JP2019102601A - Solar cell module and solar cell system - Google Patents

Abstract

To obtain a solar cell module in which the electric output of the whole solar cell module can be adjusted by the size of the solar cell, and deterioration of appearance resultant from the gap between the adjoining solar cells can be restrained.SOLUTION: A solar cell module 100 includes a design sheet 90 of similar color as that of the surface of a solar cell 10 on the light-receiving side, placed in a region between adjoining solar cells 10, in the in-plane direction of a light-receiving side protection part on the side closer to the reverse side protection part than a solar cell array 30, and corresponding to the region adjoining the solar cell 10, and the region corresponding to the solar cell 10.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a solar cell module and a solar cell system in which a plurality of solar cells are arranged, and adjacent solar cells are connected to extract an electrical output.

  In a solar cell module in which a plurality of solar cells are connected side by side, as disclosed in Patent Document 1, a plurality of bus electrodes are formed on the light receiving surface side and the back surface side of the solar cells, and a tab wire is formed on the bus electrode The connected solar cells are electrically connected to each other. In recent years, the electrical characteristics of solar cells have been dramatically improved due to the development of electrode materials and the like. In a crystalline solar cell, a photoelectric conversion efficiency of 19% or more has become common.

  On the other hand, for a plurality of solar cell modules constituting an existing solar cell system installed in an installation place such as a roof of a house, solar cells having a lower electric output than the current solar cells are used. There is something that In such a solar cell system, it may be necessary to replace some of the solar cell modules due to damage or the like.

  Here, when replacing with the current solar cell module using the current solar cell, the electric power is higher than the existing solar cell module installed in the solar cell system and the existing solar cell module. It will be mixed with the current solar cell module. In this case, variations in the electrical output among the solar cell modules within the solar cell system cause a mismatch in the amount of power generation between the solar cell modules, and in some cases there is a problem that the electrical output of the entire solar cell system is significantly reduced. The

  In order to cope with such problems, a replacement solar cell module with low electrical output is required, and a solar cell with low electrical output must be manufactured. It is conceivable to manufacture a solar battery cell by the conventional manufacturing method in order to obtain a solar battery cell with low electrical output. However, since the conventional manufacturing method of the solar battery cell is different from the current manufacturing method of the solar battery cell, it is necessary to prepare a dedicated facility, and the manufacturing is difficult in terms of equipment.

  For example, by cutting the size of the solar cell by cutting the current high-power solar cell and suppressing the generation current of the solar cell, the electric output can be properly adjusted according to the solar cell system used. A solar cell module and a solar cell system can be obtained.

JP, 2011-091284, A

  However, even when a solar cell module is manufactured using a cut and miniaturized solar cell, the size of the entire solar cell module does not change. For this reason, when the solar cell modules are manufactured by arranging the cut-out solar cells, the gap between the adjacent solar cells becomes large and becomes noticeable as the size of the solar cells decreases. The appearance of the subject may be a problem on the appearance.

  The present invention has been made in view of the above, and it is possible to adjust the electrical output of the entire solar cell module according to the size of the solar cell, and of the appearance due to the gap between adjacent solar cells. An object of the present invention is to obtain a solar cell module capable of suppressing deterioration in aesthetic appearance.

  In order to solve the problems described above and to achieve the object, the solar cell module according to the present invention is disposed on the solar cell array to which a plurality of solar cells are electrically connected, and on the light receiving surface side of the solar cells Between the light receiving surface side protective portion and the light receiving surface side protective portion having a light transmitting property and the rear surface side protective portion disposed on the back side facing the light receiving surface of the solar battery cell. And a sealing layer sealing the plurality of solar cells. Further, the solar cell module is an area between adjacent solar cells in the in-plane direction of the light receiving surface side protection portion on the back surface side protection portion side with respect to the solar cell array and adjacent to the solar cells A design sheet of the same color as the surface on the light receiving surface side of the solar battery cell is disposed in the region corresponding to the region and the region corresponding to the solar battery cell.

  According to the present invention, it is possible to adjust the electrical output of the entire solar cell module according to the size of the solar cell, and to suppress the deterioration of the appearance appearance due to the gap between the adjacent solar cells. The effect is that a module can be obtained.

The top view which looked at the solar cell module concerning Embodiment 1 of this invention from the light-receiving surface side It is principal part sectional drawing of the solar cell module concerning Embodiment 1 of this invention, and principal part sectional drawing in the II-II line of FIG. It is principal part sectional drawing of the solar cell module concerning Embodiment 1 of this invention, and principal part sectional drawing in the III-III line of FIG. The top view which looked at the photovoltaic cell concerning Embodiment 1 of this invention from the light-receiving surface side It is sectional drawing of the photovoltaic cell concerning Embodiment 1 of this invention, and is a sectional view in the VV line of FIG. 4 The flowchart which shows the procedure of the manufacturing method of the solar cell module which depends on the form 1 of execution of this invention Principal part sectional view showing a modification of the solar cell module according to the first embodiment of the present invention The top view which looked at the solar cell module concerning Embodiment 2 of this invention from the light-receiving surface side It is principal part sectional drawing of the solar cell module concerning Embodiment 2 of this invention, and principal part sectional drawing in the IX-IX line of FIG. Principal part sectional view showing a solar cell module according to a third embodiment of the present invention Principal part sectional view showing a solar cell module according to a fourth embodiment of the present invention The schematic diagram which shows the structure of the solar cell system concerning Embodiment 5 of this invention

  Hereinafter, a solar cell module and a solar cell system according to an embodiment of the present invention will be described in detail based on the drawings. The present invention is not limited by the embodiment. Further, in the drawings shown below, the scale of each member may be different from the actual one for easy understanding. The same applies to each drawing.

