JP2001203378A - Solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module having satisfactory waterproofness in which optical pollution due to reflection on a transparent surface substrate is prevented. SOLUTION: The solar cell module comprises a semiconductor photoelectric conversion layer, a filing resin 6 and a rear surface cover 7 provided on the first major surface of a transparent surface substrate 1, and a primer layer 40 and an anti-glare film 10 formed on the second major surface of the substrate 1. The anti-glare film 10 contains particles 30 of organic or inorganic material and a binder 20 of organic material, and the primer layer 40 contains an acrylic resin and acts to enhance bonding performance between the anti-glare film 10 and the substrate 1.

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, and more particularly to an antiglare method for a transparent surface substrate in a solar cell module.

[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. In addition, with the mass production of solar cells, the reduction of manufacturing costs is progressing. In the past, the form of using solar cells was mainly the form of large-scale solar cell power plants or 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 to use the energy in the same manner as electricity from a conventional electric power company.

[0003] In such a solar cell module panel, a plurality of photovoltaic cells are sealed with a resin between a front cover glass and a back cover film. As a front cover glass, a transparent glass having a mirror surface was used, and thus a problem of light pollution due to reflection occurred. 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. Also, JP-A-11-74552
Japanese Patent Application Laid-Open Publication No. H11-163873 discloses a technique for forming an uneven shape on a light incident surface of a glass substrate.

On the other hand, as a structure capable of greatly reducing the cost of a solar cell module, a transparent electrode layer, a thin film semiconductor layer, and a back electrode layer are sequentially formed on a transparent insulating substrate having the same size as the front cover glass while patterning. The substrate-integrated thin-film solar cell module obtained as described above is used. The feature of this structure is that between the wiring of each photovoltaic cell,
In addition, there is no need for a sealing resin to be filled between the cell and the cover glass, which is advantageous not only in cost, but also in that there is no characteristic deterioration due to yellowing of the resin.

FIG. 8 is a sectional view showing a schematic structure of an example of a conventional solar cell module. 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.
The semiconductor device includes an optical semiconductor layer 3 formed thereon and a back electrode layer 4 formed on the optical semiconductor layer 3. The transparent electrode layer 2, the optical semiconductor layer 3, and the back electrode layer 4, which are sequentially stacked, are separated into a plurality of photoelectric conversion cells 5, and the respective cells 5 are electrically connected to each other in series and integrated.

Further, this solar cell module is sealed and protected by a filling resin 6 and a back cover film 7 in order to protect the photoelectric conversion cells 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 film forming process such as plasma CVD and sputtering, as well as a laser scribing process for integration. 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.

[0008]

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, the use of a template glass having a light-scattering surface has been studied as a substrate, but when using such a substrate, detailed examination of the texture specification of the template glass or special laser scribe 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 solution such as a high temperature or highly reactive hydrofluoric acid. Therefore, 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 semiconductor layer and the electrode layer cannot be cut from the glass substrate surface by laser scribing. 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, since there is a difference in the color tone of the glass substrate depending on the lot, there is also a problem that the color tone differs in the completed solar cell module.

An object of the present invention is to solve the above-mentioned problems and to provide a solar cell module in which light pollution and the like due to reflection on a light incident surface are effectively prevented and a color tone is unified.

[0013]

According to the present invention, there is provided a solar cell module comprising: a transparent surface substrate having first and second main surfaces; a semiconductor photoelectric conversion layer provided on the first main surface of the substrate; A resin, and a back cover, and a primer layer and an anti-glare film sequentially laminated on the second main surface of the substrate, wherein the anti-glare film includes at least one of organic material particles and inorganic material particles and an organic material binder. The primer layer contains an acrylic resin, and acts to enhance the bonding between the antiglare film and the substrate.

Such a primer layer has a great effect of improving the bonding property between the antiglare film and the substrate when the organic material binder of the antiglare film particularly contains a fluorine resin. Further, when the fluorine-based resin contained in the organic binder contains a hydroxyl group, the primer layer can more significantly improve the bonding between the antiglare film and the substrate.

[0015] When the acrylic resin contained in the primer layer contains a hydrolyzable silyl group, it is possible to greatly improve the bonding property particularly between the antiglare film and the substrate.

