JP2015135914A - Solar cell module built-in film material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module built-in film material which, without damaging external appearance thereof when being fixed to an architectural structure, is capable of suppressing the reduction in output even under continuous use, and which can suppress damage such as wrinkle generated in a solar cell module during transportation when the film material is wound.SOLUTION: The above-described problem is solved by a reinforcement layer such as a glass woven fabric placed between a photoelectric conversion layer and a rear surface protection layer, and thickness of a sealing material layer formed between the photoelectric conversion layer and the rear surface protection layer with a sealing material.

Description

  The present invention relates to a solar cell module and a solar cell module integrated membrane material having a membrane material.

  As a solar cell module, for example, a solar cell using single crystal silicon or polycrystalline silicon is known. These solar cells normally constitute a solar cell module in a state of being sealed with a sealing material such as EVA resin between protective members (protective layers). Specifically, these solar cell modules wrap a photoelectric conversion layer in which a plurality of solar cells are connected with an electric wire or the like between protective layers such as a front surface protective layer and a back surface protective layer in an EVA resin film or the like. In general, the entire module is vacuum-manufactured by heating and pressing the entire module with a vacuum laminator.

  In recent years, solar cell modules have been reduced in weight and installed on the roofs, walls, and building materials of many buildings. In addition to reducing the weight, flexible solar cell modules can be manufactured depending on the type of resin, sealing material, and solar cells used in the protective layer. It can also be fixed to various tents and dome membranes without being trapped by.

For example, Patent Document 1 discloses a solar cell membrane structure in which a solar cell module is directly heat-sealed to a membrane material as a solar cell membrane (curtain) structure in which solar cells are fixed to the membrane material. In addition, it is described that the back protective film corresponding to the joint between the solar cell module and the film material uses the same kind of material as the film material.
Patent Document 2 discloses a flexible resin sheet (back reinforcing plate) containing glass fibers located on the sunlight incident surface side of sunlight, a polyethylene resin layer located on the resin sheet, and the polyethylene resin. A flexible solar cell module embedded in a layer and having a substrate made of a polyimide resin is described, and the resin sheet (back reinforcing plate) itself is also used as a building material.
Patent Document 3 discloses a solar cell in which a membrane material and a solar cell module are fixed by a fixing member so that the solar cell module and the membrane material can be detached, and the membrane material and the fixing member are fused via an adhesive layer. A membrane structure is described.

JP 2002-185031 A JP 2010-0050196 A JP 2011-253917 A

The solar cell module building material (film material) in which the above-described solar cell module-attached film material, film structure, or solar cell module back surface protection layer is a building material is fixed to the solar cell module and the film body using a fixing member. Even if it is, the solar cell module-integrated membrane material or the solar cell module itself may be fixed to the building using fasteners or to the building using ropes etc. as required. Used. However, when the film material is fixed to a building or the like, stress is generated by a rope or the like, and the solar cell module may be wrinkled by such stress. In addition, when carrying the solar cell module integrated membrane material, when the solar cell module integrated membrane material is housed in a scroll shape, the solar cell module is wrinkled. Thereby, when fixed to a building, the appearance due to wrinkles is impaired, and when a thin film solar cell is used as a solar cell, the thin film solar cell is damaged and a desired power generation amount cannot be obtained. There is a case.

  The present invention has been made in view of the above problems, and does not impair the appearance of the solar cell module-integrated membrane material when fixed to a building, and suppresses a decrease in output even in an outdoor environment. An object of the present invention is to provide a solar cell module-integrated membrane material that can suppress damage such as wrinkles that occur in the solar cell module during winding during transportation.

  As a result of intensive studies, the inventors have focused on the propagation of stress between the solar cell module and the film material, that is, the back surface protective layer of the solar cell module and the surface of the film material. Depending on the thickness of the sealing material layer formed between the photoelectric conversion layer and the back surface protective layer, a reinforcing layer such as a glass woven fabric is disposed between the back surface protective layer and the above problem. As a result, the present invention has been completed.

That is, the first gist of the present invention is as follows.
A solar cell module in which a photoelectric conversion layer is sealed between a front surface protective layer and a back surface protective layer by a sealing material, and a solar cell module integrated film material having a film material,
The film material surface and the back surface protective layer of the solar cell module are fixed,
The sealing material layer having a reinforcing layer between the photoelectric conversion layer and the back surface protective layer and formed of a sealing material between the photoelectric conversion layer and the back surface protective layer has a thickness of 100 μm or more and 700 μm or less. A solar cell module integrated membrane material.

The second gist of the present invention is as follows.
A solar cell module in which a photoelectric conversion layer is sealed between a front surface protective layer and a back surface protective layer by a sealing material, and a solar cell module integrated film material having a film material,
The film material surface and the back surface protective layer of the solar cell module are fixed,
A glass woven fabric is provided between the photoelectric conversion layer and the back surface protective layer, and the thickness of the sealing material layer formed of the sealing material between the photoelectric conversion layer and the back surface protective layer and the surface protective layer The solar cell module-integrated membrane material, wherein the ratio to the thickness is 3.0 or more and 15.0 or less.

