JP2002231990A - Solar battery panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery panel where a thin film solar battery module can be buried by an injection molding method by using thermoplastic resin without deteriorating the performance of the thin film solar battery module due to a thermal expansion difference, the selectivity of the number and the sizes of cells incorporated in the module and the number of series connections is wide even if the module is manufactured in a curved shape, the number of the series connection wirings of the cells can be reduced and manufacture property is superior, and to provide a manufacturing method. SOLUTION: In the solar battery panel 1, the solar battery modules 2 are stuck to a light incident face side panel 4 and a back side panel 5 by adhesion layers 7 through an elastic layer 6. The coefficient of linear expansion of the light incident face side and back side panels 4 and 5 sandwiching the modules 2 shows a minimum value αm in the direction of the length L of the module and becomes a maximum value α in a vertical direction in the face. The length L and the width W of the module satisfy a specified relational expression.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-made solar cell panel having a high degree of freedom in shape using a solar cell module obtained by forming a thin film semiconductor on a flexible substrate.
More specifically, the present invention relates to a solar cell panel which is highly adaptable to a curved surface of an automobile body, an interior member, a building, or the like, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a solar cell panel installed in a house or the like is composed of a solar cell module for a house typified by a super straight type or the like. A solar cell connected in series or in parallel by a wiring material is sealed between transparent resins, and the surroundings are protected by an aluminum frame between back covers made of a conductive film or the like. However, since the solar cell module composed of a glass plate or an aluminum frame is heavy, it is difficult to process it into a flat and non-rectangular shape, so it is limited to applications where large flat panels are installed in houses or outdoors. Tended to be.

As a solar cell panel having a possibility of solving such a problem of a solar cell panel for a house, there is a solar cell panel made of resin which is lightweight and can be formed into various shapes. As such a resin solar cell panel, for example,
There is one disclosed in Japanese Patent Application Laid-Open No. 9-511117, and one having a configuration as shown in FIG. 6 is known. In FIG. 1, solar cells 101 made of a single-crystal or polycrystalline silicon (Si) substrate are connected in series by a wiring member 102 such as a tin-plated copper foil to form a unit 1.
The solar cell panel 105 is formed by further connecting the units 103 in parallel and enclosing them in a translucent resin structure 104. Further, glass fibers are mixed in the translucent resin structure 104 in order to prevent separation at the solar cell interface due to thermal stress caused by a difference in linear expansion coefficient from the solar cell 101. Is controlled.

[0004] When a curved solar cell panel is to be manufactured using the solar cell panel having the above-described structure,
If the size of the solar cell is reduced, a gently curved panel can be produced even if a single crystal Si substrate solar cell is used. However, as a solar cell or module suitable for manufacturing a curved panel having a larger curvature,
A thin-film solar cell module formed on a flexible substrate such as a heat-resistant resin film such as polyimide or a stainless steel foil can be considered. Examples of such a thin-film solar cell module include those having a configuration as shown in FIG. 7. In this thin-film solar cell module 111, amorphous silicon or Copper indium selenium (CuInS
e ₂ ) is manufactured by sandwiching and laminating a thin film semiconductor 107 such as e ₂ ) between the back electrode film 108 and the transparent conductive film 109, and the solar cell 110 is formed.

Here, in the manufacturing process of a solar cell made of a thin film semiconductor, as shown in FIG. 7, each solar cell can be manufactured in a series connection structure simultaneously with the manufacturing of each solar cell. Since a plurality of solar cells are manufactured as a solar cell module connected in series on the same flexible substrate, unlike the case of the single crystal Si substrate shown in FIG. The step of connecting in series can be omitted. As described above, by the feature of the thin-film solar cell module capable of manufacturing a series connection structure of a plurality of solar cells on the same flexible substrate, the size and the number of built-in solar cells can be changed from the end of the curved panel to the end. Or a series connection structure of several tens of small cells,
Even with a curved panel, there is an advantage that a solar cell panel having various specifications of a large current and a low voltage and a small current and a high voltage can be manufactured, which is not obtained with a single crystal Si cell. On the other hand, in the case of a flat single-crystal Si substrate, the cell from the end to the end of the curved panel cannot be constituted by one cell.

Further, in the conventional solar cell panel shown in FIG. 6, a thermosetting resin such as unsaturated polyester is used as the resin structure 104. However, the resin structure 104 has a curved surface when applied to a curved panel. It has a high degree of freedom in manufacturing to be installed along the shape of the surrounding structure, and the back of the panel is joined to a skeletal structure such as a metal frame, so it is easy to embed screw hole parts and fastening parts in the back of the panel As described above, it is required that a pedestal-like additional shape can be simultaneously manufactured around the panel, and that it has recyclability in consideration of the environment and the like. It is easier to meet such demands by manufacturing by an injection molding method using a thermoplastic resin. Therefore, at least the resin structure on the back side is manufactured by injection molding using a thermoplastic resin, and the configuration in which the above-described thin-film solar cell module on which a plurality of solar cells connected in series are mounted is laminated. Most suitable as a solar panel.

