JP2015211553A - Holding frame, solar cell module, manufacturing device for solar cell module, and manufacturing method of solar cell module - Google Patents

Holding frame, solar cell module, manufacturing device for solar cell module, and manufacturing method of solar cell module Download PDF

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JP2015211553A
JP2015211553A JP2014091959A JP2014091959A JP2015211553A JP 2015211553 A JP2015211553 A JP 2015211553A JP 2014091959 A JP2014091959 A JP 2014091959A JP 2014091959 A JP2014091959 A JP 2014091959A JP 2015211553 A JP2015211553 A JP 2015211553A
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solar cell
frame
cell panel
outer edge
light
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JP6184369B2 (en
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葉影　秀徳
Hidenori Hakage
秀徳 葉影
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Mitsubishi Electric Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a holding frame capable of suppressing cost and simplifying assembly work in assembling a solar cell module including a solar cell panel presenting a curved surface shape.SOLUTION: The holding frame includes: a first rear-side frame 21a including a first rear-side abutment surface 25 to be abutted from a side of a rear face 10b to a first outer edge 11 of a solar cell panel 10; a first light receiving plane side frame 21b including a first light receiving side abutment surface 26 to be abutted from a side of a light receiving plane 10a to the first outer edge 11 for holding the first outer edge held therebetween; a second rear-side frame 22a including a second rear-side abutment surface 27 to be abutted from the side of the rear face 10b to a second outer edge 12; and a second light receiving plane side frame 22b including a second light receiving side abutment surface 28 to be abutted from the side of the light receiving plane 10a to the second outer edge 12 for holding the second outer edge 12 held therebetween. The first rear-side abutment surface 25, the first light receiving side abutment surface 26, the second rear-side abutment surface 27 and the second light receiving side abutment surface 28 present a curved surface shape.

Description

本発明は、保持フレーム、太陽電池モジュール、太陽電池モジュールの製造装置、および太陽電池モジュールの製造方法に関する。   The present invention relates to a holding frame, a solar cell module, a solar cell module manufacturing apparatus, and a solar cell module manufacturing method.

太陽電池モジュールの主な構成として太陽電池素子が埋設された太陽電池パネルに対し、保持フレームと呼ばれる金属製のフレーム板を太陽電池パネルの四辺に組み付けることにより太陽電池パネルの強度を保っている。   As a main configuration of the solar cell module, the strength of the solar cell panel is maintained by assembling a metal frame plate called a holding frame on the four sides of the solar cell panel with the solar cell element embedded therein.

従来の太陽電池モジュールは平面状の太陽電池パネルに対し、直線のフレームを使用しており、フレームの内側に太陽電池パネルが嵌まり込むように溝を加工して組み立てられている。   A conventional solar cell module uses a straight frame with respect to a planar solar cell panel, and is assembled by processing grooves so that the solar cell panel fits inside the frame.

また、フレーム内で太陽電池パネルがずれて移動しないように弾力性のあるゴム材、例えばブチルゴムなどをフレーム溝内に充填する方法やゴムシートをあらかじめ太陽電池パネルに貼り付けるなどして太陽電池パネルとフレーム間の隙間を埋めて固定している。   Also, the solar cell panel is made by filling the frame groove with an elastic rubber material such as butyl rubber or by attaching a rubber sheet to the solar cell panel in advance so that the solar cell panel does not move in the frame. The gap between the frame is filled and fixed.

特許第３８６１８９０号公報Japanese Patent No. 3618890 特開２０１０−１７７３０７号公報JP 2010-177307 A

上記の従来技術によれば、太陽電池パネルは平面形状を呈しているが、近年では、曲面形状を呈する太陽電池パネルを備える太陽電池モジュールへの要望もある。そこで、保持フレームに形成された溝と太陽電池パネルの曲率を合わせた状態で、保持フレームの溝に太陽電池パネルを嵌めこもうとすると、組立精度を要するため組立方法及び製造コストにおいて負担が大きくなりやすい。   According to the above prior art, the solar cell panel has a planar shape. However, in recent years, there is a demand for a solar cell module including a solar cell panel having a curved shape. Therefore, when the solar cell panel is fitted into the groove of the holding frame in a state where the groove formed in the holding frame and the curvature of the solar cell panel are matched, the assembly method and manufacturing cost are heavy because assembly accuracy is required. Prone.

特に、保持フレームの溝の曲面に合わせて太陽電池パネルを曲げながら、太陽電池パネルを溝に嵌めこむには、それぞれの部品の曲率を保持しながら、組み立てることが求められる。   In particular, in order to fit the solar cell panel into the groove while bending the solar cell panel in accordance with the curved surface of the groove of the holding frame, it is required to assemble while holding the curvature of each component.

また、太陽電池パネル作成においては曲面形状を容易に変更、調整することが出来ないため、製造仕様に対し、曲率を変更するためには製造設備及び製造方法において段取り替えが複雑となるなど、生産効率の低下を招くとともに、コストの増加という課題が発生する。   In addition, since the curved surface shape cannot be easily changed or adjusted in the creation of solar cell panels, production changes such as complicated setup changes in the manufacturing equipment and manufacturing method to change the curvature with respect to the manufacturing specifications. In addition to incurring a decrease in efficiency, there is a problem of an increase in cost.

本発明は、上記に鑑みてなされたものであって、曲面形状を呈する太陽電池パネルを備える太陽電池モジュールを組み立てるうえで、コストの抑制や組み立て作業の簡単化を図ることのできる保持フレームを得ることを目的とする。   This invention is made in view of the above, Comprising: When assembling a solar cell module provided with the solar cell panel which exhibits a curved-surface shape, the holding frame which can aim at the suppression of cost and the simplification of an assembly operation is obtained. For the purpose.

