JPH11195804A - Solar battery module, its production and its execution method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve long-term realiability of electrical joint part of an earth part and enhance bending workability, by partly connecting an earth member in a flexible state with a conductive reinforcing material provided on the non- light receiving surface side of a photovoltaic element. SOLUTION: An earth member 107 is electrically connected to the rear surface side of a conductive reinforcing material 104, and on the conductive reinforcing material 104, a filling material 102 as an adhesive layer, an insulation film 106, a filling material 102 for filling the adhesive layer and photovoltaic element 101, a photovoltaic element 101, a holding material 105 for filling material, a filling material 102 for sealing the photovoltaic element 101, and a covering material 103 for the uppermost surface are piled up in sequence, and then they are evacuated and heated to be integrally formed. Next, an excessive projecting part 108 of the filling material is cut out, thereby producing a solar battery module having an electric connection part 110 to the earth member 107. The earth member 107 is connected partly in flexible state with the conductive reinforcing material 104.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technology for earth connection of a solar cell module having an outer conductor, and more particularly to a solar cell module for realizing a highly reliable earth connection, and a method for manufacturing and installing the same.

[0002]

2. Description of the Related Art In recent years, awareness of environmental problems has been increasing worldwide. Above all, the fear of global warming caused by CO ₂ 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] There are various types of solar cells. Representative examples include (1) crystalline silicon solar cells, (2) polycrystalline silicon solar cells, (3) amorphous silicon solar cells, (4) copper indium selenide solar cells, and (5) compound semiconductor solar cells. Among these, thin-film crystalline silicon solar cells, compound semiconductor solar cells, and amorphous silicon solar cells can be made relatively large in area at relatively low cost. Among these solar cells, thin-film solar cells, typically amorphous silicon solar cells in which silicon is deposited on a conductive substrate and a transparent conductive layer is formed thereon, are lightweight, shock-resistant, and flexible. Because of its rich nature, it is promising as a future module form.

[0004] Such a thin-film solar cell having a light weight can be applied to various uses. For example, there is a so-called roof building material integrated type in which a solar cell module can be used as a roof material of a building. FIG. 9 is a schematic view of a conventional roof building material integrated type solar cell module.

FIG. 9A is a view showing a state in which a solar cell module is fixed to a gantry member as a roof material.
FIG. 9B is a diagram illustrating a combination part of the solar cell module on the gantry member. In FIG. 9, reference numeral 901 denotes a photovoltaic element; 902, a filler; 903, an outermost surface covering material;
04 is a conductive reinforcing material, 905 is a filler holding material, 906 is an insulating film, and 907 is a gantry member. As shown in FIG. 9B, the solar cell module has a conductive reinforcing material, a filler for covering the photovoltaic element on the conductive reinforcing material, and an insulating material for electrically insulating the photovoltaic element and the conductive reinforcing material. It is composed of a film, a photovoltaic element, a filler holding material, and a top surface coating material. By bending the material covering the photovoltaic element in this configuration, that is, the filler and the insulating film, the filler holding material, and the outermost covering material, by bending the solar cell module,
Can be used as roofing material. Such a solar cell module has a beautiful appearance and can handle the solar cell module itself as a metal roofing material, eliminating the need for a dedicated mounting member for the solar cell module and reducing costs. Expectations are great.

The above-described solar cell module has a structure in which a photovoltaic element is formed on a conductive reinforcing material, and has a shell conductor portion, that is, a conductive reinforcing material. The conductive reinforcement must be grounded.

The solar cell module shown in FIG.
As shown in the dotted line in (b), the tip of the bent portion of the gantry member and the conductive reinforcing material of the solar cell module come to be combined, and the tip of the gantry member comes into contact with the conductive reinforcing material so as to abut. It has been confirmed that the mount member and the conductive reinforcing material of the solar cell module are electrically connected. And the base member is connected to ground (not shown)
Thereby, the conductive reinforcing material of the solar cell module can be grounded.

However, in the above structure, there has been a demand for a more reliable grounding structure which can more positively connect the conductive reinforcing material to the ground, and which is more reliable for long-term outdoor installation.

[0009]

SUMMARY OF THE INVENTION The present invention relates to a grounding structure for a solar cell module, in which the reliability of the electrical connection of the grounding part in long-term outdoor installation has been improved or the grounding member has a grounding member. It is an object of the present invention to provide a solar cell module having improved bending workability in a state where the solar cell module is present, a method for manufacturing the same, and a method for constructing the same.