  Moreover, in this invention, the aspect whose film thickness of the said surface protective layer is 20 micrometers or more and 500 micrometers or less is preferable. Further, the fixing method is not particularly limited, but the solar cell module and the film material are fixed with a rope using heat fusion, adhesive, Velcro (registered trademark), fastener, eyelet or the like. Embodiments are preferred.

Furthermore, the third gist of the present invention is as follows.
A solar cell module-integrated structure in which the solar cell module-integrated membrane material described above is installed on an object to be installed, and the solar cell module-integrated film material and the object to be installed are fixed to be detachable Battery module integrated structure.

  By using the solar cell module-integrated membrane material of the present invention, it is possible to suppress wrinkles during installation and use, and to stably obtain power from solar power generation without damaging the appearance. . In particular, the present invention is suitably applied to a mode in which stress is easily generated, such as fixing with a rope using eyelets.

It is a schematic diagram which shows one embodiment of the solar cell module integrated membrane material which concerns on the embodiment of this invention. It is a schematic diagram which shows the layer structure of the solar cell module which concerns on the embodiment of this invention. It is a schematic diagram which shows the integrated structure body of the solar cell module and aluminum frame which was used in the comparative example 2. It is a figure which shows the structure of the aluminum frame used by the Example and the comparative example.

  Embodiments of the solar cell module of the present invention will be specifically described below, but it goes without saying that the scope of the present invention is not limited to specific embodiments.

The solar cell module-integrated membrane material according to an embodiment of the present invention has a structure in which the solar cell module and the membrane material are integrated. The solar cell module has a surface protective layer, a back surface protective layer, and a photoelectric conversion layer, and the photoelectric conversion layer is sealed with a sealing material. Further, a reinforcing layer is provided between the photoelectric conversion layer and the back surface protective layer, and the film thickness of the sealing material layer laminated with the reinforcing layer is characteristic.
A reinforcing layer is provided between the photoelectric conversion layer and the back surface protective layer, and the reinforcing layer and the sealing material layer are formed into a film by setting the film thickness of the sealing material layer laminated with the reinforcing layer to a specific range. It plays the role of a moderate cushioning material against stress from the material, and can suppress wrinkles during installation and use. Therefore, it is possible to maintain a high photovoltaic power generation capability during use, and it is possible to maintain a good design without damaging the appearance.

<Reinforcing layer>
The reinforcing layer in the present invention is a layer that is disposed between the photoelectric conversion layer and the back surface protective layer and has a function of improving the bending resistance of the solar cell module. The reinforcing layer is preferably embedded in the sealing material layer to be laminated. Embedding means that a part of the reinforcing layer is embedded in the sealing material layer. If the material of the reinforcing layer is harder than the material of the sealing material layer, a part of the reinforcing layer is sealed. It will be embedded in the stopping material layer. As the reinforcing layer, it is preferable to use a sheet-like layer having holes such as cloth, mesh, woven fabric or non-woven fabric. When the reinforcing layer has a network structure, it may be a plain weave, twill weave, satin weave, mesh or the like. The ratio of the longitudinal density (lines / 25 mm) and the lateral density (lines / density) of the fibers may be 0.3 or more and 2.0 or less, and 0.5% from the viewpoint that wrinkles are unlikely to occur in the length direction of the solar cell module. It is good also as 1.5 or less.

  As the material of the reinforcing layer, carbon fibers, glass fibers, alumina fibers, silicon carbide fibers, poron fibers, Tyranno fibers, inorganic whiskers, rock fibers, slag fibers, etc. may be used as inorganic fibers, and polyester fibers as plastic fibers. Fiber, cellulose fiber, protein fiber, cellulose acetate fiber, polyamide fiber, acrylic fiber, polyolefin fiber, polyvinyl alcohol fiber, polyvinyl chloride fiber, polyurethane fiber, polyoxymethylene fiber, polytetrafluoroethylene fiber, polyimide fiber, polypara Phenylenepenbisbisthiazole fiber, polyparaphenylenepenbisbisoxazole fiber, aramid fiber, nylon fiber, etc. may be used, and gold fiber, silver fiber, steel fiber, amorphous metal fiber, etc. are used as metal fiber. It may have.

From the viewpoint of lightness and rigidity of the module after being embedded with the sealing material layer, plastics fibers and inorganic fibers are preferable, and carbon fibers, glass fibers, polyester fibers, cellulose fibers, acrylic fibers, and cellulose acetate fibers are preferable. In addition, carbon fiber and glass fiber are preferable in the durability under an outdoor environment, particularly in a high temperature and high humidity environment.
Furthermore, among glass fiber, C glass, S glass, D glass, E glass, etc. are mentioned. In particular, S glass and E glass are preferable from the viewpoint of electrical insulation and rigidity.
Furthermore, the surface of these fibers may be treated with a surface modifier having excellent adhesion to the sealing material, such as a vinyl acetate treatment agent, an acrylic treatment agent, an epoxy treatment agent, a phenol treatment agent, It is preferable to treat with a silane-based treating agent, a polyester-based treating agent, an olefin-based treating agent, an amino-based treating agent, a dimethyl-based treating agent, a polyether-based treating agent, a vinyl chloride-based treating agent, or the like. From the viewpoint of excellent adhesion to the sealing material and permeability to the pores, vinyl acetate treatment agent, acrylic treatment agent, silane treatment agent, olefin treatment agent, epoxy treatment agent, vinyl chloride treatment agent It is preferable that it is processed.

