JP2001053315A - Solar battery module and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery module which is constituted to effectively prevent the occurrence of optical pollution, etc., due to reflection of light at the incidence side and a method for easily, and a method of inexpensively manufacturing the module. SOLUTION: A solar battery module is provided with a transparent insulating substrate 1, having first and second surfaces, a transparent electrode layer 2 formed on the first surface of the substrate 1, and an optical semiconductor layer 3 formed on the electrode layer 2. The module is also provided with a rear-surface electrode layer 4, formed on the semiconductor layer 3 and an antiglare film 10 formed on the second surface of the substrate 1, to which light is made incident. The film 10 contains organic binders 20 and inorganic particles 30.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a solar cell module and a method of manufacturing the same, and more particularly to a solar cell module used for photovoltaic power generation and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, the use of clean energy has been increasingly called out, and accordingly, the use of solar cells has been promoted. Further, along with mass production of solar cells, reduction of manufacturing costs is progressing. In the past, the main forms of solar cell utilization were the form of solar cell power plants arranged in large scale and the form for securing power in remote areas. However, in recent years, it has become mainstream to generate electric power by attaching a solar cell module panel to a roof of a house or an outer wall of a building in an urban area, and use that energy in the same way as conventional electric power companies.

In such a solar cell module panel, a plurality of photovoltaic elements are sealed with a resin between a front cover glass and a back cover film. As the front cover glass, a transparent glass having a mirror surface was used in the past, and the problem of light pollution was pointed out in part. In order to solve this problem, for example, use of a template glass formed by pressing a glass to form a unique shape on the surface has been studied. Japanese Patent Application Laid-Open No. H11-74552 discloses a technique for forming an uneven shape on a light incident surface of a glass substrate.

On the other hand, as a structure for greatly reducing the cost of the solar cell module, a transparent electrode layer, a semiconductor layer, and a back electrode layer are sequentially patterned on a transparent insulating substrate of the same size as the front cover glass from the light incident side. A substrate-integrated thin-film solar cell module obtained by formation has been proposed. The feature of this structure is that no sealing resin is required to be filled between the wiring of each photovoltaic element and between the element and the cover glass. Energy loss,
In addition, there is no characteristic deterioration due to yellowing of the resin.

FIG. 7 is a sectional view showing a schematic structure of an example of a conventional solar cell module.

Referring to FIG. 7, this solar cell module includes a transparent insulating substrate 1, a transparent electrode layer 2 formed on a surface of the transparent insulating substrate 1 different from the light incident surface, and a transparent electrode layer 2 on the transparent electrode layer 2. The semiconductor device includes the formed optical semiconductor layer 3 and the back electrode layer 4 formed on the optical semiconductor layer 3. The optical semiconductor element 5 configured by sequentially laminating the transparent electrode layer 2, the optical semiconductor layer 3, and the back electrode layer 4 is divided into a plurality of regions, and each region is electrically connected to each other in series or in parallel. I have.

The solar cell module is sealed and protected by a filling resin 6 and a back cover film 7 to protect the optical semiconductor element 5. Further, a frame 8 is attached to the solar cell thus sealed.

The manufacturing process of the conventional solar cell module configured as described above includes a laser processing process and the like in addition to a film forming process such as plasma CVD and sputtering. Therefore, in the conventional solar cell module, the surface on the light incident surface side of the transparent insulating substrate 1 is generally formed as a flat surface in order to stably perform these steps.

[0009]

However, when the conventional solar cell module configured as described above is arranged on a roof or an outer wall of a building, sunlight is reflected depending on the angle between the sun and the solar cell module. Some people pointed out the problem of light pollution such as illuminating the inside of an adjacent house.

Therefore, in order to solve such a problem,
As described above, it has been studied to make the surface of the substrate into a template glass that scatters light.However, when such a glass is used, detailed examination of the texture specification of the template glass or special laser processing conditions are required, There is a problem that the cost is increased accordingly.

Further, as disclosed in Japanese Patent Application Laid-Open No. H11-74552, when forming irregularities on the glass substrate itself, the processing of the glass requires the use of a high-temperature or highly reactive solution of hydrofluoric acid or the like. As a result, there is a problem that it cannot be performed after completion of the module. In addition, if the glass substrate itself is processed before the module is manufactured, there is a problem that the laser cut of the semiconductor layer and the electrode layer cannot be performed from the glass substrate surface. Further, as a method of forming the irregular shape on the glass substrate, blasting can be considered, but there is a problem that the strength of the glass is weakened.

On the other hand, in the production of the conventional solar cell module, there is a problem that the color tone of the glass substrate varies depending on the lot, so that the color tone also differs in the completed solar cell module.

An object of the present invention is to solve the above-mentioned problems, to effectively prevent light pollution due to light reflection on the light incident side, and to provide a solar cell module having a uniform color tone and a simple and inexpensive solar cell module. It is to provide a manufacturing method.

[0014]

A solar cell module according to the present invention comprises: a transparent insulating substrate having first and second surfaces; a first electrode layer formed on the first surface of the transparent insulating substrate; An optical semiconductor layer formed on the first electrode layer, a second electrode layer formed on the optical semiconductor layer, and an antiglare film formed on the second surface of the transparent insulating substrate on which light is incident. And the anti-glare film includes an organic binder and inorganic particles.

The solar cell module according to the present invention includes both a thin-film solar cell module and a crystalline solar cell module.

