sandwiching the solar cell and each of the multiple extraction wires that are connected to the multiple solar cells and extracted to the back side of the back protective plate through the wiring extraction holes. The portion of each of the multiple extraction wires that exits to the outside of the back protective plate through the wiring extraction holes includes a curved region that is curved in the thickness direction. The pre-assembly is heated to soften the light-receiving sealing material and the back sealing material, thereby integrating them. A portion of the softened back sealing material is moved into the wiring extraction holes, thereby forming a protruding portion that encloses each of the multiple extraction wires and protrudes beyond the wiring extraction holes to the back side of the back sealing material.
[0011] Alternatively, a supplementary sealing material, separate from the light-receiving sealing material and the back sealing material, may be placed between the light-receiving sealing material and the back sealing material, at a position surrounding the wiring outlet hole.
[0012] Alternatively, before heating the pre-assembled integral body, a mold plate with an opening for the planned formation position of the protrusion may be placed along the back protective plate.
[0013] Figure 1 is a schematic cross-sectional view of a solar cell module according to this embodiment before the lamination process. Figure 2 is a schematic cross-sectional view of the solar cell module after the lamination process (before terminal box attachment). Figure 3 is a schematic cross-sectional view of the solar cell module after the lamination process (after terminal box attachment). Figure 4 is a schematic cross-sectional view of a conventional solar cell module before the lamination process.
[0014] The embodiments of the present invention will be described below with reference to Figures 1 to 3.
[0015] As shown in Figure 1, the solar cell module 1 is a solar cell module in which multiple solar cells C (whose shape is not limited, so only the reference numerals are shown in Figures 1 to 3) are sandwiched between opposing light-receiving protective plates 2 and back protective plates 3 via a sealing material 4, and then integrated through a lamination process as shown in Figure 3. In other words, the solar cell module 1 comprises a light-receiving protective plate 2, a back protective plate 3, a sealing material 4, and multiple solar cells C. The solar cell module 1 of this embodiment is a single-sided light-receiving type. In Figures 1 to 3, the light-receiving protective plate 2 is shown at the bottom and the back protective plate 3 is shown at the top. The solar cell module 1 also includes output wiring 5 connected to the multiple solar cells C. The solar cell module 1 also includes a terminal box 6 (simplified illustration) provided on the outside of the back protective plate 3. The solar cell module 1 is plate-shaped.
[0016] The back protective plate 3 is a plate member that protects the solar cell C from the back side (opposite the light-receiving side). The back protective plate 3 is, for example, a glass plate. Furthermore, as shown in Figure 1 relating to the integrated pre-assembly 1A (described later), the back protective plate 3 has wiring outlet holes 30 that penetrate in the thickness direction. In this embodiment, the back protective plate 3 is provided with multiple wiring outlet holes 30, but it may also be provided with only one wiring outlet hole 30. In this embodiment, the plan view shape of the wiring outlet hole 30 is a round hole, but it may be a polygonal shape, a slit shape, or other shapes.
[0017] The light-receiving protective plate 2 is a plate member that protects the solar cell C from the light-receiving side. The light-receiving protective plate 2 is a plate made of a light-transmitting material, such as a transparent glass plate, in order to allow sunlight for power generation to reach the solar cell C. However, the light-receiving protective plate 2 may be a resin sheet instead of a glass plate.
[0018] Multiple solar cells C are plate-shaped and each generates electricity upon receiving light. In this embodiment, multiple solar cell strings, each consisting of two or more solar cell C connected in series, are provided on the solar cell module 1, and current is extracted from each solar cell string by an extraction wiring 5 electrically connected to it. For example, although not shown in the figures, current is extracted from multiple finger electrodes provided on the solar cell C via busbar electrodes and through an extraction wiring 5 connected to the busbar electrodes. Each solar cell C in this embodiment is a solar cell cut to a small area in order to suppress the current value. Specifically, it corresponds to a small area such as 1 / 2 of the cross-sectional area of a full-size semiconductor wafer cut from a semiconductor ingot, which is the raw material. However, the configuration (shape and area) of each solar cell C is not limited to this.