  The thickness of the reinforcing layer is preferably 10 μm or more, preferably 50 μm or more, and more preferably 70 μm or more from the viewpoint of light weight and wrinkle suppression. On the other hand, it is preferably 500 μm or less, preferably 250 μm or less, and preferably 120 μm or less. If the upper limit is exceeded, the strength of the reinforcing material will become too strong, and when integrated with the membrane material, the strength of the membrane material will be exceeded, and the membrane material may be damaged when handling the solar cell module. There is. On the other hand, if the lower limit is not reached, the effect of suppressing wrinkles may be impaired.

<Membrane material>
The membrane material in the present invention means a material that can be used for a lightweight roof such as a dome membrane or a tent. As a material of the membrane material, a type A membrane material (a material according to the membrane structure technical standards established by the Japan Membrane Structure Association), a structure requiring high durability in which a glass fiber fabric is coated with a fluororesin Suitable for objects (tents), B-type membrane materials (materials based on membrane structure technical standards established by the Japan Membrane Structure Association), and glass fiber fabrics are coated with synthetic resins such as fluororesin and PVC Suitable for structures (tents) that require high durability), C-type membrane materials (materials based on membrane structure technical standards established by the Japan Membrane Structure Association), and synthetic fiber fabrics such as PVC resin Suitable for structures (tents) that require high durability to be coated), membrane materials for tent warehouses (materials based on membrane structure technical standards established by the Japan Membrane Structure Association, and glass fiber fabrics) And synthesis維織 product structure highly durable synthetic resin PVC is coated is requested are suitable (tent)) and the like to. From the viewpoint of excellent adhesiveness with the sealing material, B-type film material, C-type film material and tent warehouse film material are preferable. Moreover, you may use waterproof sheets, such as an olefin resin, a vinyl chloride resin, and rubber | gum as needed.
Further, a glass fiber fabric is preferable as the fiber fabric applied to the membrane material or the waterproof sheet. The glass fiber fabric is excellent in the durability of strength in the outdoor environment, and can further improve the durability of the solar cell.
The film thickness of the film material is not particularly limited, but usually 0.1 to 3 mm is used.

  In particular, when used as a roofing material for a membrane structure building, the film thickness is preferably 0.1 mm or more, more preferably 0.2 mm or more from the viewpoint of rigidity. The upper limit is preferably 5 mm or less, more preferably 3.5 mm or less. By setting it as the film thickness of this range, there exists an advantage that durability is excellent, it is excellent in a softness | flexibility, and translucency is also acquired.

<Method of fixing membrane material and solar cell module>
In the present embodiment, the film material surface and the back surface protective layer of the solar cell module are fixed, but the fixing method of the solar cell module is not limited.
The method for fixing the film material and the solar cell module is not particularly limited, but a method of directly connecting the solar cell module to the fixing member can be mentioned. Further, in the case where the solar cell module is integrated with the film material, there are a method of connecting the film material and the installation object using a separate fixing member, a method of connecting the end portion of the solar cell module to the fixing member, and the like. In addition, there is a method of processing a solar cell module or an end portion of a film material and connecting the processed portion to a fixing member.
The fixing method of the solar cell module is not particularly limited. For example, the fixing method of bonding the back surface protective layer of the solar cell module and the film material surface by thermal fusion or adhesive, the back surface protective layer of the solar cell module and the film material Fixing method to join the surface by sewing, fixing method by metal fastener, fixing method by hook-and-loop fastener (magic tape (registered trademark)), fixing method by screwing, fixing method by rope using eyelet, fixing method by band, Examples include a fixing method by laminating a film material and a solar cell module, a fixing method in which a solar cell module end or a film material end has a bag binding structure, and a metal rod is inserted into the bag binding structure.
From the viewpoint of suppressing destruction of the solar cell due to deformation of the membrane material due to disturbance such as wind, a method of thermally fusing the back surface protective layer of the solar cell module and the membrane material surface, a fixing method using a metal fastener, a surface fastener It is preferable to fix the membrane material and the solar cell module by using a fixing method (magic tape (registered trademark)), a fixing method by screwing, a fixing method using a rope using eyelets, or a fixing method using a band. Among them, because it is removable, using metal fastener fixing method, hook-and-loop fastener (magic tape (registered trademark)) fixing method, screwing fixing method, rope fixing method using eyelets, band fixing method It is preferable to fix the membrane material and the solar cell module.
The number of sides to be fixed is not particularly limited, but at least two sides to be paired are preferably fixed, and more preferably four sides are fixed. By increasing the number of sides to be fixed, the influence of wrinkles and cell damage due to deformation of the solar cell module can be easily alleviated.