上述した課題を解決し、目的を達成するために、本発明は、太陽電池パネルの外周を囲んで保持する保持フレームであって、太陽電池パネルの第１の外縁に裏面側から当接する第１裏側当接面を有する第１裏面側フレームと、第１の外縁に受光面側から当接して、第１裏側当接面との間に第１の外縁を挟んで保持する第１受光側当接面を有する第１受光面側フレームと、第１の外縁に対向する第２の外縁に裏面側から当接する第２裏側当接面を有する第２裏面側フレームと、第２の外縁に受光面側から当接して、第２裏側当接面との間に第２の外縁を挟んで保持する第２受光側当接面を有する第２受光面側フレームと、を備え、第１裏側当接面と第１受光側当接面とは、受光面と平行かつ第１の外縁と垂直な方向から見た場合に曲線となる曲面形状を呈し、第２裏側当接面と第２受光側当接面とは、受光面と平行かつ第２の外縁と垂直な方向から見た場合に曲線となる曲面形状を呈することを特徴とする。   In order to solve the above-described problems and achieve the object, the present invention is a holding frame that surrounds and holds the outer periphery of a solar cell panel, and is a first frame that comes into contact with the first outer edge of the solar cell panel from the back surface side. A first light receiving side contact that holds the first outer edge between the first back side frame having the back side contact surface and the first outer edge from the light receiving surface side and sandwiching the first outer edge between the first back side contact surface and the first back side contact surface. A first light-receiving surface side frame having a contact surface, a second back-side frame having a second back-side contact surface that contacts the second outer edge facing the first outer edge from the back surface side, and light received by the second outer edge A second light-receiving surface-side frame having a second light-receiving-side contact surface that is held from the surface side and that holds the second outer edge between the second back-side contact surface and the second back-side contact surface. The contact surface and the first light receiving side contact surface are curved curves when viewed from a direction parallel to the light receiving surface and perpendicular to the first outer edge. The second back side contact surface and the second light receiving side contact surface have a curved shape when viewed from a direction parallel to the light receiving surface and perpendicular to the second outer edge. To do.

本発明によれば、曲面形状を呈する太陽電池パネルを備える太陽電池モジュールを組み立てるうえで、コストの抑制や組み立て作業の簡単化を図ることができるという効果を奏する。   According to the present invention, in assembling a solar cell module including a solar cell panel having a curved surface shape, there are effects that cost can be suppressed and assembly work can be simplified.

図１は、曲面太陽電池モジュールの斜視図である。FIG. 1 is a perspective view of a curved solar cell module. 図２は、曲面太陽電池モジュールの分解斜視図である。FIG. 2 is an exploded perspective view of the curved solar cell module. 図３は、太陽電池パネルの詳細な構成を示す断面図である。FIG. 3 is a cross-sectional view showing a detailed configuration of the solar cell panel. 図４は、太陽電池パネルのうち、第１フレームに保持された外縁部分の断面図である。FIG. 4 is a cross-sectional view of an outer edge portion held by the first frame in the solar cell panel. 図５は、太陽電池パネルのうち、第３フレームに保持された外縁部分の断面図である。FIG. 5 is a cross-sectional view of the outer edge portion held by the third frame in the solar cell panel. 図６は、挿入溝にゴム材を流し込む作業の作業例を示す図である。FIG. 6 is a diagram illustrating a work example of a work of pouring a rubber material into the insertion groove. 図７は、曲面太陽電池モジュールの製造装置（擬似曲面台）の概略構成を示す斜視図である。FIG. 7 is a perspective view showing a schematic configuration of a curved solar cell module manufacturing apparatus (pseudo-curved base). 図８は、擬似曲面台の概略構成を示す断面図である。FIG. 8 is a cross-sectional view showing a schematic configuration of the pseudo-curved surface stage. 図９は、曲面太陽電池モジュールの製造手順を説明するための図である。FIG. 9 is a diagram for explaining a manufacturing procedure of the curved solar cell module. 図１０は、曲面太陽電池モジュールの製造手順を説明するための図である。FIG. 10 is a diagram for explaining a manufacturing procedure of the curved solar cell module. 図１１は、曲面太陽電池モジュールの製造手順を説明するための図である。FIG. 11 is a diagram for explaining a manufacturing procedure of the curved solar cell module. 図１２は、曲面太陽電池モジュールの製造手順を説明するための図である。FIG. 12 is a diagram for explaining a manufacturing procedure of the curved solar cell module. 図１３は、曲面太陽電池モジュールの製造手順を説明するための図である。FIG. 13 is a diagram for explaining a manufacturing procedure of the curved solar cell module. 図１４は、第１，２裏面側フレームと第１，２受光面側フレームとの固定例を示す断面図である。FIG. 14 is a cross-sectional view showing an example of fixing the first and second back surface side frames and the first and second light receiving surface side frames. 図１５は、第１，２裏面側フレームと第１，２受光面側フレームとの固定例を示す断面図である。FIG. 15 is a cross-sectional view showing an example of fixing the first and second back surface side frames and the first and second light receiving surface side frames. 図１６は、第１，２フレームと、第３，４フレームとの連結例を示す図である。FIG. 16 is a diagram illustrating a connection example of the first and second frames and the third and fourth frames. 図１７は、第１，２フレームと、第３，４フレームとの連結例を示す図である。FIG. 17 is a diagram illustrating a connection example of the first and second frames and the third and fourth frames. 図１８は、太陽電池パネルを擬似曲面台の支持面に倣わせる構成の変形例を示す図である。FIG. 18 is a diagram showing a modification of the configuration in which the solar cell panel is made to follow the support surface of the pseudo-curved surface base. 図１９は、保持フレームの変形例を示す図である。FIG. 19 is a diagram illustrating a modified example of the holding frame.

以下に、本発明にかかる曲面太陽電池モジュールの製造方法及び製造装置の実施の形態を図面に基づいて説明する。なお、この実施の形態によりこの発明が限定されるものではない。また、本発明は以下の記述に限定されるものではなく、本発明の要旨を逸脱しない範囲において適宜変更可能である。また、以下に示す図面においては、理解の容易のため、各部材の縮尺が実際とは異なる。   EMBODIMENT OF THE INVENTION Below, embodiment of the manufacturing method and manufacturing apparatus of a curved surface solar cell module concerning this invention is described based on drawing. Note that the present invention is not limited to the embodiments. Further, the present invention is not limited to the following description, and can be appropriately changed without departing from the gist of the present invention. In the drawings shown below, the scale of each member is different from the actual scale for easy understanding.

