JP2013030678A - Solar cell module and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a compact solar cell module.SOLUTION: A solar cell module 10 includes: a translucent member 16 disposed on the light receiving side; a rear surface member 26 provided so as to face the translucent member 16; a photovoltaic device 12 provided between the translucent member 16 and the rear surface member 26; and a filler 24 filling a space between the translucent member 16 and the rear surface member 26; and a terminal box 40 housing a terminal outputting electric energy generated by the photovoltaic device 12 to the exterior. The rear surface member 26 is provided with a through hole 26a. The terminal box 40 is provided so that at least a part of the terminal box 40 is positioned in the through hole 26a and forms a clearance with an inner wall of the through hole 26a. The filler 24 fills at least a part of the clearance between the inner wall of the through hole and the terminal box 40.

Description

  The present invention relates to a solar cell module and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, so-called solar cells have been vigorously developed in various fields as photoelectric conversion devices that convert light energy into electrical energy. Solar cells are expected to be a new energy source because they can directly convert light from the sun, a clean and inexhaustible energy source, into electricity.

  In many cases, a solar cell is modularized, and includes an output terminal for outputting generated electricity to the outside. Such an output terminal is usually provided in a state of protruding to the back side opposite to the sunlight receiving surface (see, for example, Patent Document 1).

Japanese Patent Laid-Open No. 9-279789

  However, the solar cell module provided with the projecting output terminal is increased in thickness as a whole even if the solar cell panel is thin. For this reason, when a plurality of solar cell modules are loaded, a lot of useless space is generated. That is, the number of solar cell modules that can be mounted at one time during transportation is reduced. As a result, the transportation cost increases.

  The present invention has been made in view of such circumstances, and an object thereof is to provide a compact solar cell module.

  In order to solve the above problems, a solar cell module according to an aspect of the present invention includes a translucent member disposed on the light receiving side, a back member provided to face the translucent member, and a translucent member The photovoltaic device provided between the member and the back member, the filler filling the space between the translucent member and the back member, and the electrical energy generated by the photovoltaic device are output to the outside And a storage section for storing terminals to be performed. The back member is provided with a through hole, and the storage part is provided so that at least a part thereof is located inside the through hole and has a gap with the inner wall of the through hole. At least a part of the gap between the inner wall of the hole and the storage portion is filled.

  Another aspect of the present invention is a method for manufacturing a solar cell module. In this method, a step of preparing a translucent member provided with a photovoltaic device on one surface, a step of arranging a filler so as to cover the photovoltaic device, and a back surface provided with a through hole A member, a housing part that houses a terminal that is disposed in the through hole and that outputs a terminal that outputs electric energy generated by the photovoltaic device to the outside, a translucent member, and a back member; And filling the space between the translucent member and the back surface member with a filler, and fixing the storage portion with the filler that has entered the gap between the inner wall of the through hole and the storage portion.

  ADVANTAGE OF THE INVENTION According to this invention, a compact solar cell module and its manufacturing method can be provided.

It is a top view at the time of seeing the solar cell module which concerns on this Embodiment from the opposite side to a sunlight light-receiving surface. It is AA sectional drawing of the solar cell module shown in FIG. It is BB sectional drawing of the photovoltaic element shown in FIG. It is a schematic diagram of the cross section for demonstrating the process of the manufacturing method of the solar cell module which concerns on this Embodiment. It is a schematic diagram of the cross section for demonstrating the process of the manufacturing method of the solar cell module which concerns on this Embodiment. It is a schematic diagram of the cross section for demonstrating the process of the manufacturing method of the solar cell module which concerns on this Embodiment. It is a schematic diagram of the cross section for demonstrating the process of the manufacturing method of the solar cell module which concerns on this Embodiment. It is a schematic diagram of the cross section for demonstrating the process of the manufacturing method of the solar cell module which concerns on this Embodiment. It is sectional drawing of the solar cell module which concerns on the modification of this Embodiment. It is a perspective view of the terminal box used for the solar cell module concerning a modification. It is sectional drawing of the solar cell module which concerns on the other modification of this Embodiment. It is sectional drawing of the solar cell module which concerns on the other modification of this Embodiment.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate.

  The scales and shapes of each layer and each part shown in the following drawings are set for convenience of explanation, and are not limitedly interpreted unless otherwise specified.

(First embodiment)
FIG. 1 is a top view when the solar cell module according to the present embodiment is viewed from the side opposite to the sunlight receiving surface. 2 is a cross-sectional view taken along the line AA of the solar cell module shown in FIG. In FIG. 1, the sealing member, the filler, and the back surface member are omitted.

  The solar cell module 10 includes a photovoltaic device 12, a sealing member 14, a translucent member 16, an insulator 20, an interconnector 22, a filler 24, and a back member 26 as a protective material.

  The photovoltaic device 12 is a rectangular flat plate or film-like unit, and a plurality of photovoltaic elements 28 are arranged in an aligned state. Each photovoltaic element 28 is appropriately connected to each other in series or in parallel.

  The translucent member 16 is made of a material that transmits light, and a plurality of photovoltaic elements 28 are formed as the photovoltaic device 12 on the back surface 16b opposite to the light receiving surface 16a.

  Thus, the translucent member 16 is arrange | positioned so that the photovoltaic apparatus 12 may be covered when the light-receiving surface 16a is seen from the front. In addition, as the translucent member 16, insulating glass, plastic, or the like can be used, and in particular, a material having high transmittance with respect to light having a wavelength included in sunlight is preferable.

  Next, the photovoltaic element 28 will be described. 3 is a cross-sectional view of the photovoltaic element shown in FIG. The photovoltaic element 28 includes a first electrode layer 30, a semiconductor layer 32, a transparent conductive film 34, and a second electrode layer 36. The first electrode layer 30, the semiconductor layer 32, the transparent conductive film 34, and the second electrode layer 36 are sequentially stacked on the translucent member 16 while performing known laser patterning. A filler 24 and a back member 26 are laminated on the second electrode layer 36.

  The first electrode layer 30 is formed on the surface of the translucent member 16 and has conductivity and translucency. As the first electrode layer 30 according to the present embodiment, a transparent conductive oxide (TCO) is used, and in particular, zinc oxide (ZnO) having high light transmittance, low resistance, and low cost is used. Used.

  The semiconductor layer 32 generates charges (electrons and holes) by incident light from the first electrode layer 30 side. As the semiconductor layer 32, for example, an amorphous (amorphous) silicon semiconductor layer having a pin junction or a pn junction as a basic structure, or a single layer or a stacked body of a microcrystalline silicon semiconductor layer can be used. The semiconductor layer 32 according to the present embodiment is configured by laminating an amorphous silicon semiconductor and a microcrystalline silicon semiconductor from the first electrode layer 30 side. Note that in this specification, the term “microcrystal” means not only a complete crystal state but also a state partially including an amorphous state.

  The transparent conductive film 34 is formed on the semiconductor layer 32. The transparent conductive film 34 prevents the semiconductor layer 32 and the second electrode layer 36 from being alloyed, and the connection resistance between the semiconductor layer 32 and the second electrode layer 36 can be reduced.

  The second electrode layer 36 is formed on the transparent conductive film 34. A reflective metal such as silver (Ag) is used for the second electrode layer 36. The transparent conductive film 34 and the second electrode layer 36 of one photovoltaic element 28 are in contact with the first electrode layer 30 of another adjacent photovoltaic element 28. Thereby, one photovoltaic element 28 and the other photovoltaic element 28 are electrically connected in series.

  The interconnector 22 shown in FIGS. 1 and 2 guides the electric charges generated by the plurality of photovoltaic elements 28 connected in series in this way to the outside of the solar cell module 10. The interconnector 22 has a conduction portion 22a that is electrically connected to the photovoltaic elements 28 at both ends among the plurality of photovoltaic elements 28 connected in series. The interconnector 22 is preferably a low resistivity material such as copper (Cu). An insulator 20 is disposed in a predetermined region between the interconnector 22 and the plurality of photovoltaic elements 28, and the lead-out wiring 22b of the interconnector 22 and the plurality of photovoltaic elements 28 are partially insulated. Is done.

  The filler 24 is disposed so as to seal the photovoltaic device 12 and the interconnector 22 between the translucent member 16 and the back surface member 26 and to buffer the impact applied to the photovoltaic element 28. . In the present embodiment, ethylene vinyl acetate (EVA) is used as the filler 24. In the present embodiment, inexpensive blue glass (float glass) is used as the back member 26. In addition, the blue plate glass contains alkali metals, such as sodium (Na), as an impurity ion, for example. The back surface member 26 improves the strength of the entire solar cell module 10 and prevents moisture and impurities from entering from the back surface side of the solar cell module 10.

  One end of the lead-out wiring 22b of the interconnector 22 passes through the filler 24 and is connected to the terminal box 40.

(Method for manufacturing solar cell module)
Next, the manufacturing method of a solar cell module provided with the above-mentioned solar cell is demonstrated. In the following, a solar cell module including a plurality of photovoltaic elements 28 will be described. However, a solar cell module including one photovoltaic element 28 may be used.

  4 to 8 are schematic cross-sectional views for explaining the steps of the method for manufacturing the solar cell module according to the present embodiment.

First, as shown in FIG. 4A, a first electrode layer 30 made of zinc oxide (ZnO) having a thickness of 600 nm is formed on a translucent member 16 made of glass having a thickness of 4 mm by sputtering. And the YAG laser is irradiated from the 1st electrode layer 30 side of the translucent member 16, and the 1st electrode layer 30 is patterned in strip shape. For the laser separation processing, an Nd (neodymium): YAG laser having a wavelength of 1064 nm, an energy density of 13 J / cm ² and a pulse frequency of 3 kHz is used.

  Next, as shown in FIG. 4B, a semiconductor layer 32 is formed by a plasma processing apparatus (plasma CVD). The semiconductor layer 32 includes a p-type amorphous silicon semiconductor film having a thickness of 15 nm, an i-type amorphous silicon semiconductor film having a thickness of 200 nm, an n-type amorphous silicon semiconductor film having a thickness of 30 nm, a p-type microcrystalline silicon semiconductor film having a thickness of 30 nm, An i-type microcrystalline silicon semiconductor film having a thickness of 2000 nm and an n-type microcrystalline silicon semiconductor film having a thickness of 30 nm are sequentially stacked on the first electrode layer 30.

The p-type amorphous silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ), methane (CH ₄ ), hydrogen (H ₂ ), and diborane (B ₂ H ₆ ) as a source gas. The i-type amorphous silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ) and hydrogen (H ₂ ) as a source gas. The n-type amorphous silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ), hydrogen (H ₂ ) and phosphine (PH ₃ ) as a source gas.

The p-type microcrystalline silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ), hydrogen (H ₂ ), and diborane (B ₂ H ₆ ) as a source gas. The i-type microcrystalline silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ) and hydrogen (H ₂ ) as a source gas. The n-type microcrystalline silicon semiconductor film is formed using a mixed gas of monosilane (SiH ₄ ), hydrogen (H ₂ ), and phosphine (PH ₃ ) as a source gas. The details of the film forming conditions of each film by the plasma processing apparatus are shown in Table 1 below.

Note that 30 nm-thick silicon oxide (SiO _x ) may be provided as an intermediate layer between the n-type amorphous silicon semiconductor film and the p-type microcrystalline silicon semiconductor film. Such an intermediate layer is formed by sputtering or the like.

A semiconductor layer formed on the back surface side of the front glass plate 16 by irradiating a YAG laser from the front surface side (front glass plate 16 side) to a position outside the patterning position of the laminated semiconductor layer 32 and the first electrode layer 30. 32 is removed so as to be separated and patterned into strips. For the laser separation processing, an Nd (neodymium): YAG laser having a wavelength of 532 nm (second harmonic), an energy density of 0.7 J / cm ² , and a pulse frequency of 3 kHz is used.

  Next, as shown in FIG. 4C, a transparent conductive film 34 made of zinc oxide (ZnO) is formed on the semiconductor layer 32 by sputtering. The transparent conductive film 34 is also formed in regions and side edges where the semiconductor layer 32 has been removed by patterning.

  Then, as shown in FIG. 5A, a 200 nm-thick silver (Ag) film is formed on the transparent conductive film 34 by sputtering to form the second electrode layer 36. At this time, the second electrode layer 36 is also formed on the transparent conductive film 34 in the region where the semiconductor layer 32 is removed by patterning.

Next, as shown in FIG. 5B, the semiconductor layer 32 and the transparent conductive film 34 are irradiated by irradiating a portion of the semiconductor layer 32 shifted from the patterning position with a YAG laser from the surface side (surface glass plate 16 side). The second electrode layer 36 is separated and patterned into a strip shape. For the laser separation processing, an Nd (neodymium): YAG laser having a wavelength of 532 nm, an energy density of 0.7 J / cm ² , and a pulse frequency of 4 kHz is used. Thereby, a plurality of photovoltaic elements 28 are formed.

Next, as shown in FIG. 5C, the transparent conductive film 34 and the second electrode layer 36 that wrap around the side portions (outermost circumference) of the first electrode layer 30 and the semiconductor layer 32 are irradiated from the surface side. Removed by a laser. For the laser removal processing, an Nd (neodymium): YAG laser having a wavelength of 1064 nm, an energy density of 13 J / cm ² and a pulse frequency of 3 kHz is used.

  As described above, the plurality of photovoltaic elements 28 connected in series with each other are formed on the translucent member 16.

  Next, as shown in FIG. 6, the translucent member 16 provided with the photovoltaic device 12 on one surface is prepared by the method described above. And the insulator 20 and the interconnector 22 are arrange | positioned on the photovoltaic apparatus 12, and it is set as the state which started up the one end of the extraction wiring 22b.

  Next, as shown in FIG. 7, a sheet-like filler 24 made of ethylene vinyl acetate (EVA) that covers the photovoltaic device 12 is disposed on the photovoltaic device 12. Moreover, the sealing member 14 is arrange | positioned on four sides of the outer edge part of the back surface 16b of the translucent member 16 so that the photovoltaic apparatus 12 may be enclosed. The filler 24 is provided with a hole 24a so that one end of the lead wire 22b is drawn to the outside, and the lead wire 22b is passed through the hole 24a.

  Next, as shown in FIG. 8, the back surface member 26 provided with the through hole 26a and the storage for storing the terminals arranged in the through hole 26a and outputting the electrical energy generated by the photovoltaic device 12 to the outside. The terminal box 40 as a part is disposed on the filler 24. At this time, the lead wiring 22b and the terminal box 40 are connected. The through hole 26a has a shape corresponding to the terminal box 40, and is sized so that a slight gap 46 is formed between the through hole 26a and the terminal box 40 in a state where the terminal box 40 is disposed in the through hole 26a. Yes.

  Note that the rear member 26 and the terminal box 40 may be arranged in any order. For example, after the back surface member 26 is disposed on the filler 24, the terminal box 40 may be disposed so that the through hole 26 a and the gap 46 are formed in the through hole 26 a of the back surface member 26. Alternatively, the back surface member 26 may be disposed after the terminal box 40 is disposed at a predetermined position on the filler 24.

  And the solar cell module 10 is produced by heating the translucent member 16 and the back surface member 26 in this state, pressing in a vacuum atmosphere. At that time, the light-transmitting member 16 and the back surface member 26 are in close contact with each other when the molten filler 24 enters the gap 48, and the gap 46 between the inner wall of the through hole 26 a of the back surface member 26 and the terminal box 40. As a result, the terminal box 40 is firmly fixed to the back surface member 26. In addition, since the molten filler 24 enters the gap 46 and the gap 48 integrally and continuously, the terminal box 40 is more firmly fixed to the back surface member 26.

  According to such a manufacturing method, since the terminal box 40 arrange | positioned at the through-hole 26a can be fixed simultaneously when crimping | bonding the translucent member 16 and the back surface member 26, a manufacturing process can be simplified.

  As described above, the solar cell module 10 according to the present embodiment is provided so as to face the translucent member 16 disposed on the light receiving side and the translucent member 16, as shown in FIG. A back member 26, a photovoltaic device 12 provided between the translucent member 16 and the back member 26, and a filler 24 that fills a space between the translucent member 16 and the back member 26; And a terminal box 40 that houses a terminal that outputs electric energy generated in the photovoltaic device 12 to the outside. The back member 26 is provided with a through hole 26a, and the terminal box 40 is provided so that at least a part thereof is located inside the through hole 26a and has a gap with the inner wall of the through hole 26a. The filler 24 fills at least a part of the gap between the inner wall of the through hole 26 a and the terminal box 40.

  Therefore, since at least a part of the terminal box 40 is located inside the through hole 26a, the solar cell module 10 can suppress the height of the terminal box 40 protruding from the front surface 26b of the back member 26 (see FIG. 2). Therefore, the space utilization efficiency when a plurality of solar cell modules 10 are stacked can be increased.

  Note that the terminal box 40 according to the present embodiment is disposed inside the through hole 26 a so as not to protrude from the front surface 26 b of the back member 26. That is, the terminal box 40 is completely embedded in the through hole 26a. Thereby, the utilization efficiency of the space when a plurality of solar cell modules 10 are stacked can be further increased. Moreover, it becomes possible to stack | stack the several solar cell module 10 stably, and workability | operativity and transportability improve.

  In addition, as shown in FIG. 2, it is good to fill the area | region 46a in which the filler 24 does not enter among the clearance gaps around the terminal box 40 with butyl rubber 49. Thereby, the penetration | invasion of the water | moisture content from the through-hole 26a to the inside of the solar cell module 10 can be suppressed. The butyl rubber 49 may protrude from the region 46a to the front surface 26b of the back member 26 so as to cover the through hole 26a. Further, in the state where the terminal box 40 is disposed in the through hole 26a, when the upper surface 40a of the terminal box 40 is positioned inside the through hole 46a rather than the front surface 26b of the back member 26, in addition to the region 46a described above, the terminal box The upper surface 40a of 40 may be covered with butyl rubber 49. At that time, by adjusting the butyl rubber 49 covering the upper surface 40a of the terminal box 40 to be the same height as the front surface 26b of the back surface member 26, the back surface member 26 side of the solar cell module 10 becomes flat. Loadability is improved.

  Further, the through hole 26 a according to the present embodiment is provided in the substantially central portion of the back surface member 26. Thereby, the intensity | strength of the back surface member 26 and the solar cell module 10 becomes difficult to become non-uniform | heterogenous. Further, the filler 24 melted when the translucent member 16 and the back surface member 26 are pressure-bonded easily enters the gap between the through hole 26 a and the terminal box 40 uniformly.

  FIG. 9 is a cross-sectional view of a solar cell module according to a modification of the present embodiment. The solar cell module 50 shown in FIG. 9 differs from the above-described solar cell module 10 in the shape of the through hole formed in the back surface member and the shape of the terminal box. FIG. 10 is a perspective view of a terminal box used for a solar cell module according to a modification.

  As shown in FIG. 10, the terminal box 42 has a flange portion 42a at the bottom. Therefore, in the back surface member 44 shown in FIG. 9, a stepped through hole 44 a corresponding to the flange portion 42 a of the terminal box 42 is formed. The size of the through hole 44a is set such that a slight gap is formed between the through hole 44a and the terminal box 42 in a state where the terminal box 42 is disposed in the through hole 44a.

  Therefore, as shown in FIG. 9, since the terminal box 42 is embedded in the through hole 44a, it is fixed by the filler 24, and the flange portion 42a of the terminal box 42 is locked at the step of the through hole 44a. The terminal box 42 is firmly fixed by the solar cell module 50. In addition, the terminal box 42 is reliably fixed to the solar cell module 50 without providing a level | step difference in the through-hole 44a by making the above-mentioned flange part 42a into a thin sheet form. Thereby, the process at the time of forming the through-hole 44a in the back surface member 44 becomes easy, and the processing cost is reduced.

  In addition, as shown in FIG. 9, it is good to fill the area | region 46a in which the filler 24 does not enter among the clearance gaps around the terminal box 42 with the butyl rubber 49. Thereby, the penetration | invasion of the water | moisture content from the through-hole 44a to the solar cell module 10 inside can be suppressed. The butyl rubber 49 may protrude from the region 46a to the front surface 26b of the back member 26 so as to cover the through hole 44a.

  FIG. 11 is a cross-sectional view of a solar cell module according to another modification of the present embodiment. The solar cell module 60 shown in FIG. 11 is greatly different from the solar cell module 10 described above in that the filler 24 enters the entire gap 46. In particular, the solar cell module 60 shown in FIG. 11 is configured such that the position 24 a of the end portion of the filler 24 is the same position as the front surface 26 b of the back member 26. The butyl rubber 49 is provided so as to cover the through hole 26a.

  FIG. 12 is a cross-sectional view of a solar cell module according to another modification of the present embodiment. In the solar cell module 70 shown in FIG. 12, as compared with the above-described solar cell module 10, the filler 24 enters the entire gap 46, and a part of the filler 24 protrudes to the surface 26 b of the back member 26. There is a big difference. The butyl rubber 49 is provided so as to cover the through hole 26a.

  As described above, the present invention has been described with reference to the above-described embodiment. However, the present invention is not limited to the above-described embodiment, and the present invention can be appropriately combined or replaced with the configuration of the embodiment. It is included in the present invention. In addition, it is possible to appropriately change the combination and processing order in the embodiment based on the knowledge of those skilled in the art and to add various modifications such as various design changes to the embodiment. The described embodiments can also be included in the scope of the present invention.

  As the sealing member 14 and the filler 24 according to the above-described embodiment, in addition to butyl rubber and ethylene vinyl acetate (EVA), a material used for caulking such as silicone, a filling resin material such as polyvinyl butyral (PVB), ethylene ethyl acrylate You may use ethylene-type resins, such as a copolymer (EEA), urethane, an acryl, an epoxy resin.

As the first electrode layer 30 according to each of the above-described embodiments, in addition to zinc oxide (ZnO), tin oxide (SnO ₂ ), indium oxide (In ₂ O ₃ ), titanium oxide (TiO ₂ ), zinc stannate (Zn 2 _{SnO 4)} may be configured by a metal one kind selected from oxides or plural kinds of laminates such. Note that these metal oxides may be doped with fluorine (F), tin (Sn), aluminum (Al), gallium (Ga), niobium (Nb), or the like.

  DESCRIPTION OF SYMBOLS 10 Solar cell module, 12 Photovoltaic apparatus, 16 Translucent member, 16a Light-receiving surface, 16b Back surface, 24 Filler, 26 Back surface member, 26a Through-hole, 40, 42a Flange part, 44 Back surface member, 44a Through-hole

Claims (5)

A translucent member disposed on the light receiving side;
A back member provided so as to face the translucent member;
A photovoltaic device provided between the translucent member and the back member;
A filler that fills a space between the translucent member and the back member;
A storage unit for storing a terminal for outputting the electrical energy generated by the photovoltaic device to the outside, and
The back member is provided with a through hole,
The storage portion is provided so that at least a part thereof is located inside the through hole and has a gap with the inner wall of the through hole,
The solar cell module, wherein the filler fills at least a part of a gap between an inner wall of the through hole and the storage portion.   The solar cell module according to claim 1, wherein the storage portion is disposed inside the through hole so as not to protrude from the surface of the back member.   The solar cell module according to claim 1, wherein butyl rubber is provided so as to cover a through hole in which the storage portion is disposed.   The solar cell module according to any one of claims 1 to 3, wherein the through hole is provided in a central portion of the back surface member. Preparing a translucent member provided with a photovoltaic device on one side;
Arranging a filler so as to cover the photovoltaic device;
A back surface member provided with a through hole, and a storage part that is disposed in the through hole and stores a terminal that outputs electric energy generated by the photovoltaic device to the outside are disposed on the filler. Process,
The translucent member and the back member are pressure-bonded, and the space between the translucent member and the back member is filled with the filler, and enters the gap between the inner wall of the through hole and the storage portion. Fixing the storage portion with the filler;
The manufacturing method of the solar cell module characterized by including.

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