KR20240100049A - Shingled solar module structure and manufacturing method of high-durability and light-weight - Google Patents

Abstract

Front covers and back sheets made of films with long-term reliability are applied to the roof of existing buildings, facades and balconies, soundproof walls, solar power facilities mounted on vehicles, agricultural solar power generation facilities, or floating solar power facilities. It relates to a shingled solar module structure and manufacturing method prepared to have durability and high lightness, comprising a solar panel with a shingled array structure, a first sealant laminated on the top of the solar panel to protect the solar panel, and sunlight transmitting. a front cover laminated on the top of the first sealant to improve the flexibility of the solar module and protect the first sealant, a second sealant laminated on the bottom of the solar panel to protect the solar panel, and external environment It includes a backsheet laminated on the lower part of the second sealant to protect the solar panel from the sun, the front cover is made of a highly durable and lightweight multi-layered transparent film, and the backsheet is a multi-layered film. It is possible to realize high durability and light weight of shingled solar modules.

Description

Shingled solar module structure and manufacturing method of high-durability and light-weight}

The present invention relates to a highly durable and lightweight shingled solar module structure and manufacturing method, particularly for roofs, facades and balconies of existing buildings, soundproof walls, solar power facilities mounted on vehicles, and agricultural solar power generation. This relates to a shingled solar module structure and manufacturing method that is designed to have high durability and light weight by applying a front cover and back sheet made of a film with long-term reliability to facilities or floating solar power facilities.

In general, solar power generation refers to solar cell modules (photovoltaic modules) that directly produce electricity using sunlight. Solar cell modules consist of an outer glass material, solar cells encapsulated in generally transparent protective packaging, and a backsheet on the back. ) is composed of. Solar cells are made of materials containing silicon, CIS (cadmium indium selenide), CIGS (cadmium indium galliumselenide), and quantum dots for solar energy capture.

Since solar cell modules are used outdoors, high durability and weather resistance are required in their composition and material structure. In particular, solar cell modules exposed to the environment must not only have excellent long-term weather resistance and durability so that the solar cells can maintain their characteristics for more than 25 years even in harsh environments, but also have excellent water vapor and oxygen barrier properties and UV resistance.

In addition, solar cell modules go beyond the existing glass-based substrate form and apply solar cells to the surface of the building to integrate them and apply them to the exterior wall of the building. BIPV (Building Integrated PV) and BAPV (Building Applied PV) increase economic efficiency and various added values. In order to expand various application fields such as VIPV (Vehicle Integrated PV) for mounting on vehicles, research is being conducted using substrates made of various materials beyond the existing glass-based substrate materials, which have limited application fields.

The BAPV can be formed on the surface of a curved means of transportation such as a car or train, which has the advantage of dissemination and activation. These BAPVs are being used to reduce construction costs and improve the aesthetics of buildings.

In this BAPV structure, for example, a solar cell is disposed on the upper surface of a support substrate, the lower surface of the support substrate is formed to contact the outer wall of the building, and the solar cell has a relatively narrow width compared to the support substrate. It can be formed and includes a back electrode layer, a light absorption layer, a buffer layer, and a window layer, and the lower surface of the support substrate is provided in a structure that is formed to contact the outer wall of the building. The above-described BAPV support substrate can be formed of a flexible material such as metal, and the installation method using adhesive and the outer wall of a building is common. However, unlike the conventional BIPV structure, there is no gap between the structure where the solar cell is installed. Therefore, there is room for improvement in reliability due to damage to cells and reduced efficiency caused by solar heat.

Meanwhile, a solar module is composed of multiple strings connected in series. For example, 4 to 6 strings constitute one solar module, and each of them has an independent solar power generation function. The string is joined by manufacturing bus bars on the lower and upper parts of the divided strips, and connecting these bus bars with ECA.

Demand for solar modules integrated with building materials is increasing in various fields for applying solar modules as described above to building facades. However, existing solar modules have to secure durability/safety due to the weight of glass (~14 kg). The need to develop building material solar modules that can realize high output is emerging. In addition, demand for solar modules is increasing in various fields, and the need for lightweight modules to replace existing solar modules is highlighted due to the weight of glass.

An example of this technology is disclosed in Patent Documents 1 to 3 below.

For example, in Patent Document 1 below, a polyester polymer substrate selected from polyethylene terephthalate, polyethylene naphthalene, and mixtures thereof, a homopolymer of vinylidene fluoride monomer on the polymer substrate, and vinylidene fluoride A coating layer containing a fluoropolymer coating composition containing a base resin made of a fluorine-based polymer selected from a monomer and a copolymer containing one or more comonomers and an acrylic polymer containing a hydroxyl group, and a polyisocyanate containing a perfluoroalkyl group. A fluoropolymer coating film is disclosed.

In addition, Patent Document 2 below discloses a solar cell that generates electricity by converting solar light energy into electrical energy, a sealing material that seals the solar cell to prevent moisture or foreign substances from penetrating into the solar cell, and the sealing material in the form of a flat plate. A lower protection member is installed on the bottom of the solar cell sealed with a sealing material to protect the lower part of the solar cell sealed with a sealing material, and a flat plate made of a transparent material that transmits sunlight is mounted on the upper part of the solar cell sealed with the sealing material. A highly efficient, highly durable, lightweight solar cell module using an ECTFE film and an embossed cover including an upper protection member that protects the top of a sealed solar cell is disclosed.

