JP2008053419A - Sealing structure and method of manufacturing solar cell module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sealing structure of a solar cell module exhibiting stabilized bonding strength to a wide range of material, e.g. various metal materials or plastic materials, used as a substrate for roof, and enduring long time use in outdoor environment; and to provide its manufacturing method. <P>SOLUTION: A solar battery cell 103 is provided between a backside sealing material 102 and a surface side sealing material 104, a surface protection material 105 is arranged on the surface side of the surface side sealing material 104 to form a lamination sealed submodule 300, and the submodule 300 is stuck to the surface of an outdoor substrate 202. In such a solar cell module 100, pressure-sensitive sheetlike adhesive 200 and reaction curing adhesive 201 are arranged between the substrate 202 for roof and the backside sealing material 102 of the submodule 300. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a solar cell module, particularly a flexible type solar cell module, which is laid on a stand installed outdoors, a roof of a house, a rooftop of a building, etc., and generates electric power using sunlight. The present invention relates to a structure and a method for manufacturing the solar cell module.

Currently, research and development of clean energy suppliers is underway to protect the environment. Above all, solar cells are attracting attention because of their infinite resources and non-pollution.
Naturally, the environment in which solar cells are used for power supply and general housing, even if it is used in outdoor environments with good sunlight, exposed to temperature differences due to annual warming and cold weather, wind and rain due to weather changes, Performance that can maintain a product life of 10 years or more is required.

FIG. 2 is a cross-sectional view showing an example of a solar cell module according to the prior art. In FIG. 2, 100 is a solar cell module, which has the following sealing structure.
That is, reference numeral 101 denotes a roof substrate processed into a fixed size. After the back surface side sealing material 102 is placed on the roof substrate 101 and the solar battery cell 103 is placed thereon, the solar battery cell is placed. The surface side sealing material 104 and the surface protection material 105 are sequentially stacked on the surface 103 and the solar cell module is assembled.
After such assembly, internal lead wires (not shown) from the solar cells 103 are taken out as output terminals from through-holes (not shown) formed in the back surface side sealing material 102 and the roof substrate 101, and are not shown in vacuum heating. After being placed on a laminating apparatus and depressurized for about 30 minutes at a vacuum degree of 1 Torr, heat sealing is performed at 150 ° C. for about 30 minutes (min).
Further, by processing the bending allowance W into a so-called hat structure, the solar cell module 100 imparted with rigidity as a structure is completed.

As a constituent material of the solar cell module 100, the back side sealing material 102 and the front side sealing material 104 are made of EVA (ethylene vinyl acetate: trade name EVASAFE 1425 thickness 0.4 mm) manufactured by Bridgestone. As the surface protective material 105, ETFE (trade name: Aflex 25N1030D / CS thickness 25 μm) manufactured by Asahi Glass Co., Ltd. is used.
The solar battery cell 103 uses an amorphous silicon solar battery cell (thickness of about 0.35 mm) manufactured in a separate process. Further, as the roof substrate 101, a galvalume steel-coated polyester-coated steel plate or a fluorine-coated steel plate that can be used outdoors is used.
The solar cell module 100 completed as described above includes the roof substrate 101 and the back surface side sealing material 102, the back surface side sealing material 102 and the back surface side of the solar cells 103, the front surface side and the surface of the solar cells 103. There are five sealing interfaces, the side sealing material 104, the front surface sealing material 104 and the surface protection material 105, and the back surface sealing material 102 and the front surface sealing material 104. After being sealed, it has a sufficient adhesive performance.

Patent Document 1 (Japanese Patent Laid-Open No. 7-302925) discloses a back surface filling material (back surface side sealing material) in which a back surface coating film is sandwiched on a reinforcing plate (roof substrate) processed to a regular size. After placing the photovoltaic element (solar cell) thereon, a transparent surface filler (surface side sealing material) and a transparent surface protective material thereon are placed on the photovoltaic element. It is a solar cell module formed by sequentially laminating, and the main constituent resin of the surface filler (surface side sealing material) contains 60 to 80% fluorine containing vinylidene fluoride and hexafluoropropyne as main components. There is disclosed a solar cell module which is a cross-linked product of an amount of a multi-component copolymer, and wherein the surface protective material is composed of a film having a fluorine content of 40 to 60%.
JP-A-7-302925

In the conventional solar cell module shown in FIG. 2, the material used for the roof substrate 101 as the reinforcing plate constituting the solar cell module 100 is made of a metal such as titanium metal as the roof base material 101. Materials that are difficult to bond with adhesives are used up to tent plastic materials. For this reason, the part bonded to the roof substrate 101 in the solar cell module 100 requires a bonding structure having bonding performance and reliability with respect to a wide range of materials.
However, in the prior art shown in FIG. 2, the back-side sealing material 102 is merely bonded to the roof substrate 101 provided as a reinforcing plate, and the above-mentioned Patent Document 1 (Japanese Patent Laid-Open No. 7-86). No. 302925), the back surface filler is directly adhered to the reinforcing plate, and no means for solving the above problem is disclosed in any of the techniques.