実施の形態１．
図１は、曲面太陽電池モジュール１の斜視図である。曲面太陽電池モジュール１は、太陽電池パネル１０、保持フレーム２を備える。太陽電池パネル１０は、平面視において方形形状を呈し、受光面１０ａに太陽光が照射されることで、電力を発生させる。太陽電池パネル１０の受光面１０ａは、受光面１０ａ側に凸となる曲面形状を呈する。より具体的には、太陽電池パネル１０の長辺に沿った方向に曲率を持つ曲面形状となっている。 Embodiment 1 FIG.
FIG. 1 is a perspective view of the curved solar cell module 1. The curved solar cell module 1 includes a solar cell panel 10 and a holding frame 2. The solar cell panel 10 has a square shape in a plan view, and generates electric power when the light receiving surface 10a is irradiated with sunlight. The light receiving surface 10a of the solar cell panel 10 has a curved shape that is convex toward the light receiving surface 10a. More specifically, it has a curved surface shape with a curvature in the direction along the long side of the solar cell panel 10.

アルミ材を母材とする保持フレーム２は、太陽電池パネル１０の外周を囲んで保持するフレーム部材であり、太陽電池パネル１０の端部（外縁）の補強や保護を図る。また、保持フレーム２は、屋根等に取り付けられた架台に曲面太陽電池モジュール１を固定する際の固定金具としても機能する。保持フレーム２の形状に関しては例えば平地での設置、屋根への設置など設置する場所に適合した形状が採用される。   The holding frame 2 using an aluminum material as a base material is a frame member that surrounds and holds the outer periphery of the solar cell panel 10, and reinforces and protects the end (outer edge) of the solar cell panel 10. The holding frame 2 also functions as a fixture for fixing the curved solar cell module 1 to a mount attached to a roof or the like. As for the shape of the holding frame 2, for example, a shape suitable for an installation location such as installation on a flat ground or installation on a roof is adopted.

図２は、曲面太陽電池モジュール１の分解斜視図である。太陽電池パネル１０は、保持フレーム２に保持されていない状態では、受光面１０ａが平面形状を呈する。図３は、太陽電池パネル１０の詳細な構成を示す断面図である。太陽電池パネル１０は、ガラス基板４０、表面樹脂封止材４１、太陽電池アレイ４２、裏面樹脂封止材４３、保護シート４４が順に積層され加熱により一体形成されたものである。太陽電池アレイ４２は、複数の太陽電池セル４２ａが複数のリード線４２ｂを介して接続されたものである。   FIG. 2 is an exploded perspective view of the curved solar cell module 1. When the solar cell panel 10 is not held by the holding frame 2, the light receiving surface 10a has a planar shape. FIG. 3 is a cross-sectional view showing a detailed configuration of the solar cell panel 10. In the solar cell panel 10, a glass substrate 40, a front surface resin sealing material 41, a solar cell array 42, a back surface resin sealing material 43, and a protective sheet 44 are sequentially stacked and integrally formed by heating. The solar cell array 42 has a plurality of solar cells 42a connected via a plurality of lead wires 42b.

図２に示すように、保持フレーム２は、第１フレーム２１、第２フレーム２２、第３フレーム２３、第４フレーム２４を備える。図４は、太陽電池パネル１０のうち、第１フレーム２１に保持された外縁部分の断面図である。第１フレーム２１は、太陽電池パネル１０に裏面１０ｂ側から当接する第１裏面側フレーム２１ａと、受光面１０ａ側から当接する第１受光面側フレーム２１ｂとに分割されている。第１裏面側フレーム２１ａは、太陽電池パネル１０の第１の外縁１１に裏面１０ｂ側から当接する第１裏側当接面２５を有する。   As shown in FIG. 2, the holding frame 2 includes a first frame 21, a second frame 22, a third frame 23, and a fourth frame 24. FIG. 4 is a cross-sectional view of the outer edge portion held by the first frame 21 in the solar cell panel 10. The first frame 21 is divided into a first back surface side frame 21a that contacts the solar cell panel 10 from the back surface 10b side, and a first light receiving surface side frame 21b that contacts the light receiving surface 10a side. The first back surface side frame 21 a has a first back side contact surface 25 that contacts the first outer edge 11 of the solar cell panel 10 from the back surface 10 b side.

第１受光面側フレーム２１ｂは、第１の外縁１１に受光面１０ａ側から当接して、第１裏側当接面２５との間に第１の外縁１１を挟んで太陽電池パネル１０を保持する第１受光側当接面２６を有する。   The first light receiving surface side frame 21b is in contact with the first outer edge 11 from the light receiving surface 10a side, and holds the solar cell panel 10 with the first outer edge 11 sandwiched between it and the first back side contact surface 25. The first light receiving side contact surface 26 is provided.

第１裏面側フレーム２１ａと太陽電池パネル１０との間、および第１受光面側フレーム２１ｂと太陽電池パネル１０との間には、太陽電池パネル１０のずれ防止および保護用のゴム材３０が設けられる。ゴム材３０は、例えばゴム板であり、第１裏面側フレーム２１ａや第１受光面側フレーム２１ｂに貼り付けられる。   Between the first back surface side frame 21a and the solar cell panel 10 and between the first light receiving surface side frame 21b and the solar cell panel 10, a rubber material 30 for preventing and protecting the solar cell panel 10 is provided. It is done. The rubber material 30 is, for example, a rubber plate and is attached to the first back surface side frame 21a and the first light receiving surface side frame 21b.

第１裏側当接面２５と第１受光側当接面２６とは、受光面１０ａと平行かつ第１の外縁１１と垂直な方向から見た場合に曲線となる曲面形状を呈する。その曲率は、太陽電池パネル１０が長辺側に持つ曲率と等しい。   The first back-side contact surface 25 and the first light-receiving side contact surface 26 have a curved surface shape that is curved when viewed from a direction parallel to the light-receiving surface 10 a and perpendicular to the first outer edge 11. The curvature is equal to the curvature that the solar cell panel 10 has on the long side.

断面図は省略するが、第２フレーム２２も第１フレーム２１と同様の構成となる。すなわち、第２フレーム２２は、太陽電池パネル１０に裏面１０ｂ側から当接する第２裏面側フレーム２２ａと、受光面１０ａ側から当接する第２受光面側フレーム２２ｂとに分割されている。第２裏面側フレーム２２ａは、太陽電池パネル１０の第１の外縁１１と対向する第２の外縁１２に裏面１０ｂ側から当接する第２裏側当接面２７を有する。   Although the sectional view is omitted, the second frame 22 has the same configuration as the first frame 21. That is, the second frame 22 is divided into a second back surface side frame 22a that contacts the solar cell panel 10 from the back surface 10b side, and a second light receiving surface side frame 22b that contacts the light receiving surface 10a side. The second back surface side frame 22 a has a second back side contact surface 27 that contacts the second outer edge 12 facing the first outer edge 11 of the solar cell panel 10 from the back surface 10 b side.

また、第２受光面側フレーム２２ｂは、第２の外縁１２に受光面１０ａ側から当接して、第２裏側当接面２７との間に第２の外縁１２を挟んで太陽電池パネル１０を保持する第２受光側当接面２８を有する。第２裏面側フレーム２２ａと太陽電池パネル１０との間、および第２受光面側フレーム２２ｂと太陽電池パネル１０との間には、太陽電池パネル１０のずれ防止および保護用のゴム材３０が設けられる。ゴム材３０は、例えばゴム板であり、第２裏面側フレーム２２ａや第２受光面側フレーム２２ｂに貼り付けられる。   Further, the second light receiving surface side frame 22b contacts the second outer edge 12 from the light receiving surface 10a side, and sandwiches the second outer edge 12 between the second back side contact surface 27 and the solar cell panel 10. It has the 2nd light reception side contact surface 28 to hold | maintain. Between the second back surface side frame 22a and the solar cell panel 10, and between the second light receiving surface side frame 22b and the solar cell panel 10, a rubber material 30 for preventing and protecting the solar cell panel 10 is provided. It is done. The rubber material 30 is, for example, a rubber plate, and is attached to the second back surface side frame 22a or the second light receiving surface side frame 22b.

第２裏側当接面２７と第２受光側当接面２８とは、受光面１０ａと平行かつ第２の外縁１２と垂直な方向から見た場合に曲線となる曲面形状を呈する。その曲率は、太陽電池パネル１０が長辺側に持つ曲率と等しい。   The second back-side contact surface 27 and the second light-receiving side contact surface 28 have a curved surface shape that is curved when viewed from a direction parallel to the light-receiving surface 10a and perpendicular to the second outer edge 12. The curvature is equal to the curvature that the solar cell panel 10 has on the long side.

図５は、太陽電池パネル１０のうち、第３フレーム２３に保持された外縁部分の断面図である。第３フレーム２３は、第１，２フレーム２１，２２のように分割構成されておらず、太陽電池パネル１０の第３の外縁１３が挿入される挿入溝２３ａが形成されている。   FIG. 5 is a cross-sectional view of an outer edge portion held by the third frame 23 in the solar cell panel 10. The third frame 23 is not divided as the first and second frames 21 and 22, and an insertion groove 23 a into which the third outer edge 13 of the solar cell panel 10 is inserted is formed.

挿入溝２３ａには、ゴム材３２が流し込まれており、太陽電池パネル１０のずれ防止および保護が図られている。図６は、挿入溝２３ａにゴム材３２を流し込む作業の作業例を示す図である。図６に示す作業例では、第３フレーム２３を位置決め機構（図示せず）によって固定したあと、溶融タンク６１内にて加熱溶融させたゴム材３２を、ノズル６０を通して挿入溝２３ａに流し込み硬化させている。曲面太陽電池モジュール１の組立時には、太陽電池パネル１０と第３フレーム２３とを接着させるために、挿入溝２３ａ内のゴム材３２を再加熱溶融させた状態で太陽電池パネル１０の外縁を挿入溝２３ａに挿入する。   A rubber material 32 is poured into the insertion groove 23a to prevent the solar cell panel 10 from shifting and to protect it. FIG. 6 is a diagram illustrating a work example of the work of pouring the rubber material 32 into the insertion groove 23a. In the working example shown in FIG. 6, after fixing the third frame 23 by a positioning mechanism (not shown), the rubber material 32 heated and melted in the melting tank 61 is poured into the insertion groove 23a through the nozzle 60 and cured. ing. When the curved solar cell module 1 is assembled, the outer edge of the solar cell panel 10 is inserted into the insertion groove in a state where the rubber material 32 in the insertion groove 23a is reheated and melted in order to bond the solar cell panel 10 and the third frame 23. Insert into 23a.

断面図は省略するが、第４フレーム２４も第３フレーム２３と同様の構成となる。すなわち、第４フレーム２４は、第１，２フレーム２１，２２のように分割構成されておらず、太陽電池パネル１０の第４の外縁１４が挿入される挿入溝２４ａが形成されている。   Although the sectional view is omitted, the fourth frame 24 has the same configuration as the third frame 23. That is, the fourth frame 24 is not divided and configured like the first and second frames 21 and 22, and an insertion groove 24 a into which the fourth outer edge 14 of the solar cell panel 10 is inserted is formed.