Meanwhile, Patent Document 3 below discloses a lightweight aggregate layer made using bottom ash among coal ash, a PV layer disposed on top of the lightweight aggregate layer and used to produce electricity using solar energy, and a layer between the surface glass layer and the PV layer. A first bonding layer is disposed on the top of the PV layer to protect the surface glass layer and the PV layer, and is disposed between the surface glass layer and the PV layer and the lightweight aggregate layer. It includes a second bonding layer for bonding the PV layer and the lightweight aggregate layer, and the first bonding layer bonds the surface glass layer and the PV layer using ethylene vinyl acetate resin, and The second bonding layer is disclosed for a solar panel for buildings using lightweight aggregate that bonds the lightweight aggregate layer and the PV layer using ethylene vinyl acetate resin.

Republic of Korea Patent Publication No. 10-1406886 (registered on June 5, 2014) Republic of Korea Patent Publication No. 2022-0075114 (published on 2022.06.07) Republic of Korea Patent Publication No. 10-2031722 (registered on October 7, 2019)

Patent Document 1 as described above discloses a technology in which the fluoropolymer coating layer and the polymer substrate are bonded as a back sheet by an adhesive layer, and the adhesive layer has excellent water resistance to prevent deterioration of the adhesive layer due to moisture penetration during long-term use. However, the entire There was no disclosure regarding structures such as building-mounted type (BAPV), which installs solar cell modules without installing structures such as cover structures and roofs.

In addition, Patent Document 2 discloses a highly efficient, highly durable, lightweight solar cell module using ECTFE film and an embossed cover, but does not disclose the specific structure and manufacturing method of the front cover and back sheet.

Meanwhile, in Patent Document 3, a solar panel for a building was prepared using bottom ash or fly ash as a lightweight aggregate that is lighter than glass and has excellent bending strength compared to glass, but the technology for applying such crystalline silicon BAPV modules is Since it is applied by installing modules after manufacturing a steel structure in a building, there were problems with increased load on the building and increased difficulty in construction.

Additionally, in the foil-type BIPV module system, there was a problem that light conversion efficiency was lowered due to the application of thin film solar cells.

The purpose of the present invention is to solve the problems described above. It can be installed in the upper part of a curved building or a curved vehicle, and can reduce the building load and construction difficulty due to additional installation of solar modules. The goal is to provide a highly durable and lightweight shingled solar module structure and manufacturing method.

Another object of the present invention is to reduce the weight of the solar module, thereby reducing the load on the building and improving the convenience of construction, and to reduce maintenance costs through the high reliability of the solar module. To provide a shingled solar module structure and manufacturing method.

Another object of the present invention is to provide a highly durable and lightweight shingled solar module structure and manufacturing method that can shorten the manufacturing time by vacuum compressing the solar module laminate at high temperature.

In order to achieve the above object, the highly durable and lightweight shingled solar module structure according to the present invention is used for building roofs, facades and balconies, soundproof walls, solar power facilities mounted on vehicles, and agricultural solar power generation facilities. Alternatively, it is a highly durable and lightweight shingled solar module structure that can be mounted on a floating solar power facility, comprising a solar panel with a shingled array structure, a first sealant laminated on the top of the solar panel to protect the solar panel, and solar energy. A front cover laminated on top of the first sealant so as to transmit the solar panel, improve the flexibility of the solar module and protect the first sealant, a second sealant laminated on the bottom of the solar panel to protect the solar panel, It includes a backsheet laminated on the lower part of the second sealing material to protect the solar panel from the external environment, the front cover is made of a transparent film with a highly durable and lightweight multilayer structure, and the backsheet has a multilayer structure. It is characterized by being prepared with a film of.

In addition, in the shingled solar module structure according to the present invention, the front cover and back sheet are characterized in that they include ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene) in a multilayer structure.

In addition, in the shingled solar module structure according to the present invention, the front cover includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, and a transparent upper coating layer coated on the second base film. It is characterized in that it includes a transparent barrier coating layer, a transparent clear coating layer coated on the lower part of the second base film, and an adhesive layer that adheres the lower part of the first base film and the barrier coating layer.

In addition, in the shingled solar module structure according to the present invention, the backsheet includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, and a transparent upper coating layer coated on the second base film. It is characterized in that it includes a transparent barrier coating layer and an adhesive layer that adheres the lower part of the first base film and the barrier coating layer.

In addition, in the shingled solar module structure according to the present invention, the first base film has a thickness of 150 to 200 ㎛, the upper coating layer is coated to a thickness of 3 to 5 ㎛, and the second base film has a thickness of 150 ㎛. It has a thickness of ~200㎛, the barrier coating layer is coated with a thickness of 700㎚~1㎛, the adhesive layer is adhered to a thickness of 10±1㎛, and the clear coating layer is coated with a thickness of 1~2㎛. It is characterized by

In addition, in the shingled solar module structure according to the present invention, the first base film has a thickness of 150 to 200 ㎛, the upper coating layer is coated to a thickness of 3 to 5 ㎛, and the second base film has a thickness of 150 ㎛. It has a thickness of ~200㎛, the barrier coating layer is coated with a thickness of 700㎚~1㎛, and the adhesive layer is characterized in that it is adhered to a thickness of 10±1㎛.

