WO2021161847A1 - 太陽電池モジュール - Google Patents

太陽電池モジュール Download PDF

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Publication number
WO2021161847A1
WO2021161847A1 PCT/JP2021/003697 JP2021003697W WO2021161847A1 WO 2021161847 A1 WO2021161847 A1 WO 2021161847A1 JP 2021003697 W JP2021003697 W JP 2021003697W WO 2021161847 A1 WO2021161847 A1 WO 2021161847A1
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WIPO (PCT)
Prior art keywords
solar cell
layer
protective layer
cell module
filler layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2021/003697
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English (en)
French (fr)
Japanese (ja)
Inventor
俊樹 松岡
祐介 宮道
敬太 黒須
翔英 佐藤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kyocera Corp
Original Assignee
Kyocera Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kyocera Corp filed Critical Kyocera Corp
Priority to JP2022500334A priority Critical patent/JP7407266B2/ja
Priority to CN202180012049.7A priority patent/CN115039236A/zh
Priority to US17/760,002 priority patent/US12453191B2/en
Priority to EP21753196.1A priority patent/EP4106015A4/en
Publication of WO2021161847A1 publication Critical patent/WO2021161847A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/804—Materials of encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/85—Protective back sheets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • This disclosure relates to a solar cell module.
  • a solar cell module in which a plurality of solar cell elements arranged in a plane and electrically connected are sandwiched between a translucent member and a back surface member is known (for example, Japanese Patent Application Laid-Open No. See the description of JP-A-2001-250965, JP-A-2004-014791 and JP-A-2012-004146).
  • a plurality of solar cell elements are provided between a translucent member such as a glass substrate and a back member such as a back sheet by using a filler containing ethylene vinyl acetate copolymer (EVA) as a main component. Is in a covered state.
  • EVA ethylene vinyl acetate copolymer
  • the solar cell module is disclosed.
  • One aspect of the solar cell module includes a first protective layer made of resin, a second protective layer, a solar cell portion, a first filler layer made of resin, a second filler layer made of resin, and a base material. And an adhesive layer.
  • the first protective layer has a first surface and a second surface opposite to the first surface, and is translucent.
  • the second protective layer has a third surface facing the second surface and a fourth surface opposite to the third surface.
  • the solar cell unit includes one or more solar cell elements located between the second surface and the third surface.
  • the first filler layer is in a state of covering the one or more solar cell elements between the second surface and the solar cell unit.
  • the second filler layer is in a state of covering the one or more solar cell elements between the third surface and the solar cell unit.
  • the base material has a fifth surface facing the fourth surface.
  • the adhesive layer is in a state where the fourth surface and the fifth surface are adhered between the fourth surface and the fifth surface.
  • the first protective layer is in a softer state than the base material.
  • the Young's modulus of one or more of the second filler layer, the second protective layer, and the adhesive layer is larger than the Young's modulus of the first filler layer.
  • FIG. 1A is a plan view showing an example of the appearance of the solar cell module according to the first embodiment when viewed in a plan view.
  • FIG. 1B is a diagram showing an example of a virtual cut surface along the line Ib-Ib of the solar cell module of FIG. 1A.
  • FIG. 2A is a diagram showing an example of a structure when the first element surface of the solar cell element is viewed in a plan view.
  • FIG. 2B is a diagram showing an example of a structure when the second element surface of the solar cell element is viewed in a plan view.
  • FIG. 3 is a perspective view showing an example of an embodiment of the steel ball drop test.
  • FIG. 1A is a plan view showing an example of the appearance of the solar cell module according to the first embodiment when viewed in a plan view.
  • FIG. 1B is a diagram showing an example of a virtual cut surface along the line Ib-Ib of the solar cell module of FIG. 1A.
  • FIG. 2A is a diagram showing an example
  • FIG. 4A is a diagram showing the relationship between the increase in the rigidity of the second filler layer and the time change of the maximum principal stress applied to the solar cell element in the steel ball drop test.
  • FIG. 4B is a diagram showing the relationship between the increase in the rigidity of the adhesive layer and the time change of the maximum principal stress applied to the solar cell element in the steel ball drop test.
  • 5 (a) to 5 (d) are diagrams illustrating a cross-sectional state during manufacturing of the solar cell module according to the first embodiment, respectively.
  • 6 (a) and 6 (b) are diagrams illustrating a cross-sectional state during manufacturing of the solar cell module according to the first embodiment, respectively.
  • the solar cell module is, for example, in a state in which a translucent member such as a glass substrate, a back member such as a back sheet, and the translucent member and the back member are arranged in a plane and electrically connected to each other. It is equipped with a plurality of solar cell elements in the above. Further, in this solar cell module, for example, an ethylene-vinyl acetate copolymer in a state of being filled so as to cover a plurality of solar cell elements between a translucent member and a back surface member. : EVA) and other fillers are located.
  • EVA ethylene-vinyl acetate copolymer
  • the thickness of the glass substrate is, for example, about several millimeters (mm), while the thickness of the resin member is, for example, 1 mm or less.
  • the resin member is softer than the glass substrate, when a falling object such as hail or a flying object due to a strong wind collides with the resin member as a translucent member, the solar cell element May be locally deformed and cracks may occur in the solar cell element.
  • the impact resistance of the solar cell module may decrease. In this case, for example, the photoelectric conversion efficiency of the cracked solar cell element is lowered, and the output of the solar cell module is lowered.
  • the inventor of the present disclosure has created a technology capable of reducing the weight and improving the impact resistance of the solar cell module.
  • the direction along each of the two sides of the front surface 100f facing each other is the + X direction
  • the other front surface 100f is facing each other.
  • the direction along each of the two sides is the + Y direction.
  • the normal direction of the front surface 100f which is orthogonal to both the + X direction and the + Y direction, is the + Z direction.
  • the solar cell module 100 has, for example, a surface (also referred to as a light receiving surface and a front surface) 100f on which light is mainly incident, and a back surface 100b located on the opposite side of the front surface 100f.
  • the front surface 100f is in a state of facing the + Z direction.
  • the back surface 100b is in a state of facing the ⁇ Z direction.
  • the + Z direction is set, for example, to face the sun in the south.
  • the front surface 100f and the back surface 100b each have a rectangular shape.
  • the solar cell module 100 includes, for example, a module main body 120, an adhesive layer 5, and a base material 6.
  • the module main body 120 includes, for example, a first protective layer 1, a second protective layer 2, a solar cell portion 3, and a filler layer 4.
  • a terminal box 9 may be added to the solar cell module 100, for example.
  • the terminal box 9 is located, for example, on the back surface 100b of the solar cell module 100, and can output the electricity obtained by the power generation in the solar cell unit 3 to the outside.
  • the first protective layer 1 is, for example, a member (also referred to as a front member or a front member) capable of protecting the solar cell unit 3 from the front surface 100f side.
  • the first protective layer 1 has a first surface 1f and a second surface 1b.
  • the second surface 1b is the surface opposite to the first surface 1f.
  • the first surface 1f constitutes, for example, the front surface 100f of the solar cell module 100.
  • the first surface 1f is a surface facing the + Z direction
  • the second surface 1b is a surface facing the ⁇ Z direction.
  • the first surface 1f is exposed to, for example, an external space (also referred to as an external space) of the solar cell module 100.
  • the first protective layer 1 has translucency. Specifically, the first protective layer 1 has, for example, translucency with respect to light having a wavelength in a specific range.
  • the wavelength in the specific range includes, for example, the wavelength of light that can be photoelectrically converted by the solar cell unit 3. If the wavelength in a specific range includes the wavelength of light having a high irradiation intensity in sunlight, the photoelectric conversion efficiency of the solar cell module 100 can be improved.
  • Resin is applied to the material of the first protective layer 1.
  • a layer made of a translucent resin is adopted.
  • a thermoplastic resin such as polycarbonate, a fluorine-based resin, or the like is adopted.
  • Fluorine-based resins include, for example, Fluorinated Ethylene Propylene (FEP), Ethylene Tetrafluoroethylene (ETFE) and Ethylene Chlorotrifluoroethylene copolymers. : ECTFE) and the like.
  • FEP Fluorinated Ethylene Propylene
  • ETFE Ethylene Tetrafluoroethylene
  • ECTFE Ethylene Chlorotrifluoroethylene copolymers.
  • the first protective layer 1 may be composed of two or more layers of resin.
  • the resin applied to the first protective layer 1 may be, for example, two or more kinds of resins.
  • the first protective layer 1 if the resin applied to the first protective layer 1 has weather resistance, the first protective layer 1 is less likely to deteriorate and the output of the solar cell module 100 is less likely to decrease.
  • the weather resistance means, for example, a property that does not easily cause deterioration such as deformation, discoloration and deterioration when used outdoors.
  • fluorine-based resins such as FEP, ETFE and ECTFE have weather resistance.
  • the thickness of the first protective layer 1 is, for example, about 0.05 mm to 0.5 mm. Further, for example, when the first protective layer 1 is viewed in a plan view from the front surface 100f side in the ⁇ Z direction, it is conceivable that the first protective layer 1 has a rectangular outer shape.
  • the second protective layer 2 is, for example, a member (also referred to as a back member or a back surface member) capable of protecting the solar cell portion 3 from the back surface 100b side.
  • the second protective layer 2 has a third surface 2f and a fourth surface 2b.
  • the fourth surface 2b is the surface opposite to the third surface 2f.
  • the third surface 2f is in a state of facing the second surface 1b of the first protective layer 1. In the examples of FIGS. 1A and 1B, the third surface 2f is the surface facing the + Z direction, and the fourth surface 2b is the surface facing the ⁇ Z direction.
  • the direction in which the second surface 1b and the third surface 2f face each other is the + Z direction.
  • the second surface 1b and the third surface 2f are separated from each other in the + Z direction as the first direction.
  • resin is applied to the material of the second protective layer 2.
  • a thermoplastic resin such as polycarbonate, a fluorine-based resin such as FEP, ETFE or ECTFE, or the like is adopted.
  • the material of the second protective layer 2 includes, for example, one of polyvinyl fluoride (PVF), polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), or at least one of these resins. Resin may be applied.
  • the second protective layer 2 may be composed of two or more layers of resin.
  • the resin applied to the second protective layer 2 may be, for example, two or more kinds of resins.
  • the thickness of the second protective layer 2 is, for example, about 0.05 mm to 0.5 mm. Further, for example, when the second protective layer 2 is viewed in a plane from the front surface 100f side in the ⁇ Z direction, the second protective layer 2 may have a rectangular outer shape like the first protective layer 1. Be done.
  • the solar cell unit 3 is located, for example, between the second surface 1b of the first protective layer 1 and the third surface 2f of the second protective layer 2. From another point of view, the solar cell unit 3 is located, for example, in a region (also referred to as a gap region) 100 g between the second surface 1b of the first protective layer 1 and the third surface 2f of the second protective layer 2. doing.
  • the solar cell unit 3 includes, for example, one or more solar cell elements 31. In other words, for example, one or more solar cell elements 31 are located between the second surface 1b of the first protective layer 1 and the third surface 2f of the second protective layer 2. In the first embodiment, the solar cell unit 3 has a plurality of solar cell elements 31.
  • the plurality of solar cell elements 31 are located between the second surface 1b of the first protective layer 1 and the third surface 2f of the second protective layer 2.
  • the plurality of solar cell elements 31 are, for example, in a state of being two-dimensionally arranged.