挿入溝２４ａには、ゴム材３２が流し込まれており、太陽電池パネル１０のずれ防止および保護が図られている。図示は省略するが、第３フレーム２３と同様に、第４フレーム２４を位置決め機構によって固定したあと、溶融タンク６１内にて加熱溶融させたゴム材３２を、ノズル６０を通して挿入溝２４ａに流し込み硬化させている（図６も参照）。曲面太陽電池モジュール１の組立時には、太陽電池パネル１０と第４フレーム２４とを接着させるために、挿入溝２４ａ内のゴム材３２を再加熱溶融させた状態で太陽電池パネル１０の外縁を挿入溝２４ａに挿入する。   A rubber material 32 is poured into the insertion groove 24a, and the solar cell panel 10 is prevented from being displaced and protected. Although not shown, like the third frame 23, after the fourth frame 24 is fixed by the positioning mechanism, the rubber material 32 heated and melted in the melting tank 61 is poured into the insertion groove 24a through the nozzle 60 and cured. (See also FIG. 6). When the curved solar cell module 1 is assembled, the outer edge of the solar cell panel 10 is inserted into the insertion groove while the rubber material 32 in the insertion groove 24a is reheated and melted in order to bond the solar cell panel 10 and the fourth frame 24. Insert into 24a.

次に、曲面太陽電池モジュール１の製造装置（擬似曲面台）について説明する。図７は、曲面太陽電池モジュール１の製造装置（擬似曲面台）５０の概略構成を示す斜視図である。図８は、擬似曲面台５０の概略構成を示す断面図である。擬似曲面台５０には、曲面太陽電池モジュール１における太陽電池パネル１０の曲面形状と同一の曲面形状を呈する支持面５０ａが形成されている。   Next, the manufacturing apparatus (pseudo-curved surface base) of the curved solar cell module 1 will be described. FIG. 7 is a perspective view showing a schematic configuration of a manufacturing apparatus (pseudo-curved surface base) 50 for the curved solar cell module 1. FIG. 8 is a cross-sectional view showing a schematic configuration of the pseudo-curved surface table 50. The pseudo-curved surface base 50 is formed with a support surface 50 a that has the same curved surface shape as the curved surface shape of the solar cell panel 10 in the curved surface solar cell module 1.

また、支持面５０ａの周囲には、第１裏面側フレーム２１ａが載置される第１載置部５０ｂおよび第２裏面側フレーム２２ａが載置される第２載置部５０ｃが形成される。第１，２載置部５０ｂ，ｃに、第１，２裏面側フレーム２１ａ，２２ａが載置された状態で、支持面５０ａと第１裏側当接面２５と第２裏側当接面２７とが滑らかに連続する。   Further, around the support surface 50a, a first placement portion 50b on which the first back side frame 21a is placed and a second placement portion 50c on which the second back side frame 22a is placed are formed. With the first and second back-side frames 21a and 22a mounted on the first and second mounting portions 50b and 50c, the support surface 50a, the first back-side contact surface 25, and the second back-side contact surface 27 Smoothly continues.

擬似曲面台５０は、吸着パッド５１ａなどによって太陽電池パネル１０を保持するための機能を有する支持棒５１を備える。太陽電池パネル１０への曲面形成時には、太陽電池パネル１０の端部を支持する支持棒５１によって、ばねの弾力を利用しながら太陽電池パネル１０を支持面５０ａに沿って倣わせることができる。   The pseudo-curved surface table 50 includes a support bar 51 having a function for holding the solar cell panel 10 by a suction pad 51a or the like. When the curved surface is formed on the solar cell panel 10, the solar cell panel 10 can be made to follow the support surface 50 a by using the elasticity of the spring by the support bar 51 that supports the end of the solar cell panel 10.

次に、曲面太陽電池モジュール１の製造手順について説明する。図９〜１３は、曲面太陽電池モジュール１の製造手順を説明するための図である。   Next, the manufacturing procedure of the curved solar cell module 1 will be described. 9-13 is a figure for demonstrating the manufacturing procedure of the curved solar cell module 1. FIG.

まず、図９，１０に示すように、受光面１０ａおよび裏面１０ｂが平面形状を呈する太陽電池パネル１０の第３の外縁１３および第４の外縁１４に、第３フレーム２３および第４フレーム２４が取り付けられる。この際、図５，６に示したゴム材３２の流し込みや再加熱溶融も行われる。そして、太陽電池パネル１０を保持した状態で、第３フレーム２３の挿入溝２３ａおよび第４フレーム２４の挿入溝２４ａに太陽電池パネル１０の第３の外縁１３および第４の外縁１４を挿入させる。例えば、サーボモーター等の駆動ユニット（図示せず）により第３フレーム２３および第４フレーム２４を移動させる。   First, as shown in FIGS. 9 and 10, a third frame 23 and a fourth frame 24 are formed on the third outer edge 13 and the fourth outer edge 14 of the solar cell panel 10 in which the light receiving surface 10 a and the back surface 10 b have a planar shape. It is attached. At this time, the rubber material 32 shown in FIGS. 5 and 6 is poured and reheated and melted. Then, with the solar cell panel 10 held, the third outer edge 13 and the fourth outer edge 14 of the solar cell panel 10 are inserted into the insertion groove 23 a of the third frame 23 and the insertion groove 24 a of the fourth frame 24. For example, the third frame 23 and the fourth frame 24 are moved by a drive unit (not shown) such as a servo motor.

次に、図１１に示すように、第１，２載置部５０ｂ，ｃに、第１，２裏面側フレーム２１ａ，２２ａが載置される。次に、図１２に示すように、太陽電池パネル１０の裏面１０ｂを擬似曲面台５０の支持面５０ａに当接させる。このとき、平面視において、第３，４フレーム２３，２４が支持面５０ａとは重ならず、太陽電池パネル１０の第１，２の外縁１１，１２が、第１，２裏面側フレーム２１ａ，２２ａの第１，２裏側当接面２５，２７と重なる位置に太陽電池パネル１０は位置決めされる。   Next, as shown in FIG. 11, the first and second back-side frames 21a and 22a are placed on the first and second placement portions 50b and 50c. Next, as shown in FIG. 12, the back surface 10 b of the solar cell panel 10 is brought into contact with the support surface 50 a of the pseudo-curved surface table 50. At this time, in plan view, the third and fourth frames 23 and 24 do not overlap the support surface 50a, and the first and second outer edges 11 and 12 of the solar cell panel 10 are connected to the first and second back-side frames 21a and 21a, respectively. The solar battery panel 10 is positioned at a position overlapping the first and second back-side contact surfaces 25 and 27 of 22a.

