WO2019087798A1

WO2019087798A1 - Solar cell module and mobile body

Info

Publication number: WO2019087798A1
Application number: PCT/JP2018/038841
Authority: WO
Inventors: 剛士植田; 直樹栗副; 元彦杉山; 善光生駒
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2017-10-30
Filing date: 2018-10-18
Publication date: 2019-05-09

Abstract

A solar cell module (100) is provided with a front surface protection layer (10) formed from a resin. Furthermore, the solar cell module (100) is provided with a barrier layer (20) which is disposed on at least one of the surfaces of the front surface protection layer (10) and which has an oxygen permeability of 1.0 × 10-5 mol/(m2·s·Pa) or less. Moreover, the solar cell module (100) is provided with: a sealing layer (30) which is disposed under the front surface protection layer (10) and the barrier layer (20) and which seals a photoelectric conversion unit (40); and a rear surface protection layer (50) disposed under the sealing layer (30).

Description

Solar cell module and moving body

The present invention relates to a solar cell module and a mobile unit. In particular, the present invention relates to a solar cell module and a mobile using a surface protection layer made of resin.

BACKGROUND ART In recent years, solar cell modules that convert light energy into electrical energy have attracted attention from the viewpoint of environmental protection. A solar cell module is generally formed of a plurality of solar cells, a sealing layer sealing the plurality of solar cells, and a surface layer and a back layer respectively disposed on both sides of the sealing layer. .

Conventionally, glass has been used as a surface protective layer of a solar cell module, but in recent years, a resin such as polycarbonate has come to be used instead of glass in order to reduce the weight of the solar cell module.

For example, the solar cell module described in Patent Document 1 is disposed on the sealing layer formed by sealing the solar cell with a sealing material, and the side of the sealing layer on which sunlight is incident, and the resin is It is disclosed to have a structured surface layer. Moreover, it is disclosed that the solar cell module of patent document 1 has a back layer arrange | positioned on the opposite side to the side by which the surface layer of a sealing layer is arrange | positioned.

JP, 2017-073903, A

However, when the surface protective layer is formed using a resin instead of glass, the solar cell module can be made lightweight, but the sealing layer is easily yellowed by using the solar cell module for a long time There is a fear. Therefore, it is desired to improve the design of the solar cell module and improve the light energy absorption efficiency by improving the yellowing of the sealing layer.

The present invention has been made in view of the problems of the prior art. And the object of the present invention is to provide a solar cell module and a movable body in which yellowing of the sealing layer is less likely to occur even when a resin surface protection layer is used.

In order to solve the above-mentioned subject, a solar cell module concerning a first aspect of the present invention is provided with a surface protection layer formed of resin. In addition, the solar cell module includes a barrier layer disposed on at least one surface of the surface protective layer and having an oxygen permeability of 1.0 × 10 ⁻⁵ mol / (m ² · s · Pa) or less. Furthermore, the solar cell module includes a sealing layer disposed below the surface protective layer and the barrier layer and sealing the photoelectric conversion unit, and a back surface protective layer disposed below the sealing layer.

A mobile according to a second aspect of the present invention comprises a solar cell module.

FIG. 1 is a plan view showing an example of a solar cell module according to the present embodiment. FIG. 2 is a cross-sectional view taken along the line AA in FIG. FIG. 3 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 4 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 5 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 6 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 7 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 8 is a cross-sectional view showing another example of the solar cell module according to the present embodiment. FIG. 9 is a cross-sectional view showing another example of the solar cell module according to the present embodiment.

Hereinafter, the solar cell module and the mobile unit according to the present embodiment will be described in detail using the drawings. The dimensional ratios in the drawings are exaggerated for the sake of explanation, and may differ from the actual ratios. Further, in the present embodiment, with respect to the solar cell module, a light source side such as sunlight is referred to as a light receiving surface side and a surface side, and a side opposite to the light receiving surface is referred to as a back surface side.

[Solar cell module 100]
FIG. 1 is a plan view showing an example of a solar cell module 100 according to the present embodiment. In the present embodiment, five solar battery cells 42 arranged in parallel in the y-axis direction are electrically connected in series by the interconnector 44 to form one solar battery cell string 46. Further, the interconnector 44 can electrically connect two adjacent solar cell strings 46. In this embodiment, four solar battery cell strings 46 arranged in parallel in the x-axis direction are electrically connected in series by the interconnector 44. In addition, although an example of this embodiment was shown in FIG. 1, the number, arrangement | positioning, etc. of the photovoltaic cell 42 arrange | positioned at the photovoltaic module 100, and the photovoltaic cell string 46 are not specifically limited.

FIG. 2 is a cross-sectional view showing an example of a solar cell module 100 according to the present embodiment. As shown in FIG. 2, the solar cell module 100 according to the present embodiment includes a surface protection layer 10, a barrier layer 20, a sealing layer 30, and a back surface protection layer 50. The barrier layer 20 is disposed on at least one surface of the surface protective layer 10, the sealing layer 30 is disposed below the surface protective layer 10 and the barrier layer 20, and the back protective layer 50 is disposed below the sealing layer 30. Be placed. The sealing layer 30 seals the photoelectric conversion unit 40. Each component will be described in detail below.

(Surface protection layer 10)
The surface protective layer 10 is disposed on the light receiving surface side with respect to the photoelectric conversion unit 40. The surface protective layer 10 has a role of protecting the surface of the solar cell module 100 from foreign matter and the like. The shape of the surface protective layer 10 is not particularly limited, and may be a polygon such as a circle, an ellipse, or a rectangle depending on the application. The cross-sectional shape of the surface protective layer 10 may be rectangular or may be curved in the stacking direction (z-axis direction) of each layer of the solar cell module 100.

The surface protective layer 10 is formed of a resin. By forming the surface protective layer 10 with a resin instead of the glass conventionally used, the weight of the solar cell module 100 can be reduced. Therefore, the load applied to the installation portion such as the roof to which the solar cell module 100 is attached can be reduced, and the application range of the solar cell module 100 can be broadened.

Examples of the resin that forms the surface protective layer 10 include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT) and polyethylene naphthalate (PEN), polycarbonate (PC), amorphous polyarylate, polyacetal (POM) Polyether ketone (PEK), polyether ether ketone (PEEK), polyether sulfone, modified polyphenylene ether and the like can be used. Among these, the material for forming the surface protective layer 10 is preferably polycarbonate (PC) from the viewpoint of impact resistance and light transmission.

The surface protective layer 10 preferably has a light transmitting property. Although not particularly limited, the total light transmittance of the surface protective layer 10 is preferably 80% to 100%, and more preferably 85% to 100%. By setting the total light transmittance of the surface protective layer 10 in such a range, light can efficiently reach the photoelectric conversion unit 40. The total light transmittance can be determined, for example, by the method of Japanese Industrial Standard JIS K7361-1: 1997 (ISO 13468-1: 1996) (Plastic-Test method of total light transmittance of transparent materials-Part 1: Single beam method) It can be measured.

