JP2008135656A - Rear-surface protecting sheet for solar battery module, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rear-surface protecting sheet for solar battery modules and a manufacturing method thereof wherein no application of its insulating processing is required in its back process, and it can intend to reduce the size and weight of a solar battery module, and further, its moisture-resistant quality and its insulating quality are made excellent. <P>SOLUTION: The rear-surface protecting sheet 10 for solar battery modules has first resin-film layers 11, 12, 13, and has a second resin-film layer 16 disposed on the first resin-film layers, and further, has an aluminum layer 14 interposed between the first and second resin-film layers and bonded to the first and second resin-film layers. The end surfaces of the aluminum layer 14 are covered with the first and second resin-film layers. The aluminum layer 14 has pierced holes 142 for inserting thereinto output-terminal lead wires 50 of a solar battery module, and the first and second resin-film layers are bonded onto at least some portions of the inner-wall surfaces out-of which each pierced hole 142 is formed. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a back protection sheet for a solar cell module disposed on the back side of a solar cell module and a method for manufacturing the same.

  There are various types of solar cells. Typical examples include crystalline silicon solar cells and amorphous silicon solar cells. Among these solar cells, amorphous silicon-based thin-film solar cells are light and flexible, and thus are promising.

  However, as described in Japanese Patent Application Laid-Open No. 6-318728 (Patent Document 1), the amorphous silicon solar cell module is easily affected by humidity. Cause problems such as degradation. In order to solve this problem, it is necessary to use a back surface protection sheet for solar cell modules that is particularly excellent in moisture resistance.

For example, Japanese Patent Application Laid-Open No. 7-321365 (Patent Document 2) describes an example in which a moisture-proof film made of only a resin layer is used as a back surface protection sheet for an amorphous silicon thin film solar cell. Since the back surface protection sheet consisting only of the resin layer is inferior in moisture resistance, an example in which a white film having high moisture resistance in which an aluminum foil is sandwiched with polyvinyl fluoride (PVF) is used in place of the moisture resistance film is also disclosed in the above publication Has been.
JP-A-6-318728 JP-A-7-321365

  Thus, when using aluminum foil as a constituent member of a back surface protection sheet, it becomes difficult to maintain insulation if the aluminum foil is present on the entire surface. Therefore, it is necessary to insulate the back protection sheet where insulation is required.

  FIG. 9 is a diagram showing a schematic cross-sectional structure of a conventional solar cell module to which the back surface protection sheet for a solar cell module is applied.

  As shown in FIG. 9, a large number of solar cell elements 1 are arranged in the solar cell module 100. These solar cell elements 1 are electrically connected to each other through connection wires 3 via electrodes 2, and the solar cell module 100 as a whole has a terminal 5 taken out on the back side by a lead wire 4, and the terminal 5 is a terminal box 6. It is stored in. A filler 7 such as an ethylene-vinyl acetate copolymer (EVA) resin is disposed to seal a large number of solar cell elements 1. A transparent glass layer 8 is fixed to the outer surface of the filler 7 located on the light receiving surface side of the solar cell module. On the outer surface of the filler 7 located on the installation surface side of the solar cell module, a back surface protection sheet 10 for the solar cell module is fixed. An aluminum frame member 9 is attached to the side surface of the solar cell module 100 via a sealing material.

  FIG. 10 is a partial cross-sectional view showing a schematic structure of a part of a conventional solar cell module.

  As shown in FIG. 10, a through-hole is formed in the back surface protection sheet 10 for inserting the output terminal lead wire 50 of the solar cell element. Around the through hole, annular insulating seals 51 and 52 having a thickness of 20 to 100 μm and an outer diameter of D (4 to 5 cm) are attached to the front and back surfaces of the back surface protection sheet 10, respectively. Thereby, an insulating inner wall surface having an inner diameter d (about 12 mm) smaller than D is formed. An output terminal lead wire 50 is inserted into the through hole having the inner diameter d. Insulation is maintained by the insulating seals 51 and 52 in this way, but the moisture-proof function by the aluminum foil constituting a part of the back surface protection sheet 10 is impaired, and only the insulating seals 51 and 52 enter water vapor. Is preventing. For this reason, there exists a problem that the moisture-proof function of a back surface protection sheet falls.

  Further, as shown in FIG. 10, as a sealing material, the metal frame member 9 covering the outer peripheral portion of the back surface protection sheet 10 is not directly in contact with the end surface of the aluminum foil constituting a part of the back surface protection sheet 10. An insulating spacer or packing 91 needs to be disposed between the frame member 9 and the back surface protection sheet 10. For this reason, a space for disposing an insulating spacer or packing 91 is required, which is an obstacle to reducing the size and weight of the solar cell module.