そして、第１，２受光面側フレーム２１ｂ，２２ｂを太陽電池パネル１０の受光面１０ａに押し付けて、第１，２裏面側フレーム２１ａ，２２ａとの間に太陽電池パネル１０を挟み込むことで、図１３に示すように、太陽電池パネル１０の受光面１０ａを曲面形状とする。なお、第１，２受光面側フレーム２１ｂ，２２ｂを太陽電池パネル１０の受光面１０ａに押し付ける前であれば順番は問わないが、ゴム材３０が第１，２フレーム２１，２２に貼り付けられる。   Then, by pressing the first and second light receiving surface side frames 21b and 22b against the light receiving surface 10a of the solar cell panel 10, the solar cell panel 10 is sandwiched between the first and second back surface frames 21a and 22a. As shown in FIG. 13, the light receiving surface 10 a of the solar cell panel 10 has a curved shape. The rubber material 30 is affixed to the first and second frames 21 and 22 before the first and second light-receiving surface frames 21b and 22b are pressed against the light-receiving surface 10a of the solar cell panel 10. .

ここで、第１，２裏側当接面２５，２７および第１，２受光側当接面２６，２８が曲面形状を呈するので、第１，２受光面側フレーム２１ｂ，２２ｂを太陽電池パネル１０の受光面１０ａに押し付けることで、太陽電池パネル１０をその曲面形状に倣わせることができる。より具体的には、第１，２裏側当接面２５，２７の中央部を支点にしながら、第１，２受光側当接面２６，２８の端部が押し付けられて、太陽電池パネル１０が曲面形状に倣わせられる。このとき、太陽電池パネル１０は、擬似曲面台５０の支持面５０ａの曲面形状にも倣う。   Here, since the first and second back-side contact surfaces 25 and 27 and the first and second light-receiving side contact surfaces 26 and 28 are curved, the first and second light-receiving surface-side frames 21b and 22b are attached to the solar cell panel 10. The solar cell panel 10 can be made to follow the curved surface shape by being pressed against the light receiving surface 10a. More specifically, the ends of the first and second light-receiving side contact surfaces 26 and 28 are pressed while using the central portions of the first and second back-side contact surfaces 25 and 27 as fulcrums, so that the solar cell panel 10 is Followed by curved surface shape. At this time, the solar cell panel 10 also follows the curved surface shape of the support surface 50a of the pseudo-curved surface table 50.

第１，２受光面側フレーム２１ｂ，２２ｂを押し付ける速度については、ガラス基板４０の破損を防止するための速度とする。したがって、太陽電池パネル１０の変形に合わせながら第１，２受光面側フレーム２１ｂ，２２ｂを押し付ける速度を制御できる機構を備えることが好ましい。また、曲面形状の曲率も太陽電池パネル１０が割れない程度の範囲に収める必要がある。   The speed at which the first and second light receiving surface side frames 21b and 22b are pressed is a speed for preventing the glass substrate 40 from being damaged. Therefore, it is preferable to provide a mechanism capable of controlling the speed at which the first and second light receiving surface side frames 21b and 22b are pressed while matching the deformation of the solar cell panel 10. In addition, the curvature of the curved surface needs to be within a range where the solar cell panel 10 is not broken.

図１４，１５は、第１，２裏面側フレーム２１ａ，２２ａと第１，２受光面側フレーム２１ｂ，２２ｂとの固定例を示す断面図である。第１，２裏面側フレーム２１ａ，２２ａと第１，２受光面側フレーム２１ｂ，２２ｂとは、図１４に示すようにねじ５８を使用して固定してもよいし、図１５に示すようにピン５３を穴５４に嵌めこむなどの簡易組立方法で固定してもよい。   14 and 15 are cross-sectional views showing examples of fixing the first and second back surface frames 21a and 22a and the first and second light receiving surface frames 21b and 22b. The first and second back side frames 21a and 22a and the first and second light receiving side frames 21b and 22b may be fixed using screws 58 as shown in FIG. 14, or as shown in FIG. The pin 53 may be fixed by a simple assembly method such as fitting into the hole 54.

図１６，１７は、第１，２フレーム２１，２２と、第３，４フレーム２３，２４との連結例を示す図である。図１６に示すように、フレーム同士を直接ねじ３３で連結してもよいし、図１７に示すように、フレームとは別個に設けた連結板３４を利用して連結してもよい。   FIGS. 16 and 17 are diagrams illustrating an example of connection between the first and second frames 21 and 22 and the third and fourth frames 23 and 24. As shown in FIG. 16, the frames may be directly connected by screws 33, or as shown in FIG. 17, they may be connected using a connecting plate 34 provided separately from the frame.

以上説明してきたように、本実施の形態にかかる曲面太陽電池モジュール１、その製造装置、製造方法によれば、保持フレーム２の一部が受光面側と裏面側とに分割して構成されることで、太陽電池パネル１０自体に曲率を持たせる必要がないため、製造コストの抑制を図ることができる。   As described above, according to the curved solar cell module 1, the manufacturing apparatus, and the manufacturing method according to the present embodiment, a part of the holding frame 2 is divided into the light receiving surface side and the back surface side. Thus, since it is not necessary to give the solar cell panel 10 a curvature, it is possible to suppress the manufacturing cost.

また、太陽電池パネル１０を折り曲げながらフレームに形成された溝に挿入するような、面倒かつ精密性を要求される作業を不要とできるので、組み立て作業の簡素化や、歩留まりの向上を図ることができる。   Further, it is possible to eliminate the troublesome and precise work required to insert the solar cell panel 10 into the groove formed in the frame while bending it, so that the assembly work can be simplified and the yield can be improved. it can.

また、組み立て後の太陽電池パネル１０の曲率は、フレーム側の曲率によって適宜変更可能であるため、曲率ごとに異なる太陽電池パネル１０を用意する必要がない。そのため、設計変更時のコストや在庫コスト等の抑制を図ることができる。   Moreover, since the curvature of the assembled solar cell panel 10 can be appropriately changed according to the curvature on the frame side, it is not necessary to prepare a different solar cell panel 10 for each curvature. For this reason, it is possible to reduce the costs at the time of design change, inventory costs, and the like.

