CN111727509B - Solar cell module - Google Patents

Solar cell module Download PDF

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Publication number
CN111727509B
CN111727509B CN201980013226.6A CN201980013226A CN111727509B CN 111727509 B CN111727509 B CN 111727509B CN 201980013226 A CN201980013226 A CN 201980013226A CN 111727509 B CN111727509 B CN 111727509B
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solar cell
battery cell
module
solar
layer
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CN111727509A (en
Inventor
寺下徹
小泉玄介
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Kaneka Corp
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Kaneka Corp
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042PV modules or arrays of single PV cells
    • H01L31/048Encapsulation of modules
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy
    • Y02E10/52PV systems with concentrators

Abstract

A solar cell module (100) is provided with: a plurality of solar cells (10) electrically connected; an encapsulating material (103) that encapsulates the plurality of solar battery cells (10); and two protection members (105A, 105B) for sandwiching the sealing material (103) from the opposite two main surface sides of the solar cell (10). Each solar cell (10) is provided with a gas layer (13) between at least one of the two main surfaces and an encapsulation material (103) that faces the main surface.

Description

Solar cell module
Technical Field
The present invention relates to a solar cell module.
Background
As people are increasingly conscious of environmental protection, the enthusiasm for developing clean zero-energy-consumption houses (net zero energy house, ZEH) and clean zero-energy-consumption buildings (net zero energy building, ZEB) is also increasing. In order to realize the ZEH and ZEB, it is necessary to produce the required electric power from the building itself, and the use of solar cell modules as power generation units is now being studied.
Although the solar cell module is installed in a building, it cannot supply necessary electric power only on the roof of the building, and therefore, technical development has been advanced in consideration of installing the solar cell module in a place other than the roof. For example, patent document 1 describes a wall material integrated with a solar cell, and patent document 2 describes a mount for mounting a solar cell module on a wall surface.
Patent document 1: japanese laid-open patent publication 2016-186156
Patent document 2: japanese laid-open patent publication 2016-000949
Disclosure of Invention
The present invention is a solar cell module including: a plurality of solar cells, the plurality of solar cells being electrically connected; an encapsulation material that encapsulates a plurality of the solar cell units; and two protection members that sandwich the sealing material between the two opposite main surfaces of the solar cells together with the plurality of solar cells, wherein each of the solar cells has a gas layer provided between at least one of the two main surfaces and the sealing material opposite to the main surface.
Drawings
Fig. 1 is a schematic partial cross-sectional view illustrating a solar cell module according to an embodiment.
Fig. 2 is a schematic cross-sectional view illustrating a control principle of controlling reflected light by a surface of a solar cell in a conventional solar cell module.
Fig. 3 is a schematic cross-sectional view showing a case of reflected light on the surface of a solar cell unit encapsulated by an encapsulation material in a conventional solar cell module.
Fig. 4 is a schematic cross-sectional view showing a case of reflected light on the surface of a solar cell in the solar cell module according to the embodiment.
Fig. 5 is a schematic cross-sectional view showing an example of roughening the surface of the inside of a sheet that covers solar cell units in the solar cell module according to the embodiment.
Fig. 6 is a schematic cross-sectional view showing one process in a method of manufacturing a solar cell module according to an embodiment.
Fig. 7 is a schematic partial cross-sectional view showing a solar cell module according to a modification of the embodiment.
Detailed Description
Embodiments and examples are described below with reference to the drawings. The following description of the embodiments and examples is illustrative and is not intended to limit the application or use. The dimensional ratios of the constituent members in the drawings are set for convenience in illustration, and do not represent actual dimensional ratios.
Fig. 1 shows a schematic partial cross section of a solar cell module 100 (hereinafter simply referred to as "module") according to an embodiment.
The module 100 according to the embodiment includes a solar cell string 10A in which a plurality of solar cells 10 (hereinafter simply referred to as "cells") are electrically connected together via wiring (tab line) 102. The solar cell string 10A (hereinafter simply referred to as "cell string") is an electrical connection unit (output unit) in which, for example, about 15 cells 10 are connected in series.
The entire surface of the upper surface (for example, the light-receiving surface that is the surface on the light-receiving side of the two main surfaces of the battery cells 10), the lower surface (for example, the back surface that is the main surface on the opposite side from the light-receiving surface), and the periphery of each battery cell 10 are encapsulated with the encapsulation material 103 formed of the first encapsulation material 103a and the second encapsulation material 103 b.
The sealing material 103 is sandwiched between two protective members, namely, a light receiving surface protective material 105A and a back surface protective material 105B. As each of the protective materials 105A, 105B, for example, glass or a resin material is used.
The packaging process of the plurality of battery cells 10 with the packaging material 103 (the first packaging material 103a and the second packaging material 103 b) can be performed, for example, as follows: a laminate in which the first sealing material 103a, the battery cell string 10A, the second sealing material 103B, and the back surface protecting material 105B are placed in this order on the light receiving surface protecting material 105A is produced, and then the laminate is heated under predetermined conditions to be cured as a unit of the sealing material 103.
In the present embodiment, as described later, the gas layers 13 are provided between the main surface of each battery cell 10 on the light receiving side and the first sealing material 103 a. As a result, the module 100 according to the embodiment can control the color tone of the light receiving surface of each battery cell 10.
Next, a method for controlling the color tone of each battery cell 10 in the module 100 according to the embodiment will be described with reference to the drawings.
First, the surface of the silicon wafer included in the battery cell 10 has a low color tone such as gray. As shown in fig. 2, for example, the outermost layer 11 is formed on the outermost surface of the battery cell 10 by an antireflection film or the like, and in this case, the reflection light Ra of the incident light from the surface of the outermost layer 11 interferes with the reflection light Rb of the incident light from the light receiving surface of the battery cell 10 (wafer itself) to reflect the phase difference at the outermost layer 11. As a result, the reflected light Ra and the reflected light Rb mutually increase or decrease by reflecting the wavelength of the phase difference. That is, the reflected light Ra formed based on the refractive index difference between the air and the outermost layer 11 and the reflected light Rb formed based on the refractive index difference between the outermost layer 11 and the light receiving surface of the battery cell 10 interfere with each other, and appear in the form of a color tone in the human eye.
The phase difference between the reflected light Ra and the reflected light Rb is controlled by the film thickness and the refractive index in the outermost layer 11. That is, the color tone of the battery cell 10 can be controlled by the design of the outermost layer 11. The closer the intensities of the reflected light Ra and the reflected light Rb are, the stronger the interference effect is, and the clearer the color tone is. For example, as shown in fig. 3, when the battery cell 10 having the outermost layer 11 is packaged with the packaging material 103, the intensity of the reflected light RA generated by the surface of the outermost layer 11 is smaller than the intensity of the reflected light RB generated by the surface of the battery cell 10, and the interference effect becomes weak.
Therefore, in the conventional module structure, as shown in fig. 3, the outermost layer 11 of the packaged battery cell 10 is in close contact with the packaging material 103, and therefore, the refractive index difference between the packaging material 103 and the outermost layer 11 becomes small, and the intensity of the reflected light RA becomes small. Therefore, the interference between the reflected light RA and the reflected light RB becomes weak, and as a result, the reflected light RB of the battery cell 10 becomes dominant, and a color close to black appears.
In contrast, as shown in fig. 4, in the module 100 according to the embodiment, a planar (thin-layer-shaped) air layer 13 is provided between the sealing material 103 and the outermost layer 11 as an unbonded area where the sealing material 103 and the outermost layer 11 are not in close contact with each other. In this way, the refractive index difference between the reflected light RAA from the surface of the outermost layer 11 of the battery cell 10 and the reflected light RBB from the light receiving surface of the battery cell 10 increases. Therefore, the interference effect of the reflected light RAA from the outermost layer 11 and the reflected light RBB from the light receiving surface of the battery cell 10 becomes strong, whereby the desired hue of the light receiving surface color of the battery cell 10 is not impaired, and the battery cell 10 is modularized. That is, as shown in fig. 4, the module 10 has the air layer 13 covering the outermost layer 11, so that the intensity of the reflected light RAA generated by the outermost layer 11 is close to the intensity of the reflected light RBB generated by the light receiving surface of the battery cell 10, and therefore, the color tone becomes clear.
Here, as a method of providing the planar air layer 13 between the sealing material 103 and the outermost layer 11, as shown in fig. 4, a sheet 15 made of transparent resin may be provided between the outermost layer 11 of the battery cell 10 and the sealing material 103. The sheet 15 is not particularly limited as long as it is a material that adheres to the sealing material 103 and does not adhere to the battery cell 10, i.e., the outermost layer 11. Examples of the sheet 15 include polyethylene terephthalate, polyvinyl fluoride, and a fluororesin sheet. The sheet 15 may be disposed on each battery cell 10 between the battery cell 10 and the first sealing material 103a, or may be disposed over the entire surface corresponding to the protective materials 105A and 105B. The gas layer 13 is not particularly limited, and may be an air layer, a nitrogen gas layer, or the like.
The method of changing and adjusting the color of the light receiving surface of the battery cell 10 is not particularly limited, and for example, the film thickness of the outermost layer 11 of the battery cell 10 is changed. For example, a back contact solar cell (back contact cell) may be used as the cell 10. The back contact battery cell is provided with a p-type semiconductor layer and an n-type semiconductor layer alternately on the back surface side of a semiconductor substrate made of crystalline silicon or the like, and a passivation layer and an antireflection film are provided in this order from the substrate side on the light receiving surface side. By adjusting the film thickness of the antireflection film corresponding to the outermost layer 11, the color can be easily adjusted.
The semiconductor substrate is formed of a single crystal silicon substrate of one conductivity type. In general, a single crystal silicon substrate has an n-type in which an atom that introduces an electron to a silicon atom (for example, phosphorus (P)) is doped, and a P-type in which an atom that provides a hole to a silicon atom (for example, boron (B)) is doped. As used herein, "one conductivity type" refers to either of n-type and p-type. That is, the semiconductor substrate is a single crystal silicon substrate having an n-type or p-type conductivity.
In addition, as in the present embodiment, when the structure is adopted in which the air layer 13 is provided between the first sealing material 103a on the light receiving surface side of the sealing material 103 and the battery cell 10, as will be described later, propagation of the shock wave when flying objects such as birds collide with the module 10 is suppressed. Therefore, it is possible to prevent the battery cell from being broken due to the shock wave, and as a result, the performance degradation of the module 100 is suppressed, and the module 100 having high reliability is obtained.
As shown in fig. 5, the sheet 15 may be a sheet 15A having at least a surface facing the air layer 13 roughened. In this way, by roughening the sheet 15A with uneven shapes or the like, light incident into the module 100 is reflected by the roughened surface, thereby producing a re-incident effect of light incident into the battery cell 10. Further, the air layer 13 is easily provided by roughening the inner side of the sheet 15A.
The roughness degree of the roughening of the sheet 15A may be set to, for example, an arithmetic average roughness Ra 1 Is 1 μm or more and 10 μm or less. In the case of the concave-convex shape, it is preferable that the embossed shape has a width of 0.5mm or more and 1.5mm or less, a length of 0.5mm or more and 1.5mm or less, a depth of 0.01mm or more and 0.1mm or less, or a triangular shape having an inclination angle of the inclined surface set within a predetermined range.
[ modularization ]
As shown in fig. 1, in a module 100 according to the embodiment, a battery cell string 10A formed by connecting a plurality of battery cells 10 by a wiring 102 is sandwiched between a light receiving surface protecting material 105A and a back surface protecting material 105B via a packaging material 103. At least on the light-receiving surface of each cell 10, a sheet 15 is provided via a planar gas layer 13. For example, the first sealing material 103a, the sheet 15, the battery cell string 10A, the second sealing material 103B, and the back surface protecting material 105B are sequentially placed on the light receiving surface protecting material 105A to form a laminate, and the formed laminate is heated under predetermined conditions to cure the sealing materials 103a and 103B, whereby the battery cell string 10A can be sealed.
As the encapsulating material 103, a transparent resin such as a polyethylene resin composition containing an olefin elastomer as a main component, polypropylene, an ethylene/α -olefin copolymer, an ethylene/vinyl acetate copolymer (EVA), ethylene/vinyl acetate/triallyl isocyanurate (EVAT), polyvinyl butyrate (PVB), silicon, polyurethane, acrylic acid, or epoxy is used. The first sealing material 103a on the light receiving surface side and the second sealing material 103b on the back surface side may be the same material or may be different materials.
The light-receiving surface protective material 105A has light transmittance, and is made of glass or transparent plastic, for example.
On the other hand, the back surface protective material 105B has any one of light transmittance, light absorption, and light reflection. The back surface protective material 105B having light reflectivity is preferably a metallic color, white color, or the like. For example, a white resin film or a laminate in which a metal foil such as aluminum is sandwiched between resin films is suitable as the back surface protective material 105B.
As the back surface protective material 105B having light absorption, for example, a black-based member including a black resin layer or the like is suitably used. When the back contact battery cell 10 having, for example, a black light receiving surface (battery cell surface) is modularized using such a back protective member 105B (for example, a black sheet) having light absorbing properties, the back protective material 105B is close to the external color of the battery cell 10, and therefore, the gaps between the battery cell strings 10A are inconspicuous, resulting in the module 100 having a high external appearance.
In the cell string 10A, the adjacent cells 10 may have a tile roof structure (a lap-top structure) so that a part of one cell 10A overlaps a part of the other cell 10B, which is not shown. When such a shingled configuration is adopted, the battery cells 10 in the battery cell string 10A do not have a gap between each other. Therefore, for example, when the module 100 having the stacked structure is formed by using the battery cells 10 having the black-based light receiving surface, the surface of the battery cells on the light receiving side of the module 100 is uniformly black or the like, and thus, the external appearance can be improved. In addition, in such a module 100, if the back surface protection member 105B of a black system is used, for example, the entire light receiving side of the module 100 can be reliably unified to the black system, and thus, the external appearance can be further improved.
The example of the battery cell 10 having the black-based light receiving surface is described above, but the present invention is not limited to the black-based battery cell, and for example, in the case of using the module 100 having the battery cell 10 having the deep blue-based or deep green-based light receiving surface (battery cell surface), the external color of the back surface protection member 105B may be set to be similar to the color of the battery cell surface. That is, if the color of the cell surface of the battery cell 10 is made similar to the external color of the back surface protection member 105B, the external appearance of the module 100 can be improved.
Examples (example)
Examples and comparative examples are shown below.
[ production of Back contact Battery cell ]
A back contact battery cell was fabricated using a 6-inch n-type single crystal silicon substrate (half-square) having a side length of 156mm, which was textured on opposite main surfaces and had a thickness of 160 μm. Silver paste was screen-printed on the n-type semiconductor layer and the p-type semiconductor layer, respectively, as metal electrodes on the back surface, and then baked at a temperature of 150 ℃ for about 30 minutes.
On the light receiving surface, a passivation layer and an antireflection film are sequentially formed. Silicon nitride (SiN) having a refractive index of 1.9 was prepared by a chemical vapor deposition (CVD: chemical Vapor Deposition) method at three film thicknesses of 45nm, 70nm and 165nm, respectively, to obtain an antireflection film corresponding to the outermost layer 11. The thickness of the antireflection film is a value on the inclined surface of the texture, and is obtained by measuring SiN formed on the glass substrate by ellipsometry and converting the measured SiN into the inclined surface.
Examples (example)
A method of manufacturing the module 100 according to the embodiment will be described below with reference to fig. 6.
