JP2002332733A - Solar cell module and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mount a solar cell to tile-like roofing formed of a metal plate, without a sense of incongruity. SOLUTION: The solar cell 10 is formed in a size corresponding to a flat part of the tile-like roofing, and both faces are covered and sealed with weather resistant films 21 or the like. The sealing film is shaped to provide shoulder parts 26 and a step part 27 corresponding to the unevenness of the tile-like roofing. The solar cell module 20 is thus formed and stuck along the surface of the roofing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module which can be adhered to a tiled roof material formed of a metal plate, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Solar cells are widely used as solar energy conversion devices. When this is used in ordinary households, it is common to install a box-shaped solar cell device having a relatively large surface area on the roof.

[0003]

However, the above-mentioned box-type solar cell device is large, and when installed on a roof, there is a problem that the appearance of the house is significantly impaired. Therefore, it is conceivable to lay solar cells directly on the roof surface, but there are many problems in terms of weather resistance and the like. The roof surface may be flat as long as the roof material 1 is composed of a plurality of (six in the figure) tile-shaped segments 1a formed of a metal plate as shown in FIGS. 8 and 9, for example. The ridges 2, 3 and the hanging part 4 are formed at the front end, the rear end and the side edge, and there are many irregularities except for a slight concave arc-shaped flat part 5, so that a single solar cell is laid over a wide area. Is technically very difficult.

[0004] It is an object of the present invention to make it possible to mount a solar cell on a tiled roof material formed from a metal plate as described above.

[0005]

In order to solve the above-mentioned problem, in the present invention, both sides of a solar cell having an appropriate size are covered with a synthetic resin film and sealed, and a solar cell having a shape corresponding to the unevenness of a tiled roof material is formed. This was done to form a solar cell module. A lead wire is connected to the anode and the cathode of the solar cell, and this is projected outside from the sealed film. When such a solar cell module is fixed to each of a plurality of continuous tile-shaped segments and the respective solar cells are electrically connected, a roof material can be used as a solar cell device.

[0006] The method of manufacturing the solar cell module is as follows.
A step of connecting flexible lead wires to solar cells of an appropriate size, a step of arranging the solar cells at appropriate intervals and sandwiching the front and back synthetic resin films with an adhesive film therebetween, and applying the front and back films to the solar cells with an adhesive film Pressing and sealing; and dividing and shaping the front and back films sealing the solar cells into regions containing a single solar cell. The front and back films are preferably formed of a weather-resistant synthetic resin.

[0007]

Embodiments of the present invention will be described below with reference to the accompanying drawings. First, a manufacturing process of a solar cell module to be mounted on each segment 1a of the roofing material 1 shown in FIG. 8 will be described. As shown in FIG. 1, lead wires 11a and 11b are attached to a solar cell 10 cut to an appropriate size, for example, 120 × 356 mm. The solar cell 1
Reference numeral 0 denotes a bendable amorphous silicone solar cell in which the substrate 12 is made of stainless steel, the stainless steel serving as a cathode, and the surface of the solar cell 10
An anode 13 made of silver-plated copper foil is provided. Flexible lead wires 11 for each of these anode and cathode
a and 11b are connected by soldering. This lead wire 1
1a and 11b are preferably formed of copper foil. Anode 13
After connecting the lead wire 11 a to the anode 13, the anode 13 is covered with a light shielding tape 14. Anode 13 at the other end to which no lead wire is connected
Is also covered with the light shielding tape 14.

As described above, the lead wires 11a, 11b
A plurality of solar cells 10 of a predetermined size to which are connected are superimposed on various films and arranged in parallel as shown in FIGS. At this time, the lead wires 11a and 11b are projected outside by a predetermined length.

Reference numeral 21 in FIG. 4 denotes a transparent surface protective film, which is an ethylene-tetrafluoroethylene copolymer,
A synthetic resin having excellent weather resistance, such as a fluoroethylene-6-fluoropropylene copolymer, vinylidene fluoride, or vinyl fluoride, is preferable, and the thickness is about 50 to 100 μm. Reference numeral 22 denotes a back moisture-proof film,
Synthetic resins such as polyester and polycarbonate are used in addition to the same ethylene-tetrafluoroethylene copolymer as in 1 above. The thickness is about 50 to 100 μm. Sign 2
Reference numerals 3 and 24 denote heat-bondable adhesive films, which are preferably ethylene-vinyl acetate copolymers and have a thickness of 200 to 4
It is about 00 μm. Reference numeral 25 denotes a buffer layer provided as necessary, and a glass wool nonwoven fabric having a basis weight of about 30 to 50 g / m ² is suitable.

The above film and the like are superimposed together with the solar cell 10 in the order shown in FIG. 4, placed on a heat plate (not shown), evacuated, and heated at a temperature of 150 to 160 ° C. and a temperature of 15 to 18 ° C.
When pressed separately, the adhesive films 23 and 24 are melted, and the solar cell 10 is sandwiched between the surface protection film 21 and the back moisture-proof film 22 and is integrally sealed by these films 21 and 22. Thereafter, an appropriate crosslinking treatment can be performed.

A plurality of solar cells 10 sealed as described above are divided into regions including a single solar cell 10 as shown in FIG. , 22 are trimmed. At this time, the film 21 around the sealed solar cell 20a,
When arranging a plurality of solar cells 10 as shown in FIG. 3 so that an appropriate margin of 22 remains, it is necessary to determine the interval between adjacent solar cells 10 in advance. Although the shape of the sealed solar cell 20a is substantially rectangular in the illustrated case, other shapes can be adopted according to the planar shape of the roof material to be mounted.