[0019] The encapsulant 4 is a component for encapsulating multiple solar cells C. The encapsulant 4 is also layered, for example, on both the light-receiving side and the back side of the multiple solar cells C. Furthermore, the encapsulant 4 softens during the heating process of the lamination process, allowing it to wrap around the solar cells C. Therefore, after softening, the encapsulant 4 also covers the end faces (outer periphery) of the multiple solar cells C. In the solar cell module 1 after the lamination process, the encapsulant 4 is composed of, for example, a resin layer.
[0020] In this embodiment, as shown in Figure 1, the sealing material 4 includes a back sealing material 40 provided on the light-receiving side of the back protective plate 3 and a light-receiving side sealing material 41 provided on the back side of the light-receiving side protective plate 2, which are separate components before the lamination process. The sealing material 4 also includes a supplementary sealing material 42 provided between the back sealing material 40 and the light-receiving side sealing material 41 at a position that overlaps with the area around the wiring outlet hole 30 of the back protective plate 3 when viewed from the thickness direction of the sealing material 4 before the lamination process. The sealing materials 40, 41, and 42 contain a plastic resin. Specifically, the sealing materials 40, 41, and 42 are sheets made of a light-transmitting thermoplastic resin such as ethylene / vinyl acetate copolymer (EVA). In this embodiment, the sealing materials 40, 41, and 42 are formed from the same material, but they may be formed from different materials, for example, to differ in fluidity when heated. Furthermore, one of the sealing materials 40, 41, and 42 may be formed from partially different materials. As shown in Figure 2, each sealing material 40, 41, and 42 melts after the lamination process to form a single sealing material 4.
[0021] The extraction wiring 5 is a strip-shaped wiring. The extraction wiring 5 is extracted from inside the sealing material 4, which is integrated after the lamination process, through the wiring extraction hole 30 of the back protective plate 3 to the outside of the solar cell module 1. The extraction wiring 5 is, for example, a copper foil that has been solder-plated. Specifically, the extraction wiring 5 is constructed by plating the front and back surfaces of a copper foil with a thickness of 200 μm to 250 μm with solder that is 25 μm thick. The elasticity of the extraction wiring 5 is approximately the same at all points in the direction of extension.
[0022] Two output wires 5, each connected to a plurality of solar cells C, enter a single wiring outlet hole 30 from different directions (left and right in Figure 1). One of these two output wires 5 corresponds to the negative polarity, and the other corresponds to the positive polarity. The relative positions of these two output wires 5 in a plan view with respect to the wiring outlet hole 30 are not particularly limited and can be arranged in various ways, for example, depending on how they are introduced into the terminal box 6.
[0023] The terminal box 6 is a box-shaped structure having a terminal block 61 for connecting the output wiring 5 and the output cable for power extraction (simplified in Figure 3). In this embodiment, the terminal box 6 is provided so as to cover the wiring outlet hole 30 of the rear protective plate 3 from the outside of the solar cell module 1. Two output wirings 5 are arranged inside the terminal box 6.
[0024] Next, we will describe a structure designed to suppress disconnection of the output wiring 5, particularly after the completed solar cell module 1 has been installed in a power generation facility. We will assume that the portion of the output wiring 5 that passes through the wiring output hole 30 and exits the back protective plate 3 includes a curved region 51 that is curved in the thickness direction. This curved region 51 is a part where, conventionally, insufficient coverage of the injected resin (for example, the resin used to fill the inside of the terminal box 6) occurred on the inside of the curved portion (the inside of the "radius"), resulting in a gap. This gap sometimes resulted in the formation of air bubbles 18, as shown in Figure 4 of the conventional example.
