JP2011009714A - Solar cell module and method of manufacturing solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module capable of enhancing reliability of a fitting structure of a solar cell to a base for installation without reference to a material of a back-side sealing member of the solar cell and a material of the base for installation.SOLUTION: A top-side sealing member 200 and the back-side sealing member 220 hold the solar cell 100 therebetween. A buffer member 400 is provided on an external surface of the back-side sealing member 220, and fused to the back-side sealing member 220. The buffer member 400 is composed of the material to which an adhesive layer 420 is bonded more easily than the back-side sealing material 220. The top-side sealing member 200, the back-side sealing member 220, and buffer member 400 are sheet-like members.

Description

  The present invention relates to a solar cell module in which solar cells are sealed with a sealing member, and a method for manufacturing the solar cell module.

  Solar cell power generation devices have attracted attention in recent years because they are clean energy sources. The place where the solar battery power generation device is installed is sunny outdoors. For this reason, a temperature difference due to the temperature of the year is added, and it is exposed to wind and rain. In such an environment, a product life of 10 years or longer is required.

  An example of the configuration of the solar cell module constituting the solar cell power generator is shown in the schematic cross-sectional view of FIG. In this solar cell module, a back surface side sealing member 620, a solar battery cell 600, a front surface side sealing material 610, and a surface protection material 612 are stacked in this order on a roof steel plate 630. It is formed by heat fusion using.

  Patent Document 1 discloses fixing a solar cell panel to a metal roof using a double-sided tape.

JP-A-6-85306

  In order for a solar cell to spread, it is necessary to make it possible to attach the solar cell module with high reliability to an installation substrate made of a material other than metal. However, in the method shown in FIG. 5, when the base material is formed of a material that cannot be heat-sealed, the solar cell module cannot be attached to the base material.

  In the structure described in Patent Document 1, it is necessary to increase the adhesive reliability between the adhesive layer of the double-sided tape and the solar cell panel and the adhesive reliability between the adhesive layer of the double-sided tape and the installation substrate. For this reason, depending on the material of the back surface side sealing member of a photovoltaic cell and the material of a base material, sufficient adhesion reliability may not be obtained.

  This invention is made | formed in view of the said situation, The place made into the objective is the sun with respect to the base material for installation irrespective of the material of the back surface side sealing member of a photovoltaic cell, and the material of the base material for installation. An object of the present invention is to provide a solar cell module and a method for manufacturing the solar cell module that can increase the reliability of the battery cell mounting structure.

According to the present invention, solar cells,
A front surface side sealing member and a back surface side sealing member that hold the solar battery cell therebetween,
A buffer member provided on the outer surface of the back surface side sealing member, and fused to the back surface side sealing member;
With
The buffer member is provided with a solar cell module formed of a material to which an adhesive is more easily bonded than the back side sealing member.

According to the present invention, the solar battery cell is held by the front surface side sealing member and the back surface side sealing member, and the buffer member is fused to the outer surface of the back surface side sealing member,
The said buffer member provides the manufacturing method of the solar cell module formed from the material which an adhesive agent adhere | attaches more easily than the said back surface side sealing member.

  ADVANTAGE OF THE INVENTION According to this invention, the reliability of the attachment structure of the photovoltaic cell with respect to the base material for installation can be made high irrespective of the material of the back surface side sealing member of a photovoltaic cell, and the material of the base material for installation.

It is a disassembled perspective view of the solar cell module which concerns on embodiment. (A) is the cross-sectional schematic of the solar cell module shown in FIG. 1, (b) is the plane schematic of the solar cell module shown in FIG. It is a flowchart which shows the manufacturing method of the solar cell module shown in FIG.1 and FIG.2. Each figure is sectional drawing which shows the method of attaching the solar cell module shown in FIG.1 and FIG.2 to the base material for installation. It is the cross-sectional schematic which shows an example of a structure of the solar cell module which comprises a solar cell power generation device.

(Embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In all the drawings, the same reference numerals are given to the same components, and the description will be omitted as appropriate.

  FIG. 1 is an exploded perspective view of the solar cell module according to the embodiment. This solar battery module includes a solar battery cell 100, a front surface side sealing member 200, a back surface side sealing member 220, and a buffer member 400, and uses an adhesive layer 420 made of an adhesive to install a roof steel plate or the like. Attached to the material. The front surface side sealing member 200 and the back surface side sealing member 220 hold the solar battery cell 100 therebetween. The buffer member 400 is provided on the outer surface of the back side sealing member 220 and is fused to the back side sealing member 220. The buffer member 400 is made of a material that allows the adhesive layer 420 to adhere more easily than the back side sealing member 220. The front surface side sealing member 200, the back surface side sealing member 220, and the buffer member 400 are sheet-like members.

