JP6484161B2 - Solar cell module, mounting structure thereof, vehicle including the same, and method for manufacturing solar cell module - Google Patents

Description

  The present invention relates to a solar cell module, a mounting structure thereof, a vehicle including the solar cell module, and a method for manufacturing the solar cell module.

As a prior document disclosing the configuration of a solar cell module, there is JP 2013-110301 A (Patent Document 1). The solar cell module described in Patent Document 1 includes a surface protective material formed of a resin material having translucency, a sealing material that seals a power generation element, and the surface protective material is bonded to one surface. The back surface protective material joined to the sealing material from the opposite side of the surface protective material. The back surface protective material has a bending rigidity of 50000 MPa · mm ³ or more.

JP2013-110301A

  In the solar cell module described in Patent Document 1, since the occurrence of warpage of the solar cell module is suppressed by increasing the bending rigidity of the back surface protective material, the weight of the back surface protective material is increased. There is room for further weight reduction of the solar cell module.

  This invention is made | formed in view of said problem, Comprising: It aims at providing the lightweight solar cell module by which generation | occurrence | production of curvature was suppressed.

  The solar cell module according to the first aspect of the present invention is composed of a plate-shaped first cover and a resin material having a larger linear expansion coefficient than the material constituting the first cover, and is opposed to the first cover with a space therebetween. The second cover, the solar cells disposed between the first cover and the second cover, and the first cover and the second cover are filled and joined together to seal the solar cells And the entire surface of the peripheral portion of the first cover on the side opposite to the second cover side, which is made of a resin material having a linear expansion coefficient equal to or greater than the linear expansion coefficient of the material constituting the first cover. Or a resin member bonded to a part thereof. The second cover has a light transmitting part at least at a position facing the solar battery cell. The 1st cover is comprised from the center part facing the photovoltaic cell, and the peripheral part surrounding the center part.

In one form of this invention, the resin member is plate-shaped.
In one embodiment of the present invention, the second cover is composed of a light transmitting part and a light shielding part surrounding the light transmitting part.

  The solar cell module mounting structure according to the second aspect of the present invention includes the above-described solar cell module, a mounted portion on which the solar cell module is mounted, and a joint that joins the solar cell module and the mounted portion to each other. Is provided. The joint portion is sandwiched between a part of the peripheral portion and the mounted portion.

  A vehicle based on the third aspect of the present invention includes the solar cell module mounting structure described above, and the mounted portion is a part of the vehicle body.

  The manufacturing method of the solar cell module based on this invention has the process of arrange | positioning a 1st sealing material sheet on a plate-shaped 1st cover, the process of arrange | positioning a photovoltaic cell on a 1st sealing material sheet, A step of arranging the second sealing material sheet so as to cover the solar cells, and a second material made of a resin material having a larger linear expansion coefficient than the material constituting the first cover on the second sealing material sheet. The step of arranging the cover and a resin member made of a resin material having a linear expansion coefficient equal to or higher than the linear expansion coefficient of the material constituting the first cover are opposite to the second cover side of the peripheral portion of the first cover A step of adhering to all or part of the side surface, and a laminate in which the first cover, the first sealing material sheet, the solar battery cell, the second sealing material sheet, the second cover, and the resin member are laminated. And pressurizing while heating. The second cover has a light transmitting part at least at a position facing the solar battery cell. The 1st cover is comprised from the center part facing the photovoltaic cell, and the peripheral part surrounding the center part.

  In one form of the present invention, the second cover is formed by two-color molding so as to include a light transmitting part and a light shielding part surrounding the light transmitting part.

  ADVANTAGE OF THE INVENTION According to this invention, weight reduction can be achieved, suppressing generation | occurrence | production of the curvature of a solar cell module.

It is a perspective view showing the appearance of the vehicle concerning one embodiment of the present invention. It is a top view which shows the external appearance of the solar cell module with which the vehicle which concerns on one Embodiment of this invention is provided, Comprising: It is the figure seen from the arrow II direction of FIG. It is sectional drawing which shows the mounting structure of the solar cell module which the vehicle which concerns on one Embodiment of this invention contains, Comprising: It is the figure seen from the III-III line arrow direction of FIG. It is a top view which shows the shape of the resin member contained in the solar cell module with which the vehicle which concerns on one Embodiment of this invention is provided. It is sectional drawing which shows the state which has arrange | positioned the 1st sealing material sheet on the 1st cover in the manufacturing process of the solar cell module which concerns on one Embodiment of this invention. In the manufacturing process of the solar cell module which concerns on one Embodiment of this invention, it is sectional drawing which shows the state which has arrange | positioned the photovoltaic cell on the 1st sealing material sheet. It is sectional drawing which shows the state which has arrange | positioned the 2nd sealing material sheet so that a photovoltaic cell may be covered in the manufacturing process of the solar cell module which concerns on one Embodiment of this invention. In the manufacturing process of the solar cell module which concerns on one Embodiment of this invention, it is sectional drawing which shows the state which has arrange | positioned the 2nd cover on the 2nd sealing material sheet, and adhere | attached the resin member on the 1st cover. In the manufacturing process of the solar cell module which concerns on one Embodiment of this invention, it is sectional drawing which shows the state which has vacuum-bonded the laminated body of the structural member of a solar cell module. In the manufacturing process of the solar cell module which concerns on one Embodiment of this invention, it is sectional drawing which shows the state which the laminated body of the structural member of a solar cell module has cooled and contracted.

  Hereinafter, a solar cell module according to an embodiment of the present invention, a mounting structure thereof, a vehicle including the solar cell module, and a method for manufacturing the solar cell module will be described with reference to the drawings. In the following description, the same or corresponding parts in the drawings are denoted by the same reference numerals, and the description thereof will not be repeated.

  FIG. 1 is a perspective view showing an appearance of a vehicle according to an embodiment of the present invention. FIG. 2 is a plan view showing the appearance of the solar cell module provided in the vehicle according to the embodiment of the present invention, as viewed from the direction of arrow II in FIG. FIG. 3 is a cross-sectional view showing a solar cell module mounting structure included in a vehicle according to an embodiment of the present invention, as seen from the direction of arrows III-III in FIG. FIG. 4 is a plan view showing the shape of the resin member included in the solar cell module provided in the vehicle according to the embodiment of the present invention. 2 to 4, the solar cell module 110 is illustrated with the length direction as L, the width direction as W, and the thickness direction as T.

  As shown in FIGS. 1-4, the vehicle 100 which concerns on Embodiment 1 of this invention is a motor vehicle, and is provided with the solar cell module 110 which comprises a roof, and the roof side member 120 which is a part of vehicle body. The vehicle is not limited to an automobile, and may be a train, for example.

  The solar cell module 110 is composed of a plate-like first cover 111 and a resin material having a linear expansion coefficient larger than that of the material constituting the first cover 111, and is opposed to the first cover 111 with a gap therebetween. The cover 112, the solar battery cell 113 disposed between the first cover 111 and the second cover 112, and the first cover 111 and the second cover 112 are filled and joined to each other. The sealing material portion 114 to be sealed, and a resin material having a linear expansion coefficient equal to or higher than the linear expansion coefficient of the material constituting the first cover 111, and the second cover 112 side of the peripheral portion 111p of the first cover 111, Comprises a resin member 115 bonded to a part of the opposite surface.

  The first cover 111 has a substantially rectangular outer shape in plan view. The first cover 111 is a flat plate in the present embodiment, but may be curved. The 1st cover 111 is comprised by two area | regions of the center part 111c facing the photovoltaic cell 113, and the peripheral part 111p surrounding the center part 111c. The central part 111c is opposed to the entire region where the plurality of solar cells 113 are arranged, and is a substantially rectangular region in plan view. The peripheral portion 111p is a region located in a frame shape on the outer periphery of the central portion 111c in plan view.

  In the present embodiment, the first cover 111 is a plate member made of aluminum. However, the first cover 111 is not limited to this, and may be a plate member having rigidity such as CFRP (Carbon Fiber Reinforced Plastics), or a resin sheet such as polyethylene terephthalate or polyetheretherketone.

  The second cover 112 has an outer shape substantially the same as that of the first cover 111 in plan view. The second cover 112 has a substantially flat plate shape in the present embodiment, but when the first cover 111 is curved, the second cover 112 is curved with substantially the same curvature as the first cover 111. The 2nd cover 112 has the translucent part 112t in the position facing the photovoltaic cell 113 at least.

  In the present embodiment, the second cover 112 includes a light transmitting part 112t and a light shielding part 112o surrounding the light transmitting part 112t. The translucent part 112t is opposed to the entire region where the plurality of solar cells 113 are arranged, and has a substantially rectangular shape in plan view. The translucent part 112t is approximately the same size as the central part 111c. The light shielding portion 112o is provided in a frame shape on the outer periphery of the light transmitting portion 112t in plan view.

  In the present embodiment, the second cover 112 is formed by two-color molding. The light transmitting part 112t and the light shielding part 112o are integrally formed. The light transmitting portion 112t is configured by a transparent resin layer 112a made of transparent polycarbonate. The light shielding portion 112o is configured by providing an opaque resin layer 112b made of an opaque polycarbonate to which a colorant is added in an overlapping manner below the transparent resin layer 112a constituting the light transmitting portion 112t. For example, the opaque resin layer 112b is black. However, the material constituting each of the transparent resin layer 112a and the opaque resin layer 112b is not limited to polycarbonate, and other materials such as acrylic may be used as long as the linear expansion coefficient is larger than that of the material constituting the first cover 111. There may be. In addition, the light-shielding part 112o does not necessarily need to be provided, and the 2nd cover 112 may be comprised only by the translucent part 112t.

  A plurality of solar cells 113 are arranged at intervals in a matrix. The plurality of solar battery cells 113 are electrically connected to each other. Specifically, a plurality of solar cells 113 are connected in series to constitute a solar cell string. The plurality of solar cell strings are connected to each other in series or in parallel.

  The sealing material portion 114 is located in a region sandwiched between the first cover 111 and the second cover 112. In the present embodiment, a frame-shaped member 116 made of butyl rubber is disposed at the edge of the region sandwiched between the first cover 111 and the second cover 112 in order to prevent the sealing material portion 114 from flowing out. Yes. The sealing material portion 114 is located in an inner region surrounded by the frame-shaped member 116.

  In this embodiment, the sealing material part 114 is comprised by EVA (Ethylene-Vinyl Acetate). However, the material constituting the sealing material portion 114 is not limited to EVA, and may be PVB (Poly Vinyl Butyral), silicone resin, or ionomer resin.

  The resin member 115 is plate-shaped. In the present embodiment, the resin member 115 is provided in a frame shape so as to overlap the peripheral edge portion 111p of the first cover 111 in plan view. The resin member 115 is bonded to a part of the surface of the peripheral edge 111p opposite to the second cover 112 side by an adhesive.

  In the present embodiment, as will be described later, since the joint portion 130 is provided so as to be in contact with another part of the surface of the peripheral edge portion 111p opposite to the second cover 112 side, the resin member 115 is It is adhered to a part of the surface of the portion 111p opposite to the second cover 112 side, but the joining portion 130 is in contact with a place other than the surface of the peripheral portion 111p opposite to the second cover 112 side. If provided, the resin member 115 may be bonded to the entire surface of the peripheral edge 111p opposite to the second cover 112 side.

  The shape of the resin member 115 is not limited to the above shape, and may be a rod shape. The resin member 115 is preferably provided so as to extend in the longitudinal direction of the solar cell module 110, which is a direction in which warpage is likely to occur.

  In the present embodiment, the resin member 115 is made of polycarbonate. However, the material constituting the resin member 115 is not limited to polycarbonate, and other materials such as acrylic may be used as long as the resin has a linear expansion coefficient equal to or higher than that of the material constituting the first cover 111. Good.

Here, the manufacturing method of the solar cell module 110 is demonstrated.
FIG. 5 is a cross-sectional view showing a state in which the first sealing material sheet is disposed on the first cover in the manufacturing process of the solar cell module according to the embodiment of the present invention. As shown in FIG. 5, the first sealing material sheet 114 a is disposed on the first cover 111. The first sealing material sheet 114a is made of EVA. Although not shown, the frame-shaped member 116 is disposed on the first cover 111 before the first sealing material sheet 114a is disposed.

  FIG. 6 is a cross-sectional view showing a state in which solar cells are arranged on the first sealing material sheet in the manufacturing process of the solar cell module according to one embodiment of the present invention. As shown in FIG. 6, a plurality of solar cells 113 that are electrically connected to each other are arranged on the first sealing material sheet 114a.

  FIG. 7: is sectional drawing which shows the state which has arrange | positioned the 2nd sealing material sheet so that a photovoltaic cell may be covered in the manufacturing process of the solar cell module which concerns on one Embodiment of this invention. As shown in FIG. 7, the 2nd sealing material sheet | seat 114b is arrange | positioned so that the several photovoltaic cell 113 may be covered. The second sealing material sheet 114b is made of EVA.

  FIG. 8 is a cross-sectional view illustrating a state in which the second cover is disposed on the second sealing material sheet and the resin member is bonded to the first cover in the manufacturing process of the solar cell module according to the embodiment of the present invention. is there. As shown in FIG. 8, the 2nd cover 112 is arrange | positioned on the 2nd sealing material sheet 114b. The resin member 115 is bonded to the surface of the peripheral edge 111p of the first cover 111 opposite to the second cover 112 side. The stacked body 110a stacked as described above is sealed with a vacuum laminator.

  FIG. 9 is a cross-sectional view showing a state in which a laminated body of constituent members of the solar cell module is vacuum-bonded in the manufacturing process of the solar cell module according to one embodiment of the present invention. As shown in FIG. 9, the laminate 110a is placed on a hot plate 90 in the chamber of the vacuum laminator. In the present embodiment, the surface of the hot plate 90 is a substantially flat surface in which a groove is formed at a position corresponding to the resin member 115, but when the first cover 111 is curved, It is a curved surface curved with substantially the same curvature.

  While the laminated body 110a is heated by the hot plate 90, the inside of the chamber is evacuated, so that the laminated body is pressed against the hot plate 90 and pressurized as indicated by the arrow by the pressure difference. The heated first sealing material sheet 114a and second sealing material sheet 114b are melted and flow so as to fill the space between the first cover 111 and the second cover 112, and are integrated.

  As the first sealing material sheet 114a and the second sealing material sheet 114b melt and flow, the second cover 112 faces the hot plate 90 so that the second cover 112 approaches the first cover 111. Moving.

  Thereafter, by stopping the heating of the laminated body by the hot platen 90, the melted EVA is solidified to seal the plurality of solar cells 113 and to join the first cover 111 and the second cover 112. To do.

  FIG. 10 is a cross-sectional view showing a state in which the laminated body of the constituent members of the solar cell module is cooled and contracted in the manufacturing process of the solar cell module according to one embodiment of the present invention. For example, when the temperature decreases from 140 ° C. to 20 ° C., each of the first cover 111 and the second cover 112 contracts.

  In the solar cell module 110 according to the present embodiment, since the second cover 112 is made of a resin material having a larger linear expansion coefficient than the material constituting the first cover 111, the shrinkage amount of the second cover 112 is It becomes larger than the shrinkage amount of 1 cover 111. Due to the difference in the contraction amount, as shown in FIG. 10, a deformation force 112s that causes the solar cell module to warp is generated.

  The deformation force 112s acts so that a region where the solar cells 113 are not arranged in the solar cell module 110 bends toward the second cover 112 side. That is, the deformation force 112s acts so that the peripheral edge of the solar cell module 110 where the peripheral edge 111p of the first cover 111 and the light shielding part 112o of the second cover 112 are positioned bends to the second cover 112 side.

  In the solar cell module 110 according to the present embodiment, the resin member 115 made of a resin material having a linear expansion coefficient equal to or greater than the linear expansion coefficient of the material constituting the first cover 111 is the second cover 112 of the peripheral portion 111p. It is bonded to the surface opposite to the side. When the resin member 115 contracts due to the temperature drop, a deforming force 115 s that causes the peripheral portion of the solar cell module 110 to warp is generated.

  The deformation force 115s acts on the peripheral portion of the solar cell module 110 such that a warp in a direction opposite to the warp caused by the deformation force 112s occurs. Therefore, the deformation force 115s acts so as to cancel the deformation force 112s. As a result, it is possible to suppress the warpage of the peripheral edge of the solar cell module 110.

  By producing the solar cell module 110 as described above, the occurrence of warpage of the solar cell module 110 can be suppressed. Further, since the weight increase of the solar cell module 110 due to the resin member 115 is slight, the solar cell module is compared with the case where the warpage of the solar cell module 110 is suppressed by increasing the rigidity of the first cover 111. 110 can be reduced in weight.

  As shown in FIG. 3, in the mounting structure of the solar cell module 110 according to the present embodiment, the solar cell module 110 is mounted on a flange 121 that is a part of the roof side member 120 and is a mounted portion. The solar cell module 110 and the flange 121 are joined to each other by the joint 130.

  The joint portion 130 is provided between the first cover 111 and the flange 121 of the solar cell module 110. The joint portion 130 is provided so as to be in contact with another part of the surface of the peripheral edge portion 111p of the first cover 111 opposite to the second cover 112 side. That is, the joint part 130 is sandwiched between a part of the peripheral edge part 111 p of the first cover 111 and the flange 121. The joining part 130 is provided in a substantially rectangular frame shape.

  In the present embodiment, the joint 130 is an adhesive containing a urethane resin. However, the joint 130 is not limited to this, and may be an adhesive including an epoxy resin.

  Since high design is required for a vehicle, it is important that the warpage of the solar cell module 110 constituting the roof is small. The vehicle 100 according to this embodiment has high design by including the mounting structure of the solar cell module 110 described above.

  In the present embodiment, the frame-shaped member 116, the resin member 115, and the joining portion 130 overlap the light shielding portion 112 o when viewed in the thickness direction of the solar cell module 110. Thereby, when the mounting structure of the solar cell module 110 is viewed from the second cover 112 side, the frame-shaped member 116, the resin member 115, and the joint 130 can be made invisible. As a result, the design of the vehicle can be improved.

  In the present embodiment, the mounted portion is the flange 121 which is a part of the roof side member 120. However, the mounted portion is not limited to this, and may be, for example, a garage roof or an arcade.

  It should be thought that embodiment disclosed this time is an illustration and restrictive at no points. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  90 Hot plate, 91 Diaphragm, 100 Vehicle, 110 Solar cell module, 110a Laminate, 111 First cover, 111c Central part, 111p Peripheral part, 112 Second cover, 112a Transparent resin layer, 112b Opaque resin layer, 112o Light shielding part , 112p plate-like part, 112s, 115s deformation force, 112t translucent part, 113 solar cell, 114 sealing material part, 114a first sealing material sheet, 114b second sealing material sheet, 115 resin member, 116 frame Shaped member, 120 roof side member, 121 flange, 130 joint.

Claims (5)

A plate-shaped first cover;
A second cover made of a resin material having a larger linear expansion coefficient than that of the material constituting the first cover, and facing the first cover with an interval;
A solar battery cell disposed between the first cover and the second cover;
A sealing material part that fills a space between the first cover and the second cover to join each other and seals the solar battery cell;
It is comprised by the resin material which has a linear expansion coefficient more than the linear expansion coefficient of the material which comprises the said 1st cover, and adhere | attaches on the whole or a part of surface on the opposite side to the 2nd cover side of the peripheral part of the said 1st cover. A resin member,
The second cover has a translucent part at least at a position facing the solar battery cell,
The first cover is composed of a central part facing the solar battery cell and the peripheral part surrounding the central part ,
A said 2nd cover is a solar cell module comprised from the said light transmission part and the light-shielding part surrounding this light transmission part .   The solar cell module according to claim 1, wherein the resin member has a plate shape. And a solar cell module,
A mounted portion on which the solar cell module is mounted;
The solar cell module and the mounted portion are joined to each other,
The solar cell module is
A plate-shaped first cover;
A second cover made of a resin material having a larger linear expansion coefficient than that of the material constituting the first cover, and facing the first cover with an interval;
A solar battery cell disposed between the first cover and the second cover;
A sealing material part that fills a space between the first cover and the second cover to join each other and seals the solar battery cell;
It is comprised by the resin material which has a linear expansion coefficient more than the linear expansion coefficient of the material which comprises the said 1st cover, and adhere | attaches on the whole or a part of surface on the opposite side to the 2nd cover side of the peripheral part of the said 1st cover. A resin member,
The second cover has a translucent part at least at a position facing the solar battery cell,
The first cover is composed of a central part facing the solar battery cell and the peripheral part surrounding the central part,
The junction part is a solar cell module mounting structure sandwiched between a part of the peripheral part and the mounted part. The mounting structure of the solar cell module according to claim 3 ,
A vehicle in which the mounted portion is a part of a vehicle body. Placing the first sealing material sheet on the plate-like first cover;
Arranging solar cells on the first encapsulant sheet;
Arranging the second encapsulant sheet so as to cover the solar battery cells;
Placing a second cover made of a resin material having a larger linear expansion coefficient than the material constituting the first cover on the second sealing material sheet;
A resin member made of a resin material having a linear expansion coefficient greater than or equal to the linear expansion coefficient of the material constituting the first cover, the entire surface of the peripheral edge of the first cover opposite to the second cover side Or a process of adhering to a part,
Pressurizing while heating the laminate in which the first cover, the first sealing material sheet, the solar battery cell, the second sealing material sheet, the second cover, and the resin member are laminated. Prepared,
The second cover has a translucent part at least at a position facing the solar battery cell,
The first cover is composed of a central part facing the solar battery cell and the peripheral part surrounding the central part ,
The method of manufacturing a solar cell module, wherein the second cover is formed by two-color molding so as to be configured by the light transmitting part and a light shielding part surrounding the light transmitting part .

Images