[0025] In this embodiment, the sealing material 4 fills the space of the wiring outlet hole 30, that is, the space surrounded by the glass that constitutes the back protective plate 3. At the same time, the sealing material 4 that is pushed out from the wiring outlet hole 30 to the outside on the back side of the back protective plate 3 protrudes beyond the end of the wiring outlet hole 30, forming a protrusion 43. After the lamination process is completed, the sealing material 4 hardens as the temperature decreases, filling the inside of the wiring outlet hole 30 and forming the protrusion 43. The protrusion 43 formed in this way is annular in plan view, following the entire circumference of the inner circumferential surface of the wiring outlet hole 30. The curved region 51 of the wiring outlet 5 is enclosed in the sealing material 4 inside the wiring outlet hole 30 and in the protrusion 43. The dimensions of the protrusion 43 in the direction along the thickness direction of the back protective plate 3 may be uniform in the circumferential direction, or for example, the portion that encloses the wiring outlet 5 may be formed to be larger than other portions in the circumferential direction. The projection of the protruding portion 43 from the wiring outlet hole 30 can be, for example, 1 to 2 mm.
[0026] Regarding the projection dimension of the protruding portion 43 from the wiring outlet hole 30, for example, by setting it to be greater than or equal to the thickness dimension of the back protective plate 3, there is an advantage in that the curvature of the curved region 51 in the wiring outlet 5 can be reduced. Furthermore, in the radial direction of the wiring outlet hole 30, the innermost end of the curved region 51 can be controlled to be located at the position of the back end face of the back protective plate 3, or outside the position of the back end face.
[0027] By forming the protrusion 43 in this manner, the curved region 51 of the extraction wiring 5 is encased in the sealing material 4. In particular, since the protrusion 43 is formed from the sealing material 4 extruded from the wiring extraction hole 30, at least the curved region 51 can be prevented from coming into contact with air bubbles. Furthermore, the extraction wiring 5 is reinforced by the surrounding protrusion 43 at a position on the back side of the wiring extraction hole 30. As a result, even when the installation location of the solar cell module 1 is subjected to temperature changes, the protrusion 43 encasing the extraction wiring 5 absorbs the stress associated with the temperature changes, making the extraction wiring 5 less likely to break.
[0028] As shown in Figure 2, the curved region 51 in the protruding portion 43 is arranged to form an arc from the inner end to the outer end in the radial direction of the wiring outlet hole 30. Therefore, no sharp bends are formed in the outlet wiring 5, and the outlet wiring 5 is not subjected to excessive stress.
[0029] Furthermore, by forming the protrusion 43, the distance between the two output wires 5 is fixed, thus ensuring an insulating distance. Therefore, in this embodiment, there is no need to place a separate insulating member between the two output wires 5. Also, there is no need for a configuration inside the terminal box 6 to ensure the insulating distance of the output wires 5. Thus, the configuration of the terminal box 6 can be simplified.
[0030] Here, for example, if the terminal box 6 is provided so as to be in contact with the back protective plate 3, at least a portion of the inside of the terminal box 6 may be filled with resin (potting) to fill the internal space of the terminal box 6. The resin injected into the terminal box 6 is made of a different material from the sealing material 4, and is, for example, silicone resin. This resin is filled into the inside of the terminal box 6 after it has been provided on the back protective plate 3. The resin layer 7 formed by this resin can be positioned so as to be in contact with the protrusion 43. In this case, the resin (resin layer 7) filled into the inside of the terminal box 6 can further protect the output wiring 5 that is enclosed by the protrusion 43.
[0031] Next, the manufacturing method of the solar cell module 1 of this embodiment will be described. The materials used are as described above. First, the light-receiving protective plate 2 and the light-receiving sealing material 41 are placed on top of each other, and the back protective plate 3 and the back sealing material 40 are placed on top of each other. Next, the back sealing material 40 and the light-receiving sealing material 41 are placed opposite each other so as to sandwich the multiple solar cells C and the extraction wiring 5, respectively, to form the integrated pre-assembly 1A shown in Figure 1. In this integrated pre-assembly 1A, the portion of the extraction wiring 5 that passes through the wiring extraction hole 30 and comes out to the outside of the back protective plate 3 is the curved region 51 described above. Next, the integrated pre-assembly 1A is heated to soften (melt) the back sealing material 40 and the light-receiving sealing material 41 and integrate them, and a part of the softened back sealing material 40 is moved into the space inside the wiring extraction hole 30, thereby forming a protruding portion 43 that encloses the extraction wiring 5 and protrudes from the back of the back sealing material 40 beyond the wiring extraction hole 30 (Figure 2).