  The back side sealing member 220 is formed of, for example, ethylene vinyl acetate (EVA). In this case, the buffer member 400 is made of, for example, polyester such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN). The adhesive layer 420 is formed of, for example, an acrylic pressure sensitive adhesive. Moreover, the front surface side sealing member 200 is formed of the same material as the back surface side sealing member 220, for example.

  The solar battery cell 100 is, for example, a SCAF (Series Connection through Aperture on Film) type thin film solar battery. Specifically, the solar battery cell 100 includes a substrate 310, a photoelectric conversion element 115, and a connection electrode layer 314. The solar cell 100 is provided with a lead wiring 124 made of a conductive foil lead.

  The substrate 310 is an insulating substrate such as polyimide, polyamide, polyimide amide, polyethylene naphthalate, polyethylene terephthalate, polyetherimide (PEI), polyetheretherketone (PEEK), or polyethersulfone (PES). .

  The photoelectric conversion element 115 has a configuration in which a lower electrode layer 111, a photoelectric conversion layer 112, and a transparent electrode layer 113 are stacked in this order on one surface of a substrate 310. The photoelectric conversion layer 112 is formed of, for example, a microcrystalline silicon layer or an amorphous silicon layer. A connection electrode layer 314 is formed on the opposite surface (back surface) on the substrate 310. Then, the photoelectric conversion element 115 and the connection electrode layer 314 that are divided into a plurality are arranged side by side on each surface of the substrate 310.

  The photoelectric conversion element 115 is arranged as a plurality of divided blocks on one surface of the substrate 310, and the connection electrode layer 314 is arranged as a plurality of divided blocks on the opposite surface of the substrate 310. In plan view, the block of the photoelectric conversion element 115 and the block of the connection electrode layer 314 are displaced from each other, and are arranged so that the other overlaps the gap between the blocks.

  The solar battery cell 100 is provided with a plurality of through holes, which are current collecting holes 312, and the transparent electrode layer 113 and the connection electrode layer 314 are electrically connected by a conductive film provided on the inner wall of the current collecting hole 312. Connected to.

  Further, a connection hole 316 is provided at a location where the transparent electrode layer 113 is not partially formed, and the lower electrode layer 111 and the connection electrode layer 314 are provided on the inner wall of the connection hole 316. They are electrically connected by a conductive film.

  The current collecting hole 312 and the connection hole 316 are formed so as to be connected to another connection electrode layer 314 adjacent to the divided connection electrode layer 314. Specifically, the current collection hole 312 of the adjacent photoelectric conversion element 115 is connected to the connection electrode layer 314 to which the connection hole 316 is connected. For this reason, in the photoelectric conversion element 115, adjacent blocks are connected in series.

  The lead-out wiring 124 is, for example, a copper foil lead wire, and is led out of the substrate 310 from the surface of the substrate 310 where the connection electrode layer 314 is formed (the lower surface in FIG. 1). Transmit the output to the outside. Specifically, the two lead wires 124 are connected to blocks of connection electrode layers 314 located at both ends of the substrate 310.

  A portion of the lead-out wiring 124 that is led out of the substrate 310 is exposed to the outside through a through hole (not shown) provided in the back surface side sealing member 220, the buffer member 400, and the adhesive layer 420. Has been pulled out.

  However, the photoelectric conversion element 115 included in the solar battery cell 100 does not have to have the above-described structure, and may be a solar battery having another structure.

  2A is a schematic cross-sectional view of the solar cell module shown in FIG. 1, and FIG. 2B is a schematic plan view of the solar cell module shown in FIG. FIG. 2A shows an AA ′ cross section of FIG. In the example shown in this drawing, a surface protective material 202 is further provided on the outer surface side of the surface side sealing member 200 (upper side in the example shown in FIG. 2A). The surface protective material 202 is made of ETFE, for example.