  That is, in the through hole or the output terminal outlet for inserting the output terminal lead wire of the solar cell element, it is necessary to perform a process of attaching an insulating seal around the hole after drilling the back surface protection sheet. . Moreover, it is necessary to arrange | position an insulating spacer between a back surface protection sheet and a frame member so that the metal frame member which covers the outer peripheral part of a back surface protection sheet may not contact an end surface of aluminum foil directly. There is a problem that this is an obstacle to reducing the size and weight of the solar cell module.

  Accordingly, an object of the present invention is to eliminate the need for an insulation treatment in a subsequent process, and to reduce the size and weight of the solar cell module and to provide a moisture-proof and insulating back surface protection sheet for a solar cell module. And a manufacturing method thereof.

  The back surface protection sheet for solar cell modules according to this invention is a back surface protection sheet for solar cell modules arranged on the back surface side of the solar cell module, and includes a first resin film layer and a first resin film layer. The second resin film layer disposed above, and aluminum bonded between the first resin film layer and the second resin film layer, interposed between the first resin film layer and the second resin film layer And a layer. The end surface of the aluminum layer is covered with a first resin film layer and a second resin film layer. The aluminum layer has a through hole for inserting the output terminal lead wire of the solar cell module, and the first resin film layer and the second resin are formed on at least a part of the inner wall surface forming the through hole. The film layer is bonded.

  First, in the back surface protection sheet for solar cell modules of this invention, the end surface of the aluminum layer is insulated and separated from the outside by being covered with the first resin film layer and the second resin film layer. Thereby, it is not necessary to arrange | position an insulating spacer between a back surface protection sheet and a frame member so that the metal frame members which cover the outer peripheral part of a back surface protection sheet may not contact an end surface of an aluminum layer directly.

  Next, in the back surface protection sheet for the solar cell module of the present invention, the first resin is formed on at least a part of the inner wall surface of the through hole of the aluminum layer formed to insert the output terminal lead wire. Since the film layer and the second resin film layer are bonded, the first and second resin film layers insulate and separate the inner wall surface of the aluminum layer and the lead wire. For this reason, in the through hole for inserting the output terminal lead wire of the solar cell element or the output terminal take-out port, it is not necessary to apply an insulating seal around the hole after the back surface protection sheet is subjected to the drilling process. In addition, when the lead wire is inserted in a subsequent process, the first and second resin film layers are formed around the through hole of the aluminum layer in a state where a hole smaller than the through hole of the aluminum layer is opened by machining. The aluminum layer can prevent water vapor from entering. For this reason, the moisture-proof function of the back surface protection sheet in the lead wire insertion hole can be enhanced.

  Therefore, it is not necessary to perform an insulation process in a subsequent process, and the solar cell module can be reduced in size and weight, and a back protective sheet for a solar cell module excellent in moisture resistance and insulation can be obtained.

  The manufacturing method of the back surface protection sheet for solar cell modules according to this invention is a manufacturing method of the back surface protection sheet for solar cell modules arrange | positioned at the back surface side of a solar cell module, Comprising: The following processes are provided.

  (A) A step of bonding an aluminum foil on the first resin film layer.

  (B) A step of forming a resist layer having a predetermined pattern on the aluminum foil.

  (C) The process of forming the aluminum layer which has an end surface located inside the end surface of a 1st resin film layer, and a through-hole by removing an aluminum foil by an etching using a resist layer as a mask.

  (D) The first resin film layer and the second resin are coated on the end face of the aluminum layer by adhering the second resin film layer onto the aluminum layer and enter the through hole of the aluminum layer. Forming a film layer;

  As described above, according to the present invention, it is not necessary to perform an insulation process in a subsequent process, and the solar cell module can be reduced in size and weight, and the back surface for the solar cell module is excellent in moisture resistance and insulation. A protective sheet can be obtained.

  FIGS. 1-7 is schematic sectional drawing which shows the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention in order of a process.

  As shown in FIG. 1, a transparent polyethylene terephthalate (PET) film 11 is prepared, and a colored PET film 12 is adhered to the surface of one side of the PET film 11 with an adhesive as shown in FIG.

  Next, as shown in FIG. 3, the surface on one side of the silica-deposited PET film 13 is bonded to the surface on the other side of the PET film 11 with an adhesive. The 1st resin film layer of this invention is comprised as mentioned above.

  Then, as shown in FIG. 4, the aluminum foil 14 is adhere | attached on the surface of the other side of the silica vapor deposition PET film 13 with an adhesive agent.

  As shown in FIG. 5, a resist layer 15 having a predetermined pattern is formed on the aluminum foil 14. By using this resist layer 15 as a mask, the aluminum foil 14 is removed by etching, and then the resist layer 15 is peeled off, whereby the edge region 141 (width L: 10 to 10) of the aluminum foil 14 is removed as shown in FIG. 15 mm) and a through-hole 142 (diameter d0: about 15 mm) for inserting the output terminal lead wire of the solar cell module is formed. That is, the aluminum layer 14 having an end surface located inside the end surfaces of the PET films 11, 12 and 13 constituting the first resin film layer and the through hole 142 is formed.

  And as shown in FIG. 7, the end surface of the aluminum layer 14 is coat | covered by adhere | attaching the white fluorine film 16 as a 2nd resin film layer on the aluminum layer 14 with an adhesive agent, and an aluminum layer The PET film 13 and the fluorine film 16 are formed so as to enter the 14 through holes 142.

  Thus, the back surface protection sheet 10 for solar cell modules of this invention is manufactured. In the back surface protective sheet 10, the end surface of the aluminum layer 14 is covered with a PET film 13 constituting the first resin film layer and a fluorine film 16 as the second resin film layer. The aluminum layer 14 has a through hole 142 for inserting the output terminal lead wire of the solar cell module, and the first resin is formed on at least a part of the inner wall surface forming the through hole 142. The PET film 13 constituting the film layer and the fluorine film 16 as the second resin film layer are bonded. In FIG. 7, the PET film 13 and the fluorine film 16 are bonded to the aluminum layer 14 so as to fill the through holes 142.

  The obtained back surface protection sheet 10 is incorporated in the solar cell module 100 as shown in FIG.

  FIG. 8 is a partial cross-sectional view schematically showing a portion where the back surface protection sheet is incorporated in the solar cell module.

  The obtained back surface protection sheet is cut into a predetermined size, for example, a width of 800 to 900 mm and a length of 1200 to 1600 mm by machining, and the lead wire having an outer diameter of d2 as shown in FIG. In order to insert 50, a through-hole (diameter d1: about 12 mm) smaller than the through-hole 142 (FIG. 6) of the aluminum layer 14 is formed in the back surface protection sheet 10 by a punching punch. An aluminum frame member 9 is attached to the side surface of the solar cell module.

  In the back surface protection sheet 10 for solar cell modules of this invention, the end surface of the aluminum layer 14 is covered with the PET film 13 constituting the first resin film layer and the fluorine film 16 as the second resin film layer. Insulated and separated from the outside. Accordingly, it is necessary to dispose an insulating spacer between the back surface protection sheet 10 and the frame member 9 so that the metal frame member 9 covering the outer peripheral portion of the back surface protection sheet 10 does not directly contact the end surface of the aluminum layer 14. There is no.

  Moreover, in the back surface protection sheet 10 for solar cell modules of this invention, on the at least one part of the inner wall face of the through-hole 142 (FIG. 6) of the aluminum layer 14 formed in order to insert the lead wire 50 for output terminals. Since the PET film 13 constituting the first resin film layer and the fluorine film 16 as the second resin film layer are bonded to each other, the first and second resin film layers are included in the aluminum layer 13. The wall surface and the lead wire 50 are insulated and separated. For this reason, in the through hole for inserting the output terminal lead wire 50 of the solar cell element or the output terminal take-out port, it is not necessary to apply an insulating seal around the hole after the back surface protection sheet is subjected to the drilling process. .

  Furthermore, as shown in FIG. 8, in the state where the through holes smaller than the through holes of the aluminum layer 14 are opened around the through holes of the aluminum layer 14 when the lead wire 50 is inserted in a later process. The PET film 13 constituting the first resin film layer, the fluorine film 16 as the second resin film layer, and the aluminum layer 14 can prevent water vapor from entering. For this reason, the moisture-proof function of the back surface protection sheet 10 in the lead wire insertion hole can be enhanced.

  Therefore, it is not necessary to perform an insulation process in a subsequent process, and the solar cell module can be reduced in size and weight, and a back protective sheet for a solar cell module excellent in moisture resistance and insulation can be obtained.

  In the back surface protective sheet 10, the first resin film layer is formed of a polyethylene naphthalate (PEN) film, a polyethylene fluoride (PVF) film, or a polyethylene difluoride instead of the PET films 11, 12, and 13 as described above. A (PVDF) film or the like may be used, and a plurality of these types of films may be combined. As described above, instead of the fluorine film 16, the second resin film layer may be a PET film, a PEN film, a PVF film, or a PVDF film, and is configured by combining these plural types of films. Also good.

  The Example of the back surface protection sheet for solar cell modules was produced as follows.

  As shown in FIG. 1, a transparent PET film 11 (product name: Lumirror S10, manufactured by Toray Industries, Inc.) having a thickness of 188 μm is prepared, and a dry laminate is formed on the surface of one side of the PET film 11 as shown in FIG. A black PET film 12 (product name: Lumirror X30, manufactured by Toray Industries, Inc.) having a thickness of 50 μm was adhered by a dry laminating method using an adhesive.

