JPS5913380A - Solar battery panel - Google Patents

Abstract

PURPOSE:To form the solar battery panel having large intensity in spite of light weight, and enabled to obtain sufficient impact proof strength by a method wherein the solar cells are laminatedly joined on a transparent glass substrate, and a reinforcement layer formed by making inorganic fiber reinforced resin to come in contact therewith in the uncured condition and to hardened is provided. CONSTITUTION:An easily peelable mold release sheet 8 of fluoric resin, etc., is laid in a vessel type frame 7 having the flat base, the solar battery cell sheet 3 is put thereon, uncured liquid polyester resin 9 is applied, glass woven cloth 10 is stacked thereon, and after laminated of resin 9 and glass woven cloth 10 thereof is performed up to obtain the necessary thickness, resin is hardened. After resin is hardened, it is taken out from the frame 7 together with the mold release sheet 8, the mold release sheet 8 is removed, a thin and adhesive resin sheet 11 of a polyvinyl butyral film, etc., to convert transparently and to exhibit adhesion by heating and a cover glass plate 1 are laminated on the light acceptance face side of the solar battery 3, and are joined temporarily by making to pass between rolls, for example. Then the temporarily joined lamination panel thereof is really joined by heating and pressing in an autoclave.

Description

[Detailed description of the invention] The present invention relates to a lightweight and strong solar cell panel.

There are two main structural types of solar panels depending on the form of the solar cell. A large number of small plate-like cells made of silicon ribbon crystals are arranged in a plane, and these cells are connected in parallel or in series using lead wires. In the case of using a thick @battery cell sheet configured by conductive connection to the cell sheet, a transparent resin adhesive film such as polyvinyl butyral is interposed on both sides of the cell sheet, and a transparent glass plate is placed on the light-receiving surface side, and a glass plate or a glass plate is placed on the back side. It has a structure in which metal plates are laminated and joined together.

In addition, in the case of a solar cell using a thin film, a transparent conductive film such as 5NO2 + In2O3 is coated on the surface of the Gans plate serving as a cover glass, and an amorphous silicon thin film and an electrode film are laminated and coated on this conductive film. A structure is adopted in which a glass substrate on which a thick battery made of these thin films is provided is bonded to a glass plate or a metal plate with a resin adhesive layer such as a polyvinyl butyral film interposed therebetween.

All of the solar panels with conventional structures mentioned above have the problem that they are heavy compared to their light-receiving area and require a great deal of labor to install, and the installation mounts are also quite large-scale structures, increasing construction costs. Considering the static load or impact force received during use, such as wind pressure and falling hail, the thickness of the cover glass cannot be made very thin, and a minimum thickness of about 100 gm/m is required. There is a problem in that the light absorption loss due to the iron contained in the photovoltaic material is relatively large, making it difficult to obtain sufficient photoelectric conversion efficiency.

It has also been proposed to use special glass with a lower iron content than normal glass as a cover glass for solar cell panels, but in this case, the manufacturing cost is high and there are also problems with strength. There is a problem in that the thickness of the cover glass is quite thick, which increases the weight of the entire panel.

Furthermore, when using a cell sheet consisting of a large number of arrayed cells as described above, there are gaps between adjacent cells, so when a cover glass is pressure-bonded to this cell sheet through an adhesive resin film during the manufacturing process, the cover If the glass is too thin, stress concentration at the edges of the solar cell will cause it to break.

The present invention solves the above-mentioned conventional problems and is lightweight yet strong, and has a thickness of, for example, 2m/m.
The purpose of the present invention is to provide a novel solar cell panel that can obtain sufficient impact resistance even when using very thin glass such as the following.

In order to achieve the above object, the present invention involves laminating and bonding a thick battery to a transparent glass substrate, and then bringing an inorganic fiber-reinforced resin such as a glass fiber-reinforced resin into contact with the back surface of the solar cell in an uncured state and curing it. According to the above structure, the back side of the solar cell is lined with an inorganic fiber-reinforced resin layer, so the overall weight can be reduced compared to the conventional structure, and the structure can be sufficiently The strength of the glass can be maintained.

In addition, if the solar cell is a thin film type formed on the surface of a cover glass, compressive strain will occur in the surface layer of the cover glass due to contraction when the inorganic fiber reinforced resin hardens, and the inorganic fibers mixed in the resin will shrink. Since tensile force prevents the resin from expanding and restoring, compressive strain remains on the surface layer of the cover glass after the resin hardens, and the presence of this compressive strain greatly improves the cover glass's fracture resistance against tensile stress or impact force. do.

For example, the thickness of the cover glass can be adjusted by the synergistic effect with the strength and hardness of the inorganic fiber reinforced resin itself of the reinforcement layer.
Sufficient strength for practical use can be obtained even if the thickness is made as thin as 2 m/m to 0.7 m/m, making it possible to reduce the weight of solar panels and at the same time reduce the g& It is possible to increase the power generation efficiency per unit area of the solar cell.

In addition, if the solar cell is in the form of a sheet in which cells are arranged and connected, place the solar cell sheet on a flat surface with the light-receiving side facing down and apply uncured fiber-reinforced resin over it, as shown in the examples below. By laminating the resin, the resin enters between the cells, and after curing, the surface of the resin layer between the cells becomes almost flush with the light-receiving surface of the cell.

Therefore, even if a very thin cover glass is pressure-bonded to this light-receiving surface via a thin transparent adhesive layer, the entire light-receiving surface of the cell and the resin layer filling in between are covered with a flat, rigid surface. Since the glass is supported, it is less likely that the cover glass will be damaged during pressure bonding as described above, and at the same time, the uniform rigid surface will be able to withstand wind pressure or impact force applied to the cover glass during use of the solar panel. Trap catch can be stopped and excellent strength can be obtained.

Generally, unsaturated polyester resin is used as the matrix resin of the fiber reinforced resin used as the reinforcing layer in the present invention, but other resins such as Evokia resin may also be used if the hardness and strength after curing are sufficiently high. can.

Moreover, as the inorganic fiber mixed in the reinforcing resin, glass fiber is preferable, but other inorganic fibers such as carbon fiber can also be used.

Furthermore, the fibers in the resin can be mixed in the form of a woven fabric or random filaments.

If the reinforcing resin layer in the present invention is too thin, sufficient strength will not be obtained, so it is desirable that the reinforcing resin layer has a thickness of at least 2 mm or more.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to embodiments shown in the drawings.

FIG. 7 is a cross-sectional view of the solar cell panel according to the present invention,
A cover glass made of a transparent glass plate with a thickness of 11 m/m or less, for example 7 m/m, is covered with a solar cell 3 and a reinforcing layer B made of an inorganic fiber reinforced resin via a transparent adhesive layer made of a transparent resin such as polyvinyl butyral. It has a structure in which they are sequentially laminated and joined together.

Chemically strengthened glass can be used as the transparent glass cover, and a low reflection film such as a siliceous porous layer or a magnesium fluoride coating may be applied to the light-receiving surface.

The solar cell 3 has a sheet shape in which a large number of small plate-like cells l such as silicon ribbon crystals are arranged in a planar manner, and adjacent cells are conductively connected in series or in parallel with lead wires S. It is something.

The fiber-reinforced resin constituting the reinforcing layer B is brought into contact with the back surface 3B of the thick battery 3 in an uncured state, and is then cured and integrally joined by the adhesive force of the resin itself.

The resin layer also penetrates between the thick @Kameike CELTO and its surface is almost flush with the light-receiving surface 3A of the CELTO.

Next, a preferred method for manufacturing a solar cell panel having the above structure will be explained with reference to FIG.

A mold release sheet such as fluororesin that is easy to peel is placed in a container-shaped formwork 7 with a flat bottom, and the solar battery cell sheet 3 is placed on this mold release sheet g. Spray polyester resin 9.

The resin 9 and the glass fiber cloth 10 are applied by brushing or the like, and then the resin 9 and the glass fiber cloth 10 are laminated to a required thickness, and then the resin is cured.

After curing, the release sheet g is taken out from the mold 7, the release sheet is removed, and a polyvinyl butyral film is coated on the light-receiving surface side of the solar cell 3. 1) A thin film that becomes transparent by heat and exhibits adhesive strength The adhesive resin sheet// and the cover glass plate/ are laminated and temporarily joined by passing them between rolls, for example.

Next, the temporarily bonded laminated panels are heated and pressurized in an autoclave at a flow rate of /+0'C or less to be permanently bonded.

The square diagram shows another manufacturing method.

On the secondary side, a release sheet is laid in the formwork 7, and a cover glass plate/adhesive resin sheet// and solar cell cell sheet 3 are sequentially blown onto this release sheet g, and the above-mentioned example is placed on top of this. Similarly, uncured liquid resin and glass fiber cloth are alternately laminated.