<Encapsulant>
The solar cell module in this invention seals a photoelectric converting layer between a surface protective layer and a back surface protective layer with a sealing material. The sealing material is usually laminated on both sides of the photoelectric conversion layer. In this embodiment, at least one sealing material layer is provided between the photoelectric conversion layer and the back surface protective layer.
By providing the sealing material layer, the photoelectric conversion layer can be sealed, and impact resistance and the like can be imparted to the solar cell module. In the present invention, wrinkles are generated by having a reinforcing layer between the photoelectric conversion layer and the back surface protective layer and setting the ratio of the thickness of the sealing material layer existing between the photoelectric conversion layer and the back surface protective layer to a specific range. It can be suppressed. Preferably, the reinforcing layer is embedded in the sealing material layer.

  As the sealing material laminated as the sealing material layer, a resin material having a relatively high solar transmittance is used. For example, polyethylene, polypropylene, ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer is used. Polyolefin resin such as polymer, ethylene-ethyl acrylate copolymer, propylene-ethylene-α-olefin copolymer, butyral resin, styrene resin, epoxy resin, (meth) acrylic resin, urethane resin, silicone resin, synthetic rubber Etc., and a mixture of one or more of these or a copolymer can be used. Among these, EVA, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, and butyral resin are preferable from the viewpoint of excellent permeability to the pores in the reinforcing layer.

  The thickness of the sealing material layer present between the surface protective layer and the photoelectric conversion layer is preferably 100 μm or more, more preferably 200 μm or more, and further preferably 300 μm or more. On the other hand, it is preferably 1000 μm or less, more preferably 800 μm or less, and even more preferably 500 μm or less. By setting the thickness of the sealing material layer within the above range, moderate impact resistance can be obtained, which is preferable from the viewpoint of cost and weight, and power generation characteristics can be sufficiently exhibited.

The thickness of the sealing material layer present between the back surface protective layer and the photoelectric conversion layer and laminated with the reinforcing layer is preferably 100 μm or more, more preferably 200 μm or more, and 300 μm or more. Is more preferable. On the other hand, it is preferably 700 μm or less, more preferably 600 μm or less, and even more preferably 500 μm or less. By setting the thickness of the sealing material layer in the above range, the generation of wrinkles of the solar cell module can be suppressed.
In addition, the ratio of the thickness of the sealing material layer existing between the back surface protective layer and the photoelectric conversion layer and the thickness of the surface protective layer is preferably 3.0 or more, and is 4.0 or more. More preferably, it is more preferably 6.0 or more. On the other hand, it is preferably 15.0 or less, more preferably 14.0 or less, and even more preferably 12.0 or less.
Generation | occurrence | production of the wrinkle of a solar cell module can be suppressed by making the thickness of a sealing material layer and the thickness of a surface protective layer into said range.

  An ultraviolet absorber may be added to the sealing material layer of the solar cell module. Such ultraviolet absorbers can be used without particular limitation including those commercially available. Examples include benzophenone compounds, benzotriazole compounds, triazine compounds, and the like. When an ultraviolet absorber is added to the sealing material layer, the amount is preferably 0.01% by weight or more, and more preferably 0.05% by weight or more based on the total amount of the sealing material layer. On the other hand, the content is preferably 1% by weight or less, more preferably 0.8% by weight or less, and particularly preferably 0.6% by weight or less. This is because if it is less than 0.01% by weight, it is difficult to exhibit the ultraviolet absorption effect, and if it exceeds 1% by weight, it causes bleeding out.

Moreover, it is preferable that the said sealing material layer contains a silane coupling agent. By including the silane coupling agent, the adhesion between the sealing material layer and the reinforcing layer and the adhesion with the layer in contact with the sealing material layer are improved. Preferred examples of the silane coupling agent include those having an alkyl group as a functional group, and specific examples include an epoxy group, a methacryl group, and a vinyl group. From these, it is preferable to select a functional group having an affinity for the surface treating agent treated on the surface of the reinforcing layer from the viewpoint of improving adhesion, and a methacryl group, an epoxy group, and the like are preferable.
The weight ratio of the sealing material to the silane coupling agent is preferably 0.1 to 2.0, more preferably 0.3 to 1.0, when the weight of the sealing material is 100. 0.5 to 0.7 is particularly preferable. By setting it as such a range, the adhesiveness of a sealing material layer can be made suitable.
The phrase “containing a silane coupling agent” herein means adding or mixing the silane coupling agent to the encapsulant, and the silane coupling agent is added to or mixed with the encapsulant in advance before the solar cell module is stacked. It may be added, or may be added to or mixed with the sealing material during lamination.

<Back side protective layer>
The back surface protective layer in the present invention is a layer for imparting mechanical strength, weather resistance, scratch resistance, chemical resistance, gas barrier properties and the like to the solar cell module. Materials used for the back surface protective layer include polycarbonate (PC), polymethyl methacrylate (PMMA), cyclic polyolefin, polystyrene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and ethylene-tetrafluoroethylene copolymer (ETFE). , Polytetrafluoroethylene (PTFE), polypropylene (PP), polyethylene (PE) and the like. Preferably, fluorine-based resins such as ethylene-tetrafluoroethylene copolymer (ETFE) and polytetrafluoroethylene (PTFE) are used.
The thickness of the back surface protective layer is usually 20 μm or more. Preferably it is 30 micrometers or more, More preferably, it is 50 micrometers or more. On the other hand, the upper limit is not particularly limited, but is preferably 1000 μm or less, and more preferably 500 μm or less. By being in this range, moderate impact resistance and flexibility can be imparted.

