JP2003204073A - Solar battery module using frp substrate and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar battery module the rear-surface side protective member of which is lightweight and does not become rusty. <P>SOLUTION: This solar battery module 10A is provided with an FRP substrate 12A on the non lightreceiving surface side and manufactured through a sticking step in which an EVA film 13B is superimposed upon the substrate 12A and stuck to the substrate 12A by heating. The occurrence of bubbling is prevented at the time of sticking the film 13B to the substrate 12A by preheating the substrate 12A before the film 13B is stuck to the substrate 12A. <P>COPYRIGHT: (C)2003,JPO

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 using a FRP (fiber reinforced resin) substrate and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, a solar cell module which directly converts sunlight into electric energy has been attracting attention and being developed from the viewpoint of effective use of resources and prevention of environmental pollution.

As shown in FIG. 3, a solar cell module generally has an EVA (ethylene vinyl acetate copolymer resin) between a glass substrate 11 as a front surface side transparent protection member on the light receiving surface side and a back surface side protection member 12. The solar battery cell, that is, the power generation element 14 such as silicon is sealed by the sealing film of the films 13A and 13B.

In such a solar cell module 10, a glass substrate 11, an EVA film 13A for sealing film, a solar cell 14, a EVA film 13B for sealing film, and a back side protective member 12 are laminated in this order, It is manufactured by degassing under reduced pressure, pre-compressing, then heating to melt EVA, and crosslinking and hardening to bond and integrate them.

Various materials are provided as the back surface side protection member 12 of the solar cell module, but in the roof integrated solar cell module, a steel plate is generally used.

[0006]

A solar cell module using a steel plate as a back side protection member has a problem of rusting. Rusting causes not only the solar cell module but also the roof material. In addition, the heavy weight is disadvantageous in all aspects such as transportation to the site, construction, and maintenance after construction.

It is an object of the present invention to provide a solar cell module in which the back side protection member is lightweight and does not have the problem of rusting.

[0008]

A solar cell module using an FRP substrate of the present invention is provided with an FRP substrate on the non-light-receiving surface side, and an EVA film is superposed on the FRP substrate to heat the FRP substrate. It is characterized by being manufactured through a step of adhering an EVA film.

In the method of manufacturing a solar cell module using the FRP substrate of the present invention, the EVA film is superposed on the FRP substrate arranged on the non-light-receiving surface side and heated to bond the FRP substrate and the EVA film. It is characterized by including a process.

In the present invention, since the FRP substrate is used as the back surface side protection member on the non-light-receiving surface side and the EVA film is heat-bonded to the FRP substrate, the rust resistance is excellent and the weight of the solar cell module can be reduced. Is.

By the way, when the EVA film is heat-bonded to the FRP substrate, as shown in FIGS. 4 (a) (plan view) and (b) (cross-sectional view taken along line BB in FIG. 4 (a)),
The bubbles 3 remain due to foaming at the adhesive interface between the substrate 1 and the EVA film 2, resulting in poor adhesion and significantly impaired appearance. The problem of foaming is that the glass substrate and EV
Although it does not occur at the adhesive interface with the A film, it causes a problem at the adhesive interface between the FRP substrate and the EVA film. In the solar cell module, the EVA film used for sealing the solar cell and F as the back side protection member
If there is a non-adhesive portion with the RP substrate, sufficient moisture resistance cannot be obtained at this portion, which causes deterioration of the solar cell.

By preheating the FRP substrate before adhering the FRP substrate and the EVA film, the problems of poor adhesion and poor appearance due to such foaming can be solved.

That is, when heat-bonding the FRP substrate and the EVA film, the main cause of foaming at the interface between the FRP substrate and the EVA film is that the volatile substance contained in the FRP substrate is volatilized by the heating at the time of bonding. It depends. Therefore, before the bonding, the FRP substrate is preheated to remove the volatile substance in the FRP substrate that causes the foaming in advance, so that the foaming at the bonding can be prevented. (A) (plan view), (b) (B in FIG. 5 (a)
As shown in the cross-sectional view taken along the line B), there is no residual air bubbles due to foaming at the adhesive interface, the appearance is good and the FR has high adhesive strength.
A P substrate / EVA film adhesive can be obtained.

The preheating treatment of this FRP substrate is 50 to 2
It is preferable to carry out at 100C for 1 minute to 10 hours.

In the solar cell module of the present invention, EVA is provided between the glass substrate on the light receiving surface side and the FRP substrate on the non-light receiving surface side.
A solar cell in which solar cells are sealed with a film, and a moisture-proof film is preferably provided between the FRP substrate and the solar cells.

The EVA film of the EVA film used in the present invention preferably has a vinyl acetate content of 10 to 36% by weight, and the EVA film preferably contains a crosslinking agent. Organic peroxides are suitable as the crosslinking agent. The thickness of the EVA film is preferably 50 to 2000 μm.

Such an EVA film is preferably preliminarily pressure-bonded to the FRP substrate and then heated at 50 to 200 ° C. for 1 minute to 10 hours to cross-link and cure the EVA for adhesion. Further, pre-pressing and cross-linking curing may be continuously performed in the same step by applying pressure at 50 to 200 ° C. for about 1 minute to 1 hour.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a solar cell module using the FRP substrate and a method of manufacturing the same according to the present invention will be described in detail below with reference to the drawings.

1 and 2 are sectional views showing an embodiment of the solar cell module of the present invention. In FIGS. 1 and 2, members having the same functions as those shown in FIG. 3 are designated by the same reference numerals.

The solar cell module 10A of FIG. 1 has the same structure as the conventional solar cell module shown in FIG. 3 except that the FRP substrate 12A is used as the back side protection member. In the solar cell module 10B of FIG. 2, a moisture-proof film 15 is further provided between the solar cell 14 and the FRP substrate 12A to enhance the moisture-proof property.

The solar cell module 10A of FIG. 1 comprises a glass substrate 11, an EVA film 13A, and a solar cell 1
4, the EVA film 13B and the FRP substrate 12A are laminated in this order, the laminated body is degassed under reduced pressure and pre-compressed,
It is produced by melting EVA by heating, and by crosslinking and curing, EVA is bonded and integrated. In addition, the solar cell module 10B of FIG.
VA film 13A, solar cell 14, EVA film 13C, moisture-proof film 15, EVA film 13B
The EVA and the FRP substrate 12A are laminated in this order, the laminated body is degassed under reduced pressure, pre-compressed, and then heated to obtain EVA.
It is manufactured by melting and cross-linking and hardening to bond and integrate.

In the present invention, when manufacturing the solar cell modules 10A and 10B in this manner, FR
In order to prevent foaming during heat bonding between the P substrate 12A and the EVA film 13B, it is preferable that the FRP substrate 12A be preheated in advance to remove volatile substances in the FRP substrate 12A. The preheating temperature and preheating time of the FRP substrate 12A are such that the volatile substances in the surface layer portion of the FRP substrate 12A, which is the surface to be adhered, can be removed to such an extent that they do not volatilize under the heating conditions during adhesion. However, the preheating temperature is generally preferably 50 to 200 ° C., although it depends on the material and quality of the FRP substrate 12A, the heating condition at the time of bonding, and the like. If the preheating temperature is lower than 50 ° C, the volatile substances cannot be sufficiently removed, and the heating condition for bonding with the EVA film is usually 200 ° C or lower. Therefore, it is necessary to perform a heat treatment higher than 200 ° C. There is no.

The preheating time is preferably in the range of 1 minute to 10 hours, particularly 10 minutes to 5 hours, and particularly 30 minutes to 4 hours. When the heating temperature is low, it is preferably a relatively long time, and when the heating temperature is high, it is preferably a relatively short time.