  • the plurality of solar cell elements 31 are arranged in a plane so as to be located along the second surface 1b of the first protective layer 1.
  • the solar cell unit 3 has, for example, a plurality of first wiring materials 32 and a plurality of second wiring materials 33.
  • the solar cell unit 3 includes, for example, a plurality of (here, 10) solar cell strings 30.
  • the solar cell string 30 includes, for example, a plurality of (here, seven) solar cell elements 31 and a plurality of first wiring materials 32.
  • the plurality of first wiring materials 32 are in a state in which, for example, the solar cell elements 31 adjacent to each other among the plurality of solar cell elements 31 are electrically connected to each other.
  • the plurality of second wiring materials 33 are in a state in which the adjacent solar cell strings 30 of the plurality of solar cell strings 30 are electrically connected to each other. In the examples of FIGS.
  • the second wiring material 33 connected to the solar cell string 30 located at the most ⁇ X direction end and the second wiring material 33 located at the most + X direction end are located.
  • the second wiring material 33 connected to the solar cell string 30 is pulled out to the outside of the module main body 120.
  • the two second wiring materials 33 are in a state of being pulled out to the outside of the module main body 120 through, for example, through holes provided in the second protective layer 2, the adhesive layer 5, and the base material 6. Aspects are conceivable.
  • the two second wiring materials 33 may be in a state of being pulled out from the side of the gap region 100 g to the outside of the module main body 120 without penetrating the second protective layer 2, for example.
  • each of the plurality of solar cell elements 31 can convert light energy into electrical energy, for example.
  • each of the plurality of solar cell elements 31 is a surface (also referred to as a first element surface) 31f located on the front surface side. And a surface (also referred to as a second element surface) 31s on the opposite side of the first element surface 31f.
  • the first element surface 31f is in the + Z direction
  • the second element surface 31s is in the ⁇ Z direction.
  • the first element surface 31f mainly serves as a surface on which light is incident (also referred to as a front surface or a light receiving surface).
  • each of the plurality of solar cell elements 31 includes a semiconductor substrate 310, a first output extraction electrode 311 and a first current collector. It has an electrode 312, a second output extraction electrode 313, and a second current collector electrode 314.
  • the semiconductor substrate 310 includes, for example, a crystalline semiconductor such as crystalline silicon, an amorphous semiconductor such as amorphous silicon, four types of elements such as copper, indium, gallium and selenium, or two types of elements such as cadmium and tellurium.
  • a compound semiconductor using the above is applied.
  • crystalline silicon is applied to the semiconductor substrate 310.
  • the semiconductor substrate 310 mainly has a region having a first conductive type (also referred to as a first conductive type region) and a region having a second conductive type opposite to the first conductive type (second conductive type region). Also called) and.
  • the first conductive type region is located, for example, in a region of the semiconductor substrate 310 along the second element surface 31s facing the ⁇ Z direction.
  • the second conductive type region is located, for example, in the surface layer portion of the semiconductor substrate 310 along the first element surface 31f facing the + Z direction.
  • the semiconductor substrate 310 has a pn junction located at the interface between the first conductive type region and the second conductive type region.
  • the thickness of the semiconductor substrate 310 is, for example, about 0.1 mm to 0.5 mm.
  • the surface of the semiconductor substrate 310 on the first element surface 31f side may have, for example, a fine uneven structure (texture) for reducing the reflection of the irradiated light.
  • the first output take-out electrode 311 and the first current collector electrode 312 are, for example, oriented in the + Z direction of the semiconductor substrate 310 and are located on a surface along the first element surface 31f.
  • a bus bar electrode is applied to the first output take-out electrode 311.
  • a finger electrode is applied to the first current collecting electrode 312.
  • two first output extraction electrodes 311 substantially parallel to each other along the + Y direction are located along the first element surface 31f, and a large number of substantially parallel first outputs are located.
  • the 1 current collecting electrode 312 is located so as to be substantially orthogonal to the two first output extraction electrodes 311.
  • the region above the second conductive type region of the semiconductor substrate 310 where the first output extraction electrode 311 and the first current collector electrode 312 are not formed for example, the region is made of silicon nitride or the like.
  • An insulating film as a certain antireflection film 315 may be located.
  • the main component of the first output take-out electrode 311 is silver
  • the first output take-out electrode 311 is fired after the silver paste is applied to a desired shape by screen printing or the like. Can be formed.
  • the main component means the component having the largest (highest) content ratio (also referred to as content rate) among the contained components.
  • the silver paste for example, a metal powder containing silver as a main component, an organic vehicle, and a metal paste containing glass frit are applied.
  • the main component of the first current collector electrode 312 is silver
  • silver paste is applied to the first current collector electrode 312 in a desired shape by screen printing or the like, similarly to the first output extraction electrode 311. It can be formed by firing afterwards.
  • the first output take-out electrode 311 and the first current collector electrode 312 may be formed, for example, in separate steps or in the same step.
  • the second output extraction electrode 313 and the second current collector electrode 314 are, for example, oriented in the ⁇ Z direction of the semiconductor substrate 310 and are located on the surface along the second element surface 31s.
  • a bus bar electrode is applied to the second output take-out electrode 313.
  • two rows of second output take-out electrodes 313 that are substantially parallel to each other along the + Y direction are located along the second element surface 31s.
  • the second current collector electrode 314 is a second output take-out electrode except for a portion of the second element surface 31s in which the second output take-out electrode 313 and the second current collector electrode 314 are overlapped and connected to each other. It is located on substantially the entire surface of the region where 313 is not formed.
  • Each of the two rows of second output take-out electrodes 313 includes, for example, a plurality of (here, four) electrode portions arranged in a row. Further, for example, a thin film of oxide or nitride such as aluminum oxide is a passivation film between the first conductive type region of the semiconductor substrate 310 and the second output extraction electrode 313 and the second current collecting electrode 314 in a desired pattern. May exist as.