[0032] The protrusion 43 can be formed, for example, by placing a template 8 along the back protective plate 3, with the planned position for the formation of the protrusion 43 being an opening 81, before heating the pre-assembled integral body 1A (see Figures 1 and 2). By using the template 8, a protrusion 43 of a desired shape can be formed at a desired position in a plan view. The template 8 is temporarily attached to the back protective plate 3 as a jig for forming the protrusion 43. The template 8 is made of a heat-resistant plate material such as fluororesin and can be removed from the back protective plate 3 and reused after the formation of the protrusion 43. The template 8 can also be removed before the lamination process, in which case heat resistance is not required.
[0033] Furthermore, a supplementary sealant 42, separate from each sealant 40 and 41 and having a smaller volume than each sealant 40 and 41, can be placed between the light-receiving sealant 41 and the back sealant 40, surrounding the wiring outlet hole 30. By using the supplementary sealant 42, the amount (volume) of sealant in the position surrounding the wiring outlet hole 30 can be increased by the supplementary sealant 42, so that the protrusion 43 can be reliably formed with a sufficient amount of sealant 4.
[0034] The solar cell module of the present invention is not limited to the embodiments described above, and various modifications can be made without departing from the spirit of the invention. For example, the configuration of one embodiment can be added to the configuration of another embodiment, and a part of the configuration of one embodiment can be replaced with the configuration of another embodiment. Furthermore, a part of the configuration of one embodiment can be deleted.
[0035] For example, with respect to the protruding portion 43, in the above embodiment, it was annular in shape in plan view, following the entire circumference of the inner surface of the wiring outlet hole 30. However, it is not limited to this, and may be columnar in shape, protruding substantially uniformly in the radial direction from the wiring outlet hole 30. Alternatively, the protruding portion 43 may be provided intermittently in the area where the wiring outlet 5 is located.
[0036] Furthermore, the two output wires 5 that enter into a single wiring outlet hole 30 may intersect within the space provided by the wiring outlet hole 30. Specifically, the two output wires 5 may not be parallel in a side view, but may intersect at an angle. More specifically, in a side view, one of the two output wires 5 may be positioned towards the front and the other towards the back, intersecting in an X shape. Each of these output wires 5 curves and changes direction as it is brought out from inside the solar cell module 1 to the outside, and the angle of the change of direction is obtuse. In addition, in this configuration, the two output wires 5 can be positioned offset in a direction along the plane in a plan view.
[0037] In this configuration, the two output wires 5 can be brought out to the outside of the solar cell module 1 while curved and crossing each other, and each output wire 5 can be arranged without bending (without folding back to create a sharp bend). For example, during the lamination process when manufacturing the solar cell module 1, even if the output wires 5 are subjected to pressure from the softened sealing material 4, the pressure is less likely to concentrate, making it less likely for the output wires 5 to break.
[0038] Furthermore, the internal space of the wiring outlet hole 30 may be sized to allow for some degree of movement of the two outlet wires 5. In this configuration, during the lamination process, the outlet wires 5 are less likely to be pressed against the wall surface defining the internal space of the wiring outlet hole 30 and thus less likely to be damaged.
[0039] In a configuration where two output wires 5, each inserted into a single wiring outlet hole 30, intersect within the space of the wiring outlet hole 30, an insulating portion may be provided to prevent electrical conductivity between the two output wires 5. In this configuration, the insulating portion is located between the two output wires 5, specifically at the point where they intersect. Specifically, the insulating portion is positioned at least between the front output wire 5 and the back output wire 5 at the point where the two output wires 5 intersect. In this configuration, because the insulating portion is located between the front output wire 5 and the back output wire 5 at the point where the two output wires 5 intersect, it is possible to prevent electrical conductivity between the two output wires 5, 5.
