JPH0969646A - Solar battery module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable a solar battery module to be fire-retardant and nonflammable and to use it directly as a roof material by providing a net-shaped body which is impregnated with an adhesive resin between solar battery and a transparent plate and/or between the solar battery and a back cover for covering it. SOLUTION: A net-shaped body which is impregnated with adhesive resin in advance may be laminated on a transparent plate 12 and a back cover 13 but normally a vacuum lamination treatment is performed on its production. A net-shaped body 14a and an adhesive resin film 14b are included between a cell 11 and the transparent plate 12 and between the battery 11 and the back cover, respectively. Then, vacuum lamination is performed and is heated and then the adhesive resin 14b is melted, thus impregnating the net-shaped body 14a with the adhesive resin and easily obtaining a fire-retardant and nonflammable solar battery module. In this case, by using an EVA sealing material film where an organic peroxide is added as the resin film 14b, EVA can be simultaneously cross-liked in impregnation and heating.

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 flame retardant / non-combustible technology for a solar cell module.

[0002]

2. Description of the Related Art In recent years,
There are very high expectations for solar power generation systems as clean energy, and their widespread use is strongly desired. Especially, by installing a solar cell module on the roof of a house, there are great expectations as a measure to reduce the peak of electric power. However, at present, the cost is high, which is an obstacle to the spread. Therefore, as a countermeasure against this, it has been proposed to use a solar cell module instead of a roof material.

However, in the conventional solar cell module, as shown in FIG. 4, the solar cell 1 and the white glass plate 2 and the weather resistant back cover 3 are adhered to each other.
The EVA resin (ethylene-vinyl acetate copolymer) encapsulant film 4 has been interposed for encapsulation, but it is used as an adhesive between cells and glass in this solar cell module. The existing EVA resin encapsulant film is inflammable, and the EVA resin is heated and dropped during the solar cell module combustion test, and this EVA resin burns, so that it cannot be directly used as a roofing material.

The present invention has been made in view of the above circumstances.
It is an object of the present invention to provide a solar cell module which is flame-retardant / non-combustible and can be directly used as a roof material or the like.

[0005]

Means for Solving the Problems and Embodiments of the Invention In order to achieve the above object, the present invention provides a solar cell and a transparent plate and a back cover which cover the solar cell, or both. Provided is a solar cell module including a mesh body impregnated with an adhesive resin.

According to the present invention, since an adhesive resin such as an ethylene-vinyl acetate copolymer (EVA resin) is impregnated into a reticulated body such as a glass fiber non-woven fabric as described above, the resin is not dropped during the combustion test. The solar cell module is prevented from burning, and the solar cell module is made flame-retardant or non-combustible, which makes it possible to use the solar cell module as a roofing material.

The present invention will be described in more detail below. As shown in FIG. 1, the solar cell module of the present invention has a space between the solar cell 11 and the transparent plate 12 and between the cell 11 and the back plate. A mesh body 14 impregnated with an adhesive resin is interposed between the cover 13 and the cover 13.

Here, as the cell 11, the transparent plate 12, and the back cover 13, known ones can be used. In this case, as the back cover, a fluorinated polyethylene film such as monofluorinated polyethylene, difluorinated polyethylene, or trifluorinated polyethylene, a polyester film,
It is possible to use a laminate of the above-mentioned film having high weather resistance such as polyethylene monofluoride on both sides or one side of an aluminum foil.

The mesh 14 may be woven cloth, non-woven cloth, foam or the like as long as it can be impregnated with a resin, but woven cloth and non-woven cloth are preferable, and particularly light-transmissive. Nonwoven fabrics are preferably used because of their excellent properties. It is recommended that the material of the reticulate body 14 is nonflammable, and those using inorganic fibers are preferably used, but those using glass fibers that do not inhibit light transmission, especially glass fibers. Nonwoven fabric is more preferably used.

In this case, the non-woven fabric is 10 to 1000 g /
Those having a density range of m ² , particularly 10 to 100 g / m ² , are particularly preferred. If it is less than 10 g / m ² , the resin holding capacity during combustion may be lowered, and the resin may drop during the combustion test. On the other hand, if it exceeds 1000 g / m ² , the light transmittance may remarkably decrease, and the power generation efficiency of the solar cell may decrease.

As the adhesive resin impregnated in the reticulated body, polyvinyl butyral resin, vinyl chloride resin, EV
Any resin can be used as long as it has good light transmittance and can impregnate a cloth, such as A resin and modified EVA resin, but EVA resin is particularly preferable. The EVA resin used in the present invention has a vinyl acetate content of 10-5.
0% by weight, more preferably 15 to
40% by weight. Further, the EVA resin used in the present invention preferably has a melt flow rate of 0.7 to 20, and more preferably 1.5 to 10.

From the viewpoint of weather resistance, it is preferable that the EVA resin has a crosslinked structure. As a method for providing a crosslinked structure, it is preferable to add an organic peroxide to EVA resin in advance and then heat it to about 100 to 200 ° C. to crosslink it. As the organic peroxide to be added to the EVA resin, any one can be used as long as it generates a radical at 100 ° C. or higher, but if the stability at the time of compounding is taken into consideration, the decomposition temperature with a half-life of 10 hours is used. Is preferably 70 ° C. or higher, for example, 2,5-dimethylhexane-
2,5-dihydroperoxide; 2,5-dimethyl-2,5-di (t-butylperoxy) hexane-3,
Di-t-butyl peroxide; t-dicumyl peroxide; 2,5 dimethyl-2,5-di (t-butylperoxy) hexane; dicumyl peroxide; α, α ′
-Bis (t-butylperoxyisopropyl) benzene; n-butyl-4,4-bis (t-butylperoxy) butane; 2,2-bis (t-butylperoxy) butane; 1,1-bis ( t-butylperoxy) cyclohexane; 1,1-bis (t-butylperoxy) 3,3
3,5-Trimethylcyclohexane; t-butyl peroxybenzoate; benzoyl peroxide and the like can be used. The blending amount of these organic peroxides is EV
5 parts by weight or less, preferably 1 to 3 parts by weight (100 parts by weight, the same applies hereinafter) to resin A is sufficient.

In the present invention, it is also possible to add a photosensitizer to the EVA resin in advance and decompose it by irradiating it with light to give the EVA resin a crosslinked structure. The photosensitizer used in the present invention may be any as long as it produces a radical upon irradiation with light, for example, benzoin, benzoin methyl ether, benzoin isoethyl ether,
Benzoin isopropyl ether, benzoin isobutyl ether, dibenzoyl, 5-nitriacenaphthene,
Examples include hexachlorocyclopentadiene, paranitrodiphenyl, paranitroaniline, 2,4,6 trinitroaniline, and 1,2-benzanthraquinone. These photosensitizers are 10 parts by weight or less with respect to EVA, preferably 1 to
3 parts by weight is sufficient.

Further, a silane coupling agent may be added to the EVA resin for the purpose of further improving the adhesion between the EVA resin and the back cover and the power generating element. Known silane coupling agents used for this purpose, for example, γ-chloropropyltrimethoxysilane; vinyltrichlorosilane; vinyltriethoxysilane; vinyl-tris (β-methoxyethoxy) silane; γ-methacryloxypropyl. Trimethoxysilane; β- (3,
4-ethoxycyclohexyl) ethyltrimethoxysilane; γ-glycidoxypropyltrimethoxysilane; vinyltriacetoxysilane; γ-mercaptopropyltrimethoxysilane; γ-aminopropyltrimethoxysilane; N-β- (aminoethyl)- γ-aminopropyltrimethoxysilane and the like can be mentioned. The amount of these silane coupling agents to be compounded is 5 parts by weight or less, preferably 0.1 to 2 parts by weight relative to the EVA resin.

Further, by improving the gel fraction of EVA resin,
A crosslinking aid can be added to the EVA resin to improve durability. As the cross-linking aid used for this purpose, known ones include triallyl isocyanurate; trifunctional cross-linking aids such as triallyl isocyanate, and monofunctional cross-linking aids such as NK ester. . The amount of these cross-linking aids is 10 parts by weight or less, preferably 1 to 5 parts by weight, relative to the EVA resin.

Furthermore, in the present invention, EV is selected from hydroquinone, hydroquinone monomethyl ether, p-benzoquinone, methylhydroquinone and the like for the purpose of improving stability.
It can be added in an amount of 5 parts by weight or less relative to the A resin.

In addition to the above, a colorant, an ultraviolet absorber, an antiaging agent, a discoloration preventing agent, etc. may be added, if necessary. Examples of colorants include inorganic pigments such as metal oxides and metal powders, and organic pigments such as azo-based, phthalocyanine-based, achi-based, acidic or basic dye-based lakes. Examples of the ultraviolet absorber include benzophenone-based compounds such as 2-hydroxy-4-octoxybenzophenone and 2-hydroxy-4-methoxy-5-sulfobenzophenone, 2- (2′-).
Benzotriazoles such as hydroxy-5-methylphenyl) benzotriazole, phenyl salsylates, p
There are hindered amines such as -t-butylphenyl salicylate. As the antiaging agent, there are amine type, phenol type, bisphenyl type, hindered amine type, for example, di-t-butyl-p-cresol, bis (2,2,2,2
6,6-tetramethyl-4-piperazyl) sebacate and the like.

In the present invention, a flame retardant containing a halogen atom can be added to the resin to be impregnated, whereby the flame retardancy / nonflammability of the solar cell module can be further improved. Examples of the organic flame retardant used in the present invention include those containing at least one chlorine atom or bromine atom in the molecule, for example, chlorinated paraffin, chlorinated polyethylene, hexachloroendomethylenetetrahydrophthalic acid, perchloropentacyclodecane, Monomers or polymers having an aromatic ring such as tetrachlorophthalic anhydride or tris (2,3-dibromopropyl) isocyanurate and having no halogen atom directly bonded to the aromatic ring, 1,1,2,2 -Tetrabromoethane, 1,4-dibromobutane, 1,3-dibromobutane, 1,5-dibromopentane, ethyl α-bromobutyrate, 1,2,5,6,9,10-hexabromocyclodecane, etc. The thing which does not have an aromatic ring is mentioned. The amount of these flame retardants to be blended is 20 parts by weight or less, preferably 1 to 20 parts by weight, based on 100 parts by weight of the EVA resin.

In this case, in the resin to be impregnated in the present invention, antimony trioxide or expanded graphite can be added as a flame retardant aid to the resin laminated on the non-light-receiving surface side. The addition amount of 10% by weight or less is sufficient. Also,
In the resin to be impregnated in the present invention, an inorganic flame retardant can be added as a flame retardant to the resin laminated on the non-light-receiving surface side. Examples of inorganic flame retardants include aluminum hydroxide,
Examples thereof include inorganic hydroxide salts such as magnesium hydroxide, ammonium phosphate, phosphorus oxides such as zinc phosphate, and red phosphorus.

The method for manufacturing the solar cell module of the present invention is not particularly limited, and the mesh body previously impregnated with the adhesive resin may be laminated with the cell transparent plate and the back cover. Since vacuum laminating is usually applied at the time of production,
As shown in FIGS. 2 and 3, a mesh body 14a and an adhesive resin film 14b are interposed between the cell 11 and the transparent plate 12 and between the cell 11 and the back cover 13, respectively (note that the mesh body 14a Whichever of the resin film 14b and the resin film 14b may be disposed on the cell 11 side) is then vacuum laminated and heated to melt the adhesive resin film 14b, the adhesive resin is impregnated into the mesh body 14a. Thus, a flame-retardant / non-combustible solar cell module can be easily obtained. In this case, if an EVA sealing material film to which an organic peroxide is added is used as the resin film 14b, EVA is simultaneously cross-linked during impregnation heating.

In the above example, the resin-impregnated mesh is interposed between the cell and the transparent plate and between the cell and the back cover, but it is difficult to replace one of them with the resin-impregnated mesh. A flame-retardant adhesive resin encapsulation film can be provided (as the flame-retardant resin encapsulation film in this case, for example, an EVA encapsulant film to which the above-mentioned flame retardant is added. However, it is preferable to dispose the resin-impregnated mesh body on at least the light-receiving surface side (transparent plate side). In this case, the resin-impregnated network on the light-receiving surface side needs to be light transmissive, but the resin-impregnated network on the back cover side is not necessarily required to be light transmissive.

[0022]

EXAMPLES The present invention will be specifically described below by showing Examples and Comparative Examples, but the present invention is not limited to the following Examples.

[Examples, Comparative Examples] As shown in Table 1, EV
An EVA resin composition was prepared by mixing A resin as a main component and each component with a roll mill heated to 80 ° C. A sheet having a thickness of 0.5 mm (150 mm square) was formed from these compositions by a press set at 90 ° C.

[0024]

[Table 1]

Next, the sheets of Examples 1 and 2 were laminated as shown in FIG. That is, in FIG. 3, 11 is a solar cell, 12 is a white glass plate, 13 is a weather resistant back cover, 14a is a glass fiber non-woven fabric (density 75 g / m ² ),
14b is the sheet. This laminated body is pre-compressed with a vacuum laminator (temperature 150 ° C., deaeration 3 minutes, press 3
Minutes) and then heated to 150 ° C. for 30 minutes to prepare an evaluation sample. For comparison, an evaluation sample was prepared in the same manner as above except that the glass fiber nonwoven fabric 14b was not laminated.

As a result, in this example, when the edge of the sample was heated by the gas burner, the EVA resin did not melt. On the other hand, when the same experiment was performed in the comparative example, the EVA resin melted and burned.

Further, using the sheets of Examples 3 and 4, the same lamination as above was carried out, and the sheets were pressure-bonded with a vacuum laminator. The pressure bonding conditions were a set temperature of 150 ° C., a deaeration time of 3 minutes, and a pressing time of 15 minutes. At this stage, the EVA resin was sufficiently crosslinked. As a result of the same test as in Example 1, a partial EV
Although the A resin was found to be dropped, the dropped EVA resin was not burned. Similar results were obtained when chlorinated paraffin (chlorination rate 70%) was used instead of TAIC-6B.

[0028]

According to the present invention, the solar cell module is surely rendered flame-retardant or non-combustible, so that this module can be used as a roofing material.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing an example of a laminated body used for producing a solar cell module.

FIG. 3 is a cross-sectional view showing another example of the same laminate.

FIG. 4 is a cross-sectional view of a conventional solar cell module.

[Explanation of symbols]

 11 Solar Cell 12 Transparent Plate 13 Back Cover 14 Resin Impregnated Mesh

Claims (7)

[Claims] 1. A solar cell comprising a solar cell, a transparent plate and a back cover which cover the solar cell, and one or both of which is provided with a mesh body impregnated with an adhesive resin. Battery module. 2. The solar cell module according to claim 1, wherein the mesh body is a woven or non-woven fabric of inorganic fibers. 3. The solar cell module according to claim 1, wherein the inorganic fiber is glass fiber. 4. The solar cell module according to claim 1, 2 or 3, wherein the adhesive resin is an ethylene-vinyl acetate copolymer or a modified ethylene-vinyl acetate copolymer. 5. The solar cell module according to claim 4, wherein the ethylene-vinyl acetate copolymer or the modified ethylene-vinyl acetate copolymer has a crosslinked structure. 6. The solar cell module according to claim 5, which has a crosslinked structure in which an ethylene-vinyl acetate copolymer or a modified ethylene-vinyl acetate copolymer is crosslinked by heating in the presence of an organic peroxide. 7. The solar cell module according to claim 1, wherein the adhesive resin contains a halogen atom.