JPH05121773A - Solar cell module - Google Patents

Abstract

PURPOSE:To provide a solar cell module which is hardly increased in manufacturing cost and suitable for applying to a general roof construction method where a welding operation is employed. CONSTITUTION:In a solar cell module 1 where amorphous silicon solar cell elements 1A, 1B, and 1C are hermetically sealed up with a light transmission filler 7 of high molecular resin excellent in weather-resistant properties, a metal reinforcing plate 10 of a single plate is mounted on the rear of a solar cell base, and the reinforcing plate 10 is larger than the solar cell base, and the surfaces of the ends of the reinforcing plate 10 is not covered with the light transmission filler 7.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module, and more particularly to a solar cell module adapted to the existing construction method.

[0002]

2. Description of the Related Art In recent years, solar cells have been enthusiastically researched as clean and non-depleting energy, and as a practical use form, the development of a solar cell module that can be installed and used on a roof of a house is as follows. Realistic and highly valued.

Among the solar cell modules, there is an amorphous silicon solar cell which can be manufactured in a relatively large area and is inexpensive in manufacturing cost. As such an amorphous silicon solar cell, a solar cell module in which a metal reinforcing plate is attached to the back surface of the solar cell substrate, which has high reliability against external stress, has been conventionally known.

An example of an amorphous silicon solar cell module in which a metal reinforcing plate is attached to the back surface of the above solar cell substrate is shown below.

6 and 7 are a plan view and a sectional view of an amorphous silicon solar cell, respectively.

This amorphous silicon solar cell module 1 is formed by connecting three amorphous silicon solar cell elements 1A, 1B and 1C having the same structure in series and sealing them with resin.

Each amorphous silicon solar cell element 1
The configurations of A, 1B, and 1C will be described using the amorphous silicon solar cell element 1A as a typical example.

Amorphous silicon solar cell element 1A
Is a metal layer formed by a method such as sputtering on a flexible stainless substrate (not shown) and plasma C
It has an amorphous silicon semiconductor layer in which n, i, and p layers are sequentially formed by a method such as VD, and a transparent electrode layer formed by a resistance heating vapor deposition method or the like, and these layers are sequentially laminated.

Further, on the transparent electrode layer, three comb type collecting electrodes 2 such as silver paste are formed in parallel with each other by a screen printing method, and each comb type collecting electrode 2 is arranged so as to be orthogonal to them. Are electrically bonded to each other by a conductive adhesive 4. Further, in the transparent electrode layer, in order to surely separate the positive electrode and the negative electrode of each solar cell element, that is, the transparent electrode layer and the flexible stainless steel substrate in the vicinity of the periphery, the electrode separation is performed by peeling the transparent electrode layer. A section 18 is provided.
On a part of the peripheral portion separated by the electrode separating portion 18, a stainless exposed portion 20 is formed by exposing the flexible stainless substrate with a glider or the like. A metal foil 6A, which serves as one connection electrode (for example, a negative electrode) to the external circuit, is attached to the exposed stainless portion 20 by spot welding. Further, one end of the bus bar electrode 3 is extended to the outside of the amorphous silicon solar cell element 1A, and the extended portion serves as the other connection electrode (for example, positive electrode) with the external circuit. Further, in order to prevent a short circuit between the bus bar electrode 3 and the peripheral portion of the transparent electrode layer separated by the electrode separating portion 18, polyester is provided between the bus bar electrode 3 and the peripheral portion where the bus bar electrode 3 is located. An insulating material 5 such as a tape is interposed.

The three amorphous silicon solar cell elements 1A, 1B and 1C having the above-described structure are the bus bar electrode 3 of the amorphous silicon solar cell element 1A and the exposed stainless steel portion 2 of the amorphous silicon solar cell element 1B.
0 is connected to the metal foil 6B, and the bus bar electrode 3 of the amorphous silicon solar cell element 1B and the exposed stainless steel portion 20 of the amorphous silicon solar cell element 1C are connected to the metal foil 6B.
They are connected by C and are connected in series as a whole. And
Metal foil 6A attached to the exposed stainless steel portion 20 of the amorphous silicon solar cell 1A and metal foil 6D attached to the bus bar electrode 3 of the amorphous silicon solar cell 1C.
And serve as connection terminals to the outside as a negative electrode and a positive electrode, respectively.

Three amorphous silicon solar cells 1A, 1B and 1C connected in series are connected to each other as shown in FIG.
It is resin-sealed with a light-transmitting filler 7 made of VA or the like, and the surface thereof is covered with a light-transmitting protective film 8 made of a weather-resistant resin. The back surface is covered with a metal reinforcing plate 16, a nylon sheet 9 is adhered to one surface of the metal reinforcing plate 16, and the other surface is a soft polyvinyl chloride sheet for protecting the metal reinforcing plate 16. 17 is attached.

The nylon sheet 9 on one side adhered to the metal reinforcing plate 16 is for preventing a short circuit between the metal reinforcing plate 16 and each of the amorphous silicon solar cells 1A, 1B and 1C.