  Next, as shown in FIG. 3, on the surface of the other side of the PET film 11, a silica-deposited PET film 13 having a thickness of 12 μm (product name Tech Barrier, manufactured by Mitsubishi Plastics Co., Ltd.) is formed in the same manner as described above. The surface on one side of P2) was adhered. The 1st resin film layer of this invention was comprised as mentioned above.

  Thereafter, as shown in FIG. 4, a soft aluminum foil 14 having a thickness of 7 μm of JIS 1N30 was adhered on the surface of the other side of the silica-deposited PET film 13 by the dry lamination method in the same manner as described above.

  As shown in FIG. 5, a resist layer 15 having a predetermined pattern was formed on the aluminum foil 14 by a gravure printing method. By using this resist layer 15 as a mask, the aluminum foil 14 is removed by chemical etching in a ferric chloride solution, and then the resist layer 15 is peeled off in an alkaline solution to obtain aluminum as shown in FIG. While removing the edge area | region 141 (width L: 10-15 mm) of the foil 14, the through-hole 142 (diameter d0: about 15 mm) for inserting the lead wire for output terminals of a solar cell module was formed.

  Then, as shown in FIG. 7, on the aluminum layer 14, a white fluorine film 16 having a thickness of 20 μm as a second resin film layer by a dry lamination method in the same manner as described above (manufactured by Electrochemical Industry Co., Ltd., By bonding the product name Denka DX10WT01220), the PET film 13 and the fluorine film 16 were formed so as to cover the end face of the aluminum layer 14 and enter the through hole 142 of the aluminum layer 14.

  Thus, the back surface protection sheet 10 for solar cell modules of this invention as a roll-shaped sheet | seat original plate was produced.

  The obtained back surface protection sheet as a roll-shaped sheet original plate is cut into a predetermined size, for example, a width of 800 to 900 mm and a length of 1200 to 1600 mm by machining, as shown in FIG. In order to insert the lead wire 50, a through hole (diameter d1: about 12 mm) smaller than the through hole 142 (FIG. 6) of the aluminum layer 14 was formed in the back surface protective sheet 10 by punching. In this way, a single back surface protection sheet 10 incorporated in the solar cell module 100 was produced.

  It should be considered that the embodiments and examples disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is shown not by the above embodiments and examples but by the scope of claims, and is intended to include all modifications and variations within the meaning and scope equivalent to the scope of claims. .

It is rough sectional drawing which shows a 1st process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 2nd process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 3rd process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 4th process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 5th process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 6th process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is schematic sectional drawing which shows a 7th process in the manufacturing method of the back surface protection sheet for solar cell modules as one embodiment of this invention. It is a fragmentary sectional view which shows roughly the location where the back surface protection sheet was integrated in the solar cell module. It is a figure which shows schematic sectional structure of the conventional solar cell module to which the back surface protection sheet for solar cell modules is applied. It is a fragmentary sectional view which shows the schematic structure of a part of conventional solar cell module.

Explanation of symbols

  9: Frame member, 10: Back surface protection sheet for solar cell module, 11, 12, 13: PET film (first resin film layer), 14: Aluminum foil (aluminum layer), 15: Resist layer, 16: Fluorine film (Second resin film layer), 50: lead wire, 100: solar cell module, 142: through hole.

Claims (2)

A back protection sheet for a solar cell module disposed on the back side of the solar cell module,
A first resin film layer;
A second resin film layer disposed on the first resin film layer;
An aluminum layer interposed between the first resin film layer and the second resin film layer and bonded to the first resin film layer and the second resin film layer;
The end face of the aluminum layer is covered with the first resin film layer and the second resin film layer, and the aluminum layer has a through hole for inserting the output terminal lead wire of the solar cell module. The back protective sheet for a solar cell module, wherein the first resin film layer and the second resin film layer are adhered to at least a part of the inner wall surface forming the through hole. A method for manufacturing a back surface protection sheet for a solar cell module disposed on the back surface side of the solar cell module,
Bonding an aluminum foil on the first resin film layer;
Forming a resist layer having a predetermined pattern on the aluminum foil;
By removing the aluminum foil by etching using the resist layer as a mask, an aluminum layer having an end surface located inside the end surface of the first resin film layer and a first through hole is formed. Process,
By adhering the second resin film layer on the aluminum layer, the end surface of the aluminum layer is covered, and the first resin film layer and the second so as to enter the through hole of the aluminum layer. The manufacturing method of the back surface protection sheet for solar cell modules provided with the process of forming the resin film layer.

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