JP2000244000A - Solar cell module, roof with solar cell and power generation apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase a fire protection property against a neighboring fire by a method wherein a blockade means which does not fall even in a fire is installed at a hole in a rear material and a lead wire which is connected to a solar cell is inserted into, and passed through, the blockade means so as to be exposed on a side on which light is not received in a solar cell module. SOLUTION: A hole 45 is opened in a rear material 21 (a 0.8 mm-thick coating zinc-plated steel plate) in such a way that a terminal derivation part 47 is exposed. A blockade means 48 whose cross section is U-shaped and which uses a ring-shaped highly noncombustible material is installed at the hole 45. The blockade means 48 comprises a flange 54 which is larger than the hole 45 with reference to both the surface and the rear of the rear material 31. A wire through hole is formed in the center. The flange 54 can be attached to the hole 45 by single operation. A structure in which an air circulation does not exist substantially is formed in the interface between the hole 45 and the blockade means 48 and in the interface between the blockade means 48 and a lead wire 44. Then, a filler 32, an insulating film 33, a filter 32, a glass fiber 34, a solar cell element block 35, a glass fiber 34, a filler 32 and a surface protective material 36 are piled up sequentially so as to be laminated on the rear material 31.

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, a roof with a solar cell, and a power generation device having excellent fire protection, and more particularly to a solar cell module, a roof with a solar cell, and a power generation device having enhanced fire protection against a nearby fire. About.

[0002]

2. Description of the Related Art As global environmental problems become more serious, solar energy has recently attracted much attention as clean energy that does not generate harmful by-products such as thermal power and nuclear power. There is also a demand for the effective use of solar energy as infinite energy that will not be depleted for limited earth resources.

[0003] On the other hand, in the case of a disaster such as an earthquake, the existing unitary energy system has a problem in that the energy supply is cut off and it takes a very long time to recover the energy supply. Solar energy is always available as energy in sunny areas,
It has high utility value as a distributed independent energy source.

[0004] These needs have promoted the development of solar cell modules for homes, and their practical use is now rapidly progressing. In addition, a sunny roof is attracting attention as a place for installing a solar cell module in a house.

Normally, as shown in FIG. 12, these solar cell modules 49 are composed of a surface protection material 40 and a back surface material 41.
Between the solar cell elements 42 connected in series or in parallel
Is sealed with a filler 43 in a resin.

The electric power generated by the solar cell elements 42 is supplied to lead wires 44 connected to the solar cell elements 42.
Output to the outside via A lead wire connected to the solar cell element 42 is exposed outside the back surface member 41 by passing through a hole 45 of the back surface member 41 which has been opened in advance, and this portion is insulated and protected by a sealant 46 or the like. A take-out part structure is formed.

The solar cell module having the above structure is fixed on a base material by a fixing member to form a roof with solar cells.

[0008]

However, when the above-mentioned solar cell module is laid on a roof in the same manner as a general roofing material, it is necessary that the solar cell module has fire protection performance equal to or higher than that of a general roofing material. It is becoming.

Here, when considering the influence of a nearby fire, which is the most important in the fire protection performance of the roof, the most susceptible to the influence is the surface material 40 of the uppermost layer. The lowermost backing material 41 is most effective.

The backing material 41 includes a material using a resin material such as PET or Tedlar, a material using a laminated material such as Tedlar / Aluminum / Tedlar, and a material using a metallic material. Those using a metal material or the like have the highest fire protection performance, and the fire protection performance is considered to be equivalent to that of a general roofing material.

However, the present inventors have found that the portion of the hole 45 provided in the backing member 41 is likely to be affected first when the influence of the adjacent fire is extremely large.

The present invention is directed to a solar cell module, a roof with solar cells, and a power generation device which solve all of the above-mentioned drawbacks and have excellent fire protection, and more particularly, a solar cell module with improved fire protection against a nearby fire, and a solar cell-equipped solar cell. It is intended to provide a roof and a power generator.

[0013]

That is, the present invention provides at least a solar cell element, a surface protective material provided on the light incident side of the solar cell element, and a back material provided on the back side of the solar cell element. In a solar cell module made of a filler for sealing a solar cell with a resin, a lead wire connected to a solar cell element is inserted through a closing means provided in a hole of a back surface material, and is connected to a non-light-receiving surface of the solar cell module. A solar cell module characterized in that the closing means does not fall off even in the event of a fire, and a roof with solar cells, wherein the solar cell module is fixed on a base material by a fixing member This object is achieved by a power generation device having the solar cell module and a power conversion device.

In the solar cell module according to the present invention, the lead wire connected to the solar cell element is exposed on the non-light-receiving surface side of the solar cell module through the closing means provided in the hole of the back material. Since the means does not fall off even in the event of a fire, by using the solar cell module of the present invention for a roof with solar cells, even when the influence of an adjacent fire is extremely large, the means provided by the holes provided in the backing material can be used. Has a fire protection performance equal to or higher than that of the surrounding backing material, and can provide a solar cell module having excellent fire protection performance.

Here, it is more preferable that substantially no air flow occurs at the interface between the hole and the closing means and between the closing means and the lead wire at the time of fire. Accordingly, it is possible to provide a solar cell module that is capable of minimizing the flow of air onto the roof base material and having more excellent fire prevention performance.