Next, it is assumed that the amorphous silicon solar cell module 1 having the above-mentioned structure is installed on the roof of a house for use. In this case, as an example of the existing roofing material construction method, there is a construction method that is often used when roofing the roofing material of a large building such as a gymnasium. This construction method is a construction method in which roof materials arranged adjacent to each other are welded at their bent ends.

The outline of this method is shown below.

FIG. 8 is a perspective view of a roof provided with a roofing material by the above method, and FIG. 9 is a sectional view showing a state of the welded portion.

The direction of the arrow A in FIG. 8 is the roof ridge. From this building, a long roofing material is roofing from left to right as seen from the direction of the eaves.

As the construction procedure, first, as shown in FIG. 9, the roof material 23 is attached by spot welding 23a to the hanger 21 attached to the field member of the roof by the screw 21a. After that, the roof material 22 and the roof material 23 are attached by seam welding 23b.

The construction method as briefly described above is suitable as a construction method for roofing the roof of a large building, and is now widely used.

Therefore, in order for solar cells to become widespread in the future, it is required as one condition to have a structure that conforms to the above construction method. More specifically, it is necessary that the end portion of the solar cell module is made of a weldable member so as to be compatible with the above construction method.

[0020]

By the way, when a weldable member is newly provided at the end portion of the solar cell module and a solar cell module conforming to the existing roofing material construction method is manufactured, the new provision is made. In order to manufacture a member having sufficient bonding strength and waterproofness at the joint between the member and the end of the solar cell module, there was a problem to be solved that the cost was inevitably high.

[0021]

The present invention has been made to solve the above-mentioned problems, and provides a solar cell module which can be applied to a general roof construction method using welding without increasing the manufacturing cost. The purpose is to do.

According to the present invention, a translucent filler made of a polymer resin having weather resistance is attached to a back surface side of a solar cell element having a photoelectric conversion semiconductor layer formed on a solar cell substrate. In the solar cell module whose whole is sealed by, the metal reinforcing plate is composed of one plate, and the end surface of the metal reinforcing plate exists even outside the arrangement range of the solar cell base on which the solar cell element is arranged. The surface of the end portion is not covered with the translucent filler.

[0023]

(Embodiment 1) An embodiment of the present invention will be described below with reference to the drawings.

1 and 2 are a plan view and a sectional view showing an embodiment of the solar cell module of the present invention.

The internal structure of the solar cell module 1 of this embodiment is the same as that of the conventional solar cell module 1.

That is, as shown in FIG. 2, a metal electrode layer 12 is formed on a solar cell substrate, here, a stainless substrate 11.
1, the amorphous silicon semiconductor layer 13 and the transparent electrode layer 14 are sequentially laminated, and as shown in FIG. 1, the three amorphous silicon solar cell elements 1A, 1B and 1C use metal foils 6A, 6B, 6C and 6D. Are connected in series. Then, these are entirely resin-sealed with a translucent filler 7 such as a polymer resin.

As described above, the three resin-sealed amorphous silicon solar cell elements 1A, 1B, and 1C have their surfaces covered with the light-transmitting protective film 8 made of weather-resistant resin. Further, the back surface side thereof is covered with a metal reinforcing plate 10 according to the present invention through a nylon sheet 9 for preventing a short circuit.

On the other hand, the metal foils 6A and 6D are partially exposed and sealed so as to serve as connection terminals to the outside.

By the way, the metal reinforcing plate 10 is a single plate having an area such that the end portion also exists outside the solar cell substrate arrangement range L shown in the drawing, and the surface of the end portion is a polymer. It is characterized in that it is not covered with the translucent filler 7 such as resin.

In this embodiment, as shown in FIGS.
Both ends 10a and 10b, which are long, are bent inward, and one end 10a thereof is further bent outward in an inverted U shape.

With such a shape, the solar cell module 1 can be adapted to the above-described method for constructing the roof material by welding.

In this embodiment, a stainless steel material having a thickness of 0.4 mm is used as the metal reinforcing plate 10. This has sufficient performance in the corrosion resistance and weather resistance required for the roofing material. Therefore, it can be seen that the solar cell module 1 of the present invention sufficiently functions as a roof material.

In this embodiment, as shown in FIGS. 1 and 2, the end portions 10a, 10b of the solar cell module 1 are
Is treated as a product in a folded state, but as another embodiment, the product is made in a state where the end portions 10a and 10b are not folded, and a worker who constructs the roof bends and welds it into a convenient form at the site. You can also choose to do so.

(Embodiment 2) Next, a second embodiment of the present invention is shown in FIGS.

In this embodiment, the structure of the amorphous silicon solar cell module 1 is the same as that of the first embodiment. However, regarding the metal reinforcing plate 15, the end portion 15
Bend a and 15b into a predetermined shape as shown in FIG.
The roof is made so that it can be assembled. As shown in FIG. 4, the end portion 15b of the solar cell module 1 and the end portion 15a of the other solar cell module 1 which are adjacent to each other are combined, and then the end portions 15a are fastened to combine the two. Then, the roof is constructed. At this time, as shown in FIG. 3, assuming that the size of the bent portion of the end portion 15a is a and b, a = 20 mm and b = 2.
It is suitable to form a braid having a size of about 0 mm.
That is, a roofing material of this size is generally used in many cases, and if a roofing material larger than this is used, there are many inconveniences such as the inability to use existing tools for tightening.

By the way, in the complicated bending process of the end portion having the shape and dimensions as shown in FIG. 3, the end portion of the metal reinforcing plate 15 is not covered with the light-transmitting filler 7 made of polymer resin or the like. Only then can it be possible.

That is, the thickness of the translucent filler 7 made of polymer resin or the like in this embodiment is at least about 1 mm in order to sufficiently protect the solar cell elements 1A, 1B and 1C. Is. Thus, the bending work of the dimension and shape shown in FIG. 3 in the state where the transparent filler 7 having a thickness of 1 mm is entirely applied to the surface of the metal reinforcing plate 15 is Problems such as peeling occur and it is very difficult.

(Embodiment 3) Next, a third embodiment of the present invention is shown in FIG.

This embodiment shows a state in which the metal reinforcing plate 27 of the solar cell module 25 of the present invention is attached to the existing fence 24 made of lip groove type steel. As the working procedure, the metal reinforcing plate 2 of the solar cell module 25 is used.
7 After hooking one end 27a on the uppermost fence 24, the other end 27 of the metal reinforcing plate 27 is moved to the lowermost fence 2
4 is fixed by spot welding 26.

In this embodiment, the contractor adjusts the end portion 2 of the metal reinforcing plate 27 of the solar cell module 25 in accordance with the shape of the existing shelves 24 and the intervals of the fences 24 arranged on the site.
There is an advantage that 7a and 27b can be bent and constructed freely.

As can be seen from the above examples, since the end portions of the metal reinforcing plate of the solar cell module are not covered with the light-transmitting filler made of polymer resin or the like, the flexibility of construction is very high. It will be high.

[0042]

As described above, according to the present invention, in a solar cell module in which a solar cell element is sealed with a translucent filler made of a polymer resin having weather resistance, one solar cell module is provided on the back surface of the solar cell substrate. A metal reinforcing plate made of a plate is attached, the metal reinforcing plate also exists outside the arrangement range of the solar cell substrate, and the end surface of the metal reinforcing plate is not covered with the translucent filler. Therefore, the following effects can be obtained. (1) Welding can be applied to the end of the metal reinforcing plate during roof construction. (2) Since the end portion of the metal reinforcing plate is not covered with the light-transmitting filler made of polymer resin or the like, complicated bending of such a portion is possible, and the roof material can be adapted to various construction methods. (3) It can be attached to fences other than roofing materials and can be applied to various construction methods. (4) Since it is not necessary to newly provide a weldable member,
Since it is integrally formed without causing an increase in cost, there is no problem in connection strength, waterproofness and the like.

[Brief description of drawings]

FIG. 1 is a plan view showing a first embodiment of a roof material-integrated solar cell module according to the present invention.

FIG. 2 is a sectional view of the first embodiment.

FIG. 3 is a sectional view showing a second embodiment according to the present invention.

FIG. 4 is a sectional view showing a mounted state in the second embodiment.

FIG. 5 is a perspective view showing a third embodiment of the present invention.

FIG. 6 is a plan view showing an example of a conventional solar cell module.

FIG. 7 is a sectional view of the conventional solar cell module.

FIG. 8 is a perspective view showing an example of a conventional roofing material construction method.

FIG. 9 is a cross-sectional view showing an example of the conventional roofing material construction method.

[Explanation of symbols]

1, 25 amorphous solar cell module, 1A, 1B, 1C amorphous silicon solar cell element, 2 comb-shaped collecting electrode, 3 bus bar electrode, 4 conductive adhesive, 5 insulating material, 6 metal foil, 7 translucent filler, 8 Translucent protective film, 9 nylon sheet, 10, 15, 16, 27 metal reinforcing material, 11 stainless steel substrate (solar cell substrate), 12 metal electrode layer, 13 amorphous silicon semiconductor layer, 14 transparent electrode layer, 17 polyvinyl chloride Sheet, 18 electrode separation part, 20 stainless exposed part, 21 suspension, 22,23 roofing material, 24 fence, 26 spot welding.

Claims (4)

[Claims] 1. A solar cell element formed by forming a photoelectric conversion semiconductor layer on a solar cell substrate, and a metal reinforcing plate attached to the back surface side of the solar cell element. In the solar cell module with sealed
The metal reinforcing plate is composed of one plate, there is an end surface of the metal reinforcing plate even outside the arrangement range of the solar cell base for arranging the solar cell element, the end surface,
A solar cell module, which is not covered with the translucent filling material. 2. The solar cell module according to claim 1, wherein at least one end of the metal reinforcing plate is bent into an inverted U shape. 3. The metal reinforcing plate has one end formed with one bent portion for a roof assembly of a roofing material, and the other end has a size to be wrapped by the bent portion. 2. The solar cell module according to claim 1, wherein the other bent portion is formed. 4. One of the bent ends of the metal reinforcing plate is hooked on the upper fence, and the other bent end of the metal reinforcing plate is fixed to the lower fence by welding. The solar cell module according to claim 1, wherein: