JP3542515B2 - Solar cell module, roof with solar cell and solar power generation system - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a solar cell module, and more particularly to a solar cell module characterized by improved fireproof performance.
[0002]
[Prior art]
The awareness of environmental issues has been increasing worldwide. Above all, CO ₂ Concern about the global warming phenomenon associated with emission is serious, and the demand for clean energy is increasing more and more. At present, solar cells are promising as a clean energy source because of their safety and ease of handling.
[0003]
In recent years, various types of solar cell modules have been proposed. Among them, from the viewpoint of emphasizing higher ease of installation, economy, and design, we have departed from the method of installing on an existing roof and incorporated solar cells into the roof material itself. Development is taking place. Conventionally, such a solar cell can incorporate a solar cell module as it is in a place where a roof material is covered, and various developments have been made.
[0004]
FIG. 10 is a schematic finish view when a solar cell module integrated with a roof material is laid on a roof surface. In the figure, 1001 is a photovoltaic element, and 1002 is a solar cell module. Since the roofing material itself is integrated with the solar cell, there is no need for a mounting frame, and it is economical and has a good appearance. Therefore, it is promising as a future solar cell module.
[0005]
In the solar cell module as described above, a terminal extraction position for extracting electric power of the photovoltaic element may be provided in a place without the photovoltaic element.
[0006]
FIG. 11 illustrates an example of a solar cell module in which a terminal extraction position is provided at a position where no photovoltaic element is provided. In the figure, 1101 is a photovoltaic element, 1102 is a terminal box, 1103 is a cable for taking out power. When the solar cell module as shown in FIG. 11 is installed as a roof material, when the electrical connection is made on the eaves side or the ridge side, the terminal box 1102 is arranged on the eaves side or the ridge side without the photovoltaic element 1101. In addition, the operability of electrical connection using the power supply cable attached to the terminal box 1102 can be improved.
[0007]
FIG. 12 shows a second example of the solar cell module in which the terminal take-out position is similarly provided at a position where no photovoltaic element is provided. FIG. 12A shows another example of the solar cell module in which the terminal take-out position is provided without the photovoltaic element, and FIG. 12B shows the case where the terminal box is provided with no photovoltaic element. FIG. 2 is a schematic cross-sectional view illustrating a solar cell module being disposed on a roof surface. In the figure, reference numeral 1201 denotes a photovoltaic element, 1202 denotes a terminal box, 1203 denotes a power take-out cable, 1204 denotes a cover between roofing materials, 1205 denotes a roof surface, and 1206 denotes a fixing member. In the solar cell module as shown in FIG. 12, the terminal box 1202 is arranged on the bent upper part of the roofing material, so that the bottom surface of the roofing material is directly in contact with the roof surface 1205 without using a pier or the like. And the construction work can be simplified.
[0008]
As described above, depending on the form of the roofing material, the terminal extraction position of the solar cell module may be provided in a portion without the photovoltaic element.
[0009]
[Problems to be solved by the invention]
FIG. 13 is a schematic diagram for explaining the structure of a terminal extraction portion of a solar cell module in which the terminal extraction position is provided in a portion where no photovoltaic element is provided. FIG. 13A is a schematic view of a solar cell module in which a terminal extraction position is provided in a portion where no photovoltaic element is provided, FIG. 13B is a schematic cross-sectional view of the terminal extraction section, and FIG. 13C is a terminal extraction. It is a top view of a part.
[0010]
In the figure, 1301 is a photovoltaic element, 1302 is a terminal box, 1303 is a power take-out cable, 1304 is a conductive member, 1305 is a back cover, 1306 is a terminal take-out hole, 1307 is a front cover, and 1308 is a filler. is there.
[0011]
As shown in the figure, by extending the conductive member 1304, it is possible to take out a terminal without the photovoltaic element 1301. In order to perform terminal removal, a hole 1306 for terminal removal is formed in the back cover material 1305, the conductive member 1304 is extended to the hole 1306 for terminal removal, and a terminal removal hole is provided on the back side of the solar cell module. A terminal box 1302 is provided so as to cover the hole 1306, and the electrical connection between the conductive member 1304 and the power extraction cable 1303 is performed in the terminal box. As described above, the position where the photovoltaic element 1301 is taken out of electricity can be provided in a portion where the photovoltaic element 1301 is not provided.
[0012]
Such a solar cell module is often used as a roof material. When a neighboring house is burned, the first thing affected by the spark is the wall and roofing material of the house, and especially the roofing material tends to spread first on the eaves side. When the solar cell module takes out the terminals as shown in FIG. 13, if the flame is very strong, the spark jumps onto the surface covering material 1307 of the roof material, and in some cases, the surface covering material 1307 of the roof material and the filler 1308. May be burned and the fire spreads to the terminal extracting hole 1306 in some cases. As shown in FIG. 13, when the terminal extracting hole 1306 is larger than the conductive member 1304 and there is a gap between the terminal extracting hole 1306 and the conductive member 1304 when viewed from the light receiving surface, the filler 1308 in the gap is burned, If the fire proceeds further, the flame may reach the space between the roofing material and the base plate.
[0013]
[Means for Solving the Problems]
As a result of intensive research and development for solving the above-mentioned problems, the present inventors have found that the following solar cell module is the best.