Further, the linear expansion coefficient at −30 to 30 ° C. of the resin used for the back surface protective layer is not particularly limited, but is preferably 10 ppm / K or more, more preferably 30 ppm / K or more, and further preferably 50 ppm. / K or more. The linear expansion coefficient is measured by, for example, ASTM D696.
If the linear expansion coefficient is less than 30 ppm / K, thermal expansion / contraction stress that requires a reinforcing layer tends not to occur. On the other hand, the upper limit is not particularly limited, but is usually 200 ppm / K or less, preferably 150 ppm / K or less.

In addition, the Young's modulus of the resin used for the back surface protective layer is not particularly limited, but is preferably 10 GPa or less, preferably 8 GPa or less, and 6 GPa or less because it easily withstands heat shrinkage stress due to a temperature difference in an outdoor environment. Is preferred. On the other hand, the lower limit is not particularly limited, but from the viewpoint of imparting rigidity as a building material, it is usually larger than 0.1 GPa and preferably 1 GPa or more.
In addition, the glass transition temperature (Tg) of the resin (A) is not particularly limited, but the Tg of the resin is preferably 70 ° C. or higher and preferably 80 ° C. or higher from the viewpoint of heat resistance. Moreover, although it does not specifically limit about an upper limit, It is preferable that it is 200 degrees C or less from a viewpoint which is excellent in workability, and it is preferable that it is 180 degrees C or less.

<Photoelectric conversion layer>
The photoelectric conversion layer is a layer including a photoelectric conversion layer that can directly convert light energy into electric power, and is usually formed by connecting a plurality of photoelectric conversion layers with a current collector or the like. Electricity generated in the photoelectric conversion layer can be taken out via an external converter through a collector line.
As the photoelectric conversion element forming the photoelectric conversion layer, silicon-based solar cells such as a single crystal silicon solar cell element, a polycrystalline silicon solar cell element, an amorphous silicon solar cell element, a microcrystalline silicon solar cell element, and a spherical silicon solar cell element An element can be used. Moreover, compound solar cell elements, such as a CIS type solar cell element, a CIGS type solar cell element, and a GaAs type solar cell element, can also be adopted. Further, a dye-sensitized solar cell element, an organic thin film solar cell element, a multi-junction solar cell element, a HIT solar cell element, or the like may be employed.

Each electrode of the photoelectric conversion element can be formed using one or more kinds of arbitrary materials having conductivity. Examples of the electrode material (electrode constituent material) include metals such as platinum, gold, silver, aluminum, chromium, nickel, copper, titanium, magnesium, calcium, barium, sodium, and alloys thereof; indium oxide and tin oxide Metal oxides such as, or alloys thereof (ITO: indium tin oxide); conductive polymers such as polyaniline, polypyrrole, polythiophene, polyacetylene; acids such as hydrochloric acid, sulfuric acid, sulfonic acid, A material containing a dopant such as a Lewis acid such as FeCl ₃ , a halogen atom such as iodine, or a metal atom such as sodium or potassium; conductive particles such as metal particles, carbon black, fullerene, or carbon nanotubes, and a matrix such as a polymer binder And conductive composite materials dispersed in the material.
The thickness of each electrode and the thickness of the photoelectric conversion layer can be determined based on the required output and the like.
Further, an auxiliary electrode may be provided so as to be in contact with the electrode. In particular, it is effective when using a slightly conductive electrode such as ITO. As the auxiliary electrode material, the same material as the above metal material can be used as long as the conductivity is good, but silver, aluminum, and copper are exemplified.

<Surface protective layer>
The surface protective layer in the present invention is a layer for imparting mechanical strength, weather resistance, scratch resistance, chemical resistance, gas barrier properties and the like to the solar cell module. As a material used as the surface protective layer of the solar cell module, from the viewpoint of supplying a large amount of sunlight to the photoelectric conversion layer, the total light transmittance of the surface protective layer is usually 80% or more, preferably 90% or more. The measuring method of a total light transmittance is based on JISK7361-1, for example.

As the surface protective layer, polycarbonate (PC), polymethyl methacrylate (PMMA), cyclic polyolefin, polystyrene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), ethylene-tetrafluoroethylene copolymer (ET)
FE), polytetrafluoroethylene (PTFE), polypropylene (PP), polyethylene (PE) and the like. Preferably, fluorine-based resins such as ethylene-tetrafluoroethylene copolymer (ETFE) and polytetrafluoroethylene (PTFE) are used.

The thickness of the surface protective layer is usually 20 μm or more. Preferably it is 30 micrometers or more, More preferably, it is 50 micrometers or more. On the other hand, the upper limit is not particularly limited, but is preferably 1000 μm or less, and more preferably 500 μm or less. By being in this range, moderate impact resistance and flexibility can be imparted.
The Young's modulus of the surface protective layer is preferably 0.1 GPa or more, more preferably 0.2 GPa or more. On the other hand, the upper limit is preferably 15 GPa or less, more preferably 9 GPa or less. By setting it in the above range, appropriate flexibility and rigidity can be imparted.

