JPH03204979A - Solar cell module and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a solar cell module which is excellent in flexibility and attachable on the curved roof of a car or the like by a method wherein the solar cell module is formed in such a constitution that solar cell elements are pasted on the rear of a curved light transmitting plate through a light transmitting adhesive agent. CONSTITUTION:A light transmitting plate 1 is formed of transparent resin such as polycarbonate, acryl, or the like or a white plate glass, and a first half layer 3a of a light transmitting adhesive agent 3 of EVA, PVB or the like is pasted on the rear side of the plate 1. Solar cell elements 2 mutually connected to each other in series or parallel with inner leads are provided on the light transmitting adhesive agent layer 3a, and the other half layer 3b of the light transmitting agent 3 is pasted thereon so as to pinch the solar cell elements 2 between the layers 3a and 3b. Then, the light transmission plate 1 is heated at a temperature of 120 deg.C-150 deg.C to be softened, the softened plate 1 is sandwiched between the cope 4a and the drag 4b of a pressure molding die provided with curved surfaces, and a pressure is given to them in a uniaxial direction to make the light transmissive plate 1 and the adhesive agent layer 3 curved. In result, a solar cell module which is excellent in flexibility and attachable to the curved surface such as the roof or the like of a car can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a solar cell module and a method for manufacturing the same, and particularly to a solar cell module having curvature and a method for manufacturing the same.

[Conventional technology and its problems]

In a conventional solar cell module, for example, as shown in FIG. 12, a transparent resin 123 is filled between a planar transparent plate 121 and a back plate 124 made of resin, glass, etc., and the solar cell elements 122 It is common to have . Note that the back plate 124 is made of a resin sheet, a metal plate, or the like.

However, such solar cell modules have poor flexibility and cannot be installed, for example, on the roof of a curved automobile due to the problem of peeling off due to wind pressure during driving. In order to avoid this problem, even if the thickness of the solar cell module is covered to give it some degree of flexibility, the problem arises that the impact resistance of the surface decreases.

Furthermore, as shown in FIG. 13, for example, there is also a solar cell module in which an amorphous silicon solar cell 132 is formed by depositing an amorphous silicon film or the like on the surface of a transparent plate 131 made of glass, resin, etc. that has been previously formed into a curved shape. be.

However, it is difficult to deposit an amorphous silicon film uniformly over a large area, and furthermore, it is impractical to use outdoors because the conversion efficiency is significantly reduced.

Furthermore, as shown in FIG. 14, for example, a transparent plate 141 made of glass, resin, or the like is preformed into a curved shape, and a solar cell 142 made of polycrystalline silicon or the like is arranged on the back side of the transparent plate 141. Then, potting with silicone rubber or the like may be considered, but when filling the curved surface with the botting material 143 such as silicone rubber, the potting material 14
3 concentrates in the most concave central part of the light-transmitting plate 14'', causing a problem that uniform botting cannot be performed.

[Purpose of the invention]

The present invention was devised based on the above-mentioned background, and an object of the present invention is to provide a solar cell module in which a solar cell element is well adhered to the back surface of a curved transparent plate, and a method for manufacturing the same. .

[Means to solve the problem]

The above-mentioned problem is solved by the following means (a) and (b).

That is, (a) a solar cell module consisting of a plurality of solar cell elements adhered to the back surface of a curved transparent plate with a transparent adhesive;

(b) A step of attaching a plurality of solar cell elements to the back surface of a flat transparent plate with a transparent adhesive, heating the transparent plate to soften it, and bending it into a desired curved shape. A method for manufacturing a solar cell module consisting of:

[Effect]

According to the solar cell module and the manufacturing method thereof of the present invention, since a plurality of solar cell elements are attached to the back surface of the curved light-transmitting plate, flexibility is improved compared to the conventional one, and the roof of a curved car etc. Even if a solar cell module is attached to a vehicle, it can be installed in a state that conforms to the shape of the roof, so it can sufficiently withstand the wind pressure associated with driving.

Furthermore, according to the manufacturing method of the present invention, after a solar cell element is attached to the back surface of a flat transparent plate, the transparent plate is heated and softened to form a curved solar cell module. The ponting material is not concentrated in the area, making manufacturing easier.

〔Example〕

Embodiments according to the present invention will be described in detail based on the drawings.

FIG. 1 is a sectional view of a solar cell module according to the present invention, in which 1 is a curved transparent plate, 2 is a solar cell element, and 3 is a transparent adhesive.

The light-transmitting plate 1 is made of a light-transmitting resin such as polycarbonate or acrylic, or white glass.
It is pre-formed into a curved surface that is gently curved in two axial directions: the direction and the Y direction.

Each of the solar cell elements 2 is basically a flat plate, and is constructed by forming a p-n junction in, for example, a single crystal or polycrystal of silicon, or a single crystal or polycrystal of gallium arsenide. ing.