[0014]
That is, the present invention relates to a solar cell module having at least a photovoltaic element and a back surface covering material, wherein the photovoltaic element is formed through a terminal extraction hole of the back surface covering material provided in a portion where the photovoltaic element is not provided. It has a structure to take out a terminal through a conductive member electrically connected to a power element, has a non-combustible material on the light receiving surface side of the terminal taking-out hole, and the non-combustible material is provided on the entire surface of the terminal taking-out hole And a solar cell module having at least a photovoltaic element and a back surface covering material, wherein the back surface covering material provided in a portion where the photovoltaic element is not provided. The terminal extracting hole has a structure in which a terminal is extracted through a conductive member electrically connected to the photovoltaic element, and the conductive member receives light from the terminal extracting hole. A solar cell module, characterized by covering the entire surface of the hole for the extraction the terminal on the side.
[0015]
Further, the present invention is a roof with solar cells, wherein the solar cell module is arranged on a roof surface.
[0016]
Furthermore, the present invention is a photovoltaic power generation system characterized by being constructed with the above-mentioned solar cell module or the above-mentioned roof with solar cells.
[0017]
In the present invention, the back surface covering material is preferably a non-combustible material, more preferably a metal steel plate.
[0018]
Preferably, the conductive member is a copper foil.
[0019]
Further, it is preferable that the back cover material is bent, and that the non-combustible material or the conductive member is bent together with the back cover material in the bent portion, and the terminal extracting hole is vertically bent. More preferably, it is included in the part.
[0020]
Further, it is preferable that a surface coating material is provided on the light receiving surface side, and the surface coating material is a weather-resistant transparent resin.
[0021]
According to the present invention, since the non-combustible material or the conductive member covers the terminal taking-out hole of the back surface covering material, even if a flame due to a spark spreads on the surface of the solar cell module, the solar cell module passes through the terminal taking-out hole. It is difficult for the flame to reach the lower side (the space between the solar cell module and the base plate), and the spread of fire can be suppressed.
[0022]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 14 is a schematic diagram for explaining the structure of a terminal extraction portion of a solar cell module in which the terminal extraction position of the present invention is provided in a portion without a photovoltaic element. FIG. 14A is a partial schematic view of a solar cell module in which a terminal extraction position is provided in a portion where no photovoltaic element is provided, and FIG. 14B is a schematic cross-sectional view of the terminal extraction section. In the figure, 1401 is a photovoltaic element, 1402 is a terminal box, 1403 is a power take-out cable, 1404 is a conductive member, 1405 is a back surface covering material, 1406 is a filler, 1407 is a surface covering material, 1408 is a noncombustible material, and 1409 is a noncombustible material. It is a hole for taking out the terminal.
[0023]
As shown in the figure, a conductive member (electric wire in this example) 1404 electrically connected to the photovoltaic element 1401 is connected to a part without the photovoltaic element 1401 in order to perform terminal extraction at the part without the photovoltaic element 1401. The terminal extraction hole 1409 is previously opened on the back surface covering material 1405 so that the terminal extraction hole 1409 is arranged in the extended portion. Then, when the solar cell module is integrally formed, the non-combustible material 1408 is laminated on the terminal extracting hole 1409. At this time, the non-combustible material 1408 has a size sufficiently larger than the terminal extracting hole 1409 so as to cover the entire surface of the terminal extracting hole 1409 during lamination. After integral molding, the conductor of the power take-out cable 1403 is electrically connected to the conductor of the conductive member 1404, and the terminal box 1402 is adhesively fixed on the back surface covering material 1405 (the back surface side). Can be made.
[0024]
Since the non-combustible material 1408 covers the entire surface of the terminal extracting hole 1409 as described above, even if the flame reaches the terminal extracting hole 1409 due to the spread of fire due to a spark, the flame extends to the space between the ground plate under the solar cell module. Makes it difficult to spread the fire.
[0025]
FIG. 1 is another example of a solar cell module in which the terminal extraction position of the present invention is provided in a portion without a photovoltaic element, and is a schematic diagram for explaining the structure of the terminal extraction portion. FIG. 1A is a partial schematic view of a solar cell module in which a terminal extraction position is provided in a portion without a photovoltaic element, FIG. 1B is a schematic cross-sectional view of a terminal extraction section, and FIG. 1C is a terminal extraction. It is a top view of a part. In the figure, 101 is a photovoltaic element, 102 is a terminal box, 103 is a power takeout cable, 104 is a conductive member, 105 is a back cover material, 106 is a terminal takeout hole, 107 is a surface cover material, and 108 is a filler. is there.
[0026]
As shown in the figure, in order to perform terminal extraction at a portion without the photovoltaic element 101, the conductive member 104 electrically connected to the photovoltaic element is extended to a portion without the photovoltaic element, and the extended portion The terminal extraction holes 106 are previously formed on the back surface covering material 105 so that the terminal extraction holes 106 are arranged in the holes. The hole position and the hole diameter are set so that the conductive member 104 covers the terminal extracting hole. After the solar cell module is integrally formed, the conductor of the cable for terminal extraction 106 is electrically connected to the conductive member 104 in the hole for terminal extraction 106, and the terminal box 102 is placed on the back surface covering material 105 (on the back surface side). ) To form a terminal extraction portion.
[0027]
Since the conductive member 104 covers the terminal extraction hole 106 in this manner, even if the fire reaches the terminal extraction hole due to the spread of fire due to a spark, the fire spreads to the space between the base plate under the solar cell module and the fire. It becomes difficult.
[0028]
Next, a method for manufacturing a solar cell module will be described.