[0010]

Means for Solving the Problems The inventor of the present invention has conducted intensive research and development to solve the above-mentioned problems, and as a result, the present invention has the following structure.

That is, a first aspect of the present invention is that at least a photovoltaic element, a conductive reinforcing material disposed on a non-light-receiving surface side of the photovoltaic element, A solar cell module having a filler for fixing on a conductive reinforcing material, comprising a ground member partially joined to the conductive reinforcing material in a flexible state. In the battery module.

[0012] The first solar cell module of the present invention further has a feature that "the ground member is flat" and "the ground member is joined to an end of the conductive reinforcing member. "The ground member is
It is bonded to the conductive reinforcing material in a planar manner,
"The joint between the conductive reinforcing material and the earth member is covered with the filler", "the earth member is made of stainless steel", "the filler is a hot melt material", "The outermost surface on the light-receiving surface side of the photovoltaic element is covered with a weather-resistant transparent film" and "The photovoltaic element is an amorphous silicon-based material formed on a stainless steel substrate." , "Having flexibility", "being bent", and "used as a roofing material".

A second aspect of the present invention is that at least a photovoltaic element, a conductive reinforcing material disposed on a non-light-receiving surface side of the photovoltaic element, and sealing the photovoltaic element, In a method for manufacturing a solar cell module formed by integrally molding a filler for fixing on a conductive reinforcing material, a ground member is partially added to the conductive reinforcing material in advance with a flexibility. And then performing the integral molding process after joining to the solar cell module.

[0014] The second manufacturing method of the present invention is further characterized in that "the ground member is flat" and "the ground member is joined to the end of the conductive reinforcing member". "The ground member is planarly bonded to the conductive reinforcing member", "The bonding of the ground member to the conductive reinforcing member is performed by laser welding or resistance welding," Stainless steel "," the filler is a hot melt material ", and" by performing the integral molding process, the joint between the conductive reinforcing material and the ground member is covered with the filler. "", When performing the integral molding process, dispose a weather-resistant transparent film on the outermost surface on the light receiving surface side of the photovoltaic element", "the photovoltaic element is formed on a stainless steel substrate Was done Is a crystalline silicon-based "it,
"The solar cell module has flexibility",
"Bending after the integral molding process is performed".

A third aspect of the present invention is the first aspect of the present invention.
A solar cell module installation method, wherein the ground member is fixed to a conductive gantry member on which the solar cell module is installed, and the conductive gantry member is grounded. It is in.

The third construction method of the present invention further has a feature that "the ground connection of the conductive mounting member is
It is performed through a conductive structural material of a building to which the conductive gantry member is fixed. '', `` Installing the solar cell module on the conductive gantry member laid on a roof base material, Forming an air flow passage between the solar cell module and the roof base material ".

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is an example of a schematic view when a ground structure of a solar cell module according to the present invention is manufactured. FIG. 1 (a) shows an example in which a conductive reinforcing material and a ground member are electrically joined. FIG. 1 (b) is a cross-sectional view of the ground structure of the solar cell module after integral molding processing, and FIG. 1 (c) is a cross-section after trimming the solar cell module of FIG. 1 (b). FIG. 1 (d) is a perspective view of a planar solar cell module having an electrical junction with a ground member,
FIG. 1E is a perspective view of the solar cell module after the last bending. In FIG. 1, 101 is a photovoltaic element, 102 is a filler, 103 is an outermost surface covering material, 104 is a conductive reinforcing material, 105 is a filler holding material, 106 is an insulating film, 107 is a ground member, and 108 is a filler. The protrusion of the material, 109 is a trimming position, and 110 is an electrical joint.

As shown in FIG. 1, by integrally molding the solar cell module, the filler 102 constituting the solar cell module flows out (filler protrusion 108), and the conductive reinforcing member 104 and the ground member 107 are separated. Electrical joint 1
10 is covered with a filler 102.