Embodiment 1
FIG. 1 is a top view of a solar cell module 100 according to a first embodiment of the present invention as viewed from a light receiving surface side. FIG. 2: is principal part sectional drawing of the solar cell module 100 concerning Embodiment 1 of this invention, and is principal part sectional drawing in the II-II line of FIG. FIG. 3: is principal part sectional drawing of the solar cell module 100 concerning Embodiment 1 of this invention, and is principal part sectional drawing in the III-III line of FIG. In addition, in FIG. 1, the state which permeate | transmits and is seen in the light-receiving surface side protection part 50 and the sealing layer 60 is shown.

  The solar cell module 100 is a replacement solar cell module used when it is necessary to replace the solar cell module due to a failure or the like in an existing solar cell module installed at an installation place such as on a roof. is there. In addition, the solar cell module 100 has higher photoelectric conversion efficiency per unit area than the existing solar cells used in the existing solar cell modules, and the electrical output per unit area is higher than that of the existing solar cells. High current solar cells are used.

  In the solar cell module 100 according to the first embodiment, a reinforcing frame 80 is fixed to a part or the entire circumference of the outer peripheral edge portion of the solar cell panel 40 via a silicon adhesive or the like. Is surrounded by a frame 80. In the solar cell panel 40, the light receiving surface side of the solar cell array 30 is covered with the light receiving surface side sealing layer 60 a which is the sealing layer 60 and the light receiving surface side protective portion 50, and the opposite direction to the light receiving surface of the solar cell array 30 The back surface side which faces is covered with the back surface side sealing layer 60b which is the sealing layer 60, and the back surface side protection part 70, and is comprised. That is, in the solar cell module 100, the solar cell array 30 is covered with the sealing layer 60 and sealed between the light receiving surface side protective portion 50 and the back surface side protective portion 70. Further, on the back surface side of the solar cell array 30, the design sheet 90 is covered and sealed by the back surface side sealing layer 60b.

  The frame 80 is made by extrusion of a metal material such as aluminum.

  The light receiving surface side protection unit 50 protects the light receiving surface side of the solar cell array 30. The light receiving surface side protective unit 50 is a light transmitting substrate having light transmitting property and electrical insulating property, and for example, a synthetic resin material such as a glass material or a polycarbonate resin is used. Sunlight is incident on the solar cell module 100 from the light receiving surface side protection unit 50 side.

  The back surface side protection unit 70 protects the back surface side of the solar cell array 30. The back surface side protection unit 70 is a back sheet made of an electrically insulating material having electrical insulation, and for example, polyethylene terephthalate (PET) is used.

  For the light receiving surface side sealing layer 60a, an ethylene-vinyl acetate (EVA) copolymer which is a resin having thermoplasticity and light permeability is used. In the first embodiment, EVA is used for the light receiving surface side sealing layer 60a, but in addition to this, thermosetting resin having translucency including polyethylene, polypropylene, polycarbonate, polyurethane resin, polyolefin resin, etc. It is possible to use a resin or a laminate thereof. For the back side sealing layer 60b, the same material as the light receiving side sealing layer 60a can be used.

  The solar cell array 30 is configured by electrically and mechanically connecting a plurality of solar cells 10 in series electrically and mechanically using the tab lines 20 and the horizontal tab lines 25. The plurality of solar cells 10 are electrically connected in series in the X direction, which is the first direction, by the tab wires 20. Then, a solar cell string consisting of a plurality of solar cells 10 connected by the tab line 20 is disposed along the Y direction in the figure, which is the second direction, and electrically and mechanically in series with the horizontal tab line 25. Connected to and configured. The first direction is the connection direction of the plurality of solar cells 10 connected by the tab wire 20 in the in-plane direction of the solar cell module 100. The second direction is a direction orthogonal to the first direction in the in-plane direction of the solar cell module 100.

  FIG. 4 is a top view of the solar battery cell 10 according to the first embodiment of the present invention as viewed from the light receiving surface side. FIG. 5 is a cross-sectional view of the solar battery cell 10 according to the first embodiment of the present invention, and is a cross-sectional view taken along the line V-V in FIG. 4. In FIG. 5, the upper side is the light receiving surface side.

  The solar battery cell 10 is cut out from a standard solar battery cell 110 which is a current standard solar battery cell manufactured by the current manufacturing method, and a part of the current solar battery cell is cut. It is. The standard solar battery cell 110 is a standard solar battery cell mass-produced by the current method of manufacturing a solar battery cell, and a solar battery having an existing photoelectric conversion efficiency per unit area in the in-plane direction of the solar battery cell. It is higher than the cell and has the same shape and dimensions as the existing solar cell.

  Therefore, the solar cell 10 has higher photoelectric conversion efficiency per unit area in the in-plane direction of the solar cell 10 than the existing solar cell used in the existing solar cell module. The electrical output per unit area in the in-plane direction is higher than that of the existing solar cell. In FIG. 4, a part of the outer shape of the standard solar battery cell 110 is indicated by a medium thick broken line.

  In the photovoltaic cell 10, the light receiving surface of the n-type single crystal silicon substrate 11 is formed with a concavo-convex structure having a texture 11T that reduces light reflection. Then, the p-type impurity diffusion layer 12 is formed on the concavo-convex structure, and the anti-reflection film 13 made of a silicon nitride film is stacked on the p-type impurity diffusion layer 12. The n-type single crystal silicon substrate 11 and the p-type impurity diffusion layer 12 form a semiconductor substrate 18 having a pn junction.

  A light receiving surface grid electrode 16G and a light receiving surface bus electrode 16B as a first current collection electrode are formed on the light receiving surface 11A which is the first main surface of the semiconductor substrate 18 having a pn junction. The light receiving surface grid electrode 16 G and the light receiving surface bus electrode 16 B are in contact with the p-type impurity diffusion layer 12.