First, a first sealing material 103a made of an ethylene/vinyl acetate copolymer (EVA) and a PET sheet as a transparent resin sheet 15 are sequentially disposed on a white glass as a light receiving surface protecting material 105A. Further, a plurality of battery cells 10 and a second sealing material 103B made of EVA are placed, and a back sheet having a black resin layer 105a provided on a PET film 105B as a base material is disposed thereon as a back surface protecting material 105B.
Next, after thermocompression bonding was performed at atmospheric pressure for 5 minutes, EVA was crosslinked by holding at a temperature of 150 ℃ for 60 minutes, to obtain a module 100. In this case, the battery cells having antireflection films with three film thicknesses were modularized.
The PET sheet as the sheet 15 is uniformly and entirely placed on the first encapsulating material 103a, but is not limited thereto. That is, the PET sheet may be disposed so as to cover at least the light receiving surface (lower surface in fig. 6) of each battery cell 10. The gas layer 13 formed on the light-receiving surface of each battery cell 10 by the PET sheet may cover at least one half of the area of the light-receiving surface of each battery cell 10. The comparative examples below are also the same.
Comparative example
A first EVA packaging material, a plurality of battery cells, and a second EVA packaging material are disposed on a white plate glass as a light-receiving surface protecting material. A back sheet having a black resin layer provided on a PET film as a base material was disposed thereon as a back surface protective material.
Next, after thermocompression bonding was performed at atmospheric pressure for 5 minutes, the EVA was crosslinked at a temperature of 150 ℃ for 60 minutes to obtain a module. Here, the battery cells having antireflection films with three film thicknesses were also modularized.
As described above, the embodiment is different from the comparative example in that in the embodiment, the sheet 15 for forming the gas layer 13 is arranged between the first sealing material 103a and the light receiving surface of the battery cell 10.
[ color tone confirmation of solar cell and in-Module cell ]
The light-receiving surface of each of the three battery cells 10 was observed, and the color tone was confirmed. The modules according to examples and comparative examples were also observed under sunlight. The color tone of the antireflection film passing through the battery cell 10 was evaluated by a, and the color tone of the back sheet itself was evaluated by B, and the results are shown in the following [ table 1 ].
TABLE 1
As is clear from the comparison between the examples and the comparison examples, in the comparison examples, the hues of the three types of battery cells 10 in the module were all close to the hue of the back plate, that is, the black color, whereas in the comparison examples, the module 100 in which the hues of the three types of battery cells 10 in the module were all close to the hue of the battery cells 10 could be produced. In the module structure of the comparative example, since the surface of the battery cell is in close contact with the packaging material, the refractive index difference between the packaging material and the outermost layer of the battery cell becomes small. As a result, the reflected light generated from the outermost layer becomes small, so that the interference light becomes weak, and the reflected light generated from the light receiving surface of the battery cell becomes dominant, and a color close to black is developed.
In contrast, in the present embodiment, a planar gas layer 13 is provided between the sealing material 103 and the outermost layer 11 of the battery cell 10. By the planar gas layer 13, the reflected light RAA generated by the outermost layer 11 and the reflected light RBB generated by the light receiving surface of the battery cell 10 are increased in refractive index difference, and the reflected light based on the refractive index difference between the reflected light RAA and the reflected light RBB interferes. As a result, the module 100 is realized without impairing the color tone of the light receiving surface of the battery cell 10.
Impact resistance of solar cell Module
Next, a case where the impact resistance of the module 100 of the example is improved as compared with the comparative example will be described.
After manufacturing the battery cell 10 having a film thickness of 70nm, which was an antireflection film made of silicon nitride (SiN), the modularization of the above-described examples and comparative examples was performed, and impact resistance tests were performed, respectively. Weights of 1.5kg, 2.6kg, and 4.8kg were dropped from a height of 80cm, and whether or not cracks were observed in the battery cells 10 in each module was confirmed by Photoluminescence (PL). As a result of the confirmation, the case where no crack was observed was evaluated by a, and the case where a crack was observed was evaluated by B, and the results are shown in the following [ table 2 ].