Moreover, in the solar cell module of this invention, you may provide a surface protection sheet further in the outer side (sunlight side) of a surface protection layer. In the present invention, it is preferable to provide a surface protective sheet in order to suppress damage and deterioration of the surface protective layer and maintain the total light transmittance. The material constituting the surface protective sheet is preferably a weather-resistant film, and commonly used known materials can be used.
Examples of the resin used as the material for the weather resistant film include ethylene-tetrafluoroethylene copolymer (PTFE), silicone, polyethylene terephthalate (PET), polyamide, and the like. Among these, ethylene-tetrafluoroethylene copolymer (ETFE) is preferable.

<Method for manufacturing solar cell module>
Although the manufacturing method of the solar cell module of this invention can use a well-known method, for example, a surface protective layer, a sealing material layer, a photoelectric converting layer, a sealing material layer, a reinforcement layer, an adhesive layer (sealing material layer), A solar cell module can be obtained by disposing a multilayer sheet including a back surface protective layer or the like in a vacuum lamination apparatus, heating it after evacuation, and cooling it after a certain period of time.
The heat laminating conditions are not particularly limited, and heat laminating is possible under normal conditions.
It is preferably performed under vacuum conditions, and the degree of vacuum is usually 30 Pa or more, preferably 50 Pa or more, more preferably 80 Pa or more. On the other hand, the upper limit is usually 150 Pa or less, preferably 120 Pa or less, more preferably 100 Pa or less. By setting it as the said range, since generation | occurrence | production of a bubble can be suppressed in each layer in a module and productivity is also improved, it is preferable.

The heat lamination may be carried out under a normal pressure of 50 kPa or more, preferably 70 kPa or more, more preferably 90 kPa or more. On the other hand, the upper limit is preferably 3010 kPa or less. By setting it as the pressurization conditions of the said range, since moderate adhesiveness can be acquired, without damaging a solar cell module, it is preferable also from a durable viewpoint.
The temperature condition of the heat laminate is usually 80 ° C. or higher, preferably 100 ° C. or higher, more preferably 120 ° C. or higher. On the other hand, the upper limit is usually 180 ° C. or lower, preferably 160 ° C. or lower, more preferably 150 ° C. or lower.
Moreover, the press time of the said temperature is 10 minutes or more normally, Preferably it is 12 minutes or more, More preferably, it is 15 minutes or more. On the other hand, the upper limit is 60 minutes or less, preferably 45 minutes or less, more preferably 30 minutes or less. By setting it as the said heating time, since durability of a sealing material is bridge | crosslinked moderately and it can have moderate softness | flexibility, it is preferable.

Another embodiment of the present invention is a solar cell module-integrated structure in which the solar cell module-integrated membrane material is installed on an object to be installed. The installation object is not particularly limited as long as the solar cell module integrated membrane material according to this embodiment can be installed, such as a building, a building material, a slope, an inclined surface, and the like. Moreover, it is preferable that the solar cell module-integrated membrane material and the object to be installed are fixed in such a manner that stress is applied to the solar cell module, and as such a mode, for example, it is fixed with a rope using eyelets. An embodiment is mentioned.

Hereinafter, the solar cell module-integrated membrane material according to an embodiment of the present invention will be described in more detail with reference to the drawings.
FIG. 1 shows one embodiment of the solar cell module-integrated membrane material according to the present invention, and is a schematic view of the solar cell module as viewed from the incident light side. Further, the solar cell module-integrated membrane material is installed on the aluminum frame 2 which is an installation object, and constitutes the solar cell module-integrated structure 100. The object to be installed is not limited to the aluminum frame, and is not particularly limited as long as the solar cell module integrated membrane material according to this embodiment can be installed, such as a building, a building material, and a steel material.

The solar cell module 10 has the eyelet 4 attached to a non-power generation region. A grommet 4 is also attached to the membrane material 1. Then, the eyelet attached to the non-power generation region of the solar cell module and the eyelet attached to the film material 1 are fixed by the rope 3.
In addition to the eyelets for fixing the film material 1 and the solar cell module 10, eyelets for fixing the film material 1 and the aluminum frame 2 are attached to the film material 1. Then, the eyelet attached to the membrane material 1 and the aluminum frame 2 are fixed by the rope 3.
Fixing members for fixing the solar cell module and the film material are not limited to eyelets and ropes, and magic tape (registered trademark), fasteners, screws, bands, and the like can be used. The present invention is preferably applied when using a fixing member capable of generating stress on the solar cell module 10.

