JP2014013859A - Solar cell module and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module which improves the weather resistance, and to provide a manufacturing method of the solar cell module.SOLUTION: In a solar cell module, a lower protection material 6, a lower sealing material 5, a solar battery cell sheet 1, a transparent upper sealing material 2, a transparent upper protection material 3, and a transparent surface coat material 4 are sequentially laminated. Surfaces of a boundary surface between the upper sealing material 2 and the upper protection material 3 and a boundary surface between the upper protection material 3 and the surface coat material 4 and a surface of the surface coat material 4 are formed into irregular shapes.

Description

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

  Patent Document 1 discloses a solar cell module in which a light-receiving surface is composed of silica as a main component and an antireflection film having an uneven surface with a step of 0.01 to 1 μm is deposited, and the antireflection is provided on a glass substrate. There is disclosed a solar cell module in which films are laminated and an antifouling agent containing silicone oil as a main component is applied to the surface of the antireflection film.

  In Patent Document 2, a resin layer having a thickness distribution is provided on the light receiving surface side of a photovoltaic element having a laminated structure in which at least an electrode layer and a photoelectric conversion layer are laminated, and the thickness of the resin layer is The photovoltaic element end is thicker than the photovoltaic element center, the resin layer contains an ultraviolet absorber, and a concentration distribution of the ultraviolet absorber is formed from the light-receiving surface side to the non-light-receiving surface side. A photovoltaic device is disclosed.

  Patent Document 3 discloses a solar cell module in which a coating material provided on a light incident side surface of a photovoltaic element is composed of at least two layers of a filler made of an organic resin and a surface film made of a fluororesin. The solar cell module is characterized in that the surface film contains an ultraviolet absorber.

  In Patent Document 4, in a solar cell module in which at least a light incident side of a photovoltaic element is sequentially coated with a transparent organic polymer resin layer and a transparent fluororesin film layer, polysilazane is coated on at least one surface of the fluororesin layer. A solar cell module characterized by having a transparent thin film layer made of silicon oxide or silicon nitride obtained by firing or a mixture thereof is disclosed.

Japanese Patent Laid-Open No. 2002-270866 JP 2002-335002 A JP 7-297439 A JP-A-9-199740

  The above-mentioned Patent Document 1 is an example in which an antireflection film mainly composed of silica is laminated on a glass substrate, and a layer obtained by crosslinking silicone oil and liquid chlorofluorocarbon on the glass substrate has a higher moisture permeability than glass. The solar cell using a resin weak in thermal stress as a sealing material cannot be applied as it is because of insufficient weather resistance. Even when an antireflection film mainly composed of silica is laminated on a resin sealing material, there is a problem that peeling is likely to occur at this interface.

  Since the above-mentioned Patent Document 2 has a resin layer having a thickness distribution in which the end of the photovoltaic element is thicker than the central part of the photovoltaic element, the photovoltaic element is caused by uneven thermal expansion of the resin layer. There was a problem that it was easily deformed.

  Patent Document 3 discloses that a fluororesin surface is exposed to an outdoor environment, and corrosive substances such as nitrates, sulfates, iron and titanium derived from acid rain, yellow sand, and factory exhaust gas adhere to the resin on the fluororesin surface. There was a problem that there was a possibility that some of them would deteriorate.

In Patent Document 4, since polysilazane is coated and baked, there is a problem that energy required for heating during production is large.
The subject of this invention is providing the solar cell module which improved the weather resistance, and its manufacturing method.

  In order to solve the above problems, a solar cell module as a first aspect of the present invention includes a lower protective material, a lower sealing material, a solar cell sheet, a transparent upper sealing material, a transparent upper protective material, and Transparent surface coating materials are sequentially laminated, and the interface between the upper sealing material and the upper protective material, the interface between the upper protective material and the surface coating material, and the surface of the surface coating material are uneven. It is characterized by.

  According to such a configuration, the surface coating material improves the heat resistance, durability, and chemical resistance of the solar cell module. Furthermore, resistance to thermal stress can be improved by forming irregularities on each interface.

Moreover, it is desirable that the thickness of the surface coating material is smaller than the height of the unevenness on the surface of the surface coating material.
According to such a configuration, since the thickness of the surface coating material is thin, it is possible to prevent the unevenness from being buried and to maintain the antiglare property.

For example, it is desirable to use at least one selected from a transparent silicone resin, a transparent acrylic resin, or a transparent fluororesin as the surface coating material.
According to such a structure, it is used suitably as a material of a surface coating material. Here, the light transmittance of the surface coating material is desirably 85% or more and more desirably 90% or more of light having a wavelength of 380 nm to 1000 nm.

The surface coating material may contain an ultraviolet absorber.
According to such a configuration, when the surface coating material contains an ultraviolet absorber, the lower protective material, the lower sealing material, the solar cell sheet, the transparent upper sealing material, and the transparent upper protective material In addition, at least one of the transparent surface coating materials can be prevented from being deteriorated by ultraviolet rays. In addition, it is desirable that the ultraviolet absorber has a lower absorption rate of light having a wavelength of 380 nm to 1000 nm. Specifically, the absorptance of light having a wavelength of 380 nm to 1000 nm is preferably 15% or less, and more preferably 10% or less.

The surface coating material preferably has a smaller coefficient of thermal expansion than the upper sealing material.
According to such a configuration, when the surface coating material has a smaller thermal expansion coefficient than the upper sealing material, the temperature of the solar cell module rises and the solar cell module is rounded with the non-light-receiving surface side inward. Can be prevented.

  The manufacturing method of the solar cell module as the second aspect of the present invention includes a lower protective material, a lower sealing material, a solar cell sheet, a transparent upper sealing material, a transparent upper protective material, and a transparent surface coat. A step of making a laminate in which materials are laminated in sequence, and the laminate provided with the surface coating material is laminated while being brought into contact with an irregularity forming member having irregularities on the surface coating material side, and the upper sealing material and the An interface with the upper protective material, an interface between the upper protective material and the surface coating material, and a step of making the surface of the surface coating material uneven.

  According to such a configuration, the heat resistance, durability, and chemical resistance of the solar cell module can be improved by the surface coating material. By forming irregularities on each interface, it is possible to make it difficult to peel off the interface between the upper sealing material and the upper protective material and the interface between the upper protective material and the surface coating material by an anchor effect.

In the step of forming the laminate, it is preferable that the surface coating material is cured on the upper protective material by thermal curing or ultraviolet curing.
According to such a configuration, the curing treatment speed of the surface coating material can be increased by increasing the temperature in the case of thermosetting, or by increasing the amount of ultraviolet light in the case of ultraviolet curing.

  ADVANTAGE OF THE INVENTION According to this invention, the solar cell module which improved the weather resistance, and its manufacturing method can be provided.

It is a schematic block diagram concerning the embodiment of the solar cell module of the present invention. FIG. 3 is a flow diagram according to an embodiment of the method of the present invention. It is the result of the high-temperature, high-humidity test of Example 1, 2 and the comparative example 1, a xenon weathering test, and an outdoor exposure test.

  FIG. 1 is a schematic configuration diagram according to an embodiment of the solar cell module of the present invention. A solar cell module 10 according to an embodiment of the present invention includes a lower protective material 6, a lower sealing material 5, a solar cell sheet 1, a transparent upper sealing material 2, a transparent upper protective material 3, and a transparent surface coat. The material 4 is laminated in order, and the interface between the upper sealing material 2 and the upper protective material 3, the interface between the upper protective material 3 and the surface coating material 4, and the surface of the surface coating material 4 are uneven. It has become.

In the solar cell sheet 1, a plurality of solar cells are electrically connected in series, and a pair of electrodes are provided for extracting current.
As the material of the transparent upper sealing material 2, for example, a transparent thermoplastic resin such as ethylene-vinyl acetate resin (EVA) or bralar resin can be used.

  As the material of the transparent upper protective material 3, for example, a fluorinated resin film such as ethylene-tetrafluoroethylene copolymer (ETFE) or polyvinyl fluoride (PVF) can be used.

  It is preferable that the transparent surface coating material 4 has deterioration resistance, ultraviolet resistance, and chemical resistance that are difficult to be transparent even after long-term outdoor use. As an example of a specific material, any of transparent silicone resin (trade name FX-V5400, manufactured by ADEKA Corporation), acrylic resin or fluororesin (trade name: New Garmet # 230, manufactured by Toupe Co., Ltd.) A resin containing one or more main components can be used. The light transmittance of the surface coating material 4 is more desirable as the transmittance in the wavelength region of 380 nm to 1000 nm is higher. Specifically, the transmittance in a wavelength region of 380 nm to 1000 nm is desirably 85% or more, and more desirably 90% or more. Further, from the viewpoint of improving the ultraviolet resistance, it is more desirable that the surface coating material 4 contains an ultraviolet absorber.

  Furthermore, it is desirable that the surface coating material 4 has a smaller coefficient of thermal expansion than the upper sealing material. When the surface coating material 4 is laminated as a part of the solar cell module 10, the solar cell module 10 can be prevented from warping. The glass transition temperature of the surface coating material 4 is desirably 90 ° C. or higher. The thickness of the surface coating material is thinner than the height of the irregularities on the surface of the surface coating material. For example, the thickness of the surface coating material is desirably 10 μm or more and 100 μm or less. If it is thinner than 10 μm, the protection of the upper protective material 3 becomes insufficient, and if it is thicker than 100 μm, the unevenness on the surface of the solar cell module tends to be crushed. If it does so, the anti-glare effect produced by the unevenness | corrugation of the surface will be reduced. The height of the unevenness on the light-receiving surface side of the surface protective material is desirably 50 μm or more and 150 μm or less. When it is thinner than 50 μm, the antiglare effect is insufficient, and when it is thicker than 150 μm, the sealing material layer becomes thin and the insulating property becomes insufficient.

The lower side sealing material 5 will not be specifically limited if it is a thermoplastic resin with favorable adhesiveness with the upper side sealing material 2. FIG. The same resin as the upper sealing material 2 may be used.
As the lower protective material 6, for example, a fluorinated resin film such as ethylene-tetrafluoroethylene copolymer (ETFE) or polyvinyl fluoride (PVF), or a steel plate can be used.

  Next, the manufacturing method of the solar cell module of this invention is demonstrated. FIG. 2 is a flow diagram according to an embodiment of the method of the present invention. The embodiment of the method of the present invention includes a lower protective material 6, a lower sealing material 5, a solar cell sheet 1, a transparent upper sealing material 2, a transparent upper protective material 3 and a transparent surface coating material 4. Step (S1) for making a laminated body sequentially laminated, and laminating the laminated body provided with the surface coating material 4 while contacting the surface coating material 4 side with a concavo-convex forming member, the upper sealing A step (S2) of making the interface of the material 2 and the upper protective material 3, the interface of the upper protective material 3 and the surface coating material 4, and the surface of the surface coating material 4 uneven.

  A method for applying the surface coating material 4 to the upper protective material 3 in the step S1 is not particularly limited, and for example, a brush coating, a spray coater, a roll coater, a stamp coater, a spin coater, or the like can be used. As the curing conditions for the surface coating material 4, curing by radiation such as ultraviolet rays and electron beams, and curing by heat can be applied. The curing by radiation and the curing by heat may be used in combination.

Step S2 is performed after step S1.
Next, examples and the like will be described. FIG. 3 shows the results of the high-temperature and high-humidity test, the xenon weathering test, and the outdoor exposure test of Examples 1 and 2 and Comparative Example 1.
Example 1
The solar cell module shown in FIG. 1 was used. The specific material of each part is as follows.

  As the solar cell sheet 1, a sheet in which a plurality of amorphous silicon cells were electrically connected in series was used. As the transparent upper sealing material 2, EVA which is a commercially available thermoplastic resin was used. As the transparent upper protective material 3, ETFE, which is a commercially available fluororesin, was used. As the transparent surface coating material 4, a fluororesin (main agent New Garmet # 230, curing agent # 400, manufactured by Tope Corporation) was used. The lower sealing material 5 was the same as the upper sealing material 2. The lower protective material 6 was the same as the upper protective material 3.

In step S1, the fluororesin was applied as a transparent surface coating material 4 to the upper protective material 3 with a brush. Thereafter, heat treatment was performed at 140 ° C. for 30 minutes to cure the fluororesin.
Next, the laminated body which laminated | stacked the upper side protective material 6 which provided the lower side protective material 6, the lower side sealing material 5, the photovoltaic cell sheet 1, the upper side sealing material 2, and the surface coating material 4 in the light-receiving surface side in order. Had made.

Next, in step S <b> 2, the laminate including the surface coating material 4 is laminated while being brought into contact with an unevenness forming member having unevenness on the surface coating material 4 side, and the upper sealing material 2 and the upper protection are formed. The interface with the material 3, the interface between the upper protective material 3 and the surface coating material 4, and the surface of the surface coating material 4 were made uneven.
(Example 2)
The solar cell module of Example 2 was manufactured under the same conditions except that the coating method of the transparent surface coating material 4 of Example 1 was changed from brush coating to coating with a roll coater.
(Comparative Example 1)
The solar cell module of Comparative Example 1 was manufactured under the same conditions except that the transparent surface coating material 4 of Example 1 was not applied and cured.

About three types of solar cell modules obtained as mentioned above, the external appearance inspection was implemented after implementing the following weather resistance test.
High temperature and high humidity test: exposed at 85 ° C. and 85% Rh for 3000 hours.

Xenon-weather test: 120 W / m ² , 300-400 nm light was irradiated, and exposure was performed for 5000 hours while switching the presence or absence of water spraying with one cycle of water injection 12 minutes and no water injection 48 minutes.

Outdoor exposure test: exposed to sunlight outdoors for 6 months from January to June.
The judgment criteria were determined by visual inspection, and the case where there was a discoloration or defect with a diameter of 0.1 mm or more was considered abnormal. Other than that, there was no abnormality.

As shown in FIG. 3, only the outdoor exposure test of Comparative Example 1 showed an abnormality. In Examples 1 and 2, it was confirmed that there was no abnormality.
In addition, this invention is not limited to said embodiment, It can deform | transform suitably and implement in the range which does not change the summary.

DESCRIPTION OF SYMBOLS 1 Solar cell sheet 2 Transparent upper side sealing material 3 Transparent upper side protective material 4 Transparent surface coating material 5 Lower side sealing material 6 Lower side protective material 10 Solar cell module

Claims (7)

A lower protective material, a lower sealing material, a solar cell sheet, a transparent upper sealing material, a transparent upper protective material, and a transparent surface coating material are sequentially laminated.
The solar cell module in which the interface between the upper sealing material and the upper protective material, the interface between the upper protective material and the surface coating material, and the surface of the surface coating material are uneven. The solar cell module according to claim 1, wherein the thickness of the surface coating material is thinner than the height of the unevenness on the surface of the surface coating material. The solar cell module according to claim 1 or 2, wherein at least one kind selected from a transparent silicone resin, a transparent acrylic resin, or a transparent fluororesin is used as the surface coating material. The solar cell module according to any one of claims 1 to 3, wherein the surface coating material contains an ultraviolet absorber. The solar cell module according to any one of claims 1 to 4, wherein the surface coating material has a smaller coefficient of thermal expansion than the upper sealing material. A step of making a laminate in which a lower protective material, a lower sealing material, a solar cell sheet, a transparent upper sealing material, a transparent upper protective material and a transparent surface coating material are sequentially laminated;
The laminate including the surface coating material is laminated while being in contact with an unevenness forming member having unevenness on the surface coating material side, an interface between the upper sealing material and the upper protective material, the upper protective material, The step of making the interface with the surface coating material and the surface of the surface coating material uneven,
A method for manufacturing a solar cell module comprising: The method for manufacturing a solar cell module according to claim 6, wherein in the step of forming the laminate, the surface coating material is cured on the upper protective material by thermal curing or ultraviolet curing.

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