After the resin has hardened, it is removed from the mold 7, the release sheet g is peeled off, and the laminate is autoclaved. 'Next, an example of a method for manufacturing a solar cell according to the present invention using a thin film solar cell is shown in the diagram.

In the method of this example, a transparent conductive film /, 2 such as 5n021-n203 is provided on one side of the cover glass plate l, and this film /'2
An amorphous silicon thin film 13 (P, N doping) and an electrode film/41 are coated on top of the substrate IIA.
S is connected and a thin film solar cell 3 is placed on the surface of the cover glass L.
form.

Next, the above-mentioned substrate is placed on the mold release sheet g spread in the mold 7 with the thick @battery 3 side facing up, and from above the uncured unsaturated polyester resin etc. The liquid resin wax and the glass fiber cloth 10 are sequentially laminated.

After the resin has hardened, the mold release sheet g is removed from the mold frame 7, and the mold release sheet is peeled off.

As a result, a transparent cup (-
A solar cell panel is manufactured in which a thin film solar cell 3 is provided on a glass surface, and a reinforcing layer B made of an inorganic fiber reinforced resin bonded to the back surface of the solar cell 3 by the adhesive force of the resin itself is provided. can do.

In the above examples, the reinforcing layer B was formed by alternately laminating glass fiber woven fabric and uncured resin, but filament-shaped glass fibers were mixed in the uncured resin and this mixed resin liquid was sprayed and applied. Alternatively, it may be applied to the back surface of the solar cell.

Further embodiments of the present invention are shown in Figures 1 and 7.

In the example of the Fang Otsu diagram, a moisture permeation prevention sheet /j such as aluminum foil is inserted into the reinforcing layer of fiber-reinforced resin, and in the off diagram example, a moisture permeation prevention sheet /j such as an aluminum plate is reinforced on the outer surface of the reinforcing layer O. This is an example in which the lifespan of the solar cell 3 is improved by stacking the resin layers in an uncured state and then curing them as they are to integrally join them.

In all of the illustrated examples above, the bottom surface of the reinforcing layer B is shown as being flat, but in order to give the panel a large bending rigidity, ribs of fiber-reinforced resin may be integrally molded on the side where the reinforcing layer ≦ the bottom surface.

[BRIEF DESCRIPTION OF THE DRAWINGS] The off view is a sectional view showing one embodiment of the present invention, FIG. 2 is an open plan view, and FIGS. FIG. 1 is a cross-sectional view showing an example step by step, and FIG. 1 is a cross-sectional view showing another manufacturing method example. Figures 5 (a), (b), and (c) are cross-sectional views showing another example of a method for manufacturing the solar cell panel of the present invention, and Figures 5 (a), (b), and (c) show other embodiments of the present invention, respectively. FIG. ／・・・・・・・・・Cover glass ・・・・・・・・・・
Transparent adhesive layer 3... Solar cell l...
River/Selta・・・・Lead line Otsu・・・・・・
Reinforcement layer of fiber reinforced resin Fig. 1 Fig. 2 Fig. 3 Fig. 1 Fig. 4 Factor 5 Fig. 6 Fig. 7

Claims (1)

[Claims] ■) A solar cell is laminated and bonded to a transparent glass substrate, and a reinforcing layer formed by contacting and curing an inorganic fiber-reinforced resin in an uncured state is provided on the back surface of the solar cell. and solar panels. 2. A solar cell panel according to claim 5, wherein the thickness of the transparent glass substrate is Jm7m or less. 3) A solar cell panel according to claim 5, wherein the reinforcing layer made of inorganic fiber reinforced resin has a thickness of 2 m/m or more. 4) A solar cell panel according to claim 5, wherein the solar cell is formed of a thin film of amorphous silicon or the like provided on a glass substrate surface with a transparent conductive film interposed therebetween. 5) In Claims E/C, a solar cell is made up of a cell sheet made up of a large number of cells such as silicon ribbon crystals arranged in a plane and electrically connected to each other, and is transparent to a transparent glass substrate. Solar cell panels are bonded together via a resin adhesive layer. 6. The solar cell panel according to claim 6, wherein a resin constituting the reinforcing layer fills spaces between adjacent solar cells, and the resin surface is substantially flush with the light-receiving surface of the cell.