[0029]
FIG. 2 is a schematic diagram for explaining a method for manufacturing a solar cell module according to the present invention, and FIG. 2 is a schematic diagram for explaining a manner in which materials constituting the solar cell module are stacked, and FIG. Is a schematic cross-sectional view of the solar cell module after integral molding, and FIG. 2C is a schematic cross-sectional view of the solar cell module after forming a terminal extraction portion.
[0030]
In FIG. 2, 201 is a photovoltaic element, 202 is a filler, 203 is a surface covering material, 204 is a back surface covering material, 205 is a conductive member, 206 is a terminal extracting hole, 207 is a terminal box, and 208 is a power extracting. A cable 209 is a soldering portion, and 210 is a lead-in electric wire.
[0031]
First, a filler 202, a photovoltaic element 201 to which a conductive member 205 is electrically connected, a filler 202, and a surface covering material 203 are laminated in this order on a back surface covering material 204 in which a terminal extraction hole 206 is formed. Then, the filler 202 is cross-linked and integrally molded by evacuating and heating to produce a solar cell module (FIG. 2 (b)). At this time, in the stacked state, the position of the conductive member 205 and the position of the terminal extracting hole 206 formed on the back surface covering material 204 match so that the terminal extracting hole 206 is viewed from the light receiving surface side. The diameter is smaller than the width of the conductive member 205 so that the conductive member 205 covers the entire surface of the terminal extracting hole 206.
[0032]
Next, the lead-in wire 210 is soldered (209) to the conductive member 205 in the terminal taking-out hole 206 of the solar cell module after integral molding. Thereafter, the terminal box 207 to which the power take-out cable 208 is attached is adhesively fixed to the terminal take-out portion from the back side of the solar cell module. At this time, the terminal box 207 has an opening on the bonding surface side, and the lead-in wire 210 is inserted into the terminal box 207 from this opening. Then, finally, the lead-in wire 210 and the conductor of the power takeout gable 208 are electrically connected in the terminal box 207, and the terminal box 207 is covered to form a solar cell module terminal takeout part (FIG. 2C). .
[0033]
Next, each material constituting the solar cell module used in the present invention will be described.
[0034]
(Solar cell element)
The photovoltaic element in the present invention is not particularly limited, but is preferably a photovoltaic element having flexibility. For example, a semiconductor photoactive layer as a light conversion member is formed on a conductive gas. FIG. 3 shows a schematic configuration diagram as an example, in which 301 is a conductive substrate, 302 is a metal electrode layer, 303 is a semiconductor photoactive layer, 304 is a transparent conductive layer, and 305 is a current collecting electrode.
[0035]
The conductive substrate 301 serves as a substrate for the photovoltaic element and also serves as a lower electrode. Examples of the material include silicon, tantalum, molybdenum, tungsten, stainless steel, aluminum, copper, titanium, a carbon sheet, a lead-plated steel sheet, a resin film on which a conductive layer is formed, and ceramics.
[0036]
On the conductive substrate 301, a metal layer, a metal oxide layer, or a metal layer and a metal oxide layer may be formed as the metal electrode layer 302. For the metal layer, for example, Ti, Cr, Mo, W, Al, Ag, Ni, or the like is used. For the metal oxide layer, for example, ZnO, TiO ₂ , SnO ₂ Are used. Examples of a method for forming the metal electrode layer 302 include a resistance heating evaporation method, an electron beam evaporation method, and a sputtering method.
[0037]
The semiconductor photoactive layer 303 is a portion that performs photoelectric conversion, and specific examples of the material include pn junction type polycrystalline silicon, pin junction type amorphous silicon, and CuInSe. ₂ , CuInS ₂ , GaAs, CdS / Cu ₂ S, CdS / CdTe, CdS / InP, CdTe / Cu ₂ And compound semiconductors such as Te. As a method for forming the semiconductor photoactive layer 303, in the case of polycrystalline silicon, a sheet of molten silicon or heat treatment of amorphous silicon is used. In the case of amorphous silicon, plasma CVD using silane gas or the like is used. Examples include ion plating, ion beam deposition, vacuum evaporation, sputtering, and electrodeposition.
[0038]
The transparent conductive layer 304 functions as an upper electrode of the photovoltaic device. As a material to be used, for example, In ₂ O ₃ , SnO ₂ , In ₂ O ₃ -SnO ₂ (ITO), ZnO, TiO ₂ , Cd ₂ SnO ₄ And a crystalline semiconductor layer doped with a high concentration of impurities. Examples of the formation method include resistance heating evaporation, sputtering, spraying, CVD, and impurity diffusion.
[0039]
A grid-like current collecting electrode 305 (grid) may be provided on the transparent conductive layer 304 in order to efficiently collect current. Specific examples of the material of the current collecting electrode 305 include Ti, Cr, Mo, W, Al, Ag, Ni, Cu, Sn, and a conductive paste such as a silver paste. As a method for forming the current collecting electrode 305, sputtering using a mask pattern, resistance heating, a CVD method, a method in which an unnecessary portion is removed by etching after depositing a metal film over the entire surface, and a patterning method using a photo-CVD method are used. There are a method of forming a current electrode pattern, a method of forming a negative pattern mask of a current collecting electrode pattern and then plating, and a method of printing a conductive paste. As the conductive paste, one obtained by dispersing silver, gold, copper, nickel, carbon, or the like in a fine powder form in a binder polymer is usually used. Examples of the binder polymer include resins such as polyester, epoxy, acrylic, alkyd, polyvinyl acetate, rubber, urethane, and phenol.
[0040]
Generally, when handling a solar cell, it is preferable to be lightweight from the viewpoint of workability. In addition, there is an increasing need for solar cell modules in which the solar cell is integrated with the roofing material, or in which the solar cell is installed on the outer wall of a building. It is required to be. In contrast, a thin-film semiconductor photovoltaic element formed on a stainless steel substrate is very suitable. That is, since the photovoltaic element itself can be considerably thinned, and can be thinned to about 0.1 mm including the substrate, the amount of the filler for sealing the photovoltaic element is reduced. Because you can do it. As a result, the weight of the solar cell can be reduced, and the thickness can be reduced. If the thickness can be reduced, the stress on the surface coating material when the solar cell is bent can be reduced. Cracking of the coating material can be suppressed against tension, and twisting of the coating material can be suppressed against shrinkage. In addition, since the solar cell is formed on a stainless steel substrate and has flexibility, unnecessary rigidity is not required for the solar cell, so that the thickness of the filler or the covering material can be reduced. As a result, the weight of the solar cell can be reduced, and the solar cell can be made flexible and flexible and suitable for bending.
[0041]
Therefore, it is understood that the thin film semiconductor formed on the stainless steel substrate is optimal for the photovoltaic element.
[0042]
(Surface coating material)
The properties required for the surface coating material include light transmission and weather resistance, and are required to be hardly stained. Translucent glass or organic resin can be used as the material, but in order to treat solar cells in the same way as ordinary roofing materials, it is convenient if the solar cells themselves can be bent. Preferably, it is a flexible material.
[0043]
For the above reasons, an organic resin, more preferably a weather-resistant transparent film, is preferably used for the surface coating material. By using a weather-resistant transparent film, the filling property is improved, the weight can be reduced, and the film is not broken by an impact, and can be used as a roofing material by bending. Further, by giving an embossing treatment to the film surface, an effect is produced that the surface reflection of sunlight is not dazzling.
[0044]
As a material, a fluororesin film such as polyethylene tetrafluoroethylene (ETFE), polytrifluoroethylene, or polyvinyl fluoride can be used as an organic resin, but is not limited thereto. A surface treatment such as a corona discharge treatment can be applied to the surface to be bonded with the filler so that the filler is easily bonded. When glass is used as the material, for example, white plate tempered glass can be used.
[0045]
(Filler)
In the present invention, the filler is used for the purpose of sealing the photovoltaic element and bonding and fixing the photovoltaic element on the surface coating material or the back surface coating material.
[0046]
Properties required for the filler include thermoplasticity, weather resistance, thermal adhesion, and light transmittance. Materials include EVA (vinyl acetate-ethylene copolymer), butyral resin, silicone resin, fluororesin, EEA (ethylene ethyl acrylate), EMA (ethylene methyl acrylate), EBA (ethylene butyl acrylate), acrylic resin, urethane resin A transparent resin such as PVA (polyvinyl alcohol) can be used, but is not limited thereto. Further, in order to suppress light deterioration, it is desirable that an ultraviolet absorber is contained.
[0047]
(Back coating material)
It functions as a covering material on the back surface side of the solar cell module or as a back surface reinforcing material. The material is not particularly limited, but in addition to resin materials such as PET and Tedlar, laminated materials such as Tedlar / aluminum / Tedlar can also be used. More preferable materials include materials capable of imparting moisture resistance and rigidity, such as aluminum sheets and stainless steel sheets, as well as galvanized steel sheets and metal materials used for roofing materials such as galvanized steel sheets and the like. Can be used. Non-combustible materials such as tiles and slate materials can also be used.
[0048]
(Non-combustible material)
When the solar cell modules are integrally laminated, they are laminated so as to cover the entire surface of the hole for extracting a terminal.
[0049]
Any material can be used as long as it is nonflammable, but generally a metal material such as stainless steel or copper is used.
[0050]
Since they are integrally laminated, they are preferably in the form of a sheet. However, since they are laminated on a conductive member, it is more convenient if the thickness is small so as to follow irregularities.
[0051]
Further, when the solar cell module is bent, it is more preferable to arrange the non-combustible material so as to be bent at the same time. The reason is that the non-combustible material is mechanically fixed on the roof structure by bending, so that even if the filler burns, it does not roll up or peel off.
[0052]
(Conductive member)
In order to take out electricity from the photovoltaic element, it is used for a portion extending from the photovoltaic element to a terminal extraction part.
[0053]
Generally, the maximum temperature of the flame during the spread of the fire is about 950 ° C., and therefore, the melting point of the material used for the conductive member is preferably 950 ° C. or more. As a material, a metal such as copper can be used.
[0054]
Further, the shape is preferably a sheet because it is necessary to fill the filler constituting the solar cell module at the time of integral molding. In addition, when the flame spreads, the conductive member may be deformed or displaced by heat, so if the conductive member covers the hole for taking out the terminal, the conductive member should be sufficient for the size of the hole. Larger is preferable. Generally, a copper foil can be used as the conductive member.
[0055]
Further, when the solar cell module is bent, it is more preferable to arrange the conductive member so as to be bent at the same time. The reason is that since the conductive member is mechanically fixed on the roof structure by bending, the filler does not roll up or peel off even if the filler burns.
[0056]
【Example】
Hereinafter, the present invention will be described in detail based on examples.