FIG. 2 is a schematic diagram showing the layer configuration of the solar cell module 10 used in the present invention, and is equivalent to the solar cell module produced in Example 1 described later.
The solar cell module 10 is laminated | stacked in order of the surface protective layer 11, the sealing material layer 12, the photoelectric converting layer 13, the reinforcement layer 14, and the back surface protective layer 15 from the sunlight light-receiving surface side. Layers other than these, such as an adhesive layer and an antifouling layer, can also be included as appropriate.
In the solar cell module used in the present invention, the reinforcing layer 14 is provided between the photoelectric conversion layer 13 and the back surface protective layer 15. As shown in FIG. 2, the reinforcing layer 14 is preferably embedded in the sealing material layer 12. In addition, the thickness of the sealing material layer 12 existing between the photoelectric conversion layer 13 and the back surface protective layer 15 is in a specific range.
As described above, the reinforcing layer 14 and the sealing material layer 12 are provided between the photoelectric conversion layer 13 and the back surface protective layer 15, and the effect of the present invention is achieved by setting the sealing material layer 12 to an appropriate thickness. be able to.

EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, it cannot be overemphasized that this invention is not limited only to such a specific aspect.
The following methods were used for evaluation in the examples of the present invention.
[Durability test]
Using an environmental tester (manufactured by ESPEC Co., Ltd., model: TBE), exposure is performed for 2 hours in an atmosphere at −40 ° C. and for 2 hours in an atmosphere at 80 ° C., and 200 cycles are tested.
[Appearance evaluation]
The appearance before and after the temperature cycle test was visually observed, and when wrinkles having a length of 2 cm or more were generated, wrinkles were generated.
[Output evaluation]
In accordance with JIS C8991, the output (Pmax) of the solar cell module at the time of irradiation with pseudo-sunlight 1000 W / m ² was measured, and the output after the durability test was calculated when Pmax was 100%.
[Winding test]
Winding was performed so that the back surface protective layer of the solar cell module hit a cylindrical surface having an outer diameter of 70 mm, and the presence or absence of wrinkles after winding was visually evaluated. When wrinkles having a length of 2 cm or more occurred, the wrinkles were generated.

<Example 1>
<Solar cell module manufacturing method>
Surface protective layer: ethylene-tetrafluoroethylene copolymer (hereinafter referred to as ETFE) film (width 650 mm × length 2000 mm × thickness 50 μm) (50 MW-DCS manufactured by Asahi Glass Co., Ltd.),
Sealing material layer: width 600 mm × length 2000 mm × thickness 400 μm ethylene-vinyl acetate copolymer (hereinafter referred to as EVA) film (CVA, EVA),
Solar cell (photoelectric conversion layer): Solar cell (polyethylene naphthalate (hereinafter referred to as PEN) film laminated with an amorphous silicon-based power generation layer),
Sealing material layer: the same EVA film having a width of 600 mm × a length of 2000 mm × a thickness of 400 μm,
Reinforcing layer: Glass cloth using E glass having a width of 600 mm × a length of 2000 mm × a thickness of 100 μm (manufactured by Nittobo Co., Ltd., KS5375),
Back surface protective layer: Superposed in the order of the front surface protective layer and the same ETFE film.
Using a vacuum laminator manufactured by NPC, heat-pressed at 150 ° C. (degree of vacuum 80 Pa, vacuum time 5 minutes, pressurization time 5 minutes, hold 35 minutes), and cooled press at a temperature 60 ° C. (pressure 103 kPa, pressurization time 20 To prepare a solar cell module. The layer structure of the produced solar cell module is as shown in FIG.

  On a 2000 mm × 700 mm aluminum frame shown in FIG. 4, a 0.53 mm thick turpolone membrane (G3500, manufactured by Hiraoka Oryome Co., Ltd.) was fixed. Specifically, eyelets were attached to the turbolon film at a pitch of 150 mm, and the aluminum frame and the tarpolon film were fixed to the eyelet using a rope (manufactured by Trusco Nakayama Co., Ltd., vinylon rope, hereinafter referred to as rope). Further, eyelets were attached to the end of the solar cell module at a pitch of 150 mm, and the turpolone film and the solar cell module were fixed to the eyelet using a rope. The solar cell module integrated membrane material fixed to the aluminum frame is as shown in FIG.

The solar cell module integrated membrane material fixed to the aluminum frame was put into an environmental testing machine, and a durability test was conducted. The results are shown below. In addition, the value of the column of “the thickness of the sealing material embedding the reinforcing layer” in Table 1 is the thickness of the sealing material layer between the photoelectric conversion layer and the back surface protective layer in each of Examples and Comparative Examples described later. Point to.
(Appearance evaluation)
As a result of visual observation, wrinkles did not occur before and after the durability test.
(Output evaluation)
The output after the durability test was 99.2%.
(Winding test)
As a result of the winding test, no wrinkles occurred.

<Example 2>
<Solar cell module manufacturing method>
The same EVA film having a width of 600 mm × length of 2000 mm × thickness of 300 μm is used as a sealing material layer between the solar cell and the reinforcing layer, and the same EVA of width 600 mm × length of 2000 mm × thickness of 300 μm is used between the reinforcing layer and the back surface protective layer. A solar cell module was produced in the same manner as in Example 1 except that the film (sealing material layer) was laminated. The produced solar cell module was evaluated in the same manner as in Example 1. The results are shown below.
(Appearance evaluation)
As a result of visual observation, wrinkles did not occur before and after the durability test.
(Output evaluation)
The output after the durability test was 97.1%.
(Winding test)
As a result of the winding test, no wrinkles occurred.

