JP2002151718A - Aluminum composite plate having optical power- generating function - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a construction material having an optical power-generating function which provides larger area, less weight, flexibility, and freedom in construction. SOLUTION: A thin-film solar cell is provided in which a heat-resistant resin film layer, a metal electrode layer, an amorphous silicon layer, a transparent electrode layer, and a protective layer are sequentially laminated on the surface of an aluminum laminated plate in which an aluminum sheet is laminated and integrated on both surfaces sandwiching a core material layer. The thin-film solar cells are laminated to provide an aluminum composite plate having the optical power-generating function.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an aluminum composite plate having a photovoltaic function which can be used as a building material to which thin film solar cells are bonded.

[0002]

2. Description of the Related Art In recent years, the development of solar cells for electric power has progressed, and it has become popular to install solar cells on the roof of a house to supply electric power. As another application, attempts of solar power generation for buildings, public facilities, and the like have been active. Also,
Speaking of roofing materials, so-called solar cell tiles integrated with tiles are also on the market.

[0003]

However, solar cells, particularly building-integrated solar cells having a large area, light weight, flexibility and bendability utilizing the features of amorphous silicon thin film solar cells, are still commercially available. Nothing has been transformed. In addition, the appearance of the solar cell panel is so-called ultra-blue in view of the design as a building material for the outer wall, and there are restrictions on the design.

[0004]

SUMMARY OF THE INVENTION Accordingly, the present invention provides an aluminum resin composite plate utilizing the excellent features of a solar cell, particularly an amorphous silicon solar cell, such as large area, light weight, flexibility, and flexibility in construction. The combination is intended to provide a building material having a photovoltaic function. The gist of the present invention is to provide a heat-resistant resin film layer, a metal layer on the surface of an aluminum laminate obtained by laminating and integrating an aluminum sheet on both sides sandwiching a core layer made of any one or more of a polyolefin resin and an inorganic powder. An aluminum resin plate having a photovoltaic function formed by laminating thin-film solar cells formed by sequentially laminating an electrode layer, an amorphous silicon layer, a transparent electrode layer, and a protective layer.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail. The aluminum composite plate of the present invention is obtained by laminating a thin-film solar cell on an aluminum laminated plate obtained by laminating and integrating aluminum sheets on both sides sandwiching a core material layer. The material of the core material of the aluminum laminate here is not particularly limited, but is composed of a thermoplastic resin, a thermosetting resin, an inorganic powdery substance, and the like, but is preferable in terms of moldability and lightness. Is preferably a material mainly composed of a polyolefin resin. Further, the olefin resin may be made of an inorganic filler such as a metal hydroxide to make it flame-retardant. In addition, a binder, a reinforcing fiber, and the like may be added. The matching difference between the core layers is usually 2 to 20 mm, preferably 3 to 15 mm.

The aluminum sheet laminated on both sides sandwiching the core material layer as described above usually has a thickness of 0.1 to 1.
0 mm, preferably 0.2 to 0.8 mm. Such aluminum may be either pure aluminum or an aluminum alloy. At the time of lamination, a known adhesive may be used.

In the present invention, the above-described aluminum laminate functions as a support for the thin-film solar cell. Specifically, a thin-film solar cell is formed by sequentially laminating a heat-resistant resin film layer, a metal electrode layer, an amorphous silicon layer, a transparent electrode layer, and a protective layer on the surface of an aluminum laminate.

The heat-resistant resin film here has a glass transition temperature of usually 200 ° C. or higher. In order to form a solar cell on this heat-resistant resin film, a metal electrode layer, an amorphous silicon layer and a transparent electrode layer are formed by sputtering and CVD. A resin film is required. Examples of the heat-resistant resin film include a polyimide resin, a polyetherimide resin, and a polyetherketone resin, and among them, a polyimide resin film is preferably used.

The metal electrode layer is formed by sputtering silver or aluminum to a thickness of 1 μm or more. The metal electrode functions as a reflection film of the solar cell, and if the thickness is less than 1 μm, cracks occur due to a difference in thermal expansion between the metal electrode and the heat-resistant resin film at the time of bonding with the aluminum resin composite board. Therefore, it is necessary to make the film thickness thicker than the metal electrode of a normal amorphous silicon solar cell. The amorphous silicon layer is formed by plasma CVD in the order of a p-layer (doped with B), an i-layer (non-doped layer), and an n-layer (doped with P). The above three layers of the metal electrode layer and the amorphous silicon layer have a total thickness of usually 200 to 2000 n.
m, preferably 500 to 1000 nm. As the transparent electrode, ITO and SnO ₂ are generally used.
The film is formed to a thickness of 00 nm, preferably 30 to 100 nm.

For the protective layer, a transparent material having excellent weather resistance and durability is used in order to protect the solar cell and effectively absorb sunlight. In the present invention, a fluororesin film (trade name: Tedlar) is preferably used. When a polyolefin resin is used as the core material of the aluminum laminate, the bonding of the aluminum laminate and the thin-film solar cell having the heat-resistant film as a support is preferably performed at a temperature of usually 80 ° C. or lower. In addition, it is necessary to consider the restriction on the use temperature of the adhesive used here. Examples of adhesives that can be used include vinyl acetate, acrylic, urethane, and epoxy adhesives, and vinyl acetate and high molecular weight acrylic adhesives that exhibit an adhesive effect only by evaporating the solvent are preferred.

[0011]

EXAMPLES The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following description unless it exceeds the gist. Example 75 μm polyimide resin film (trade name Kapton)
DuPont) 1.2μ by sputtering
A silver film was formed to a thickness of m. Amorphous silicon was formed on the surface by plasma CVD so as to have a p-layer of 50 nm, an i-layer of 500 nm, and an n-layer of 100 nm. Further, an ITO film was formed on the surface by sputtering so as to have a thickness of 50 nm. The amorphous silicon solar cell prepared as described above was used as an aluminum laminate (Alpolic: aluminum plate thickness 0.5 mm, PE sheet thickness 3.0 m).
m, total thickness 4.0 mm, width 1.2 m, length 2.4 m,
After applying a vinyl acetate-based adhesive to the
It was dried at 0 ° C. and bonded. Thereafter, a fluororesin-based film (trade name: Tedlar) was laminated as a protective layer to prepare an amorphous silicon solar cell panel.
The present amorphous silicon solar cell panel and a white-painted aluminum laminate were combined and arranged, and installed as a component of a building.

[0012]

According to the present invention, it is possible to manufacture a building material having a photovoltaic function having a large area, light weight, flexibility, and excellent construction flexibility. Further, by arranging in combination with an aluminum resin composite plate having a design property and an aluminum resin composite plate to which a solar cell is pasted, it is possible to freely design the exterior of the building with an accent.

Claims (3)

[Claims] 1. A heat-resistant resin film layer, a metal electrode layer, an amorphous silicon layer, a heat-resistant resin film layer, an aluminum silicon layer, and an aluminum sheet laminated and integrated on both sides of a core material layer.
An aluminum composite plate having a photovoltaic function formed by laminating thin-film solar cells formed by sequentially laminating a transparent electrode layer and a protective layer. 2. The aluminum composite plate according to claim 1, wherein the heat-resistant resin film has a glass transition temperature of 200 ° C. or higher. 3. The aluminum composite plate according to claim 1, wherein the metal electrode is silver or aluminum having a thickness of 1 μm.