  The present invention has been made in view of such a situation, and the object thereof is to have a stable adhesive strength with respect to a wide range of materials such as various metal materials and plastic materials used as a substrate for a roof, and an outdoor environment. An object of the present invention is to provide a solar cell module sealing structure and a solar cell module manufacturing method that can withstand long-term use.

In order to solve the above-described problems of the prior art, the present invention of claim 1 is configured such that a solar battery cell is provided between a back surface side sealing material and a front surface side sealing material, In the solar cell module, in which a surface protection material is disposed on the surface side to form a laminate-sealed submodule, and the submodule is bonded to the surface of the outdoor substrate, the roof substrate and the submodule A pressure-sensitive sheet-like adhesive and a reaction-curing adhesive are disposed between the back-side sealing material.
In this invention, it is preferable that the reaction-curable adhesive is disposed in the vicinity of the outer periphery of the roof substrate, and the pressure-sensitive sheet-like adhesive is disposed closer to the inner periphery than the reaction-curable adhesive.

Moreover, this invention of Claim 3 is related with the manufacturing method of the solar cell module comprised as mentioned above, and installs a photovoltaic cell between the back surface side sealing material and the surface side sealing material, A surface protection material is arranged on the surface side of the surface side sealing material, and heat-sealed by vacuum pressurization to form a laminate-sealed submodule, and the submodule is bonded to the surface of the outdoor substrate. A method for producing a solar cell module comprising: applying a pressure-sensitive sheet-like adhesive and a reaction-curing adhesive along the top surface of the roof substrate; and the pressure-sensitive sheet-like adhesive and the reaction-curing adhesive The roof-side sealing material and the sub-module are bonded together by laminating the back-side sealing material of the laminate-sealed sub-module.
In this invention, the pressure sensitive sheet-like adhesive is applied in the vicinity of the central portion on the roof substrate, and then the reaction hardening type is applied to a portion closer to the outer periphery than the pressure sensitive sheet adhesive on the roof substrate. It is preferable that an adhesive is applied and the back-side sealing material of the laminate-sealed submodule is bonded to the pressure-sensitive sheet-like adhesive and the reaction-curable adhesive.

As described above, according to the present invention, a solar battery cell is provided between the back surface side sealing material and the front surface side sealing material, and the surface protection material is disposed on the surface side of the front surface side sealing material. In a solar cell module configured by forming a laminated sub-module and bonding the sub-module to the surface of an outdoor substrate, a pressure-sensitive sheet-like adhesive and reaction hardening are performed along the upper surface of the roof substrate. Since the mold adhesive is applied and the back side sealing material of the sub-module that is laminated and sealed is bonded to the upper side of the sub-module, the roof substrate and the sub-module are bonded to each other. It has a high adhesive strength regardless of the type of material used, but it has a pressure-sensitive sheet-like adhesive that has a problem in peel resistance against peeling caused by bending and the like, and hardly peels off against peeling caused by bending. nature The combined use of a reaction-curing adhesive with, the two kinds of strengths of adhesives, disadvantages are covered by another adhesive, stable adhesion performance.
As a result, it has stable adhesion performance to a wide range of materials such as various metal materials and plastic materials that are used as roof substrates, eliminates poor adhesion, and is durable enough to withstand long-term use in outdoor environments. A solar cell module can be provided.

  In addition, a reaction curable adhesive having a property that is difficult to peel off due to peeling caused by bending or the like is disposed near the outer periphery of the roof substrate on which the bent portion is formed, and the inner periphery of the reaction curable adhesive is more By placing a pressure-sensitive sheet-like adhesive with high adhesive strength on the main adhesive part on the side, regardless of the type of material used for the roof substrate, the roof substrate and submodule can be bonded with high adhesion performance. It can be bonded evenly.

  Below, the embodiment is described in detail about the sealing structure of a solar cell module concerning the present invention, and the manufacturing method of a solar cell module.