In addition, in the shingled solar module structure according to the present invention, the back sheet is made of a transparent material to transmit sunlight, and the solar module is characterized by a double-sided light receiving structure.

In addition, in the shingled solar module structure according to the present invention, the back sheet is made of an opaque material, and the solar module is characterized in that it is provided with a single-sided light receiving structure.

In addition, in order to achieve the above object, the method of manufacturing the shingled solar module structure according to the present invention is the roof of the building, the facade and balcony, the soundproof wall, solar power equipment mounted on a vehicle, agricultural solar power generation equipment, or A method of manufacturing a highly durable and lightweight shingled solar module structure that can be mounted on floating solar power facilities, comprising: (a) a front cover made of multilayer ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene); , a first sealant made of EVA (Ethylene Vinyl Acetate) or POE (Poly Olefin Elastomer), a solar panel with a shingled array structure, a second sealant made of EVA (Ethylene Vinyl Acetate) or POE (Poly Olefin Elastomer), and a multi-layer ETFE. or preparing a backsheet made of ECTFE, (b) preparing a laminate by sequentially stacking the front cover, first sealant, shingled array solar panel, second sealant, and backsheet, (c) ) It is characterized in that it includes the step of manufacturing a set of modules by heat-compressing the laminate prepared in step (b).

In addition, in the method of manufacturing a shingled solar module structure according to the present invention, the front cover includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, and the second base film. It consists of a transparent barrier coating layer coated on the top, a transparent clear coating layer coated on the bottom of the second base film, and an adhesive layer that adheres the bottom of the first base film to the barrier coating layer, and the clear coating layer is It is characterized in that it is prepared after adhesion of the lower part of the first base film and the barrier coating layer.

In addition, in the method of manufacturing a shingled solar module structure according to the present invention, the back sheet includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, and the second base film. It includes a transparent barrier coating layer coated on the top, and is characterized in that it is prepared by adhering the lower part of the first base film to the barrier coating layer.

As described above, according to the shingled solar module structure and manufacturing method according to the present invention, high durability and light weight of the shingled solar module can be realized by providing the front cover and back sheet with a multi-layer structure film. The effect that there is is obtained.

In addition, according to the shingled solar module structure and manufacturing method according to the present invention, a highly durable and lightweight solar module is provided, thereby reducing the weight of the module itself to facilitate storage, movement, and installation. Lose.

In addition, according to the shingled solar module structure and manufacturing method according to the present invention, a flexible solar module can be prepared and can be easily installed in response to curved surfaces such as buildings, thereby improving aesthetics. The effect is also obtained.

1 is a diagram illustrating the structure of a first embodiment of a highly durable and lightweight shingled solar module structure according to the present invention;
Figure 2 is a front and back photo showing ETFE (Ethylene Tetra Fluoro Ethylene) applied as the front cover and first back sheet in the highly durable and lightweight shingled solar module structure shown in Figure 1;
Figure 3 is a front and back photo showing ECTFE (Ethylene Chloro Tri Fluoro Ethylene) applied as the front cover and first back sheet in the highly durable and lightweight shingled solar module structure shown in Figure 1;
Figure 4 is a diagram for explaining the structure of the front cover applied to the present invention.
5 is a photographic image of the front cover manufactured according to the present invention;
6 is a graph showing the light transmittance of the front cover manufactured according to the present invention;
7 is a diagram for explaining the structure of the first back sheet applied to the present invention;
8 is a diagram for explaining the structure of a second embodiment of a highly durable and lightweight shingled solar module structure according to the present invention;
Figure 9 is a front and back photo showing ETFE (Ethylene Tetra Fluoro Ethylene) applied as the front cover and second back sheet in the highly durable and lightweight shingled solar module structure shown in Figure 8;
FIG. 10 is a front and back photo showing ECTFE (Ethylene Chloro Tri Fluoro Ethylene) applied as the front cover and first back sheet in the highly durable and lightweight shingled solar module structure shown in FIG. 8;
Figure 11 is a graph showing the results of the Damp Heat test of the solar module shown in Figure 2;
Figure 12 is a graph showing the thermal cycle test results of the solar module shown in Figure 2;
Figure 13 is a graph showing the results of the Damp Heat test of the solar module shown in Figure 3;
Figure 14 is a graph showing the thermal cycle test results of the solar module shown in Figure 3;
Figure 15 is a graph showing the results of the Damp Heat test of the solar module shown in Figure 9;
Figure 16 is a graph showing the thermal cycle test results of the solar module shown in Figure 9;
Figure 17 is a graph showing the results of the Damp Heat test of the solar module shown in Figure 10;
Figure 18 is a graph showing the thermal cycle test results of the solar module shown in Figure 10.

The above and other objects and new features of the present invention will become more clear by the description of this specification and the accompanying drawings.

The term "wafer" used herein refers to a wafer for solar cells made of single crystal or polycrystalline silicon, and "solar cell" is prepared by screen printing electrodes on a P-type silicon substrate. It can be formed as PERC (Passivated Emitter and Rearside Contact), n-HIT (Hetrojunction with Intrinsic Thin Lyaer), n-PERT (Passivated Emitter and Rear Totally diffused), and CSC (Charge Selective Contact).