In the manufacturing method, first, as shown in FIG. 1A, a ground member 107 is electrically connected to the back surface of the conductive reinforcing member 104. Next, a filler 102 as an adhesive layer on the conductive reinforcing material 104, then an insulating film 106, and a filler 10 for filling the adhesive layer and the photovoltaic element 101.
2. Photovoltaic element 101 and filler holding material 10
5. The filler 102 for sealing the photovoltaic element 101 and the outermost covering material 103 are laminated in this order, evacuated, heated, and integrally molded (FIG. 1B). Next, trimming position 1
At 09, the protrusion 108 of the filler is cut (FIG. 1).
(C)), a planar solar cell module having an electrical joint 110 with the ground member 107 can be manufactured (FIG. 1).
(D)). Thereafter, the solar cell module is bent as shown in FIG.

Next, a structure for connecting the conductive reinforcing material of the solar cell module to ground will be described. FIG. 7 is a view for explaining a structure for connecting the conductive reinforcing material to the ground. Reference numeral 701 denotes a photovoltaic element, 702 denotes a filler, 703 denotes an outermost surface covering material, 704 denotes a conductive reinforcing material, and 705 denotes a conductive reinforcing material. Is a filler holding material, 706 is an insulating film, 707 is a ground member,
708 is a screw / nut for fixing the ground member and the gantry member, 709 is a screw / nut for fixing the gantry member and the metal roof structure material, 710 is a metal roof structure material, and 711 is a gantry member. is there. As shown in FIG. 7, the grounding member 707 electrically connected to the conductive reinforcing member 704 is fixed to the gantry member 711, and the gantry member 711 is fixed to the metal roof structural member 710 to form the conductive reinforcing member 7.
04 can be electrically connected to the metal roof structural member 710. Generally, the metal roof structural material 710 is fixed to the structural material of the building, and the structural material (metal column) of the building is anchored deep underground, so that the metal roof structural material 710 is grounded. It is connected. In this way, the conductive reinforcing member 704 of the solar cell module can be grounded via the gantry member 711 and the roof structural member 710.

In the structure shown in FIG. 7, when there is no metal structural material under the gantry member 711, a cable in which a round terminal is connected is prepared, and the round terminal portion is directly attached to the gantry member 711. The ground wire can be drawn indoors and electrically grounded like the cable wire of the solar cell module output.

When the solar cell module of the present invention is used as a solar cell integrated roof material, it can be constructed as a part of a house air circulation device as shown in FIG. 8, for example. Specifically, by installing the solar cell integrated roof material 802 on a conductive gantry member (not shown) laid on the roof base material 803, the solar cell integrated roof material 8
An air passage can be formed between the base material 02 and the roof base material 803.

The arrows in FIG. 8 indicate the flow of air.
The outside air taken in from the eaves section 801 passes through a space 804 between the solar cell integrated roofing material 802 and the roof underlaying material 803, and is taken in from the ridge 805 into the room. A fan F is provided in the middle of the air flow passage to circulate air.
In the cold season, the air warmed in the space 804 is taken in, and in the hot season, it is discharged to the outside through the exhaust port 806 to enhance the heat insulation performance of the roof. When the air warmed in the space 804 is introduced under the floor, it is preferable to form a heat storage tank under the floor.

The electric power generated by the solar cell integrated roofing material 802 is introduced indoors from the ridge, converted by the inverter I, and consumed by the load L such as an electric light. Inverter I may have a function of linking with system power E.

Next, each material constituting the solar cell module of the present invention will be described in detail.

[Photovoltaic 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 substrate.
FIG. 2 shows a schematic configuration diagram as an example, in which 201 is a conductive substrate, 202 is a metal electrode layer, 20
3 is a semiconductor photoactive layer, 204 is a transparent conductive layer, and 205 is a current collecting electrode.

The conductive substrate 201 serves as a substrate for the photovoltaic element and also serves as a lower electrode. Materials include silicon, tantalum, molybdenum, tungsten,
Examples include stainless steel, aluminum, copper, titanium, carbon sheets, lead-plated steel sheets, resin films having a conductive layer formed thereon, and ceramics. On the conductive substrate 201, a metal layer, a metal oxide layer, or a metal layer and a metal oxide layer may be formed as the metal electrode layer 202. For example, Ti, Cr, Mo, W, A
For example, ZnO, TiO ₂ , SnO _2, etc. are used for the metal oxide layer. Examples of a method for forming the metal layer and the metal oxide layer include a resistance heating evaporation method, an electron beam evaporation method, and a sputtering method.