As the organic material binder, an acrylic resin, a fluorine resin, a mixed resin thereof, or a resin containing these resins or the mixed resin as a main component is used.

Further, as the inorganic material particles, particles made of silica are used.

Preferably, the inorganic material particles have a diameter of 0.0
It is good to be 5-200 μm.

[0019] More preferably, the inorganic material particles have a diameter of 1 to 10 µm.

Preferably, the weight ratio of the organic material binder to the inorganic material particles is 0.1 to 2,000 when the weight of the organic material binder is 100.

More preferably, the diameter of the inorganic material particles is 1
When the weight is 10 to 10 μm, the weight ratio of the inorganic material particles is preferably 1 to 10 when the weight ratio of the organic material binder to the inorganic material particles is 100.

Preferably, the thickness of the antiglare film is 0.1 to 5
It is preferably 00 μm.

In the antiglare film, the inorganic material particles may be arranged in a single layer or in two or more layers.

In the present invention, a film made of an interfacial treatment agent may be further interposed between the transparent insulating substrate and the antiglare film.

Preferably, the anti-glare film has an uneven shape on its surface.

Further, in the solar cell module according to the present invention, it is preferable that a surface protective film is further formed on the antiglare film.

According to the method of manufacturing a solar cell module of the present invention, a step of forming a first electrode layer on a first surface of a transparent insulating substrate having first and second surfaces; Forming an optical semiconductor layer on the layer;
Forming a second electrode layer on the formed optical semiconductor layer; and forming an anti-glare film including an organic binder and inorganic particles on a second surface of the transparent insulating substrate on which light is incident. And forming the antiglare film after forming the first electrode layer, the optical semiconductor layer, and the second electrode layer on the first surface of the transparent insulating substrate.

[0028]

FIG. 1 is a sectional view showing a schematic configuration of a solar cell module according to a first embodiment of the present invention.

Referring to FIG. 1, this solar cell module includes a transparent insulating substrate 1, a transparent electrode layer 2 formed on a surface of the transparent insulating substrate 1 different from the light incident surface, and a transparent electrode layer 2 on the transparent electrode layer 2. The semiconductor device includes the formed optical semiconductor layer 3 and the back electrode layer 4 formed on the optical semiconductor layer 3. The optical semiconductor element 5 configured by sequentially laminating the transparent electrode layer 2, the optical semiconductor layer 3, and the back electrode layer 4 is divided into a plurality of regions, and the respective regions are electrically connected to each other in series or in parallel. .

The solar cell module is sealed and protected by a filling resin 6 and a back cover film 7 to protect the optical semiconductor element 5. further,
The solar cell thus sealed includes a transparent insulating substrate 1,
A frame 8 used to hold the filling resin 6 and the back cover film 7 and the like and to be attached to a frame such as a roof is attached. However, the presence or absence of a frame is not limited, and may be a frameless frame or a tile embedded, and is not limited.

Further, an antiglare film 10 containing an organic binder and inorganic particles, which is a feature of the present invention, is provided on the light incident surface side of the transparent insulating substrate 1 via a film 40 made of an interface treatment agent. Is formed. The surface of the anti-glare film 10 has an uneven shape. Further, a surface protection film 50 having a flat surface is further formed on the surface of the antiglare film 10 on which the uneven shape is formed.

The anti-glare film 10 may be a film that irregularly reflects light incident from the light incident surface side, or a film that improves the transmittance of incident light and reduces the amount of light that is reflected. .

The characteristics of the resin which can be used as the organic material binder include sufficient weather resistance, good light transmittance, and a temperature at which the solar cell element is not deteriorated in the film forming process, specifically, a temperature. Materials that form a film at a temperature of 200 ° C. or lower, more preferably 150 ° C. or lower are preferably used.

As the organic binder used in the present invention, an acrylic resin, a fluorine resin, a mixed resin thereof, or a resin containing these resins or the mixed resin is used.

The resin or the resin mixture is not particularly limited as long as it satisfies the above-mentioned characteristics. However, the acrylic resin, the fluorine resin, or the mixed resin thereof is not less than 50% by weight in the binder resin. The content is preferably 80% by weight or more, more preferably 95% by weight or more.

The acrylic resin is preferably a resin obtained by polymerizing or copolymerizing a monomer containing an acrylic monomer as a main component, and the fluororesin is preferably a resin obtained by polymerizing using a fluorine-containing monomer.