  • the main component of the second output take-out electrode 313 is silver
  • the second output take-out electrode 313 has a desired shape when the silver paste is screen-printed or the like, similarly to the first output take-out electrode 311. It can be formed by being applied to and then fired.
  • the second current collector electrode 314 can be formed by applying an aluminum paste to a desired shape by screen printing or the like and then firing the paste. ..
  • the aluminum paste for example, a metal powder containing aluminum as a main component, an organic vehicle, and a metal paste containing glass frit are applied.
  • the first wiring material 32 is, for example, the first output take-out electrode 311 of the first solar cell element 31 and the second output take-out electrode 313 of the second solar cell element 31 adjacent to the first solar cell element 31. Is in a state of being electrically connected to.
  • the outer edge of the first wiring material 32 joined to each of the plurality of solar cell elements 31 is virtually drawn by a two-dot chain line.
  • the first wiring material 32 is in a state of being joined to, for example, the first output take-out electrode 311 and the second output take-out electrode 313.
  • 321 also referred to as a joint portion
  • the first wiring material 32 is in a state of being joined to the first output take-out electrode 311 of the first solar cell element 31 via the first joining portion 321.
  • a portion located between the first wiring material 32 and the second output take-out electrode 313 and joining the first wiring material 32 and the second output take-out electrode 313 both the second joint portion.
  • the first wiring material 32 is joined to the second output extraction electrode 313 of the second solar cell element 31 adjacent to the first solar cell element 31 via the second joining portion 322. It is in.
  • a linear or strip-shaped conductive metal body is applied to the first wiring material 32.
  • a low melting point alloy such as solder or a low melting point simple substance metal is applied. More specifically, for example, a copper foil having a thickness of about 0.1 mm to 0.2 mm and a width of about 1 mm to 2 mm is applied to the first wiring material 32, and solder is applied to the entire surface of the first wiring material 32. Is in a covered state.
  • the first wiring material 32 is in a state of being electrically connected to the first output take-out electrode 311 and the second output take-out electrode 313 by, for example, soldering.
  • the solder located between the first wiring material 32 and the first output take-out electrode 311 constitutes the first joint portion 321.
  • the solder located between the first wiring material 32 and the second output take-out electrode 313 is in a state of forming the second joint portion 322.
  • the filler layer 4 is in a state of covering the solar cell portion 3 between the first protective layer 1 and the second protective layer 2. In other words, the filler layer 4 is in a state of covering a plurality of solar cell elements 31 between the first protective layer 1 and the second protective layer 2. From another point of view, the filler layer 4 is, for example, in a state where the gap region 100 g between the first protective layer 1 and the second protective layer 2 is filled while covering the solar cell portion 3.
  • the filler layer 4 has, for example, a first filler layer 41 and a second filler layer 42.
  • the first filler layer 41 is located, for example, between the first protective layer 1 and the solar cell unit 3 in the gap region 100 g.
  • the first filler layer 41 is in a state of covering the entire surface of the solar cell unit 3 on the first protective layer 1 side, for example.
  • the first filler layer 41 is in a state of covering one or more solar cell elements 31 between the second surface 1b of the first protective layer 1 and the solar cell unit 3, for example.
  • the second filler layer 42 is located, for example, between the second protective layer 2 and the solar cell unit 3 in the gap region 100 g.
  • the second filler layer 42 is in a state of covering the entire surface of the solar cell unit 3 on the second protective layer 2 side, for example.
  • the second filler layer 42 is in a state of covering one or more solar cell elements 31 between the third surface 2f of the second protective layer 2 and the solar cell unit 3, for example. Therefore, in the first embodiment, the solar cell unit 3 is surrounded so as to be sandwiched between, for example, the first filler layer 41 and the second filler layer 42. Thereby, for example, the attitude of the solar cell unit 3 can be maintained by the filler layer 4.
  • the filler layer 4 has, for example, translucency.
  • the filler layer 4 has, for example, translucency with respect to light having a wavelength in the above-mentioned specific range.
  • the front surface 100f side is used. The incident light of the above can reach the solar cell unit 3.
  • a resin is applied to each of the materials of the first filler layer 41 and the second filler layer 42.
  • the filler layer 4 has a first filler layer 41 made of resin and a second filler layer 42 made of resin.
  • a resin such as ethylene vinyl acetate copolymer (EVA) or ionomer is applied to each of the materials of the first filler layer 41 and the second filler layer 42.
  • the first filler layer 41 and the second filler layer 42 may be composed of, for example, two or more kinds of materials.
  • the thickness of the first filler layer 41 in the + Z direction as the first direction is, for example, about 0.2 mm to 1 mm
  • the thickness of the second filler layer 42 in the + Z direction as the first direction is, for example. , 0.2 mm to 1 mm.
  • the base material 6 is, for example, a member (also referred to as a support member) in a state of supporting the module main body 120.
  • the base material 6 is in a harder state than, for example, the first protective layer 1.
  • the first protective layer 1 is in a softer state than the base material 6.
  • the state in which the first protective layer 1 is softer than the base material 6 includes, for example, a state in which the first protective layer 1 has a lower rigidity than the base material 6.
  • the base material 6 can support the module main body 120 so as to maintain the shape of the module main body 120.
  • the first protective layer 1 and the base material 6 are respectively. It is possible to calculate and evaluate from the measurement result of Vickers hardness using a Vickers hardness tester. Further, for example, the solar cell module 100 is disassembled to take out the first protective layer 1 and the base material 6, and the mechanical test method, the resonance method and the ultrasonic pulse method are applied to each of the first protective layer 1 and the base material 6. It may be used to calculate and evaluate the relative softness and hardness relationship between the first protective layer 1 and the substrate 6.