図１８は、太陽電池パネル１０を擬似曲面台５０の支持面５０ａに倣わせる構成の変形例を示す図である。図１８に示すように、擬似曲面台５０の支持面５０ａとの間に、太陽電池パネル１０の全面または一部を挟み込む擬似上面板５２によって、太陽電池パネル１０を変形させてから、保持フレーム２を取り付けてもよい。擬似上面板５２のうち、支持面５０ａと対向する面は、支持面５０ａと同様の曲面形状を呈する。   FIG. 18 is a diagram showing a modification of the configuration in which the solar cell panel 10 is made to follow the support surface 50a of the pseudo-curved surface table 50. As shown in FIG. 18, the solar cell panel 10 is deformed by the pseudo upper surface plate 52 that sandwiches the entire surface or a part of the solar cell panel 10 between the support surface 50 a of the pseudo-curved surface table 50, and then the holding frame 2. May be attached. Of the pseudo upper surface plate 52, the surface facing the support surface 50a has a curved surface shape similar to that of the support surface 50a.

図１９は、保持フレーム２の変形例を示す図である。図１９に示すように、第３フレーム２３や第４フレーム２４も第３，４裏面側フレーム２３ｂ、２４ｂと第３，４受光面側フレーム２３ｃ、２４ｃとに分割して構成してもよい。   FIG. 19 is a view showing a modified example of the holding frame 2. As shown in FIG. 19, the third frame 23 and the fourth frame 24 may be divided into third and fourth rear surface side frames 23 b and 24 b and third and fourth light receiving surface side frames 23 c and 24 c.

なお、本実施の形態では、方形形状の太陽電池パネルを例に挙げて説明したが、これ以外の形状であっても構わない。また、太陽電池パネルの長辺側に曲率を持たせる例を挙げて説明したが、短辺側に曲率を持たせてもよいし、長辺、短辺の両方に曲率を持たせてもよい。   In the present embodiment, a rectangular solar cell panel has been described as an example, but other shapes may be used. Moreover, although the example which gives a curvature to the long side of a solar cell panel was given and demonstrated, you may give a curvature to a short side, and you may give a curvature to both a long side and a short side. .

以上のように、本発明にかかる保持フレームは、曲面形状を呈する太陽電池パネルを備える太陽電池モジュールの保持フレームに有用である。   As described above, the holding frame according to the present invention is useful for a holding frame of a solar cell module including a solar cell panel having a curved shape.

１ 曲面太陽電池モジュール、２ 保持フレーム、１０ 太陽電池パネル、１０ａ 受光面、１０ｂ 裏面、１１ 第１の外縁、１２ 第２の外縁、１３ 第３の外縁、１４ 第４の外縁、２１ 第１フレーム、２１ａ 第１裏面側フレーム、２１ｂ 第１受光面側フレーム、２２ 第２フレーム、２２ａ 第２裏面側フレーム、２２ｂ 第２受光面側フレーム、２３ 第３フレーム、２３ａ 挿入溝、２３ｂ 第３裏面側フレーム、２３ｃ 第３受光面側フレーム、２４ 第４フレーム、２４ａ 挿入溝、２４ｂ 第４裏面側フレーム、２４ｃ 第４受光面側フレーム、２５ 第１裏側当接面、２６ 第１受光側当接面、２７ 第２裏側当接面、２８ 第２受光側当接面、３０，３２ ゴム材、３３ ねじ、３４ 連結板、４０ ガラス基板、４１ 表面樹脂封止材、４２ 太陽電池アレイ、４２ａ 太陽電池セル、４２ｂ リード線、４３ 裏面樹脂封止材、４４ 保護シート、５０ 擬似曲面台、５０ａ 支持面、５０ｂ 第１載置部、５０ｃ 第２載置部、５１ 支持棒、５１ａ 吸着パッド、５２ 擬似上面板、５３ ピン、５４ 穴、５８ ねじ、６０ ノズル、６１ 溶融タンク。   DESCRIPTION OF SYMBOLS 1 Curved solar cell module, 2 Holding frame, 10 Solar cell panel, 10a Light-receiving surface, 10b Back surface, 11 1st outer edge, 12 2nd outer edge, 13 3rd outer edge, 14 4th outer edge, 21 1st frame 21a 1st back side frame, 21b 1st light receiving side frame, 22 2nd frame, 22a 2nd back side frame, 22b 2nd light receiving side frame, 23 3rd frame, 23a Insertion groove, 23b 3rd back side Frame, 23c 3rd light receiving surface side frame, 24 4th frame, 24a Insertion groove, 24b 4th back surface side frame, 24c 4th light receiving surface side frame, 25 1st back side contact surface, 26 1st light reception side contact surface 27, second back side contact surface, 28 second light receiving side contact surface, 30, 32 rubber material, 33 screw, 34 connecting plate, 40 glass substrate, 41 surface resin sealing Material, 42 Solar cell array, 42a Solar cell, 42b Lead wire, 43 Back surface resin sealing material, 44 Protection sheet, 50 Pseudo-curved surface base, 50a Support surface, 50b 1st mounting part, 50c 2nd mounting part, 51 support rod, 51a suction pad, 52 pseudo top plate, 53 pins, 54 holes, 58 screws, 60 nozzles, 61 melting tank.