Further, as the acrylic resin, a resin containing a hydrolyzable silyl group is preferable, and the main chain is substantially composed of a polyvinyl type bond, and one or more silicon atoms bonded to the terminal or side chain with the hydrolyzable group are preferred. A silyl group-containing vinyl resin having at least one in the molecule, which is obtained by copolymerization of a vinyl monomer and a hydrolyzable silyl group-containing monomer, and may partially include a urethane bond or a siloxane bond in a main chain or a side chain. . The vinyl monomer is not particularly limited, and may be methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, stearyl (meth) acrylate, benzyl (meth) acrylate, cyclohexyl (meth) ) Crylate, trifluoroethyl (meth) acrylate, pentafluoropropyl (meth) acrylate, polycarboxylic acid (maleic acid, fumaric acid, itaconic acid, etc.)
Esters of unsaturated carboxylic acids such as diesters or half-esters with linear or branched alcohols having 1 to 20 carbon atoms; styrene, a-methylstyrene, chlorostyrene, styrenesulfonic acid, 4-hydroxystyrene,
Aromatic hydrocarbon vinyl compounds such as vinyl toluene; vinyl esters and allyl compounds such as vinyl acetate, vinyl propionate and diallyl phthalate; nitrile group-containing vinyl compounds such as (meth) acrylonitrile; epoxy such as glycidyl (meth) acrylate Group-containing vinyl compounds; amino group-containing vinyl compounds such as dimethylaminoethyl (meth) acrylate, diethylaminoethyl (meth) acrylate, vinylpyridine, and aminoethyl vinyl ether;
(Meth) acrylamide, itaconic acid diamide, a-ethyl (meth) acrylamide, crotonamide, maleic acid diamide, fumaric acid diamide, N-vinylpyrrolidone,
Amide group-containing vinyl compounds such as N-butoxymethyl (meth) acrylamide, N, N-dimethylacrylamide, N-methylacrylamide, and acryloylmorpholine;
2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 2-hydroxyethyl vinyl ether, N-methylol (meth) acrylamide, Alonix 5700 (manufactured by Toagosei Co., Ltd.), Placce
l FA-1, Placcel FA-4, Placcel FM-1, Placcel FM-4
(Including those produced by Daicel Chemical Industries, Ltd.); (meth) acrylic acid, maleic acid, fumaric acid, itaconic acid and salts thereof (alkali metal salts, ammonium salts, amine salts, etc.), maleic anhydride And other vinyl compounds such as vinyl methyl ether, vinyl chloride, vinylidene chloride, chloroprene, propylene, butadiene, isoprene, maleimide, N-vinylimidazole, and vinyl sulfonic acid. Is mentioned.

As the alkoxysilane vinyl monomer, specifically,

[0039]

Embedded image And the like.

These alkoxysilane vinyl monomer units are preferably 5 to 90% by weight, more preferably 20% by weight, of the vinyl copolymer containing a hydrolyzable silyl group.
-80% by weight, particularly preferably 30-70% by weight.

The method for producing a copolymer of an alkoxysilane vinyl monomer and a vinyl monomer is described in, for example, JP-A-54-36395, JP-A-57-36109, and JP-A-58-36109.
157810 or the like may be used. Solution polymerization using an azo radical initiator such as azobisisobutyronitrile is most preferred. If necessary, n-dodecyl mercaptan, t-dodecyl mercaptan, n-butyl mercaptan, γ-mercaptopropyltrimethoxysilane, γ-mercaptopropyltriethoxysilane, γ-mercaptopropylmethyldimethoxysilane,
γ-mercaptopropylmethyldiethoxysilane, (H
_{3 CO) 3 Si-S-} S-Si (OCH 3) 3, (CH
_The molecular weight can be controlled by using a chain transfer agent such as ₃ O) ₃ Si—S ₈ —Si (OCH ₃ ) ₃ . In particular, when a chain transfer agent having a hydrolyzable silyl group in the molecule, for example, γ-mercaptopropyltrimethoxysilane, a hydrolyzable silyl group can be introduced into the terminal of the vinyl copolymer containing a silyl group. Polymerization solvents include hydrocarbons (toluene, xylene, n-hexane, cyclohexane, etc.), acetates (ethyl acetate, butyl acetate, etc.), alcohols (methanol, ethanol, isopropanol, n
Non-reactive solvents such as butanol, ethers (ethyl cellosolve, butyl cellosolve, cellosolve acetate, etc.), ketones (methyl ethyl ketone, ethyl acetoacetate, acetylacetone, diacetone alcohol, methyl isobutyl ketone, acetone, etc.) There is no particular limitation.

Further, as the fluorine-based resin, a hydroxyl group
It is preferable that the resin
An example of a hydroxyl group-containing fluorocopolymer is chlorotoluene.
Trifluoroethylene, tetrafluoroethylene, trif
Fluoroolefins such as fluoroethylene; CH_Two= CH
COOCH_TwoCF_Three, CH_Two= C (CH_Three) COOCH_TwoC
F_Three, CH_Two= CHCOOCH (CF_Three)_Two, CH_Three= C
(CH_Three) COOCH (CF _Three)_Two, CH_Two= CHCOOC
H_TwoCF_TwoCF_TwoCF_Three, CH_Two= CHCOOCF_Three, CH_Two
= C (CH_Three) COOCH_TwoCF_TwoCF_TwoCF_Three, CH_Two= C
(CH_Three) COOCF _Three(Meth) acrylic acid full including
Fluoro-containing vinyl monomers such as oloalkyl, hydro
Xylethyl vinyl ether, hydroxypropyl vinyl
Ether, hydroxybutyl vinyl ether, hydroxy
Hydroxyalkyl vinyl such as sihexyl vinyl ether
Ether; 2-hydroxyethyl acrylate, 2-
Hydroxyethyl methacrylate, 2-hydroxypro
Pill acrylate, 2-hydroxypropyl methacrylate
N-methylol acrylamide, N-methylol
Methacrylamide, Aronix 5700 (Toa Gosei
Co., Ltd.), Placcel FA-1, FA-4, FM-1, FM-4
(Including those manufactured by Daicel Chemical Co., Ltd.)
Nomer, ethyl vinyl ether, propyl vinyl A
Alkyl vinyl ethers such as ter and butyl vinyl ether
Cyclohexyl vinyl ether; maleic acid, fuma
Acrylic acid, acrylic acid, methacrylic acid, carboxylic acid
Carboxyl-group-containing monomers such as kyl vinyl ether;
Ethylene, propylene, vinyl chloride, vinylidene chloride,
Vinyl acetate; methyl methacrylate, methyl acrylate, etc.
Unsaturated carboxylic acid ester of vinyltriethoxysila
Γ- (meth) acryloyloxypropyltrimeth
Hydrolyzable silyl group-containing monomers such as xysilane;
The hydroxyl value obtained by copolymerizing
mgKOH / g, preferably 10-250 mgKOH / g
g.