[0057]
(Example 1)
First, a photovoltaic device composed of a thin film semiconductor (a-si) was manufactured. This manufacturing procedure will be described with reference to FIG.
[0058]
In FIG. 3, reference numeral 301 denotes a stainless steel substrate as a conductive substrate, 302 denotes a metal electrode layer, 303 denotes a semiconductor photoactive layer, 304 denotes a transparent conductive layer, and 305 denotes a current collecting electrode. On the cleaned stainless steel substrate 301, an Al layer (thickness 5000 °) and a ZnO layer (5000 ° thickness) are sequentially formed as a back metal electrode layer 302 by a sputtering method. Then, by plasma CVD, the SiH ₄ And PH ₃ And H ₂ N-type a-Si layer from a mixed gas of ₄ And H ₂ Of the i-type a-Si layer from the mixed gas of ₄ And BF ₃ And H ₂ A p-type microcrystalline μc-Si layer is formed from a mixed gas of the following, and the thickness of the n-layer is 150 ° / i-layer thickness 4000 ° / p-layer thickness 100 ° / n-layer thickness 100 ° / i-layer thickness 800 ° / p-layer thickness A tandem a-Si-based photoelectric conversion semiconductor layer 303 having a layer structure of 100 ° was formed. Next, as the transparent conductive layer 304, In ₂ O ₃ A thin film (thickness 700 mm) is ₂ It was formed by depositing In by a resistance heating method in an atmosphere.
[0059]
On this, the current collecting electrode 305 was formed by pattern printing of a silver paste by a screen printer and drying.
[0060]
The photovoltaic elements produced as described above were connected in series, and a terminal taking-out conductive member was soldered to electrode taking-out portions at both ends. Copper foil (thickness: 0.1 mm) was used as a conductive member for taking out terminals.
[0061]
Next, a process of integrally forming the manufactured photovoltaic element and then manufacturing a terminal extracting portion will be described with reference to FIG. FIG. 2 is a schematic diagram for explaining a method of manufacturing the solar cell module according to the first embodiment of the present invention, and FIG. FIG. 2B is a schematic cross-sectional view of the solar cell module after integral molding, and FIG. 2C is a schematic cross-sectional view of the solar cell module after forming a terminal extraction portion (each reference numeral in the drawing). Has already been mentioned above).
[0062]
First, the materials constituting the solar cell module were laminated to perform an integral molding process (FIG. 2A).
[0063]
The back cover material 204, the filler material 202, the photovoltaic element 201 to which the conductive member 205 manufactured as described above was attached, the filler material 202, and the surface coating material 203 were laminated in this order. The back surface coating material 204 is a painted steel plate (manufactured by Nissin Steel Co., Ltd., trade name: Galbuster, 0.4 mm thickness), the filling material 202 is EVA (ethylene-vinyl acetate copolymer weatherproof grade, Bridgestone Corporation, 460 μm), front surface As the coating material 203, a fluororesin film (ethylene tetrafluoroethylene, 50 μm thick, manufactured by Daikin, trade name: NEOFLON EF-0050SB1) was used. The material laminated in this manner was heated to 160 ° C. in a vacuum state, and heat was applied to the filler 202 to crosslink it, thereby performing an integral molding process. At this time, a hole 206 for taking out a terminal was formed in the back surface coating material 204 before the integral molding process. The position and the diameter of the terminal extracting hole 206 are such that the conductive member 205 covers the entire surface of the terminal extracting hole 206 when viewed from the light receiving surface side when the layers are stacked. Also, in order to smoothly perform the electrical connection of the lead-in wire 210 to the conductive member 205 in a later step, a hole is made in the filler 202 on the non-light-receiving surface side of the photovoltaic element 201 in the terminal extraction hole 206, The hole was filled with a silicon stopper (not shown).
[0064]
Thereafter, cooling was performed to produce an integrally molded solar cell module as shown in FIG.
[0065]
Next, a manufacturing process of the terminal extracting portion will be described.
[0066]
First, the silicon plug in the terminal extraction hole 206 was removed, and the wire 210 was drawn into the conductive member 205 and soldered (209). As the lead-in electric wire 210, an IV electric wire (conductor area 0.5sq) was used. Next, the terminal box 207 integrated with the power take-out cable 208 was bonded and fixed to the terminal take-out hole 206. The terminal box 207 is made of polycarbonate, the power take-out cable 208 is a CV cable (conductor area 2 sq), and the terminal box 207 is bonded with an RTV silicone sealant (trade name: Silastic 739 Black, Dow Corning Asia). Manufactured). Further, the terminal box 207 has an opening (not shown) on the solar cell module side, and the terminal box 207 is drawn into the opening and adhered through the electric wire 210. Then, the lead-in wire 210 and the power take-out cable 208 were electrically connected in the terminal box 207, and a cover (not shown) of the terminal box 207 was attached to produce a terminal take-out portion.
[0067]
Next, a process of bending the solar cell module manufactured as described above and installing it on a roof will be described. 4A and 4B are schematic diagrams for explaining the solar cell module of the first embodiment. FIG. 4A is a schematic diagram of the solar cell module after bending, and FIG. 4B is a solar cell after bending. It is an outline sectional view for explaining that a module is fixed on a roof. In the figure, 401 is a photovoltaic element, 402 is a terminal box, 403 is a power take-out cable, 404 is a fixing member, 405 is a cover member, 406 is a crosspiece, and 407 is a field board.