The primer layer containing an acrylic resin can significantly improve the bonding between the antiglare film and the substrate, particularly when the substrate is a glass plate.

[0017] The semiconductor photoelectric conversion layer included in such a solar cell module may include a plurality of interconnected single-crystal photoelectric conversion cells or a layer including an integrated plurality of thin-film photoelectric conversion cells. .

[0018]

FIG. 1 is a sectional view showing a schematic configuration of a solar cell module as an example of an embodiment according to the present invention. In each drawing of the present application, the dimensional relationship is appropriately changed for clarification and simplification of the drawing, and does not reflect the actual dimensional relationship. In particular, fine irregularities on the surface of the antiglare film are exaggerated.

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 The semiconductor device includes the formed optical semiconductor layer 3 and the back electrode layer 4 formed on the optical semiconductor layer 3. The transparent electrode layer 2, the optical semiconductor layer 3, and the back electrode layer 4, which are sequentially laminated, are separated into a plurality of photoelectric conversion cells 5, and the cells 5 are electrically connected to each other in series.

The solar cell module is sealed and protected by a filling resin 6 and a back cover film 7 to protect the photoelectric conversion cells 5. Further, the solar cell sealed in this manner is provided with a frame 8 used for holding the transparent insulating substrate 1, the filling resin 6, the back cover film 7, and the like, and for mounting the frame on a roof or the like. ing. However, the frame 8 is not indispensable to the solar cell, and the solar cell may be one without a frame or embedded in a tile, and is not limited by the frame.

On the light incident surface side of the transparent insulating substrate 1, as a feature of the present invention, a barrier including at least one of organic material particles and inorganic material particles 30 and an organic material binder 20 via a primer layer 40. The glare film 10 is formed. An uneven shape is formed on the surface of the anti-glare film 10. In addition,
A surface protective film 50 having a flat surface may be formed on the anti-glare film 10 on which the uneven surface shape is formed, for the purpose of preventing contamination and the like.

The primer layer 40 acts to improve the bonding between the transparent insulating substrate 1 and the anti-glare film 10. An acrylic resin can be preferably used as a material for such a primer layer. Further, among acrylic resins, a resin containing a hydrolyzable silyl group can be particularly preferably used.

The anti-glare film 10 may be one that diffusely reflects light incident from the light incident surface side, or one that improves the transmittance of incident light to reduce reflection.

Organic binder 20 constituting antiglare film 10
As a characteristic of the resin that can be used as a resin, the resin has sufficient weather resistance, good light transmittance, and a temperature that does not deteriorate the solar battery cell in the film forming process, specifically, 20 ° C.
A material capable of forming a film at 0 ° C. or lower, more preferably 150 ° C. or lower is preferably used.

As a material satisfying such characteristics, it is preferable to contain at least one of an acrylic resin and a fluorine resin, and the content is 50% by weight or more, preferably 80% by weight or more, and 95% by weight or more. More preferred.

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.

The acrylic resin is more preferably a resin containing a hydrolyzable silyl group, 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.

Specific examples of the alkoxysilane vinyl monomer include:

[0029]

Embedded image

And the like. These alkoxysilane vinyl monomer units are preferably from 5 to 90% by weight, more preferably from 20 to 80% by weight, particularly preferably from 30 to 7% by weight, of the hydrolyzable silyl group-containing vinyl copolymer.
0% 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 fluororesin, a hydroxyl group may be further added.
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 hydroxyl group-containing fluorine resin or resin composition include Lumiflon manufactured by Asahi Glass Co., Ltd .; (Registered trademark).

Lumiflon has the following basic physical properties.

[0035]

[Table 1]

On the other hand, the organic material particles 3 constituting the anti-glare film 10
As 0, an acrylic resin, a fluororesin, a polyethylene wax, a mixture of at least two or more of these, or a resin containing these resins or a mixed resin as a main component can be used. Specifically, for example, MBX-8 made of PMMA (polymethyl methacrylate) of φ8 μm manufactured by Sekisui Chemical, average φ15 μm
m, SE480-10T manufactured by Kusumoto Chemicals, which is made of PE (polyethylene) having a maximum diameter of 30 μm, or the like can be used.

As the inorganic material particles 30 constituting the anti-glare film 10, those made of silica can be 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 can be used.

The diameter of the organic or inorganic particles 30 is preferably 0.05 to 200 μm, more preferably 0.5 to 200 μm.
-100 μm, particularly preferably 1-10 μm. If the diameter of the particles 30 is in this range, the degree of reflection can be reduced.

The weight ratio of the organic material binder 20 to the organic material or inorganic material particles 30 is such that when the particle size is less than 1 μm, the weight of the particles is 50 to 2,000 with respect to the weight of the organic material binder of 100. It is preferable that there be 1
It is preferably from 00 to 1500. On the other hand, the particle diameter of the organic or inorganic material is 1 μm or more, preferably 1 to 10 μm.
When the weight ratio of the organic material binder and the particles is 0.1 to 98, more preferably 1 to 50, particularly 1 to 10 as the weight of the particles with respect to the weight of the organic material binder of 100.
Is preferred. If the particle size is too small, the antiglare effect of the present invention will not be sufficiently exhibited, and if the particle size is too large, dispersibility in the binder resin will be 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 an enlarged sectional view showing a part of the anti-glare film 10 as an example of the solar cell module according to the present invention. Although not shown, the antiglare film may be a single layer, or an antiglare film having different materials, shapes, and thicknesses may be superposed on multiple layers to improve the antiglare effect and the transmittance. It may be. Anti-glare film 10 of solar cell module shown in FIG.
In the above, the organic material or 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 an enlarged sectional view showing a part of an antiglare film 10 of another example of the solar cell module according to the present invention. In the anti-glare film 10 of the solar cell module, the organic material or inorganic material particles 30 are arranged in the organic material binder 20 so that the stacking thereof is changed. With such a structure, the antiglare effect can be increased.

The layer of the organic or inorganic particles may be a single layer or a multilayer on the entire surface of the formed antiglare film, or a single layer and a multilayer may be mixed. .

By forming the anti-glare film 10 on the light incident surface side of the transparent insulating substrate 1 as described above, the solar light incident on the solar cell module contributes to power generation for the most part. 2-4 of incident light reflected from the surface
A component of about% is irregularly reflected in an unspecified direction. The diffusely scattered sunlight is not a parallel ray. Therefore, the light diffusely reflected from the solar cell module is in a blurred state as a whole, and does not feel dazzling when the solar cell is directly viewed.

In the solar cell module according to this embodiment, the transparent electrode layer 2 is made of ITO, Sn
A conductive material that can transmit light, such as O ₂ , or a stacked body of these materials, such as ITO / SnO ₂ or ZnO, can be 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 as an ni type, pn type, MIS type, heterojunction type, homojunction type, Schottky barrier type, or a combination thereof can be 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.

The back electrode layer 4 may be a metal or a composite film of a metal and a metal oxide.

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

In this embodiment, a thin-film solar cell module has been described. However, it goes without saying that the present invention can be applied to a single-crystal solar cell module.

Next, a method for manufacturing the solar cell module of the first embodiment shown in FIG. 1 will be described. First, a transparent electrode layer 2 is formed on a surface of the transparent insulating substrate 1 which is different from the light incident surface.
The optical semiconductor layer 3 and the back electrode layer 4 are sequentially formed. 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 laser processing, etching, lift-off, or the like after forming the film by vapor deposition or sputtering.

After the photoelectric photoelectric conversion cell 5 composed of the transparent electrode layer 2, the optical semiconductor layer 3 and the back electrode layer 4 is formed on the transparent insulating substrate 1 in this manner, to protect them,
Sealed and fixed with the filling resin 6, and the back cover film 7
Attach.

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 photoelectric conversion cells 5 are formed. The formation of the antiglare film 10 is possible at any time after the back electrode layer is formed and scribed,
Immediately after that, after sealing the back surface, or after attaching the terminal box,
After the solar cell is installed on the roof or the like, the method is not particularly limited, though it depends on the coating method. At this time, a primer layer 40 is interposed between the transparent insulating substrate 1 and the anti-glare film 10. By interposing such a primer layer 40, the bonding strength between the transparent insulating substrate 1 and the anti-glare film 10 is increased.