Examples of the resin containing a hydrolyzable silyl group include Zemurac (registered trademark) manufactured by Kaneka Corporation.
Examples of the hydroxyl group-containing fluororesin or resin composition include Lumiflon and Bonflon manufactured by Asahi Glass Coat and Resin Co., Ltd., New Gamet manufactured by Toube Co., Ltd., and V Freon manufactured by Dainippon Paint Co., Ltd. (all are registered trademarks).

Lumiflon has the following basic physical properties.

[0045]

[Table 1] Zemrak has the molecular structure shown below.

[0046]

Embedded image (Wherein, R ₁ is an alkyl group having 1 to 10 carbon atoms, R ₂ is a hydrogen atom or a monovalent hydrocarbon group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, an aryl group and an aralkyl group, a represents 0, 1 or 2) It is preferable that a film-forming speed can be controlled by adding a curing catalyst to the resin containing a hydrolyzable silyl group before coating.

Specific examples of the curing catalyst include organic tin compounds such as dibutyltin dilaurate, dibutyltin dimaleate, dioctyltin dilaurate, dioctyltin dimaleate and tin octylate; phosphoric acid, monomethyl phosphate, monoethyl phosphate, monobutyl phosphate , Monooctyl phosphate, monodecyl phosphate, dimethyl phosphate, diethyl phosphate, dibutyl phosphate, dioctyl phosphate,
Phosphoric acid or phosphoric acid ester such as didecyl phosphate; propylene oxide, butylene oxide, cyclohexene oxide, glycidyl methacrylate, glycidol, acrylic glycidyl ether, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-glycidoxypropylmethyldimethoxysilane,

[0048]

Embedded image Cardeura E (Yuka Kasei Co., Ltd.), Epikote 82
No. 8 (manufactured by Yuka Shell), Epicoat 1001 (manufactured by Yuka Shell), and the like, an addition reaction product of an epoxy compound and phosphoric acid and / or a monoacid phosphate; an organic titanate compound; an organic aluminum compound; Maleic acid,
Acidic compounds such as paratoluenesulfonic acid and hydrochloric acid; aliphatic diamines such as ethylenediamine and hexanediamine; diethylenetriamine, triethylenetetramine;
Aliphatic polyamines such as tetraethylenepentamine;
Alicyclic amines such as piperidine and piperazine; other aromatic amines such as metaphenylenediamine; ethanolamines; triethylamine; γ-aminopropyltriethoxysilane; N-β- (aminoethyl) -γ-
Aminopropyltrimethoxysilane; hexylamine,
Amines such as di-2-ethylhexylamine, N, N-dimethyldodecylamine and dodecylamine; reactants of these amines with acidic phosphoric acid esters; alkaline compounds such as sodium hydroxide and potassium hydroxide;
Alkyl mercaptans such as dodecyl mercaptan and tert-butyl mercaptan; mercaptosilanes such as r-mercaptopropyltrimethoxysilane; carboxylic acids such as 2-mercaptopropionic acid, thiosalicylic acid and acetic acid; ester compounds such as 2-ethylhexyl thioglycolate; (Diamond Shamrock Chemicals, polyether with mercapto groups at both ends)
And a mercapto group-containing compound such as thiophenol and thiobenzoic acid, and BT120S (organotin-based compound manufactured by Kanegafuchi Chemical Industry Co., Ltd.). Among these curing catalysts, organotin compounds, acid phosphates, amines, reactants of acid phosphates and amines, saturated or unsaturated polycarboxylic acids or acid anhydrides thereof, reactive silicon compounds, Organic titanate compounds, organoaluminum compounds, or mixtures thereof are preferred in terms of workability, and among them, a curing catalyst containing an organotin compound or an organotin compound is particularly preferable, in which an organotin compound and an amine, and / or a mercapto compound are used. The curing catalyst used is preferred in terms of workability.

On the other hand, as the inorganic material particles constituting the antiglare film 10, those made of silica are used. Specifically, for example, TS100 manufactured by Degussa Japan made of silica of φ4 μm, Degussa OK-607 manufactured by Degussa Japan made of silica of φ2 μm, and EG-ST manufactured by Nissan Chemical Industries, Ltd. made of silica sol of φ0.07 to 0.1 μm
-ZL or the like is used.

The diameter of the inorganic material particles is preferably 0.05 to 200 μm, more preferably 0.5 to 100 μm.
μm, particularly preferably 1 to 10 μm. If the diameter of the particles is in this range, the degree of reflection can be reduced.

The mixing weight ratio between the organic binder and the inorganic material particles is 5 when the inorganic material particle diameter is less than 1 μm.
0 to 2000, especially 100 to 1500 is preferred.

When the particle diameter of the inorganic material is 1 μm or more, preferably 1 to 10 μm, the mixing weight ratio between the organic material binder and the inorganic material particles is 0.1 to 98, more preferably 1 to 98.
50, particularly preferably 1 to 10. If the particle size is small, the antiglare effect of the present invention is not sufficiently exhibited, and if the particle size is large, dispersibility in the binder resin is undesirably reduced.

The thickness of the anti-glare film 10 is 0.1 to 50.
0 μm, further 0.5 to 100 μm, especially 1 to 30 μm
m is preferable.

FIG. 2 is a cross-sectional view showing, on an enlarged scale, a portion of the antiglare film 10 as an example of the solar cell module according to the present invention.

Although not shown, these anti-glare films may be a single layer, or an anti-glare effect and transmission can be obtained by superimposing anti-glare films of different materials, shapes and thicknesses in multiple layers. In some cases, it is effective to increase the rate.

In the antiglare film 10 of this solar cell module, as shown in FIG. 2, the inorganic material particles 30 are arranged in a single layer in the organic material binder 20. With such a structure, a decrease in transmittance can be prevented.

FIG. 3 is a cross-sectional view showing a part of an antiglare film 10 of another example of the solar cell module according to the present invention in an enlarged manner.

In the anti-glare film 10 of this solar cell module, as shown in FIG. 3, inorganic material particles 30 are arranged in multiple layers in an organic material binder 20. With such a structure, the antiglare effect can be increased.

In the layer of the inorganic material particles, the entire surface of the formed antiglare film may be a single layer or multiple layers, or a single layer and multiple layers may be mixed.

By forming the anti-glare film on the light incident surface side of the transparent insulating substrate in this way, the sunlight incident on the solar cell module contributes to power generation for the most part and is reflected from the surface. About 2 to 4% of the incident light is reflected in an unspecified direction. The diffusely scattered sunlight is not a parallel ray. Therefore, the light reflected from the solar cell module is in a blurred state as a whole, and does not feel dazzling even when directly looking at the solar cell.

In the solar cell module according to this embodiment, the transparent electrode layer 2 is made of ITO, Sn
A material that can transmit light, such as O ₂ , or a laminate of these materials, such as ITO / SnO ₂ or ZnO, is used.

The optical semiconductor layer 3 is made of amorphous silicon a
-Si, hydrogenated amorphous silicon a-Si: H, hydrogenated amorphous silicon carbide a-SiC: H, amorphous silicon nitride, etc., and other elements such as silicon and carbon, germanium, tin, etc. An amorphous or microcrystalline amorphous silicon-based semiconductor made of an alloy of
A semiconductor layer synthesized into an ni type, pn type, MIS type, heterojunction type, homojunction type, Schottky barrier type, or a combination thereof is used. In addition, the optical semiconductor layer may be a CdS-based, GaAs-based, InP-based, or the like, and is not limited at all.

As the back electrode layer 4, a metal or a composite film of a metal and a metal oxide is used.

Further, as the filling resin 6, silicon,
Ethylene vinyl acetate, polyvinyl butyral, or the like is used. As the back cover film 7, a fluorine-based resin film, a metal film such as polyethylene terephthalate or aluminum, or a film having a multilayer structure in which a thin film such as SiO ₂ is laminated is used. .

In this embodiment, a thin-film solar cell module will be described, but it goes without saying that the present invention can be applied to a crystalline solar cell module.

Next, a method of manufacturing the solar cell module of the first embodiment shown in FIG. 1 will be described.

First, a transparent electrode layer 2, an optical semiconductor layer 3, and a back electrode layer 4 are sequentially formed on a surface of the transparent insulating substrate 1 different from the light incident surface. Each of these layers is separated into a plurality of regions by patterning means such as laser scribe. For example, the transparent electrode layer 2 is formed in a predetermined pattern shape by a method such as laser processing, etching, and lift-off. The back electrode layer 4 is formed into a predetermined pattern by a method such as laser processing, etching, and lift-off after forming the film by vapor deposition or sputtering.

After the optical semiconductor element 5 including the transparent electrode layer 2, the optical semiconductor layer 3 and the back electrode layer 4 is formed on the transparent insulating substrate 1 as described above, the optical semiconductor element 5 is sealed with a filling resin 6 in order to protect them. Then, the back cover film 7 is attached.

Subsequently, an antiglare film 10, which is a feature of the present invention, is formed on the light incident surface side of the transparent insulating substrate 1 on which the optical semiconductor element 5 is formed. The anti-glare film can be formed at any time after the second electrode layer is formed and scribed. Immediately, after sealing the back surface, after attaching the terminal box, after installing on the roof, etc., the coating method can be used. Although not limited, it is not particularly limited.

At this time, a film 40 made of an interfacial treatment agent may be interposed between the transparent insulating substrate 1 and the anti-glare film 10.
By interposing such a film 40, the adhesive strength between the transparent insulating substrate 1 and the anti-glare film 10 is increased, and the coating unevenness is reduced.

In this embodiment, the antiglare film 10 is formed after the optical semiconductor element 5 is formed. Conversely, if the optical semiconductor element 5 is formed after the formation of the antiglare film 10, if laser irradiation is performed during the formation of the optical semiconductor element 5, the problem of blurring of the focus or the formation of the optical semiconductor element 5 may occur. This is because there is a possibility that a problem that the vacuum chamber cannot be used may occur.

FIGS. 4 and 5 are cross-sectional views for explaining an example of a method for manufacturing a solar cell module according to the present invention, and are views showing an example of a method for forming the antiglare film 10.

First, referring to FIG. 4, an organic binder resin 20 mixed with inorganic particles 30 is applied on the light incident surface of the transparent insulating substrate 1 of the sealed solar cell module.

At this time, when the size of the particles 30 is large, as shown in FIG. 5, when the binder resin 20 is formed, an uneven shape is formed on the surface of the anti-glare film 10 due to the distribution of the particles 30. You.

FIG. 6 is a cross-sectional view for explaining another example of the method for manufacturing the solar cell module according to the present invention, and is a view showing another example of the method for forming the antiglare film 10.

Referring to FIG. 6, organic binder resin 20
Is applied, the roller 9 around which the cloth having the predetermined pattern shape is wound is moved as shown by the arrow B while rotating as shown by the arrow A, and the predetermined pattern is transferred. By forming the film, an uneven shape can be formed on the surface of the antiglare film 10.

As a method of forming the uneven shape on the light incident surface of the anti-glare film 10, a method utilizing the action of the mixed particles as described above, or a method of applying a binder resin and forming by pressing or the like is used. In addition to the method of forming the film after the formation, the surface can be formed in an uneven shape by devising the shape of the nozzle when applying the binder resin.

In this embodiment, a surface protection film 50 having a further flat surface is formed on the surface of the antiglare film 10 having the uneven surface. By forming such a surface protective film 50, it is possible to effectively prevent dust from collecting on the surface and lowering the photoelectric conversion rate.

[0079]

EXAMPLES An antiglare film was formed on a glass substrate under various conditions, and the optical characteristics and the like were evaluated.

Example 1 A TCO (transparent conductive oxide) film was formed on one surface of a glass substrate having a flat surface, and an antiglare film was formed on the other surface under the following conditions.

First, "Zemlac YC3623" manufactured by Kanegabuchi Chemical Industry Co., Ltd. was used as an organic material binder, BT120S (tin-based) was used as a curing agent, and xylene was used as a diluent to dilute to a solid content of 25%. did.

As the inorganic material particles, silica “TS100” (φ4 μm) manufactured by Degussa Japan was used and dispersed in the above-mentioned binder resin using a shaker. The compounding ratio of the particles is as follows: binder resin: particles = 100:
It was prepared to be 2.5.

The liquid thus obtained was applied on a glass substrate by spraying and dried at room temperature for 5 minutes.
Further drying was performed at 80 ° C. for 30 minutes.

Thus, the sample of Example 1 in which the TCO film was formed on one surface of the glass substrate and the irregular reflection film was formed on the other surface, was obtained.

The sample of Example 1 was irradiated with light from the surface on which the anti-glare film was formed to obtain “60 ° gloss” and “20 ° gloss”.
Gloss "and" total transmittance "were measured to evaluate optical characteristics.

“60 ° gloss” refers to JIS Z8741.
According to the specular gloss measurement method of -1983, 60 ° specular gloss was measured.

“20 ° gloss” refers to JIS Z8741.
According to the specular gloss measurement method of -1983, 20 ° specular gloss was measured.

Next, the sample of Example 1 was subjected to a film thickness measurement and an X-cut test to evaluate the initial film.

The “X-cut test” is based on JIS K540
Perform according to 0, and if the whole surface has been peeled off,
The evaluation was made such that the better the score, the higher the score, assuming that there were no points and no defects.

Further, with respect to the sample of Example 1, J
A durability test was performed according to IS C 8938, and the subsequent films were evaluated.

The durability test was carried out by leaving the film at 85 ° C. for 264 hours, and leaving it at 85 ° C. and 85% humidity for 270 hours.
The test was performed under three conditions of repeating 10 cycles between a temperature of 85 ° C., a humidity of 85% and −20 ° C., and an X-cut test and evaluation of appearance were performed on the film after the test.

(Example 2) Binder resin: particles = 10
The mixing ratio of the particles was adjusted so as to be 0: 5, and a sample of Example 2 was produced in the same manner as in Example 1.

With respect to the sample of Example 2 thus obtained, the optical characteristics, the initial film, and the film after the durability test were evaluated in the same manner as in Example 1.

(Example 3) Instead of ZEMRAC YC3623, ZEMRAC YC592 manufactured by Kaneka Corporation
Using 0, the blending ratio of the particles was adjusted so that the ratio of binder resin: particles = 100: 5, and a sample of Example 3 was produced in the same manner as in Example 1.

With respect to the sample of Example 3 thus obtained, the optical characteristics, the initial film, and the film after the durability test were evaluated in the same manner as in Example 1.

Example 4 After a TCO film was formed on one surface of a glass substrate having a flat surface, pretreatment of the substrate was performed using acetone and IPA (isopropyl alcohol), and then the other surface of the substrate was used. An irregular reflection film was formed under the following conditions.

First, as an organic material binder, “Bonflon® 2020S” manufactured by Asahi Glass Coat and Resin Co., Ltd.
R ", and this was diluted 2-fold using a special thinner.

As the inorganic material particles, silica “OK-607” (φ2 μm) manufactured by Degussa Japan was used and dispersed in the binder resin described above. The blending ratio was adjusted so that binder resin: particles = 100: 5.

The liquid thus obtained was applied on a glass substrate by spraying and dried at normal temperature.

Thus, the fourth embodiment in which the TCO film was formed on one surface of the glass substrate and the irregular reflection film was formed on the other surface of the glass substrate
Sample was obtained.

The optical characteristics and the initial film of the sample of Example 4 were evaluated in the same manner as in Example 1.

Example 5 A liquid in which particles were dispersed in a binder resin was applied twice on a glass substrate by spraying.
Other than that produced the sample of Example 5 like Example 4.

The optical characteristics and the initial film of the sample of Example 5 were evaluated in the same manner as in Example 1.

Example 6 Binder Resin: Particle = 10
The mixing ratio of the particles was adjusted so as to be 0: 3, and a sample of Example 6 was produced in the same manner as in Example 4.

The optical characteristics and the initial film of the sample of Example 6 thus obtained were evaluated in the same manner as in Example 1.

(Example 7) A sample in Example 7 was prepared by applying a liquid in which particles were dispersed in a binder resin to a glass substrate twice by spraying, and using the other conditions exactly as in Example 6. .

With respect to the sample of Example 7 thus obtained, the optical characteristics and the initial film were evaluated in the same manner as in Example 1.

(Example 8) As the binder resin, only Bonflon # 2020SR was used, and no diluent was used.
In addition, the blending ratio of the particles was adjusted so that binder resin: particles = 100: 5, and a sample of Example 8 was produced in the same manner as in Example 4.

The optical characteristics and the initial film of the sample of Example 8 thus obtained were evaluated in the same manner as in Example 1.

(Example 9) A liquid in which particles were dispersed in a binder resin was applied twice on a glass substrate by spraying, and the other conditions were exactly the same as those of Example 8, to thereby prepare a sample of Example 9. .

The optical characteristics and the initial film of the thus obtained sample of Example 9 were evaluated in the same manner as in Example 1.

Example 10 As a pretreatment of a substrate, only acetone was used, and the mixing ratio of the particles was adjusted so that the binder resin: particles = 100: 5. Was applied onto a glass substrate, and a sample of Example 10 was prepared in the same manner as in Example 4.

The optical characteristics and the initial film of the sample of Example 10 thus obtained were evaluated in the same manner as in Example 1.

(Example 11) A sample of Example 11 was produced using a 16th piano wire coater under exactly the same conditions as in Example 10.

With respect to the sample of Example 11 thus obtained, the optical characteristics and the initial film were evaluated in the same manner as in Example 1.

(Example 12) Binder resin: particles = 10
The mixing ratio of the particles was adjusted so as to be 0: 3, and a sample of Example 12 was produced in the same manner as in Example 10 using an eighth-number piano wire coater.

The optical characteristics and the initial film of the sample of Example 12 thus obtained were evaluated in the same manner as in Example 1.

(Example 13) A sample of Example 13 was produced using a 16th piano wire coater under the same conditions as in Example 12 except for the above conditions.

The optical characteristics and the initial film of the sample of Example 13 thus obtained were evaluated in the same manner as in Example 1.

(Example 14) Binder resin: particles = 10
The blending ratio of the particles was adjusted so as to be 0: 1, and a sample of Example 14 was produced in the same manner as in Example 10 using a piano wire coater of 8th.

The optical characteristics and the initial film of the sample of Example 14 thus obtained were evaluated in the same manner as in Example 1.

(Example 15) Binder resin: particles = 10
The mixing ratio of the particles was adjusted so as to be 0: 5, and a sample of Example 15 was produced using an 8th-rank piano wire coater under exactly the same conditions as in Example 10.

The optical characteristics and the initial film of the sample of Example 15 thus obtained were evaluated in the same manner as in Example 1.

(Example 16) A sample of Example 16 was produced using a 16th piano wire coater under the same conditions as in Example 15 except for the above conditions.

The optical characteristics and the initial film of the sample of Example 16 thus obtained were evaluated in the same manner as in Example 1.

(Example 17) As inorganic material particles, a silica sol “EG-ST-ZL” manufactured by Nissan Chemical Industries, Ltd. (φ
0.07 to 0.1 μm) and binder resin: particles =
The mixing ratio of the particles is adjusted so as to be 100: 1900,
The other conditions were exactly the same as those of Example 14, and the sample of Example 17 was produced.

With respect to the thus obtained sample of Example 17, the optical characteristics and the initial film were evaluated in the same manner as in Example 1.

Example 18 Binder Resin: Particle = 10
The blending ratio of the particles was adjusted to be 0: 900, and a sample of Example 18 was produced in the same manner as in Example 17.

The samples of Example 18 thus obtained were evaluated for optical characteristics and initial film in the same manner as in Example 1.

(Example 19) Binder resin: particles = 10
The blending ratio of the particles was adjusted to be 0: 400, and a sample of Example 19 was produced in the same manner as in Example 17.

The optical characteristics and the initial film of the sample of Example 19 thus obtained were evaluated in the same manner as in Example 1.

(Example 20) Binder resin: particles = 10
The blending ratio of the particles was adjusted to be 0:90, and
In the same manner as in Example 7, a sample of Example 20 was produced.

The optical characteristics and the initial film of the sample of Example 20 thus obtained were evaluated in the same manner as in Example 1.

(Example 21) Binder resin: particles = 10
The mixing ratio of the particles was adjusted so as to be 0:67, and Example 1 was used.
In the same manner as in Example 7, a sample of Example 21 was produced.

With respect to the sample of Example 21 thus obtained, the optical characteristics and the initial film were evaluated in the same manner as in Example 1.

Comparative Example 1 A sample of Comparative Example 1 was prepared in which a TCO film was formed on one surface of a glass substrate having the same flat surface as in Example 1 and no antiglare film was formed on the other surface.