TABLE 2
In the impact resistance test, when the examples were compared with the comparative examples, cracks were observed in the battery cells 10 for the weights of 2.6kg and 4.8kg in the comparative examples. On the other hand, in the embodiment, no crack was observed in the battery cell 10 for any weight. This is considered to be because propagation of a shock wave upon collision with the module 100 is suppressed by the planar gas layer 13 provided between the packaging material 103 and the battery cell 10, and rupture of the battery cell due to the shock wave is prevented.
(modification of embodiment)
In the solar cell module 100 shown in fig. 1, a back contact cell (back contact cell)) is used as the cell 10, but the invention is not limited thereto, and the invention can be applied to a double-sided electrode cell 10a as shown in fig. 7.
As shown in fig. 7, in the module 100A according to the present modification, the front electrode (for example, p-type electrode) of one cell 10A and the back electrode (for example, n-type electrode) of the other cell 10A adjacent thereto are alternately connected. In the battery cell string 10A configured as described above, a sheet 15 made of transparent resin is provided between the first sealing material 103a and the outermost layer that is the light-receiving surface of each battery cell 10A.
When a module is provided on a wall surface of a building, the module may not be fused with the outer surface of the wall surface (for example, the color tone of the wall surface) because of lack of change in the outer surface, and may cause deterioration in the outer surface appearance of the building. In addition, when a flying object collides with the module, the battery cells in the module may be broken, and the performance of the battery cells may be degraded.
However, as described above, according to the module 100 and the module 100A according to the above embodiments and examples, the air layer 13 is provided between the sealing material 103 and the light receiving surface of each battery cell 10, 10A, so that the color tone of the battery cell 10, 10A is not impaired, and excellent external appearance can be achieved.
Further, since cracks generated in the battery cells 10, 10A of the modules 100, 100A due to impact of flying objects can be suppressed, the modules 100, 100A having excellent reliability are realized.
Further, since the light receiving surfaces of the respective battery cells 10, 10a are covered with the gas layer 13, the resistance to the potential induced degradation (Potential Induced Degradation, PID) phenomenon can also be improved. The PID phenomenon is a decrease in output caused by, for example, sodium (Na) ions or the like diffusing from the protective materials 105A, 105B into the sealing material 103 under high voltage and penetrating into the surfaces or the inside of the respective battery cells 10, 10a when glass is used as the protective materials 105A, 105B. Therefore, the modules 100 and 100A suppress the PID phenomenon, and exhibit high reliability.
Symbol description-
100. 100A solar cell module (Module)
102. Wiring
103. Encapsulating material
103a first encapsulation material
103b second encapsulation material
105A light-receiving surface protective material (protective member)
105B backside protective material (protective member)
105a black resin layer
105b PET film
10. 10a solar cell (Battery cell)
10A solar cell (cell) string
11. Surface layer (antireflection film)
13. Air layer
15. Sheet (transparent resin/PET sheet).

Claims (5)

1. A solar cell module, comprising: a plurality of solar cells, the plurality of solar cells being electrically connected; an encapsulation material that encapsulates a plurality of the solar cell units; and two protection members for sandwiching the sealing material together with the plurality of solar cells from opposite main surface sides of the solar cells, wherein:
each of the solar cells is provided with a gas layer between at least one of the two main faces and an encapsulating material opposing the main face,
an antireflection film and a transparent resin sheet disposed on the antireflection film are provided in this order on a main surface of each solar cell on a light receiving side, the gas layer being a void layer between the antireflection film and the sheet,
the surface of the sheet facing the antireflection film is roughened.
2. The solar cell module of claim 1, wherein:
the gas layer is planar and is provided between the encapsulant and the main surface of each solar cell on the light receiving side.
3. The solar cell module according to claim 1 or 2, characterized in that:
the gas layer covers at least one half of the area of the main surface in each of the solar cells.
4. The solar cell module according to claim 1 or 2, characterized in that:
the air layer is an air layer.
5. The solar cell module according to claim 1 or 2, characterized in that:
each of the solar cells is a back contact solar cell.
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