Further, it is more preferable to use a non-combustible material, a semi-non-combustible material or a flame-retardant material as a material of the closing means. This makes it possible to provide a solar cell module having better fire prevention performance.

Further, it is more preferable that the back material is a noncombustible back material. This prevents the solar cell module from igniting from the back side of the solar cell module due to not only a nearby fire but also a self-fire, thereby preventing the combustion from the front side and the back side of the solar cell module. At the same time, it is possible to provide a solar cell module having more excellent fire prevention performance.

Further, it is more preferable to use a highly insulating material for the closing means. Thus, even when a conductive material is used for the back surface material, the hole of the back surface material is reliably insulated from the lead wire, and the attachment can be easily performed. Furthermore,
Since the insulation distance between the hole in the back material and the lead wire can be set arbitrarily, the size of the hole in the back material can be made as small as possible.

Further, it is more preferable that the hole, the closing means, and the lead wire of the back material are covered with a terminal box provided on the back material. As a result, the weather resistance, waterproofness, mechanical strength, and the like around the terminal take-out portion are improved.

Further, the closing means is provided at least on the light receiving surface side.
It is more preferable to have a flange larger than the hole of the back material.
Thus, even when some mechanical force is applied to the closing means in the event of a fire, the closing means does not fall out, so that it is possible to provide a solar cell module having more excellent fire prevention performance.

Further, it is more preferable that the closing means has a plurality of lead wire openings. As a result, a positive lead wire and a negative lead wire can be taken out from one hole, the hole on the back material can be made one, and the size of the hole can be designed to be as small as possible. Can be provided. In addition, costs can be reduced because only one terminal box is required.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The construction of a typical solar cell module according to the present invention and a method for manufacturing the same will be described with reference to FIGS.

In this example, an amorphous silicon solar cell element (photovoltaic element) formed on a stainless steel substrate was used.
This is an example of a solar cell module in which a solar cell element block in which are connected in series is insulated and sealed with a sealing material on a galvanized steel plate serving as a back surface material, and an output is taken out from a terminal take-out portion.

As shown in FIG. 2, a laminated film of Al and ZnO (backside reflective layer 12) is formed on a cleaned 0.1 mm roll-shaped long stainless steel substrate (conductive substrate 11) by sputtering. A thickness of 5000 mm was formed. Next, n / i /
p-type amorphous silicon semiconductor layer (semiconductor layer 13), n-type as the semiconductor PH _3, a SiH _4, H ₂ gas, as the i-type semiconductor to gas SiH _4, H _2, also P-type semiconductor Using B ₂ H ₆ , SiH ₄ , and H ₂ gases, respectively.
The n-type semiconductor layer is formed by plasma CVD at 300 °
The type semiconductor layer was formed at 4000 ° and the p-type semiconductor layer was formed at 100 °, respectively. After that, a 800Å thick ITO
(Transparent conductive layer 14) was formed by a sputtering method to form an amorphous silicon solar cell element.

Next, as shown in FIG. 3A, the long solar cell element manufactured as described above was punched into a square shape having a size of 30 cm × 30 cm using a press machine. Then, a plurality of solar cell elements were produced.

Here, on the cut surface of the solar cell element cut by the press machine, the solar cell element is crushed, and the transparent conductive layer 14 and the conductive base 11 are in a short-circuit state. In addition, since the amorphous solar cell has an extremely small thickness, the amorphous solar cell has a short-circuit portion in the semiconductor layer 13. Then, next, in order to repair this short circuit, FIG.
As shown in (b), an element isolation portion 22 was provided around the transparent conductive layer 14 of each solar cell element 21 to remove a short circuit around the edge of the substrate. This removal is specifically performed as follows. First, the solar cell element is immersed in an aqueous solution of 8% aluminum chloride hexahydrate to form a transparent conductive layer 14 of the solar cell element.
The opposing poles patterned 1 mm narrower and 0.5 mm wide than the element were opposed to each other with a distance of 1 mm, and a direct current of 0.5 S and 25 A was applied by a sequence controller to form an element separating portion 22. Next, the counter electrode was changed to a stainless steel plate of the same size as the solar cell element, and a 4.0 V bias was applied by a sequence controller while facing each other 4.0 cm. The layer 14 is removed. In this way, a solar cell element in which the short-circuit portion was repaired was formed.

After that, the solar cell was subjected to water washing and drying steps.

Next, as shown in FIG.
A silver coated 100 was formed thereon as a grid electrode for current collection.
A micron copper wire (collecting electrode) 23 was fixed with a thermoplastic carbon conductive adhesive 24. At this time, as shown in FIG. 3B, a polyimide tape 25 is attached to a non-power generation area around the solar cell element 21 so that the copper wire 23 does not contact the end face of the conductive base 11, and The busbar copper tape 26 was adhered to the positive electrode to form a positive electrode of the solar cell element.

Next, as shown in FIG. 3 (a), the bus bar copper tape 26 attached to the solar cell element 21 is wound around the back conductive substrate 11 side of the adjacent solar cell element 21 ', and laser welding is performed. Thereby, the conductive base 11 of the solar cell element 21 ′ was connected in series. In this way, a solar cell element (solar cell element block) connected in series was prepared.

