JP2021069172A - Solar cell module and rubber frame included in solar cell module - Google Patents

Abstract

To provide a solar cell module and a rubber frame included in the module that can prevent a glass layer from cracking and suppress the amount of deflection of a solar cell module body while making it a lightweight solar cell module.SOLUTION: A solar cell module includes a solar cell module body 4 having a glass layer 41 including a light receiving surface 40, a sealing layer 42 including a cell 43, and a back surface protective layer 45, and a rubber frame 6 attached to the outer circumference of the solar cell module body 4. The rubber frame 6 includes a first plate portion 61 facing the outer peripheral portion of the light receiving surface 40, and a second plate portion 62 facing the outer peripheral portion of the back surface protective layer 45. The first plate portion 61 and the second plate portion 62 are formed so as to have a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and a dimension D1 from the inner edges of the first plate portion 61 and the second plate portion 62 to the corresponding end of the solar cell module body 4 of 8 mm or more and 20 mm or less.SELECTED DRAWING: Figure 3

Description

The present invention relates to a solar cell module and a rubber frame included therein.

In a solar cell module, generally, a surface glass having a thickness of 2.0 mm or more and 3.2 mm or less, a sealing material, a crystalline silicon solar cell, a sealing material, and a back surface protective sheet are laminated in this order, and one sheet is used. The weight per hit is about 18 kg (= 11 kg / m ² ). Therefore, it is difficult for an operator to perform the work of installing the conventional solar cell module in a high place such as on a roof by himself / herself. In addition, when trying to install a conventional solar cell module on the roof of a simple structure such as a carport, it may not be possible to install the solar cell module on one side of the roof due to the load capacity limitation of the roof. is there.

Under these circumstances, in order to reduce the weight of the solar cell module, it is being studied to make the surface glass thinner. Patent Document 1 describes a solar cell module capable of suppressing cell damage even when a thin surface glass is used. Further, Patent Document 2 describes a solar cell module main body having a thin surface glass. The end of the solar cell module main body is inserted into the groove portion of the support frame, and in this groove portion, 0.3 mm or more is formed between the glass plate on the surface of the solar cell module main body and the inner surface of the groove portion. There is a gap.

International Publication No. 2019/059072 JP-A-2017-60374

However, in the technique described in Patent Document 1, in a load test which is a reliability test of a solar cell module assuming strong wind pressure and considerable snowfall, when a test load exceeding 3600 Pa is applied to the solar cell module, it is made of metal. The gantry and the surface of the glass layer or the like may come into contact with each other, causing cracks or the like on the surface of the glass layer or the like.

Further, in the technique described in Patent Document 2, since the dimension between the support frame and the solar cell module main body is relatively large, when a test load exceeding 3600 Pa is applied to the solar cell module, the deflection generated in the solar cell module main body is generated. There is a problem that the amount is large and the cell is easily damaged.

The present invention has been made in view of the above circumstances, and provides a solar cell module capable of preventing cracking of the glass layer and suppressing the amount of deflection of the solar cell module main body while being a lightweight solar cell module, and a rubber frame provided therein. The purpose is to do.

One aspect of the solar cell module according to the present invention includes a solar cell module main body having a light receiving surface that receives sunlight on one surface, and a rubber frame attached to an outer peripheral portion of the solar cell module main body. The solar cell module main body includes a light receiving surface, a glass layer formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer. And a sealing layer provided between the glass layer and the back surface protective layer and sealing a plurality of cells. The back surface protective layer is provided with a first resin layer made of a foamed resin having a flexural modulus of 200 MPa or more and 1000 MPa or less and a side opposite to the light receiving surface with respect to the first resin layer, and has a flexural modulus of 10,000 MPa or more and 25,000 MPa. Includes a second resin layer that is less than and fiber reinforced. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the glass layer, the sealing layer, the first resin layer and the second resin layer The sum of the flexural rigidity of each of the above is 4000 MPa or more. The rubber frame includes a first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface, and a second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface. Has. Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the corresponding end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.

One aspect of the solar cell module according to the present invention includes a solar cell module main body having a light receiving surface that receives sunlight on one surface, and a rubber frame attached to the outer peripheral portion of the solar cell module main body. The solar cell module main body includes a light receiving surface, a glass layer formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer. And a sealing layer provided between the glass layer and the back surface protective layer and sealing a plurality of cells. The back surface protective layer includes a second glass layer having a thickness of 0.4 mm or more and 1.6 mm or less. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the flexural rigidity of each of the glass layer, the sealing layer, and the second glass layer The sum is 4000 MPa or more. The rubber frame includes a first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface, and a second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface. Has. Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.

One aspect of the solar cell module according to the present invention includes a solar cell module main body having a light receiving surface that receives sunlight on one surface, and a rubber frame attached to the outer peripheral portion of the solar cell module main body. The solar cell module main body includes a light receiving surface, a glass layer formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer. And a sealing layer provided between the glass layer and the back surface protective layer and sealing a plurality of cells. The back surface protective layer is provided with a first resin layer made of a foamed resin having a bending elasticity of 200 MPa or more and 1000 MPa or less and a side opposite to the light receiving surface side with respect to the first resin layer, and has a bending elasticity of 10,000 MPa or more. A second resin layer having a pressure of 25,000 MPa or less and reinforced with fibers is provided between the sealing layer and the first resin layer, and the sealing layer is formed by vacuum lamination at 130 ° C. or higher and 160 ° C. or lower. It includes an easy-adhesion resin layer exhibiting adhesiveness, and a third resin layer provided between the easy-adhesion resin layer and the first resin layer and having a bending elasticity of 1500 MPa or more and 4000 MPa or less. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the glass layer, the sealing layer, the first resin layer, and the second resin layer The sum of the flexural rigidity of each of the easy-adhesion resin layer and the third resin layer is 4000 MPa or more. The rubber frame includes a first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface, and a second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface. Has. Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the corresponding end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.

The rubber frame of one aspect according to the present invention is a rubber frame used for the above-mentioned solar cell module. It is configured to be mountable on the outer periphery of the solar cell module body, and is composed of natural rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, urethane rubber, and silicon. A rubber frame having a thickness of 1 mm or more and a tensile elasticity of 3 MPa or more and 200 MPa or less, which is selected from the group consisting of rubber and fluororubber.

The solar cell module of the above aspect according to the present invention and the rubber frame provided therein have an advantage that the glass layer can be prevented from cracking and the amount of deflection of the solar cell module main body can be suppressed while being a lightweight solar cell module. is there.

FIG. 1 is a perspective view of a state in which a solar cell module according to an embodiment of the present invention is installed. FIG. 2 is an exploded perspective view of the solar cell module of the same as above. FIG. 3 is a cross-sectional view of the solar cell module of the same as above. FIG. 4 is a cross-sectional view of the same solar cell module in a state where a load is applied. FIG. 5 is a cross-sectional view of the solar cell module according to the first modification. FIG. 6 is a cross-sectional view of the solar cell module according to the second modification.

Hereinafter, embodiments of the present invention will be described in detail.

(1) Embodiment (1.1) Overall configuration As shown in FIG. 1, the solar cell module 3 according to the present embodiment is attached to the installation surface 1 by the gantry 2. Hereinafter, the mounting structure in which the solar cell module 3 is mounted on the mounting surface 1 is referred to as a “mounting structure of the solar cell module 3”. The mounting structure of the solar cell module 3 includes an installation surface 1, a gantry 2, and a solar cell module 3. The solar cell module 3 according to the present embodiment is formed in a rectangular shape, but in the present invention, the shape is not limited, and for example, a polygon such as a parallel quadrilateral shape, a rhombus shape, a pentagonal shape, or a hexagonal shape, or a circle. It may be formed in a shape or the like. Here, the term "rectangular" as used herein means a rectangle and includes a square.

(1.2) Installation surface The installation surface 1 is the surface on which the solar cell module 3 is installed. The installation surface 1 is not particularly limited in the present invention, and examples thereof include a roof surface of a building, a roof surface of a building / condominium, a wall surface, the ground, and a road. Examples of buildings here include residential houses, factories, gymnasiums, stores, school buildings, hospitals, and the like. The shape of the installation surface 1 is not particularly limited in the present invention, and may be, for example, flat, arched, spherical, uneven, or the like. The installation surface 1 according to the present embodiment is a flat roof surface and is inclined with respect to a horizontal plane.

(1.3) Stand The stand 2 is a stand that supports at least one solar cell module 3 and is installed on the installation surface 1. The gantry 2 includes an outer frame body 21 for holding the solar cell module 3 and an attachment body (not shown).

The mounting body is for mounting the outer frame body 21 on the installation surface 1, and is fixed to the installation surface 1. For example, when the installation surface 1 is the roof surface and the solar cell module 3 is arranged along the roof surface, the mounting body is composed of, for example, brackets, rails, etc., and the installation surface 1 is the ground. When the solar cell module 3 is arranged so as to stand up against the ground surface, it is composed of legs (so-called legs of a high-legged pedestal), columns, poles, etc. that stand up from the installation surface 1. Further, when the outer frame body 21 is directly mounted on the installation surface 1, a fixing member (for example, a screw, a bolt, a rivet, an adhesive layer, etc.) for fixing the installation surface 1 and the outer frame body 21 is an attachment body.

The outer frame 21 surrounds the solar cell module 3 and thereby holds the solar cell module 3. As shown in FIG. 2, the outer frame body 21 is formed of a pair of first frame members 211 and a pair of second frame members 212 in a substantially rectangular frame shape, and is formed on the outer peripheral portion of the solar cell module 3. It is installed along the entire length. However, the outer frame 21 according to the present invention does not have to be continuous over the entire length with respect to the outer peripheral portion of the solar cell module 3, and may be divided at a plurality of locations in the outer peripheral portion. The "outer peripheral portion" as used herein means a range from the outer peripheral end surface of the solar cell module 3 to a portion inside the outer peripheral end surface.

The outer frame 21 is made of metal and is made of, for example, one or more materials selected from the group consisting of aluminum and iron. From the viewpoint of strength and rust prevention, the outer frame 21 is preferably made of aluminum. When the outer frame 21 is made of aluminum, the thickness is preferably 30 mm or more and 100 mm or less. However, the outer frame 21 (frame 2) according to the present invention is not limited to these materials, and may be made of, for example, titanium, stainless steel, gold, silver, copper, zinc, a composite material thereof, or the like.

The outer frame body 21 is attached to the attachment body. In the present embodiment, the outer frame body 21 is fixed to the mounting body, but may be rotatably mounted to the mounting body. The rotation axis of the outer frame 21 may be set along the installation surface 1, for example, and the outer frame 21 may be configured so that the angle of the solar cell module 3 with respect to the horizontal plane can be adjusted. The outer frame 21 may be configured so as to be orthogonal to the surface 1 so that the angle around the axis orthogonal to the installation surface 1 of the solar cell module 3 can be adjusted.

The first frame member 211 is a part of the outer frame body 21 corresponding to the side along the direction orthogonal to the longitudinal direction (sometimes referred to as the lateral direction) of the solar cell module 3. The first frame member 211 is formed in a straight line, and is formed to have a dimension equal to or longer than the length in the lateral direction of the solar cell module 3. As shown in FIG. 3, the first frame member 211 includes a lower horizontal plate 23, a vertical plate 24 protruding upward from the outer end of the lower horizontal plate 23, and an upper portion protruding inward from the upper end of the vertical plate 24. A horizontal plate 25 is provided, and the cross section is formed in a substantially C shape. The lower horizontal plate 23 and the upper horizontal plate 25 are substantially parallel to each other, and the lower horizontal plate 23 and the upper horizontal plate 25 are substantially orthogonal to the vertical plate 24. The pair of first frame members 211 are arranged so that the opening surfaces face each other.

As shown in FIG. 2, the second frame member 212 is a part of the outer frame body 21 corresponding to the side along the longitudinal direction of the solar cell module 3, and is orthogonal to the first frame member 211. Like the first frame member 211, the second frame member 212 is formed in a straight line, and is formed to have a dimension equal to or longer than the length in the longitudinal direction of the solar cell module 3. Since the second frame material 212 has the same structure as the first frame material 211, the description thereof will be omitted.

When the solar cell module 3 is installed on the outer frame 21, the lower horizontal plate 23 faces the lower surface of the outer peripheral portion of the solar cell module 3 (the lower surface of the rubber frame 6 described later) as shown in FIG. The vertical plate 24 faces the outer peripheral end surface of the solar cell module 3 (the outer end surface of the rubber frame 6), and the upper horizontal plate 25 faces the upper surface of the outer peripheral portion of the solar cell module 3 (the upper surface of the rubber frame 6). ..

(1.4) Solar Cell Module The solar cell module 3 is a power generation unit in which a plurality of cells 43 are sealed in a sealing layer 42 between a glass layer 41 on the front surface and a protective layer 45 on the back surface. A plurality of solar cell modules 3 are installed on the installation surface 1 and can be used as a solar cell array, or can also be used as a single solar cell module. As shown in FIG. 2, the solar cell module 3 includes a solar cell module main body 4 and a rubber frame 6.

(1.4.1) Main body of solar cell module The main body 4 of the solar cell module constitutes the main body of the solar cell module 3. The solar cell module main body 4 has a light receiving surface 40 that receives sunlight on one surface, and is formed in a rectangular shape and a plate shape when viewed from above (hereinafter referred to as a plan view). As shown in FIG. 3, the solar cell module main body 4 has a glass layer 41, a sealing layer 42, and a back surface protective layer 45 laminated in this order from the light receiving surface 40 in the thickness direction (direction orthogonal to the main surface). There is. A plurality of cells 43 are sealed in the sealing layer 42.

The “light receiving surface 40” as used in the present invention means a surface on which sunlight is incident on the solar cell module main body 4 in the installed state. In the present specification, the "thickness direction" may be referred to as the "vertical direction", and in particular, the direction from the installation surface 1 side to the light receiving surface 40 side in the vertical direction is defined as "upward", and the opposite direction is defined as "downward". Is defined as. It should be noted that the definitions of these directions are not intended to specify the usage mode of the solar cell module 3.

Further, "lamination" in the present embodiment means that adjacent layers are fixed to each other in an overlapping state. "Fixing" here is realized by, for example, adhesion, welding, melting, or the like.

(1.4.1.1) Glass layer The glass layer 41 is a layer containing glass, and is mainly composed of a glass plate. The glass layer 41 may be composed of only a glass plate, or the surface of the glass plate may be coated with a transparent coating film. The upper surface of the glass layer 41 is a light receiving surface 40. The thickness of the glass layer 41 is preferably 0.4 mm or more and 1.6 mm or less, and more preferably 0.5 mm or more and 1.2 mm or less, from the viewpoint of strength and weight reduction. From the results of the hail drop test, it is possible to secure the strength against the hail with a thickness of 0.4 mm or more, but when the thickness of the glass layer 41 exceeds 1.6 mm, the weight of the solar cell module 3 is, for example, one general female. There is a high possibility that it will exceed 13 kg, which is the weight that can be worked in.

Here, the thickness of the glass layer 41 used in the conventional solar cell module 3 is generally about 3.2 mm or more and 4.2 mm or less. That is, in the solar cell module 3 according to the present embodiment, the glass layer 41 can be made to be 1/2 or less of the thickness of the glass layer 41 of the conventional solar cell module 3, so that the conventional solar cell module It is easier to reduce the weight compared to 3.

The glass plate used for the glass layer 41 is not particularly limited, but physically tempered glass or chemically tempered glass is preferably used.

Further, when the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) ³ ) ÷ 12], the flexural rigidity of the glass layer 41 is preferably 300 MPa or more and 21000 MPa or less.

(1.4.1.2) Sealing layer The sealing layer 42 is a layer that seals a plurality of cells 43, and is composed of a first sealing layer 421 and a second sealing layer 422. There is. The first sealing layer 421 is laminated on the lower side with respect to the glass layer 41, and the second sealing layer 422 is located below the first sealing layer 421 with the cell 43 interposed therebetween. .. The first sealing layer 421 and the second sealing layer 422 may be made of different materials, but in the present embodiment, they are made of the same material. In the present embodiment, the first sealing layer 421 and the second sealing layer 422 may be collectively referred to as a "sealing layer 42".

The material used for the sealing layer 42 is preferably, for example, EVA (polyethylene resin with ethylene vinyl acetate), a polyolefin-based sealing material, or the like, but in order to seal the cell 43 in another general solar cell module 3. The encapsulant used can also be used. The material used for the sealing layer 42 is not particularly limited, and for example, known additives may be appropriately added in order to improve transparency, flexibility, adhesiveness, tensile strength, weather resistance, and the like.

The sealing layer 42 wraps around the plurality of cells 43. Here, when the first sealing layer 421 and the second sealing layer 422 are made of different materials, or when the interface between the first sealing layer 421 and the second sealing layer 422 appears. , The thickness of each of the first sealing layer 421 and the second sealing layer 422 can be measured with reference to the interface. On the other hand, when the first sealing layer 421 and the second sealing layer 422 have substantially the same composition, the first sealing layer 421 and the second sealing layer 422 are melted and interface with each other. In this case, among the virtual planes parallel to the light receiving surface 40, the upper sealing layer 42 is first sealed with reference to the virtual plane passing through the center in the thickness direction of the cell 43. The thickness of each layer can be measured by using the layer 421 and the lower sealing layer 42 as the second sealing layer 422.

However, since the first sealing layer 421 and the second sealing layer 422 melt each other, the first sealing layer 421 and the second sealing layer 421 and the second sealing layer are used in the calculation of the flexural rigidity of the present invention. The total thickness of the 422 can be regarded as the thickness of the sealing layer 42. In this case, when the bending rigidity is defined as [(flexural modulus (MPa) × thickness (mm) ³ ) ÷ 12] as described above, the bending rigidity of the sealing layer 42 is 1 MPa or more and 10 MPa or less. It is preferable to have.

(1.4.1.3) Cell Cell 43 is a semiconductor element that directly converts light energy into electric power by the photovoltaic effect, and means a structural unit smaller than that of the solar cell module 3. The cell 43 is formed in a substantially rectangular plate shape, for example. The plurality of cells 43 are arranged at regular intervals along a surface parallel to the light receiving surface 40, and are sealed by the sealing layer 42.

The type of the cell 43 is not particularly limited. For example, a silicon (Si) semiconductor, a CIS compound semiconductor made from copper (Cu), indium (In) and selenium (Se), and copper (Cu) and indium (In). CIGS compound semiconductors made from selenium (Se) and gallium (Ga), compound semiconductors made from cadmium (Cd) and tellurium (Te), and GaAs compound semiconductors made from gallium (Ga) and arsenic (As). Etc. are used.

Further, the cell 43 may be provided with wiring or electrodes for extracting electric power on the upper surface, the lower surface and / and the end surface thereof.

(1.4.1.4) Back surface protective layer The back surface protective layer 45 is a layer provided below the cell 43 and protects the lower surface of the cell 43. The back surface protective layer 45 is laminated on the lower side of the sealing layer 42 (second sealing layer 422). The back surface protective layer 45 includes a first resin layer 46 and a second resin layer 47.

(1.4.1.4.1) First Resin Layer The first resin layer 46 is a layer made of foamed resin (sometimes referred to as “foamed resin layer”) and has a flexural modulus of 200 MPa or more and 1000 MPa. It is less than or equal to, preferably 300 MPa or more and 800 MPa or less. In the present embodiment, the first resin layer 46 is adjacent to the sealing layer 42, and is located on the uppermost side of the back surface protective layer 45 in the vertical direction.

The first resin layer 46 may have a bending elasticity in the range of 200 MPa or more and 1000 MPa or less, and the type of resin is not particularly limited. For example, polyethylene, polyproprene, polyamide, polystyrene, polyurethane, and polyvinyl chloride. , Polycarbonate, polymethylmethacrylate, polyethylene terephthalate, polybutylene terephthalate, acrylonitril styrene resin, acrylonitrile butadiene styrene resin, polyacetal, polyphenylene sulfide, polyether sulfone, polyether ether ketone resin, epoxy resin, unsaturated polyester, phenol resin, A foam of one or more kinds of resins selected from the group consisting of a urea resin, a melamine resin or a fluororesin can be used, and polypropylene is particularly preferable from the viewpoint of strength, heat deformation resistance and weather resistance.

If the flexural modulus is less than 200 MPa, the required rigidity cannot be obtained, but if it exceeds 1000 MPa, it may cause the solar cell module 3 to be significantly warped in the vacuum lamination when manufacturing the solar cell module 3. Further, increasing the flexural modulus increases the weight, which is not preferable.

The thickness of the first resin layer 46 is preferably 2 mm or more and 6 mm or less, and more preferably 3 mm or more and 5 mm or less. If the thickness of the first resin layer 46 is less than 2 mm, the required rigidity may not be obtained, and the cell 43 may not be properly protected. On the other hand, if the thickness of the first resin layer 46 exceeds 6 mm, heat does not easily escape in the vacuum lamination when manufacturing the solar cell module 3, and the thermal stress causes residual stress, so that the solar cell module 3 is greatly warped. Can be the cause.

The density of the first resin layer 46 ^{is preferably 100 kg / m 3} or more and 700 kg / m ³ or less. When the density of the first resin layer 46 ^{exceeds 700 kg / m 3} or more, it becomes hard and heavy, so that it becomes difficult for heat to escape in the vacuum lamination when manufacturing the solar cell module 3, and the thermal stress causes residual stress. It can cause the solar cell module 3 to warp significantly. Further, if the density of the first resin layer 46 ^{is less than 100 kg / m 3,} it is too soft and cracks due to the bending stress of the load test, and at about 150 ° C. in the vacuum lamination when manufacturing the solar cell module 3. The hot press may cause the bubbles generated by foaming to collapse.

Further, when the bending rigidity is defined as [(flexural modulus (MPa) × thickness (mm) ³ ) ÷ 12] as described above, the bending rigidity of the first resin layer 46 is 100 MPa or more and 20000 MPa or less. It is preferable to have.

The method for forming the first resin layer 46 into a foamed state is not particularly limited, but for example, physical foaming, chemical foaming, or the like can be applied, and the chemical foaming method is applied from the viewpoint of controlling the foamed particles. Is preferable. The expansion ratio of the first resin layer 46 is preferably 1.5 times or more and 8 times or less, and more preferably 2 times or more and less than 5 times. If the foaming ratio is less than 1.5 times, the density becomes 700 kg / m ³ or more, and as described above, the solar cell module 3 may be greatly warped in the vacuum lamination when manufacturing the solar cell module 3. There is. On the other hand, if the foaming ratio is larger than 8 times, the density becomes 100 kg / m ³ or less, and as described above, it is cracked by the bending load in the load test, and foaming is performed in the vacuum lamination when manufacturing the solar cell module 3. There is a risk that the bubbles generated by this will collapse.

(1.4.1.4.2) Second Resin Layer The second resin layer 47 is a fiber-reinforced resin layer (sometimes referred to as a “fiber-reinforced resin layer”) and has a flexural modulus of 10,000 MPa. It is 25,000 MPa or more, preferably 15,000 MPa or more and 30,000 MPa or less. In the present embodiment, the second resin layer 47 is adjacent to the first resin layer 46 and is laminated on the lower side with respect to the first resin layer 46.

The second resin layer 47 may have a bending elasticity in the range of 10,000 MPa or more and 25,000 MPa, and the type of resin is not particularly limited. For example, from the viewpoints of strength, heat deformation resistance, and weather resistance, polyethylene and polypro Plen, polyamide, polystyrene, polyurethane, polyvinyl chloride, polycarbonate, polymethylmethacrylate, polyethylene terephthalate, polybutylene terephthalate, acrylonitril styrene resin, acrylonitrile butadiene styrene resin, polyacetal, polyphenylene sulfide, polyether sulfone, polyether ether ketone resin , Epoxy resin, unsaturated polyester, phenol resin, urea resin, melamine resin, or fluororesin, and one or more resins containing fibers can be used.

The fiber used for the second resin layer 47 is preferably excellent in fire resistance, resistance to deformation against temperature changes, and dimensional stability, and for example, glass fiber is preferable. Resins containing glass fibers are also called glass fiber reinforced plastics (GFRP), and are obtained by infiltrating fine glass fibers into the resin while keeping the fibers oriented. The type of glass fiber contained in the second resin layer 47 is not particularly limited, and for example, known roving cloth-shaped glass fiber, mat-shaped glass fiber and the like can be used, but from the viewpoint of strength and surface accuracy, it is possible to use. Plain woven glass cloth is preferably used.

In the second resin layer 47, the ratio of the glass fiber to the resin is not particularly limited. For example, the resin 30 is made of glass fiber having an average thickness of 1 μm or more and 10 μm or less and an average length of 1 mm or more and 20 mm or less with respect to 100 parts by weight. It is preferably 7 parts by weight or more and 70 parts by weight or less.

If the flexural modulus is less than 10,000 MPa, the required rigidity cannot be obtained, which may cause the solar cell module 3 to be significantly warped in the vacuum lamination when manufacturing the solar cell module 3. Further, in the fiber-reinforced resin layer, if the flexural modulus exceeds 25,000 MPa, the weight may increase.

The thickness of the second resin layer 47 is preferably 0.5 mm or more and 2.0 mm or less, and more preferably 0.5 mm or more and 1.0 mm or less. If the thickness of the second resin layer 47 is less than 0.5 mm, the required rigidity may not be obtained, and the cell 43 may not be properly protected. On the other hand, if the thickness of the second resin layer 47 exceeds 2.0 mm, the rigidity is too high, the followability is lowered, and the adhesive surface may be lifted when adhering to another layer.

The density of the second resin layer 47 ^{is preferably 1500 kg / m 3} or more and 2500 kg / m ³ or less. If the density of the second resin layer 47 is 1500 kg / m ³ or less, the density becomes substantially the same as that of ordinary resin, resulting in insufficient strength. On the other hand, if the ^{density exceeds 2500 kg / m 3} , the density becomes substantially the same as that of glass. , The weight becomes excessive.

When the flexural rigidity is defined as [(flexural modulus (MPa) x thickness (mm) ³ ) ÷ 12] as described above, the flexural rigidity of the second resin layer 47 shall be 100 MPa or more and 20000 MPa or less. Is preferable.

The method for forming the second resin layer 47 is not particularly limited, and for example, a resin extrusion method, a resin liquid impregnation method, or the like can be used.

(1.4.1.5) Sum of flexural rigidity As described above, the solar cell module main body 4 includes a first resin layer 46 and a second resin layer 47 as the back surface protective layer 45. In the solar cell module main body 4, the sum of the bending rigidity of each of the glass layer 41, the sealing layer 42, the first resin layer 46, and the second resin layer 47 is set to 4000 MPa or more (preferably 4000 MPa or more and 30,000 MPa or less). Has been done. Therefore, in the solar cell module 3 in which the thickness of the glass layer 41 is suppressed, the rigidity can be increased, and damage to the cell 43 during transportation or installation can be prevented.

When the sum of the flexural rigidity of each of the glass layer 41, the sealing layer 42, the first resin layer 46 and the second resin layer 47 is less than 4000 MPa, the amount of deflection of the module due to the evenly distributed load in the load test 2400 Pa. Exceeds 50 mm, which may affect the function of the cell 43, such as damaging the cell 43.

The conventional general solar cell module 3 includes a layer called a back surface protective sheet (back sheet) as the back surface protective layer 45. As the back surface protective sheet, a laminate of sheets such as polyethylene terephthalate (PET), low-density polyethylene, and vinylidene fluoride is usually used. However, if the above-mentioned back surface protective sheet is used for the back surface protective layer 45 while reducing the thickness of the glass layer 41 as the solar cell module 3, the rigidity of the solar cell module 3 is lowered, and the solar cell module 3 is reduced in rigidity during transportation or installation. At that time, the cell 43 may be damaged.

Further, it is preferable that the total thickness of the solar cell module 3 is 4 mm or more and 8 mm or less. If the total thickness of the solar cell module 3 is less than 4 mm, the bending displacement of the load test may affect the function of the cell 43, while if the total thickness exceeds 8 mm, the total weight is large. Therefore, there is a risk of adversely affecting the mounting work on the gantry 2 and the manufacturing process.

(1.4.2) Rubber frame As shown in FIG. 2, the rubber frame 6 is attached to the outer peripheral portion of the solar cell module main body 4. In the present embodiment, the rubber frame 6 is continuous over the entire length of the outer peripheral portion of the solar cell module 3, but in the present invention, a part of the outer peripheral portion may be omitted or may be provided intermittently. .. The rubber frame 6 may be adhered to the outer peripheral portion of the solar cell module 3 or may be attached only by being fitted.

The rubber frame 6 is made of a material containing rubber. The type of rubber is not particularly limited, for example, natural rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, urethane rubber, silicon rubber, fluorine. One type or two or more types selected from the group consisting of rubber and the like can be mentioned.

The rubber frame 6 may contain a material other than rubber in order to improve weather resistance, durability, and / and workability. The rubber frame 6 can be formed of, for example, a material containing 10% by weight or more, preferably 20% by weight or more, and more preferably 30% by weight or more of rubber. Further, the rubber frame 6 can be formed of, for example, a material containing a filler such as carbon black or silicic acid in an amount of 10% by weight or more, preferably 20% by weight or more, and more preferably 30% by weight or more. In addition, mineral oil as a plasticizer, a cross-linking agent as an additive, an anti-aging agent, and the like may be added.

As shown in FIG. 3, the rubber frame 6 has a first plate portion 61 facing the outer peripheral portion of the upper surface of the glass layer 41 and a second plate portion facing the outer peripheral portion of the lower surface of the back surface protective layer 45. A third plate portion 63 facing the end surface of the outer peripheral portion of the solar cell module 3 and connecting the first plate portion 61 and the second plate portion 62 is provided. The first plate portion 61, the second plate portion 62, and the third plate portion 63 are integrally formed, and are formed in a substantially C-shaped cross section. When the rubber frame 6 is attached to the outer peripheral portion of the solar cell module main body 4, the outer peripheral portion can be covered. The rubber frame 6 is arranged between the solar cell module main body 4 and the outer frame body 21.

The inner end of the first plate portion 61 is at substantially the same position (here, flush with each other) in a plan view with respect to the inner end of the upper horizontal plate 25 of the outer frame body 21 of the gantry 2. Further, the inner end of the second plate portion 62 is at substantially the same position (here, flush with each other) with respect to the inner end of the lower horizontal plate 23 of the outer frame body 21 in a plan view.

However, the rubber frame 6 according to the present invention does not necessarily include all of the first plate portion 61, the second plate portion 62, and the third plate portion 63, and the solar cell module main body 4 comes into contact with the outer frame body 21. For example, the rubber frame 6 may be composed of only the first plate portion 61 and the second plate portion 62, or the rubber frame 6 may be composed of only the first plate portion 61 and the second plate portion 62 so as to cover only the corner portions of the solar cell module main body 4. The plate portion 63 may be separated in the vertical direction. Further, the inner end of the first plate portion 61 and / and the second plate portion 62 may be displaced from the inner end of the outer frame body 21 in a plan view.

In the rubber frame 6, the thickness t1 of each of the first plate portion 61 and the second plate portion 62 is preferably 1 mm or more, more preferably 1.5 mm or more. If the thickness t1 is less than 1 mm, the glass layer 41 or the back surface protective layer 45 comes into contact with the inner angle 231 of the inner end of the lower horizontal plate 23 or the upper horizontal plate 25 of the outer frame 21 during the load test (FIG. 4). (See), the glass layer 41 or the back surface protective layer 45 may be cracked or damaged. The thickness t2 of the third plate portion 63 is not particularly limited, and may be thinner, thicker, or the same as the first plate portion 61 and / and the second plate portion 62.

The dimension D1 from the inner end of the first plate portion 61 and the second plate portion 62 to the end of the corresponding solar cell module main body 4 in one direction parallel to the light receiving surface 40 of the solar cell module main body 4 is 8 mm or more. It is preferably formed to be 20 mm or less, more preferably 10 mm or more and 15 mm or less. If the dimension D1 is less than 8 mm, the rubber frame 6 may fall off from the outer frame body 21. On the other hand, when the dimension D1 exceeds 20 mm, as shown in FIG. 4, the thickness at the inner end of the rubber frame 6 when the amount of deflection at the center of the solar cell module main body 4 during the load test is 30 mm or more. Since the deformation example (compression amount) in the direction becomes large, the glass layer 41 or the back surface protective layer 45 may come into contact with the inner angle 231 of the inner end of the lower horizontal plate 23 or the upper horizontal plate 25 of the outer frame body 21. , Cracks or damage may occur.

The "end of the corresponding solar cell module main body 4" as used herein means "the first end of the solar cell module main body 4 that appears in one cross section (vertical facing in the present embodiment) orthogonal to the light receiving surface 40". It means the end of the solar cell module main body 4 to which the cross section of the rubber frame 6 having the "inner ends of the plate portion 61 and the second plate portion 62" is attached.

The tensile elastic modulus of the rubber frame 6 is preferably 3 MPa or more and 200 MPa or less, and more preferably 4 MPa or more and 150 MPa or less. If the tensile elastic modulus is less than 3 MPa, when a load is applied to the solar cell module body 4, the stress generated in the rubber frame 6 causes the rubber frame 6 to be torn due to insufficient cohesive force, and the solar cell module body 4 falls off. There is a risk. On the other hand, if the tensile elastic modulus is larger than 200 MPa, it becomes hard (for example, as hard as plastic), so that the load received by the deflection of the solar cell module main body 4 at the time of the load test cannot be elastically received, and the glass cannot be elastically received. The layer 41 or the back surface protective layer 45 may be cracked or damaged.

(2) Modified Example The above embodiment is only one of various embodiments of the present disclosure. The embodiment can be changed in various ways depending on the design and the like as long as the object of the present disclosure can be achieved. The modifications described below can be applied in combination as appropriate.

(2.1) Modification 1
In the solar cell module main body 4 according to the above embodiment, the back surface protective layer 45 includes the first resin layer 46 and the second resin layer 47, but in the modified example 1, as shown in FIG. 5, the back surface is provided. The protective layer 45 includes a first resin layer 46, a second resin layer 47, an easy-adhesion resin layer 48, and a third resin layer 49. This modification is different from the first embodiment in this respect, and other configurations are the same. The first resin layer 46 and the second resin layer 47 are provided with an easily adhesive resin layer 48 and a third resin layer 49 between the first resin layer 46 and the second sealing layer 422, except that the first resin layer 46 and the second resin layer 47 are provided with the easy-adhesion resin layer 48 and the third resin layer 49. Is the same as that of the first embodiment, and the description of the first resin layer 46 and the second resin layer 47 will be omitted.

(2.1.1) Easy-Adhesive Resin Layer The easy-adhesive resin layer 48 is provided between the sealing layer 42 and the first resin layer 46, and is formed by vacuum lamination at 130 ° C. or higher and 160 ° C. or lower. For example, adhesion to the sealing layer 42 is exhibited by adhesion by heat melting or chemical bonding such as van der Waals bond.

The material used for the easy-adhesion resin layer 48 is not particularly limited, and for example, a polyolefin resin such as polyethylene (high density polyethylene, low density polyethylene, linear low density polyethylene), polypropylene, polybutene, and (meth) acrylic. Based resin, polyvinyl chloride based resin, polystyrene resin, polyvinylidene chloride resin, ethylene-vinyl acetate copolymer saponified product, polyvinyl alcohol, fluororesin (polyvinylidene fluoride, polyvinyl fluoride, ethylene detrafluoroethylene) , One or more polyvinyl chloride resin films or sheets or coating layers can be used. The film or sheet of these resins may be stretched in the uniaxial or biaxial direction.

Among them, the easy-adhesion resin layer 48 is made of polyethylene (high-density polyethylene, low-density polyethylene, linear low-density polyethylene) from the viewpoint of ensuring good adhesion to EVA, which is the sealing layer 42 of the solar cell module 3. Is preferable, and more preferably, linear low-density polyethylene. Linear low-density polyethylene (LLDPE) is preferable because it has a higher density than low-density polyethylene (LDPE) and is excellent in heat resistance and weather resistance.

As a film forming method for the easy-adhesive resin layer 48, for example, T-die molding, inflation molding, or the like is used, and molding by a multi-layer extruder is also possible. Further, the easy-adhesion resin layer 48 may be colored (white, black, etc.). Examples of the coloring means include coating and film molding by kneading pigments. The thickness of the easy-adhesion resin layer 48 is preferably 3 μm or more and 150 μm or less, and more preferably 6 μm or more and 70 μm or less.

(2.1.2) Third Resin Layer The third resin layer 49 is provided between the easy-adhesion resin layer 48 and the first resin layer 46, and has a flexural modulus of 1500 MPa or more and 4000 MPa or less. It is preferably 2000 MPa or more and 3500 MPa or less. If it is less than 1500 MPa, the required rigidity cannot be obtained, but if it exceeds 4000 MPa, the flexibility is lost, the adhesive applicability is deteriorated, and cracks are likely to occur. The third resin layer 49 is laminated on the easy-adhesion resin layer 48 and the first resin layer 46.

The third resin layer 49 is made of a film or a sheet. The resin used for the third resin layer 49 is not particularly limited, and for example, a (meth) acrylic resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, a polycarbonate resin, an acetal resin, and a polyester resin ( Polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate), polyamide resin, polyphenylene ether resin, and other various resin films or sheets can be used. The film or sheet of these resins may be uniaxially or biaxially stretched.

Among them, the third resin layer 49 is preferably a polyester resin from the viewpoint of ensuring electrical insulation, handleability and the like. Further, the third resin layer 49 may be colored (white, black, etc.). Examples of the coloring means include coating and film molding by kneading pigments. As the film forming method of the third resin layer 49, for example, T-die molding, inflation molding and the like are used, and molding by a multi-layer extruder is also possible.

The thickness of the third resin layer 49 is preferably 0.03 mm or more and 0.5 mm or less, and more preferably 0.05 mm or more and 0.3 mm or less. If the thickness of the third resin layer 49 is less than 0.03 mm, the required rigidity cannot be obtained, but if it exceeds 0.5 mm, it is difficult to roll up the film or sheet before manufacturing, and the handleability is improved. It is impaired and the manufacturability is reduced.

The solar cell module 3 according to this modification can also achieve the same effect as that of the above embodiment.

(2.2) Modification 2
In the solar cell module main body 4 according to the above embodiment, the back surface protective layer 45 includes the first resin layer 46 and the second resin layer 47, but in the second modification, as shown in FIG. 6, the back surface is provided. The protective layer 45 includes a glass layer. This modification is different from the first embodiment in this respect, and other configurations are the same.

The solar cell module main body 4 according to this modification includes a first glass layer 41, a sealing layer 42, and a back surface protective layer 45 in order from the light receiving surface 40 in the thickness direction. The first glass layer 41 is the same as the glass layer 41 of the above embodiment.

As described above, the back surface protective layer 45 includes a glass layer (second glass layer 50). The second glass layer 50 is formed to have a thickness of 0.4 mm or more and 1.6 mm or less (preferably 0.5 mm or more and 1.2 mm or less) like the first glass layer 41. The second glass layer 50 may be made of the same glass plate as the first glass layer 41, or a different glass plate may be used.

The solar cell module 3 according to this modification can also achieve the same effect as that of the above embodiment.

(2.3) Other Modifications Examples of modifications are listed below.

From the viewpoint of improving weather resistance, the back surface protective layer 45 according to the above embodiment may have a weather resistant layer laminated on the lower side of the second resin layer 47. The resin used for the weather resistant layer is not particularly limited, and is, for example, a polyolefin resin such as polyethylene (high density polyethylene, low density polyethylene, linear low density polyethylene), polypropylene, polybutene, (meth) acrylic resin, and poly. Vinyl chloride resin, polystyrene resin, polyvinylidene chloride resin, ethylene-vinyl acetate copolymer saponified product, polyvinyl alcohol, polycarbonate resin, fluororesin (polyvinylidene fluoride, vinyl fluoride, ethylene detrafluoroethylene) , Polyvinyl acetate resin, acetal resin, polyester resin (polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate), polyamide resin, polyphenylene ether resin, and other various resin films or sheets can be used. The film or sheet of these resins may be uniaxially or biaxially stretched. Of these, polyester resin is preferable because it can ensure electrical insulation and handleability. Further, the weather-resistant layer can be colored (for example, white, black, etc.). Examples of the coloring means include coating and film molding by kneading pigments. As the film forming method, for example, T-die molding, inflation molding and the like are used, and molding by a multi-layer extruder is also possible.

Further, the back surface protective layer 45 is provided with another layer between the first resin layer 46 and the second resin layer 47 or in the outermost layer in order to appropriately improve water resistance, power generation efficiency, and withstand voltage. May be good. For example, the surface of the first resin layer 46 opposite to the surface on which the second resin layer 47 is laminated, between the first resin layer 46 and the second resin layer 47, and of the second resin layer 47. One or more layers selected from the group consisting of an adhesive layer and the weather resistant layer on any one or two or more of the surfaces opposite to the surface on which the first resin layer 46 is laminated. May be provided.

As the adhesive and bonding method used for the adhesive layer, for example, a two-component curable urethane adhesive, a polyether urethane adhesive, a polyester adhesive, a polyester polyol adhesive, a polyester polyurethane polyol adhesive, etc. are used. It is possible to employ the dry laminating method, the coextrusion method, the extrusion coating method, the thermal laminating method using an anchor coating agent, and the like.

The thickness of the adhesive layer for adhering the easy-adhesive resin layer 48 and the third resin layer 49 is preferably 3 μm or more and 30 μm or less, and more preferably 5 μm or more and 20 μm or less.

Further, when the third resin layer 49 and the first resin layer 46, the first resin layer 46 and the second resin layer 47, and the second resin layer 47 and the weather resistant layer are adhered to each other, they are adhered to each other. The thickness of the layer is preferably 20 μm or more and 200 μm or less, and more preferably 30 μm or more and 150 μm or less.

Further, in the solar cell module 3 according to the above embodiment, it is attached to the fixed type pedestal 2, but in the present invention, it can also be attached to the so-called tracking type pedestal.

(3) Examples The present invention will be specifically described below with reference to Examples and Comparative Examples. Although each configuration is designated by reference with reference to the above embodiment for reference, the present invention is not limited to the examples.

(3.1) Example (3.1.1) Example 1
First, as the back surface protective layer 45, the first resin layer 46 and the second resin layer 47 were configured as follows. The first resin layer 46 has a foaming magnification of 3 times, a density of 400 kg / m ³ , a flexural modulus of 400 MPa, and a thickness of 3.0 mm, a foamed polypropylene (PP) sheet, and the second resin layer 47 has a density of 1600 kg / m ³ , bending. A glass cloth reinforced polypropylene resin-based FRP (glass fiber density 50 wt%) having an elastic modulus of 20000 MPa and a thickness of 0.5 mm was prepared, and these were bonded with a commercially available adhesive.

A urethane isocyanate-based adhesive for sheet coating (thickness 70 μm) was used for bonding the first resin layer 46 and the second resin layer 47. As a result, a back surface protective layer 45 (“foamed PP + FRP”) having a thickness of 3.6 mm was obtained.

Next, as the glass layer 41 (first glass layer 41), a tempered glass having a density of 2500 kg / m ³ , a flexural modulus of 60,000 MPa, a size of 1323 mm × 990 mm × a thickness of 0.85 mm, and a sealing layer 42 of the first seal. Each of the stop layer 421 and the second sealing layer 422 has the same dimensions as the glass layer 41, a density of 960 kg / m ³ , a tensile elastic modulus of 100 MPa, an EVA having a thickness of 0.5 mm, and a cell 43 having a size of 156 mm × 156 mm ×. Forty-eight single crystal cells 43 having a thickness of 200 μm were prepared, and a commercially available interconnector (manufactured by Hitachi Metals Co., Ltd.) and a bus bar (manufactured by Hitachi Metals Co., Ltd.) were attached to the cells 43.

A glass layer 41, a first sealing layer 421, a plurality of cells 43, a second sealing layer 422, and a back surface protective layer 45 were laminated in this order on a hot plate of a vacuum laminator, and laminating at 140 ° C. for 15 minutes was performed. The cells 43 were arranged in an orderly manner with respect to the glass layer 41 so as to have 6 rows in the lateral direction and 8 rows in the longitudinal direction.

As a result, the solar cell module 3 in which the glass layer 41, the sealing layer 42, and the back surface protective layer 45 (the first resin layer 46 as the back surface protection layer 45 + the second resin layer 47) were laminated in this order was obtained. The solar cell module 3 had a size of 1323 mm × 990 mm, a 48 straight module, an overall thickness of 5.4 mm, and an overall weight of 7.5 kg (5.7 kg / m ² ).

The sum of the flexural rigidity of each of the glass layer 41, the sealing layer 42, the first resin layer 46, and the second resin layer 47 is (60000 × 0.85 ³ + 100 × 0.5 ³ + 400 × 3 ³ + 20000 × It was 0.5 ³ ) × (1/12) = 4187 MPa.

Next, as the rubber frame 6, the thickness t1 = 1.5 mm of the first plate portion 61 and the second plate portion 62, the thickness t2 = 1.5 mm of the third plate portion 63, and the inner end of the rubber frame 6 A frame made of ethylene propylene diene monomer (EPDM) rubber having a substantially U-shaped cross section and having a dimension D1 = 10.5 mm to the end of the corresponding solar cell module main body 4 was used. The tensile elastic modulus of the rubber was measured by a tensile tester based on JIS K 7161 and was 4 MPa. This was attached to all four sides of the solar cell module main body 4 to form a solar cell module 3.

A load test is carried out in which the solar cell module 3 is attached to the gantry 2 (outer frame body 21) and an evenly distributed load is alternately applied to the glass layer 41 and the back surface protective layer 45 of the solar cell module main body 4 for 1 hour each for 3 cycles. went.

The test load was increased from 3600 Pa to 900 Pa, and the load at which the cell 43 or the glass layer 41 was not cracked was recorded. Those without cracks at 4500 Pa were rated as “◯”, and those with cracks in the cell 43 or the glass layer 41 at a test load of less than 4500 Pa were rated as “x”.

As a result of applying a load of 4500 Pa, the solar cell module 3 according to the first embodiment was passed “◯”.

(3.1.2) Example 2
As the solar cell module 3 of the second embodiment, the sun under the same conditions as the first embodiment except that the thickness of the first plate portion 61 and the second plate portion 62 of the rubber frame 6 is t1 = 3.0 mm. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.3) Example 3
As the solar cell module 3 of Example 3, the rubber frame 6 used in Example 1 was thermoset in an oven at 85 ° C. for 1000 hours, and the conditions were the same as those of Example 1 except that the tensile elastic modulus was set to 120 MPa. , Solar cell module 3 was obtained.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.4) Example 4
As the solar cell module 3 of the fourth embodiment, the sun under the same conditions as the third embodiment except that the thickness of the first plate portion 61 and the second plate portion 62 of the rubber frame 6 is t1 = 3.0 mm. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.5) Example 5
As the solar cell module 3 of the fifth embodiment, the back surface protective layer 45 is composed of an easy-adhesion resin layer 48, a third resin layer 49, a first resin layer 46, and a second resin layer 47, as follows. did.

As the easy-adhesion resin layer 48, ^{a white polyethylene (PE) film having a density of 1050 kg / m 3} and a bending elasticity of 1000 MPa and a thickness of 0.050 mm, and as a third resin layer 49, a density of 1350 kg / m ³ and a bending elasticity of 2400 MPa, A transparent polyethylene terephthalate (PET) film with a thickness of 0.125 mm, a foamed polypropylene (PP) sheet with a ^{foaming magnification of 3 times, a density of 400 kg / m 3, a bending elasticity of 400 MPa, and a thickness of 3.0 mm as the first resin layer 46.} As the second resin layer 47, ^{a glass cloth reinforced polypropylene resin-based FRP (glass fiber density 50 wt%) having a density of 1600 kg / m 3} , a bending elasticity of 20000 MPa, and a thickness of 0.5 mm was prepared, and these were prepared by using a commercially available adhesive. I pasted them together.

A urethane isocyanate-based adhesive for dry lamination (thickness: 10 μm) was used for bonding the easy-adhesion resin layer 48 and the third resin layer 49. A urethane isocyanate adhesive (thickness 70 μm) for sheet coating was used for bonding the third resin layer 49, the first resin layer 46, and the second resin layer 47.

As a result, the back surface protective layer 45 is implemented except that the easy-adhesion resin layer 48, the third resin layer 49, the first resin layer 46, and the second resin layer 47 have a total thickness of 3.8 mm. The solar cell module 3 was obtained under the same conditions as in Example 1. The solar cell module 3 had a size of 1323 mm × 990 mm, a 48 straight module, an overall thickness of 5.7 mm, and an overall weight of 7.9 kg (6.1 kg / m ² ).

The sum of the flexural rigidity of each of the glass layer 41, the sealing layer 42, the easy-adhesion resin layer 48, the third resin layer 49, the first resin layer 46, and the second resin layer 47 is (60,000 × 0.85). ^{It was 3} + 100 × 0.5 ³ + 1000 × 0.05 ³ + 2400 × 0.125 ³ + 400 × 3 ³ + 20000 × 0.5 ³ ) × (1/12) = 4188 MPa.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, as a result of applying a load of 6400 Pa, the result was "○".

(3.1.6) Example 6
The solar cell module 3 of the sixth embodiment was implemented except that the first resin layer 46 and the second resin layer 47 as the back surface protective layer 45 of the first embodiment were replaced with 0.85 mm tempered glass. The solar cell module 3 was obtained under the same conditions as in Example 1. The solar cell module 3 was 1323 mm × 990 mm, had a 60 straight module, had an overall thickness of 2.7 mm, and had an overall weight of 7.5 kg (5.8 kg / m ² ).

The sum of the flexural rigidity of each of the glass layer 41 (first glass layer 41), the sealing layer 42, and the second glass layer 50 is (60000 × 0.85 ³ + 100 × 1 ³ + 60000 × 0.85 ³ ). × (1/12) = 6150 MPa.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.7) Example 7
As the solar cell module 3 of the seventh embodiment, the sun under the same conditions as the sixth embodiment except that the thickness of the first plate portion 61 and the second plate portion 62 of the rubber frame 6 is t1 = 3.0 mm. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.8) Example 8
As the solar cell module 3 of Example 8, the rubber frame 6 used in Example 6 was thermoset in an oven at 85 ° C. for 1000 hours, and the tensile elastic modulus was changed from 4 MPa to 120 MPa in the same manner as in Example 6. Obtained a solar cell module 3.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.1.9) Example 9
As the solar cell module 3 of the ninth embodiment, the sun under the same conditions as the eighth embodiment except that the thickness t1 = 3.0 mm of the first plate portion 61 and the second plate portion 62 of the rubber frame 6 was set. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was carried out by the same method as in Example 1, the result of applying a load of 4500 Pa was "○".

(3.2) Comparative Example (3.2.1) Comparative Example 1
Examples except that one-component silicone rubber manufactured by Shin-Etsu Chemical was applied to the four sides of the solar cell module main body 4 so as to have a thickness of 1.5 mm, and an aluminum frame was attached to the four sides of the solar cell module main body 4. The solar cell module 3 was obtained under the same conditions as in 1. The tensile elastic modulus of the silicone rubber was 0.4 MPa.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the silicon rubber was torn, the solar cell module main body 4 fell off, and the result was "x". ..

(3.2.2) Comparative Example 2
As the solar cell module 3 of Comparative Example 2, the sun was set under the same conditions as in Example 1 except that the thickness t1 = 0.5 mm of the first plate portion 61 and the second plate portion 62 of the rubber frame 6. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hits the corner of the inner end of the gantry 2 (outer frame 21), and cracks were generated. It occurred and was rejected with "x".

(3.2.3) Comparative Example 3
As the solar cell module 3 of Comparative Example 3, the sun was set under the same conditions as in Example 3 except that the thickness t1 = 0.5 mm of the first plate portion 61 and the second plate portion 62 of the rubber frame 6. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hits the corner of the inner end of the gantry 2 (outer frame 21), and cracks were generated. It occurred and was rejected with "x".

(3.2.4) Comparative Example 4
A solar cell module 3 was obtained under the same conditions as in Example 1 except that a polycarbonate (PC) frame having a thickness of 1.5 mm was attached to the four sides of the solar cell module main body 4. The tensile elastic modulus of the polycarbonate frame was 2,000 MPa.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hit the corner of the polycarbonate frame and cracked, resulting in a failure "x". ..

(3.2.5) Comparative Example 5
Examples except that one-component silicone rubber manufactured by Shin-Etsu Chemical was applied to the four sides of the solar cell module main body 4 so as to have a thickness of 1.5 mm, and an aluminum frame was attached to the four sides of the solar cell module main body 4. The solar cell module 3 was obtained under the same conditions as in 6.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the silicon rubber was torn, the solar cell module main body 4 fell off, and the result was "x". ..

(3.2.6) Comparative Example 6
As the solar cell module 3 of Comparative Example 6, the sun was set under the same conditions as in Example 6 except that the thickness t1 = 0.5 mm of the first plate portion 61 and the second plate portion 62 of the rubber frame 6. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hits the corner of the inner end of the gantry 2 (outer frame 21), and cracks were generated. It occurred and was rejected with "x".

(3.2.7) Comparative Example 7
As the solar cell module 3 of Comparative Example 7, the sun was set under the same conditions as in Example 8 except that the thickness t1 = 0.5 mm of the first plate portion 61 and the second plate portion 62 of the rubber frame 6. A battery module 3 was obtained.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hits the corner of the inner end of the gantry 2 (outer frame 21), and cracks were generated. It occurred and was rejected with "x".

(3.2.8) Comparative Example 8
A solar cell module 3 was obtained under the same conditions as in Example 6 except that a polycarbonate (PC) frame having a thickness of 1.5 mm was attached to the four sides of the solar cell module main body 4. The tensile elastic modulus of the polycarbonate frame was 2,000 MPa.

When the evaluation test of the solar cell module 3 was performed by the same method as in Example 1, as a result of applying a load of 4500 Pa, the glass layer 41 hit the corner of the polycarbonate frame and cracked, resulting in a failure "x". ..

As shown in the above results, in the solar cell module 3 of Example 1-9, even if a relatively thin glass layer 41 having a thickness of 0.4 mm or more and 1.6 mm or less is used, the amount of deflection of the solar cell module 3 is large. It is suppressed and the glass layer 41 and the like are not cracked. From this, it was found that the solar cell module 3 of the first to ninth embodiments has a high load bearing capacity.

Further, in the solar cell module 3 of the fifth embodiment, the load bearing capacity is increased as compared with the other examples. That is, as the back surface protective layer 45, in addition to the first resin layer 46 and the second resin layer 47, an easy-adhesive resin that exhibits adhesiveness to the sealing layer 42 by vacuum lamination at 130 degrees or more and 160 degrees or less. It was found that when the layer 48 and the third resin sheet layer having a flexural modulus of 1500 MPa or more and 4000 MPa or less were provided, the load bearing capacity was increased even though the thickness was substantially the same (difference of 1 mm or less).

(4) Aspects As described above, the solar cell module 3 according to the first aspect is attached to a solar cell module main body 4 having a light receiving surface 40 for receiving sunlight on one surface and an outer peripheral portion of the solar cell module main body 4. The rubber frame 6 is provided. The solar cell module main body 4 includes a light receiving surface 40, and has a glass layer 41 formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface protection provided on the side opposite to the light receiving surface 40 with respect to the glass layer 41. It has a layer 45 and a sealing layer 42 provided between the glass layer 41 and the back surface protective layer 45 to seal a plurality of cells 43. The back surface protective layer 45 is provided on the side opposite to the light receiving surface 40 with respect to the first resin layer 46 made of a foamed resin having a flexural modulus of 200 MPa or more and 1000 MPa or less and the first resin layer 46, and has a flexural modulus of 10,000 MPa or more. It contains a second resin layer 47 which is 25,000 MPa or less and is fiber-reinforced. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the glass layer 41, the sealing layer 42, the first resin layer 46, and the second resin layer 47 The sum of the flexural rigidity of each of these is 4000 MPa or more. The rubber frame 6 has a first plate portion 61 facing the outer peripheral portion of the light receiving surface 40 of the glass layer 41 and a second plate portion 62 facing the outer peripheral portion of the surface of the back surface protective layer 45 opposite to the light receiving surface 40. And have. Each of the first plate portion 61 and the second plate portion 62 has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and is a first plate in one direction parallel to the light receiving surface 40 of the solar cell module main body 4. The dimension from the inner end of the portion 61 and the second plate portion 62 to the corresponding end of the solar cell module main body 4 is formed to be 8 mm or more and 20 mm or less.

According to this aspect, even if a relatively thin glass layer 41 having a thickness of 0.4 mm or more and 1.6 mm or less is used, the amount of deflection of the solar cell module 3 is suppressed, and the glass layer 41 and the like are less likely to crack and are high. Withstand load can be obtained.

The solar cell module 3 according to the second aspect includes a solar cell module main body 4 having a light receiving surface 40 that receives sunlight on one surface, and a rubber frame 6 attached to an outer peripheral portion of the solar cell module main body 4. The solar cell module main body 4 includes the light receiving surface 40, and has a glass layer 41 formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface provided on the glass layer 41 on the opposite side of the light receiving surface 40. It has a protective layer 45 and a sealing layer 42 provided between the glass layer 41 and the back surface protective layer 45 to seal a plurality of cells 43. The back surface protective layer 45 includes a second glass layer 50 having a thickness of 0.4 mm or more and 1.6 mm or less. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the flexural rigidity of each of the glass layer 41, the sealing layer 42, and the second glass layer 50 The sum is 4000 MPa or more. The rubber frame 6 has a first plate portion 61 facing the outer peripheral portion of the light receiving surface 40 of the glass layer 41 and a second plate portion 62 facing the outer peripheral portion of the surface of the back surface protective layer 45 opposite to the light receiving surface 40. And have. Each of the first plate portion 61 and the second plate portion 62 has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and is a first plate in one direction parallel to the light receiving surface 40 of the solar cell module main body 4. The dimension from the inner end of the portion 61 and the second plate portion 62 to the end of the solar cell module main body 4 is formed to be 8 mm or more and 20 mm or less.

According to this aspect, even if a relatively thin glass layer 41 having a thickness of 0.4 mm or more and 1.6 mm or less is used, the amount of deflection of the solar cell module 3 is suppressed, and the glass layer 41 and the like are less likely to crack and are high. Withstand load can be obtained.

The solar cell module 3 according to the third aspect includes a solar cell module main body 4 having a light receiving surface 40 for receiving sunlight on one surface, and a rubber frame 6 attached to an outer peripheral portion of the solar cell module main body 4. The solar cell module main body 4 includes a light receiving surface 40, and has a glass layer 41 formed to have a thickness of 0.4 mm or more and 1.6 mm or less, and a back surface protection provided on the side opposite to the light receiving surface 40 with respect to the glass layer 41. It has a layer 45 and a sealing layer 42 provided between the glass layer 41 and the back surface protective layer 45 to seal a plurality of cells 43. The back surface protective layer 45 includes a first resin layer 46, a second resin layer 47, an easy-adhesion resin layer 48, and a third resin layer 49. The first resin layer 46 is made of a foamed resin having a flexural modulus of 200 MPa or more and 1000 MPa or less. The second resin layer 47 is provided on the side opposite to the light receiving surface 40 side with respect to the first resin layer 46, and has a flexural modulus of 10,000 MPa or more and 25,000 MPa or less and is fiber-reinforced. The easy-adhesive resin layer 48 is provided between the sealing layer 42 and the first resin layer 46, and the adhesiveness with the second sealing layer 42 is exhibited by vacuum lamination at 130 ° C. or higher and 160 ° C. or lower. .. The third resin layer 49 is provided between the easy-adhesion resin layer 48 and the first resin layer 46, and is formed to have a flexural modulus of 1500 MPa or more and 4000 MPa or less. When the flexural rigidity is defined as [(flexural modulus (MPa) × thickness (mm) 3) ÷ 12], the glass layer 41, the sealing layer 42, the first resin layer 46, and the second resin layer 47 The sum of the flexural rigidity of each of the easy-adhesion resin layer 48 and the third resin layer 49 is 4000 MPa or more. The rubber frame 6 has a first plate portion 61 facing the outer peripheral portion of the light receiving surface 40 of the glass layer 41 and a second plate portion 62 facing the outer peripheral portion of the surface of the back surface protective layer 45 opposite to the light receiving surface 40. And have. Each of the first plate portion 61 and the second plate portion 62 has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and is a first plate in one direction parallel to the light receiving surface 40 of the solar cell module main body 4. The dimension from the inner end of the portion 61 and the second plate portion 62 to the corresponding end of the solar cell module main body 4 is formed to be 8 mm or more and 20 mm or less.

According to this aspect, even if a relatively thin glass layer 41 having a thickness of 0.4 mm or more and 1.6 mm or less is used, the amount of deflection of the solar cell module 3 is suppressed, and the glass layer 41 and the like are less likely to crack and are high. Withstand load can be obtained. In addition, the load bearing capacity can be improved without significantly increasing the thickness.

The rubber frame 6 according to the fourth aspect is configured to be mountable on the outer peripheral portion of the above-mentioned solar cell module main body 4, and is composed of natural rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene propylene rubber, and chloroprene. A rubber frame selected from the group consisting of rubber, acrylic rubber, chlorosulfonated polyethylene rubber, urethane rubber, silicon rubber, and fluororubber, having a thickness of 1 mm or more and a tensile elasticity of 3 MPa or more and 200 MPa or less.

According to this aspect, by attaching to the solar cell module 3 using a relatively thin glass layer 41 having a thickness of 0.4 mm or more and 1.6 mm or less, the amount of deflection of the solar cell module 3 can be suppressed, and the glass layer 41 or the like can be suppressed. It is hard to crack and high load resistance can be obtained.

3 Solar cell module 4 Solar cell module body 40 Light receiving surface 41 Glass layer 42 Sealing layer 43 Cell 45 Back surface protective layer 46 First resin layer 47 Second resin layer 48 Easy-adhesive resin layer 49 Third resin layer 50th Second glass layer 6 Rubber frame 61 First plate part 62 Second plate part

Claims (4)

The main body of the solar cell module, which has a light receiving surface that receives sunlight,
A rubber frame attached to the outer periphery of the solar cell module body and
With
The solar cell module body is
A glass layer including the light receiving surface and formed to have a thickness of 0.4 mm or more and 1.6 mm or less.
A back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer,
A sealing layer provided between the glass layer and the back surface protective layer to seal a plurality of cells,
Have,
The back surface protective layer is
A first resin layer made of a foamed resin having a flexural modulus of 200 MPa or more and 1000 MPa or less,
A second resin layer provided on the side opposite to the light receiving surface with respect to the first resin layer, having a flexural modulus of 10,000 MPa or more and 25,000 MPa or less and fiber-reinforced.
Including
Flexural rigidity,
[(Bending elastic modulus (MPa) x thickness (mm) 3) ÷ 12]
When defined as, the sum of the flexural rigidity of each of the glass layer, the sealing layer, the first resin layer and the second resin layer is 4000 MPa or more.
The rubber frame is
A first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface and
A second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface, and
Have,
Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the corresponding end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.
Solar cell module. The main body of the solar cell module, which has a light receiving surface that receives sunlight,
A rubber frame attached to the outer periphery of the solar cell module body and
With
The solar cell module body is
A glass layer including the light receiving surface and formed to have a thickness of 0.4 mm or more and 1.6 mm or less.
A back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer,
A sealing layer provided between the glass layer and the back surface protective layer to seal a plurality of cells,
Have,
The back surface protective layer includes a second glass layer having a thickness of 0.4 mm or more and 1.6 mm or less.
Flexural rigidity,
[(Bending elastic modulus (MPa) x thickness (mm) 3) ÷ 12]
When defined as, the sum of the flexural rigidity of each of the glass layer, the sealing layer and the second glass layer is 4000 MPa or more.
The rubber frame is
A first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface and
A second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface, and
Have,
Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.
Solar cell module. The main body of the solar cell module, which has a light receiving surface that receives sunlight,
A rubber frame attached to the outer periphery of the solar cell module body and
With
The solar cell module body is
A glass layer including the light receiving surface and formed to have a thickness of 0.4 mm or more and 1.6 mm or less.
A back surface protective layer provided on the side opposite to the light receiving surface with respect to the glass layer,
A sealing layer provided between the glass layer and the back surface protective layer to seal a plurality of cells,
Have,
The back surface protective layer is
A first resin layer made of a foamed resin having a flexural modulus of 200 MPa or more and 1000 MPa or less,
A second resin layer provided on the side opposite to the light receiving surface side with respect to the first resin layer, having a flexural modulus of 10,000 MPa or more and 25,000 MPa or less and fiber-reinforced.
An easily adhesive resin layer provided between the sealing layer and the first resin layer and exhibiting adhesiveness to the sealing layer by vacuum lamination at 130 ° C. or higher and 160 ° C. or lower.
A third resin layer provided between the easy-adhesive resin layer and the first resin layer and having a flexural modulus of 1500 MPa or more and 4000 MPa or less,
Including
Flexural rigidity,
[(Bending elastic modulus (MPa) x thickness (mm) 3) ÷ 12]
When defined as, the sum of the flexural rigidity of each of the glass layer, the sealing layer, the first resin layer, the second resin layer, the easily adhesive resin layer, and the third resin layer is It is 4000 MPa or more,
The rubber frame is
A first plate portion of the glass layer facing the outer peripheral portion of the light receiving surface and
A second plate portion of the back surface protective layer facing the outer peripheral portion of the surface opposite to the light receiving surface, and
Have,
Each of the first plate portion and the second plate portion has a thickness of 1 mm or more and a tensile elastic modulus of 3 MPa or more and 200 MPa or less, and in one direction parallel to the light receiving surface of the solar cell module main body, the first plate portion. The dimension from the inner end of the plate portion and the second plate portion to the corresponding end of the solar cell module main body is formed to be 8 mm or more and 20 mm or less.
Solar cell module. A rubber frame used in the solar cell module according to any one of claims 1 to 3.
It is configured to be mountable on the outer periphery of the solar cell module body, and is composed of natural rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, urethane rubber, and silicon. It is selected from the group consisting of rubber and fluororubber, and is formed to have a thickness of 1 mm or more and a tensile elasticity of 3 MPa or more and 200 MPa or less.
Rubber frame.

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