  On the back surface 11B, which is the second main surface facing the light receiving surface 11A in the semiconductor substrate 18, in a direction opposite to the light receiving surface 11A, a concavo-convex structure having texture 11T is formed as in the light receiving surface 11A. An n-type impurity diffusion layer 14, a passivation film 15, and a back surface bus electrode 17B, which is a second current collection electrode penetrating the passivation film 15, are formed on the back surface 11B.

  Although the light receiving surface bus electrode 16B and the back surface bus electrode 17B are shown in the form of four straight lines in the first embodiment, they may be two, three or five or more, and other than the straight shape It may be formed in other shapes such as a dotted line shape or a dot shape. Further, the light receiving surface bus electrodes 16B and the back surface bus electrodes 17B are provided in the same number, and are formed at positions facing each other through the semiconductor substrate 18. The light receiving surface bus electrode 16B and the back surface bus electrode 17B are usually formed of an electrode material mainly composed of silver.

  In the solar battery cell 10, the light receiving surface bus electrode 16B of one solar battery cell 10 of the adjacent solar battery cell 10 and the back surface bus electrode 17B of the other solar battery cell 10 are electrically connected in series by the tab wire 20. Thus, the solar cell array 30 is obtained. For bonding of the light receiving surface bus electrode 16B and the tab wire 20, and bonding of the back surface bus electrode 17B and the tab wire 20, bonding by solder or bonding by an adhesive is used.

  In addition, although the tab wire 20 is used in accordance with the width dimension of the light receiving surface bus electrode 16B and the back surface bus electrode 17B, the light receiving surface bus electrode 16B and the back surface bus electrode are used for the purpose of reducing the light receiving area of the solar battery cell 10. A width larger than that of 17B may be used. Moreover, it is also possible to reduce the output of the photovoltaic cell 10 by enlarging the light reception surface bus electrode 16B and the back surface bus electrode 17B.

  The arrangement of the solar cells 10 in the solar cell array 30, that is, the number of the solar cells 10, the arrangement of the solar cells 10, and the cell arrangement pitch which is the pitch of the arrangement of the solar cells 10 is an exchange target of the solar cell module 100. And the solar cell array of the existing solar cell module. In the solar cell module 100, the number of solar cells 10 is 20, and the arrangement of the solar cells 10 is a rectangular grid.

  As described above, in the solar cell module 100, the cell arrangement pitch of the solar cells 10 is the same cell arrangement pitch as the solar cell array of the existing solar cell module. In the solar cell array of the existing solar cell module, the cell arrangement pitch in the longitudinal direction of the light receiving surface bus electrode 16B, ie, the X direction, and the cell arrangement pitch in the width direction of the light receiving surface bus electrode 16B, ie, the Y direction, are equal. In this case, in the solar cell module 100, the cell arrangement pitch in the X direction and the cell arrangement pitch in the Y direction are equal. Thus, the solar cell module 100 has a structure in which the arrangement of the solar cells 10 has an appearance similar to that of the existing solar cell module.

  The solar battery cell 10 is a part of the solar battery cell of the first outer dimension which is the outer dimension of the standard solar battery cell 110 and is the predetermined standard outer dimension is cut away, and the solar cell of the predetermined standard outer dimension It has a second outside dimension smaller than the battery cell. Therefore, in the solar battery cell 10, the area in the in-plane direction of the solar battery cell 10 is smaller than that of the standard solar battery cell 110, and the light receiving area is smaller than that of the standard solar battery cell 110. That is, the area of the solar battery cell 10 in the in-plane direction of the solar battery cell 10 is smaller than that of the existing solar battery cell, and the light receiving area is smaller than that of the existing solar battery cell. The external dimensions of the solar cell here mean the dimensions of the external and the shape of the external in the in-plane direction of the solar cell. Therefore, the photovoltaic cell 10 is cut out to the 2nd outside dimension from the standard photovoltaic cell 110 which is the existing product which has a 1st outside dimension.

  For this reason, the amount of generated current generated by the solar battery cell 10 is smaller than that of the standard solar battery cell 110 and the existing solar battery cells. Therefore, compared with a solar cell module configured using standard solar cells 110 by the same number as the number of solar cells 10 configuring solar cell module 100, solar cell module 100 The amount of generated current can be suppressed, and the electrical output can be suppressed.

  One example of the predetermined standard outer shape of the standard solar battery cell 110 is a square of 156 mm square. For example, when four light reception surface bus electrodes 16B are arranged in parallel in parallel, light reception surface bus electrodes at a bus electrode arrangement pitch which is a size obtained by equally dividing the length of one square side of the solar battery cell 10 into four. 16B are arranged in parallel in parallel. The bus electrode arrangement pitch is a distance between center positions of the light receiving surface bus electrodes 16B in the light receiving surface bus electrodes 16B adjacent to each other in the second direction in the solar battery cell 10. In the solar battery cell 10, the longitudinal direction of the light receiving surface bus electrode 16B corresponds to the first direction, that is, the X direction in the drawing. Further, in the solar battery cell 10, the direction in which the light receiving surface bus electrodes 16B are arranged, that is, the width direction of the light receiving surface bus electrodes 16B corresponds to the second direction, that is, the Y direction in the drawing.

  In the case of such a standard solar battery cell 110, the light receiving surface bus electrodes 16B are arranged in parallel at a pitch of 39 mm in the width direction of the light receiving surface bus electrode 16B, and one side 10a in the width direction of the light receiving surface bus electrode 16B in a square shape The distance between the light receiving surface bus electrode 16B adjacent to one side 10a in the width direction of the light receiving surface bus electrode 16B is 19.5 mm, which is a half of the arrangement pitch. The spacing between the other side 10b in the width direction of the light receiving surface bus electrode 16B in the square shape and the light receiving surface bus electrode 16B adjacent to the other side 10b in the width direction of the light receiving surface bus electrode 16B is also 1 It is 19.5 mm which is 1/2. That is, in the width direction of the light receiving surface bus electrode 16B, the distance between the outer periphery of the standard solar battery cell 110 and the light receiving surface bus electrode 16B is 19.5 mm, which is 1/2 of the arrangement pitch of the light receiving surface bus electrodes 16B.