As shown in FIG. 4 (b), the final electric output of the solar cell element prepared in this manner is converted into a solar cell having each final output in advance in order to take out the lead wire from the back side. The bus bar copper tape 26 is wound around the back surface of the element using an insulating member sandwiched between the conductive base 11 and the negative pole.
Terminal extraction part 4 by soldering copper tape to
7 was formed. A lead wire 44 (UL Style 3133 silicone rubber insulated wire) with both ends stripped was attached to the terminal outlet by soldering.

Next, as shown in FIG. 4, a hole 45 is formed in a 0.8 mm-thick coated galvanized steel plate (back surface member 31) so that the terminal extraction portion 47 is exposed. A ring-shaped closing means 48 made of a letter is attached.

Here, as shown in FIG. 5, the closing means 48 has a shape having a flange 54 larger than the hole 45 on both the front and back surfaces of the back material 31, so that it does not fall off even in the event of a fire. ing. In the center of the closing means 48,
A line through hole 55 is provided. The material of the closing means 48 is TSE2185U, a high flame retardant Toshiba Silicone Co., Ltd.
(UL94V-0 certified product with a t of 0.36 mm), which can be attached to the hole 45 provided on the back surface member 31 with one touch, and the hole 45, the closing means 48, and the closing means 4
At each interface between the lead wire 8 and the lead wire 44, there is substantially no air flow.

Next, the plan view of FIG. 4A and the plan view of FIG.
(A cross-sectional view taken along line BB 'in FIG. 4A), the backing material 31 has a filler 32 / insulating film 33 as shown in FIG.
/ Filler 32 / glass fiber 34 / solar cell element block 35 / glass fiber 34 / filler 32 / fluororesin film (surface protective material 36) were sequentially laminated.

A hole for inserting a lead wire is made in advance in the material on the back surface material 31 side from the solar cell element block 35, and the lead wire 44 connected to the solar cell element block 35 is connected to the glass fiber 34. Hole, filler 32
Hole, the hole of the insulating film 33, the hole of the filler 32, and the hole of the closing means 48 attached to the back material 31, in this order,
The exposed lead wire 44 was bent along the back material 31.

Next, using a vacuum laminator,
By melting the filler at 30 ° C. for 30 minutes, a planar solar cell module 49 sealed with resin was produced as shown in FIG.

Next, the terminal box 50 and the external output line 51 were attached as shown in FIG. The terminal box 50 includes a main body 52 and a lid 53. The main body 52 has a bathtub shape having openings on the bottom surface and one side surface. Next, the terminal box body 5
2 was fixed to the back surface member 31 with an adhesive. At this time, lead wire 4
4 was guided into the main body 52 through an opening provided on the bottom surface of the main body 52, and was fastened together with the external output line 51 on a terminal block in the main body 52. Finally, the lid 53 was attached.

The solar cell module prepared as described above has a connector at the end of the external output line 51. After connecting the connectors of adjacent solar cell modules in series or in parallel, a fixing member is placed on the base material. The solar cell array and the roof with the solar cells were configured by fixing with the above, and connected to an inverter or a junction box for controlling the output to configure a solar power generation device.

Although this embodiment has been described with respect to a solar cell module in which an amorphous solar cell is resin-sealed on a steel plate, the present invention is not limited to such a module. It goes without saying that the present invention is also applicable to (for example, a device using a crystalline solar cell or a module using an aluminum frame).

In the following, the details of each member forming the solar cell module will be described with reference to the definition thereof and the general theory of the present invention.

(Closing Means 48) Since the closing means 48 used in the present invention is mainly intended to improve the fire resistance, it closes the gap between the hole 45 of the back material 31 and the lead wire 44, and Back material 31 even when affected by heat or temperature
It is necessary that the hole 45 has a shape and material that hardly affects the underlying material.

The material of the closing means 48 used in the present invention is preferably one having excellent flame retardancy and heat resistance. The effect can be obtained by using a flame-retardant material that can suppress combustion and fire spread as much as possible.
Even more preferably, a non-combustible material is used. Further, those having high self-extinguishing properties are more preferable. Further, those which generate toxic gas during combustion, such as those containing a large amount of a flame retardant such as an organic halogen compound, are not preferred. Further, a material having a low strength deterioration due to a temperature rise is more preferable.

The closing means 48 used in the present invention must not fall off even in the event of a fire. In addition, the closing means 48
Even when a certain amount of mechanical external force is applied, it is more preferable that the resin does not fall off.

Specifically, the hole 4 is located on the light incident side with respect to the hole 45.
A structure having a flange 54 larger than 5; a structure in which a slightly larger closing means 48 is pressed into the hole 45;
And the closing means 48 are connected by a chemical force or a physical force. In addition, the collar 54 is a back material 31.
Is preferably provided on both front and back surfaces, but the effect can be obtained by providing only on the front (light receiving surface) surface side.

Further, by using a binding material that does not fall off from the backing material 31 in the event of a fire as the closing means 48, an effect can be obtained without mechanical fixing such as a flange or press-fitting. Further, the effect can be obtained even if the closing means 48 is attached to the back surface member 31 with the above-mentioned bonding material.

The lead wire through-hole 55 provided in the closing means 48
Is preferably provided in the center of the closing means 48 in terms of function. However, when the insulation between the lead wire 44 and the back material 31 is not a problem, a notch or the like is provided at the end of the closing means 48 so that The space defined by the hole of the material 31 may be used as a substitute for the lead wire through hole 55. Further, in order to make the structure in which heat and temperature received from the solar cell module surface are difficult to be transmitted to the base material in the same portion, it is preferable that the air flow in the same portion is minimized.

Specific examples of the material of the closing means include flame-retardant engineered plastic (heat-resistant about 180 ° C.), flame-retardant fluororesin (heat-resistant about 200 ° C.), flame-retardant polyimide (heat-resistant about 260 ° C.), flame-retardant Silicone rubber (heat resistant about 280
° C) and flame-retardant fluoro rubber (heat resistance about 300 ° C).
These materials are excellent in moldability and have a certain degree of elasticity after molding. Therefore, by providing a locking structure, these materials can be attached with a single touch to the holes provided in the back material.

Further, materials having further excellent flame retardancy and heat resistance include heat-resistant glass (heat resistance of about 700 ° C.) and ceramics (heat-resistant temperature of 1200 ° C., and mica ceramics are particularly capable of being machined and having electrical insulation properties. , And very good because it shows almost the same expansion coefficient as metal.) Since these materials have poor elasticity, the backing material 31
In order to mechanically attach it to the hole 45 provided in the hole, it is necessary to devise a shape.

Further, by using a composite material instead of a single material, it is possible to produce a closing means excellent in flame retardancy and heat resistance at low cost. Specifically, an organic insulating layer is formed by applying and baking an organic heat-resistant paint such as polyester, polyester imide, or polyamide imide to a metal member (heat resistance of about 400 ° C.), or an inorganic member to a metal member. There is a product in which an inorganic insulating layer is formed by applying and baking a polymer paint (heat resistance: about 400 ° C.).

Furthermore, in the case of the above-mentioned closing means 48 made of an inelastic inorganic material such as ceramics, a lead wire through hole 55 having a size of a lead wire is opened in advance, and the inside is formed of an elastic flame-retardant silicone or the like. Thus, the flow of air in the same part can be suppressed as much as possible.

Alternatively, a member may be provided in the vicinity of the hole 45 in advance, and may expand when receiving heat at the time of fire to form the closing means 48. Specifically, there are a heat-expandable ceramic fiber-based composite material and a heat-expandable flame-retardant rubber-based composite material.

In all of the above, assuming that a conductive material is used for the back member 31, a material having a high insulating property is selected as the material of the closing means 48. However, if the back member 31 is an insulating material. For example, a conductive material such as a metal can be used as the material of the closing means 48.

The closing means 48 also serves to mechanically protect the lead wires 44 from the edges of the holes 45 provided in the backing material 31.

(Surface Protecting Material 36) It is desired that the surface protecting material 36 used in the present invention is a material having a light-transmitting property, weather resistance, and to which dirt does not easily adhere. Transparent glass or organic resin can be used as the material, but in order to handle solar cells in the same way as general roofing materials, they must be flexible materials because the solar cells themselves can be bent. Is desirable. Surface protection material 3 for the above reasons
6 is preferably an organic resin, more preferably a weather-resistant transparent film. By using a weather-resistant transparent film, the filling property is improved, the weight can be reduced, and the film is not broken by an impact, and can be used as a roofing material by bending. Further, by performing the embossing treatment on the film surface, the effect of suppressing the surface reflection of sunlight can be produced.

As a material, a fluororesin film such as polyethylene tetrafluoroethylene (ETFE), polytrifluoroethylene, or polyvinyl fluoride can be used as an organic resin, but is not limited thereto. A surface treatment such as a corona discharge treatment can be applied to the surface to be bonded with the filler 32 so that the filler 32 is easily bonded.

When glass is used as the material, for example, tempered white glass can be used.

(Back Material 31) The representative back material 31 forming the shape of the solar cell module according to the present invention is a metal, and is made of a steel plate having strength similar to a conventional metal roof and a non-ferrous material having excellent corrosion resistance. Can be used. Surface treatment for steel sheet,
In addition to coated steel sheets, alloys containing other elements, or special steel, there are composite steel sheets laminated with heat insulating materials. Generally, hot-dip galvanized steel sheets, hot-dip zinc-5% aluminum alloy-coated steel sheets , Hot-dip 55% aluminum-zinc alloy coated steel sheet, hot-dip aluminum coated steel sheet, electro-galvanized steel sheet, electro-alloy coated steel sheet, electro-copper coated steel sheet, vapor-deposited galvanized steel sheet, hot-dip galvanized stainless steel sheet, hot-dip aluminum plated stainless steel sheet, electrolytic copper Plated stainless steel sheet, hot-rolled stainless steel sheet, cold-rolled stainless steel sheet, vinyl chloride coated steel sheet, fluororesin steel sheet, vibration damping steel sheet, heat-insulating galvanized steel sheet, weather-resistant steel sheet and the above-mentioned painted steel sheet are used. Copper plate, aluminum alloy plate, zinc alloy plate, lead plate, titanium plate and the above-mentioned painted color plate are used

In this embodiment, the back material 31 is used.
Although the present invention is not limited to this, the present invention is not limited to this, and resin materials such as PET and Tedlar, laminated materials such as Tedlar / Aluminum / Tedlar, and roofs such as ceramic and plastic widely used for roofs Needless to say, application to materials, roof tiles, and slate materials is possible.

(Solar Cell Element) The type of the solar cell element used in the present invention is not particularly limited, but is preferably made of stainless steel, resin, or the like because of the advantage that the light receiving area of the solar cell can be obtained in a curved portion. A flexible solar cell element formed on a flexible substrate is effective.

FIG. 2 shows an amorphous silicon solar cell which is a flexible solar cell element.

The substrate 11 is a member for mechanically supporting the semiconductor layer 13 in the case of a thin-film solar cell such as amorphous silicon, and is sometimes used as an electrode. The substrate 11 is required to have heat resistance to withstand the heating temperature when the semiconductor layer 13 is formed, but may be a conductive material or an electrically insulating material. Ni, Cr, Al, Mo, Au, Nb, Ta,
Metals such as V, Ti, Pt, Pb or alloys thereof, for example, thin plates such as brass and stainless steel, and composites thereof, carbon sheets, galvanized steel plates, and the like. Examples of the electrically insulating material include polyester, polyethylene, and the like. Polycarbonate, cellulose acetate, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamide, polyimide, epoxy or other heat-resistant synthetic resin film or sheet or glass fiber,
Composites with carbon fiber, boron fiber, metal fiber, and the like, and thin metal films of different materials and / or SiO ₂ , Si ₃ N on the surfaces of thin plates and resin sheets of these metals
₄ , those obtained by subjecting an insulating thin film such as Al ₂ O ₃ , AlN or the like to a surface coating treatment by a sputtering method, a vapor deposition method, a plating method, or the like, glass, ceramics and the like.

The lower electrode (backside reflection layer) 12 is one electrode for taking out the electric power generated in the semiconductor layer 13, and is required to have a work function with respect to the semiconductor layer 13 so as to form an ohmic contact. Is done. Materials include Al, Ag, Pt, Au, Ni, Ti, Mo, W,
A so-called simple metal or alloy such as Fe, V, Cr, Cu, stainless steel, brass, nichrome, SnO ₂ , In ₂ O ₃ , ZnO, ITO, and a transparent conductive oxide (TCO) are used. The surface of the lower electrode 12 is preferably smooth. However, when irregular light reflection is caused, the lower electrode 12 may be textured and is also referred to as a back reflection layer. Also,
When the substrate is conductive, the lower electrode need not be provided.

The lower electrode 12 is formed by a method such as plating, vapor deposition, or sputtering. As a method for manufacturing the upper electrode 14, a resistance heating evaporation method, an electron beam heating evaporation method, a sputtering method, a spray method, or the like can be used, and is appropriately selected as desired.

The semiconductor layer 13 which is a photoelectric conversion element
Examples thereof include amorphous silicon, amorphous silicon germanium, and amorphous silicon carbon. The semiconductor material constituting the i-layer includes a-Si: H, a-Si: F, a
-Si: H: F, a-SiGe: H, a-SiGe:
F, a-SiGe: H: F, a-SiC: H, a-Si
Examples include so-called Group 4 and Group 4 alloy-based amorphous semiconductors such as C: F and a-SiC: H: F. The semiconductor material forming the p-layer or the n-layer can be obtained by doping the above-described semiconductor material forming the i-layer with a valence electron controlling agent. As a raw material, a compound containing the third element in the periodic table is used as a valence electron controlling agent for obtaining a p-type semiconductor. As the third element, B, Al, Ga,
In is mentioned. As a valence electron controlling agent for obtaining an n-type semiconductor, a compound containing a fifth element of the periodic table is used. Group 5 elements include P, N, As, and Sb.

Examples of the method for forming the amorphous silicon semiconductor layer include a vapor deposition method, a sputtering method, an RF plasma CVD method, a microwave plasma CVD method, an ECR method, a thermal CVD method, and an LP method.
A known method such as a CVD method is used as required. As a method adopted industrially, an RF plasma CVD method in which a raw material gas is decomposed by RF plasma and deposited on a substrate is preferably used. Furthermore, in RF plasma CVD, the decomposition efficiency of the source gas is as low as about 10%,
There is a problem that the deposition rate is as low as about 1 A / sec to about 10 A / sec. However, a microwave plasma CVD method has attracted attention as a film forming method that can improve this point. As a reaction apparatus for performing the above film formation, a known apparatus such as a batch type apparatus or a continuous film formation apparatus can be used as desired. The solar cell of the present invention can also be used for a so-called tandem cell or triple cell in which two or more semiconductor junctions are stacked for the purpose of improving spectral sensitivity and voltage.

The upper electrode (transparent conductive film) 14 is an electrode for extracting an electromotive force generated in the semiconductor layer 13, and forms a pair with the lower electrode 12. Upper electrode 14
Is required to be transparent because it is located on the light incident side, and is also called a transparent conductive film. The upper electrode 14 desirably has a light transmittance of 85% or more in order to efficiently absorb light from the sun, a white fluorescent lamp, or the like into the semiconductor layer. Sheet resistance value is 10 so that
It is desirably 0 Ω / □ or less. Materials having such characteristics include SnO ₂ , In ₂ O ₃ , ZnO, and Cd.
Metal oxides such as O, CdSnO ₄ and ITO (In ₂ O ₃ + SnO ₂ ) are exemplified.

In order to determine the power generation active area of the photoelectric conversion element, the transparent conductive film 14 is removed by a known etching technique, for example, a desired method such as chemical etching, print etching, or electrochemical etching. An etching line for the electrode 23 can be formed.

After that, the current collecting electrode 23 is formed on the transparent conductive film 14 by a method such as sputtering, vapor deposition, printing, and adhesion of metal or conductive paste.

The amorphous solar cell manufactured in this manner has great flexibility in itself, and becomes a flexible solar cell having characteristics suitable for the present invention.

It is preferable that the arrangement of the solar cells on the shingle is limited to the working width only in view of simultaneous processing with the shingle.

Further, since the interface between the current collecting electrode 23 and the transparent conductive film 14 of the solar cell is the portion having the weakest adhesive strength, when the solar cell element itself is bent by press working or the like,
It is desirable that the longitudinal direction and the bending direction of the current collecting electrode 23 are parallel.

(Sealing Material) The sealing material used in the present invention is, for the adhesive layer (filler), EVA (ethylene vinyl acetate) or EEA in terms of adhesion to a solar cell, weather resistance, and buffer effect. (Ethylene ethyl acrylate),
PVB (polyvinyl butyral) or the like can be suitably used, and is used in combination with a reinforcing material such as a glass nonwoven fabric or silica to improve mechanical properties. Further, in order to further improve the moisture resistance and the scratch resistance, a fluorine-based resin is laminated as the surface protective layer. As a fluorine-based resin,
For example, a polymer TFE of tetrafluoroethylene (manufactured by DuPont)
TEFLON), tetrafluoroethylene / ethylene copolymer ETFE (Dupont TEFZEL, etc.), polyvinyl fluoride (Dupont TEDLAR, etc.), polychlorofluoroethylene CTFE (Daikin Industries, Ltd.)
Neoflon) and the like. The weather resistance may be improved by adding a known ultraviolet absorber to these resins. Further, in order to improve the adhesiveness with the adhesive layer, a film whose surface is roughened by a method such as corona discharge treatment is more preferable. Further, a non-stretch type is more preferable so that it can cope with various bending.

As a sealing method, for example, a known apparatus such as a vacuum laminator is used to heat a reinforcing plate (metal plate, glass, ceramic, plastic, etc.), a solar cell substrate, and the resin film in a vacuum. The method of crimping is well known.

(Terminal Box 50) The terminal box 50 used in the present invention protects the terminal extraction portion on the back surface of the solar cell element and the junction with the lead wire 44 from mechanical external force,
It has the role of protecting it from foreign substances such as water and dust. Therefore, a material having excellent heat resistance, water resistance, electrical insulation and aging properties is required.

In consideration of the above factors, the material is preferably plastic, and in view of flame retardancy, flame retardant plastics and ceramics are preferred.

For example, as the plastic, Noryl,
Polycarbonate polyamide, polyacetal, modified P
There are engineering plastics such as PE, polyester, polyarylate, unsaturated polyester, phenolic resin, and epoxy resin, which are excellent in strength, impact resistance, heat resistance, hardness, and aging. ABS resin, PP, P
Thermoplastics such as VC can also be used.

(External Output Line 51) The external output line 51 used in the present invention preferably has a cable structure.

An external output wire which satisfies heat resistance, cold resistance, mechanical strength, electrical insulation, water resistance, oil resistance, abrasion resistance, acid resistance and alkali resistance required according to the use environment can be used. Specifically, JIS C 3605 standard 60
0V polyethylene cable (EV, EE, CV, C
E), JIS C 3621 standard 600 VEP rubber insulated cable (PN / PV), JIS C 3342 standard 600 V vinyl insulated vinyl sheath (flat) cable (VVR, VVF), JIS C 3327 standard 1
Type 2, Type 3 or Type 4 rubber insulated rubber cabtire cable (1CT, 2CT, 3CT, 4CT), JIS
C3327 standard 2, 3 or 4 rubber insulated chloroprene cabtire cable (2RNCT, 3RNC
T, 4RNCT), two types of JIS C 3327 standard,
Three or four EP rubber insulated chloroprene cabtire cables (2PNCT, 3PNCT, 4PNCT) or JISC 3312 standard vinyl insulated vinyl cabtire cables can be used.

(Lead Wire 44) The lead wire 44 used in the present invention is not particularly limited, but heat resistance, cold resistance, mechanical strength, electrical insulation, water resistance, and oil resistance required according to the use environment. -It is necessary to select a material that has wear resistance, acid resistance and alkali resistance. For example, IV, KI
V, HKIV, insulated wires of cross-linked polyethylene, fluorine rubber, silicone rubber, fluorine resin and the like. In particular, the flame retardancy and heat resistance of the insulating material of the lead wire together with the flame retardancy and heat resistance of the closing means enhance the effect of the present invention.

As the lead wire 44, a copper tab, a copper wire or the like can be used other than the electric wire.

[0080]

EXAMPLES Hereinafter, the present invention will be described in detail with reference to examples, but the present invention is not limited to these examples.

(Example 1) This example is different from the example of embodiment in that mica ceramics was used as the material of the closing means. Also, since the above materials have little elasticity,
The shape is designed in consideration of the mounting properties and the retention in holes.

The shape of the closing means and its mounting method will be described below with reference to FIG.

The closing means 48 has a shape of a cross section L, and has a sleeve shape having a peripheral groove 60 and a peripheral flange 61. The flange 61 is slightly larger than the hole 45 of the back material 41.

Hereinafter, the attachment of the closing means 48 to the hole 45 will be described.

To attach the closing means 48 to the hole 45, the closing means 48 is inserted into the hole 45 from the light receiving surface side of the back material 41. At this time, it stops when the flange 61 of the closing means 48 comes into contact with the back material 41. Finally, a fixing pin 62 is attached to the groove 60 of the closing means 48 protruding on the non-light receiving surface side of the back material 41,
The closing means 48 was fixed so as not to come off even when subjected to a mechanical external force.

The mica ceramics used as the material of the closing means is a non-combustible material, has a high heat-resistant temperature, and has a high insulating property. In addition, since it is excellent in machinability, the above-described groove 60 and flange 61 can be easily formed. Although it has little elasticity, it can be easily mechanically fixed to the hole of the back material by using a two-part structure.

With the above configuration, a non-combustible material having low elasticity can be easily used as the closing means.

(Example 2) This example differs from the example of the embodiment in that a heat-resistant putty was used as the material of the closing means.

Hereinafter, attachment of the closing means to the hole will be described with reference to FIG.

A rod 71 slightly thicker than the diameter of the lead wire used was erected at the center of the hole 45 of the back material 41, and a heat-resistant putty 70 was filled from the light receiving surface side of the back material over a wider area than the hole. At this time, a jig 72 was used so that the rod 71 could be stood at the center of the hole 45 without fail. For the rod 71 and the jig 72, a metal coated with Teflon was used in order to enhance the releasability when the heat-resistant putty 70 was cured.

Next, after the heat-resistant putty 70 was cured at 20 ° C. for 8 hours, the rod 71 was pulled out to form the closing means 48.

The closing means 48 is filled from the light receiving surface side of the back material 41, so that a portion wider than the hole 45 functions as a flange, and the closing means 48 is placed on the non-light receiving surface side of the back material 41 by a load. Prevents falling off.

The heat-resistant putty used for the material of the closing means is a heat-resistant putty for repairing a muffler of an automobile (Cemedine Co., Ltd.
(Product name: fire-resistant putty, heat-resistant temperature 1100 ° C) or the like can be used. In addition, it is necessary to select a material in consideration of heat resistance, flame retardancy, and insulation.

According to the above configuration, even when a heat-resistant putty or the like that can be used by curing is used, the hole of the closing means can be reliably brought to the center of the hole, and the insulation distance is reliably secured. As well as being able to design the hole size as small as possible, fire prevention performance was improved.

(Embodiment 3) This embodiment is different from the embodiment example in that the closing means is integrally formed on the back material.

Hereinafter, the attachment of the closing means to the hole will be described with reference to FIG.

The back member 41 is set on the lower die 81. Next, a fixed amount of silicone rubber 82 is set above the hole 45 of the back material 41. Here, as the silicone rubber 82, the same TSE218 as TOSHIBA SILICON CO., LTD.
5U (unvulcanized product) was used. Next, the upper die 80 and the lower die 81
Pressing (primary vulcanization) in the hole 45 closes the hole 48
Was molded. At this time, press pressure 200kgf / c
The test was performed at 170 ° C. for 5 minutes with both m ² and heater temperature upper die 80 and lower die 81. Next, the backing material 41 with the closing means 48 was held at 200 ° C. for 4 hours, and the secondary curing of the closing means 48 was performed.

As described above, the closing means 48 is connected to the backing material 41.
By integrally molding on the top, a large closing means of a flange or a closing means of a complicated shape can be easily attached to the hole,
Mass productivity is also improved.

As shown in FIG. 9, the insulation distance can be easily controlled by changing the thickness of the closing means 48, and the creepage distance can be easily controlled by changing the size of the flange of the closing means 48.

Embodiment 4 This embodiment is different from the embodiment in that a copper tab is used as a lead wire. Also,
By bringing the terminal extraction portions of the positive electrode and the negative electrode on the solar cell element close to each other, a single hole is provided in the back surface material.

The shape of the closing means and the method of attaching the closing means will be described below with reference to FIG.

In the hole 45 of the back material 41, the lead wire through hole 5 is provided.
5 attached two closing means 48, and inserted a positive copper tab 90 and a negative copper tab 90 from the respective lead wire through holes 55. Next, a terminal box common to plus and minus was attached. The shape of the closing means 48 was determined in consideration of the insulation distance and creepage distance between each lead wire 90 and the hole 45, and the insulation distance, creepage distance and space distance between the plus lead wire 90 and the minus lead wire 90.

(Example 5) This example is different from the example of the embodiment in that a solar cell module was prepared with a vacuum laminator, and then lead wires and closing means were attached.

The method of attaching the closing means will be described below with reference to FIG.

First, with a plug 91 made of silicone rubber having low adhesiveness to the filler previously attached to the place where the closing means is to be attached, the filler / insulating film / filler / glass fiber / solar cell is applied to the galvanized steel sheet. The element block / glass fiber / filler / fluororesin film were sequentially stacked and laminated. Next, using a vacuum laminator at 150 ° C., 3
By melting the filler in 0 minutes, a planar solar cell module 49 sealed with resin was produced.

Next, after removing the plug 91, the lead wire 44 (UL
(Style 3133 silicone rubber insulated wire) was attached by soldering. Next, a silicone-based heat-resistant sealant 46 was applied and cured so as to cover the terminal extraction portion 47 and the soldered portion of the lead wire 44.

As a result, the silicone heat-resistant sealant wraps around the portion A in the figure, and the closing means forms a flange larger than the hole of the back material on the light incident side with respect to the hole. An effective closing means capable of coping with the falling off of the closing means due to a decrease in the adhesive force can be constituted.