These plurality of solar cell elements 2 are made of aluminum, silver,
Alternatively, they are connected to each other by inner leads 4 made of a conductive material such as copper, and are configured so that output can be taken out from any specific location. Note that these plurality of solar cell elements 2 are connected in series or in parallel to obtain a desired output.

The solar cell element 2 is attached to the back surface of the transparent plate 1 with an adhesive 3. This adhesive 3 is made of room temperature curing two-component silicone rubber, thermosetting ethylene vinyl acetate (E
VA) resin or polyvinyl butyral (PVB)
Use resin etc.

As described above, a solar cell module is basically composed of a transparent plate 1, a plurality of solar cell elements 2, and an adhesive 3. For example, a so-called back sheet made of a suitable combination of resin sheets, aluminum foil, etc. may be attached to the solar cell module, and in order to increase the mechanical strength of the solar cell module,
A reinforcing material or the like in which a honeycomb member made of aluminum or the like is held by a thin aluminum plate may be appropriately attached to the back side of the solar cell module.

Furthermore, as shown in FIG. 2(a), a rising portion 1a may be provided on the peripheral edge of the transparent plate 1, a colored layer 1b may be provided as shown in FIG. 2(b), or a colored layer 1b may be provided as shown in FIG. 2(C). When the colored member 1c is provided as shown in the figure, the installation cost for the solar cell module can be easily secured.

Next, a method for manufacturing the solar cell module will be explained.

First, on the back side of the planar transparent plate 1, use EVA or PVB.
Only half the layer 3a of the translucent adhesive 3 made of, etc. is pasted.

Next, a plurality of solar cell elements 2 connected to each other in series or in parallel via inner leads 4 are arranged on the transparent adhesive 3a.

Next, a transparent adhesive 3 is applied onto the plurality of solar cell elements 2.
Paste the other half of the layer 3b to form the two layers 3a and 3b.
A plurality of solar cell elements 2 are sandwiched between them.

Next, in a state in which the transparent plate 1 is softened by heating at a temperature of about 1.20 to about 150°C, upper and lower molds 5a and 5b of a pressure molding machine having a curved part as shown in FIG. Sandwiched between -
By applying pressure in the axial direction, the transparent plate 1 and the adhesive 3 are curved. In this case, since each solar cell element 2 is divided into a plurality of small-area pieces, the solar cell element 2 itself will not curve, and the heat forming of the transparent plate 1 will not be hindered. do not have. In addition, as shown in FIG. 4, the solar cell module is placed on the mold 6 and about 1
The transparent plate 1 and the adhesive 3 may be bent into a predetermined shape by evacuation from the pores 6a in the mold 6 while heating to 20 to about 150°C. Furthermore, if the portion where the upper and lower molds 5a, 5b or mold 6 and the solar cell module come into contact is formed into a desired curved shape, the transparent plate l can be
Alternatively, the curved surface shape corresponds to the shape of the mold 6. In the solar cell module according to the present invention, for example, the radius of curvature R in the X direction is approximately 10,000 mm, and the radius of curvature R in the Y direction is approximately 10,000 mm.
5. It is molded into a curved shape with a diameter of approximately 000 mm.

After hot forming, the transparent plate 1 is completed by cooling to room temperature and solidifying the transparent plate 1 in a curved state.

In addition, when using two-component silicone rubber as the adhesive 3, apply a primer to the back side of the translucent plate so that there is a gap between the translucent plate 1 and the solar cell element 2. After the battery element 2 is arranged and tied, the solar cell element 2 is surrounded and filled with two-component silicone rubber to form a flat solar cell module, which is then bent and formed. In this case, as shown in FIG.
After forming the transparent plate 1 into a curved shape, the adhesive 3 on the peripheral edge of the transparent plate 1 can be easily removed, and the mounting cost for the solar cell module can be secured.

Next, an example will be described in which the solar cell module and the method for manufacturing the same according to the present invention are applied to, for example, a solar cell-powered vehicle in which a solar cell is mounted on the roof of the vehicle body.

FIG. 6 shows the structure of the solar cell module divided into three parts, each of which is shown in cross-sectional view. That is, a plurality of flat solar cell elements 1 are interconnected by inner leads 14 so as to obtain a desired output.
2, an adhesive 13a affixed to the back surface of the flat upper transparent plate 11, and an adhesive affixed to the permanent surface of the flat lower transparent plate 15 impregnated with a pigment that matches the color of the vehicle body] , 3 with 3b
It shows two parts. Here, inner lead 14,
Upper transparent plate 11, lower transparent plate 15, and adhesive 13 a
, 13b are the same as those in the previously described embodiments, so their explanation will be omitted. Upper transparent plate 11. The thickness of the lower transparent plate 15 is about 2 to about 3 mm, and the adhesive 13 a
, 13b each have a thickness of about 0.6 mm,
The thickness of these pieces is almost the same. Further, the color of the lower transparent plate 15 does not necessarily have to be the same as the color of the vehicle body.
The type of pigment may be selected as appropriate to create a beautiful appearance with various colors.