The thickness of the surface protective layer 10 is not particularly limited as long as it plays a role of protecting the surface of the solar cell module 100, but is preferably 0.1 mm to 100 mm, and more preferably 0.5 mm to 50 mm. By setting the thickness of the surface protective layer 10 in such a range, the solar cell module 100 can be appropriately protected, and light can efficiently reach the photoelectric conversion unit 40.

The surface protective layer 10 preferably contains a UV absorber. Such an ultraviolet absorber can absorb ultraviolet rays that cause deterioration of the resin. Therefore, the oxygen barrier function of the barrier layer 20 can be maintained for a long time. In particular, a resin having a hydroxyl group in the molecule as described later tends to be easily deteriorated as compared with other resins. Therefore, in order to suppress degradation of resin, it is preferable that the surface protection layer 10 contains the ultraviolet absorber.

The UV absorber is not particularly limited, and examples thereof include benzophenone-based UV absorbers, benzotriazole-based UV absorbers, and triazine-based UV absorbers. A ultraviolet absorber may be used individually by 1 type, and may be used in combination of multiple types.

Examples of benzophenone-based UV absorbers include 2-hydroxy-4-n-octyloxybenzophenone, 2-hydroxy-4-methoxybenzophenone, and 2,2'-dihydroxy-4,4'-dimethoxybenzophenone.

Examples of benzotriazole-based UV absorbers include 2- (2H-benzotriazol-2-yl) -4- (1,1,3,3-tetramethylbutyl) phenol and 2,2'-methylenebis [6- ( 2H-benzotriazol-2-yl) -4- (1,1,3,3-tetramethylbutyl) phenol], 2- (2H-benzotriazol-2-yl) -p-cresol, 2- (5-) Chloro-2H-benzotriazol-2-yl) -6-tert-butyl-4-methylphenol and the like.

Examples of triazine-based UV absorbers include 2- (4,6-diphenyl-1,3,5-triazin-2-yl) -5- [2- (2-ethylhexanoyloxy) ethoxy) phenol, 4,6-tris (2-hydroxy-4-hexyloxy-3-methylphenyl) -1,3,5-triazine and the like.

The content of the ultraviolet absorber is not particularly limited, but is preferably 0.1% by mass to 10% by mass with respect to the entire surface protective layer 10. By making content of a ultraviolet absorber into 0.1 mass% or more, the ultraviolet-ray absorption effect of the surface protective layer 10 can be heightened. Moreover, the fall of the mechanical strength of the surface protective layer 10 can be suppressed by content of a ultraviolet absorber being 10 mass% or less. The content of the ultraviolet absorber is more preferably 1% by mass to 5% by mass with respect to the entire surface protective layer 10.

The surface protective layer 10 according to the present embodiment may further include a light stabilizer in addition to the above-described ultraviolet light absorber. As the light stabilizer, for example, a hindered amine light stabilizer (HALS) can be used. Examples of hindered amine light stabilizers include tetrakis (2,2,6,6-tetramethyl-4-piperidyl) butane-1,2,3,4-tetracarboxylate, bis (2,2,6,6) -Tetramethyl-4-piperidyl) sebacate, bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, tetrakis (1,2,2,6,6-pentamethyl-4-piperidyl) butane- 1,2,3,4-tetracarboxylate, bis (1-undecanoxy-2,2,6,6-tetramethylpiperidin-4-yl) carbonate and the like. One of these light stabilizers may be used alone, or two or more thereof may be used in combination. The content of the light stabilizer is not particularly limited, but is preferably 0.01% by mass to 3% by mass, and more preferably 0.1% by mass to 1% by mass with respect to the entire surface protective layer 10 preferable.

In addition, as shown in FIG. 3, the solar cell module 100 according to the present embodiment further includes a light resistant layer 60 containing an ultraviolet absorber on the surface of the surface protective layer 10 opposite to the sealing layer 30. Is also preferred. The light-resistant layer 60 may be formed by laminating a resin layer containing an ultraviolet absorber, but from the viewpoint of reduction of manufacturing cost, a coating composition containing an ultraviolet absorber is applied to the surface on the light receiving surface side of the surface protective layer 10 It may be formed by curing. That is, the light-resistant layer 60 is preferably a coating layer formed by curing the coating composition.

The ultraviolet absorber contained in the light resistant layer 60 is not particularly limited, and the above-mentioned ultraviolet absorber can be used. The content of the ultraviolet absorber is also the same as above, and is preferably 0.1% by mass to 10% by mass, and more preferably 1% by mass to 5% by mass, with respect to the entire light-resistant layer 60. Moreover, the light resistant layer 60 may further contain the light stabilizer mentioned above. The content of the light stabilizer is also the same as above, and is preferably 0.01% by mass to 3% by mass, and more preferably 0.1% by mass to 1% by mass, with respect to the whole of the light resistant layer 60. preferable.

The coating composition used for the light-resistant layer 60 is not particularly limited, and includes, for example, monomers such as styrenic monomers, olefin monomers, vinyl monomers, and acrylic monomers. As a styrene-type monomer, styrene etc. are mentioned, for example. Examples of olefin monomers include ethylene and propylene. Examples of vinyl monomers include vinyl chloride and vinylidene chloride. As an acryl-type monomer, a methacrylate, an acrylate, etc. are mentioned, for example. The above monomer components may be used alone or in combination of two or more.

The paint composition used for the light resistant layer 60 can contain a polymerization initiator for promoting the polymerization reaction of the monomer having a carbon-carbon unsaturated bond. The content of the polymerization initiator is not particularly limited, but is preferably 1% by mass to 10% by mass with respect to the entire light resistant layer 60. As the polymerization initiator, although at least one of a photopolymerization initiator and a thermal polymerization initiator can be used, it is preferable to use a photopolymerization initiator. By using the photopolymerization initiator, the monomer is instantaneously cured by irradiating the active energy ray, so that the manufacturing process can be shortened.

The photopolymerization initiator used to form the coating layer is a compound having a function of initiating the polymerization reaction of the monomer, absorbs light of a specific wavelength from the active energy ray to be in an excited state, and generates radicals and ions. It is a substance. As such a photopolymerization initiator, for example, at least one selected from the group consisting of benzoin ether type, ketal type, acetophenone type, benzophenone type, and thioxanthone type can be used.

The thermal polymerization initiator used for the light resistant layer 60 is a compound having a function of initiating a polymerization reaction of monomers, and is a substance which generates active species such as radicals and ions by heating. As the thermal polymerization initiator, at least one selected from the group consisting of azo compounds such as 2,2'-azobis (isobutyronitrile), peroxides such as benzoyl peroxide, benzenesulfonic acid ester and alkyl sulfonium salt It can be used.

The method of applying the coating composition used for the light-resistant layer 60 is not particularly limited, and methods such as spray coating, dip coating, flow coating, spin coating, roll coating, brush coating, and sponge coating may be used. Can. Then, the light resistant layer 60 can be formed by curing the applied coating composition.

(Barrier layer 20)
The solar cell module 100 according to the present embodiment includes a barrier layer 20 disposed on at least one surface of the surface protective layer 10. Such a barrier layer 20 can suppress oxygen from the side of the surface protective layer 10 in the solar cell module 100. Therefore, yellowing of the sealing layer 30 can be suppressed.

