JP2004071793A - Thin solar battery module and its arrangement structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an arrangement structure of solar battery modules wherein a manual operation is eliminated, the number of the manufacturing processes is reduced, the manufacturing cost is low, construction at a time of laying on a roof or the like is easy, the external appearance after construction is superior, and deterioration of the function caused by the direction of the sunbeam is eliminated. <P>SOLUTION: A solar battery module of a super straight structure is constituted by laminating light receiving side resin, a solar battery cell, back side resin and a weather-resistant film, in this order, on a transparent substrate and collectively formed integrally by laminating work. For another way, a solar battery module of a sub-straight structure is constituted by laminating substrate side resin, a solar battery cell, light receiving surface side resin and a transparent weather-resistant film, in this order, on a substrate, and collectively formed integrally by laminating work. The modules are characterized by that power is led out by using a flat cable. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a solar cell module, and more particularly to a structure of a thin solar cell module with low manufacturing cost and an arrangement structure thereof.
[0002]
[Prior art]
The solar cell module that constitutes the power generation system needs to have high weather resistance in its structure, because it is used outdoors. Therefore, in order to utilize its power generation function and maintain its characteristics over the long term, the solar cell is filled with a transparent resin, the light receiving surface side resin is laminated, and then the peripheral part is made of a weather resistant resin. And seal. In addition, the output part wired to the solar cell is taken out of the non-light-receiving surface by penetrating each member, and the terminal box and the cover material are tightly adhered to each other with a weather-resistant resin, thereby preventing erosion from the penetrating part. In. Also, in the terminal box, after connecting the solar cell output section and the system cable, the connection section is filled with a weather-resistant insulating resin, thereby improving the overall environmental resistance.
[0003]
Due to such a basic structure, there are many steps that depend on manual work, and it is difficult at present to completely automate. In addition, as the number of steps increases, the manufacturing cost of the solar cell module increases. Furthermore, if the existing cable is used to perform integral molding, the thickness of the cable will not allow the air bubbles in the gaps to be completely removed, resulting in incomplete lamination or exposure to high temperatures during the curing process. Function is easily impaired.
[0004]
When the solar cell module is installed, the light receiving surface is smooth, so that the scattered light of the sunlight not only causes light pollution to pedestrians and nearby residents, but also is slippery in the installation work. In addition, when used as a residential power generation system, the presence of the terminal box requires a unique method for increasing the thickness of the solar cell module, which is different from a general roof material having a small thickness. In addition, when installing as a residential power generation system, there are cases where a hole is made in the roof of the house, the mounting method is installed after fixing the gantry, and a special fixing tool is used before roofing other roofing materials. The mainstream is to adopt a construction method different from that of roof materials. In addition, the appearance of the roof after construction is not in harmony with the surroundings, and perforating the roofing material gives the user anxiety. In addition, roofing materials are often used in an overlapping manner for the purpose, and the overlapping portion is sometimes shaded by the direction of solar radiation, impairing the function of the solar cell.
[0005]
[Problems to be solved by the invention]
A first object of the present invention is to provide a solar cell module with low manufacturing cost by eliminating manual operations and reducing the number of manufacturing steps. Secondly, it is an object of the present invention to provide a solar cell module which can be easily constructed when laid on a roof or the like and has an excellent appearance after the construction. A third object of the present invention is to provide an array structure of solar cell modules that does not deteriorate in function due to the direction of sunlight.
[0006]
[Means for Solving the Problems]
The present invention provides a solar cell having a super straight structure in which a light receiving surface side resin, a solar cell, a back surface side resin, and a weather resistant film are laminated in this order on a transparent substrate, and integrated by laminating. A substrate-type solar cell module in which a substrate-side resin, a solar cell, a light-receiving-side resin, and a transparent weather-resistant film are laminated in this order on a module or a substrate, and integrated by laminating. Wherein the output is taken out by a flat cable.
[0007]
The flat cable is preferably covered with a material having high heat resistance and high withstand voltage and having a connector. Further, the matrix circuit of the solar cell preferably has a diode, and the thin solar cell module preferably has the same or similar shape as the slate roof tile. Further, it is preferable that the weather-resistant film has a metal plate on one side, on both sides, or sandwiched inside, and that the resin is sprayed on the light-receiving surface. On the other hand, at least one of the substrate, the light-receiving surface side resin, the back surface side resin, the substrate side resin, and the weather resistant film preferably has a hole.
[0008]
The arrangement structure of the solar cell module of the present invention is characterized in that the solar cells are arranged in series so as to be parallel to the eaves of the roof.
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
The present invention is characterized in that in a solar cell module having a superstrate structure or a substrate structure, output is taken out by a flat cable. By using a flat cable, the cable can be wired at the same time as the cell is wired. Therefore, even in the solar cell matrix formed in the process, there is no noticeable difference in the overall thickness, and even if the material is set and then directly inputted to the laminating process, there are no irregularities causing bubbles. Thus, molding without any problem in appearance becomes possible. At this time, since the flat cable is taken out from between resin layers sandwiching the solar cell matrix or through each layer, it can be used as an output outlet. This structure eliminates the need for a terminal box and is effective in reducing the cost of the solar cell module.
[0010]
A solar cell module with a super straight structure is obtained by laminating a resin on the light-receiving surface, a solar cell, a resin on the back surface, and a weather-resistant film in this order on a transparent substrate, and integrating them by laminating. In addition, a solar cell module having a substrate structure is formed by laminating a substrate-side resin, a solar cell, a light-receiving surface-side resin, and a permeable weatherproof film on a substrate in this order, and laminating. And a layer in which other layers are laminated as necessary.
[0011]
The flat cable is made of a conductor having a sufficient capacity for the current of the solar cell, and the conductor preferably has a flat structure in which a flat foil wire or a thin wire is woven. By wiring this flat cable as an output take-out part after wiring the solar cells, the solar cell matrix can be set on the substrate with almost no thickness. The setting here means that the lamination process is prepared by lamination.
[0012]
The flat cable is preferably covered with a material having high heat resistance and high withstand voltage. By using a high heat-resistant and high-voltage resistant material as the coating material for the flat cable, deformation and tearing of the coating material due to exposure to high temperatures during the integral molding of the solar cell module can be prevented, and to the outside An output cable having a high withstand voltage function even after being taken out can be obtained. As a material having high heat resistance and high insulation properties, for example, there is polyethylene terephthalate. The coating can be widely used depending on the application from a single-layer coating to a multi-layer coating.
[0013]
The flat cable preferably has a connector. By using a flat cable having a connector at the time of integral molding of the solar cell module, an output lead wire taken out to the outside after integral molding can be directly used as an output terminal. As the material of the connector, a material that maintains weather resistance, heat resistance, waterproofness, and insulation is preferable because the environmental resistance function of the solar cell module can be maintained. Further, by making the thickness of the connector as thin as possible, it becomes possible to arrange the connector in the gap between the module back surface and the roof material at the time of wiring.
[0014]
The matrix circuit of the solar cell preferably has a diode. The function as a bypass diode, which was conventionally incorporated in the terminal box, can be maintained by incorporating a small chip-shaped diode in the wiring of the solar cell matrix. With such a structure, the work of bonding the terminal box and the work of connecting the output terminal to the cable and the like become unnecessary. Therefore, it is possible to input into the laminating process only by setting and aligning the position of the substrate, the resin on the substrate side, the solar cell matrix, the resin on the film side, and the cover film in this order. It can be commercialized in an automated manufacturing line.
[0015]
If a diode having a small chip shape is used, integrated molding becomes easier, and by disposing the diode on a wide metal wiring (bus bar), the heat radiation effect of itself can be enhanced. Furthermore, by taking a stress relief structure in the fixed part of the diode, flexibility against thermal stress can be provided. At this time, by designing the position of the bypass diode at the position of the alignment mark of the slate roof tile, it is not necessary to write the alignment mark on the glass or make a cut.
[0016]
The thin solar cell module preferably has the same or similar shape as the slate roof tile. By making the outer shape of the solar cell module the same or similar to that of existing slate roof tiles, it is possible to provide compatibility with the slate roof tiles on the construction surface of the main body except for the wiring, and to be able to roof by the same method. . For this reason, the burden on the worker can be reduced, and the working time can be shortened. In addition, by providing compatibility, even after roofing, it can be synchronized with other roofing materials, and an appearance that is in harmony with the surroundings can be provided. Furthermore, by making the thickness of the solar cell module as close as possible to a roof material such as a straight tile, it becomes possible to synchronize the appearance of the roof after construction with the surroundings.
[0017]
The weather-resistant film used for manufacturing the thin solar cell module preferably has a metal plate on one side, on both sides, or sandwiched inside. On the opposite side of the light receiving surface of the solar cell module, the metal plate is sealed in the back cover material, sandwiched between multiple back covers, the metal plate is adhered to one side of the back cover, or the metal plate is By adhering to both sides, the fire prevention function and the heat radiation function of the solar cell module can be enhanced.
[0018]
It is preferable that the light receiving surface of the thin solar cell module is sprayed with a resin. By spraying the resin on the light receiving surface of the solar cell module, the surface of the solar cell module can have an antiglare effect and an anti-slip effect during construction work. In addition, at least one of the substrate, the light-receiving side resin, the backside resin, the substrate-side resin, and the weatherproof film used for manufacturing the thin solar cell module is provided with a screw (or a nail) for convenience of assembly. Those having holes are preferred.
