JP4948865B2 - Frameless solar cell module - Google Patents

Description

  The present invention relates to a frameless solar cell module, and more particularly to a solar cell module having improved impact resistance by protecting the outer peripheral end of a light-transmitting substrate.

  Solar cell elements are often manufactured using a single crystal silicon substrate or a polycrystalline silicon substrate. For this reason, the solar cell element is vulnerable to physical impact, and when the solar cell is installed outdoors, it is necessary to protect it from rain. Moreover, since the electric output generated in one solar cell element is small, it is necessary to be able to take out a practical electric output from a plurality of solar cell elements connected in series and parallel. For this reason, a solar cell module is usually manufactured by connecting a plurality of solar cell elements and enclosing with a filler mainly composed of a light-transmitting substrate and an ethylene vinyl acetate copolymer (EVA). .

  Solar cell modules include a type having a module frame on the outer periphery and a frameless type having no module frame. The frameless solar cell module is characterized by being smaller, lighter, easier to handle, and less expensive than the moduleless frame type module frame.

  FIG. 7 shows an example when the frameless solar cell module is installed outdoors. In FIG. 7, reference numeral 1 denotes a foundation, 2 denotes a frame, 3 denotes a frameless solar cell module, and 4 denotes a fastener.

  In this case, for example, a frame 2 is assembled with an iron frame or the like on a concrete base 1 provided on a flat roof of a building or a general house or directly on the ground, and a solar cell module 3 is arranged on the frame 2, and further this solar cell module. A part of each side of the outer peripheral portion 3 is fastened with a fastener 4 to fix the solar cell module 3 to the gantry 2.

  In the case of such a solar cell module 3 installation method, the outer peripheral end of the translucent substrate is exposed, so that it is cracked by being applied at the time of construction, or by a scattered matter at the time of a typhoon.

For this reason, it has been proposed by the present applicant to attach a simple frame member to the outer peripheral portion of the frameless solar cell module to protect the outer peripheral end portion of the solar cell module. (See Patent Document 1)
JP 2004-22761 A

  However, attaching a simple frame member to the frameless solar cell module as described above has a problem in that it takes time and cost to attach the frame member, and the price of the frameless solar cell module increases.

  The present invention has been made in view of such problems, and an object thereof is to provide a highly reliable frameless solar cell module by protecting the outer peripheral edge of the solar cell module by a simple and inexpensive method. is there.

The frameless solar cell module of the present invention is a frameless solar cell module in which a light-transmitting substrate, a light-receiving surface side filler, a solar cell element, a back surface side filler, and a back surface material are arranged in order. In addition, the translucent substrate has a chamfered portion only at the outer peripheral portion on the non-light-receiving surface side, and at least one of the back surface material, the light receiving surface side filler, and the back surface side filler. The outer peripheral portion is covered so as to be flush with the light receiving surface .

  In another frameless solar cell module of the present invention, the chamfered portion is formed of a C surface, and the length of the chamfered portion in a cross section perpendicular to the main surface and the side surface of the light transmissive substrate is the light transmissive substrate. The angle between the chamfered portion and the non-light-receiving surface side main surface of the translucent substrate is 120 degrees or more and 150 degrees or less.

  In another frameless solar cell module of the present invention, the chamfered portion is an R surface, and the radius r of the R surface in a cross section perpendicular to the main surface and the side surface of the translucent substrate is 1 mm or more. It is characterized in that the thickness is equal to or less than the thickness.

According to the frameless solar cell module of the present invention, a frameless solar cell module comprising a translucent substrate, a light-receiving surface-side filler, a solar cell element, a back-side filler, and a back-surface material disposed in order. The light-transmitting substrate has a chamfered portion only on the outer peripheral portion on the non-light-receiving surface side, and at least one of the back material, the light-receiving surface-side filler, and the back-surface-side filler is used for the light-transmitting property By covering the outer peripheral portion so as to be flush with the light receiving surface of the substrate, the outer peripheral end portion of the translucent substrate is not exposed, so that the end surface portion of the solar cell module can be protected, and the solar cell module Will not break when applied at the time of construction, or will be broken by scattered objects during typhoons.

  According to another frameless solar cell module of the present invention, the chamfered portion is formed of a C surface, and a length of the chamfered portion in a cross section perpendicular to a main surface and a side surface of the light transmissive substrate is the light transmissive portion. The angle between the chamfered portion and the non-light-receiving surface side main surface of the translucent substrate is approximately 120 degrees or more and 150 degrees or less, which is substantially the same as the thickness of the conductive substrate. Since it becomes easy to cover a back material along the shape of a translucent board | substrate, the effect of protection of said solar cell module end surface part can be made reliable.

  Furthermore, according to another frameless solar cell module of the present invention, the chamfered portion includes an R surface, and a radius r of the R surface in a cross section perpendicular to the main surface and the side surface of the translucent substrate is 1 mm or more. Since the thickness of the substrate is equal to or less than the thickness of the substrate, the filler and the back surface material can be easily covered along the shape of the translucent substrate, thereby ensuring the effect of protecting the end surface portion of the solar cell module. be able to.

  Hereinafter, the solar cell module of the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a sectional view showing an example of the structure of a frameless solar cell module according to the present invention.