For example, as shown in FIGS. 2 and 3, the solar cell module 100 according to the present embodiment preferably includes a barrier layer 20 disposed below the surface protective layer 10. More specifically, the solar cell module 100 preferably includes a barrier layer 20 disposed between the surface protective layer 10 and the sealing layer 30. More specifically, the solar cell module 100 preferably includes the barrier layer 20 disposed between the surface protective layer 10 and the surface sealing layer 32.

In addition, as shown in FIG. 4, the solar cell module 100 according to the present embodiment preferably includes a barrier layer 20 disposed on the surface protective layer 10. Specifically, the solar cell module 100 preferably includes the barrier layer 20 disposed on the side opposite to the sealing layer 30 with respect to the surface protective layer 10.

Furthermore, as shown in FIG. 5, the solar cell module 100 according to the present embodiment preferably includes barrier layers 20 disposed on both sides of the surface protective layer 10. Arranging the barrier layer 20 on both sides of the surface protective layer 10 is preferable because the oxygen barrier property of the solar cell module 100 can be further improved.

The barrier layer 20 is preferably disposed on at least one surface of the surface protective layer 10 and at least one surface of the back surface protective layer 50. In the present embodiment, the barrier layer 20 is disposed not only on the side of the surface protective layer 10 with respect to the sealing layer 30 but also on the side of the back surface protective layer 50 with respect to the sealing layer 30. Because the amount of oxygen can be reduced, yellowing of the sealing layer 30 can be suppressed. In particular, in the case where a material through which oxygen is easily transmitted is used for the back surface protective layer 50, it is effective if the barrier layer 20 is disposed also on the back surface protective layer 50 side with respect to the sealing layer 30.

For example, as shown in FIG. 6, the solar cell module 100 according to the present embodiment preferably includes the barrier layer 20 disposed on the back surface protective layer 50. Specifically, the solar cell module 100 preferably includes the barrier layer 20 disposed between the sealing layer 30 and the back surface protective layer 50. More specifically, the solar cell module 100 preferably includes the barrier layer 20 disposed between the back surface sealing layer 34 and the back surface protective layer 50.

Moreover, as shown in FIG. 7, it is also preferable that the solar cell module 100 according to the present embodiment includes a barrier layer 20 disposed below the back surface protective layer 50. Specifically, the solar cell module preferably includes the barrier layer 20 disposed on the side opposite to the sealing layer 30 with respect to the back surface protective layer 50.

Furthermore, as shown in FIG. 8, it is preferable that the solar cell module 100 according to the present embodiment also includes barrier layers 20 disposed on both sides of the back surface protective layer 50. Arranging the barrier layer 20 on both sides of the back surface protective layer 50 is preferable because the oxygen barrier property of the solar cell module 100 can be further improved.

In the embodiment shown in FIGS. 6 to 8, an example is shown in which one barrier layer 20 is disposed between the surface protective layer 10 and the sealing layer 30. However, the present embodiment is not limited to the illustrated mode, and the barrier layer 20 may be disposed on at least one of the surface of the surface protective layer 10 and at least one of the back surface protective layer 50. The materials forming the plurality of barrier layers 20 may be the same as or different from one another.

The solar cell module 100 according to the present embodiment includes the barrier layer 20 having an oxygen permeability of 1.0 × 10 ⁻⁵ mol / (m ² · s · Pa) or less. In the present embodiment, as described above, since the surface protective layer 10 is formed of resin, the weight of the solar cell module 100 is reduced. However, since the resin has a lower oxygen permeability than glass, the sealing layer 30 easily yellows due to metal ions forming the interconnector 44 in the photoelectric conversion unit 40. However, in the present embodiment, yellowing of the sealing layer 30 can be suppressed by setting the oxygen permeability to the above numerical value or less. The oxygen permeability of the barrier layer 20 is preferably 1.0 × 10 ⁻⁹ mol / (m ² · s · Pa) or less, and 1.0 × 10 ⁻¹² mol / (m ² · s ···· Pa) or less is more preferable. Further, the oxygen permeability can be measured in accordance with JIS K 7126-2 (Plastics-Films and Sheets-Gas Permeability Test Method-Part 2: Equal Pressure Method). The oxygen permeability can be measured at a measurement temperature of 23 ° C. and a measurement humidity of 90% RH.

The barrier layer 20 is an inorganic deposition layer formed by depositing an inorganic material, a resin composed of an organic polymer, a layered clay mineral-containing layer in which a layered clay mineral is dispersed in a resin composed of an organic polymer Etc.

As an inorganic material which forms an inorganic vapor deposition layer, metals, such as silicon, aluminum, magnesium, nickel, tin, and titanium, and the oxide of the said metal, nitride, and carbide etc. are mentioned. Among these, the material for forming the inorganic deposition layer is preferably at least one of silicon oxide and aluminum oxide, and more preferably silicon oxide. The inorganic vapor deposition layer can be formed on at least one surface of the surface protective layer 10 by, for example, physical vapor deposition (PVD) or chemical vapor deposition (CVD).

As resin composed of organic polymer, acrylic polymer, vinyl alcohol polymer, polyamide polymer, polyether polymer, polyester polymer, polyvinylidene chloride polymer, polymer modified with epoxy group, etc. may be used it can.

As the acrylic polymer, for example, polyacrylamide, polyacrylic acid and the like can be used. Also, as the vinyl alcohol polymer, for example, polyvinyl alcohol (PVA), partially saponified polyvinyl alcohol, ethylene-vinyl alcohol copolymer (EVOH), etc. can be used. As the polyamide polymer, for example, 6-nylon, 6,6-nylon and the like can be used. As a polyether type polymer, polyalkylene ether etc. can be used, for example. As the polyester-based polymer, for example, a polymer containing a dicarboxylic acid component and a glycol component as constituent components, and a polymer containing an aliphatic hydroxycarboxylic acid component as constituent components can be used. As the polyvinylidene chloride-based polymer, a polymer whose component contains a vinylidene chloride component can be used. As the polymer modified with an epoxy group, for example, polymers obtained by modifying the above-mentioned various polymers with glycidyl group, such as polyglycidyl (meth) acrylate and polyalkylene ether glycidyl ether, can be used. Various vinyl alcohol polymers, various polyamide polymers, and various polyether polymers are preferable from the viewpoint of barrier property, availability, and affinity with layered clay minerals etc. Various vinyl alcohol polymers, various polyether polymers Is more preferred. The above polymers can be used alone or in combination of two or more.

In addition, polyvinyl alcohol and partially saponified polyvinyl alcohol are marketed in various grades as, for example, Kuraray Co., Ltd. and Nippon Kayaku Bi. Poval Co., Ltd. as "Poval" and Nippon Synthetic Chemical Industry Co., Ltd. as "Gosenol (registered trademark)". And any of them can be preferably used. In addition, various grades of ethylene-vinyl alcohol copolymer are marketed by Kuraray Co., Ltd. as "EVAL (registered trademark)" and Nippon Synthetic Chemical Industry Co., Ltd. as "Soranol (registered trademark)". It can be used preferably.

The layered clay mineral-containing layer preferably contains a resin composed of the organic polymer and a layered clay mineral dispersed in the resin composed of the organic polymer. In the present embodiment, when the layered clay mineral is contained in the resin, the layered clay mineral blocks part of the oxygen passage in the resin, so the oxygen permeability of the barrier layer 20 is reduced. can do.

In addition, the layered clay mineral-containing layer generally tends to have a large tensile breaking strain. Therefore, even when the solar cell module 100 is processed into a curved surface shape or the like, in the manufacturing process of the solar cell module 100, a crack which is a cause of the decrease in the barrier property does not easily occur in the inorganic vapor deposition layer. Therefore, the barrier layer 20 is preferably a layered clay mineral-containing layer in which a layered clay mineral is dispersed in a resin.

Although resin which comprised the said organic polymer can be used for resin which forms a layered clay mineral containing layer, it is preferable to have a hydroxyl group in a molecule | numerator. Specifically, the resin forming the barrier layer 20 preferably contains at least one of polyvinyl alcohol (PVA) and ethylene-vinyl alcohol copolymer (EVOH). These resins have high oxygen barrier properties. Also, these resins have hydroxyl groups in the molecule. Moreover, since a layered clay mineral generally has a chemical structure which chemically bonds a hydroxyl group such as a hydrogen bond, a resin and a layered clay mineral can be obtained by using a resin having a hydroxyl group in the molecule. Chemical bond with can be strengthened. Therefore, the oxygen barrier property of the barrier layer 20 can be further improved.

Layered clay minerals include sheet structures such as tetrahedral sheets and octahedral sheets formed by atoms such as oxygen, silicon and aluminum. And layered clay minerals generally have a layered structure in which a sheet structure is layered. Therefore, the path through which oxygen in the resin passes is narrowed and lengthened by this layered clay mineral, so that the oxygen permeability of the barrier layer 20 can be reduced.

The thickness (size in the minor axis direction) of the sheet structure is generally about 0.1 nm to 5 nm, and the size in the planar direction (size in the major axis direction) perpendicular to the thickness direction of the sheet structure It is about 10 nm to 5 μm, and the sheet structure has a high aspect ratio. The aspect ratio of the sheet structure is generally 20 to 10000. The thickness of the sheet structure and the size in the plane direction can be observed by an electron microscope or the like. The aspect ratio is the ratio of the size in the major axis direction to the size in the minor axis direction of the sheet structure.

Layered clay minerals are not particularly limited. For example, layers such as saponite, hectorite, smectite such as montmorillonite, beidellite and Stephenite, kaolin minerals such as kaolinite, mica such as muscovite and illite, talc, and vermiculite It is preferable that it is a silicate.

The content of the layered clay mineral in the barrier layer 20 is not particularly limited, but is preferably 30% by mass to 80% by mass. By setting the content of the layered clay mineral to 30% by mass or more, the path of oxygen passing through the inside of the resin becomes narrower and longer, so that the oxygen permeability can be further reduced. Further, by setting the content of the layered clay mineral to 80% by mass or less, the flexibility of the barrier layer 20 is improved, so that breakage or the like of the barrier layer 20 can be suppressed. The content of the layered clay mineral in the barrier layer 20 is more preferably 30% by mass to 50% by mass.

The layered clay mineral-containing layer may further contain inorganic particles. When the barrier layer 20 contains inorganic particles, the mechanical strength of the barrier layer 20 is improved, so that the rigidity of the barrier layer 20 can be improved. Moreover, the thermal contraction of the barrier layer 20 can be suppressed by the barrier layer 20 containing inorganic particles.

The material for forming the inorganic particles is not particularly limited, but an inorganic material having high affinity to the resin is preferable. Specifically, when a hydroxyl group is contained in the molecule forming the resin, the material forming the inorganic particles is preferably an inorganic material having a high affinity for the hydroxyl group. The inorganic material having high affinity to the hydroxyl group is preferably silicon oxide, aluminum oxide, titanium oxide, zirconium oxide or the like. Since these oxides easily hydrogen bond with hydroxyl groups, they have high affinity with the resin, and the rigidity can be improved while suppressing the decrease in the oxygen permeability of the barrier layer 20.

The average particle size of the inorganic particles is not particularly limited, but preferably 0.01 μm to 200 μm. By setting the average particle size of the inorganic particles to 0.01 μm or more, the rigidity of the barrier layer 20 can be further improved. Moreover, the fall of the light transmittance of the barrier layer 20 can be suppressed by the average particle diameter of an inorganic particle being 200 micrometers or less. The average particle diameter of the inorganic particles is more preferably 0.01 μm to 100 μm. Furthermore, in the present specification, the average particle size represents the particle size when the cumulative value of the particle size distribution on a volume basis is 50%, and can be measured by, for example, a laser diffraction / scattering method.

The content of the inorganic particles in the barrier layer 20 is not particularly limited, but is preferably 30% by mass to 80% by mass. By setting the content of the inorganic particles to 30% by mass or more, the rigidity of the barrier layer 20 can be further improved. Moreover, the fall of the light transmittance of the barrier layer 20 can be suppressed by content of an inorganic particle being 80 mass% or less. The content of the inorganic particles in the barrier layer 20 is more preferably 30% by mass to 70% by mass.

The thickness of the barrier layer 20 is not particularly limited, but is preferably 5 nm or more and 100 μm or less. By setting the thickness of the barrier layer 20 to 5 nm or more, the oxygen barrier function can be improved. In addition, by setting the thickness of the barrier layer 20 to 100 μm or less, light can efficiently reach the photoelectric conversion unit 40. In addition, when the barrier layer 20 is an inorganic vapor deposition layer, it is preferable that the thickness of the barrier layer 20 is 5 nm or more and 800 nm or less. When the barrier layer 20 is a layered clay mineral-containing layer, the thickness of the barrier layer 20 is preferably 100 nm or more and 100 μm or less, and more preferably 1 μm or more and 30 μm or less.

The barrier layer 20 preferably has translucency. Although not particularly limited, the total light transmittance of the barrier layer 20 is preferably 60% to 100%, and more preferably 70% to 100%. The total light transmittance of the barrier layer 20 is more preferably 80% to 100%. By setting the total light transmittance of the barrier layer 20 in such a range, light can efficiently reach the photoelectric conversion unit 40. The total light transmittance can be measured, for example, by a method such as JIS K7361-1: 1997.

The layered clay mineral-containing layer can be formed, for example, as follows. The resin, layered clay mineral and inorganic particles can be dispersed in a solvent or the like to prepare a coating composition. Next, the layered clay mineral-containing layer can be formed by applying the prepared coating composition on at least one surface of the surface protective layer 10 and drying the solvent.

The method for preparing the coating composition is not particularly limited. For example, a layered clay mineral and inorganic particles can be uniformly stirred with a stirrer or the like in a solution in which a resin is dissolved in a solvent to prepare a coating composition.

The solvent is not particularly limited as long as it can dissolve the resin, and at least one of water and an organic solvent can be used. Examples of the organic solvent include aromatic hydrocarbons (such as toluene and xylene), alcohols (such as methanol, ethanol and isopropyl alcohol), ketones (such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone), aliphatic hydrocarbons Examples include (such as hexane and heptane), ethers (such as tetrahydrofuran), amide solvents (such as N, N-dimethylformamide (DMF) and dimethylacetamide (DMAc)), methyl acetate, butyl acetate and the like. One of these solvents may be used alone, or two or more thereof may be used in combination. Although the addition amount of the solvent is not particularly limited, it can be, for example, 0.1 part by mass to 500 parts by mass with respect to 100 parts by mass of the coating composition.

In addition, when using polyvinyl alcohol (PVA) as resin, it is preferable to use water and alcohol as a solvent from an affinity viewpoint, for example. When ethylene-vinyl alcohol copolymer (EVOH) is used as the resin, it is preferable to use an organic solvent such as aromatic hydrocarbon as the solvent from the viewpoint of affinity.

The method of applying the coating composition used to form the barrier layer 20 is not particularly limited, and spray coating, dip coating, flow coating, spin coating, roll coating, brush coating, sponge coating, etc. Methods can be used. Then, the barrier layer 20 can be formed by removing the solvent by heating or the like.

The barrier layer 20 can be formed by applying and drying the coating composition as described above, whereby the interlayer distance of the layered clay mineral can be reduced and the barrier property of the barrier layer 20 can be further enhanced. When the barrier property of the barrier layer 20 is high, the film thickness of the barrier layer 20 can be reduced. When the film thickness of the barrier layer 20 is reduced, the surface protection layer 10 can easily follow the surface protection layer 10 without wrinkles when processing the curved surface of the solar cell module 100. Further, in the present embodiment, since the surface protective layer 10 contains a resin, even when the surface protective layer 10 is processed into a curved surface, since the resin itself has elasticity, cracking is unlikely to occur. Therefore, it is preferable to make the barrier layer 20 a layered clay mineral-containing layer, since the solar cell module 100 suitable for curved surface processing can be produced.

(Sealing layer 30)
The sealing layer 30 is disposed under the surface protective layer 10 and the barrier layer 20 and seals the photoelectric conversion unit 40. By providing the sealing layer 30 as described above, the solar cell module 100 can protect the photoelectric conversion unit 40 from external impact and the like. The shape of the sealing layer 30 is not particularly limited as in the case of the surface protective layer 10, and may be a polygon such as a circle, an ellipse, or a rectangle depending on the application. Further, similarly to the surface protective layer 10, the cross-sectional shape of the sealing layer 30 may be rectangular or may be curved in the stacking direction (z-axis direction) of each layer of the solar cell module 100.

The thickness of the sealing layer 30 is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less, and more preferably 0.2 mm or more and 1.0 mm or less. By setting the thickness of the sealing layer 30 in such a range, the photoelectric conversion portion 40 can be appropriately protected, and light can efficiently reach the photoelectric conversion portion 40.

The photoelectric conversion unit 40 may be disposed in contact with the surface protective layer 10 or the barrier layer 20, and may be disposed in contact with the back surface protective layer 50 or the barrier layer 20 described later. However, from the viewpoint of impact absorption, the sealing layer 30 is disposed on the surface protection layer 10 side with respect to the photoelectric conversion unit 40 and the back surface protection layer 50 side with respect to the photoelectric conversion unit 40. The back surface sealing layer 34 arrange | positioned at may be provided.

The surface sealing layer 32 is disposed between the surface protective layer 10 and the photoelectric conversion unit 40, and can protect the photoelectric conversion unit 40 from external impact or the like. The shape of the surface sealing layer 32 is not particularly limited as in the case of the surface protective layer 10, and may be a polygon such as a circle, an ellipse, or a rectangle depending on the application. Further, similarly to the surface protective layer 10, the cross-sectional shape of the surface sealing layer 32 may be rectangular or may be curved in the stacking direction (z-axis direction) of each layer of the solar cell module 100.

The material which forms the surface sealing layer 32 is not specifically limited, For example, ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB), polyethylene terephthalate (PET), polyolefin (PO), polyimide (PI) etc. And at least one selected from the group consisting of thermosetting resins such as epoxy resins, urethane resins, and polyimide resins. These resins may be modified resins or may be used in combination. Among these, the material forming the surface sealing layer 32 is preferably at least one of ethylene-vinyl acetate copolymer (EVA) and polyolefin (PO).

The surface sealing layer 32 preferably has a light transmitting property. Although not particularly limited, the total light transmittance of the surface sealing layer 32 is preferably 60% to 100%, and more preferably 70% to 100%. Further, the total light transmittance of the surface sealing layer 32 is more preferably 80% to 100%. By setting the total light transmittance of the surface sealing layer 32 in such a range, light can efficiently reach the photoelectric conversion unit 40. The total light transmittance can be measured, for example, by a method such as JIS K7361-1: 1997.

The thickness of the surface sealing layer 32 is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less, and more preferably 0.2 mm or more and 1.0 mm or less. By setting the thickness of the surface sealing layer 32 in such a range, the photoelectric conversion unit 40 can be appropriately protected, and light can efficiently reach the photoelectric conversion unit 40.

The back surface sealing layer 34 can be disposed between the photoelectric conversion unit 40 and the back surface protective layer 50. That is, the back surface sealing layer 34 is disposed under the front surface sealing layer 32 and the photoelectric conversion unit 40, and protects the photoelectric conversion unit 40 from external impact and the like on the light receiving surface side.

The material for forming the back surface sealing layer 34 is not particularly limited. For example, ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB), polyethylene terephthalate (PET), polyolefin (PO), polyimide (PI), etc. And at least one selected from the group consisting of thermosetting resins such as epoxy resins, urethane resins, and polyimide resins. These resins may be modified resins or may be used in combination. Among these, the material forming the back surface sealing layer 34 is preferably at least one of ethylene-vinyl acetate copolymer (EVA) and polyolefin (PO). A material similar to that of the surface sealing layer 32 may be used as a material for forming the back surface sealing layer 34, and the material may be formed of a material different from that of the surface sealing layer 32.

The thickness of the back surface sealing layer 34 is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less, and more preferably 0.2 mm or more and 1.0 mm or less. By setting the thickness of the back surface sealing layer 34 in such a range, the photoelectric conversion unit 40 can be appropriately protected from impact or the like.

(Photoelectric conversion unit 40)
The photoelectric conversion unit 40 converts light energy into electrical energy. The photoelectric conversion unit 40 may include the solar battery cell 42, and may include the solar battery cell string 46 in which the solar battery cells 42 are connected by the interconnector 44.

Examples of the solar battery cell 42 include a silicon solar cell, a compound solar cell, and an organic solar cell. As a silicon system solar cell, a monocrystal silicon system solar cell, a polycrystalline silicon system solar cell, a microcrystalline silicon system solar cell, an amorphous silicon system solar cell etc. are mentioned. Examples of compound solar cells include GaAs solar cells, CIS solar cells, CIGS solar cells, and CdTe solar cells. As an organic type solar cell, a dye-sensitized solar cell, an organic thin film solar cell, etc. are mentioned. Further, as the solar battery cell 42, a heterojunction solar cell or a multijunction solar cell can also be used.

Finger electrodes (not shown) can be disposed on the light receiving surface side and the back surface side of the solar battery cell 42. The finger electrode is formed by arranging a plurality of metal wires substantially in parallel. The finger electrodes can have, for example, a height of 10 μm to 30 μm and a width of 100 μm to 500 μm. The finger electrodes collect a current generated by light such as sunlight and supply the current to bus bar electrodes (not shown).

The bus bar electrodes are generally formed by two to three metal wires, and are disposed to intersect the finger electrodes substantially perpendicularly. Although the bus bar electrodes are not particularly limited, the height can be 10 μm to 30 μm, and the width can be 100 μm to 500 μm. The bus bar electrodes supply the current collected from the finger electrodes to the interconnector 44.

In the present embodiment, the solar cell string 46 includes a plurality of solar cells 42 and an interconnector 44 electrically connecting the plurality of solar cells 42. In the solar battery cell string 46, the interconnector 44 electrically connects the bus bar electrode provided on the light receiving surface side of one solar battery cell 42 and the bus bar electrode provided on the back surface side of the other solar battery cell 42. It can be formed by connecting to

Resin or solder can be used to connect the interconnector 44 and the bus bar electrode. This resin may be either conductive or nonconductive. In the case of the nonconductive resin, the interconnector 44 and the bus bar electrode are electrically connected by being directly connected.

The interconnector 44 is not particularly limited as long as it can electrically connect the solar cells 42 to each other, and can be, for example, an interconnector 44 formed of an elongated foil-like metal substrate.

The material for forming the metal base is not particularly limited, and metals such as gold, silver, copper, platinum, aluminum and nickel can be used. Among these, from the viewpoint of processability, durability and economy, the material forming the metal base is preferably copper.

The width of the metal substrate is preferably 0.5 mm to 10 mm, and more preferably 1 mm to 3 mm. The thickness of the metal base is preferably 0.01 mm to 3.0 mm, and more preferably 0.05 mm to 1.0 mm.

(Back surface protection layer 50)
The solar cell module 100 according to the present embodiment includes a back surface protection layer 50 disposed below the sealing layer 30. The back surface protective layer 50 can be disposed on the opposite side to the light receiving surface side of the photoelectric conversion unit 40. That is, the back surface protective layer 50 is disposed on the back surface side with respect to the photoelectric conversion unit 40. In the present embodiment, the back surface protective layer 50 is disposed below the back surface sealing layer 34. The back surface protective layer 50 can protect the back surface side of the solar cell module 100.

The material for forming the back surface protective layer 50 is not particularly limited. For example, inorganic materials such as glass, metal materials such as aluminum, and polyimide (PI), cyclic polyolefin, polycarbonate (PC), polymethyl methacrylate (PMMA), Using at least one material selected from the group consisting of resin materials such as polyetheretherketone (PEEK), polystyrene (PS), polyethylene terephthalate (PET), polyethylene naphthalate (PEN) and fiber reinforced plastic (FRP) Can. Examples of fiber reinforced plastic (FRP) include glass fiber reinforced plastic (GFRP), carbon fiber reinforced plastic (CFRP), aramid fiber reinforced plastic (AFRP), and cellulose fiber reinforced plastic. Glass epoxy etc. are mentioned as a glass fiber reinforced plastic (GFRP). The fiber reinforced plastic may be a UD (UniDirection) material in which fibers are aligned in one direction, or may be a woven material woven by intersecting fibers. When a UD material is used for the back surface protective layer 50, it is difficult to expand and shrink in the fiber direction, and therefore, depending on the direction in which the UD material is disposed, breakage of the solar battery cell 42 or cutting of the interconnector 44 can be suppressed. The back surface protective layer 50 is preferably made of carbon fiber reinforced plastic because it is not easily deformed and is lightweight.

Furthermore, the back surface protective layer 50 is more preferably at least one selected from the group consisting of a honeycomb structure, a foam and a porous body. Such a structure can reduce the weight of the solar cell module 100 while maintaining rigidity. The materials for forming the honeycomb structure, the foam and the porous body are not particularly limited, and the above-mentioned materials can be used. From the viewpoint of rigidity and weight reduction, the honeycomb structure is preferably formed of a material containing at least one of aluminum and cellulose. Preferably, at least one of the foam and the porous body is formed of a resin material such as polyurethane, polyolefin, polyester, polyamide, or polyether.

The thickness of the back surface protective layer 50 is not particularly limited, but is preferably 0.01 mm or more and 10 mm or less, more preferably 0.05 mm or more and 5.0 mm or less, and is 0.07 mm or more and 1.0 mm or less Is more preferred. In particular, when the back surface protective layer 50 is a fiber reinforced plastic, the diameter of one fiber is preferably the lower limit value of the thickness. By setting the thickness of the back surface protective layer 50 in such a range, the deflection of the back surface protective layer 50 can be suppressed, and the weight of the solar cell module 100 can be further reduced.

When the thickness of the back surface protective layer 50 is thin (for example, 0.2 mm or less), the following effects can be expected in addition to the reduction in weight and thickness. That is, it is possible to reduce the warpage of the entire solar cell module 100 due to the reduction in the influence of thermal contraction when the temperature difference occurs in the back surface protective layer 50 and the decrease in the rigidity of the back surface protective layer 50. .

Also, when the back surface protective layer 50 is made of fiber reinforced plastic of UD material and the thickness of the back surface protective layer 50 is reduced, the UD material is partially overlapped as needed to reinforce a desired portion, etc. It is possible to make the characteristics of the back surface protective layer 50 strong and weak. In the case of overlapping the UD material, fibers of the UD material may be overlapped in the same direction or fibers of the UD material may be overlapped in different directions such as perpendicular, depending on desired characteristics.

Moreover, when the thickness of the back surface protective layer 50 becomes thin, the back surface protective layer 50 can be bonded together while following the shape of the sealing layer 30 (surface to be bonded), and between the sealing layer 30 and the back surface protective layer 50 Air bubbles can be difficult to mix. In addition, even if the surface protective layer 10 has a curved surface, for example, the back surface protective layer 50 can be bonded to fit the shape of the surface protective layer 10 through the sealing layer 30. Therefore, it is possible to easily manufacture the solar cell module 100 having a curved surface shape while suppressing the mixture of air bubbles. In this case, if the film module is manufactured in a state where the back surface protective layer 50, the sealing layer 30, and the barrier layer 20 are attached to each other, the film module itself has flexibility. Bonding can be facilitated. In addition, since the followability of the back surface protective layer 50 is high, for example, when manufacturing the solar cell module 100 having a curved surface shape by laminating the respective layers, it is difficult for a local load to be applied to the solar cells 42 etc. Damage to the cell 42 can be suppressed. This suppression of breakage of the solar battery cell 42 is particularly effective when the solar battery module 100 further includes a gel layer 70 described later. Furthermore, since the sealing layer 30 can be quickly heated and crosslinked when the thickness of the back surface protective layer 50 becomes thin, not only the manufacturing time of the solar cell module 100 is shortened but also the surface protective layer 10 is thermally deformed. Can be suppressed.