In addition, as a term used herein, “photovoltaic structure” refers to a device that can convert light into electricity and may include a number of semiconductors or other types of materials, and “photovoltaic structure” refers to a device that can convert light into electricity. A "solar cell" or "cell" is a photovoltaic (PV) structure that can convert light into electricity, can have various sizes and shapes, and can be manufactured from a variety of materials, such as semiconductors (e.g., silicon). It may be a PV structure fabricated on a wafer or substrate, or one or more thin films fabricated on a substrate (e.g., glass, plastic, metal, or any other material capable of supporting a photovoltaic structure).

In addition, the term "shingled array structure" refers to cutting solar cells equipped with front and back electrodes to form a plurality of strips to increase the conversion efficiency and output per unit of solar cell modules, and connecting the front and back electrodes to each other. It refers to a string structure connected by bonding with conductive adhesive.

In addition, a “solar module or solar cell module” refers to a solar cell string in which multiple shingled array structures are electrically connected on a frame, and is implemented with hardware or software consisting of a mechanical or electrical and electronic configuration, or a combination of hardware and software. It can be.

The present invention is, for example, a highly durable and lightweight shingled solar module that can be applied to curved surfaces of buildings. It reduces the weight of solar modules in shingled silicon solar BAPV modules and provides solar modules that can be applied to curved surfaces of buildings. In order to improve the flexibility of the module, the transparent film provided on the front of the solar cell and the backsheet provided on the back of the solar cell are made of ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene) material to ensure high durability and durability. A highly lightweight silicon solar module was manufactured. In addition, in the following description, it is explained as building-attached type (BAPV), which installs solar modules without installing structures on the exterior wall or roof of the building, but it is not limited to this and can also be used as BIPV (Building Integrated PV) or VIPV (Vehicle Integrated PV). Applicable.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.

Figure 1 is a diagram for explaining the structure of a first embodiment of a highly durable and lightweight shingled solar module structure according to the present invention, and Figure 2 is a highly durable and lightweight shingled solar module shown in Figure 1. A front and back photo showing ETFE (Ethylene Tetra Fluoro Ethylene) applied as the front cover and first back sheet in the module structure. Figure 2 (a) is a front photo of a solar module using ETFE, and Figure 2 (b) is a photo showing the front of a solar module using ETFE. This is a photo of the back of a solar module using ETFE, and Figure 3 shows a photo of the highly durable and lightweight shingled solar module structure shown in Figure 1, where ECTFE (Ethylene Chloro Tri Fluoro Ethylene) is applied as the front cover and first back sheet. As front and back photos, Figure 3 (a) is a front photo of a solar module to which ECTFE is applied, and Figure 3 (b) is a rear photo of a solar module to which ECTFE is applied.

As shown in FIG. 1, the solar module according to the first embodiment of the present invention is a shingled solar module structure 100 for double-sided light reception and is highly durable and lightweight, and includes a solar panel (solar panel) of a shingled array structure. 110), a first sealing material 120 laminated on the solar panel 110 to protect the solar panel 110, allowing sunlight to pass through and improving the flexibility of the solar module 100, and the first sealing material A front cover 130 laminated on the top of the first sealant 120 to protect the solar panel 120, and a second sealant laminated on the bottom of the solar panel 110 to protect the solar panel 110 ( 140), and may include a first back sheet 150 laminated on the lower part of the second sealing material 140 to protect the solar panel 110 from the external environment.

As shown in FIG. 1, the solar module structure 100 includes a front cover 130, a first sealant 120, a solar panel 110, a second sealant 140, and a first back sheet 150. They are stacked in that order, and the front cover 130, first sealant 120, solar panel 110, second sealant 140, and first back sheet 150 may each be provided in sizes corresponding to each other. . For example, the solar module 100 as shown in FIGS. 1 to 3 may be provided with a module area of 1.254 m2 of 1,280 mm × 980 mm (W*L), and the weight per area is 2.03 kg/m2. It can be prepared by.

For example, in order to increase the conversion efficiency and output per unit of the solar cell module, the solar panel 110 of the shingled array structure forms a plurality of strips by cutting solar cells provided with front and rear electrodes, and these front electrodes are formed by cutting solar cells. It can be provided as a string structure connected by bonding the and rear electrodes with a conductive adhesive. The solar panel 110 with such a shingled array structure can increase output by 20% compared to a regular solar panel compared to the same area.

The first sealing material 120 and the second sealing material 140 are respectively provided to protect the fragile solar cell and circuit from impact and for interlayer bonding, for example, EVA (Ethylene Vinyl Acetate) or POE that transmits sunlight. (Poly Olefin Elastomer) can be applied. However, it is not limited to this, and any material that serves as an electrically insulating sealant, has a bonding function, and has light transmittance can be applied as the sealant of the present invention. The first sealant 120 and the second sealant 140 are shingles. It is attached to the front and rear of the solar panel 130 of the de-array structure and not only protects the solar panel 110 from external environments such as moisture penetration, but also has a buffering function to prevent damage. That is, the first sealant 120 is laminated on the upper part of the solar panel to protect the solar panel 110, and the second sealant 140 is laminated on the lower part of the solar panel to protect the solar panel 110. is laminated on

As shown in FIGS. 1 to 3, the front cover 130 is made of ETFE or ECTFE to reduce weight and improve solar transmittance compared to glass materials, and to have high durability and light weight, and is a transparent material with a multi-layer structure. It can be done with

Additionally, as shown in FIGS. 1 to 3, the first back sheet 150 may be made of a transparent material with a multi-layer structure to transmit sunlight. Accordingly, the solar module 100 according to the first embodiment of the present invention may be provided with a double-sided light receiving structure.

In the present invention, by applying a multi-layered transparent material to the front cover 130 and the first back sheet 150, not only can the weight of conventional glass materials be reduced, but also the glass material can be used during transportation or installation. Loss due to damage to members can be prevented.

In addition, in the above description, a transparent material made of ETFE or ECTFE with a multi-layer structure is shown, but it is not limited thereto, and includes, for example, PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PP (polypropylene), and PC ( polycarbornate), PS (polystylene), POM (polyoxyethylene), AS (acrylonitrile styrene copolymer) resin, ABS (acrylonitrile butadiene styrene copolymer) resin, or TAC (Triacetyl cellulose).

Next, the multilayer structure of the front cover 130 described above will be described with reference to FIG. 4.

Figure 4 is a diagram for explaining the structure of the front cover applied to the present invention.

As shown in FIG. 4, the front cover 130 applied to the present invention has a structure in which a transparent first base film and a transparent second base film are adhered. The first base film and the second base film may be films made of ETFE or ECTFE, respectively. As described above, the front cover 130 can have high durability by being provided by an adhesive structure of the first base film and the second base film.

The first base film has a thickness of 150 to 200㎛, and acrylic silane resin is coated to a thickness of 3 to 5㎛ on the top of the first base film to form a transparent upper coating layer. In addition, the second base film has a thickness of 150 to 200㎛, and Al ₂ O ₃ is coated on the top of the second base film to a thickness of 700㎚ to 1㎛ to form a transparent barrier coating layer.

The lower part of the first base film and the barrier coating layer are adhered to a thickness of 10 ± 1㎛ by a transparent acrylic resin to form an adhesive layer, and then a transparent hybrid silicone resin is applied to the lower part of the second base film to a thickness of 1 to 2㎛. The front cover 130 according to the present invention is completed by being coated with to form a clear coating layer.

The front cover 130 manufactured as described above is shown in Figure 5.

Figure 5 is an image photograph of the front cover manufactured according to the present invention, where Figure 5 (a) is a photograph of a film made of ETFE, and Figure 5 (b) is a photograph of a film made of ECTFE.

In addition, the light transmittance of the front cover 130 as a film made of ETFE and ECTFE shown in FIG. 5 was analyzed. As shown in FIG. 6, the front cover 130 according to the present invention is a thin transparent film that can replace the conventional front glass cover and has a high light transmittance of about 90% or more. Figure 6 is a graph showing the light transmittance of the front cover manufactured according to the present invention.

Next, the multilayer structure of the above-described first back sheet 150 will be described with reference to FIG. 7.

Figure 7 is a diagram for explaining the structure of the first back sheet applied to the present invention.

As shown in FIG. 5, the first backsheet 150 applied to the present invention has a structure in which a transparent first base film and a transparent second base film are adhered. The first base film and the second base film may be films made of ETFE or ECTFE, respectively.

The first base film of the first backsheet 150 has a thickness of 150 to 200 ㎛, and acrylic silane resin is coated to a thickness of 3 to 5 ㎛ on the top of the first base film to form a transparent upper coating layer. . The upper coating layer may use an acrylate, urethane, epoxy, or siloxane-based resin instead of the acrylic silane resin.

In addition, the second base film of the first backsheet 150 has a thickness of 150 to 200㎛, and Al ₂ O ₃ is coated on the top of the second base film to a thickness of 700㎚ to 1㎛ to form a transparent barrier. (Barrier) Forms a coating layer.

The lower part of the first base film and the barrier coating layer are bonded to a thickness of 10 ± 1 μm by transparent acrylic resin to form an adhesive layer, thereby completing the first backsheet 150 according to the present invention.

Meanwhile, the highly durable and lightweight shingled solar module structure 100 according to the first embodiment of the present invention further includes a frame provided on the front cover 130 and surrounding the circumference of the module, and the frame It is provided to protect the module, and may be made of, for example, a synthetic polymer material to reduce weight or aluminum to add weight reduction and heat dissipation functions and may be provided in a curved shape.

Next, a second embodiment of the present invention will be described with reference to FIGS. 8 to 10.

Figure 8 is a diagram for explaining the structure of a second embodiment of the highly durable and lightweight shingled solar module structure according to the present invention, and Figure 9 is a diagram showing the highly durable and lightweight shingled solar module shown in Figure 8. A front and back photo showing ETFE (Ethylene Tetra Fluoro Ethylene) applied as the front cover and second back sheet in the module structure. Figure 9 (a) is a front photo of a solar module using ETFE, and Figure 9 (b) is a photo of the front of a solar module using ETFE. This is a rear photo of a solar module using ETFE. Figure 10 shows a photo of the high durability and lightweight shingled solar module structure shown in Figure 8, where ECTFE (Ethylene Chloro Tri Fluoro Ethylene) is applied as the front cover and first back sheet. As front and back photos, Figure 10 (a) is a front photo of a solar module to which ECTFE is applied, and Figure 10 (b) is a rear photo of a solar module to which ECTFE is applied.

As shown in FIG. 8, the solar module structure 100' according to the second embodiment of the present invention includes a front cover 130, a first sealant 120, a solar panel 110, and a second sealant 140. ), the second backsheet 160 is laminated in that order, and the structures of the front cover 130, the first sealant 120, the solar panel 110, and the second sealant 140 are the same as the first embodiment, The second backsheet 160 is a sheet to enhance durability and lightness, and is made of an opaque material, protects the solar cell from external environments such as heat, humidity, and ultraviolet rays, and protects the solar cell from external environments such as heat, humidity, and ultraviolet rays, and protects the solar cell from the external environment such as heat, humidity, and ultraviolet rays. It can be provided as a single-sided light receiving structure to increase the efficiency of the module through re-reflection of sunlight.

In addition, the structure of the front cover 130 and the second back sheet 160 of the second embodiment may be provided in the same structure as the first embodiment described above, and the first base film of the second back sheet 160 or The second base film may be made of an opaque material.

The highly durable and lightweight shingled solar module structure described above includes a front cover made of multi-layered ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene), EVA (Ethylene Vinyl Acetate) or POE (Poly Polymer). A first sealant made of Olefin Elastomer, a solar panel with a shingled array structure, a second sealant made of EVA (Ethylene Vinyl Acetate) or POE (Poly Olefin Elastomer), and a multi-layer ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro) A backsheet made of (Tri Fluoro Ethylene) is prepared, a laminate is prepared by sequentially stacking the front cover, first sealant, shingled array structure solar panel, second sealant, and backsheet, and the laminate is heated. It can be manufactured into one set of modules by pressing.

In other words, the highly durable and lightweight shingled solar module structure is achieved, for example, by placing the laminate in a vacuum pack and applying a pressure of 30 kpa for 10 to 15 minutes at a temperature of 120 to 150 ° C. , Preferably, it can be simply manufactured by performing a lamination process uniformly by applying a pressure of 30 kpa for 660 seconds at a temperature of 140°C.

Meanwhile, as described above, the durability of the solar module prepared according to the first or second embodiment was tested.

In the durability test of the solar module, a damp heat test and a thermal cycle test were performed on the solar module prepared according to the first or second embodiment.

The Damp Heat test is a durability test for the bonding strength of solar modules, corrosion of solar elements or electrodes, and deformation of sealing materials, and is tested under harsh high-temperature and high-humidity conditions (temperature: 85℃±2℃, humidity: 85%±5%). After testing the solar module according to exposure conditions, the output reduction rate was evaluated before and after.

In addition, the Thermal Cycle test is an evaluation for physical or chemical durability testing according to changes in the temperature environment of solar modules. After testing the solar module, the output reduction rate was evaluated before and after. For example, the temperature cycle was performed by maintaining the temperature at -40°C for about 10 minutes for 6 hours, then raising the temperature and maintaining it at 85°C for about 10 minutes as one cycle.

As shown in Figure 2, a damp heat test and a thermal cycle test were conducted on a solar module manufactured using a front cover made of ETFE and a transparent back sheet. The Damp Heat test was run for 200 hours, and the Thermal cycle test was run for 50 cycles.

FIG. 11 is a graph showing the results of the Damp Heat test of the solar module shown in FIG. 2. FIG. 11 (a) shows the module output characteristics before the test, and FIG. 11 (b) shows the module output characteristics after the test. .

As shown in Figure 11 (a), the module output characteristics before the damp heat test were short circuit current (Isc) of 8.51A, open-circuit voltage (Voc) of 38.25V, curve factor (FF) of 0.753, and measured power (Pm) of 245.27W. , The module output characteristics after the Damp Heat test are as shown in Figure 11 (b), short circuit current (Isc) 8.50A, open-circuit voltage (Voc) 38.56V, curve factor (FF) 0.753, and measured power (Pm) 247.09W. It was.

Figure 12 is a graph showing the thermal cycle test results of the solar module shown in Figure 2. Figure 12 (a) shows the module output characteristics before the test, and Figure 12 (b) shows the module output characteristics after the test. .

As shown in Figure 12 (a), the module output characteristics before the thermal cycle test were short-circuit current (Isc) 8.52A, open-circuit voltage (Voc) 38.28V, curve factor (FF) 0.762, and measured power (Pm) 248.38W. , The module output characteristics after the thermal cycle test are as shown in (b) of Figure 12, short-circuit current (Isc) 8.52A, open-circuit voltage (Voc) 38.40V, curve factor (FF) 0.763, and measured power (Pm) 249.62W. It was.

As can be seen in Figures 11 and 12, the output reduction rate after the Damp Heat 200-hour test was -0.74%, and after the Thermal 50 cycle test, the output reduction rate was -0.50%. Although the output increased slightly, the output was within the measurement error range. Since there was almost no reduction, it was determined that the solar module according to the present invention as shown in FIG. 2 has high durability.