The inner lead 14 has a diameter of 0.0 mm as shown in FIG.
The central part 14c of a 4 mm wire rod is bent into a U-shape, and both ends 14a and 14b are flattened as shown in FIG.
A thin plate with a thickness of about 0.1 mm is used. Note that the inner lead 14 may be formed by punching a thin plate approximately 001 mm thick into the shape shown in FIG. 8.

Next, a process of manufacturing the solar cell module according to the shape of the roof of a vehicle body will be explained.

First, each member is arranged as shown in FIG. 6, and a solar cell module integrally formed by vacuum heating lamination as shown in FIG. 9 is manufactured. Here, the vacuum heating lamination is a method in which a solar cell module is formed by pressure molding by introducing atmospheric air after heating in a vacuum chamber.

Next, as shown in FIG. 10, the solar cell module is placed on a mold 17 made using the shape of the roof of the vehicle as a mask. At this time, when the curvature of the mold 17 is small, the solar cell module deforms along the shape of the mold 17 due to its own weight simply by heating to about 150°C. Type 17
If the curvature of Or, as shown in Figure 3, an upper mold is provided above the mold 17 and pressure is applied from one axis.
As shown in FIG. 4, the mold 17 can be deformed into the shape of the mold 17 by providing vacuum holes and using the vacuum method.

Next, after cooling to room temperature, the excess corners 18 of the deformed solar cell module are trimmed to fit an appropriate mounting space using a cutting method such as a laser, water jet, press cutting, or wire saw, as shown in FIG. 11. Make a cut.

According to this embodiment, the following effects can be expected.

First, the steps up to vacuum heating lamination do not need to be manufactured to match the curved surface of the roof of the vehicle, and can be easily standardized.

Further, the process of deforming the solar cell module is extremely suitable for producing a wide variety of products, since it can be adapted to various roof shapes just by preparing a mold 17 made using the roof of the vehicle body as a mask.

Furthermore, the color of the lower transparent plate 15 can be selected to match the color of the vehicle body to create an aesthetic appearance.
Even if there are scratches or dirt on the first prize, it will not spoil its aesthetic appearance.

Furthermore, since the inner lead 14 has a shape that absorbs the stress between the solar cell elements 12 when the solar cell module is deformed, even if the mold 17 has a large curvature, it can be sufficiently handled.

It should be noted that the present invention is not limited to the embodiments described above and shown in the drawings, but can be implemented with appropriate modifications within the scope of the invention.

〔Effect of the invention〕

As described above, according to the solar cell module of the present invention, a plurality of solar cell elements are adhered with a transparent adhesive to the back surface of a curved transparent plate that has a thickness of about 0.5 mm over the entire surface. Because of this, it has good flexibility, and the solar cell module can be attached to curved surfaces, such as the roof of a car, where wind pressure is applied, for example.

Further, according to the method for manufacturing a solar cell module according to the present invention, after a plurality of solar cell elements are pasted with a transparent adhesive on the back surface of a planar transparent plate having a thickness of about 100 psi over the entire surface, Since the transparent plate is heated and softened to form a curved surface into a desired curved shape, it is possible to easily form a curved solar cell module with a large area without making the material uneven in thickness. It is possible to provide a method for manufacturing a solar cell module that has improved impact resistance and hardness and also has good waterproof properties.

[Brief explanation of drawings]

FIGS. 1 to 11 are views showing embodiments of the present invention, respectively. FIG. 1 is a sectional view of the structure of an embodiment of the solar cell module, and FIGS. ) are cross-sectional views showing modified examples of the solar cell module, FIG. 3 are cross-sectional views showing a method of manufacturing the solar cell module, and FIGS. 4 and 5 are respectively modified examples of the manufacturing method of the solar cell module. 6 and 9 are sectional views showing other embodiments of the solar cell module, and FIGS. 7 and 8 are sectional views showing other embodiments of the solar cell module, respectively.
Each figure is a perspective view illustrating the inner lead 14, and FIGS. 10 and 11 are perspective views illustrating other embodiments of the method for manufacturing a solar cell module, respectively. FIGS. 12 to 14 are sectional views of conventional solar cell modules, respectively. 11゜2 3 4 5 Translucent plate, solar cell element, translucent adhesive, inner lead,

Claims (2)

[Claims] (1) A solar cell module consisting of a plurality of solar cell elements adhered to the back surface of a curved transparent plate using a transparent adhesive. (2) A step of attaching a plurality of solar cell elements to the back surface of a flat transparent plate with a transparent adhesive, heating the transparent plate to soften it, and bending it into a desired curved shape. A method for manufacturing a solar cell module consisting of: