JP2004281796A - Solar cell module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent separation of the rear material at the corner of a solar cell module, and to improve the long-term weather-proof and the electrostatic breakdown voltage. <P>SOLUTION: In the solar cell module where a solar cell element enclosed with a filler is arranged between a translucent substrate 10 and the rear material, the corner 12 of the rear surface material 11 is cut off and is set in an irregularity shape, the filler having high flowability or the thin filler and the surface side and/or the front and/or rear side of a module frame is cut off, thus preventing the separation of the corner section 12 of the rear material 11 when a solar cell panel is fitted into the module frame. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a solar cell module, and more particularly to a solar cell module in which corner portions of a back surface material are prevented from peeling.
[0002]
[Prior art]
Solar cell elements are often manufactured using a single crystal silicon substrate or a polycrystalline silicon substrate. For this reason, the solar cell element is vulnerable to physical impact, and when the solar cell is installed outdoors, it is necessary to protect it from rain etc. Therefore, a light-transmitting substrate and ethylene vinyl acetate copolymer (EVA) etc. It is common practice to create a solar cell module by enclosing it with a filler as a main component.
[0003]
FIG. 10 is a diagram showing the structure of a conventional solar cell module. In FIG. 10, reference numeral 1 denotes a light-transmitting substrate made of, for example, tempered glass or the like, 2a denotes a light-receiving-surface-side filler made of ethylene vinyl acetate copolymer (EVA), and 2b denotes an ethylene vinyl acetate copolymer (EVA). 3 is a solar cell element made of polycrystalline silicon or the like, 4 is a back material made of polyethylene terephthalate (PET) or the like, 5 is a connection tab made of copper foil or the like, 6 is a solar cell element and a terminal Wiring material between boxes.
[0004]
The plurality of solar cell elements 3 connected by the connection tabs 4 are sandwiched between the light-receiving surface-side filler 2a and the back-side filler 2b between the translucent substrate 1 and the back surface member 4, and the entire device is called a laminator. A solar cell module is formed by pressing and integrating while heating (for example, see Patent Document 1).
[0005]
FIG. 11 is a diagram showing a state where the module frame 8 and the terminal box 9 are attached to the integrated solar cell panel 7. A suitable amount of butyl rubber (not shown) is applied to a module frame 8 made of aluminum or the like, and the solar cell panel 7 is fitted. When the solar cell panel 7 is fitted, the butyl rubber spreads in the module frame 8 and the module frame 8 can be firmly fixed. After the solar cell panel 7 is fitted into the module frame 8 in this manner, each corner of the module frame 8 is fixed with screws, and finally, the terminal box 9 is bonded with an adhesive.
[0006]
Prior art document information related to the invention of this application includes the following.
[0007]
[Patent Document 1]
JP-A-5-121772
[Problems to be solved by the invention]
However, in the conventional solar cell module, since the four corners of the solar cell panel 7 do not rise in temperature as compared with the other parts when they are integrated with the laminator, the back material 4 and the back filler 2b are Adhesive strength is weaker than other parts.
[0009]
The back material 4 is finished to have substantially the same shape and the same dimensions as the translucent substrate 1, and the width of the groove portion of the module frame 8 into which the solar cell panel 7 is fitted is not too large compared to the thickness of the solar cell panel 7. Since the solar cell panel 7 is made, when the solar cell panel 7 is fitted into the module frame 8, the corners of the back surface member 4 are easily peeled off from the back surface side filler 2b. When peeling occurs on the back material 4, the electrostatic withstand performance of the solar cell module is reduced, or after the solar cell module is installed outdoors, the peeling of the back material 4 progresses, and the moisture-proof effect is reduced, and the internal solar cell is deteriorated. Problems such as deterioration of element performance occur.
[0010]
The present invention has been made in view of such a problem, and an object of the present invention is to provide a solar cell module in which a corner of a back material does not peel when a solar cell panel is fitted into a module frame. It is in.
[0011]
[Means for Solving the Problems]
In order to achieve the above object, a solar cell module according to claim 1 is a solar cell module in which a solar cell element sealed with a filler is disposed between a light-transmitting substrate and a back surface material. The part is cut off.
[0012]
Further, the solar cell module according to claim 2 is a solar cell module in which a solar cell element sealed with a filler is disposed between a translucent substrate and a back material, wherein the filler at a corner of the back material is used. It is characterized in that the contacting part is made uneven.
[0013]
Further, in the solar cell module according to the third aspect, in the solar cell module in which the solar cell element filled with the filler is disposed between the translucent substrate and the back material, the filler at the corner of the back material flows. It is characterized by being a filler having high properties.
[0014]
Further, the solar cell module according to claim 4 is a solar cell module in which a solar cell element sealed with a filler is disposed between a light-transmitting substrate and a back material, wherein the filler at a corner of the back material is thinned. It is characterized by having done.
[0015]
In the solar cell module according to the fifth aspect, the solar cell element sealed with a filler is disposed between the translucent substrate and the back surface member so that the front surface side, the end surface side, and the back surface side of the peripheral portion are covered. In the solar cell module having the module frame attached to the above, the front side and / or the rear side of the module frame at the corners of the back side material are cut off.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
The basic configuration of the solar cell module of the present invention is the same as that of the conventional solar cell module shown in FIG. That is, a plurality of solar cell elements 3 connected by the connection tabs 4 are sandwiched between the light-receiving surface-side filler 2a and the back-side filler 2b between the light-transmitting substrate 1 and the back surface member 4 and pressed and integrated. It is.
[0017]
The translucent substrate 1 is made of, for example, tempered glass having a thickness of about 3 to 5 mm. As the light-receiving-side filler 2a and the back-side filler 2b, those containing ethylene vinyl acetate copolymer (EVA) or polyvinyl butyral (PVB) as a main component are often used. And both the back side filler 2b are about 0.6 to 0.8 mm. The solar cell element 3 is made of a single crystal silicon or polycrystalline silicon substrate having a thickness of about 0.3 mm, and the size thereof is, for example, about 150 mm square in a polycrystalline silicon solar cell. The back material 4 is made of PET (polyethylene terephthalate) or PVF (vinyl fluoride resin) sandwiching an aluminum foil so as not to transmit moisture.
[0018]
The connection tab 5 electrically connects the solar cell elements, and is formed by cutting a copper foil having a thickness of about 0.1 mm and a width of 2 mm, which is entirely coated with solder, into a predetermined length. The wiring member 6 transmits the electric output from the solar cell element to the terminal of the terminal box. The wiring member 6 cuts a predetermined position of the backside filler 2b and the backside member 6, and leads out of the cutout to the outside. The wiring member 6 is usually formed by cutting a copper foil having a thickness of about 0.1 mm and a width of 6 mm, which is entirely coated with solder, into a predetermined length.
[0019]
FIG. 1 is a view of the solar cell module according to claim 1 as viewed from a non-light receiving surface side. In FIG. 1, reference numeral 10 denotes a light-transmitting substrate, 11 denotes a back surface member, and 12 denotes a corner of a solar cell panel.
[0020]
The back material 11 is cut so that the four corners 12 have substantially the same size on both sides. The size to be cut needs to be such that the cut portion of the backing material 11 is not exposed from the module frame 8 when the solar cell panel is fitted. For a general module frame 8, about 3 to 10 mm is optimal. It is. In addition, a sealing agent such as butyl rubber is interposed between the back material 11 and the module frame 8.
[0021]
As described above, since the corners of the back member 11 are cut off, the back member 11 does not peel off from one corner in the step of attaching the module frame 8. Further, the portion where the back material 11 is cut off is hidden by the module frame when the module frame 8 is fitted, and the function of the butyl rubber does not hinder the reliability of the solar cell module.
[0022]
FIG. 2 is a view showing a solar cell module according to a second aspect. In FIG. 2, reference numeral 13 denotes a back surface material, and 14 denotes a corner thereof. A portion of the corner portion 14 of the back material 13 which is in contact with the back side filler is processed into an uneven shape. In the case of a normal solar cell module having an output of about 160 W, the portion processed into the uneven shape has an optimum radius of about 10 to 30 mm from each corner.
[0023]
FIG. 3 is a diagram showing a cross section of a portion processed into an uneven shape. Reference numeral 15 in FIG. 3 indicates the unevenness, and the height from the concave portion to the convex portion is optimally about 0.1 to 1.5 mm. The uneven shape of the corner portion 14 is manufactured by press working or the like.
[0024]
When the portion of the corner 14 of the back material 13 that contacts the back side filler is made uneven, the surface area increases, the bonding area between the corner 14 of the back material 13 and the filler increases, and the adhesive strength is reduced. Can be improved. Therefore, in the process of attaching the module frame 8, the back material 11 does not peel off from one corner.
[0025]
FIG. 4 is a view showing a solar cell module according to a third aspect. In FIG. 4, 16 is a translucent substrate, 17 is a backside filler, and 18 is a backside filler having high fluidity. The backside filler 17 has a melt flow rate of about 4 g / 10 minutes that indicates fluidity during lamination. Each corner of the backside filler 17 is cut off by about 5 to 10 mm, and the backside filler 18 having high fluidity is disposed here.
[0026]
The backside filler 18 having high fluidity has a melt flow rate of about 8 to 15 g / 10 minutes. For example, it is possible to increase the melt flow rate in EVA as described above by increasing the content of vinyl acetate in EVA. This is cut into substantially the same shape as the corner where the normal backside filler 17 is cut off, and is arranged at the corner where the normal backside filler 17 is cut off as shown in FIG. Laminate the backing material on top of the above.
[0027]
FIG. 5 is a diagram showing a side surface of a corner portion of the laminated product. In FIG. 5, reference numeral 19 denotes a portion using the normal backside filler 17, and reference numeral 20 denotes a portion using the backside filler 18 having high fluidity.
[0028]
The portion 20 using the backside filler 18 having high fluidity has a higher fluidity at the time of lamination than the portion 19 using the normal backside filler 17, so that the amount of the portion 20 protruding outside the light-transmitting substrate is reduced. More. For this reason, the thickness of the portion 20 using the backside filler 18 having high fluidity is thinner than the portion 19 using the normal backside filler 17. Therefore, when the module frame is fitted, even the corners of the back material smoothly enter the module frame, and the corners of the back material do not peel off.
[0029]
In the above-described example, the description has been given of the case where the backside filler 18 having high fluidity is arranged and laminated at the corners of the backside material, but the backside filler having a smaller thickness than other portions is arranged at the corners of the backside material. The same effect can be obtained by laminating. This is the solar cell module according to claim 4.
[0030]
For example, it is possible to use a material having a thickness of 0.8 mm before lamination as a normal backside filler 17 and a material having a thickness of about 0.6 mm before lamination as a backside filler having a thinner corner. it can.
[0031]
FIG. 6 is a view showing a solar cell module according to claim 5. In FIG. 6, 21 is a solar cell panel, and 22 is a module frame. The module frame 22 is made of aluminum or the like, and a solar cell element 21 filled with a filler is disposed between a light-transmitting substrate and a back surface material to form a solar cell panel 21. The module frame 22 is attached so that the end face and the back face are covered.
[0032]
As shown in FIG. 6, the light receiving surface side of the solar cell module, that is, about 5 to 30 mm of the corner on the surface side is cut off on both sides.
[0033]
FIG. 7 is a view of a cross section taken along the line aa of the solar cell module shown in FIG. In FIG. 7, 21 is a solar cell panel, and 22 is a module frame. Since the surface side of the corner of the module frame 22 into which the corner of the solar cell panel 21 is fitted is cut off, the solar cell panel 21 enters the corner smoothly, and the corner of the back material does not peel off.
[0034]
FIG. 8 is a diagram showing an example in which the back side of the corner of the module frame is cut away, and FIG. 9 is a diagram showing an example in which both the front side and the back side of the corner portion of the module frame are cut out. 8 and 9, 21 indicates a solar cell panel, and 22 indicates a module frame.
[0035]
In FIGS. 8 and 9, as in FIGS. 6 and 7, the corners of the module frame 22 into which the corners of the solar cell panel 21 are fitted are cut off on the back side and the front and back sides. It enters the frame 22 smoothly, and the corners of the backing material do not peel off. The vertical and horizontal module frames 22 are fixed with screws at the respective corners of the portions that cover the end faces of the solar cell panel 21. Therefore, a part of the front and back sides of the module modules 22 at the corners is cut off. Even if it does not hinder assembly.
[0036]
Finally, the terminal box 10 is fixed to the back material 4 with an adhesive such as a silicone sealant on the solar cell panel 21 with the module frame 22 attached thereto. The terminal box 10 connects a wiring material from the solar cell element and a cable for connection to an external circuit, and is usually made of a modified PPE resin or the like in a black color in consideration of weather resistance to ultraviolet rays and the like. . The approximate size of the completed solar cell module is about 100 × 60 × 15 mm in a general solar cell module having an electric output of about 160 W.
[0037]
The present invention is not limited to the above embodiment, and many modifications and changes can be made to the above embodiment within the scope of the present invention. For example, a solar cell element is not limited to a crystalline solar cell such as a single crystal or polycrystalline silicon, but is also applicable to a thin film solar cell or the like as long as a solar cell module having a back material disposed on a non-light receiving surface side. You.
[0038]
【The invention's effect】
As described above, according to the solar cell module according to claim 1, since the corners of the back member are cut off, the corners of the back member do not peel off when the solar cell panel is fitted into the module frame, A solar cell module with excellent long-term weather resistance and electrostatic withstand voltage performance.
[0039]
According to the solar cell module of the second aspect, since the surface of the corner of the surface in contact with the filler of the back material is uneven, the back material and the back material are firmly bonded to each other, and Peeling of corners of the material does not occur.
[0040]
Further, according to the solar cell module of the third aspect, since the filler having more fluidity is arranged at the corner of the back member than at other portions, the thickness of the corner of the back member is reduced, and the solar cell panel is provided. When the is fitted into the module frame, the corners of the back material do not peel off.
[0041]
According to the solar cell module of the fourth aspect, since the filler that is thinner than the other portions is disposed at the corners of the back member, the thickness of the corners of the back member is reduced, and the solar cell panel is mounted on the module frame. The corners of the backing material do not come off when fitted into the backing material.
[0042]
Further, according to the solar cell module of the fifth aspect, since the front and / or rear side module frames of the corners of the back member are cut off, the corners of the back member when the solar cell panel is fitted into the module frame. Is removed, and dust and dirt collected on the step between the module frame and the light-transmitting substrate after installation of the solar cell module fall off the corners where there is no module frame and are removed, and the power generation efficiency of the solar cell module Does not decrease.
[0043]
Thus, after the solar cell module is installed outdoors, there is no problem such as the peeling of the back material progressing and the moisture-proof effect is reduced, and the long-term weather resistance and electrostatic withstand performance of the solar cell module can be ensured.
[Brief description of the drawings]
FIG. 1 is a view showing a solar cell module according to claim 1;
FIG. 2 is a view showing a solar cell module according to claim 2;
FIG. 3 is a diagram showing a cross-sectional shape of a corner of a back material of the solar cell module of FIG. 2;
FIG. 4 is a view showing a solar cell module according to claim 3;
FIG. 5 is a diagram showing a cross-sectional shape of a corner of a back-side filler of the solar cell module of FIG. 4;
FIG. 6 is a view showing a solar cell module according to claim 5;
FIG. 7 is a diagram showing a cross-sectional shape of a corner of a back material of the solar cell module of FIG. 7;
8 is a diagram showing another cross-sectional shape of the corner of the back material of the solar cell module of FIG.
9 is a diagram showing another cross-sectional shape of the corner of the back material of the solar cell module of FIG.
FIG. 10 is an exploded view of a conventional solar cell module.
FIG. 11 is a view showing an assembled state of a conventional solar cell module.
[Explanation of symbols]
1, 10 and 16; translucent substrate, 2a; light-receiving surface side filler, 2b; backside filler, 3; solar cell element, 4, 11, 13; backside material, 5; connection tab, 6; Wiring material between element and terminal box, 7, 19, 20, 21, 23; solar cell panel, 8, 22: module frame, 9; terminal box, 12; corner of solar cell panel, 14; Corner portion, 15; irregular shape of back material, 17; normal back-side filler, 18; highly fluid back-side filler

Claims (5)

A solar cell module in which a solar cell element sealed with a filler is disposed between a translucent substrate and a back surface member, wherein a corner of the back surface member is cut off. In a solar cell module in which a solar cell element filled with a filler is disposed between a light-transmitting substrate and a back material, a portion of the corner of the back material that contacts the filler is made uneven. Solar cell module. In a solar cell module in which a solar cell element encapsulated with a filler is disposed between a translucent substrate and a back material, the filler at a corner of the back material is a highly fluid filler. Solar cell module. A solar cell module in which a solar cell element sealed with a filler is disposed between a translucent substrate and a back member, wherein a filler at a corner of the back member is thinned. In a solar cell module in which a solar cell element encapsulated with a filler is disposed between a light-transmitting substrate and a back surface material, and a module frame is attached so that a front surface side, an end surface side, and a back surface side of a peripheral portion are covered. A solar cell module, wherein a front side and / or a back side of the module frame at a corner of a back side member is cut off.

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