[0068]
First, the solar cell module manufactured as described above was bent to manufacture a solar cell module as shown in FIG. The bending process used a roller former.
[0069]
Next, the pier 406 was fixed on the roof plate 407 on the roof surface. The pitch of the crosspiece 406 was the total length of the width of the solar cell module and the width of the fixing member 404. Then, the solar cell modules were previously arranged so as to straddle between the crosspieces 406, and the solar cell modules were fixed on the crosspieces 406 by the fixing members 404. The fixing member 404 was fixed on the crosspiece 406 with a drill screw. Then, a cover member 405 was covered from above the fixing member 404 so as to cover the hanging part of the solar cell module and the fixing member 404, and was fixed on the crosspiece 406 with nails. The power supply cable 403 of the solar cell module was connected to the solar cell module adjacent on the eaves side and the ridge side. By repeating the above operation, a roof with solar cells as shown in FIG. 10 was completed.
[0070]
As described above, in the case where the terminal extracting portion is provided in a portion without the photovoltaic element, the conductive member covers the entire surface of the terminal extracting hole, so that even if the flame due to the spark spreads over the solar cell module, the solar cell module To the back side (the space between the solar cell module and the base plate), and further fire spread can be suppressed.
[0071]
(Example 2)
This is an example of using a type in which the terminal extraction portion of the solar cell module is provided beside the vertically bent portion in Example 1.
[0072]
FIG. 5 is a schematic diagram for explaining the solar cell module of the second embodiment. FIG. 5A is a schematic diagram of the solar cell module after bending, and FIG. 5B is a solar cell after bending. FIG. 5C is a schematic cross-sectional view of a terminal extracting portion of a bent portion, for explaining a place where the module is fixed on a roof. In the figure, 501 is a photovoltaic element, 502 is a terminal box, 503 is a power take-out cable, 504 is a fixing member, 505 is a cover member, 506 is a field plate, and 507 is a conductive member.
[0073]
In the second embodiment, the number of photovoltaic elements manufactured in the first embodiment is reduced in series to shorten the length of the solar cell module, and the mounting position of the conductive member 507 is changed to change the vertical position of the solar cell module. A module having a terminal take-out portion beside the upper bent portion was manufactured. At this time, the conductive member 507 was arranged so as to cover the vertically bent portion (FIG. 5C). Since the conductive member 507 is mechanically fixed to the bent portion when the solar cell module is fixed as a roof material, the conductive member 507 is not easily turned up even if the filler burns. The conductive member 507 was integrally molded by sandwiching the conductive member 507 by arranging a polyester tape (without an adhesive) wider than the conductive member 507 in the bent portion at the top and bottom. By bending the sandwiched portion, the conductive member 507 in the sandwich portion slides in the tape, so that the conductive member 507 does not break even when bent.
[0074]
Also, during the integral molding process, the number of photovoltaic elements 501 in series is reduced to change the size of the back surface coating material, filler, and surface coating material, and the mounting position of the conductive member 507 is changed to change the back surface coating material. Also changed the position of the hole for taking out the terminal. As in Example 1, the position and diameter of the terminal extracting hole were such that the conductive member 507 covers the entire surface of the terminal extracting hole when viewed from the light receiving surface side. Except for the above, a solar cell module was produced in the same manner as in Example 1.
[0075]
Next, the solar cell module was fixed on the roof surface. As shown in FIG. 5B, the solar cell module produced above was arranged on the roof surface (field board 506), and the solar cell module was fixed on the roof surface 506 by the fixing member 504. A fixing member 504 having a sufficiently shorter length than the roof material was used, and was fixed on the roof surface 506 by drill screws. Then, the cover member 505 was covered so as to cover the fixing member 504 and the vertically bent portion of the solar cell module, and was fixed with a nail (not shown). The electrical connection between the eaves and the ridge of the solar cell module was made in the space below the solar cell module. The horizontal electrical connection on the eaves side and on the ridge side was made inside each eaves and inside the eaves storage member (not shown).
[0076]
By repeating the above operation, a roof with solar cells as shown in FIG. 6 was completed. FIG. 6 is a schematic finished view of a roof with solar cells using the solar cell module of the second embodiment.
[0077]
In this way, the conductive member covers the entire surface of the terminal extraction hole, and is bent by being applied to the bent portion, so that even if a flame due to a spark spreads over the solar cell module, the conductive member can be used. Since it is difficult to float or roll up, it is difficult to reach the back side of the solar cell module (the side of the base plate under the solar cell module).
[0078]
(Example 3)
In the first embodiment, the solar cell module is of a horizontal roofing type, and a terminal extracting portion is provided in a vertically bent portion.
[0079]
FIG. 7 is a schematic diagram for explaining the solar cell module according to the third embodiment. FIG. 7A is a schematic diagram of the solar cell module after bending, and FIG. 7B is a solar cell after bending. It is a schematic sectional drawing for demonstrating the place which fixed the module on the roof. In the figure, 701 is a photovoltaic element, 702 is a terminal box, 703 is a power take-out cable, and 704 is a field plate.
[0080]
The number of photovoltaic elements manufactured in Example 1 was reduced in series to shorten the length of the solar cell module, and the mounting position of the conductive member was changed to remove the terminal to the vertically bent portion of the solar cell module. And the bending shape of the solar cell module was changed to a horizontal roofing type. To reduce the number of photovoltaic elements in series, and to change the size of the back coating, filler, and back coating to bend into a horizontal roofing type, and change the mounting position of the conductive member, the back coating Also changed the position of the hole for taking out the terminal. As in Example 1, the position and the diameter of the terminal extracting hole were such that the conductive member covered the entire surface of the terminal extracting hole when viewed from the light receiving surface side. After the solar cell module was bent, the terminal box was attached.