[0019]
The arrangement structure of the thin solar cell module of the present invention is characterized in that the solar cells of the above-described solar cell module are arranged in series so as to be parallel to the eaves of the roof. The roofing material has some overlap vertically with the eaves line. Therefore, depending on the incident angle of sunlight, the slight overlapping portion may affect and cause a shadow on the solar cell module. By arranging the cells in the solar cell module in series so as to be parallel to the eaves line, it is possible to minimize a decrease in the output of the solar cell module due to the shadow of the overlapping portion of the roofing material.
[0020]
【Example】
Example 1
A flat cable having a thin connector at the tip was attached to the solar cell as an output take-out portion from the solar cell. That is, after the photovoltaic cell is placed on a hot plate with the light receiving surface of the photovoltaic cell facing upward and heated to a temperature at which the solder melts, the solder-dipped output take-out interconnector 5, as shown in FIG. It was wired on the front electrode of the cell. Next, the strings of the respective solar cells were wired linearly in accordance with their polarities (plus / minus). A flat cable 6 having a thin connector 7 was wired from both ends with the same polarity. At this time, the coating of the cable at the part involved in the wiring was removed in advance. Also, the bypass diode 8 was wired on a flat cable 6 which is a metal wire for the purpose of releasing heat when it was heated, and the other end was connected to a cable having the other polarity. By attaching the flat cable 6 in this manner, the solar cell matrix 4 can take out the output in a flat state, and can not only be wired, but also can be easily formed integrally. It turned out that the automation of the production line can be realized.
[0021]
Using the obtained solar cell matrix 4, a thin solar cell module was manufactured. In FIG. 1, the substrate 1 (light receiving surface glass) side is drawn upward, but since it is manufactured on the production line with the substrate 1 side down, the description will be made according to the manufacturing method.
[0022]
A 3.2 mm thick white plate reinforced glass is used as the substrate 1, and an EVA layer (ethylene acetate acetate) serving as an adhesive film layer, a solar cell sealing material and a buffer material is formed on the substrate 1 as a light receiving surface side resin and a back surface side resin. A vinyl copolymer layer 2 was used, and the solar cell matrix 4 was interposed therebetween. Here, the thickness of the EVA layer 2 was set to 0.6 mm on the side in contact with the hard substrate 1 and 0.4 mm on the side of the flexible weather-resistant film 3 in order to have a more cushioning effect. Finally, a weather-resistant film 3 having a withstand voltage function was mounted thereon as a back sealing cover. The material of the weather-resistant film 3 used was polyethylene terephthalate (PET) in which a metal layer was enclosed in order to enhance weather resistance and fire resistance.
[0023]
The solar cell module thus set with the materials is integrated by a vacuum laminating method, which is a known sealing processing technique, and the bonding is completed at a fusion welding temperature before the cross-linking reaction of EVA. And the EVA cross-linking temperature was maintained for a certain period of time to complete the integration step. In this cross-linking step, the size of the EVA layer 2 and the weather-resistant film 3 to be laminated is made several mm smaller than the end surface of the substrate 1 so that the lamination cross-section near the end surface where the substrate 1 protrudes is simultaneously sealed with resin. The weather resistance around the solar cell module has been improved.
[0024]
In addition, after the integration process is completed, by spraying a resin (for matting) on the light receiving surface side of the substrate 1, the anti-glare effect and the effect of preventing slippage during construction work are enhanced. The thickness of the glass and the thickness, shape, and material of the EVA layer are not limited, and even in the wiring method of the solar cell matrix, the solar cells are connected in series so as to be parallel to the eaves line of the roof. Arbitrary if not arranged. Furthermore, in the manufacturing process, by making the solar cell module the same shape as the straight roof tile, simultaneous construction with the roof material became possible. In addition, since the laminated members except for the solar cell matrix 4 were pre-drilled for screws (or nails), the construction was carried out with screws (or nails) 9 through a cushioning material 10 with a waterproof function. Could do it. The number of screw holes is arbitrary as long as the strength can be maintained.
[0025]
Example 2
As shown in FIG. 2, a solar cell module was manufactured in the same manner as in Example 1 except that a nonflammable building material 11 was used as a weather-resistant film for sealing the back surface. The fire prevention function was enhanced by using the material used as the roof material and the material used as the wall material as the material of the module.
[0026]
Example 3
As shown in FIG. 3, a metal plate 12 having a thickness of 1 mm was used as a back substrate, on which a silicone resin 13 was laminated as an adhesive film layer and a module end face sealing material. A PET film is laminated thereon as a weather-resistant film 3 having insulation withstand voltage, and an EVA layer 2 which is an adhesive film layer, a solar cell sealing material and a cushioning material is laminated as a substrate side resin and a light receiving surface side resin. The solar cell matrix 4 to which the flat cable 6 was attached for taking out output was interposed therebetween. Finally, a high-permeability weather-resistant film 14 was laminated thereon as a surface light receiving cover. The material was based on FEP (fluorinated ethylene propylene) or PET, and was composed of a plurality of FEP layers or PET layers including a PET layer on which SiOx was deposited to enhance weather resistance. Here, the thickness of the EVA layer 2 was set to 0.6 mm on the soft light-receiving surface side of the front surface to give a more cushioning effect, and was set to 0.4 mm on the back surface side to reduce the overall module thickness.