In this embodiment, the anti-glare film 10 is formed after the formation of the photoelectric conversion cell 5. Conversely, if the photoelectric conversion cell 5 is formed after the formation of the anti-glare film 10, if laser irradiation is performed during the formation of the photoelectric conversion cell 5, the focus may be out of focus, or the formation of the photoelectric conversion cell 5 may be difficult. In this case, there is a possibility that a problem that a vacuum chamber for plasma CVD cannot be used may occur.

FIGS. 4 and 5 are cross-sectional views illustrating an example of a method for manufacturing a solar cell module according to the present invention, and show an example of a method for forming an antiglare film 10. First, referring to FIG. 4, after forming a primer layer 40 on a light incident surface of a transparent insulating substrate 1 of a sealed solar cell module, an organic material binder mixed with organic material or inorganic material particles 30 is used. The coating material 20 is applied. At this time, particles 30
When the size of is large, as shown in FIG. 5, when the binder coating material 20 is formed, an uneven shape is formed on the surface of the antiglare film 10 due to the distribution of the particles 30.

FIG. 6 is a cross-sectional view for explaining another example of the method of manufacturing the solar cell module according to the present invention, and shows another example of the method of forming the antiglare film 10. That is, after applying the organic binder coating material 20 on the primer layer 40, the roller 9 around which a cloth having a predetermined pattern shape is wound is moved in the direction of arrow B while rotating as shown by arrow A. After transferring the predetermined pattern,
By forming the binder coating material 20, the anti-glare film 10 is formed.
An irregular shape can be formed on the surface of the substrate.

As a method of forming an 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 coating material and embossing or the like is used. In addition to the method of forming a film after molding, the surface can be formed in an uneven shape by devising the shape of the nozzle when applying the binder coating material.

Since the anti-glare film 10 formed as described above covers the entire surface of the glass substrate 1 via the primer layer 40, a difference in the color tone of the glass substrate 1 due to variations among manufacturers and lots is masked. It is also possible to enhance the aesthetic appearance by unifying the color tone between the plurality of solar cell modules arranged on the roof.

FIG. 7 is an enlarged sectional view showing a part of the antiglare film 10 of still another example of the solar cell module according to the present invention. In the above, an example in which fine irregularities are formed on the surface of the anti-glare film 10 has been mainly described. However, even if the surface of the anti-glare film 10 is flat as shown in FIG. Depending on the difference in the refractive index of the particles, an antiglare effect may be exhibited.

[0059]

EXAMPLES In the following, an example in which an antiglare film is formed on a glass substrate will be described with reference to a result of evaluation of optical characteristics and bonding properties, together with a reference example.

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

First, in order to form a primer layer, 5
6.6 parts by weight of methyl methacrylate, 30.7 parts by weight of butyl acrylate, 11.8 parts by weight of γ-methacryloxypropyltrimethoxysilane, 0.9 parts by weight of acrylamide, 17.9 parts by weight of xylene , And after completion of the dropwise addition of the mixture containing 1.0 part by weight of 2,2-azobisisobutylnitrile, 0.5 part by weight of 2,2-azobisisobutylnitrile and 8.1 parts by weight of toluene are added over 1 hour. The mixture was rapidly dropped, and after completion of the dropping, was aged at 110 ° C. for 2 hours and then cooled, and xylene was added to the resin solution to adjust the solid content concentration to 50%. The number average molecular weight of the obtained resin was 15,000.

In order to form an anti-glare film on the primer layer formed of this resin, Lumiflon LF-200 manufactured by Asahi Glass Co., Ltd. was used as an organic binder, and silica “OK- manufactured by Degussa Japan” was used as inorganic material particles. 607 ”(φ
2 μm) and dispersed in the organic binder described above. The compounding ratio is as follows: organic material binder: particles = 100: 5
It was prepared so that

The coating material thus obtained was applied on a glass substrate by spraying and dried at room temperature. as a result,
A sample of an example in which a TCO film was formed on one surface of a glass substrate and a primer layer and an antiglare film were formed on the other surface was obtained.

The sample of this example was irradiated with light from the anti-glare film surface side to measure “60 ° gloss”, “20 ° gloss”, and “total transmittance”, and evaluated the optical characteristics. “60 ° gloss” and “20 ° gloss” are defined in JIS.
It was measured according to the specular gloss measurement method of -Z-8741-1983.

As a result, in the sample of this example, the 60 ° gloss was 3 and the 20 ° gloss was 1.