FIG. 1 is a cross-sectional view of a solar cell module according to an embodiment of the present invention.
In FIG. 1, a solar cell module 100 according to the present embodiment includes a roof substrate 202, a back surface side sealing material 102, a solar cell 103, a surface side sealing material 104, and a surface protection material 105, which are bonded to each other. It is constituted by.
The roof substrate 202 is processed into a standard size and is laid on a roof of a house or the like. A solar battery cell 103 is provided between the back surface side sealing material 102 and the stop surface side sealing material 104, and the back surface side sealing material 102 is bonded to the lower side of the solar battery cell 103. A surface side sealing material 104 is bonded to the upper side of the cell 103. Further, a pressure-sensitive sheet-like adhesive 201 is applied to the upper side of the roof substrate 202, and a reaction-curing adhesive 201 is applied between the vicinity of the outer periphery of the roof substrate 202 and the back-side sealing material 102. Yes.

Next, the manufacturing method of the solar cell module 100 comprised as mentioned above is demonstrated.
First, the back surface side sealing material 102 processed into a regular size is laminated, then the solar cell 103 is laminated on the upper side of the back surface side sealing material 102, and then the surface side on the upper side of the solar cell 103. The sealing material 104 and the surface protection material 105 are sequentially laminated on the upper side to form a laminated body.
Next, the laminate is placed on a vacuum heating laminating apparatus (not shown), and in this state, the pressure is reduced for about 30 minutes (min) at a degree of vacuum of 1 Torr, and then laminated at 150 ° C. for about 30 minutes (min). Then, the submodule 300 made of the above laminated body heat sealed is formed.

Next, the pressure sensitive sheet-like adhesive 201 is applied onto the roof substrate 202, and then the reaction-curable adhesive 201 is applied to the vicinity of the outer periphery of the roof substrate 202, and the above-described laminating process is completed. The bottom surface of the back side sealing material 102 of 300 is bonded to the pressure sensitive sheet adhesive 200 and the reaction curable adhesive 201. At this time, an internal lead wire (not shown) from the submodule 300 is taken out from a through hole (not shown) of the roof substrate 202 as an output terminal, and a pressure load is further applied from above to complete the bonding. The reactive curable adhesive 201 in the vicinity of the outer periphery reacts with moisture in the atmosphere and cures at room temperature in about 3 to 4 hours.
Further, by processing the bending allowance W into a so-called hat structure, the solar cell module 100 imparted with rigidity as a structure is completed.

As a constituent material of the solar cell module 100, EVA (ethylene vinyl acetate: trade name EVASAFE1425 thickness 0.4 mm) manufactured by Bridgestone is used for the back surface side sealing material 102 and the front surface side sealing material 104. Further, ETFE (trade name: Aflex 25N1030D / CS thickness 25 μm) manufactured by Asahi Glass Co., Ltd. is used for the surface protective material 105.
Moreover, the solar cell 103 uses an amorphous silicon solar cell (thickness of about 0.35 mm) manufactured in a separate process. Further, as the roof substrate 101, a polyester-coated steel plate of a galvalume steel plate that can be used outdoors or a fluorine-coated steel plate is used.

  The pressure sensitive sheet adhesive 200 is preferably an acrylic pressure sensitive sheet adhesive Y4920 manufactured by Sumitomo 3M, and the reaction curable adhesive 201 is a silicone-modified adhesive manufactured by Cemedine. Super X is preferred. Further, as the roof substrate 202, a titanium substrate is used in the present embodiment, but a plate material having strength such as a steel plate may be used.

The reason for using two types of pressure-sensitive sheet-like adhesive 200 and reaction-curing adhesive 201 for bonding the roof substrate 202 and the back surface side sealing material 102 is the material used for the roof substrate 202. The pressure-sensitive sheet-like adhesive 200 can be bonded to any type, but the pressure-sensitive sheet-like adhesive 200 has a performance that is easy to peel off due to peeling caused by bending or the like. Therefore, the reactive curable adhesive 201 is used to compensate for this peeling. Such a reaction curable adhesive 201 is preferably used in the outer peripheral portion where the peeling is likely to occur.
Further, the reaction curable adhesive 201 requires a curing time of 3 to 4 hours at room temperature. However, as shown in FIG. 1, the maintenance of the adhesive form during this time is maintained by the pressure-sensitive sheet-like adhesive 200. Thus, the advantages and disadvantages of the two types of adhesives 200 and 201 are covered with each other's adhesive.