As shown in FIG. 9, in the solar cell module 100 according to the present embodiment, it is preferable that a gel layer 70 be disposed between the surface protective layer 10 and the sealing layer 30. When the barrier layer 20 is disposed between the surface protective layer 10 and the sealing layer 30, it is preferable that the gel layer 70 be disposed between the barrier layer 20 and the sealing layer 30. In the present embodiment, the surface protective layer 10 is formed of a resin, and the surface protective layer 10 easily undergoes thermal expansion and contraction due to temperature change. However, when the solar cell module 100 is provided with the gel layer 70, the thermal expansion and contraction of the surface protective layer 10 becomes difficult to be transmitted to the solar cell string 46. Therefore, the thermal expansion and contraction due to the temperature change of the surface protective layer 10 can suppress the breakage of the solar battery cell 42 and the disconnection of the interconnector 44.

The tensile elastic modulus of the gel layer 70 is not particularly limited as long as breakage of the solar battery cell 42 and cutting of the interconnector 44 can be suppressed, but it is preferably 0.1 kPa or more and less than 5 MPa. By setting the tensile elastic modulus of the gel layer 70 to 0.1 kPa or more, the rigidity of the solar cell module 100 can be improved. Further, by setting the tensile elastic modulus of the gel layer 70 to less than 5 MPa, breakage of the solar battery cell 42 and cutting of the interconnector 44 can be further suppressed. The tensile modulus of elasticity of the gel layer 70 is more preferably 1 kPa or more and 1 MPa or less.

The material for forming the gel layer 70 is not particularly limited, and various gels can be used. Although the gel is not particularly limited, it is classified into a gel containing a solvent and a gel not containing a solvent. Examples of the gel containing a solvent include a hydrogel whose dispersion medium is a water gel, and an organogel whose dispersion medium is a gel of an organic solvent. Further, as the gel containing a solvent, any of a polymer gel having a number average molecular weight of 10000 or more, an oligomer gel having a number average molecular weight of 1000 to less than 10000, and a low molecular gel having a number average molecular weight of less than 1000 can be used. Among these, from the viewpoint of improving the rigidity of the solar cell module 100, it is preferable to use a polymer gel containing a solvent or a gel containing no solvent. Further, from the viewpoint of suppressing breakage of the solar cell 42 and cutting of the interconnector 44, the gel layer 70 more preferably contains at least one selected from the group consisting of silicone gel, acrylic gel and urethane gel.

The thickness of the gel layer 70 is not particularly limited, but is preferably 0.1 mm or more and 10 mm or less. By setting the thickness of the gel layer 70 to 0.1 mm or more, breakage of the solar battery cell 42 and disconnection of the interconnector 44 can be further suppressed. In addition, by setting the thickness of the gel layer 70 to 10 mm or less, light can efficiently reach the photoelectric conversion unit 40. The thickness of the gel layer 70 is more preferably 0.2 mm or more and 1.0 mm or less.

The gel layer 70 preferably has a light transmitting property. Although not particularly limited, the total light transmittance of the gel layer 70 is preferably 60% to 100%, and more preferably 70% to 100%. The total light transmittance of the gel layer 70 is more preferably 80% to 100%. By setting the total light transmittance of the gel layer 70 to such a range, light can efficiently reach the photoelectric conversion unit 40. The total light transmittance can be measured, for example, by a method such as JIS K7361-1: 1997.

(flame)
The solar cell module 100 according to the present embodiment may include a frame (not shown). The frame supports the peripheral edge of the solar cell module 100 and is used when installing the solar cell module 100 on a roof or the like. The material for forming the frame is not particularly limited, but is preferably made of aluminum from the viewpoint of strength and weight reduction.

The solar cell module 100 according to the present embodiment can be mounted on the roof or the like of a vehicle including a building or an automobile. At this time, the shape of the solar cell module 100 may have a curved surface so as to conform to the shape of the roof.

As described above, the solar cell module 100 according to the present embodiment includes the surface protection layer 10 formed of resin. In addition, the solar cell module 100 is disposed on at least one surface of the surface protective layer 10, and the barrier layer 20 has an oxygen permeability of 1.0 × 10 ⁻⁵ mol / (m ² · s · Pa) or less. Equipped with Furthermore, the solar cell module 100 is disposed under the surface protective layer 10 and the barrier layer 20, and the sealing layer 30 that seals the photoelectric conversion unit 40, and the back surface protective layer 50 disposed under the sealing layer 30. And. The solar cell module 100 according to the present embodiment includes the barrier layer 20 having a high oxygen barrier property, and thus can suppress the entry of oxygen into the sealing layer 30. Therefore, according to the present embodiment, it is possible to provide the solar cell module 100 in which the yellowing of the sealing layer 30 is unlikely to occur even when the resin surface protection layer 10 is used.

<Mobile body>
The mobile unit of the present embodiment includes a solar cell module 100. As the said moving body, vehicles, such as a motor vehicle, a train, or a ship etc. are mentioned, for example. When the solar cell module 100 is mounted in a car, it is preferable that the solar cell module 100 be installed on an upper surface portion of the car body such as a bonnet or a roof. In any moving object, the current obtained by the power generation by the solar cell module 100 is supplied to an electric device such as a fan or a motor and used for driving and controlling the electric device.

[Method of manufacturing a solar cell module]
The solar cell module 100 sequentially heats the surface protection layer 10, the barrier layer 20, the surface sealing layer 32, the solar cell string 46, the back surface sealing layer 34, the back surface protection layer 50, etc. It can be formed by compression. However, the detailed steps are not particularly limited, for example, compression molding in which each layer is divided into several steps, and molding can be performed according to the purpose.

Although the heating conditions are not particularly limited, for example, heating to about 150 ° C. may be performed in a vacuum state. Heating under vacuum conditions is preferable because the defoaming property is further improved. Moreover, a frame etc. can also be attached to the laminated body obtained by heating.

It is preferable that the manufacturing method of the solar cell module 100 which concerns on this embodiment is provided with the process of apply | coating the barrier layer 20 on the surface protection layer 10, and the process of shape-processing the surface protection layer 10 in a curved surface. By applying and forming the barrier layer 20, generation of wrinkles in the barrier layer 20 can be suppressed as compared to the case where the barrier layer 20 is formed by lamination.

The step of applying the barrier layer 20 on the surface protective layer 10 is preferably a step of applying and curing the barrier layer 20 on the surface of the surface protective layer 10. The barrier layer 20 is preferably the above-described layered clay mineral-containing layer. Materials and contents for forming the layered clay mineral-containing layer are as described above. Specifically, a coating composition for forming a layered clay mineral-containing layer can be applied to, for example, a substantially flat surface protective layer 10 and cured. The step of applying and drying the layered clay mineral-containing layer is also as described above. By using such a layered clay mineral-containing layer as the barrier layer 20, it is possible to reduce the film thickness while maintaining the oxygen barrier properties of the barrier layer 20, thereby further suppressing the occurrence of wrinkles in the barrier layer 20. be able to. Further, since the layered clay mineral-containing layer contains a resin, it is difficult to be broken even if it is bent so as to have a curved surface shape, and the barrier properties of the barrier layer 20 are easily maintained.

The light resistant layer 60 described above may be formed on the surface of the surface protective layer 10 opposite to the side on which the barrier layer 20 is applied. In this case, the order of applying the barrier layer 20 and the light resistant layer 60 is not particularly limited.