The optical characteristics of the sample of Comparative Example 1 thus obtained were evaluated in the same manner as in Example 1.

(Comparative Example 2) FIG. 8 is a sectional view showing a schematic configuration of another example of a conventional solar cell module.

Referring to FIG. 8, in this solar cell module, a reinforced embossed glass 11 having an uneven shape formed by embossing on a semiconductor layer forming surface side is used as a glass substrate.

The tempered embossed glass 11 used in this conventional solar cell module was used as a sample of Comparative Example 2,
The sample of Comparative Example 2 was also irradiated with light from the direction opposite to the direction in which the irregularities were formed.
The optical characteristics were evaluated.

Examples 1 to 21 described above and Comparative Examples 1 to
The film forming conditions of the anti-glare film of Sample 2 and the evaluation result were
The results are shown in Tables 2 to 4.

[0142]

[Table 2]

[0143]

[Table 3]

[0144]

[Table 4]

[0145]

As described above, since the solar cell module according to the present invention is provided with the anti-glare film on the light incident surface of the transparent insulating substrate, problems such as light pollution due to light reflection are effectively prevented. You. In particular, according to the present invention, the antiglare film can effectively utilize sunlight without reducing the amount of incident light to such an extent that it affects practically. Further, since the inorganic material particles are less likely to deteriorate, a solar cell module excellent in weather resistance can be obtained.

The method for manufacturing a solar cell module according to the present invention comprises the steps of: forming an element portion on the surface of a transparent insulating substrate;
Since the anti-glare film is formed, the appearance of the solar cell module can be improved so as to prevent glare and light pollution without using expensive template glass or the like as a substrate.
Also, by forming an anti-glare film at the end,
The above-described improvement in appearance can be achieved without any change in a conventional basic solar cell module manufacturing process.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a schematic configuration of a solar cell module according to a first embodiment of the present invention.

FIG. 2 is a partially enlarged cross-sectional view showing a part of an antiglare film of an example of a solar cell module according to the present invention.

FIG. 3 is a partially enlarged cross-sectional view showing a part of an antiglare film of another example of the solar cell module according to the present invention.

FIG. 4 is a cross-sectional view illustrating an example of a method for manufacturing a solar cell module according to the present invention.

FIG. 5 is a cross-sectional view illustrating an example of a method for manufacturing a solar cell module according to the present invention.

FIG. 6 is a cross-sectional view for explaining another example of the method for manufacturing a solar cell module according to the present invention.

FIG. 7 is a cross-sectional view illustrating a schematic configuration of an example of a conventional solar cell module.

FIG. 8 is a cross-sectional view illustrating a schematic configuration of another example of a conventional solar cell module.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 transparent insulating substrate 2 transparent electrode layer 3 optical semiconductor layer 4 back electrode layer 5 optical semiconductor element 6 filling resin 7 back cover film 8 frame 9 roller 10 anti-glare film 20 organic binder 30 inorganic material particles Same in each drawing Symbols indicate the same or corresponding parts.

Claims (9)

[Claims] A transparent insulating substrate having first and second surfaces; a first electrode layer formed on the first surface of the transparent insulating substrate; and a first electrode layer formed on the first electrode layer. An optical semiconductor layer; a second electrode layer formed on the optical semiconductor layer; and an antiglare film formed on the second surface of the transparent insulating substrate on which light is incident; The film includes an organic binder and inorganic particles,
Solar cell module. 2. The organic binder according to claim 1, wherein the main component is an acrylic resin, a fluorine resin, a mixed resin thereof, or a resin or a mixed resin thereof.
The solar cell module as described. 3. The acrylic resin has the following molecular structure: (Wherein, R ₁ is an alkyl group having 1 to 10 carbon atoms, R ₂ is a hydrogen atom or a monovalent hydrocarbon group selected from the group consisting of an alkyl group having 1 to 10 carbon atoms, an aryl group and an aralkyl group, a represents 0, 1 or 2) comprising a hydrolyzable silyl group-containing acrylic copolymer containing a group represented by the formula: wherein the fluorine-based resin is a hydroxyl-containing fluorine-based resin,
The solar cell module according to claim 2. 4. The solar cell module according to claim 1, wherein said inorganic material particles are made of silica. 5. The inorganic material particles having a diameter of 1 to 10 μm and a mixing weight ratio of the organic material binder and the inorganic material particles, wherein the weight of the organic material binder is 100, The weight of the particles is between 1 and 10.
The solar cell module as described. 6. The solar cell module according to claim 1, further comprising a film made of an interfacial treatment agent interposed between the transparent insulating substrate and the antiglare film. 7. The solar cell module according to claim 1, wherein the antiglare film has an uneven shape on a surface. 8. The solar cell module according to claim 1, further comprising a surface protective film formed on the anti-glare film. 9. A step of forming a first electrode layer on the first surface of a transparent insulating substrate having first and second surfaces; and forming an optical semiconductor layer on the formed first electrode layer. Forming; forming a second electrode layer on the formed optical semiconductor layer; and forming, on the second surface of the transparent insulating substrate on which light is incident,
Forming an antiglare film including an organic binder and inorganic material particles, wherein the antiglare film includes a first electrode layer, an optical semiconductor layer, and a second electrode layer on a first surface of the transparent insulating substrate. A method for manufacturing a solar cell module, which is formed after forming an electrode layer.