The semiconductor photoactive layer 203 is a portion where photoelectric conversion is performed, and specific materials include pn junction type polycrystalline silicon, pin junction type amorphous silicon, and CuIn.
Se 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, 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. Plating, ion beam deposition, vacuum deposition,
There are a sputtering method and an electrodeposition method.

The transparent conductive layer 204 serves 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 (I
TO), ZnO, TiO ₂ , Cd ₂ SnO ₄ , and a crystalline semiconductor layer doped with a high concentration of impurities. Examples of the forming method include resistance heating evaporation, sputtering, spraying, and CVD.
And an impurity diffusion method.

On the transparent conductive layer 204, in order to efficiently collect current, a grid-like current collecting electrode 205 (grid)
May be provided. As a specific material of the current collecting electrode 205, for example, Ti, Cr, Mo, W, Al, Ag, N
i, Cu, Sn, or a conductive paste such as a silver paste. As a method for forming the current collecting electrode 205, 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 on the entire surface, and a patterning method using a photo-CVD method are used. There are a method of forming a current collector electrode pattern, a method of forming a negative pattern mask of a current collector 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 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.

In general, when a solar cell module is installed, it is desired that the solar cell module be lightweight from the viewpoint of workability. In addition, there is an increasing need for a solar cell module that is integrated with a roofing material or that is installed on an outer wall of a building, and a flexible solar cell module is required to be bent or installed on a curved surface. On the other hand, an amorphous silicon photovoltaic device formed on a stainless steel substrate is very suitable. That is, the photovoltaic element itself can be considerably thinned, and the thickness of the photovoltaic element including the substrate is 0.1 mm.
Because the thickness can be reduced to about 1 mm, the amount of the filler for sealing the photovoltaic element can be reduced. As a result, the weight of the solar cell module can be reduced, and the thickness can be reduced. If the thickness can be reduced, the stress on the surface covering material when the solar cell module is bent can be reduced. Cracking of the coating material can be controlled for tension, and twisting of the coating material for shrinkage can be suppressed. Further, since the solar cell module is formed on a stainless steel substrate and has flexibility, unnecessary rigidity is not required for the solar cell module, so that the thickness of the module can be reduced. As a result, it is flexible, suitable for bending, and can be reduced in weight.

Thus, it can be seen that an amorphous silicon-based photovoltaic element formed on a stainless steel substrate is most suitable for the photovoltaic element.

[Outermost surface coating material] The outermost surface coating material is required to have a light-transmitting property and weather resistance and to be hardly stained. When glass is used as a material, there is a problem that a filling failure occurs unless the filler is thick. Further, when glass is used, there is a problem that not only the weight is increased but also the glass is easily broken by an external impact. Also, the use of the solar cell module as a roofing material is expanding. When the solar cell module is used as a roofing material, the solar cell module itself is bent and processed, so that the outermost surface needs to be a flexible material.

For the above reasons, a weather-resistant transparent film is preferably used as the outermost surface coating material. By using the 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, there is also an effect that the surface reflection of sunlight is not dazzling.

As the material, a fluororesin film such as polyethylene tetrafluoroethylene (ETFE), polytrifluoroethylene, and polyvinyl fluoride can be used, but the material 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.

[Filler] In the present invention, the filler is used for sealing the photovoltaic element and fixing the photovoltaic element on the conductive reinforcing material. It is possible to cover the electrical joint between the conductive reinforcing material and the earth member.

The 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
Transparent resins such as (ethylene ethyl acrylate), EMA (ethylene methyl acrylate), EBA (ethylene butyl acrylate), acrylic acid, urethane resin, and PVA (polyvinyl alcohol) can be used, but are not limited thereto. Absent. Further, in order to suppress light deterioration, it is desirable that an ultraviolet absorber is contained.

[Conductive reinforcing material] The conductive reinforcing material functions as a covering material on the rearmost side of the solar cell module or as a reinforcing material for the solar cell module. As the material, for example, a plated steel plate such as a galvanized steel plate and a galvalume steel plate can be used in addition to an aluminum plate and a stainless steel plate, but is not limited thereto. In the roof-integrated solar cell module, by bending the conductive reinforcing material, the solar cell module can be handled in the same manner as a general metal roof material.

[Filling Material Retaining Material] On the light incident side of the photovoltaic element of the solar cell module, in addition to the purpose of holding the filling material so as not to flow out during the integral molding process of the solar cell module, the photovoltaic device Used to protect the device from external scratching. The material may be, for example, a woven or non-woven fabric of a polymer resin such as glass or polypropylene, but is not limited thereto.

[Insulating film] Used for maintaining electrical insulation between the photovoltaic element and the conductive reinforcing material. The filler alone has insulation properties, but its thickness varies,
In a thin portion or a pinhole portion, a short circuit may occur between the photovoltaic element and the conductive reinforcing material. Insulating film is used to prevent it.
As the material, a material that can secure sufficient electrical insulation, has excellent long-term durability, and has flexibility that can withstand thermal expansion and thermal contraction is preferable. Nylon, polyethylene terephthalate (PE
T).

[Earth Member] The electrically conductive reinforcing member constituting the solar cell module is electrically connected to the electrically conductive reinforcing member for the purpose of earth connection. Since such a grounding member is partially joined to the conductive reinforcing member in a flexible state, the end opposite to the side joined to the conductive reinforcing member is fixed to the gantry member or the gantry member. It can be easily electrically connected to a member connected to the ground such as a metal column. As the connection method, for example, by drilling a hole in the ground member, a bolt is passed through the hole, and the bolt ~ toothed washer ~
It can be electrically connected by tightening and fixing with a nut.

As a joining method with the conductive reinforcing material, resistance welding, laser welding, or the like can be used. When a metal plate is used for the grounding member, the material is preferably stainless steel in consideration of the influence of corrosion.

When an insulated wire is used, the internal copper wire is liable to corrode. Therefore, it is necessary to perform processing such as sealing with a sealant so that the internal copper wire is not exposed as much as possible.

The shape of the grounding member is desirably a flat plate so as to be integrally molded with the conductive reinforcing material in the manufacturing process and then to perform an integral molding process. The reason is that the solar cell module needs to be formed into a sheet shape (plate shape) at the time of the integral molding process, so that the shape needs to be close to the sheet shape. Therefore, it is desirable that the ground member has a flat plate shape having no unevenness or having no locally thick portion. When the solar cell module is treated as a roof-integrated building material, the integrated solar cell module is bent. In this case, it is convenient if the ground member previously attached is flat. The bending process is performed by, for example, roller forming, bender, press, etc., but if the ground member is a flat plate, the interference with the processing machine is extremely small, and the solar cell module is formed in the same manner as that having no ground member. Can be handled. Therefore, the ground member is preferably a flat plate.

[Bending] There is no particular limitation, but, for example, roller forming, pressing and bender bending can be performed as bending, and a conventional metal roofing machine can be used as it is.

[0046]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on embodiments.

Example 1 First, amorphous silicon (a-
An Si) -based photovoltaic element was manufactured. The manufacturing procedure will be described with reference to FIG.

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 electrode layer, and 305 denotes a current collecting electrode. On the cleaned stainless steel substrate 301, an Al layer (film thickness: 5000 °) as a back metal electrode layer 302 by a sputtering method.
And a ZnO layer (thickness 5000 °) are sequentially formed. Then, SiH ₄ , PH _3, and H ₂ were formed by plasma CVD.
, An i-type a-Si layer from a mixed gas of SiH ₄ and H ₂ , SiH ₄ , BF ₃ and H ₂
A p-type microcrystalline a-Si layer is formed from a mixed gas of
n-layer thickness 100 ° / i-layer thickness 800 ° / p-layer thickness 100
The tandem type a-Si based photoelectric conversion semiconductor layer 3 having the layer structure of Å
03 was formed. Next, as the transparent electrode layer 304, In
_{A 2} O ₃ thin film (thickness: 700 °) was formed by depositing In by a resistance heating method in an O ₂ atmosphere.

On this, the current collecting electrode 305 was formed by pattern-printing silver paste with a screen printer and drying.

Next, a step of laminating the above-prepared photovoltaic element with a covering material will be described with reference to FIG.

FIG. 4 is a schematic diagram for explaining the manufacturing steps of the solar cell module according to the present embodiment from bonding of the earth member to lamination to finishing. FIG. 4A is a schematic view for explaining the joining between the conductive reinforcing material and the ground member, and FIG.
FIG. 4B is an end cross-sectional view for explaining lamination of materials for the integral molding process, FIG. 4C is an end cross-sectional view of the solar cell module after the integral molding process, and FIG. FIG. 4E is an overall view of the solar cell module after bending.