[0007]

However, as a result of studies by the present inventors, as a result of combining the thin film solar cell module with a method of manufacturing a resin structure in which such a thermoplastic resin is molded by an injection molding method. It has been found that the following technical problems occur. That is, the linear expansion coefficient of a resin film such as polyimide or a stainless steel foil used for a flexible substrate of a thin-film solar cell module is 2 × 10 ^−5.
/ ° C or lower, while the linear expansion of the thermoplastic resin is 7 × 1
Since the temperature is 0 ⁻⁵ / ° C. or more, glass fibers having a small linear expansion coefficient are used for the resin structure in order to prevent the thin film semiconductor of the solar cell module from being cracked due to a difference in thermal expansion coefficient and reducing power generation performance. Mixed. However, when the resin structure is molded by the injection molding method, a phenomenon occurs in which the mixed glass fibers are oriented along the flow of the resin when the resin material is injected into the molding die. And, since the mixed glass fiber exerts the strain suppressing effect only in the length direction, in the resin structure in which the glass fiber is oriented as described above, the linear expansion coefficient in the orientation direction of the glass fiber is small. However, the coefficient of linear expansion in the direction perpendicular to the direction of orientation of the glass fibers is almost the same as the coefficient of linear expansion of the matrix resin material, and when the thin film solar cell module is buried by such a manufacturing method, the above-described failure may occur. Yes, there is a problem in durability performance.

[0008] The present invention has been made in view of such technical problems, and a thin film solar cell module is formed by an injection molding method using a thermoplastic resin without deteriorating the performance of the thin film solar cell module due to a difference in thermal expansion. The battery module can be embedded, and even if it is manufactured in a curved shape, the number and size of cells incorporated in the module and the selectivity of the number of series connection are wide, and the number of series connection wiring between cells is excellent, and the productivity is excellent. ,
An object is to provide a solar cell panel and a method for manufacturing the same.

[0009]

Means for Solving the Problems The present inventors have conducted intensive studies to achieve the above object, and as a result, have appropriately controlled the linear expansion coefficient of a resin panel sandwiching a solar cell module, and have obtained the shape of the module. It has been found that the above-mentioned object can be achieved by, for example, specifically controlling the relationship with the elastic layer, thereby completing the present invention.

That is, a solar cell panel according to the present invention is a solar cell panel in which a light incident surface side and a rear surface side of a solar cell module are sandwiched by a thermoplastic resin panel via an elastic layer. The resin panel has transparency, and the light incident surface side and the back side resin panel have substantially the same minimum value of linear expansion coefficient α _m in a specific direction of the panel surface direction, and the panel surface has In the direction substantially perpendicular to the specific direction in the direction, the anisotropy of the linear expansion coefficient having the maximum value of the linear expansion coefficient α in the direction, the light incident surface side and the back side panel, so that the specific direction coincides Are arranged, the solar cell module has two or more solar cells connected in series, and this series connection direction coincides with the specific direction, and in the series connection direction of the solar cell modules Kicking length and a width, the formula and

[0011]

(Equation 3)

[0012]

(Equation 4)

(Where d is the elastic modulus of the elastic layer, E is its thickness, L is the length of the solar cell module in the series connection direction, and W is its width). It is characterized by the following.

[0014] Preferred embodiments of the solar cell panel of the present invention, the linear expansion coefficient minimum value alpha _m of the light-incident side resin panel and the back-side plastic panel 3.1 × ¹⁰ -5 ~4.9 × ^10
-5 (/ ° C.).

Further, in another preferred embodiment of the solar cell panel according to the present invention, the light incident surface side resin panel and the rear surface side resin panel orient the glass fibers on the thermoplastic resin in a direction to minimize the linear expansion coefficient. And the volume fraction of glass fibers is in the range of 40 to 60 vol%.

In still another preferred embodiment of the solar cell panel according to the present invention, the elastic layer comprises a thermoplastic elastomer, a synthetic rubber having a molecular weight between crosslinks of 500 or less, and a thermoplastic resin to which a plasticizer is added. A sheet containing at least one selected from the group consisting of:

Further, according to the method for manufacturing a solar cell panel of the present invention, a resin material containing glass fibers in a temperature range of 150 to 260 ° C. is injected into a cavity for giving a desired shape.
Orienting the glass fibers in this direction of emission, forming a light incident surface side panel and a rear side panel with a minimum linear expansion coefficient in this direction, and then a solar cell module,
The series connection direction coincides with the minimum direction of the coefficient of linear expansion, and a margin equal to or greater than the thickness D of the panel is secured around the light incident surface side panel and the rear side panel. It is characterized by being arranged and sandwiched between panels.

[0018]

According to the first aspect of the present invention, there is provided a solar cell panel, typically between a thin film solar cell module and a light incident surface side resin panel, and between a thin film solar cell module and a back side resin. An elastic layer is provided between the panel and the upper limit of the width of the substantially rectangular thin-film solar cell module, so that the elastic layer can reduce the difference in thermal expansion between the resin panel and the thin-film solar cell module. Therefore, it is possible to suppress the performance of the thin-film solar cell module from deteriorating due to thermal expansion. In addition, since the length direction of the solar cell module coincides with the direction in which the linear expansion coefficients of the light incident surface side and the back side resin panel are minimized, the length can be set longer than the width. Since multiple solar cells can be installed, the degree of design freedom is widened, and the length of the module can be increased, so that the number of solar cell modules embedded in the same solar panel can be reduced so that the number of solar cells can be reduced. Since the lower limit can be set, the wiring of each solar cell module can be reduced.

Further, according to according to the solar panel sections 2, the light incident surface and the back side thereof the minimum coefficient of linear expansion of the resin panel alpha _m is 3.1 × ^{10 -5} ~4.9 × ¹⁰ -5 (/
C), the length L of the thin-film solar cell module can be increased to the length of the solar panel, and a plurality of solar cells can be installed in the module. The advantages can be maximized and wiring between solar cell modules in the panel is not required. Furthermore, according to the solar cell panel according to claim 3, the linear expansion rate of the minimum value alpha _m of 4 × 10 ^-5 ~
By setting the range to 4.9 × 10 ⁻⁵ (/ ° C.), the advantages of the above-described thin-film solar cell module can be more effectively utilized, and a solar cell panel that does not require wiring between solar cell modules in the panel can be obtained. Produced with good yield.

According to the solar cell panel of the fourth aspect, the light incident surface side and the back side resin panel are produced by orienting glass fibers in a direction of minimizing the coefficient of linear expansion of the thermoplastic resin. 40-60vol% of glass fiber content
With the above range, the advantages of the thin-film solar cell module described above can be utilized, and a solar panel that does not require wiring between the solar cell modules in the panel can be manufactured using a recyclable thermoplastic resin, thereby reducing the environmental burden. Can be reduced. Further, according to the solar cell panel of the fifth aspect, by setting the glass fiber content to 40 to 50%, the advantages of the thin film solar cell module can be further utilized, and wiring between the solar cell modules in the panel can be achieved. A solar cell panel which does not require a high reproducibility can be obtained using a recyclable thermoplastic resin.

Further, according to the solar cell panel of the present invention, as the elastic layer, a thermoplastic elastomer, a synthetic rubber having a molecular weight between crosslinks of 500 or less, a thermoplastic resin to which a plasticizer is added, and an arbitrary mixture thereof. By using a sheet containing, a plurality of solar cells can be installed in a thin-film solar cell module, the degree of design freedom in specifications can be increased, and the wiring of each solar cell module can be reduced.

Further, according to the method for manufacturing a solar cell of the present invention, the advantages of the above-mentioned thin-film solar cell module can be utilized, and the solar cell panel which does not require wiring between the solar cell modules in the panel can be recycled. It can be manufactured by an injection molding method which is excellent in mass productivity using a plastic resin.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a solar cell panel and a method of manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings. In addition, in this specification, "%" shows a mass percentage unless otherwise specified.

1 (a), 1 (b) and 1 (c) show an embodiment of a solar cell panel of the present invention, wherein (a) is a perspective view and (b) is an arrow in FIG. FIG. 3C is a plan view as viewed from a view A (light incident surface side), and FIG. 3C is a cross-sectional view taken along line BB ′ in FIG. In these figures, a thin-film solar cell module 2 is connected by a conductor wire 3 such as a tin-plated copper foil and is covered and sandwiched between a light incident surface side panel 4 and a back side panel 5 to form a curved resin solar cell. Panel 1 is constituted.

FIG. 1 is a cross-sectional view of the solar cell panel 1.
As shown in (c), the thin-film solar cell module 2 is bonded to the light incident surface side panel 4 and the back side panel 5 via an adhesive layer 7 via an elastic layer 6. On the other hand, the thin-film solar cell module 2 has a configuration shown in FIGS. 2A and 2B, and is formed on a flexible substrate 8 such as a polyimide, polyamide, or polyester heat-resistant resin film or a stainless steel foil. Amorphous silicon or CuInSe ₂
A solar cell 12 is formed by sandwiching a thin-film semiconductor 9 such as the above with a back electrode film 10 and a transparent electrode film 11. In the present embodiment, one or more solar cells 12 can be manufactured by connecting one or more of them in series on the same substrate, and the power generation characteristics of the solar cells 12 are large current / low voltage, small current / high voltage, etc. It has a degree of freedom that can be set to the specifications.

Here, the material and properties of each member will be described. First, the light incident surface side panel 4 is desirably made of a recyclable thermoplastic resin.
A material in which glass fibers are oriented and dispersed in acryl or polycarbonate capable of securing a visible light transmittance of 80% or more to impart anisotropy to the coefficient of linear expansion is used. As a glass fiber, generally, the diameter is 3 to 25 μm and the length is 3
５０50 mm and a coefficient of linear expansion of 5 × 10 ⁻⁶ (/ ° C.) are used.
The flowability of the raw material is better when the thickness is 9 mm or less.

It is also desirable to use a thermoplastic resin for the back panel 5 for the same reason. In addition to the above-mentioned materials, a glass fiber is oriented and dispersed in an ABS resin or a polypropylene (PP) resin. One having anisotropy in the coefficient of linear expansion is used. Note that the definition of the coefficient of linear expansion used in this specification conforms to the provisions of JIS K7197-1991.

The thickness of the elastic layer 6 (FIG. 1)
The symbol d) in (c) may be the same on the light incident surface side and the back side, but sufficient softness for covering the thin-film solar cell module 2 and also sealing the gap of the thin-film solar cell module 2 at the same time. Preferably have a thickness and an elastic modulus of 5
It is desirable to use one having a thickness d of not more than MPa and a thickness d of the portion of the thin film solar cell module after panel lamination of not less than 0.1 mm. In addition, from the viewpoint of the amount of transmitted light, the total thickness of the panel, the weight, and the like, the thickness (d) is desirably 5 mm or less. As an elastic body having an elastic modulus of 5 MPa or less, a rubber-modified thermoplastic resin, a thermoplastic elastomer, and a molecular weight between crosslinks of 500 or more from the viewpoint of ease of molding, cost, durability, and adhesion to a resin panel. Or a thermoplastic resin to which a plasticizer is added, and an arbitrary mixture thereof. The elastic modulus used in the present specification is JIS.
K7113-1995 (rubber is JIS K6245-
1993).

The rubber-modified thermoplastic resin includes a polymer of polymethyl methacrylate and acrylates or silicone, a polymer of vinylidene fluoride and hexafluoropropylene, and a polystyrene of ethylene propylene rubber. Dispersed materials, and those in which ethylene propylene rubber or the like is dispersed in syndiotactic polypropylene, and the like can be given. Examples of the thermoplastic elastomer include styrene-based, olefin-based, urethane-based, and polyester-based thermoplastic elastomers. Examples of the synthetic rubber having a molecular weight between crosslinks of 500 or more include ethylene propylene rubber, acrylonitrile butadiene rubber, butyl rubber, chlorosulfonated polyethylene, acrylic rubber, fluorine rubber, and silicone rubber. If the molecular weight between crosslinks is less than 500, the fluidity is so high that the structure cannot be held, so that a molecular weight of 500 or more is preferable. Examples of the thermoplastic resin to which a plasticizer is added include polyvinyl chloride and polyvinylidene chloride, and the like.Plasticizers are preferably those with little bleeding or volatilization, and include phthalic acid esters and polyesters. .

The thin-film solar cell module 2 is shown in FIG.
As shown in (b), a plurality of solar cells 12 can be manufactured by connecting a plurality of solar cells 12 in series on the same substrate. Utilizing this feature, the conventional configuration in which individual solar cells are connected by conductor lines in a solar cell panel is replaced with a series connection configuration of solar cells in the same thin-film solar cell module, and connection by conductor lines In order to reduce the number of locations, it is desirable that at least the length L of the thin-film solar cell module 2 in the series connection direction is longer than the width W and that a plurality of solar cells can be mounted (FIG. 2A).

In the present invention, the light incident surface side and the back side panels 4 and 5 on which the thin film solar cell modules are laminated are formed by injecting a thermoplastic resin in which glass fibers are dispersed into a molding die by an injection molding method. At this time, the glass fibers are oriented in the direction of arrow G over the entire surface of the panel in FIG. 1B by a manufacturing method described later utilizing the phenomenon that the glass fibers are oriented in the injection direction. Therefore, the linear expansion coefficients α of the light incident surface side and the rear side panels 4 and 5 are given anisotropy such that they show the minimum value α _m in the direction of arrow G in FIG. 1B.

The thin-film solar cell module 2 is arranged such that the direction of serial connection of the internal solar cells 12 (the direction of length L in FIG. 2A) coincides with the direction of arrow G in FIG. By being sandwiched between the front panel 4 and the rear panel 5, the length L can be set longer than the width W within the range described below.

That is, the solar cell panel of the present invention has the structure shown in FIG.
With the configuration shown in (b), the light incident surface side and the rear side panels 4 and 5 where the thin film solar cell module is sandwiched are provided.
Has a minimum value α _m in the length L direction of the thin-film solar cell module, and has a maximum value α in a vertical direction (the width W direction of the thin-film solar cell module) in the plane. Due to the difference between the linear expansion coefficient of each direction and the linear expansion coefficient of the flexible substrate of the thin-film solar cell module, the thermal stress applied to the flexible substrate is reduced by the above-mentioned elastic layer 6, and the present invention is applied. Use environment of automobiles and outdoor buildings (-40
(130 ° C.), the length L and the width W of the solar cell module are calculated by the following equation to prevent the failure of the solar cell module.

[0034]

(Equation 5)

[0035]

(Equation 6)

(Where d is the elastic modulus of the elastic layer, E is its thickness, L is the length of the solar cell module in the series connection direction, and W is its range). Is desirable. In the expression, the right side is an upper limit value at which the solar cell does not deteriorate in performance due to tensile strain generated in the flexible substrate due to thermal expansion of the panel material having a linear expansion coefficient α _m as shown in the examples. There is an upper limit in the case of panels which right is similarly made linear expansion coefficient alpha _m in formula. In addition, the left side of the expression has a length L and a width W as described above.
This is the lower limit for longer length. Furthermore, the left side of the equation is
The total number of thin-film solar cell modules when a solar cell panel is configured according to the present invention is manufactured without adding glass fibers to a thermoplastic resin regardless of the present invention, and the generated thermal expansion strain is determined only by the thickness of the elastic layer. This is the lower limit value that can be reduced (the number of wiring portions can be reduced) as compared with the case where it is relaxed.

When a panel material is manufactured without adding glass fibers and the generated thermal expansion strain is reduced only by the elastic layer, the linear expansion coefficient of the panel material is determined by the above-described oriented glass fibers. It is equal to the maximum value of the coefficient of linear expansion of the applied panel material. In this case, both the length L and the width W of the thin-film solar cell module must be equal to or less than the upper limit of the equation. In other words, the number of thin film solar cell modules is the smallest when both the length and the width are the upper limit values of the formula and the area per module (the square of the upper limit value) is the largest. In the solar cell panel according to the present invention, the total number of modules is less than this when the area (L × W) of the thin-film solar cell module is larger than this.
It is for a length L set to satisfy the equation,
The width W is

[0038]

(Equation 7)

(L, d, E, α and W in the formula are the same as those described above).

[0040] Further, in the solar cell panel of the present invention, when the length L of the thin-film solar cell module can be set equal to the total length L _p of the minimum linear expansion coefficient becomes the direction of the solar cell panel, as shown in FIG. 3, All the conductor wires for series connection can be omitted, and the solar cell design flexibility of the thin-film solar cell module can be used over the entire panel.

Usually, solar battery panels are used for outdoor buildings and automobiles.
1000mm x 1000mm size
Length L is 1000m
m, it is desirable to be able to set
The minimum value of the linear expansion coefficient α of the entrance surface side and rear side panels 4 and 5_m
Is 4.9 × 10^-5(/ ° C) or less
No. In order to obtain this linear expansion coefficient, it will be shown in a later example.
So that the glass fibers are oriented and dispersed in the thermoplastic resin
In the case where the volume ratio of the glass fiber is
Desirably above. Also disperse the glass fiber
When molding thermoplastic resin by injection molding,
In order to ensure the fluidity of the fat material, the volume content of glass fiber
It is desirable that the rate be 60 vol% or less. Therefore,
Glass fiber volume content is in the range of 40-60 vol%
Is desirable, and the minimum value of the linear expansion α _mIs 3.1 × 10
^-5~ 4.9 × 10^-5(/ ° C)
It is desirable to use In addition, resin is injected by injection molding.
When molding, add a pedestal-shaped additional shape around the panel
In order to form the target shape with good productivity, the glass fiber body
It is more preferable that the volume content is in the range of 40 to 50 vol%.
Desirably, the minimum value of linear expansion α_mIs 4 × 10 ^-5~ 4.9 ×
10^-5(/ ° C)
Is more desirable.

Next, a method for manufacturing a solar cell panel according to the present invention will be described. In order to manufacture the light incident surface side or rear side panel, for example, a female mold 13a and a male mold 13b having the target shape shown in FIG. 4A are prepared. The female mold 13b is provided with a gate 14 for injecting a thermoplastic resin in which glass fibers are dispersed in the cavity. At the time of molding, the thermoplastic resin material is uniformly injected over the entire cavity, As shown in FIG. 14B, it is desirable that the gate 14 has a fan-shaped or expanded shape so as to gradually reach the cavity width so that the glass fibers are oriented in one direction after molding.

Next, as shown in FIG.
And 13b are clamped, and a thermoplastic resin in which glass fibers are dispersed is injected from the gate 14 to obtain the curved panel 5 on the light incident surface side or the rear panel side of the target shape shown in FIG. Regarding the curved panel 5 on the light incident surface side or the back panel side, the volume content of glass fibers is made the same, and the anisotropy and the minimum value of the linear expansion coefficient are made equal. The light incident surface side panel is desirably heated to 150 to 200 ° C. using a transparent resin such as acrylic or polycarbonate and injected into a mold, and the rear side panel is formed of, for example, ABS.
It is desirable that the resin or the like be heated to 170 to 260 ° C. and injected.

In the light incident surface side or rear side panel manufactured by such a manufacturing method, glass fibers are oriented and dispersed,
While anisotropic, such as the linear expansion coefficient in the resin flow direction is minimum alpha _m at the time of molding is applied, in the end portion of the flow near the injection gate and the injection resin stops, disturbed orientation of the glass fibers Therefore, it is desirable that the thin-film solar cell module be disposed so as to avoid the above-described portion by a width corresponding to the panel thickness D.

Next, the thin-film solar cell module sandwiching surface of the light incident surface side or the back side panel manufactured as described above is
The elastic layer 6 is attached by using a two-part cold-setting epoxy adhesive 7. Then, the thin-film solar cell module 2 connected by the elastic conductor wire is sandwiched between them, and similarly laminated and bonded using a two-pack type cold-setting epoxy adhesive (see FIG. 1 (c)). The solar cell panel shown in FIG.

[0046]

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

(Examples 1-3, Comparative Examples 1-3) Size 6
A curved panel having a size of 00 × 600 mm and a radius of curvature of 500 mm was produced by an injection molding method. The light incident side panel is made of glass fiber (linear expansion coefficient 5 × 10 ⁻⁵ (/
C), a thickness of 15 μm, and a length of 15 mm) are oriented and dispersed so as to be 20 vol%.
The same glass fibers were oriented and dispersed in a BS resin so as to be 20 vol%. The linear expansion coefficient, the minimum value 5.7 × ¹⁰ -5 in the orientation direction of the glass fibers in both panels (/
° C) and 7.5 × 10 ^-6 (/ ° C) in the direction perpendicular to the plane. A sheet of an olefin-based thermoplastic elastomer composed of a 0.1 mm thick hard segment: polypropylene, a soft segment: hydrogenated styrene butadiene rubber (elastic modulus E to 5 MPa) on the solar cell module laminated surface (sandwich surface) of these panels. Was adhered using a two-part cold-setting epoxy resin adhesive.

On the other hand, as a thin-film solar cell module,
On a polyimide resin film, one having 10 solar cells made of amorphous silicon thin film semiconductor mounted in series is used for one panel, and the light incident surface side where the elastic layer is attached and The two panels were sandwiched between the rear panels so that the length direction coincided with the direction in which the linear expansion coefficients of both panels were minimized, and the panels were adhered with a two-part cold-setting epoxy resin adhesive. As shown in Table 1, the length L and width W of the solar cell used were 400 mm in length and 200 mm in width, 450 mm in width and 200 mm in width, and 500 mm and 200 mm in width as Examples 1, 2 and 3. did. Further, as Comparative Examples 1, 2, and 3, a length of 400 mm
And width 300mm, length 450mm and width 350mm,
And those having a length of 500 mm and a width of 400 mm were used. In addition, the solar cells in the module used were connected in series at equal intervals of 10 in the module length direction, the length was one-tenth of the module length, and the width was the same as the module. .

Before the endurance test, first, each solar cell panel test piece was subjected to a light intensity A by a solar simulator.
The conversion efficiency was measured by irradiating light equivalent to M1.5 and used as the initial value of each test piece. Next, these test pieces were placed in a thermo-hygrostat, and a heat cycle durability test was performed. This test was performed at room temperature for 0.5 h → 100 ° C for 4.0 h → room temperature for 0.5 h →
1.5h at -40 ° C → 0.5h at room temperature → 70 ° C, 95%
3.0h at RH → 0.5h at room temperature → 1.5h at -40 ° C
Is one cycle, and this was performed for 10 cycles.
After this heat cycle durability test, the conversion efficiency was measured in the same manner as described above, and the performance was compared with the performance before the test. As a result, in Examples 1 to 3 in which the length and width of the module were less than the upper limit values shown in the formulas and formulas, no decrease in performance was observed, but the length or width was shown in the formulas and formulas. In Comparative Examples 1 to 3 using modules exceeding the upper limit,
In each case, the conversion efficiency was lower than before the test, indicating that the solar cell was damaged by the tensile stress due to the difference in linear expansion coefficient.

[0050]

[Table 1]

(Examples 4 to 6, Comparative Examples 4 and 5) A curved panel having a size of 1000 × 1000 mm and a radius of curvature of 500 mm was produced by an injection molding method. The light incident surface side panel is made of glass fiber (linear expansion coefficient 5 × 10 ⁻⁶⁾
(/ ° C.), thickness 15 μm, and length 15 mm) are oriented and dispersed so as to have a volume content as shown in Table 2.
The rear panel was produced by dispersing and dispersing the same glass fiber in an ABS resin so as to have a volume content as shown in Table 2. As shown in Table 2, the volume content of the glass fibers was 60, 50 and 40 vo in Examples 4, 5 and 6, respectively.
1%, and 30 and 20 vol% in Comparative Examples 4 and 5.

The linear expansion coefficient of both panels was 7.5 × 10 ⁻⁵ (//) in a direction perpendicular to the plane of the glass fiber orientation.
° C), and the minimum value shown in Table 2 was shown in the orientation direction of the glass fiber. Trimellitic ester-based tri-2 is used as a plasticizer on the solar cell module laminated surface of these panels.
0.1 mm thick polyvinyl chloride sheet to which 50 phr of ethylhexyl trimellitate was added (elastic modulus E to 3)
MPa) was attached using a two-part cold curing type epoxy adhesive. The thin-film solar cell module uses 20 amorphous silicon thin-film semiconductor solar cells mounted in series on a polyimide resin film and is used in parallel with three parallel connections to one panel at 50 mm intervals. Then, between the light incident surface side and the back side panel to which the elastic layer is attached, the length direction is sandwiched in the center so that the linear expansion coefficient of both panels becomes the minimum direction, and the two liquid Lamination was performed with a cold-setting epoxy resin adhesive. In all the examples and comparative examples in Table 2,
The length L of the solar cell was 950 mm, and the width W was 200 mm.

Before the endurance test, first, each solar cell panel test piece was subjected to a light intensity A by a solar simulator.
The conversion efficiency was measured by irradiating light equivalent to M1.5 and used as the initial value of each test piece. Next, these test pieces were placed in a thermo-hygrostat, and a heat cycle durability test was performed. This test was performed at room temperature for 0.5 h → 100 ° C for 4.0 h → room temperature for 0.5 h →
1.5h at -40 ° C → 0.5h at room temperature → 70 ° C, 95%
3.0h at RH → 0.5h at room temperature → 1.5h at -40 ° C
Is one cycle, and this was performed for 10 cycles.
After this heat cycle durability test, the conversion efficiency was measured in the same manner as described above, and the performance was compared with the performance before the test. As a result, the volume content of the glass fiber was 40 to 60 vol%, and the minimum value of the coefficient of linear expansion of the panel was 3.1 × 10 ^{−5 to} 4.9 × 10 ⁻⁵ (/
° C), no decrease in performance was observed in any of Examples 4 to 6, but in Comparative Examples 4 and 5, which were not produced within the above range, the conversion efficiency was lower than that before the test. This indicated that the solar cell was damaged by the tensile stress due to the difference in linear expansion coefficient.

[0054]

[Table 2]

[0055]

As described above, according to the present invention, the coefficient of linear expansion of the resin panel sandwiching the solar cell module is appropriately controlled, and the shape of the module is specifically controlled in relation to the elastic layer. The thin-film solar cell module can be embedded by an injection molding method using a thermoplastic resin without deteriorating the performance of the thin-film solar cell module due to the difference in thermal expansion. It is possible to provide a solar cell panel and a method of manufacturing the solar cell panel having excellent selectivity of the number and size of cells to be built in and the number of serially connected cells, and having excellent manufacturability to reduce the number of serially connected wires between cells.

That is, in the solar cell module according to the present invention, the configuration is such that an elastic layer is provided between the thin film solar cell module and the light incident surface side and the back side panel, and the upper limit of the width of the thin film solar cell module is set. Since the elastic layer is set so as to reduce the difference in thermal expansion between the panel and the thin-film solar cell module, it is possible to prevent the performance of the thin-film solar cell module from deteriorating due to the thermal expansion. In addition, since the length direction of the solar cell module and the direction in which the linear expansion coefficients of the light incident surface side and the back side panel are minimized coincide with each other, the length can be set longer than the width, and a plurality of modules can be provided in the module. The solar cells can be set, the degree of design freedom can be improved, and the longer length reduces the number of solar cell modules embedded in the same solar cell panel. The effect that the number of wirings can be reduced is obtained.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing one embodiment of a solar cell panel of the present invention.