  The planar shapes of the surface protective material 202, the front surface side sealing member 200, the back surface side sealing member 220, and the buffer member 400 are the same as each other and larger than the solar battery cell 100. These are also provided outside the solar battery cell 100 in plan view. As shown in FIG.2 (b), in this embodiment, the planar shape of the photovoltaic cell 100 is a substantially rectangular shape or a square. And the surface protection material 202, the surface side sealing member 200, the back surface side sealing member 220, and the buffer member 400 are provided also outside the photovoltaic cell 100 in each of the four sides of the photovoltaic cell 100. A portion provided outside the solar battery cell 100 is used as a bending allowance 50.

  FIG. 3 is a flowchart showing a method for manufacturing the solar cell module shown in FIGS. 1 and 2. First, the buffer member 400, the back surface side sealing member 220, the solar battery cell 100, the front surface side sealing member 200, and the surface protection material 202 are laminated in this order (step S10). At this time, the portion of the lead-out wiring 124 that is led out of the substrate 310 is connected to the lower surface of the buffer member 400 through a back surface side sealing member 220 and a through hole (not shown) provided in the buffer member 400. Pull out from the side.

  Next, the laminate is placed on a vacuum heating laminator, depressurized for a predetermined time, and then heated for a predetermined time. Thereby, the photovoltaic cell 100 is laminated and sealed by the front surface side sealing member 200 and the back surface side sealing member 220, and is sandwiched between them. The buffer member 400 is heat-sealed to the back surface side sealing member 220, and the surface protective material 202 is heat-sealed to the front surface side sealing member 200 (step S20).

  4 is a cross-sectional view showing a method for attaching the solar cell module shown in FIGS. 1 and 2 to the installation base material 500. FIG. The installation base 500 is formed of at least one selected from the group consisting of painted steel, titanium, and plastic. As the coated steel, for example, a galvalume steel plate coated with polyester or fluorine can be used.

  First, as shown to Fig.4 (a), the contact bonding layer 420 is provided in the attachment surface of the solar cell module of the base material 500 for installation. The adhesive layer 420 is, for example, a sheet-like adhesive, and is attached to the installation base material 500.

  Next, as shown in FIG. 4B, the solar cell module is pressed against the adhesive layer 420. At this time, the lead-out wiring 124 shown in FIG. 1 is drawn out to the surface opposite to the mounting surface of the installation base material 500 through the through holes provided in the installation base material 500 and the adhesive layer 420. Accordingly, the solar cell module is attached to the installation base 500 via the adhesive layer 420. When the adhesive layer 420 is a pressure-sensitive adhesive, the adhesive layer 420 is cured by applying a pressure load to the adhesive layer 420 and the attachment of the solar cell module to the installation base 500 is completed. .

  The planar shape of the base material 500 for installation is larger than that of the solar battery cell 100, and for example, is the same shape as the back surface side sealing member 220. For this reason, in the state shown in FIG. 4B, the bending allowance 50 is also provided on the installation base material 500. The bending allowance 50 is subjected to a bending process, and the cross-sectional shape becomes, for example, a hat shape. Thereby, the rigidity of the solar cell module including the installation base material 500 is improved.

  Next, the operation and effect of this embodiment will be described. According to this embodiment, the buffer member 400 is fused to the outer surface of the back surface side sealing member 220. The buffer member 400 is formed of a material having better adhesion of the adhesive layer 420 than the back side sealing member 220. Since the back surface side sealing member 220 and the buffer member 400 are fused, they are firmly bonded. The bonding strength between the buffer member 400 and the adhesive layer 420 and the strength of the back surface side sealing member 220 and the buffer member 400 are both the back surface side sealing member when the adhesive layer 420 is provided directly on the back surface side sealing member 220. The bonding strength between 220 and the adhesive layer 420 is higher. For this reason, joining of the laminated body of the photovoltaic cell 100, the surface side sealing member 200, and the back surface side sealing member 220, and the base material 500 for installation becomes strong. Therefore, by appropriately selecting the material of the buffer member 400, the reliability of the mounting structure of the solar battery cell 100 with respect to the installation base material 500 regardless of the material of the back surface side sealing member 220 and the material of the installation base material 500. Sexuality can be increased.

  Further, when an insulating material such as polyethylene terephthalate is used as the buffer member 400, the insulation on the back side of the solar cell module is improved, so that the insulation reliability and durability of the solar cell module are also improved.

  Further, since a pressure-sensitive adhesive can be used as the adhesive layer 420, the adhesive layer 420 can be easily attached to the installation base material 500.