[0040] This insulating portion may be composed of, for example, a resin filled into the space of the wiring outlet hole 30. This resin is formed when the sealing material 4 (and supplementary sealing material 42), softened by heating during the lamination process in the manufacturing of the solar cell module 1, protrudes into the space of the wiring outlet hole 30. This resin may also be filled into the space of the wiring outlet hole 30 after the lamination process, and may be, for example, a silicone resin. In this configuration, the filling resin in the space of the wiring outlet hole 30 can also serve as an insulating portion that prevents electrical conductivity between the two intersecting outlet wires 5.
[0041] In addition, the two extraction wirings 5 may intersect within the internal space of the terminal box 6, in addition to intersecting within the space of the wiring extraction hole 30 of the backside protection plate 3. In this configuration, an insulating portion is interposed within the terminal box 6 between the two extraction wirings 5 at the portion where the two extraction wirings 5 intersect. This insulating portion may be an insulating sheet sandwiched between the front extraction wiring 5 and the rear extraction wiring 5 among the intersecting portions of the two extraction wirings 5 in the internal space of the terminal box 6. In this configuration, the filling resin within the terminal box 6 can also serve as an insulating portion that prevents conduction between the two intersecting extraction wirings 5, 5. Note that the insulating portion may be composed of resin filled in the internal space of the terminal box 6.
[0042] Furthermore, the extraction wiring 5 may have an expansion / contraction portion whose expansion / contraction rate in the extension direction is set to be larger than that of other portions. In this configuration, during the lamination process in the manufacture of the solar cell module 1, the expansion / contraction portion can absorb the generated stress due to thermal expansion and contraction occurring in the extraction wiring 5 by expanding and contracting, and it is difficult to affect other portions (portions other than the expansion / contraction portion). Therefore, the extraction wiring 5 is less likely to break.
[0043] This expansion / contraction portion may have a plurality of wave portions in which a solid conductive material undulates in the thickness direction. That is, the expansion / contraction portion may have a plurality of wave portions that are curved portions without corners (bent portions) in side view. Since the wave portions do not have corners, stress concentration is less likely to occur. In this configuration, the expansion / contraction portion of the extraction wiring 5 can be formed only by bending. Note that the expansion / contraction portion may be formed in a bellows shape, that is, having a plurality of bent portions.
[0044] Also, the expansion / contraction portion may be sandwiched between the light-receiving side protection plate 2 and the backside protection plate 3 and disposed around the wiring extraction hole 30 of the backside protection plate 3. That is, the expansion / contraction portion may be disposed between the light-receiving side protection plate 2 and the backside protection plate 3 and in the vicinity of the wiring extraction hole 30. In this configuration, since the extraction wiring 5 is bent for extraction outside the module 1, the expansion / contraction portion can absorb the generated stress in the vicinity of the wiring extraction hole 30 where the stress generated due to thermal expansion and contraction is likely to increase.
[0045] Note that the telescopic part may be made of a hollow conductive material. Specifically, the telescopic part may be a net-like part made of a conductive material, or a part in which a plurality of through holes or cutouts penetrating in the thickness direction are formed. In this case, the telescopic part of the extraction wiring 5 can be formed into a flat shape (a shape without undulations). In addition to the wave part, a net-like part or the like made of a conductive material may be provided. Further, the telescopic part may be a net-like part or the like and may have an undulated shape.