Claims (6)

太陽電池パネルの外周を囲んで保持する保持フレームであって、
前記太陽電池パネルの第１の外縁に裏面側から当接する第１裏側当接面を有する第１裏面側フレームと、
前記第１の外縁に受光面側から当接して、前記第１裏側当接面との間に前記第１の外縁を挟んで保持する第１受光側当接面を有する第１受光面側フレームと、
前記第１の外縁に対向する第２の外縁に裏面側から当接する第２裏側当接面を有する第２裏面側フレームと、
前記第２の外縁に受光面側から当接して、前記第２裏側当接面との間に前記第２の外縁を挟んで保持する第２受光側当接面を有する第２受光面側フレームと、を備え、
前記第１裏側当接面と前記第１受光側当接面とは、前記受光面と平行かつ前記第１の外縁と垂直な方向から見た場合に曲線となる曲面形状を呈し、
前記第２裏側当接面と前記第２受光側当接面とは、前記受光面と平行かつ前記第２の外縁と垂直な方向から見た場合に曲線となる曲面形状を呈することを特徴とする保持フレーム。 A holding frame that surrounds and holds the outer periphery of the solar panel,
A first back-side frame having a first back-side contact surface that contacts the first outer edge of the solar cell panel from the back side;
A first light-receiving surface side frame having a first light-receiving-side contact surface that is in contact with the first outer edge from the light-receiving surface side and holds the first outer edge with the first back-side contact surface. When,
A second back-side frame having a second back-side contact surface that comes into contact with the second outer edge facing the first outer edge from the back side;
A second light-receiving surface-side frame having a second light-receiving-side contact surface that is in contact with the second outer edge from the light-receiving surface side and holds the second outer edge with the second back-side contact surface. And comprising
The first back-side contact surface and the first light-receiving side contact surface have a curved surface shape that is curved when viewed from a direction parallel to the light-receiving surface and perpendicular to the first outer edge,
The second back-side contact surface and the second light-receiving side contact surface have a curved surface shape that is curved when viewed from a direction parallel to the light-receiving surface and perpendicular to the second outer edge. Holding frame. 前記第１裏側当接面、前記第１受光側当接面、前記第２裏側当接面および前記第２受光側当接面と、前記太陽電池パネルとの間に設けられるゴム材をさらに備えることを特徴とする請求項１に記載の保持フレーム。   And a rubber material provided between the first back-side contact surface, the first light-receiving side contact surface, the second back-side contact surface, the second light-receiving side contact surface, and the solar cell panel. The holding frame according to claim 1. 請求項１または２に記載の保持フレームと、
前記保持フレームに保持される太陽電池パネルと、を備えることを特徴とする太陽電池モジュール。 The holding frame according to claim 1 or 2,
A solar cell module comprising: a solar cell panel held by the holding frame. 裏面側が曲面形状を呈する太陽電池パネルを備える太陽電池モジュールの製造装置であって、
前記太陽電池パネルの裏面側の曲面形状と同一の曲面形状を呈する支持面と、
支持面の周囲に形成されて、曲面形状を呈して前記太陽電池パネルの第１の外縁に裏面側から当接する第１裏側当接面を有する第１裏面側フレームが載置される第１載置部と、
支持面の周囲に形成されて、曲面形状を呈して前記太陽電池パネルの第２の外縁に裏面側から当接する第２裏側当接面を有する第２裏面側フレームが載置される第２載置部と、が形成され、
前記第１載置部および前記第２載置部に前記第１裏面側フレームと前記第２裏面側フレームとが載置された状態で、前記支持面と前記第１裏側当接面と前記第２裏側当接面とが滑らかに連続することを特徴とする太陽電池モジュールの製造装置。 A solar cell module manufacturing apparatus comprising a solar cell panel whose back side has a curved shape,
A support surface exhibiting the same curved shape as the curved shape on the back side of the solar cell panel;
A first mount on which a first back-side frame having a first back-side contact surface that is formed around the support surface and has a curved shape and contacts the first outer edge of the solar cell panel from the back-surface side is placed. A placement unit;
A second mounting on which a second back-side frame having a second back-side contact surface that is formed around the support surface and has a curved surface shape and contacts the second outer edge of the solar cell panel from the back-surface side is placed. Is formed,
With the first back surface side frame and the second back surface side frame being placed on the first placement portion and the second placement portion, the support surface, the first back side contact surface, and the first 2. A solar cell module manufacturing apparatus, characterized in that the back-side contact surface is smoothly continuous. 請求項４に記載の製造装置を用いた太陽電池モジュールの製造方法であって、
前記第１載置部に前記第１裏面側フレームを載置し、
前記第２載置部に前記第２裏面側フレームを載置し、
前記支持面に前記太陽電池パネルを載置し、
曲面形状を呈して前記太陽電池パネルの第１の外縁に受光面側から当接する第１受光側当接面を有する第１受光面側フレームと、前記第１裏面側フレームとの間に前記第１の外縁を挟み、
曲面形状を呈して前記太陽電池パネルの第２の外縁に受光面側から当接する第２受光側当接面を有する第２受光面側フレームと、前記第２裏面側フレームとの間に前記第２の外縁を挟むことを特徴とする太陽電池モジュールの製造方法。 A method for manufacturing a solar cell module using the manufacturing apparatus according to claim 4,
Placing the first back side frame on the first placement unit;
Placing the second back frame on the second placement section;
Placing the solar cell panel on the support surface;
The first light receiving surface side frame having a curved surface and having a first light receiving side contact surface that contacts the first outer edge of the solar cell panel from the light receiving surface side, and the first back surface side frame, the first back surface side frame. 1 between the outer edges,
The second light receiving surface side frame having a curved surface and having a second light receiving side contact surface that contacts the second outer edge of the solar cell panel from the light receiving surface side, and the second back surface side frame between the second back surface side frame and the second back surface side frame. A method for manufacturing a solar cell module, comprising sandwiching two outer edges. 請求項４に記載の製造装置を用いた太陽電池モジュールの製造方法であって、
前記第１載置部に前記第１裏面側フレームを載置し、
前記第２載置部に前記第２裏面側フレームを載置し、
前記支持面に前記太陽電池パネルを載置し、
前記支持面の全部または一部を覆う上面板と、前記支持面との間に前記太陽電池パネルを挟むことを特徴とする太陽電池モジュールの製造方法。 A method for manufacturing a solar cell module using the manufacturing apparatus according to claim 4,
Placing the first back side frame on the first placement unit;
Placing the second back frame on the second placement section;
Placing the solar cell panel on the support surface;
A method for manufacturing a solar cell module, comprising sandwiching the solar cell panel between an upper surface plate covering all or part of the support surface and the support surface.
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