  That is, when, for example, N light receiving surface bus electrodes 16B are arranged in parallel in parallel to the standard solar battery cell 110, light is received at an arrangement pitch obtained by equally dividing the length of one square of the standard solar battery cell 110 by N. The plane bus electrodes 16B are arranged in parallel in parallel. In the case of such a standard solar battery cell 110, the light receiving surface bus electrodes 16B are arranged at a pitch of (156 / N) mm in the width direction of the light receiving surface bus electrodes 16B.

  The distance between one square side 10a in the width direction of the light receiving surface bus electrode 16B and the light receiving surface bus electrode 16B adjacent to the one side 10a is 1/2 of the arrangement pitch (156 / N). ) / 2 mm. Further, the distance between the other square side 10b in the width direction of the light receiving surface bus electrode 16B and the light receiving surface bus electrode 16B adjacent to the other side 10b in the width direction of the light receiving surface bus electrode 16B is also 1 It is (156 / N) / 2 mm which is / 2. That is, in the width direction of light receiving surface bus electrode 16B, the distance between the outer periphery of solar cell 10 and light receiving surface bus electrode 16B is 1/2 of the arrangement pitch of light receiving surface bus electrodes 16B (156 / N) / 2 mm It becomes.

  In the solar battery cell 10, in the standard solar battery cell 110, two cut areas CA adjacent to a side parallel to the light receiving surface bus electrode 16B out of four sides in a square shape are along the longitudinal direction of the light receiving surface bus electrode 16B. Is cut off. That is, in the solar battery cell 10, the cutting area CA adjacent to the square-shaped side is cut in parallel with the longitudinal direction of the light receiving surface bus electrode 16B on both sides in the width direction of the light receiving surface bus electrode 16B in the standard solar battery cell 110 It is done.

  The cutting width CW of the cutting area CA in the width direction of the light receiving surface bus electrode 16B is, for example, 10 mm. That is, in the solar battery cell 10, areas on both sides in the width direction of the light receiving surface bus electrode 16B are cut by 10 mm from the standard solar battery cell 110, respectively. Thereby, in the width direction of the light receiving surface bus electrode 16B, the distance between the outer periphery of the solar battery cell 10 and the light receiving surface bus electrode 16B is 9.5 mm, which is smaller than 1/2 of the arrangement pitch of the light receiving surface bus electrode 16B. .

  Thus, a solar battery cell 10 having a rectangular shape in which the length in the longitudinal direction of the light receiving surface bus electrode 16B is 156 mm and the length in the width direction of the light receiving surface bus electrode 16B is 136 mm can be obtained. The ratio of the generated current amount of the solar battery cell 10 having such external dimensions to the generated current amount of the standard solar battery cell 110 is the ratio of the length in the width direction of the light receiving surface bus electrode 16B, 136 mm / 156 mm ≒ It will be 87%.

  That is, when the solar battery cell 10 cut out from the standard solar battery cell 110 has a rectangular shape and the number of the light receiving surface bus electrodes 16B is N, the light receiving surface bus electrode 16B in the width direction of the light receiving surface bus electrode 16B Is 1 / N of the length of the long side of the rectangular shape, and the distance between the outermost light receiving surface bus electrode 16B and the rectangular short side in the width direction of the light receiving surface bus electrode 16B is the light receiving surface bus electrode 16B. Less than half of the placement pitch of

  The area of the solar battery cell 10 measures the output of the standard solar battery cell 110, and in consideration of the quantity of the solar battery cell 10 included in the solar battery module 100, the generated current amount required for the solar battery module 100 It is decided together. The amount of generated current required for the solar cell module 100 is the amount of generated current of the existing solar cell module operating normally. Therefore, the cut width CW in the width direction of the light receiving surface bus electrode 16B from the standard solar battery cell 110 measures the amount of generated current of the standard solar battery cell 110, and the number of solar battery cells 10 included in the solar battery module 100 In consideration of the above, the cutting area is calculated and determined in accordance with the amount of generated current of the existing solar cell module.

  Therefore, the solar cell module 100 can adjust the amount of generated current of the entire solar cell module 100 while using the same number of solar cells 10 as the number of the existing solar cells in the existing solar cell module, A solar cell module having the same electrical output as the solar cell module can be configured.

  In the solar battery cell 10 shown in FIG. 4, the corner in the in-plane direction of the solar battery cell 10, that is, the rectangular corner is not chamfered. From the viewpoint of measures against cracking, corner corners in the in-plane direction of the solar battery cell 10 may be chamfered. That is, as for the photovoltaic cell 10, it is preferable that the corner | angular part of the external shape in in-plane direction is chamfered.

  The design sheet 90 is disposed on the back surface side of the solar cell array 30 and is fixed to the inside of the solar cell module 100, thereby enhancing the design of the solar cell module 100. The design sheet 90 is an area between the adjacent solar cells 10 in the in-plane direction of the light receiving surface side protection portion 50 on the back surface side protection portion 70 side of the solar cell array 30, It is arrange | positioned in the area | region corresponding to the adjacent area | region adjacent, and the area | region corresponding to the photovoltaic cell 10. FIG. Further, the design sheet 90 has the same color as the surface on the light receiving surface side of the solar battery cell 10. That is, the design sheet 90 is disposed on the back side of the solar cell array 30. That is, the design sheet 90 is disposed on the back surface side, that is, on the back surface side protection portion 70 side of the tab line 20 provided on the back surface side in the solar cell array 30, and is fixed by the back surface side sealing layer 60b. The design sheet 90 is surrounded and fixed by the solar cell array 30 and the back side sealing layer 60b. Moreover, the tab wire 20 and the back surface side sealing layer 60b are in contact with the surface by the side of the solar cell array 30 of the design sheet 90. FIG.