[0046] The configuration and operation of the above embodiment will be summarized below. The solar cell module 1 of the above embodiment is a solar cell module 1 in which a plurality of solar cells C are sandwiched between a light-receiving side protective plate 2 and a back side protective plate 3 facing each other via a sealing material 4 containing a plastic resin. The back side protective plate 3 has a wiring extraction hole 30 penetrating in the thickness direction. A plurality of extraction wirings 5, which are strip-shaped for extracting current to the outside of the solar cell module 1, are connected to the plurality of solar cells C. The extraction wiring 5 is taken out to the outside of the solar cell module through the wiring extraction hole 30. A portion of each of the plurality of extraction wirings 5 that exits the outside of the back side protective plate 3 through the wiring extraction hole 30 includes a curved region 51 that is curved in the thickness direction. The sealing material 4 fills the space of the wiring extraction hole 30 and forms a protruding portion 43 protruding to the outside of the wiring extraction hole 30. Among each of the plurality of extraction wirings 5, the curved region 51 is wrapped by the sealing material 4 inside the wiring extraction hole 30 and the protruding portion 43.
[0047] According to the above configuration, the curved region 51 in the extraction wiring 5 is wrapped by the sealing material 4. In particular, since the protruding portion 43 is formed of the sealing material 4 extruded from the wiring extraction hole 30, at least the curved region 51 can be prevented from contacting air bubbles.
[0048] Also, a resin different from the sealing material 4 may be arranged to contact the protruding portion 43.
[0049] According to the above configuration, for example, when a terminal box 6 is provided so as to contact the back side protective plate 3, the resin filled inside the terminal box 6 can further protect the extraction wiring wrapped by the protruding portion 43.
[0050] Furthermore, a terminal box 6 is provided on the back side of the back protective plate 3 so as to cover the wiring outlet hole 30, and the plurality of outlet wires 5 with different polarities are passed through the wiring outlet hole 30, and the protruding portion 43 ensures an insulating distance from the plurality of outlet wires 5 with different polarities, and the terminal box 6 may not have any configuration to ensure the insulating distance.
[0051] According to the above configuration, the configuration of the terminal box 6 can be simplified.
[0052] The manufacturing method for the solar cell module 1 of the above embodiment is a method for manufacturing a solar cell module 1 in which a plurality of solar cells C are sandwiched between opposing light-receiving protective plates 2 and back protective plates 3 via a sealing material 4 containing a plastic resin, the back protective plate 3 has wiring outlet holes 30 that penetrate in the thickness direction, the sealing material 4 is formed by heating a light-receiving sealing material 41 and a back sealing material 40 to integrate them, strip-shaped outlet wiring 5 for taking out current to the outside of the solar cell module 1 is connected to the plurality of solar cells C, the outlet wiring 5 is taken out to the outside of the solar cell module 1 through the wiring outlet holes 30, the light-receiving protective plate 3 and the light-receiving sealing material 41 are superimposed, and the back protective plate 4 and the back sealing material 40 are superimposed, and the plurality of solar cells A pre-assembly 1A is formed by placing the light-receiving sealing material 41 and the back sealing material 40 opposite each of the multiple output wires 5 that are connected to the multiple solar cells C and are taken out to the back side of the back protective plate 3 through the wiring outlet hole 30, sandwiching each of the multiple output wires 5. The portion of each of the multiple output wires 5 that passes through the wiring outlet hole 30 and goes to the outside of the back protective plate 3 includes a curved region 51 that is curved in the thickness direction. By heating the pre-assembly 1A, the light-receiving sealing material 41 and the back sealing material 40 are softened to perform the integration, and a part of the softened back sealing material 40 is moved into the wiring outlet hole 30, thereby forming a protruding portion 43 that encloses each of the multiple output wires 5 and protrudes from the back side of the back sealing material 40 beyond the wiring outlet hole 30.
[0053] According to the above configuration, in the manufactured solar cell module 1, the curved region 51 of the take-out wiring 5 is encased in the sealing material 4, and in particular the protruding portion 43 is formed from the sealing material 4 extruded from the wiring take-out hole 30, so that at least the curved region 51 does not come into contact with air bubbles.
[0054] Alternatively, a supplementary sealing material 42, separate from the light-receiving sealing material 41 and the back sealing material 40, may be placed between the light-receiving sealing material 41 and the back sealing material 40, and surrounding the wiring outlet hole 30.
[0055] According to the above configuration, the amount of sealing material 4 surrounding the wiring outlet hole 30 can be increased by the supplementary sealing material 42, so that the protruding portion 43 can be reliably formed.