In the step of forming the surface protection layer 10 into a curved shape, a laminate in which the barrier layer 20 formed by curing as described above is laminated on the surface of the surface protection layer 10 is deformed to have a curved shape. It can be set as the process of forming by bending. By such bending, the solar cell module 100 can be formed into a desired shape.

Hereinafter, the present embodiment will be described in more detail by way of examples and comparative examples, but the present embodiment is not limited to these examples.

Example 1
A paint composition for forming a barrier layer was prepared. The coating composition was mixed until the resin was fully dissolved in the solvent. At this time, the materials used for the coating composition are as follows.

Resin: Polyvinyl alcohol (PVA) (Gorecenol (registered trademark) manufactured by Nippon Synthetic Chemical Industry Co., Ltd.)
Solvent: water

Next, the above coating composition is applied by a bar coater to a surface protective layer of 1 mm thickness which has been subjected to a hydrophilization treatment by corona discharge so that the film thickness after drying becomes 10 μm, and heated at 120 ° C. for 60 minutes. A barrier layer was formed.

Next, a surface protection layer on which a barrier layer is formed, a surface sealing layer with a thickness of 1 mm, solar cell cell strings, a back surface sealing layer with a thickness of 1 mm, and a back surface protection layer with a thickness of 2 mm are stacked sequentially from the top and compressed at 145 ° C. The solar cell module was produced by heating. The barrier layer was disposed between the surface protective layer and the surface sealing layer.

In a solar cell string, the bus bar electrode provided on the light receiving surface side of one solar cell and the bus bar electrode provided on the back side of the other solar cell are interconnected by an interconnect made of copper. It formed by connecting.

The material of each layer which comprises a solar cell module is as follows.
Surface Protective Layer Polyethylene terephthalate (PET)
Surface sealing layer Ethylene-vinyl acetate copolymer (EVA)
Back side sealing layer ethylene-vinyl acetate copolymer (EVA)
Back surface protection layer Carbon fiber reinforced plastic (CFRP)

Example 2
As a resin used for the barrier layer, ethylene-vinyl alcohol copolymer (EVOH) (Soarol (registered trademark) manufactured by Japan Synthetic Chemical Industry Co., Ltd.) was used instead of polyvinyl alcohol (PVA). A solar cell module was produced in the same manner as in Example 1 except for the above.

[Example 3]
As a resin used for the barrier layer, a vinylidene chloride copolymer (Saran latex (registered trademark) manufactured by Asahi Kasei Corporation) was used in place of polyvinyl alcohol (PVA). A solar cell module was produced in the same manner as in Example 1 except for the above.

Example 4
The coating composition was prepared by dispersing the resin, layered clay mineral and inorganic particles in a solvent and mixing until the resin was sufficiently dissolved in the solvent. A solar cell module was produced in the same manner as in Example 1 except for the above. The materials used for the coating composition at this time are as follows.

Resin: Ethylene-vinyl alcohol copolymer (EVOH) (Soanol (registered trademark) manufactured by Japan Synthetic Chemical Industry Co., Ltd.) 100 parts by mass (solid content)
Layered clay mineral: Smectite (Kunimine Kogyo Co., Ltd. Smecton (registered trademark)) 100 parts by mass Inorganic particles: silicon dioxide 0.2 parts by mass Solvent: toluene

Comparative Example 1
No barrier layer was formed on the surface protective layer. A solar cell module was produced in the same manner as in Example 1 except for the above.

[Evaluation]
The solar cell modules of each example were evaluated as follows. Details of each example and evaluation results are shown in Table 1.

(Oxygen permeability)
The oxygen permeability is measured according to JIS K 7126-2 (Plastics-Films and sheets-Gas Permeability Test Method-Part 2: Equal Pressure Method) using an oxygen permeability measuring device at a temperature of 23 ° C and a humidity of 90%. It measured by RH. The oxygen permeability measurement apparatus used was OX-TRAN 10 / 50A manufactured by MOCON.

(Yellowing degree)
The degree of yellowing was evaluated by the following procedure. First, the solar cell module of each example was heated at 85 ° C. for 1000 hours according to the heat resistance test in JIS C8917: 1998 (environmental test method and durability test method for crystalline solar cell module). Next, before and after the heat resistance test, the b ^* value was determined from the surface of the surface protective layer using a spectrocolorimeter by measuring the area where the interconnector was disposed in plan view. And the yellowing degree was evaluated by calculating the difference of b < ^* ^> value before and behind a heat resistance test, and calculating | requiring the value of (DELTA ⁾ b ^* .

The color measurement was performed under the following conditions in accordance with JIS Z8722.
Spectrophotometer: Konica Minolta Japan Co., Ltd. Spectrophotometer CM-600d
Illumination / receiving optical system: SCI (including regular reflection light) method Observation condition: 2 ° field of view light source: D65 light source Color system: L ^* a ^* b ^*

As shown in Table 1, in the solar cell modules of Examples 1 to 3, since the oxygen permeability is 1.0 × 10 ⁻⁵ mol / (m ² · s · Pa) or less, the value of Δb ^* is Was 3 or less, and it was difficult to visually distinguish the difference in color before and after the test. On the other hand, in the solar cell module of Comparative Example 1, the oxygen permeability exceeds 1.0 × 10 ⁻⁵ mol / (m ² · s · Pa), so the value of Δb ^* exceeds 3, and the test The color difference before and after was also visually confirmed. As described above, by setting the oxygen permeability of the barrier layer to a predetermined value or less, it was possible to suppress yellowing of the sealing layer to such an extent that it is difficult to distinguish visually.

The entire contents of Japanese Patent Application No. 2017-208988 (filing date: October 30, 2017) are incorporated herein by reference.

As mentioned above, although this embodiment was described, this embodiment is not limited to these, A various deformation | transformation is possible within the range of the summary of this embodiment.

According to the present invention, it is possible to provide a solar cell module and a movable body in which yellowing of the sealing layer is less likely to occur even when the resin surface protective layer is used.

DESCRIPTION OF SYMBOLS 10 surface protective layer 20 barrier layer 30 sealing layer 32 surface sealing layer 34 back surface sealing layer 40 photoelectric conversion part 50 back surface protective layer 60 light-resistant layer 70 gel layer 100 solar cell module

Claims

A surface protection layer formed of a resin,
A barrier layer disposed on at least one surface of the surface protective layer and having an oxygen permeability of 1.0 × 10 −5 mol / (m 2 · s · Pa) or less;
A sealing layer disposed under the surface protective layer and the barrier layer and sealing a photoelectric conversion unit;
A back surface protection layer disposed under the sealing layer,
A solar cell module comprising:
The solar cell module according to claim 1, wherein the surface protective layer contains a UV absorber.
The solar cell module according to claim 1, further comprising a light resistant layer containing an ultraviolet light absorber on the surface of the surface protective layer opposite to the sealing layer.
The solar cell module according to any one of claims 1 to 3, wherein the barrier layer is disposed on at least one of the surface protective layer and at least one of the back surface protective layer.
A mobile comprising the solar cell module according to any one of claims 1 to 4.