[0027]
The solar cell module thus set with the materials is integrated by a vacuum laminating method, which is a known sealing processing technique, and the bonding is terminated at a fusion welding temperature before a crosslinking reaction of EVA. The integration process was completed by maintaining the device at a crosslinking temperature for a certain period of time. In this cross-linking step, the size of the laminated EVA layer 2, weather-resistant film 3 and high-permeability weather-resistant film 14 is reduced by several mm from the end face of the metal plate 12 so that the metal plate 12 protrudes. It is possible to simultaneously seal the laminated cross-section near the end face with an end face sealing material such as a silicone resin 13, thereby improving the weather resistance around the solar cell module.
[0028]
The thickness of the metal plate, the thickness of the EVA layer, the shape and material of the other members, and the like are not limited. In the wiring method of the solar cell matrix, the solar cells are parallel to the eaves of the roof. If they are not arranged in series such that Furthermore, in the manufacturing process, by making the solar cell module the same shape as the straight roof tile, simultaneous construction with the roof material became possible. Also, since screw holes were provided in the laminated members, the work could be performed with the screws 9. The number of screw holes is arbitrary as long as the strength can be maintained.
[0029]
Example 4
As shown in FIG. 4, a glass plate was used as a front light receiving cover, and the resin (for matting) was sprayed on the light receiving surface side of the glass plate after the integration process was completed. To produce a solar cell module. This solar cell module was excellent in anti-glare effect and anti-slip effect during construction work. Also, by making the module the same shape as the slate tile, simultaneous construction with the roof material was possible.
[0030]
The embodiments and examples disclosed this time are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.
[0031]
【The invention's effect】
By eliminating manual operations and reducing the number of manufacturing steps, a solar cell module with low manufacturing cost can be provided. Further, it is possible to provide a solar cell module that is easy to perform when laying on a roof or the like and has an excellent appearance after the construction. Further, it is possible to provide a solar cell module array structure in which the function is not deteriorated by the direction of sunlight.
[Brief description of the drawings]
FIG. 1 is a perspective view illustrating a structure of a solar cell module of the present invention.
FIG. 2 is a perspective view illustrating a structure of a solar cell module of the present invention.
FIG. 3 is a perspective view illustrating a structure of a solar cell module of the present invention.
FIG. 4 is a perspective view illustrating a structure of a solar cell module of the present invention.
FIG. 5 is a perspective view illustrating a structure of a solar cell matrix constituting the solar cell module of the present invention.
[Explanation of symbols]
Reference Signs List 1 substrate, 2 EVA layer, 3 weatherproof film, 4 solar cell matrix, 5 interconnector, 6 flat cable, 7 thin connector, 8 bypass diode, 9 screw, 10 cushioning material, 11 incombustible building material, 12 metal Board, 13 silicone resin, 14 highly permeable weatherproof film.

Claims (9)

On a transparent substrate, a light receiving surface side resin, a solar cell, a back surface side resin, and a weather resistant film are laminated in this order, and a solar cell module having a super straight structure or a substrate integrated by lamination processing, or a substrate. On the substrate-side resin, the solar cell, the light-receiving surface-side resin, and the permeable weatherproof film are laminated in this order, and in a solar cell module having a substrate structure integrated by lamination processing, A thin solar cell module characterized in that extraction is performed by a flat cable. 2. The thin solar cell module according to claim 1, wherein the flat cable is covered with a material having high heat resistance and high withstand voltage. 3. The thin solar cell module according to claim 1, wherein the flat cable has a connector. The thin solar cell module according to any one of claims 1 to 3, wherein the matrix circuit of the solar cell has a diode. The thin solar cell module according to any one of claims 1 to 4, wherein the thin solar cell module has the same or similar shape as the slate roof tile. The thin solar cell module according to any one of claims 1 to 5, further comprising a metal plate on one side, on both sides, or sandwiched inside the weather resistant film. The thin solar cell module according to claim 1, wherein a resin is sprayed on the light receiving surface. The thin solar cell module according to any one of claims 1 to 7, wherein at least one of the substrate, the light receiving surface side resin, the back surface side resin, the substrate side resin, and the weather resistant film has a hole. An arrangement structure of thin solar cell modules, wherein the solar cells of the solar cell module according to any one of claims 1 to 8 are arranged in series so as to be parallel to a roof eaves line.

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