[0056] Alternatively, before heating the pre-assembled body 1A, a mold plate 8 with an opening for the planned formation position of the protrusion 43 may be placed along the back protective plate 3.
[0057] According to the above configuration, the protrusion 43 can be formed at a desired position.
[0058] Based on the above, the present invention provides a solar cell module 1 in which the output wiring 5 is less likely to break, especially after the completed solar cell module 1 has been installed.
[0059] 1...Solar cell module, 1A...Integrated pre-assembly, 2...Light-receiving side protective plate, 3...Back side protective plate, 4...Sealing material, 5...Outlet wiring, 6...Terminal box, 7...Resin layer, 8...Mold, 30...Wiring outlet hole, 40...Back side sealing material, 41...Light-receiving side sealing material, 42...Refill sealing material, 43...Protrusion, 51...Curved region, 81...Opening, C...Solar cell
Claims
1. A solar cell module in which a plurality of solar cells are sandwiched between an opposing light-receiving protective plate and a back protective plate via a sealing material containing a plastic resin, wherein the back protective plate has wiring exit holes penetrating in the thickness direction, a plurality of strip-shaped exit wirings for extracting current to the outside of the solar cell module are connected to the plurality of solar cells, and the exit wirings are extracted to the outside of the solar cell module through the wiring exit holes, each of the plurality of exit wirings that exits to the outside of the back protective plate through the wiring exit holes includes a curved region that is curved in the thickness direction, the sealing material fills the space of the wiring exit holes and also protrudes to the outside of the wiring exit holes to form a protruding portion, and the curved region of each of the plurality of exit wirings is enclosed in the sealing material inside the wiring exit holes and at the protruding portion.
2. The solar cell module according to claim 1, wherein a resin different from the sealing material is arranged in contact with the protruding portion.
3. A terminal box is provided on the back side of the back protective plate so as to cover the wiring outlet hole, the plurality of outlet wires with different polarities are passed through the wiring outlet hole, the protruding portion ensures an insulating distance from the plurality of outlet wires with different polarities, and the inside of the terminal box is not provided with a configuration for ensuring the insulating distance, as described in claim 1 or 2.
4. A method for manufacturing a solar cell module in which a plurality of solar cells are sandwiched between an opposing light-receiving protective plate and a back protective plate via a sealing material containing a plastic resin, wherein the back protective plate has wiring exit holes penetrating in the thickness direction, the sealing material is formed by heating the light-receiving sealing material and the back sealing material together, a plurality of strip-shaped exit wirings for extracting current to the outside of the solar cell module are connected to the plurality of solar cells, and each of the plurality of exit wirings is extracted to the outside of the solar cell module through the wiring exit holes, the light-receiving protective plate and the light-receiving sealing material are overlapped, and the back protective plate and the back sealing material are overlapped, and the light-receiving sealing material and the back sealing material are opposed to each of the plurality of solar cells and the plurality of exit wirings connected to the plurality of solar cells and extracted to the back of the back protective plate through the wiring exit holes to form an integrated pre-assembly, A method for manufacturing a solar cell module, wherein each of the plurality of output wires includes a curved region that is curved in the thickness direction, the portion of which passes through the wiring output hole and exits the back protective plate, the light-receiving side sealing material and the back sealing material are softened by heating the pre-integrated assembly to perform the integration, and a portion of the softened back sealing material is moved into the wiring output hole to form a protruding portion that encloses each of the plurality of output wires and protrudes beyond the wiring output hole to the back of the back sealing material.
5. The method for manufacturing a solar cell module according to claim 4, wherein a supplementary sealant, separate from the light-receiving sealant and the back sealant, is placed between the light-receiving sealant and the back sealant, and at a position surrounding the wiring outlet hole.
6. The method for manufacturing a solar cell module according to claim 4 or 5, wherein, before heating the integrated pre-assembly, a template plate having an opening for the planned formation position of the protrusion is placed along the back protective plate.