In addition, as shown in Figure 3, a damp heat test and a thermal cycle test were conducted on a solar module manufactured using a front cover made of ECTFE and a transparent back sheet. The Damp Heat test was run for 200 hours, and the Thermal cycle test was run for 50 cycles.

Figure 13 is a graph showing the results of the damp heat test of the solar module shown in Figure 3. Figure 13 (a) shows the module output characteristics before the test, and Figure 13 (b) shows the module output characteristics after the test. .

As shown in (a) of Figure 13, the module output characteristics before the damp heat test were short-circuit current (Isc) 8.75A, open-circuit voltage (Voc) 38.30V, curve factor (FF) 0.679, and measured power (Pm) 227.66W. , The module output characteristics after the Damp Heat test are as shown in (b) of Figure 13, short circuit current (Isc) 8.86A, open-circuit voltage (Voc) 38.51V, curve factor (FF) 0.670, and measured power (Pm) 223.84W. It was.

Figure 14 is a graph showing the thermal cycle test results of the solar module shown in Figure 3. Figure 14 (a) shows the module output characteristics before the test, and Figure 14 (b) shows the module output characteristics after the test. .

As shown in Figure 14 (a), the module output characteristics before the thermal cycle test were short-circuit current (Isc) 8.69A, open-circuit voltage (Voc) 38.28V, curve factor (FF) 0.726, and measured power (Pm) 210.61W. , The module output characteristics after the thermal cycle test are as shown in Figure 14 (b), short-circuit current (Isc) 8.65A, open-circuit voltage (Voc) 38.37V, curve factor (FF) 0.618, and measured power (Pm) 205.37W. It was.

As can be seen in Figures 13 and 14, the output reduction rate after the Damp Heat 200 hour test was 1.68%, and the output decrease rate after the Thermal 50 cycle test was 2.58%, which showed a slight decrease in output, but as shown in Figure 3. The solar module according to the invention was also judged to have high durability.

Next, as shown in Figure 9, a damp heat test and a thermal cycle test were conducted on a solar module manufactured using a front cover made of ETFE and an opaque back sheet. The Damp Heat test was run for 200 hours, and the Thermal cycle test was run for 50 cycles.

Figure 15 is a graph showing the results of the damp heat test of the solar module shown in Figure 9. Figure 15 (a) shows the module output characteristics before the test, and Figure 15 (b) shows the module output characteristics after the test. .

As shown in (a) of Figure 15, the module output characteristics before the damp heat test were short-circuit current (Isc) 8.28A, open-circuit voltage (Voc) 38.18V, curve factor (FF) 0.745, and measured power (Pm) 235.61W. , The module output characteristics after the Damp Heat test are as shown in Figure 15 (b), short circuit current (Isc) 8.24A, open-circuit voltage (Voc) 38.45V, curve factor (FF) 0.747, and measured power (Pm) 236.664W. It was.

Figure 16 is a graph showing the thermal cycle test results of the solar module shown in Figure 9. Figure 16 (a) shows the module output characteristics before the test, and Figure 16 (b) shows the module output characteristics after the test. .

As shown in Figure 16 (a), the module output characteristics before the thermal cycle test were short-circuit current (Isc) 8.35A, open-circuit voltage (Voc) 38.27V, curve factor (FF) 0.762, and measured power (Pm) 243.30W. , The module output characteristics after the thermal cycle test are as shown in (b) of Figure 16, short-circuit current (Isc) 8.35A, open-circuit voltage (Voc) 38.35V, curve factor (FF) 0.761, and measured power (Pm) 243.70W. It was.

As can be seen in Figures 15 and 16, after the Damp Heat 200 hour test, the output reduction rate was -0.45%, and after the Thermal 50 cycle test, the output reduction rate was -0.16%. Although the output increased slightly, the output was within the measurement error range. Since there was almost no reduction, it was determined that the solar module according to the present invention as shown in FIG. 9 has high durability.

In addition, as shown in Figure 10, a damp heat test and a thermal cycle test were conducted on a solar module manufactured using a front cover made of ECTFE and an opaque back sheet. The Damp Heat test was run for 200 hours, and the Thermal cycle test was run for 50 cycles.

Figure 17 is a graph showing the results of the Damp Heat test of the solar module shown in Figure 10. Figure 17 (a) shows the module output characteristics before the test, and Figure 17 (b) shows the module output characteristics after the test. .

As shown in (a) of Figure 17, the module output characteristics before the damp heat test were short-circuit current (Isc) 8.58A, open-circuit voltage (Voc) 38.28V, curve factor (FF) 0.726, and measured power (Pm) 238.32W. , The module output characteristics after the Damp Heat test are as shown in (b) of Figure 17, short circuit current (Isc) 8.56A, open-circuit voltage (Voc) 38.36V, curve factor (FF) 0.708, and measured power (Pm) 232.44W. It was.

Figure 18 is a graph showing the thermal cycle test results of the solar module shown in Figure 10. Figure 18 (a) shows the module output characteristics before the test, and Figure 18 (b) shows the module output characteristics after the test. .

As shown in (a) of Figure 18, the module output characteristics before the thermal cycle test were short-circuit current (Isc) 8.49A, open-circuit voltage (Voc) 38.17V, curve factor (FF) 0.740, and measured power (Pm) 239.85W. , The module output characteristics after the thermal cycle test are as shown in (b) of Figure 18, short-circuit current (Isc) 8.42A, open-circuit voltage (Voc) 38.39V, curve factor (FF) 0.730, and measured power (Pm) 236.09W. It was.