In FIG. 4, reference numeral 401 denotes a photovoltaic element;
02 is a filler, 403 is an outermost surface covering material, 404 is a conductive reinforcing material, 405 is a filler holding material, 406 is an insulating film, 407 is a ground member, 408 is a protrusion of the filler,
409 is a trimming position, and 410 is an electrical joint.

First, the ground member 40 is added to the conductive reinforcing material 404.
7 was joined by laser welding. Conductive reinforcing material 404
Is a galvalume steel plate (manufactured by Nisshin Steel, trade name: galbuster, 0.4 mm thick), and 0.1 mm is used for the ground member 407.
SUS304 having a thickness (size 15 mm width × 150 mm length) was used. Laser welding is made by Miyachi Technos Y
Using an AG laser, welding conditions are: output: 3 ~
5J, spot diameter: 0.4 mm, pulse: 3 pulse
/ Sec. As shown in FIG. 4 (a), the end of the conductive reinforcing material 404 and the end of the ground member 407 are overlapped with each other and welded at about 5 mm from the end in the width direction of the ground member. did. At this time, the coating film on the welded portion of the conductive reinforcing material was peeled off, and the peeled surface was polished before welding.

Next, the integral molding process will be described.
As shown in FIG. 4B, the conductive reinforcing material 404, the filler 402, the insulating film 406, and the ground member 407 welded thereto.
Filler 402, photovoltaic element 401, filler holding material 40
5, the filler 402, and the outermost surface covering material 403 were laminated in this order. Next, the material was heated to 160 ° C. in a state of being evacuated, and heat was applied to the filler 402 to cure it, thereby performing an integral molding process. The filler 402 is made of EVA (ethylene-vinyl acetate copolymer weatherproof grade, manufactured by Bridgestone Corporation, 46
0 μm), and the outermost surface coating material 403 is a fluororesin film (ethylene tetrafluoroethylene, 50 μm thick, manufactured by Daikin, trade name: NEOFRON EF-0050SB)
1) The glass fiber nonwoven fabric (Glasper GMC-00-040 (B), manufactured by Oji Paper) was used as the filler holding material 405, and the PET (Lumirror S50, manufactured by Toray) was used as the insulating film.

FIG. 4C is a cross-sectional view of the end of the solar cell module after the integral molding process, in which the filler 402 flows out (the flowing filler 408), and the conductive reinforcing material 404 and the ground member. 407 can be covered with the electrical junction 410. Then, as shown in FIG. 4D, the position of the end of the conductive reinforcing material 404, that is, the trimming position 409 is set.
Then, the protruding filler 408 was trimmed.

Finally, bending was performed using a roller former to complete a roofing-integrated solar cell module as shown in FIG. 4 (e).

As described above, since the conductive reinforcing member is electrically connected to the ground member before the integral molding process of the solar cell module, the electric joint portion is covered with the filler by the integral molding process. can do. Further, since the grounding member is flat, it can be formed in the same plane as the solar cell module, and the solar cell module can be formed into a sheet when integrally molded, which is convenient in the process. In addition, since the ground member has a flat plate shape, it can be processed without interfering with the machine during bending.

(Embodiment 2) FIG. 5 is a schematic view for explaining the joining between the conductive reinforcing member and the earth member according to the second embodiment of the present invention. Is shown. In FIG. 5, reference numeral 501 denotes a conductive reinforcing material;
2 is a ground member, and 503 is an electrical joint. Laser welding was performed in the same manner as in Example 1, except that the cross section of the end of the ground member 502 was applied to the cross section of the end of the conductive reinforcing member 501 as shown in FIG. Except for this, it was produced in the same manner as in Example 1.

As described above, by welding the ground member 502 to the end of the conductive reinforcing member 501 and welding it, there is no need to peel off the coating film of the conductive reinforcing member 501, and the manufacturing process of the ground structure is simplified. Can be

(Embodiment 3) FIG. 6 is a schematic view for explaining the connection between the conductive reinforcing member and the ground member according to the third embodiment of the present invention. FIG. FIG. 6 (b) is a schematic view of the joining of the members, and FIG. 6 (b) is a schematic view after bending the ground member. In FIG. 6, 601 is a conductive reinforcing material, 602 is a grounding member, and 603 is an electrical joint. Laser welding was performed in the same manner as in Example 1, but FIG.
As shown in (a), the ground member 602 was welded to the cross section of the end of the conductive reinforcing material 601 vertically. After welding, in order to make the solar cell module into a sheet shape, FIG.
As shown in (b), the ground member 602 was bent into a flat plate shape, and the next step of lamination was performed. Except for this, it was produced in the same manner as in Example 1.

As described above, the ground member 602 is perpendicularly applied to the end of the conductive reinforcing member 601 and is welded.
Positioning is simplified, and workability during welding of the ground member is improved. Further, similarly to the second embodiment, the conductive reinforcing material 60
It is not necessary to peel off one coating film, and the manufacturing process of the ground structure can be simplified.

Example 4 In Example 1, the joining between the conductive reinforcing material and the earth member was performed by resistance welding instead of laser welding. In the same manner as in Example 1, the ends of the conductive reinforcing material and the ground member were overlapped so as to be aligned, and the coating of the conductive reinforcing material at the joint was peeled off and soldered. When it was peeled off, it was manufactured without performing the polishing treatment on the peeled surface. Resistance welding is performed by Seiwa Micro Spot Welder MCW-15.
00, and the joining conditions were 5 msec. 300x with electricity
The test was performed at 10 mV. Except for this, it was produced in the same manner as in Example 1.

In the resistance welding, a current is applied by applying a mechanical pressure between the joining materials, so that the joining surface can be welded without any particular polishing treatment, and the welding can be performed relatively easily.

[0064]

As described above, according to the present invention, the following effects can be obtained. (1) In the solar cell module of the present invention, the ground member is partially joined to the conductive reinforcing member while having flexibility, thereby connecting the ground member such as the gantry member and the metal pillar for fixing the gantry member. Electrical connection can be easily and surely made to the member, and a highly reliable ground connection can be realized. (2) In particular, by using a flat earth member,
When the solar cell module is bent in a later step, the ground member does not interfere with the molding machine, and the bending property is improved. (3) In particular, in the case where the electrical joint between the conductive reinforcing material and the earth member is covered with the filler, the long-term reliability of the electrical joint at the joint is improved. (4) In the method of manufacturing a solar cell module according to the present invention, the grounding member is bonded to the conductive reinforcing member before the integral molding, so that the joint is covered with the filler during the integral molding process. And a more reliable ground structure can be relatively easily manufactured. (5) In the method for constructing a solar cell module according to the present invention, a highly reliable earth connection can be realized very easily by connecting an earth member previously joined to the conductive reinforcing member to the conductive gantry member. can do.

[Brief description of the drawings]

FIG. 1 is a schematic diagram for explaining an example of a method for manufacturing a solar cell module according to the present invention.

FIG. 2 is a schematic configuration diagram of a photovoltaic element constituting the solar cell module of the present invention.

FIG. 3 is a schematic configuration diagram of a photovoltaic element constituting the solar cell module of Example 1.

FIG. 4 is a schematic diagram for explaining an example of a method for manufacturing a solar cell module of Example 1.

FIG. 5 is a schematic diagram for explaining joining of a conductive reinforcing material and an earth member according to a second embodiment.

FIG. 6 is a schematic diagram for explaining joining of a conductive reinforcing material and a ground member according to a third embodiment.

FIG. 7 is a schematic view showing a state where the solar cell module of the present invention is fixed to a gantry member as a roof material.

FIG. 8 is a schematic diagram showing an example in which the solar cell module of the present invention is used as a roof material and applied to an air circulation device.

FIG. 9 is a schematic view showing a state in which a conventional solar cell module is fixed to a gantry member as a roof material.