  • Mechanical test methods include, for example, tensile tests, torsional tests and compression tests using test pieces.
  • Young's modulus is easily calculated from the slope of the stress-strain diagram obtained by the mechanical test method.
  • forced vibration can be mechanically or electrically applied to the test piece, the resonance frequency (natural frequency) of the test piece can be measured, and the Young's ratio can be calculated from this resonance frequency.
  • forced vibration includes longitudinal vibration, lateral vibration, and torsional vibration.
  • the Young's modulus of the test piece can be obtained from the resonance frequencies of longitudinal vibration and transverse vibration, and the rigidity of the test piece (transverse elastic coefficient) can be obtained from the resonance frequency of torsional vibration. ) Is obtained.
  • an ultrasonic pulse of about 1 megahertz (MHz) to 20 MHz is propagated to a test piece using a longitudinal wave oscillator and a transverse wave oscillator, and propagation of longitudinal waves and transverse waves propagating in the test piece. Young ratio and rigidity ratio can be calculated from the speed.
  • the base material 6 is, for example, a plate-shaped member (also referred to as a plate material).
  • the base material 6 has, for example, a fifth surface 6f and a sixth surface 6b.
  • the sixth surface 6b is located on the opposite side of the fifth surface 6f of the base material 6.
  • the fifth surface 6f is a surface facing the + Z direction
  • the sixth surface 6b is a surface facing the ⁇ Z direction.
  • the fifth surface 6f is in a state of facing the fourth surface 2b of the second protective layer 2.
  • the outer panel of the body of a moving body such as a vehicle or a ship, the roofing material or the outer wall material of a building, or the like is applied to the plate material constituting the base material 6.
  • the solar cell module 100 can be easily applied to a moving body such as a vehicle or a ship or a building.
  • the plate material for example, a steel plate such as a plated steel plate or a stainless steel plate, or a metal plate material such as an aluminum plate is adopted.
  • the plated steel sheet for example, a hot-dip galvanized steel sheet or a hot-dip galvanized aluminum-plated steel sheet or other variously plated steel sheets is applied.
  • a plate-shaped base material 6 having a rigidity higher than that of the module main body 120 can be easily realized.
  • the shape of the plate material constituting the base material 6 may be, for example, a flat plate shape or a shape having a bend such as a slight curvature.
  • the thickness of the base material 6 is, for example, about 0.5 mm to several centimeters (cm).
  • Adhesive layer The adhesive layer 5 is in a state where, for example, the module main body 120 is adhered to the base material 6.
  • the adhesive layer 5 is located, for example, between the fourth surface 2b of the second protective layer 2 and the fifth surface 6f of the base material 6. Therefore, the adhesive layer 5 is in a state where, for example, the fourth surface 2b and the fifth surface 6f are adhered to each other.
  • an adhesive tape or a resin such as ethylene vinyl acetate copolymer (EVA) or ionomer is applied to the adhesive layer 5.
  • the adhesive tape has, for example, a support and an adhesive located on both sides of the support.
  • both sides of the support are the front surface (also referred to as the first surface or the front surface) of the strip-shaped support and the surface opposite to the front surface (the first surface). 2 Both front and back).
  • the thickness of the adhesive layer 5 in the + Z direction as the first direction is, for example, about 0.1 mm to 1 mm.
  • one or more of the second filler layer 42, the second protective layer 2, and the adhesive layer 5 has a Young's modulus larger than that of the first filler layer 41. If so, the rigidity of at least one layer between the solar cell element 31 and the base material 6 is increased. As a result, for example, even if a falling object such as hail or a flying object due to a strong wind collides with the first surface 1f of the first protective layer 1 made of resin, which is softer than the glass substrate, the solar cell element 31 and the base material 6 The part located between and is less likely to cause local deformation.
  • the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked. Therefore, for example, the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be enhanced. Therefore, for example, even if the first protective layer 1 is made of a resin in order to reduce the weight of the solar cell module 100, one or more of the second filler layer 42, the second protective layer 2, and the adhesive layer 5 are used. By making the Young's modulus of the first filler layer 41 larger than the Young's modulus of the first filler layer 41, the impact resistance of the solar cell module 100 can be improved. Therefore, for example, the weight of the solar cell module 100 can be reduced and the impact resistance can be improved.
  • the Young's modulus of the second filler layer 42 is made larger than the Young's modulus of the first filler layer 41.
  • the second filler layer is more than the Young's modulus of the first filler layer 41.
  • the Young's modulus of 42 can be increased.
  • the ionomer for example, Hymilan (registered trademark) manufactured by Mitsui Dow Polychemical Co., Ltd. can be adopted. Further, for example, an ionomer of an ethylene / unsaturated carboxylic acid copolymer may be applied to this ionomer.
  • the ionomer of this ethylene / unsaturated carboxylic acid copolymer can be obtained, for example, by reacting the ethylene / unsaturated carboxylic acid copolymer with a metal compound.
  • the rigidity of the second filler layer 42 located immediately on the base material 6 side of the solar cell element 31 can be increased.
  • the second filler layer 42 is less likely to be locally deformed.
  • the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked. Therefore, for example, the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be enhanced.
  • the Young's modulus of the adhesive layer 5 is made larger than the Young's modulus of the first filler layer 41.
  • EVA the material of the first filler layer 41
  • ionomer the Young's modulus of the adhesive layer 5 is larger than the Young's modulus of the first filler layer 41.
  • the ionomer for example, Hymilan (registered trademark) manufactured by Mitsui Dow Polychemical Co., Ltd. can be adopted.
  • an ionomer of an ethylene / unsaturated carboxylic acid copolymer may be applied to this ionomer.
  • the adhesive layer 5 is more than the Young's modulus of the first filler layer 41. Young's modulus may be increased. In this way, for example, the rigidity of the adhesive layer 5 located between the solar cell element 31 and the base material 6 can be increased. As a result, for example, even if a falling object or a flying object collides with the first surface 1f of the first protective layer 1, the adhesive layer 5 is less likely to be locally deformed. As a result, for example, the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked. Therefore, for example, the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be enhanced.
  • a resin first protective layer 1 is adopted as a front member instead of a glass substrate. ..
  • the roughness of the surface of the glass substrate may be increased due to the influence of the unevenness on the outer peripheral surface of the roll used when manufacturing the glass substrate.
  • the arithmetic mean roughness (Ra) of the surface of this glass substrate is, for example, about several ⁇ m to several hundred ⁇ m.
  • the surface of the semiconductor substrate 310 on the first element surface 31f side has a fine uneven structure (texture), so that the roughness of the first element surface 31f can be increased to some extent.
  • the arithmetic mean roughness (Ra) of the first element surface 31f is, for example, about 100 nm to several hundred nm.
  • the surface roughness of the first protective layer 1 made of resin can be smaller than the surface roughness of the glass substrate.
  • the arithmetic mean roughness (Ra) of the surface of the first protective layer 1 made of resin is, for example, about several nm to several tens of nm.
  • the front member and the first filler layer 41 can be formed.
  • the contact area becomes smaller. Therefore, for example, peeling is likely to occur between the front member and the first filler layer 41.
  • peeling occurs between the first protective layer 1 and the first filler layer 41, and the first protective layer 1 and the first filler layer 1 and the first filler layer 41 are separated from each other. Sliding with the layer 41 is likely to occur, and the rigidity of the entire solar cell module 100 may decrease.
  • the solar cell element 31 is likely to be locally deformed, and the solar cell element 31 is likely to be cracked. , The impact resistance of the solar cell module 100 may be lowered.
  • the roughness (also referred to as the first roughness) at the interface (also referred to as the first interface) 10 between the first protective layer 1 and the first filler layer 41 is the first filler layer 41. It is conceivable that the roughness is smaller than the roughness (also referred to as the second roughness) at the interface (also referred to as the second interface) 20 with the one or more solar cell elements 31.
  • the arithmetic mean roughness (Ra) was obtained for the first interface 10 and the second interface 20 for the solar cell modules 100 before and after being placed in a high temperature and high humidity environment, respectively.
  • the arithmetic mean roughness (Ra) of the first interface 10 was about 5 nm to 15 nm
  • the arithmetic mean roughness (Ra) of the second interface 20 was about 150 nm to 250 nm.
  • an image is acquired by photographing the cut surface obtained by cutting each solar cell module 100 along the XZ plane by using an electron microscope (SEM) or an optical microscope, and this image is used as the target.
  • the arithmetic average roughness (Ra) was calculated after detecting the cross-sectional shapes of the first interface 10 and the second interface 20 by image processing such as digitization.
  • the first roughness at the first interface 10 between the first protective layer 1 and the first filler layer 41 is the second interface between the first filler layer 41 and one or more solar cell elements 31.
  • the contact area between the first protective layer 1 and the first filler layer 41 becomes smaller. Therefore, for example, as compared with the case where a glass substrate is used as the front member, peeling easily occurs between the first protective layer 1 and the first filler layer 41 as the front member, and one or more solar cells The element 31 is easily cracked. Even in such a case, for example, by increasing the rigidity of at least one layer between the one or more solar cell elements 31 and the base material 6, the rigidity of the first surface 1f of the first protective layer 1 is increased.
  • the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be improved. Therefore, for example, the weight of the solar cell module 100 can be reduced and the impact resistance can be improved.
  • the length (also referred to as width) W1 of the two opposing sides of the base material 6 along the X direction is 200 mm
  • the lengths (also referred to as depth) of the two opposing sides of the base material 6 along the Y direction. ) D1 was set to 200 mm.
  • the solar cell module 100 is first filled with the adhesive layer 5, the second protective layer 2, the second filler layer 42, the layer of the solar cell element 31, and the first filling on the base material 6.
  • the material layer 41 and the first protective layer 1 were simply laminated in the order described in this description to form a laminated body.
  • the base material 6 was an iron plate having a thickness of 0.7 mm.
  • the adhesive layer 5 was a layer of adhesive tape, EVA or ionomer having a thickness of 0.4 mm.
  • the second protective layer 2 was a PET layer having a thickness of 0.2 mm.
  • the second filler layer 42 was used as an EVA layer having a thickness of 0.31 mm.
  • the solar cell element 31 was made into a layer of crystalline silicon having a thickness of 0.18 mm.
  • the first filler layer 41 was used as an EVA layer having a thickness of 0.51 mm.
  • the first protective layer 1 was a FEP layer having a thickness of 0.10 mm. Each thickness was defined as the thickness in the + Z direction as the first direction.
  • the initial velocity when the steel ball 800 collides with the first surface 1f is set to 4.43 meters per second (m / s).
  • the solar cell element is set to 1 when the value (E2 / E1) obtained by dividing the Young's modulus (E2) of the second filler layer 42 by the Young's modulus (E1) of the first filler layer 41 is 1.
  • the simulation result of the time change of the maximum principal stress applied to the 31 layers is shown by a thick broken line.
  • the simulation result of the time change of the maximum principal stress applied to the layer of the solar cell element 31 is shown by a thick alternate long and short dash line.
  • the simulation result of the time change of the maximum principal stress applied to the layer of the solar cell element 31 is shown by a thick solid line.