Also, in contrast to the present embodiment, the most suitable combination of materials for the backing material and the closing means is selected, such as gypsum board which is a non-combustible material on the backing material and gypsum is applied and cured as the closing means. As in the present embodiment, it is possible to constitute a closing means that does not drop off from the backing material in the event of a fire without forming a wraparound portion as shown in FIG.

[0109]

According to the solar cell module of the present invention, the lead wire connected to the solar cell element is exposed on the non-light-receiving surface side of the solar cell module through the closing means provided in the hole of the back material. Since the closing means does not fall off even in the event of a fire, by using the solar cell module of the present invention for a roof with solar cells, even when the influence of an adjacent fire is extremely large, the holes provided in the back surface material are not removed. The fire protection performance at the portion was equal to or higher than that of the surrounding backing material, and a solar cell module having excellent fire protection performance could be provided.

This effect is further enhanced when the solar cell module is fixed on the base material with a mounting bracket and there is a space between the solar cell module and the base material.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a schematic configuration of a solar cell module according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram of a schematic configuration of a solar cell element used in the solar cell module of FIG.

FIG. 3 is an explanatory diagram of a schematic configuration of a solar cell element used in the solar cell module of FIG.

FIG. 4 is an explanatory diagram of a schematic configuration of a solar cell module according to an embodiment of the present invention.

FIG. 5 is an explanatory view of a closing means used in the solar cell module of FIG.

FIG. 6 is an explanatory diagram of a closing means used in the solar cell module of Example 1.

FIG. 7 is an explanatory view of a closing means used in the solar cell module of Example 2.

FIG. 8 is an explanatory view of a closing means used in the solar cell module of Example 3.

FIG. 9 is an explanatory view of a closing means used in the solar cell module of Example 3.

FIG. 10 is an explanatory view of a closing means used in the solar cell module of Example 4.

FIG. 11 is a schematic diagram of a solar cell module based on Example 5.

FIG. 12 is an explanatory diagram of a schematic configuration of a conventional solar cell module.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Stainless steel substrate (conductive base) 12 Lower electrode (backside reflection layer) 13 Semiconductor layer 14 Upper electrode (transparent conductive layer) 21, 21 'Solar cell element 22 Element separation part 23 Current collecting electrode (copper wire) 24 Carbon conductive bonding Agent 25 Polyimide tape 26 Busbar copper tape 31 Galvanized steel plate (Back material) 32 Adhesive layer (Filler) 33 Insulating film 34 Glass fiber 35 Solar cell element block 36 Fluororesin film (Surface protection material) 40 Surface protection material 41 Back material 42 Solar Cell Element 43 Filler 44 Lead Wire 45 Hole 46 Sealant 47 Terminal Outlet 48 Closing Means 49 Solar Cell Module 50 Terminal Box 51 External Output Wire 52 Main Body 53 Lid 54 Flange 55 Lead Through Hole 60 Groove 61 Flange 62 Fixing Pin 70 heat-resistant putty 71 rod 72 jig 73 jig 80 press (Upper die) 81 Press (lower die) 82 Silicone rubber 90 Copper tab 91 Plug

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hidehisa Makita 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Masahiro Mori 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon (72) Inventor Ayako Komori 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Yoshitaka Nagao 3-30-2, Shimomaruko 3-chome, Ota-ku, Tokyo Canon Inc. ( 72) Inventor Seiki Itoyama 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc. (72) Inventor Toshihiko Mimura 3-30-2 Shimomaruko 3-chome, Ota-ku, Tokyo Inside Canon Inc. (72) Inventor Yuji Inoue 3-30-2 Shimomaruko, Ota-ku, Tokyo F-term (reference) in Canon Inc. 5F051 AA05 BA03 BA11 BA14 CA15 CA22 DA04 EA01 EA17 EA 18 GA02 JA02 JA04 JA08

Claims (10)

[Claims] At least a solar cell element, a surface protection material provided on a light receiving surface side of the solar cell element, a back surface material provided on a back surface side of the solar cell element, and a resin sealed with the solar cell In a solar cell module comprising a filler for stopping, a lead wire connected to the solar cell element is exposed to a non-light-receiving surface side of the solar cell module through a closing means provided in a hole of the back surface member. The solar cell module is characterized in that the closing means does not fall off even in the event of a fire. 2. The solar cell module according to claim 1, wherein substantially no airflow occurs at the interface between the hole and the closing means, and between the closing means and the lead wire at the time of fire. 3. The device according to claim 1, wherein said closing means is made of a non-combustible material, a semi-combustible material, or a flame-retardant material.
A solar cell module according to item 1. 4. The solar cell module according to claim 1, wherein the back member is a non-combustible back member. 5. The solar cell module according to claim 1, wherein said closing means is made of a material having an insulating property. 6. The solar cell according to claim 1, wherein the hole of the back material, the closing means, and the lead wire are covered with a terminal box provided on the back material. module. 7. The solar cell module according to claim 1, wherein the closing means has a flange larger than the hole of the back material on the light incident side with respect to the hole. 8. The solar cell module according to claim 1, wherein said closing means has a plurality of lead wire openings. 9. A roof with solar cells, wherein the solar cell module according to claim 1 is fixed on a base material by a fixing member. 10. A power generator comprising the solar cell module according to claim 1 and a power converter.