FIG. 2 is an explanatory diagram showing a configuration of another embodiment of the solar cell panel of the present invention as viewed from a light incident surface.

FIG. 3 is a plan view of a thin-film solar cell module used for the solar cell panel of the present invention.

FIG. 4 is an explanatory view of an injection mold used for manufacturing a resin panel on a light incident surface side and a rear surface side, which are components of the solar cell panel of the present invention.

FIG. 5 is an explanatory view showing a production example of a resin panel on a light incident surface side and a back surface side, which is a component of the solar cell panel of the present invention.

FIG. 6 is a perspective view showing a configuration example of a conventional resin-based solar cell panel.

FIG. 7 is a perspective view illustrating a configuration example of a thin-film solar cell module.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1,105 Solar cell panel 2,111 Thin film solar cell module 3,102 Conductor wire 4 Light incidence surface side panel 5 Back side panel 6 Elastic layer 7 Adhesive layer 8,106 Flexible substrate 9,107 Thin film semiconductor 10,108 Back surface Electrode layer 11, 109 Transparent electrode layer 12, 110 Thin-film solar cell 13a, 13b Mold 14 Resin injection gate 16 Resin injection gate 101 Single-crystal Si solar cell 103 Solar cell series connection unit 104 Translucent resin structure Body Lp The direction in which the linear expansion coefficient of the solar cell panel shows the minimum value L The length of the solar cell module in the direction of connecting the built-in cells in series W The width of the solar cell module d The thickness of the elastic layer at the position facing the solar cell module D Thickness of light incident surface and rear panel

Claims (7)

[Claims] 1. A solar cell panel in which a light incident surface side and a back surface side of a solar cell module are sandwiched between thermoplastic resin panels via an elastic layer, at least the light incident surface side resin panel has transparency. The light incident surface side and the back side resin panel each have substantially the same minimum value of linear expansion coefficient α _m in a specific direction in the panel surface direction, and substantially the same as the specific direction in the panel surface direction. Exhibiting an anisotropy of linear expansion coefficient having a maximum value of linear expansion coefficient α in a direction orthogonal to the direction, wherein the light incident surface side and the rear side panel are arranged so that the specific direction coincides with the solar cell; The module has two or more solar cells connected in series, and the serial connection direction coincides with the specific direction, and the length and the width of the solar cell module in the series connection direction are expressed by the following formula and (Equation 1) (Equation 2) (Where d is the elastic modulus of the elastic layer, E is its thickness, L is the length of the solar cell module in the series connection direction, and W is its width). And solar panel. Wherein the linear expansion coefficient minimum value alpha _m of the light-incident side resin panel and the back-side plastic panel 3.1 × 10 ^-5 ~
2. The solar cell panel according to claim 1, wherein the solar cell panel is set in a range of 4.9 × 10 ⁻⁵ (/ ° C.). 3. The linear expansion coefficient minimum value α _{m is set} to 4 × 10 ⁻⁵ or ^less .
The solar cell panel according to claim 2, wherein the solar cell panel is set in a range of 4.9 × 10 ⁻⁵ (/ ° C.). 4. The light incident surface side resin panel and the back side resin panel are obtained by mixing glass fibers in a thermoplastic resin while orienting the glass fibers in a direction that minimizes the coefficient of linear expansion thereof.
The solar cell panel according to claim 2, wherein a volume content of the glass fiber is in a range of 40 to 60 vol%. 5. A glass fiber content of 40 to 50 vol.
5. The solar cell panel according to claim 4, wherein the ratio is in the range of%. 6. The method according to claim 1, wherein the elastic layer is a thermoplastic elastomer,
At least one selected from the group consisting of a synthetic rubber having a molecular weight between crosslinks of 500 or less and a thermoplastic resin added with a plasticizer.
The solar cell panel according to any one of claims 1 to 5, wherein the solar cell panel is a sheet containing species. 7. 150 to 260 ° C. containing glass fiber
A resin raw material having a temperature range of 5 mm is injected into a cavity for imparting a desired shape, and the glass fibers are oriented in the injection direction to form a light incident surface side panel and a rear side panel having a minimum linear expansion coefficient in this direction. Then, the solar cell module, the series connection direction is aligned with the minimum direction of the coefficient of linear expansion, and the peripheral portion of the light incident surface side panel and the back side panel more than the thickness D of the panel A method for manufacturing a solar cell panel, comprising arranging and sandwiching between panels so that a margin is secured.