  It is preferable that the design sheet 90 has high adhesion to the back side sealing layer 60b on the surface in contact with the back side sealing layer 60b. The design sheet 90 preferably has a structure in which fibers are folded, such as a non-woven fabric having a large specific surface area, in order to enhance the adhesion with the back side sealing layer 60b. The material of the non-woven fabric is preferably a highly weather resistant resin such as PET or polyvinyl fluoride. In the first embodiment, for the design sheet 90, a non-woven sheet made of PET is used. In the first embodiment, by using a non-woven sheet made of PET for the design sheet 90, the adhesion to the back side sealing layer 60b is enhanced. In addition, it is also possible to use for the design sheet 90 the insulation sheet which consists of a solid material of resin which does not have space inside, ie, has no space | gap inside. In the first embodiment, the case where a nonwoven fabric is used for the design sheet 90 will be described.

  Further, the shape and size of the design sheet 90 are the same as those of the standard solar battery cell 110 before cutting. In other words, the design sheet 90 has the same shape and size as the existing solar cell. In the design sheet 90, the arrangement position in the plane of the solar cell module 100 is the same as the arrangement position of the existing solar cells in the existing solar cell module.

  Moreover, the color tone of the design sheet 90 is a color tone of the same type | system | group as an existing solar cell so that the same appearance as an existing solar cell may be obtained. The color tone of the design sheet 90 is, for example, black.

  Therefore, as shown in FIG. 1, the design sheet 90 is an area corresponding to the solar cell 10 in the plane of the solar cell module 100 and an adjacent area adjacent to the solar cell 10 in the width direction of the light receiving surface bus electrode 16B. Are arranged in the area corresponding to. In the adjacent area, an area adjacent to the solar battery cell 10 on one side in the width direction of the light receiving surface bus electrode 16B, and an area adjacent to the solar battery cell 10 on the other side in the width direction of the light receiving surface bus electrode 16B. , Is included. The combined area of the area corresponding to the solar cell 10 and the adjacent area adjacent to the solar cell 10 in the plane of the solar cell module 100 is the arrangement area of the existing solar cells in the plane of the existing solar cell module It corresponds to

  In the design sheet 90, the color tone of the surface on the solar cell array 30 side is the same as the color tone of the light receiving surface side of the solar battery cell 10. A similar color is a combination of colors that differ only in lightness or saturation among the three attributes of color, hue, lightness and saturation, a combination of colors that have different lightness and saturation but the same hue, lightness and saturation There are three patterns of the same but a combination of adjacent colors in terms of hue. In FIG. 1, the design sheet 90 is hatched for easy understanding. When the actual product is viewed from the light receiving surface side, the color tone of the solar battery cell 10 and the color tone of the design sheet 90 become similar.

  The basic configuration and size of the solar cell module 100 are the same as those of the existing solar cell module except for the shape and size of the solar cell 10 and the addition of the design sheet 90.

  As described above, the solar cell module 100 can adjust the amount of generated current of the entire solar cell module 100 while using the same number of solar cells 10 as the number of the existing solar cells in the existing solar cell module. The electric output can be made equal to that of the existing solar cell module.

  Further, in the solar cell module 100, the design sheet 90 having the same color tone as the solar cell 10 has the same external dimensions as the existing solar cell at the same position as the existing solar cell in the existing solar cell module. It is arranged by. That is, in the plane of the solar cell module 100, the solar cell 10 and the area corresponding to the adjacent area adjacent to the solar cell 10 in the width direction of the light receiving surface bus electrode 16B A design sheet 90 having the same color tone is disposed.

  For this reason, in the solar cell module 100, even if the solar cells 10 smaller than the existing solar cell modules are arranged in the same arrangement pattern as the existing solar cell modules, the gaps between the adjacent solar cells 10 in appearance Can be made inconspicuous. Thereby, the solar cell module 100 has no sense of incongruity in appearance, is excellent in design, and can obtain the effect of being able to improve the aesthetic appearance of the appearance.

  And since the arrangement position of the design sheet 90 in the surface of the solar cell module 100 is the same position as the arrangement position of the existing solar cell in the existing solar cell module, the appearance of the solar cell module 100 is the existing It is possible to obtain an effect that looks equivalent to the solar cell module of

  When replacing a solar cell module of a part of the solar cell system installed on the roof of a house, etc., a plurality of solar cell systems in the solar cell system can be used by using the existing solar cell module and the solar cell module 100 having different electric characteristics. Mismatches in the amount of power generation between solar cell modules can be prevented or minimized. Thereby, the fall of the electrical output of the whole solar cell system resulting from the mismatch of the electric power generation amount between solar cell modules can be prevented or suppressed. As a result, it is not necessary to manufacture a solar battery cell having a lower electrical output than the current solar battery cell 10, which is not currently distributed, for replacement of the existing solar battery module.

  Below, the manufacturing method of the solar cell module 100 concerning this Embodiment 1 is demonstrated. FIG. 6 is a flowchart showing the procedure of the method of manufacturing the solar cell module 100 according to the first embodiment of the present invention.

  First, in step S10, a solar battery cell 10 is formed. First, using a square n-type single crystal silicon substrate 11 as a starting material, a solar battery cell is formed by a known technique. That is, in order to increase the light collection ratio of the n-type single crystal silicon substrate 11, the surface and back surfaces of the n-type single crystal silicon substrate 11 are formed with a concavo-convex shape by texture etching. Then, a p-type impurity diffusion layer 12 is formed on the light receiving surface side of the n-type single crystal silicon substrate 11 by diffusion to form a pn junction, whereby a semiconductor substrate 18 is formed. Further, a silicon nitride film as the antireflective film 13 is formed on the p-type impurity diffusion layer 12.