<Comparative Example 1>
<Solar cell module manufacturing method>
A solar cell module was produced in the same manner as in Example 1 except that the reinforcing layer was not used. The produced solar cell module was evaluated in the same manner as in Example 1. The results are shown below.
(Appearance evaluation)
As a result of visual observation, wrinkles occurred after the durability test.
(Output evaluation)
The output after the durability test was 93.1%.
(Winding test)
As a result of the winding test, no wrinkles occurred.

<Comparative Example 2>
<Solar cell module manufacturing method>
Comparative Example 1 except that an ethylene-tetrafluoroethylene copolymer (hereinafter referred to as ETFE) film (100MW-DCS manufactured by Asahi Glass Co., Ltd.) having a width of 600 mm, a length of 2000 mm, and a thickness of 100 μm was used for the surface protective layer. A solar cell module was produced in the same manner as described above.
The produced solar cell module was fixed to an aluminum frame of 2000 mm × 700 mm shown in FIG. Specifically, eyelets were attached to the ends of the solar cell module at a pitch of 150 mm, and the solar cell module and the aluminum frame were secured to the end using a rope. The solar cell module fixed to the aluminum frame is as shown in FIG.

The solar cell module fixed to the aluminum frame was evaluated in the same manner as in Example 1. (Appearance evaluation)
As a result of visual observation, wrinkles occurred after the durability test.
(Output evaluation)
The output reduction rate after the durability test was 62.7%.
(Winding test)
As a result of the winding test, no wrinkles occurred.

<Comparative Example 3>
<Solar cell module manufacturing method>
It implemented by the method similar to Example 1 except not using a reinforcement layer and a film | membrane material.
(Appearance evaluation)
As a result of visual observation, wrinkles occurred after the durability test.
(Output evaluation)
The output reduction rate after the durability test was 99.0%.
(Winding test)
As a result of the winding test, no wrinkles occurred.
<Comparative Example 4>
<Solar cell module manufacturing method>
A solar cell module in the same manner as in Example 1 except that a sealing material layer similar to the sealing material layer existing between the reinforcing layer and the solar cell was laminated between the reinforcing layer and the back surface protective layer. Was made. The produced solar cell module was evaluated in the same manner as in Example 1. The results are shown below.
(Appearance evaluation)
As a result of visual observation, wrinkles did not occur in the initial stage.
(Winding test)
As a result of the winding test, wrinkles occurred on the back surface protective layer side.

<Reference Example 1>
<Solar cell module manufacturing method>
A solar cell module was produced in the same manner as in Example 1 except that the solar cell module was not fixed to the membrane material, but the eyelet of the solar cell module and the aluminum frame were directly fixed. The produced solar cell module was evaluated in the same manner as in Example 1. The results are shown below.
(Appearance evaluation)
As a result of visual observation, wrinkles did not occur before and after the durability test.
(Output evaluation)
The output after the durability test was 97.3%.
(Winding test)
As a result of the winding test, no wrinkles occurred.

  As can be seen from the results of Examples and Comparative Examples, the solar cell module-integrated membrane material of the present invention has a reinforcing layer and the thickness of the sealing material layer between the photoelectric conversion layer and the back surface protective layer. Is within a certain range, it is possible to suppress a decrease in output even under continuous use without impairing the appearance of the solar cell module-integrated membrane material when fixed to a building, and It can be understood that wrinkles and the like generated in the solar cell module during winding during transportation can be suppressed.

DESCRIPTION OF SYMBOLS 1 Film | membrane material 2 Aluminum frame 3 Rope 4 Eyelet 10 Solar cell module 11 Surface protection layer 12 Sealing material layer 13 Photoelectric conversion layer 14 Reinforcement layer 15 Back surface protection layer

Claims (4)

A solar cell module in which a photoelectric conversion layer is sealed between a front surface protective layer and a back surface protective layer by a sealing material, and a solar cell module integrated film material having a film material,
The film material surface and the back surface protective layer of the solar cell module are fixed,
The sealing material layer having a reinforcing layer between the photoelectric conversion layer and the back surface protective layer and formed of a sealing material between the photoelectric conversion layer and the back surface protective layer has a thickness of 100 μm or more and 700 μm or less. A solar cell module integrated membrane material. A solar cell module in which a photoelectric conversion layer is sealed between a front surface protective layer and a back surface protective layer by a sealing material, and a solar cell module integrated film material having a film material,
The film material surface and the back surface protective layer of the solar cell module are fixed,
A glass woven fabric is provided between the photoelectric conversion layer and the back surface protective layer, and the thickness of the sealing material layer formed of the sealing material between the photoelectric conversion layer and the back surface protective layer and the surface protective layer The solar cell module-integrated membrane material, wherein the ratio to the thickness is 3.0 or more and 15.0 or less.   The solar cell module integrated membrane material according to claim 1 or 2, wherein the surface protective layer has a thickness of 20 µm or more and 500 µm or less.   The solar cell module integrated membrane material according to any one of claims 1 to 3, wherein the solar cell module and the membrane material are fixed by a detachable fixing method.

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