After the FRP substrate 12A is preheated, the respective members can be laminated and heat-bonded by a conventional method as described above. That is, the laminated body is vacuum gauge pressure of 1 to 10 Torr (1.
After vacuuming to about 3 × 10 ^{2 to} 1.3 × 10 ³ Pa), pressing is performed at a pressure of 1.013 × 10 ^{4 to} 1.013 × 10 ⁵ Pa for about 1 to 10 minutes to perform pressure bonding, and then 50 ~ 20
It is preferable to heat EVA at 0 ° C. for about 1 minute to 10 hours to cross-link and cure EVA. Also, 1 minute to 1 at 50 to 200 ° C.
Pre-press bonding and cross-linking curing may be continuously performed in the same step by applying pressure for about an hour.

As described above, by pre-heating the FRP substrate 12A prior to the sealing of the solar cell 14, the defective adhesion and appearance due to foaming can be prevented, and the protective performance of the solar cell 14 can be prevented. It is possible to manufacture a high-quality solar cell module having excellent heat resistance.

Next, each member constituting the solar cell module of the present invention will be described.

In the present invention, there is no particular limitation on the FRP substrate 12A as the back side protection member, and general polyester, vinyl ester, epoxy resin type FRP is used.
A substrate may be mentioned, and its thickness is preferably about 1 to 10 mm.

Glass substrate 1 as front surface side transparent protective member
As for 1, a material having a thickness of about 1 to 10 mm is usually used.

As the moisture-proof film 15 used in the solar cell module 10B shown in FIG. 2, a moisture-proof film made of a vapor-deposited film of an inorganic oxide is formed on the surface of a substrate film by CVD (chemical vapor deposition), PVD (reactive vapor deposition), or the like. A film having a layer formed thereon is preferable. With such a moisture-proof film, high moisture-proof property can be obtained, and since it is insulating, there is no problem of leak current.

The base film of the moisture-proof film 15 is not particularly limited as long as it is a heat-resistant film that can withstand the heat and pressure conditions during the production of the solar cell module.
Generally, polytetrafluoroethylene (PTF
E), 4-fluoroethylene-perchloroalkoxy copolymer (PFA), 4-fluoroethylene-6-fluoropropylene copolymer (FEP), 2-ethylene-4-fluoroethylene copolymer ( ETFE), poly 3-fluoroethylene chloride (PCTFE), polyvinylidene fluoride (PVD)
F) and fluororesin films such as polyvinyl fluoride (PVF), various resin films such as polyesters such as polyethylene terephthalate (PET), polycarbonate, polymethylmethacrylate (PMMA) and polyamide, preferably PET films. it can.
This base film may contain two or more of these resins, or may be a laminated film of two or more films. If necessary, various additives such as pigments and ultraviolet absorbers may be impregnated, coated or kneaded on the base film.

The thickness of such a base film is preferably about 5 to 200 μm from the viewpoints of durability, handleability, thinning and the like.

Aluminum oxide and silicon oxide are used as the inorganic oxide constituting the vapor-deposited film of the inorganic oxide as the moisture-proof layer, and silicon oxide is particularly preferable because of its excellent durability under wet heat conditions. is there.

The composition of the silicon oxide vapor deposition film is SiO.
Although it is generally close, SiO _xAnd x is less than 1.7
In the endurance test and the like, the water vapor permeability gradually decreases, and x = 1.
Those exceeding 9 are disadvantageous in terms of productivity and cost.
Therefore, SiO of the silicon oxide vapor deposition film as the moisture-proof layer_xset
It is desirable that the composition is x = 1.7 to 1.9.

If the thickness of this vapor-deposited film is too thin, sufficient moisture resistance cannot be obtained, and if it is too thick, no further improvement effect of moisture resistance can be obtained, but rather cracks easily occur and moisture resistance is poor. This film thickness is 100 because it may decrease.
It is preferably set to 500 Å, particularly 200 to 400 Å.

As the EVA films 13A, 13B and 13C, those obtained by forming the following EVA resin composition into a film are preferable, and the thickness thereof is generally 50 to 200.
It is preferably about 0 μm.