  Next, the n-type impurity diffusion layer 14 and the passivation film 15 are formed on the back surface of the n-type single crystal silicon substrate 11. Then, on the light receiving surface 11A of the semiconductor substrate 18, the light receiving surface grid electrode 16G and the light receiving surface bus electrode 16B are formed. Further, the back surface bus electrode 17B is formed on the back surface 11B of the semiconductor substrate 18. As a result, the current solar cell having a square shape and higher than the existing solar cells is formed, and by cutting a part of the square solar cells, the solar cell 10 is formed. Ru.

  Next, the tab wire 20 is connected to the photovoltaic cell 10 in step S20. That is, one end side of tab wire 20 is disposed on light receiving surface bus electrode 16B of one solar battery cell 10, and the other end side of tab wire 20 is disposed on back surface bus electrode 17B in the other adjacent solar battery cell 10 Ru. Then, the solder coated on the tab wire 20 is melted by heating and then solidified. As a result, the solder bonding of one end side of tab wire 20 to light receiving surface bus electrode 16B and the solder bonding of the other end side of tab wire 20 to back surface bus electrode 17B are performed, and tab wire 20 is connected to solar battery cell 10. Electrically and mechanically connected. Then, the solar cell array 30 is obtained by electrically and mechanically connecting the solar cell strings obtained by repeating this process with the horizontal tab lines 25.

  Next, in step S30, the sealing layer sheet to be the light receiving surface side sealing layer 60a and the light receiving surface side protective portion 50 are disposed on the light receiving surface side of the solar cell array 30, and the back surface side of the solar battery array 30 A stacked layer is formed by arranging the sealing layer sheet to be the side sealing layer 60 b and the back surface side protective portion 70. A design sheet 90 is disposed between the back surface side of the solar battery cell 10 and the sealing layer sheet to be the back surface-side sealing layer 60 b.

  Next, in step S40, the laminate is mounted on a laminating apparatus, and heat treatment and lamination treatment are performed for about 30 minutes, for example, at a temperature of 140 ° C. to 160 ° C. By the lamination process, the solar cell array 30 and the light receiving surface side protective portion 50 are bonded by the light receiving surface side sealing layer 60a, and the solar cell array 30, the design sheet 90 and the back surface side protective portion 70 are the back surface side sealing layer 60b. Bonded by Thereby, the component part of a laminated body is integrated and the solar cell panel 40 is obtained. Thereafter, the frame 80 is fixed to the entire periphery of the outer peripheral edge portion of the solar cell panel 40 via a silicon-based adhesive, whereby the solar cell module 100 is obtained.

  FIG. 7 is a cross-sectional view of relevant parts showing a modification of the solar cell module 100 according to the first embodiment of the present invention, and is a view corresponding to FIG. In the solar cell module 100 described above, as shown in FIG. 3, the design sheet 90, the back side sealing layer 60b, and the back side protection portion 70 are disposed in this order on the back side of the solar cell 10. As shown in FIG. 7, on the back surface side of the solar battery cell 10, the intermediate sealing layer 60c, the design sheet 90, the back surface side sealing layer 60b, and the back surface side protection portion 70 may be arranged in this order. The arrangement of the design sheet 90 in the plane direction of the light receiving surface side protection unit 50 is the same as that of the solar cell module 100. Also in this case, the same effect as that of the solar cell module 100 can be obtained.

  Further, as shown in FIG. 3, when the design sheet 90, the back side sealing layer 60 b and the back side protection portion 70 are arranged in this order on the back side of the solar battery cell 10, the design sheet 90 is sealed. EVA does not penetrate sufficiently in the sealing layer 60, and air bubbles are generated on the surface of the design sheet 90 made of non-woven fabric, and the presence of the air bubbles causes adhesion strength between the solar battery cells 10 and the tab wires 20 and the design sheet 90 made of non-woven fabric It may decrease. On the other hand, as shown in FIG. 7, when the middle sealing layer 60c, the design sheet 90, the back side sealing layer 60b, and the back side protection portion 70 are disposed in this order on the back side of the solar battery cell 10. The EVA of the sealing layer 60 easily penetrates the design sheet 90 made of non-woven fabric, and the generation of air bubbles on the surface of the design sheet 90 is suppressed.

  As described above, the solar cell module 100 according to the first embodiment can make the electrical output equal to that of the existing solar cell module by using the solar cell 10. In addition, by arranging the design sheet 90, the solar cell module 100 can make the gaps between the adjacent solar cells 10 inconspicuous, so that the appearance of the appearance can be improved and the aesthetic appearance of the appearance can be improved.

  Therefore, according to the solar cell module 100 according to the first embodiment, the electrical output of the entire solar cell module can be adjusted by the size of the solar cell, and the gap between the adjacent solar cells is caused. The solar cell module capable of suppressing the deterioration of the appearance of the appearance can be obtained.

Second Embodiment
Although Embodiment 1 demonstrated the case where one design sheet 90 was arrange | positioned for every one photovoltaic cell 10, the arrangement pattern of the design sheet 90 is not limited to this. FIG. 8 is a top view of the solar cell module 200 according to the second embodiment of the present invention as viewed from the light receiving surface side. FIG. 9 is a cross-sectional view of main parts of a solar cell module 200 according to a second embodiment of the present invention, and is a cross-sectional view of main parts along line IX-IX in FIG. In addition, in FIG. 8, the state which permeate | transmits and is seen in the light-receiving surface side protection part 50 and the sealing layer 60 is shown.

  In the solar cell module 200, one design sheet 91 in which the gaps between all the design sheets 90 in the solar cell module 100 are connected is disposed on the back side of the solar cell array 30. In other words, the solar cell module 200 is provided with the design sheet 91 for the plurality of solar cells 10, and the gaps between the plurality of solar cells 10 are connected by the design sheet 91.

  The solar cell module 200 according to the second embodiment can achieve the same effect as the solar cell module 100 according to the first embodiment described above.