[Explanation of symbols]

101, 401, 701, 901 Photovoltaic element 102, 402, 702, 902 Filler 103, 403, 703, 903 Top surface coating 104, 404, 501, 601, 704, 904 Conductive reinforcing material 105, 405 705, 905 Filler holding material 106, 406, 706, 906 Insulating film 107, 407, 502, 602, 707 Ground member 108, 408 Filler protrusion 109, 409 Trimming position 201, 301 Conductive base 202, 302 Metal electrode Layers 203, 303 Semiconductor photoactive layers 204, 304 Transparent conductive layers 205, 305 Current collecting electrodes 110, 410, 503, 603 Electrical joints 708, 709 Screws / nuts 710 Metal roof structural materials 711, 907 Mounting members 801 Part 802 Solar cell integrated roofing material 8 03 Roofing material 804 Space 805 Building 806 Exhaust port

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Meiji Takabayashi 3-30-2 Shimomaruko, Ota-ku, Tokyo Inside Canon Inc.

Claims (27)

[Claims] At least a photovoltaic element, a conductive reinforcing material disposed on a non-light receiving surface side of the photovoltaic element, and sealing and fixing the photovoltaic element on the conductive reinforcing material A solar cell module comprising: a filler member for performing the following: a solar cell module, comprising: a ground member partially joined to the conductive reinforcing member in a flexible state. 2. The solar cell module according to claim 1, wherein the ground member has a flat shape. 3. The grounding member according to claim 1, wherein the grounding member is joined to an end of the conductive reinforcing member.
A solar cell module according to item 1. 4. The ground member is planarly joined to the conductive reinforcing member.
A solar cell module according to any one of the above. 5. The solar cell module according to claim 1, wherein a joint between the conductive reinforcing material and the ground member is covered with the filler. 6. The solar cell module according to claim 1, wherein the ground member is made of stainless steel. 7. The solar cell module according to claim 1, wherein the filler is a hot melt material. 8. The solar cell module according to claim 1, wherein the outermost surface on the light receiving surface side of the photovoltaic element is covered with a weather-resistant transparent film. 9. The solar cell module according to claim 1, wherein said photovoltaic element is made of amorphous silicon based on a stainless steel substrate. 10. The solar cell module according to claim 1, wherein the solar cell module has flexibility. 11. The solar cell module according to claim 10, wherein a bending process is performed. 12. The solar cell module according to claim 1, which is used as a roof material. 13. At least a photovoltaic element, a conductive reinforcing material disposed on a non-light-receiving surface side of the photovoltaic element, and sealing and fixing the photovoltaic element on the conductive reinforcing material. A method for manufacturing a solar cell module, which is formed by integrally molding a filler material for forming a ground member, wherein a ground member is partially joined to the conductive reinforcing member in advance in a state of having flexibility, and then the integrated member is formed. A method for manufacturing a solar cell module, comprising performing a molding process. 14. The method according to claim 13, wherein the ground member has a flat shape. 15. The grounding member is joined to an end of the conductive reinforcing member.
3. The method for manufacturing a solar cell module according to item 1. 16. The ground member is planarly joined to the conductive reinforcing material.
The method for manufacturing a solar cell module according to any one of the above. 17. The method for manufacturing a solar cell module according to claim 13, wherein the bonding of the ground member to the conductive reinforcing member is performed by laser welding or resistance welding. 18. The method according to claim 13, wherein the ground member is made of stainless steel. 19. The method for manufacturing a solar cell module according to claim 13, wherein said filler is a hot melt material. 20. By performing the integral molding process,
The joint between the conductive reinforcing material and the ground member is covered with the filler.
10. The method for manufacturing a solar cell module according to any one of 9 above. 21. A weather-resistant transparent film is provided on the outermost surface on the light-receiving surface side of the photovoltaic element when performing the integral molding process. Of manufacturing a solar cell module. 22. The method for manufacturing a solar cell module according to claim 13, wherein said photovoltaic element is made of amorphous silicon based on a stainless steel substrate. 23. The method according to claim 13, wherein the solar cell module has flexibility. 24. The method for manufacturing a solar cell module according to claim 23, wherein bending is performed after performing the integral molding process. 25. The method for constructing a solar cell module according to claim 1, wherein the grounding member is fixed to a conductive mounting member on which the solar cell module is installed, and the conductive mounting member is provided. A method for constructing a solar cell module, comprising: 26. The ground connection of the conductive mounting member,
The method according to claim 25, wherein the method is performed via a conductive structural material of a building to which the conductive mounting member is fixed. 27. The method according to claim 27, wherein the solar cell module is installed on the conductive mounting member laid on a roof base material, and an air flow passage is formed between the solar cell module and the roof base material. The method for constructing a solar cell module according to claim 25 or 26.