[0081]
Except for the above, a solar cell module was produced in the same manner as in Example 1.
[0082]
Next, the solar cell module was fixed on the roof surface. As shown in FIG. 7 (b), the solar cell module produced above was arranged on the roof surface (field board 704), and the solar cell module was fixed on the roof surface by a hook (not shown). The suspension was fixed on the roof surface 704 with a drill screw.
[0083]
FIG. 8 is a schematic finished view of a solar cell integrated roof using the solar cell module of Example 3 as a roofing type roofing material. In the figure, 801 is a photovoltaic element, 802 is a solar cell module, and 803 is a general roofing material.
[0084]
The electric connection in the eaves-building direction of the solar cell module was made under the general roofing material 803 on the keraba side, and the electric connection in the lateral direction was made in the space between the solar cell module and the base plate.
[0085]
The above operation was repeated, and the general roofing material of both the keraba portions was also fixed on the roof surface by the hangers (not shown) to complete the roof with solar cells as shown in FIG.
[0086]
As described above, in the case where the terminal extracting portion is provided in a portion without the photovoltaic element, the conductive member covers the entire surface of the terminal extracting hole, so that even if the flame due to the spark spreads over the solar cell module, the solar cell module To the back side (the side of the base plate under the solar cell module), and further fire spread can be suppressed. Also, by bending the solar cell module between the photovoltaic element and the terminal take-out part, by covering the bent part when the adjacent solar cell modules are assembled, it is possible to spread the fire to the back side of the solar cell module. It can be further suppressed.
[0087]
(Example 4)
A solar power generation system was constructed by connecting the solar cell module manufactured in Example 1 to a system power circuit.
[0088]
FIG. 9 is a schematic diagram for explaining a solar power generation system according to Embodiment 4 of the present invention. In the figure, reference numeral 901 denotes a photovoltaic element, reference numeral 902 denotes a solar cell module, reference numeral 903 denotes a connection box, reference numeral 904 denotes an inverter, reference numeral 905 denotes a switchboard, reference numeral 906 denotes home electrical equipment, reference numeral 907 denotes an integrated wattmeter, and reference numeral 908 denotes a system power circuit.
[0089]
In brief, the electric power generated by the solar cell module is collected in a junction box 903, cross-current converted by an inverter 904, and sent to a home electric device 906 via a switchboard 905. Here, if there is a surplus of power generated, the power can be transmitted to the system power circuit 908 to be purchased by a power company. Conversely, when the amount of power generation is small or the power consumption of the home electric device 906 is large, the shortage can be supplemented by the system power circuit 908 and purchased from the power company.
[0090]
In this way, it is possible to construct a system cooperation system by connecting to the system power circuit.
[0091]
【The invention's effect】
According to the present invention, that is, a solar cell module having at least a photovoltaic element and a back surface covering material, and a terminal extraction hole of the back surface covering material provided in a portion where the photovoltaic element is not provided, It has a structure to take out a terminal through a conductive member electrically connected to the photovoltaic element, has a non-combustible material on the light receiving surface side of the terminal taking-out hole, and the non-combustible material is used for the terminal taking-out. A solar cell module, which covers the entire surface of the hole, and a solar cell module having at least a photovoltaic element and a back surface covering material, wherein the back surface provided in a portion without the photovoltaic element A terminal is formed through a conductive member electrically connected to the photovoltaic element from a terminal extracting hole of the covering material, and the conductive member is provided with the terminal extracting hole. The following effects according to the solar cell module, characterized by a light-receiving surface side covering the entire surface of the hole for the extraction the terminal is obtained.
[0092]
Since the non-combustible material or the conductive material covers the front surface of the hole for taking out the terminal of the back surface coating material, even if the flame due to the spark spreads on the solar cell module, the flame is under the solar cell module (the solar cell module and the field). (A space between the base plate) and fire spread.
[0093]
By bending the conductive member at the time of processing the solar cell module so as to pass the conductive member to the bent portion, even if a flame due to a spark spreads over the solar cell module, the conductive member is unlikely to float or roll up. Therefore, it is difficult to reach the back side of the solar cell module (the side of the base plate under the solar cell module).
[0094]
Bending the back cover material between the terminal extraction hole and the photovoltaic element, providing a terminal extraction part in the vertically bent part of the solar cell module, disposing a cover member on the vertically bent part, Alternatively, by placing it in a portion that is assembled with an adjacent solar cell module, it is possible to further suppress the spread of fire to the lower side of the solar cell module.
[Brief description of the drawings]
FIG. 1 is a schematic diagram for explaining the structure of a terminal extracting portion of a solar cell module in which a terminal extracting position of the present invention is provided in a portion having no photovoltaic element, and FIG. FIG. 1B is a schematic cross-sectional view of a terminal extraction part, and FIG. 1C is a top view of the terminal extraction part, showing a partial view of a solar cell module provided in a part without a photovoltaic element.
FIG. 2 is a schematic diagram for explaining a method for manufacturing a solar cell module of the present invention, and FIG. 2A is a schematic diagram for explaining a process of stacking each material constituting the solar cell module; 2 (b) is a schematic cross-sectional view of the solar cell module after integral molding, and FIG. 2 (c) is a schematic cross-sectional view of the solar cell module after forming a terminal extraction portion.
FIG. 3 is a schematic cross-sectional view for explaining a photovoltaic element constituting the solar cell module of the present invention.
4A and 4B are schematic diagrams for explaining the solar cell module of Example 1, in which FIG. 4A is a schematic diagram of the solar cell module after bending, and FIG. 4B is a solar cell after bending. It is an outline sectional view for explaining that a module is fixed on a roof.
5A and 5B are schematic diagrams for explaining the solar cell module of Example 2, in which FIG. 5A is a schematic diagram of the solar cell module after bending, and FIG. 5B is a solar cell after bending. FIG. 5C is a schematic cross-sectional view of a terminal extraction part of a bent part, for explaining a place where the module is fixed on a roof.
FIG. 6 is a schematic finished view of a roof with solar cells using the solar cell module of Example 2.
FIGS. 7A and 7B are schematic diagrams for explaining the solar cell module of Example 3, in which FIG. 7A is a schematic diagram of the solar cell module after bending, and FIG. 7B is a solar cell after bending. It is a schematic sectional drawing for demonstrating the place which fixed the module on the roof.
FIG. 8 is a schematic finished view of a roof with solar cells using the solar cell module of Example 3.
FIG. 9 is a schematic diagram illustrating a photovoltaic power generation system according to a fourth embodiment.
10 is a schematic finished view of a roof with solar cells using the solar cell module of Example 1. FIG.
FIG. 11 illustrates an example of a solar cell module in which a terminal extraction position is provided at a position where no photovoltaic element is provided.
12A and 12B show a second example of a solar cell module in which a terminal extraction position is provided at a position where no photovoltaic element is provided. FIG. FIG. 12B shows another example of the solar cell module provided therein, in which the terminal box is provided on the roof surface where the photovoltaic element is not provided. It is a schematic sectional drawing.
FIG. 13 is a schematic diagram for explaining the structure of a terminal extraction portion of a solar cell module provided at a portion where a terminal extraction position is not provided with a photovoltaic element, and FIG. FIG. 13B is a schematic cross-sectional view of a terminal extraction portion, and FIG. 13C is a top view of the terminal extraction portion, which is a schematic diagram of a solar cell module provided in a portion without a power element.
FIG. 14 is a schematic view for explaining the structure of a terminal extracting portion of a solar cell module in which the terminal extracting position of the present invention is provided in a portion having no photovoltaic element, and FIG. FIG. 14 (b) is a schematic cross-sectional view of a terminal extracting portion, showing a partial schematic view of a solar cell module provided in a portion having no photovoltaic element.
[Explanation of symbols]
101,201,401,501,601,701,801,901,1001,1101,1201,1301,1401 Photovoltaic element
102, 207, 402, 502, 702, 1102, 1202, 1302, 1402 Terminal box
103, 208, 403, 503, 703, 1103, 1203, 1303,
1403 Power take-out cable
104, 205, 507, 1304, 1404 conductive member
106, 206, 1306, 1409 Holes for removing terminals
209 Soldering part
210 Service wire
404, 504, 1206 fixing member
405, 505 cover member
406 pier
407, 506, 704 Field board
803 General roofing material
602, 802, 902, 1002 solar cell module
903 junction box
904 inverter
905 switchboard
906 Home electrical equipment
907 Integrated power meter
908 grid power circuit
108, 202, 1308, 1406 Filler
107, 203, 1307, 1407 Surface coating material
105, 204, 1305, 1405 Back covering material
301 conductive substrate
302 Metal electrode layer
303 Semiconductor Photoactive Layer
304 transparent conductive layer
305 current collecting electrode
1204 Cover between roofing materials
1205 Roof surface
1408 Non-combustible material

Claims (11)

A solar cell module having at least a photovoltaic element and a back cover material, wherein the photovoltaic element is electrically connected to a terminal extraction hole of the back cover material provided in a portion where the photovoltaic element is not provided. Has a structure to take out the terminal through a conductive member connected to the terminal, has a non-combustible material on the light receiving surface side of the terminal taking-out hole, and the non-combustible material covers the entire surface of the terminal taking-out hole A solar cell module characterized by the above-mentioned. A solar cell module having at least a photovoltaic element and a back cover material, wherein the photovoltaic element is electrically connected to a terminal extraction hole of the back cover material provided in a portion where the photovoltaic element is not provided. A solar cell having a structure for taking out a terminal through a conductive member connected to the terminal, wherein the conductive member covers the entire surface of the terminal taking-out hole on the light receiving surface side of the terminal taking-out hole. module. The solar cell module according to claim 1, wherein the back surface covering material is a non-combustible material. The solar cell module according to claim 3, wherein the back surface covering material is a metal steel plate. The solar cell module according to claim 1, wherein the conductive member is a copper foil. The solar cell module according to claim 1, wherein the back cover is bent, and the non-combustible material or the conductive member is bent together with the back cover in the bent portion. The solar cell module according to claim 6, wherein the terminal takeout hole is provided in a vertically bent portion. The solar cell module according to claim 1, further comprising a surface coating material on a light receiving surface side, wherein the surface coating material is a weather-resistant transparent resin. A roof with solar cells, wherein the solar cell module according to claim 1 is arranged on a roof surface. A solar power generation system comprising the solar cell module according to claim 1. A photovoltaic power generation system comprising a roof with a solar cell according to claim 9.

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