Third Embodiment
FIG. 10 is a cross-sectional view of relevant parts showing a solar cell module 300 according to Embodiment 3 of the present invention, and is a view corresponding to FIG. In the solar cell module 300, the back surface side protection portion is a back surface side protection portion 71 of the same color as the surface on the light receiving surface side of the solar battery cell 10. And in the solar cell module 300, not the nonwoven fabric but the back surface side protection part 71 of a similar color to the surface by the side of the light-receiving surface of the photovoltaic cell 10 is used as the design sheet 90. FIG. That is, the back side protection part 71 is used as the design sheet 90 instead of providing the design sheet 90 separately.

  The solar cell module 300 according to the third embodiment can achieve the same effect as the solar cell module 100 according to the first embodiment described above.

Fourth Embodiment
FIG. 11 is a cross-sectional view of main parts showing a solar cell module 400 according to a fourth embodiment of the present invention, and corresponds to FIG. In the solar cell module 400, not a nonwoven fabric but a part of the back surface side protection unit 70 is used as the design sheet 90. The back surface side protection unit 70 has a color tone that is not the same color as the surface on the light receiving surface side of the solar battery cell 10. And in the solar cell module 400, it is the surface by the side of the solar cell array 30 of the back surface side protection part 70, Comprising: The area corresponding to the solar cell 10 and the area corresponding to the adjacent area adjacent to the solar cell A color similar to the surface on the light receiving surface side of the cell 10 is used, and the region of the similar color is used as the design sheet 90. A homogeneous color layer 92 in which the pattern of the shape of the solar cell array 30 is depicted in the homogeneous color is formed in the homogeneous color region.

  The solar cell module 400 according to the fourth embodiment achieves the same effect as the solar cell module 100 according to the first embodiment described above.

Embodiment 5
In the fifth embodiment, a solar cell system 500 configured using the solar cell module 100 described in the first embodiment will be described. FIG. 12 is a schematic view showing the configuration of a solar cell system 500 according to the fifth embodiment of the present invention. The solar cell system 500 according to the fifth embodiment includes a first solar cell module 510 in which square first solar cells 511 are arranged in a rectangular grid, and a rectangular second solar cell 521. Are arranged in a rectangular grid, and the non-woven fabric 522 which is a square design sheet on the back surface side of the second solar battery cell 521 is the same rectangular as the second solar battery cell 521 as in the first embodiment. The second solar cell modules 520 are arranged in a grid shape.

  The first solar cell module 510 corresponds to the existing solar cell module described in the first embodiment, and includes a first solar cell array to which the plurality of first solar cells 511 are electrically connected. The second solar cell module 520 corresponds to the solar cell module 100 described in the first embodiment, and includes a second solar cell array to which the plurality of second solar cells 521 are electrically connected. Therefore, the first solar battery cell 511 has a square outer shape in the in-plane direction of the first solar battery cell 511. Further, the external shape of the second solar battery cell 521 in the in-plane direction of the second solar battery cell 521 is the same as the length of one side of the square shape of the first solar battery cell 511 in the length of a pair of sides. The other pair of sides has a rectangular shape shorter than the length of one square side of the first solar battery cell 511.

  The nonwoven fabric 522 of the second solar cell module 520 has the same outer shape and the same color tone as the first solar cell 511 of the first solar cell module 510.

  The external dimensions of the first solar cell module 510 in the in-plane direction of the first solar cell module 510 are the same as the external dimensions of the second solar cell module 520 in the in-plane direction of the second solar cell module 520. It is. The shape of the outer shape of the first solar cell module 510 in the in-plane direction of the first solar cell module 510 is the same as the shape of the outer shape of the second solar cell module 520 in the in-plane direction of the second solar cell module 520 It is.

  Further, in the first solar cell module 510 and the second solar cell module 520, solar cells having the same number of columns and the same number of rows are arranged. That is, in the first solar cell module 510 and the second solar cell module 520, the same number of solar cells are arranged.

  The distance between adjacent first solar cells 511 in a solar cell string in the first solar cell array of the first solar cell module 510, and the solar in the second solar cell array of the second solar cell module 520 The distance between the adjacent second solar cells 521 in the cell string is the same size. That is, the arrangement pitch of the center of the first solar battery cell 511 in the first direction in the solar cell string in the first solar cell array, and the first pitch in the solar cell string in the second solar cell array The arrangement pitch of the centers of the second solar cells 521 in the direction is the same. The first direction is, as described above, the connection direction of the plurality of solar cells connected by the tab line.

  The distance between adjacent solar cell string centers in the first solar cell array of the first solar cell module 510 and the distance between adjacent solar cell string centers in the second solar cell array of the second solar cell module 520 And have the same dimensions. That is, the arrangement pitch of the solar cell string center in the second direction in the first solar cell array and the arrangement pitch of the solar cell string center in the second direction in the second solar cell array are the same. . The second direction is, as described above, a direction orthogonal to the first direction in the in-plane direction of the solar cell module. That is, the first solar cells 511 of the first solar cell module 510, and the second solar cells 521 and the non-woven fabric 522 of the second solar cell module 520 are arranged in the same rectangular grid. There is.

  Each of the first solar battery cell 511 and the second solar battery cell 521 is a two-bus electrode having two light receiving surface bus electrodes on the light receiving surface side and the back surface side. The first solar battery cell 511 is a square solar battery cell. The second solar battery cell 521 is a rectangular solar battery cell. The photoelectric conversion efficiency, which is the output per unit area of the second solar battery cell 521 in the surface direction of the second solar battery cell 521, is the surface of the first solar battery cell 511 of the first solar battery cell 511. Higher than the photoelectric conversion efficiency which is the output per unit area in the direction.

  The second solar cell 521 has higher photoelectric conversion efficiency than the first solar cell 511. In addition, the second solar battery cell 521 has a smaller outside dimension than the first solar battery cell 511. That is, in the second solar battery cell 521, the area in the surface direction of the second solar battery cell 521 is smaller than the area in the surface direction of the first solar battery cell 511 in the first solar battery cell 511, The area of the surface is small. The amount of generated current of the second solar cell 521 is equal to the amount of generated current of the first solar cell 511. Therefore, the amount of generated current of the second solar cell module 520 is made equal to the amount of generated current of the first solar cell module 510.

  With this configuration, even if the first solar battery cell 511 and the second solar battery cell 521 having different photoelectric conversion efficiencies per unit area are used, it is a solar battery module having a similar output. A solar cell module 510 and a second solar cell module 520 can be formed, and a solar cell with a matched amount of power generation between the first solar cell module 510 and the second solar cell module 520 System 500 can be provided.

  Further, in the solar cell system 500 configured as described above, the light receiving surface bus electrodes of the solar cells are configured with the same number and the same color tone in any solar cell module, and arranged as a solar cell system In addition, it is possible to provide a solar cell system having a harmonious appearance.

  In FIG. 12, the first solar battery module 510 in which the first solar battery cells 511 are arranged in 3 columns × 4 rows, and the first solar battery module 521 in which the second solar battery cells 521 are arranged in 3 columns × 4 rows Although the solar cell system 500 in which the two solar cell modules 520 are arranged in two columns and two rows is shown, the number of vertical and horizontal arrangement of solar cells and the number of vertical and horizontal arrangement of solar cell modules can be arbitrarily selected.

  The configurations shown in the above embodiments show an example of the contents of the present invention, and the techniques of the above embodiments can be combined, and can be combined with other known techniques. It is also possible to omit or change part of the configuration without departing from the scope of the present invention.

  10 solar battery cell 10a one side 10b the other side 11 n-type single crystal silicon substrate 11A light receiving surface 11B back surface 11T texture 12 p-type impurity diffusion layer 13 anti-reflection film 14 n-type impurity diffusion Layer, 15 passivation film, 16B light receiving surface bus electrode, 16G light receiving surface grid electrode, 17B back surface bus electrode, 18 semiconductor substrate, 20 tab lines, 25 horizontal tab lines, 30 solar cell array, 40 solar cell panel, 50 light receiving surface side Protective part, 60 sealing layer, 60a light receiving side sealing layer, 60b back side sealing layer, 60c intermediate sealing layer, 70, 71 back side protecting part, 80 frame, 90, 91 design sheet, 92 similar color layer 100, 200, 300, 400 solar cell modules, 110 standard solar cells, 500 solar cell systems, 5 0 first solar cell module, 511 the first solar cell, 520 the second solar cell module, 521 a second solar cell, 522 nonwoven, CA cutting region, CW cutting width.

Claims (10)

A solar cell array in which a plurality of solar cells are electrically connected;
A light receiving surface side protective portion disposed on the light receiving surface side of the solar battery cell;
A back surface side protection portion disposed on the back surface side facing the light receiving surface of the solar battery cell;
A sealing layer which has optical transparency and is sandwiched between the light receiving surface side protection portion and the back surface side protection portion to seal the plurality of solar cells;
In the area between the adjacent solar cells in the in-plane direction of the light receiving surface side protection portion on the back surface side protection portion side with respect to the solar cell array, in an adjacent region adjacent to the solar cells A design sheet of the same color as the surface on the light receiving surface side of the solar battery cell disposed in the corresponding region and the region corresponding to the solar battery cell;
A solar cell module comprising: The solar battery cell includes a semiconductor substrate having a first main surface and a second main surface facing in a direction opposite to the first main surface, and a plurality of rows of first current collectors formed on the first main surface. An electrode, and a second current collection electrode formed on the second main surface,
In the solar cell array, a first current collection electrode of one solar cell of two adjacent solar cells and a second current collection electrode of the other solar cell are connected by tab wires. Connected along the direction,
The adjacent area is an area adjacent to the solar battery cell in a second direction orthogonal to the first direction in the in-plane direction of the light receiving surface side protection unit,
The solar cell module according to claim 1, characterized in that The sealing layer, the design sheet, and the sealing layer are disposed from the solar cell array side between the solar cell array and the back surface side protection portion.
The solar cell module according to claim 1 or 2, characterized in that The design sheet is a non-woven fabric,
The solar cell module according to claim 3, characterized in that The design sheet is provided for the plurality of solar cells, and gaps between the plurality of solar cells are connected by the design sheet,
The solar cell module according to claim 4, characterized in that That the design sheet is the back surface side protection portion having the same color as the surface on the light receiving surface side of the solar battery cell;
The solar cell module according to claim 2, characterized in that In the area corresponding to the solar battery cell and the adjacent region adjacent to the solar battery cell in the surface on the solar cell array side of the back surface side protection unit, the design sheet is a part of the back surface side protection unit The corresponding region is a region made similar to the surface on the light receiving surface side of the solar battery cell,
The solar cell module according to claim 2, characterized in that In the solar battery cell, the corners of the outer shape in the in-plane direction are chamfered;
The solar cell module according to any one of claims 1 to 7, characterized in that A first solar cell module having a first solar cell array to which a plurality of first solar cells are electrically connected;
A second solar cell module comprising the solar cell module according to any one of claims 1 to 8;
Equipped with
The photovoltaic cell of the second solar cell module has a higher photoelectric conversion efficiency per unit area of the light receiving surface than the first photovoltaic cell, and has a light receiving surface than the first photovoltaic cell. The area of is small,
Solar cell system characterized by The first solar battery cell has a square outer shape in the in-plane direction of the first solar battery cell,
The external shape of the second solar cell in the in-plane direction of the second solar cell has a pair of sides having the same length as that of one side in the square shape, and the other pair of sides has a length of Having a rectangular shape shorter than the length of one side of the square shape,
The solar cell system according to claim 9, characterized by

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