  Further, when the solar battery cell 100 is laminated and sealed with the front surface side sealing member 200 and the back surface side sealing member 220, the buffer member 400 is thermally fused to the back surface side sealing member 220. For this reason, it can suppress that the manufacturing process number of a solar cell module increases.

  As mentioned above, although embodiment of this invention was described with reference to drawings, these are the illustrations of this invention, Various structures other than the above are also employable. For example, the bending processing allowance 50 may be formed only on the long side or only the short side of the solar cell module.

Example 1
As the solar battery cell 100, an amorphous silicon solar battery cell was used. An ethylene vinyl acetate sheet was used as the front surface side sealing member 200 and the back surface side sealing member 220. A polyethylene terephthalate (PET) film was used as the buffer member 400. As the adhesive layer 420, an acrylic pressure sensitive sheet adhesive was used. As the base material 500 for installation, a titanium steel plate was used. As the surface protective material 202, ETFE was used.

  And in a vacuum laminating apparatus, after depressurizing the laminated body of the buffer member 400, the back surface side sealing member 220, the photovoltaic cell 100, the surface side sealing member 200, and the surface protection material 202 for 30 minutes by setting the degree of vacuum to 1 Torr. And heat treatment at 150 ° C. for 30 minutes.

  In this solar cell module, the laminate of the solar battery cell 100, the front surface side sealing member 200, and the back surface side sealing member 220 and the installation base material 500 were firmly bonded. In addition, even when installed on a stand or a roof of a building installed outdoors, the bonding strength did not decrease and showed good durability.

(Example 2)
Except for using a PEN film as the buffer member 400, a solar cell module having the same structure as in Example 1 was manufactured in the same manner as in Example 1. Also in this example, the same effect as in Example 1 was obtained.

50 Bending processing cost 100 Solar cell 111 Lower electrode layer 112 Photoelectric conversion layer 113 Transparent electrode layer 115 Photoelectric conversion element 124 Lead wire 200 Front surface side sealing member 202 Surface protective material 220 Back surface side sealing member 310 Substrate 312 Current collecting hole 314 Connection electrode layer 316 Connection hole 400 Buffer member 420 Adhesive layer 500 Installation base material 600 Solar cell 610 Surface side sealing material 612 Surface protection material 620 Back surface side sealing member 630 Steel plate for roof

Claims (8)

Solar cells,
A front surface side sealing member and a back surface side sealing member that hold the solar battery cell therebetween,
A buffer member provided on the outer surface of the back surface side sealing member, and fused to the back surface side sealing member;
With
The said buffer member is a solar cell module currently formed from the material which an adhesive agent adheres more easily than the said back surface side sealing member. The solar cell module according to claim 1, wherein
The back side sealing member is made of ethylene vinyl acetate,
The buffer member is a solar cell module formed of polyethylene terephthalate or polyethylene naphthalate. In the solar cell module according to claim 1 or 2,
The adhesive is a solar cell module which is a pressure-sensitive acrylic adhesive. In the solar cell module according to any one of claims 1 to 3,
The front surface side sealing member, the back surface side sealing member, and the buffer member have a larger planar shape than the solar cell, and are also provided outside the solar cell in plan view. In the solar cell module according to any one of claims 1 to 4,
The solar cell, the front surface side sealing member, the back surface side sealing member, and the base material for installation to which the buffer member is attached by the adhesive,
The installation base material is a solar cell module formed of at least one selected from the group consisting of painted steel, titanium, and plastic. While holding the solar cell with the front surface side sealing member and the back surface side sealing member, the buffer member is fused to the outer surface of the back surface side sealing member,
The said buffer member is a manufacturing method of the solar cell module formed from the material which an adhesive agent adheres more easily than the said back surface side sealing member. In the manufacturing method of the solar cell module according to claim 6,
The buffer member, the back surface side sealing member, the solar battery cell, and the front surface side sealing member are laminated in this order to form a laminate.
By vacuum-laminating the laminate, the solar cell is held by the front surface side sealing member and the back surface side sealing member, and the buffer member is fused to the outer surface of the back surface side sealing member. Manufacturing method of solar cell module. In the manufacturing method of the solar cell module according to claim 7,
The adhesive is applied to the buffer member to form an adhesive layer, and the solar cell, the front surface side sealing member, the back surface side sealing member, and the buffer member are installed on the installation base using the adhesive layer. A method for manufacturing a solar cell module to be attached to a material.

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