Next, an EVA resin composition suitable as a raw material for forming an EVA film according to the present invention will be described.

The EVA resin used in the present invention preferably has a vinyl acetate content of 10 to 36% by weight, particularly 10 to 33% by weight.

The EVA resin has a high vinyl acetate content,
In particular, when the amount exceeds 40% by weight, the resin becomes very easy to flow during heat crosslinking, and the tackiness is increased to easily cause tacking, resulting in poor handleability.

E containing less than 10% by weight of vinyl acetate
VA resin has poor processability, and the film is too hard, resulting in poor deaeration.

The EVA resin composition used in the present invention has a cross-linking structure by adding a cross-linking agent in order to improve weather resistance. As the cross-linking agent, a radical is generally generated at 100 ° C. or higher. An organic peroxide is used, and in particular, taking into consideration the stability at the time of compounding, one having a decomposition temperature with a half-life of 10 hours of 70 ° C. or higher is preferable. Examples of such an organic peroxide include 2,5-dimethylhexane;
2,5-Dihydroperoxide; 2,5-Dimethyl-2,5-di (t-butylperoxy) hexane; 3-
Di-t-butyl peroxide; t-dicumyl peroxide; 2,5-dimethyl-2,5-di (t-butylperoxy) hexine; dicumyl peroxide; α,
α'-bis (t-butylperoxyisopropyl) benzene; n-butyl-4,4-bis (t-butylperoxy) butane; 2,2-bis (t-butylperoxy) butane; 1,1- Bis (t-butylperoxy) cyclohexane; 1,1-bis (t-butylperoxy) 3,
3,5-Trimethylcyclohexane; t-butyl peroxybenzoate; benzoyl peroxide and the like can be used. The compounding amount of these organic peroxides is generally 5 parts by weight or less, preferably 1 to 3 parts by weight, based on 100 parts by weight of the EVA resin.

Further, a silane coupling agent can be added to the EVA resin as a sealing film for the solar cell for the purpose of improving the adhesive strength with the power generation element. Known silane coupling agents used for this purpose, for example, γ-chloropropyltrimethoxysilane; vinyltrichlorosilane; vinyltriethoxysilane; vinyl-tris-
(Β-methoxyethoxy) silane; γ-methacryloxypropyltrimethoxysilane; β- (3,4-ethoxycyclohexyl) ethyltrimethoxysilane; γ-glycidoxypropyltrimethoxysilane; vinyltriacetoxysilane; γ-mercapto Propyltrimethoxysilane; γ-aminopropyltrimethoxysilane; N-β
Examples thereof include-(aminoethyl) -γ-aminopropyltrimethoxysilane. The compounding amount of these silane coupling agents is generally 5 parts by weight or less, preferably 0.1 to 2 parts by weight, based on 100 parts by weight of EVA resin.

Further, by improving the gel fraction of EVA resin,
A cross-linking aid can be added to the EVA resin in order to improve durability. Known crosslinking aids for this purpose include triallyl isocyanurate; trifunctional crosslinking aids such as triallyl isocyanate, and N
A monofunctional crosslinking aid such as K ester can also be used. The amount of these cross-linking aids to be added is generally EVA resin 1
10 parts by weight or less with respect to 00 parts by weight, preferably 1 to 5
Parts by weight.

Further, for the purpose of improving the stability of the EVA resin, hydroquinone; hydroquinone monomethyl ether; p-benzoquinone; methyl hydroquinone and the like can be added, and the blending amount thereof is generally 100 parts by weight of the EVA resin. It is 5 parts by weight or less.

Furthermore, if necessary, in addition to the above, a colorant, an ultraviolet absorber, an antiaging agent, a discoloration preventing agent and the like can be added. Examples of colorants include inorganic pigments such as metal oxides and powders, and organic pigments such as azo-based, phthalocyanine-based, azi-based, acidic or basic dye-based lakes. Examples of the ultraviolet absorber include 2-hydroxy-4-octoxybenzophenone; benzophenone compounds such as 2-hydroxy-4-methoxy-5-sulfobenzophenone; 2- (2′-hydroxy-5-methylphenyl) benzotriazole and the like. Benzotriazoles; phenyl salsylates; pt-
There are hindered amines such as butylphenyl salsylate. As anti-aging agents, amine-based; phenol-based;
Bisphenyl type; hindered amine type, for example, di-t-butyl-p-cresol; bis (2,2,6,6)
-Tetramethyl-4-piperazyl) sebacate and the like.

An experimental example showing the foaming condition of the FRP substrate at the time of heat-bonding using the EVA film will be given below.

Experimental Example 1 (heat bonding between FRP substrate and EVA film: with preheating) A FRP substrate (glass fiber reinforced polyester substrate) having a thickness of 150 mm × 150 mm × 3 mm was preheated at 150 ° C. for 2 hours and then An EVA film having a thickness of 0.6 mm formed by depositing the EVA resin composition was superposed, pre-pressed under the following conditions, and then heated to crosslink the EVA resin to bond them. [Eva resin composition formulation (parts by weight)] EVA resin (vinyl acetate content 26% by weight): 100 Crosslinking agent (2,5-dimethyl-2,5-bis (t-butylperoxy) hexane): 0. 65 Silane coupling agent (γ-methacryloxypropyltrimethoxysilane): 0.65 UV absorber: 0.03 Anti-yellowing agent: 0.1 [Preliminary pressure bonding] Vacuuming (2 Torr (2.6 × 10 ² Pa )) 2 minutes Press (pressure 1.013 × 10 ⁵ Pa) 8 minutes [heat bonding] 150 ° C., 45 minutes

The FRP substrate / EVA film adhesive obtained had a good appearance with no foaming at the interface between the FRP substrate and the EVA film, and had an adhesive strength of 4.6 kgf / i.
The adhesive strength was as high as n (3.0 × 10 ⁶ Pa).

Experimental Example 2 (Heat Adhesion of FRP Substrate and EVA Film: No Preheating) In Experimental Example 1, the adhesion was performed in the same manner except that the heat treatment of the FRP substrate was not performed prior to the adhesion. A large amount of foaming occurred at the bonding interface between the FRP substrate and the EVA film, so the appearance was significantly impaired, and the bonding strength could not be measured due to foaming.

Experimental Example 3 (Heat Adhesion between Glass Substrate and EVA Film) Adhesion was performed in the same manner as in Experimental Example 2 except that a glass substrate having the same size was used instead of the FRP substrate.
No foaming occurs, and the adhesive strength is 7.0 kg
The value was f / in (4.5 × 10 ⁶ Pa), which was a sufficiently high value.

From these results, foaming at the time of heat-bonding with the EVA film is a problem peculiar to the FRP substrate, and this foaming can be solved by heat-treating the FRP substrate prior to bonding. I know that I can do it.

[0051]

As described above in detail, according to the present invention, the use of the FRP substrate as the back side protection member provides a solar cell module which is lightweight and has no problem of rusting.

In particular, by preheating the FRP substrate prior to heat-bonding the FRP substrate and the EVA film at the time of sealing the solar cell, a high adhesion can be achieved without causing problems such as poor adhesion due to foaming and poor appearance. It is possible to manufacture a quality solar cell module.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a solar cell module of the present invention.

FIG. 2 is a cross-sectional view showing another embodiment of the solar cell module of the present invention.

FIG. 3 is a cross-sectional view showing the configuration of a general solar cell.

FIG. 4 is an FRP when the FRP substrate is not preheated.
It is a figure which shows a board | substrate / EVA film adhesive body, Comprising:
4A is a plan view, and FIG. 4B is a sectional view taken along the line BB of FIG. 4A.

FIG. 5 is a diagram showing an FRP substrate / EVA film adhesive when the FRP substrate is preheated.
5A is a plan view, and FIG. 5B is a cross-sectional view taken along the line BB of FIG.

[Explanation of symbols]

1 FRP substrate 2 EVA film 10,10A, 10B Solar cell module 11 glass substrate 12 Back side protection member 12A FRP substrate 13A, 13B, 13C EVA film 14 Solar cell 15 Moisture-proof film

Claims (20)

[Claims] 1. An FRP substrate is provided on a non-light-receiving surface side of the FR.
A solar cell using an FRP substrate, characterized by being manufactured through a step of adhering the ethylene vinyl acetate copolymer resin (EVA) film on a P substrate and heating the FRP substrate and the EVA film. module. 2. The FRP substrate and EV according to claim 1.
A solar cell module using an FRP substrate, wherein the FRP substrate is preheated before being bonded to the A film. 3. The preheating treatment according to claim 2, wherein
A solar cell module using an FRP substrate, which is performed at 0 to 200 ° C. for 1 minute to 10 hours. 4. The solar cell according to claim 1, wherein the solar cell is sealed between the glass substrate on the light-receiving surface side and the FRP substrate on the non-light-receiving surface side with an EVA film interposed therebetween. A solar cell module using a FRP substrate, which is a solar cell, wherein a moisture-proof film is provided between the FRP substrate and the solar cell. 5. The solar cell module using the FRP substrate according to claim 1, wherein the EVA has a vinyl acetate content of 10 to 36% by weight. 6. The solar cell module using an FRP substrate according to claim 1, wherein the EVA film contains a cross-linking agent. 7. The solar cell module according to claim 6, wherein the crosslinking agent is an organic peroxide. 8. The solar cell module using an FRP substrate according to claim 1, wherein the EVA film has a thickness of 50 to 2000 μm. 9. The EVA film according to claim 1, wherein the EVA film is preliminarily pressure-bonded to the preheated FRP substrate and then heated at 50 to 200 ° C. for 1 minute to 10 hours. A solar cell module using an FRP substrate, characterized in that an FRP substrate and an EVA film are bonded together. 10. The solar cell module using an FRP substrate according to claim 9, wherein the temporary pressure bonding is performed by vacuuming and pressing. 11. An EVA film is superposed on a FRP substrate arranged on the non-light-receiving surface side to heat the FRP substrate.
A method of manufacturing a solar cell module using an FRP substrate, comprising a step of adhering an RP substrate and an EVA film. 12. The method of manufacturing a solar cell module using an FRP substrate according to claim 11, wherein the FRP substrate is preheated before the FRP substrate is bonded to the EVA film. 13. The method of manufacturing a solar cell module using an FRP substrate according to claim 12, wherein the preliminary heat treatment is performed at 50 to 200 ° C. for 1 minute to 10 hours. 14. The solar cell according to claim 11, wherein the solar cell module has an EVA film between a glass substrate on the light receiving surface side and an FRP substrate on the non-light receiving surface side. A method for manufacturing a solar cell module using a FRP substrate, wherein a moisture-proof film is provided between the FRP substrate and the cells for solar cells. 15. The method of manufacturing a solar cell module using an FRP substrate according to claim 11, wherein the EVA has a vinyl acetate content of 10 to 36% by weight. 16. The method of manufacturing a solar cell module using an FRP substrate according to claim 11, wherein the EVA film contains a crosslinking agent. 17. The method of manufacturing a solar cell module using an FRP substrate according to claim 16, wherein the crosslinking agent is an organic peroxide. 18. The EVA film according to claim 11, wherein the thickness of the EVA film is 50 to 2000 μm.
m is a method of manufacturing a solar cell module using an FRP substrate. 19. The FRP according to claim 11, wherein the EVA film is temporarily pressure-bonded to the preheated FRP substrate and then heated at 50 to 200 ° C. for 1 minute to 10 hours. A method for manufacturing a solar cell module using an FRP substrate, which comprises bonding the substrate and an EVA film. 20. The method of manufacturing a solar cell module using an FRP substrate according to claim 19, wherein the temporary pressure bonding is performed by vacuuming and pressing.