As can be seen in Figures 17 and 18, the output reduction rate after the Damp Heat 200 hour test was 2.67%, and after the Thermal 50 cycle test, the output reduction rate was 1.57%, which showed a slight decrease in output, but as shown in Figure 10. The solar module according to the invention was also judged to have high durability.

Although the invention made by the present inventor has been described in detail according to the above-mentioned embodiments, the present invention is not limited to the above-described embodiments and can of course be changed in various ways without departing from the gist of the invention.

By using the highly durable and lightweight shingled solar module structure and manufacturing method according to the present invention, high durability and light weight of the shingled solar module can be realized.

100: Shingled solar module structure
110: solar panel
120: first sealant
130: front cover
140: second sealant
150: first back sheet

Claims (11)

It is a highly durable and lightweight shingled solar module structure that can be mounted on the roof of a building, façade, balcony, soundproof wall, solar power facility mounted on a vehicle, agricultural solar power generation facility, or floating solar power facility,
Solar panels with a shingled array structure,
A first sealant laminated on top of the solar panel to protect the solar panel,
A front cover laminated on top of the first sealant to transmit sunlight, improve the flexibility of the solar module, and protect the first sealant,
A second sealant laminated on the lower part of the solar panel to protect the solar panel,
It includes a backsheet laminated on the lower part of the second sealing material to protect the solar panel from the external environment,
The front cover is made of a transparent film with a highly durable and lightweight multi-layer structure,
A shingled solar module structure, wherein the backsheet is made of a multi-layer film. In paragraph 1:
A shingled solar module structure wherein the front cover and back sheet include a multi-layer structure of ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene). In paragraph 2,
The front cover is
a transparent first base film,
A transparent upper coating layer coated on the first base film,
a transparent second base film,
A transparent barrier coating layer coated on the second base film,
A transparent clear coating layer coated on the lower part of the second base film,
A shingled solar module structure comprising an adhesive layer that adheres the lower part of the first base film to the barrier coating layer. In paragraph 2,
The back sheet is
a transparent first base film,
A transparent upper coating layer coated on the first base film,
a transparent second base film,
A transparent barrier coating layer coated on the second base film,
A shingled solar module structure comprising an adhesive layer that adheres the lower part of the first base film to the barrier coating layer. In paragraph 3,
The first base film has a thickness of 150 to 200 μm,
The upper coating layer is coated to a thickness of 3 to 5㎛,
The second base film has a thickness of 150 to 200 μm,
The barrier coating layer is coated to a thickness of 700 nm to 1 μm,
The adhesive layer is adhered to a thickness of 10 ± 1㎛,
A shingled solar module structure, characterized in that the clear coating layer is coated with a thickness of 1 to 2㎛. In paragraph 4,
The first base film has a thickness of 150 to 200 μm,
The upper coating layer is coated to a thickness of 3 to 5㎛,
The second base film has a thickness of 150 to 200 μm,
The barrier coating layer is coated to a thickness of 700 nm to 1 μm,
A shingled solar module structure, characterized in that the adhesive layer is adhered to a thickness of 10 ± 1㎛. In paragraph 3,
The backsheet is made of a transparent material to allow sunlight to pass through,
The solar module is a shingled solar module structure, characterized in that the solar module is provided with a double-sided light receiving structure. In paragraph 3,
The backsheet is made of an opaque material,
A shingled solar module structure, characterized in that the solar module is provided with a single-sided light receiving structure. We manufacture highly durable and lightweight shingled solar module structures that can be mounted on building roofs, facades, balconies, soundproof walls, solar power plants mounted on vehicles, agricultural solar power plants, or floating solar power plants. As a method,
(a) A front cover made of multi-layer ETFE (Ethylene Tetra Fluoro Ethylene) or ECTFE (Ethylene Chloro Tri Fluoro Ethylene), a first sealant made of EVA (Ethylene Vinyl Acetate) or POE (Poly Olefin Elastomer), and a shingled array structure. Preparing a solar panel, a second sealant made of EVA (Ethylene Vinyl Acetate) or POE (Poly Olefin Elastomer), and a backsheet made of multilayer ETFE or ECTFE;
(b) preparing a laminate by sequentially stacking the front cover, first sealant, shingled array solar panel, second sealant, and backsheet,
(c) A method of manufacturing a shingled solar module structure, comprising the step of heat-compressing the laminate prepared in step (b) to manufacture a set of modules. In paragraph 9:
The front cover includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, a transparent barrier coating layer coated on the second base film, and the second base film. It consists of a transparent clear coating layer coated on the lower part and an adhesive layer that adheres the lower part of the first base film to the barrier coating layer,
A method of manufacturing a shingled solar module structure, characterized in that the clear coating layer is prepared after adhering the lower part of the first base film and the barrier coating layer. In paragraph 9:
The backsheet includes a transparent first base film, a transparent upper coating layer coated on the first base film, a transparent second base film, and a transparent barrier coating layer coated on the second base film. 1 A method of manufacturing a shingled solar module structure, characterized in that prepared by adhering the lower part of the base film and the barrier coating layer.