  • the larger the Young's modulus (E2) of the second filler layer 42 with respect to the Young's modulus (E1) of the first filler layer 41 the larger the solar cell element. It was confirmed that the maximum principal stress applied to 31 was reduced. Therefore, for example, the Young's modulus of the second filler layer 42 is made larger than the Young's modulus of the first filler layer 41 to increase the rigidity of the second filler layer 42, thereby increasing the rigidity of the first protective layer 1. It is presumed that even if a falling object or a flying object collides with the first surface 1f, the solar cell element 31 is less likely to be locally deformed and the solar cell element 31 is less likely to be cracked.
  • the layer of the solar cell element 31 is set to 1 when the value (E5 / E1) obtained by dividing the Young's modulus (E5) of the adhesive layer 5 by the Young's modulus (E1) of the first filler layer 41 is 1.
  • the simulation result of the time change of the maximum principal stress applied to is shown by a thick broken line.
  • the simulation result of the time change of the maximum principal stress applied to the layer of the solar cell element 31 is shown by a thick two-dot chain line.
  • the Young's modulus of the adhesive layer 5 is made larger than the Young's modulus of the first filler layer 41 to increase the rigidity of the adhesive layer 5, so that the adhesive layer 5 falls on the first surface 1f of the first protective layer 1. It was presumed that even if an object or a flying object collides with the solar cell element 31, local deformation is unlikely to occur, and cracks are unlikely to occur in the solar cell element 31. Further, as shown in FIG. 4B, when the Young's modulus (E5) of the adhesive layer 5 is increased to some extent with respect to the Young's modulus (E1) of the first filler layer 41, the Young's modulus of the adhesive layer 5 (E1) is increased.
  • the maximum principal stress is less likely to decrease with the increase of E5). Therefore, for example, when the Young's modulus (E5) of the adhesive layer 5 is increased to prevent cracks from occurring in the solar cell element 31, it is easy to increase the Young's modulus (E5) of the adhesive layer 5. In consideration, it is considered that there is an embodiment in which the magnitude of the Young's modulus (E5) of the adhesive layer 5 with respect to the Young's modulus (E1) of the first filler layer 41 is set in an appropriate range.
  • the Young's modulus (E5) of the adhesive layer 5 is larger than the Young's modulus (E1) of the first filler layer 41. It was confirmed that the maximum principal stress applied to the solar cell element 31 tends to be smaller when the Young's modulus (E2) of the second filler layer 42 is increased.
  • E2 Young's modulus
  • the rigidity of the second filler layer 42 located immediately on the base material 6 side of the solar cell element 31 is increased, falling objects or flying objects are generated on the first surface 1f of the first protective layer 1. It was presumed that even if a collision occurs, the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked.
  • the plurality of heights are 11 cm (cm), 50 cm, 100 cm, 125 cm, 150 cm and 190 cm in the height direction with respect to the first surface 1f.
  • the steel ball 800 is a sphere having a diameter of 38 mm.
  • the base material 6 was an iron plate having a thickness of 0.7 mm.
  • the second protective layer 2 was a PET layer having a thickness of 0.2 mm.
  • the second filler layer 42 was used as an EVA layer having a thickness of 0.4 mm. Crystalline silicon having a thickness of 0.18 mm was used as the semiconductor substrate 310 of the solar cell element 31.
  • the first filler layer 41 was made of EVA and had a thickness of 0.6 mm.
  • the first protective layer 1 was a FEP layer having a thickness of 0.10 mm. Then, the solar cell module 100 in which the adhesive layer 5 is a layer of an adhesive tape having a thickness of 0.4 mm, and the solar cell module 100 in which the adhesive layer 5 is a layer of an ionomer having a thickness of 0.4 mm. , was used. Each thickness was defined as the thickness in the + Z direction as the first direction.
  • As the adhesive tape 3M (registered trademark) VHB (registered trademark) tape manufactured by 3M Co., Ltd. was used.
  • As an ionomer Hymilan (registered trademark) manufactured by Mitsui Dow Polychemical Co., Ltd. was used.
  • the Young's modulus of the adhesive layer 5 using the adhesive tape is lower than the Young's modulus of the first filler layer 41 made of EVA, and the Young's modulus of the adhesive layer 5 using the ionomer is the first filling made of EVA. It was higher than the Young's modulus of the material layer 41.
  • the sun is intended for the solar cell module 100 in which the steel balls 800 are dropped on the first surface 1f from a position of 100 cm or less.
  • the Young's modulus of the adhesive layer 5 is made larger than the Young's modulus of the first filler layer 41 to increase the rigidity of the adhesive layer 5, so that the adhesive layer 5 falls on the first surface 1f of the first protective layer 1. It was presumed that even if an object or a flying object collides with the solar cell element 31, local deformation is unlikely to occur, and cracks are unlikely to occur in the solar cell element 31.
  • a solar cell for a solar cell module 100 in which a steel ball 800 is dropped onto a first surface 1f from a height of 100 cm by using the adhesive layer 5 as an ionomer layer having a thickness of 0.1 mm.
  • the adhesive layer 5 not only the Young's modulus but also the thickness is appropriately adjusted to increase the rigidity of the adhesive layer 5, so that a falling object or a flying object collides with the first surface 1f of the first protective layer 1. Even so, it is presumed that the solar cell element 31 is less likely to be locally deformed and the solar cell element 31 is less likely to be cracked.
  • the second protective layer 2, the second sheet 42s, the solar cell unit 3, the first sheet 41s and the first protective layer 1 are laminated in the order described.
  • the laminated body 110 is formed.
  • wiring for being pulled out from the solar cell unit 3 to the outside of the module main body unit 120 and connected to the terminal box or the like is appropriately arranged.
  • the first sheet 41s is, for example, a sheet made of a resin (EVA or the like) that is a base of the first filler layer 41.
  • the second sheet 42s is, for example, a sheet of a resin (EVA, ionomer, etc.) that is a base of the second filler layer 42.
  • the second surface 1b which is one side of the first protective layer 1
  • a treatment for activating the surface such as a corona treatment or a plasma treatment in advance
  • the first protection is performed in the laminating treatment described later.
  • the adhesion between the layer 1 and the first filler layer 41 can be improved.
  • a laminating process is performed on the laminated body 110.
  • a laminating device laminator
  • the laminate 110 is placed on a heater board in the chamber, and the laminate 110 is depressurized from 50 Pascal (Pa) to about 150 Pa while the laminate 110 is charged from 100 degrees Celsius (100 ° C.) to 200 degrees Celsius. Heat to about degree (200 ° C).
  • the first sheet 41s and the second sheet 42s are in a state where they can flow to some extent by heating.
  • the module main body 120 can be manufactured as shown in FIG. 5 (c).
  • the solar cell module 100 can be manufactured.
  • the solar cell module 100 may be manufactured by performing a laminating process on the laminated body 111 formed by laminating the first protective layer 1 and the first protective layer 1 in the order described.
  • the terminal box 9 may be appropriately attached to the solar cell module 100.
  • the wiring drawn from the solar cell unit 3 to the outside of the module main body unit 120 may be appropriately connected to the terminals in the terminal box.
  • the solar cell module 100 does not have to have, for example, the terminal box 9.
  • the solar cell module 100 for example, the second filler layer 42, the second protective layer 2, and the adhesive layer located between one or more solar cell elements 31 and the base material 6.
  • One or more of the five layers has a greater Young's modulus than the first filler layer 41. Therefore, for example, the rigidity of at least one layer between the solar cell element 31 and the base material 6 can be increased. As a result, for example, even if a falling object or a flying object collides with the first surface 1f of the first protective layer 1 made of resin, which is softer than the glass substrate, the solar cell element 31 and the base material 6 are located between the solar cell element 31 and the base material 6.
  • the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked. Therefore, for example, even if the first protective layer 1 is made of a resin in order to reduce the weight of the solar cell module 100, the impact resistance of the solar cell module 100 can be improved. Therefore, for example, the weight of the solar cell module 100 can be reduced and the impact resistance can be improved.
  • At least one of the second filler layer 42 and the adhesive layer 5 may be a layer in which a large number of granules harder than the resin are dispersed in the resin. ..
  • the Young's modulus of at least one of the second filler layer 42 and the adhesive layer 5 may be larger than the Young's modulus of the first filler layer 41.
  • an insulating inorganic oxide or an organic filler is applied to a large number of granules.
  • the diameter of a large number of granules is, for example, about several nm to several ⁇ m.
  • the second sheet 42s which is the base of the second filler layer 42
  • a large number of particles are added to the resin constituting the second filler layer 42.
  • Granules can be dispersed. If such a configuration is adopted, for example, the rigidity of the second filler layer 42 located immediately on the base material 6 side of the solar cell element 31 can be easily increased. Thereby, for example, the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be easily enhanced.
  • the adhesive layer 5 is a resin layer
  • the adhesive layer 5 is formed by adding a large number of granules to the resin when the resin sheet that is the base of the adhesive layer 5 is produced.
  • a large number of granules can be dispersed in the resin constituting the above.
  • the cross-linking rate of the resin constituting the second filler layer 42 is made larger than the cross-linking rate of the resin constituting the first filler layer 41.
  • the Young's modulus of the second filler layer 42 may be larger than the Young's modulus of the filler layer 41.
  • the cross-linking rate of the resin constituting the first filler layer 41 is higher than that of the second filler layer 42.
  • the cross-linking rate of the resins constituting the above can be increased.
  • the cross-linking rate of the resin constituting the adhesive layer 5 is higher than the cross-linking rate of the resin constituting the first filler layer 41.
  • the Young rate of the adhesive layer 5 may be larger than the Young rate of the first filler layer 41.
  • the cross-linking rate of the resin constituting at least one of the second filler layer 42 and the adhesive layer 5 is higher than the cross-linking rate of the resin constituting the first filler layer 41. May also be large.
  • the thickness of the second filler layer 42 may be smaller than the thickness of the first filler layer 41 in the + Z direction as the first direction.
  • a dent in the second filler layer 42 located immediately behind the solar cell element 31 is formed.
  • the amount can be small.
  • the solar cell element 31 is less likely to be locally deformed, and the solar cell element 31 is less likely to be cracked.
  • the impact resistance of the solar cell module 100 having the first protective layer 1 made of resin can be improved.
  • the base material 6 may be a plate material made of a material other than metal. Various materials such as resin, ceramics, concrete or wood can be applied to the non-metal material. Further, for example, the base material 6 may have a shape other than the plate shape. Various shapes such as a lump shape can be applied to the shape other than the plate shape.
  • the first protective layer 1 and the second protective layer 2 are adhered to each other between the first protective layer 1 and the second protective layer 2.
  • 100 g of the gap region of the above may be sealed.
  • a sealing material such as a butyl resin is arranged on the outer peripheral portion of the module main body 120 to seal the gap region 100 g between the first protective layer 1 and the second protective layer 2. good.
  • the 17 international goals adopted at the United Nations Summit in September 2015 are the “Sustainable Development Goals (SDGs)".
  • SDGs Sudinable Development Goals
  • the solar cell module 100 according to the first embodiment and various modifications is, for example, "7. Energy for everyone and clean", “9. Let's lay the foundation for industry and technological innovation”. , And can contribute to the achievement of the goals such as "11. Creating a town where people can continue to live”.

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US17/760,002 US12453191B2 (en) 2020-02-12 2021-02-02 Solar cell module
EP21753196.1A EP4106015A4 (en) 2020-02-12 2021-02-02 SOLAR CELL MODULE

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US12453191B2 (en) 2025-10-21
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