When a single sealed solar cell 20a divided as shown in FIG. 5 is shaped into a shape as shown in FIG. 6, a solar cell module 20 is completed. This shaping process is performed in order to correspond to the three-dimensional shape of each segment 1a of the tiled roofing material 1 shown in FIG. 8, and the portion corresponding to the solar cell 10 is curved in a concave arc shape, and the ridge 2 is formed at the tip. An engaging shoulder 26 is formed, and a step 27 engaging the hanging portion 4 is formed at the rear end. These shoulders 26 and steps 27 are formed in the film portion without the solar cell 10. At this time, the lead wires 11a and 11b are also
Bend with 6.

FIG. 7 shows the solar cell module 20 mounted on each segment 1a of the roofing material 1. As shown in the figure, the concave arc-shaped portion corresponding to the solar cell 10 of the solar cell module 20 is applied to the concave arc-shaped flat portion 5 (see FIG. 8) between the adjacent ridges 3 of the roofing material 1, and the shoulder 2 at the tip end
6 is engaged with the ridge 2 of the segment 1a, and the step 27 at the rear end is engaged with the hanging portion 4 of the tile-like segment 1a. Then, the solar cell module 20 is fixed to each segment 1a by applying an adhesive or interposing a double-sided adhesive film to a surface where the tile-shaped segment 1a and the solar cell module 20 are in contact with each other. In consideration of workability at this time and weather resistance after fixing, it is preferable to use a double-sided pressure-sensitive adhesive film having a butyl rubber foam as a base material and an acrylic pressure-sensitive adhesive applied to both surfaces thereof.

After fixing the solar cell module 20,
When the connectors 30 are attached to the ends of the lead wires 11a and 11b, and the connectors 30 are connected by wiring 31, a roofing material with solar cells is completed. Since the roofing material 1 is mounted in a state where the solar cell module 20 is in close contact with each segment 1a, the roofing material 1 does not have a sense of incongruity in appearance and is very preferable. In addition, desired power can be obtained by appropriately selecting the number of roof materials to which the solar cell module 20 is attached.

[0015]

According to the present invention, as described above, a sheet-like solar cell sealed with a weather-resistant synthetic resin film is formed along the unevenness of a tile-like roofing material, so that it is bonded to the roofing material. It can be installed simply by touching it, and there is no discomfort in appearance, and it can be electrically connected to each other by a connector, so that the desired power can be obtained only by appropriately selecting the number of solar cell modules. .

Furthermore, a solar cell module can be manufactured by a simple process of sealing, dividing, and shaping a plurality of solar cells at once with a film, thereby providing a photovoltaic power generation device which is advantageous in cost. can do.

[Brief description of the drawings]

FIG. 1 is a plan view showing a solar cell used for a solar cell module of the present invention.

FIG. 2 is an enlarged vertical sectional view of a front end of a solar cell.

FIG. 3 is a plan view showing a manufacturing process of the solar cell module.

FIG. 4 is a sectional view of the above.

FIG. 5 is a plan view showing a sheet-shaped or plate-shaped sealed solar cell.

FIG. 6 is a perspective view showing a solar cell module.

FIG. 7 is a perspective view showing a state where the solar cell module is mounted on a roof material.

FIG. 8 is a perspective view showing a tiled roof material formed by molding a metal plate.

FIG. 9 is a cross-sectional view of the above.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Roof material 1a Tile-like segment 2, 3 Ridge 4 Hanging part 5 Concave flat part 10 Solar cell 11a, 11b Lead wire 12 Substrate 13 Anode 14 Light shielding tape 20 Solar cell module 20a Sheet or plate-shaped sealed solar cell 21 Surface protection Film 22 Back moisture-proof film 23, 24 Adhesive film 25 Buffer layer 26 Shoulder 27 Step 30 Connector 31 Wiring

 ──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Masayoshi Ishida 2-11-46 Morimachi, Izumiotsu-shi, Osaka (72) Inventor Ichizo Shimizu 1-13-11 Yayoi-cho, Izumi-shi, Osaka F-term (reference) 2E108 KK04 LL02 MM01 NN07 5F051 BA03 BA18 GA02 GA05 JA05 JA06 JA09

Claims (5)

[Claims] 1. A solar cell module in which both sides of an appropriately sized solar cell are covered with a synthetic resin film and sealed, and the solar cell module is shaped according to the unevenness of a tiled roof material. 2. The solar cell module according to claim 1, wherein flexible lead wires connected to an anode and a cathode of the solar cell are projected outside from the sealed film. 3. A solar cell module according to claim 1 or 2 fixed to each of a plurality of continuous tile segments.
Metal-formed tile-like roofing material in which each solar cell is electrically connected. 4. A step of connecting a flexible lead wire to a solar cell of an appropriate size, a step of arranging the solar cells at appropriate intervals, and sandwiching the solar cell between the front and back synthetic resin films via an adhesive film; A method for manufacturing a solar cell module, comprising: pressing and sealing the solar cell with an adhesive film, and dividing and shaping the front and back films sealing the solar cell into regions including a single solar cell. 5. The method according to claim 4, wherein the front and back films are made of a weather-resistant synthetic resin.