In the solar cell module 100 completed by the above-described configuration and manufacturing method, as a result of conducting an adhesion performance confirmation experiment using a titanium substrate as the metal material of the roof substrate 202, as shown in FIG. It was confirmed that the solar cell module 100 configured by bonding 202 and the submodule 300 to each other using the pressure-sensitive sheet adhesive 200 and the reaction curable adhesive 201 has sufficient adhesive strength.
Furthermore, as a result of performing a long-term durability confirmation test by installing the solar cell module 100 manufactured by the above-described configuration and manufacturing method on a mount or a roof of a house installed in an outdoor environment, However, the problem that the adhesive strength was lowered did not occur, and good durability was exhibited.

As described above, according to the embodiment of the present invention, the solar cell 103 is provided between the back surface side sealing material 102 and the front surface side sealing material 104, and surface protection is provided on the surface side of the front surface side sealing material 104. In the solar cell module 100 formed by laminating the material 105 and laminating and sealing the submodule 300 and bonding the submodule 300 to the surface of the outdoor substrate 202, along the upper surface of the roof substrate 202. The pressure sensitive sheet adhesive 200 and the reaction curable adhesive 201 are applied, and the back surface side sealing material 102 of the laminate-sealed submodule 300 is bonded to the upper side of the pressure sensitive sheet adhesive 200 and the reaction curing adhesive 201. Since the module 300 is bonded to the module 300, the material used for the roof substrate 202 (in this embodiment, a titanium substrate) has high adhesive strength regardless of the type. However, the pressure-sensitive sheet-like adhesive 200 having a problem in resistance to peeling caused by bending or the like and the reaction-curing adhesive 201 having a property difficult to peel against peeling caused by bending or the like are used in combination. As a result, the advantages and disadvantages of the two types of adhesives are covered with each other, and stable adhesive performance is obtained.
Thus, it is possible to provide a solar cell module 100 that has stable adhesive strength to a wide range of materials such as various metal materials and plastic materials used as the roof substrate 202 and can withstand long-term use in an outdoor environment. it can.

  In addition, a reaction curable adhesive 201 having a property that is difficult to peel off due to peeling caused by bending or the like is disposed in the vicinity of the outer periphery of the roof substrate 202 where the bent portion is formed. In addition, the pressure sensitive sheet adhesive 200 having a high adhesive strength regardless of the type used for the material used for the roof substrate 202 is disposed at the main adhesion portion on the inner peripheral side, whereby the roof substrate 202 and the submodule are arranged. 300 can be bonded uniformly with high bonding performance.

  While the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes can be made based on the technical idea of the present invention.

It is sectional drawing which shows the solar cell module which concerns on embodiment of this invention. It is sectional drawing which shows the solar cell module of a prior art.

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 Solar cell module 102 Back surface side sealing material 103 Solar cell 104 Front surface side sealing material 105 Surface protective material 200 Pressure sensitive sheet-like adhesive 201 Reaction hardening type adhesive 202 Roof substrate 300 Submodule W Folding processing allowance

Claims (4)

  A photovoltaic cell is installed between the back side sealing material and the front side sealing material, and a surface protection material is arranged on the surface side of the front side sealing material to form a laminate-sealed submodule. In the solar cell module configured by bonding the submodule to the surface of the outdoor substrate, a pressure-sensitive sheet-like adhesive and reaction curing are provided between the roof substrate and the back-side sealing material of the submodule. A sealing structure for a solar cell module, wherein a mold adhesive is disposed.   2. The reaction-curable adhesive is disposed in the vicinity of the outer periphery of the roof substrate, and the pressure-sensitive sheet-like adhesive is disposed closer to the inner periphery than the reaction-curable adhesive. Solar cell module sealing structure.   A solar battery cell is installed between the back surface side sealing material and the front surface side sealing material, and a surface protective material is disposed on the surface side of the front surface side sealing material, and is thermally fused by vacuum pressurization. A method for manufacturing a solar cell module comprising: forming a laminate-sealed sub-module; and bonding the sub-module to the surface of an outdoor substrate, the pressure-sensitive sheet-like adhesive along the upper surface of the roof substrate And the reaction-curing adhesive, the back-side sealing material of the laminate-sealed submodule is bonded to the pressure-sensitive sheet-like adhesive and the reaction-curing adhesive, and the roof substrate A method for manufacturing a solar cell module, comprising bonding the submodule.   The pressure sensitive sheet adhesive is applied in the vicinity of the central portion on the roof substrate, and then the reaction curable adhesive is applied to a portion closer to the outer periphery than the pressure sensitive sheet adhesive on the roof substrate. A method for producing a solar cell module, comprising: bonding the back-side sealing material of the laminate-sealed submodule to the pressure-sensitive sheet-like adhesive and the reaction-curable adhesive.

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