Further, in order to evaluate the bondability between the antiglare film and the substrate in the sample of this example, JIS 5400
An accelerated water resistance test was performed to measure the bondability between the antiglare film and the substrate in boiling water in accordance with JIS.

As a result, in the sample of the example, no peeling was observed between the antiglare film and the substrate even after 50 hours of the accelerated water resistance test.

Reference Example A sample of the reference example was prepared in the same manner as in the above example, except that no primer layer was inserted between the substrate and the antiglare film. When the optical characteristics of the sample of this reference example were measured in the same manner as in the example, the optical characteristics were almost the same as in the example. However, when the accelerated water resistance test was performed on the sample of the reference example, peeling began to occur between the substrate and the antiglare film after only 8 hours.

As is clear from the above, it can be seen that low glossiness can be realized in both the examples and the reference examples while maintaining a sufficient total transmittance desired for a solar cell module. However, it can be seen that the sample of the example in which the primer layer is inserted has properties that can satisfy the water resistance, whereas the sample of the reference example is inferior to the sample of the example in water resistance.

[0070]

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 addition, since the primer layer is inserted between the substrate and the anti-glare film, the water resistance characteristic regarding the peeling of the anti-glare film is sufficient.

Further, in this solar cell module, after forming a photoelectric conversion cell on one main surface of a transparent insulating substrate and then forming an anti-glare film on the other main surface, an expensive template glass or the like can be used as a substrate. Without use, the appearance of the solar cell module can be improved to prevent glare and light pollution. Further, by forming an antiglare film at the end, it is possible to achieve the above-described improvement in appearance without any change in a conventional basic solar cell module manufacturing process.

Further, in the anti-glare film, when both the binder and the particles are made of organic materials, the adhesion between them is good, and the loss of particles and the peeling of the film itself are reduced. On the other hand,
When the anti-glare film is composed of the organic material binder and the inorganic material particles, the anti-glare effect is exhibited without reducing the amount of incident light as much as practically affected, and sunlight can be effectively used for photoelectric conversion. . Further, the inorganic material particles are also excellent in weather resistance since they have little problem of deterioration.

[Brief description of the drawings]

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

FIG. 2 is an enlarged sectional view showing a part of a primer layer and an anti-glare film of an example of a solar cell module according to the present invention.

FIG. 3 is an enlarged sectional view showing a part of a primer layer and 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 sectional view for explaining the effect of the manufacturing method of FIG. 4;

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 an enlarged cross-sectional view showing a part of a primer layer and an antiglare film of still another example of the solar cell module according to the present invention.

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

[Explanation of symbols]

Reference Signs List 1 transparent insulating substrate, 2 (front) transparent electrode layer, 3 optical semiconductor layer (semiconductor photoelectric conversion layer), 4 back electrode layer, 5 photoelectric conversion cell, 6 filling resin (back protection filling layer), 7 back cover film (back) Protective film), 8 frames, 9 (embossed) rollers, 10 anti-glare films, 20 organic binders, 30 organic or inorganic particles, 40
Primer layer, 50 surface protective layer.

Claims (6)

[Claims] A transparent surface substrate having first and second main surfaces; a semiconductor photoelectric conversion layer, a filling resin, and a back cover provided on the first main surface side of the substrate; A primer layer and an anti-glare film sequentially laminated on the second main surface, wherein the anti-glare film contains at least one of organic material particles and inorganic material particles and an organic material binder, and the primer layer is made of an acrylic resin. A solar cell module comprising: a solar cell module that acts to enhance the bonding between the antiglare film and the substrate. 2. The solar cell module according to claim 1, wherein the organic material binder contains a fluorine-based resin. 3. The fluorinated resin contained in the base material binder has a hydroxyl group.
A solar cell module according to item 1. 4. The solar cell module according to claim 1, wherein the acrylic resin contained in the primer layer contains a hydrolyzable silyl group. 5. The solar cell module according to claim 1, wherein the substrate is a glass plate. 6. The semiconductor photoelectric conversion layer according to claim 1, wherein the semiconductor photoelectric conversion layer includes a plurality of interconnected single-crystal photoelectric conversion cells or a plurality of integrated thin-film photoelectric conversion cells.
The solar cell module according to any one of the above items.