  In the figure, 10 is a translucent substrate, 11 is a light receiving surface side filler, 12 is a solar cell element, 13 is a back surface side filler, 14 is a back surface material, and 15 is a connection tab. The lower side of the figure is the light receiving surface side of the solar cell module, and the upper side of the figure is the back side of the solar cell module.

  As the translucent substrate 10, a substrate made of glass or polycarbonate resin is used. As for the glass substrate, white plate glass, tempered glass, double tempered glass, heat ray reflective glass and the like are used, but generally white plate tempered glass having a thickness of about 3 mm to 5 mm is used. On the other hand, when a substrate made of a synthetic resin such as polycarbonate resin is used, a substrate having a thickness of about 5 mm is often used.

  The light-receiving surface side filler 11 and the back surface side filler 13 are made of an ethylene-vinyl acetate copolymer (hereinafter, ethylene-vinyl acetate copolymer is abbreviated as EVA), and have a sheet shape with a thickness of about 0.4 to 1 mm. A form is used. These are fused and integrated with other members by applying heat and pressure under reduced pressure using a laminating apparatus.

  EVA may contain titanium oxide, a pigment, etc., and may be colored white. In the light-receiving surface side filler 11 according to the present invention, when it is colored, the amount of light incident on the solar cell element 12 tends to decrease and the power generation efficiency tends to decrease.

  Moreover, although EVA used for the back surface side filler 13 is good to comprise a transparent material, it may contain titanium oxide, a pigment, etc. according to the installation environment around a solar cell module, and this may be colored white etc. Good.

The solar cell element 12 is made of polycrystalline silicon or the like as described above,
A PN junction is formed inside, and an electrode is formed on the surface.

  The connection tab 15 is usually used by cutting the entire surface of a copper foil having a thickness of about 0.1 to 1.0 mm and a width of about 1 to 8 mm into a predetermined length. This connection tab 15 is attached to the electrode of the solar cell element 12 by soldering, and electrically connects the adjacent solar cell elements.

  The back material 14 is made of a weather-resistant fluorine-based resin sheet sandwiching an aluminum foil or a polyethylene terephthalate (PET) sheet deposited with alumina or silica so as not to transmit moisture.

  The areas of the light receiving surface side filler 11, the back surface side filler 13, and the back surface material 14 according to the present invention are larger than the translucent substrate 10 by the thickness of the translucent substrate 10.

  The manufacturing method of the frameless solar cell module according to the present invention is as follows.

  First, the above-described translucent substrate 10, the light receiving surface side filler 11, the solar cell element 12 connected to the connection tab 15, the back surface side filler 13, and the back surface material 14 are superimposed. At this time, the above-mentioned chamfered portion of the translucent substrate 10 is provided. As an example of the chamfered portion, for example, a portion subjected to the C surface treatment or the R surface treatment is arranged on the non-light-receiving surface side (outside). Thereafter, the superposed product is set in a device called a laminator, and is integrated by applying pressure while heating at a temperature of about 100 to 200 ° C. for about 15 to 60 minutes under a reduced pressure of about 50 to 150 Pa.

  In this case, the translucent substrate 10 of the present invention is characterized in that at least one side of a corner portion of the translucent substrate 10 on the non-light-receiving surface side is subjected to C surface treatment or R surface treatment.

  FIG. 2A shows a perspective view of the translucent substrate 10 that has been subjected to the C-surface treatment, as viewed from the light-receiving surface side, and FIG. 2B shows a partial enlargement of the translucent substrate 10 that has undergone the C-surface treatment. A cross-sectional view is shown. 2 (a) and 2 (b), 17 is a portion subjected to C surface treatment, 18 is the size (length) of the C surface treatment portion, 19 is the thickness of the translucent substrate 10, and a is the C surface treatment portion. And the angle formed by the non-light-receiving surface side plane of the translucent substrate.

  As shown in FIG. 2A, the C-plane treatment is performed in advance before the lamination over almost the entire area of at least the corner portion on the non-light-receiving surface side of the translucent substrate 10.

  Further, the length 18 of the C surface treatment portion is substantially the same as the thickness 19 of the translucent substrate in the test repeatedly performed by the present inventors, and the length of the C surface treatment portion and the translucent property are the same. The angle a formed by the non-light-receiving surface side plane of the substrate is desirably 120 degrees or more and 150 degrees or less.

  That the length 18 of the C-surface treatment portion is substantially the same as the thickness 19 of the translucent substrate means that it is within a range of −10% to + 10% with respect to the thickness of the translucent substrate. That is, according to the results of the tests repeatedly performed by the inventors, the above effect can be obtained without problems if the length of the C-surface treatment portion is in the range of −10% to + 10% with respect to the thickness of the light-transmitting substrate. be able to. For example, when glass having a thickness of 3 mm is used as the translucent substrate, the length of the C-surface treatment portion may be 2.7 to 3.3 mm.

  The length 18 of the C surface processing unit 17 is increased beyond the thickness 19 of the light transmitting substrate, or the angle a formed by the C surface processing unit and the non-light receiving surface side plane of the light transmitting substrate is increased beyond 150 degrees. Then, although the effect that the outer peripheral edge part of a translucent board | substrate can be protected along the shape can be enlarged, there exists a problem that the intensity | strength of the C surface process part 17 will fall.

  Conversely, if the length 18 of the C-surface treatment portion 17 is made smaller than the thickness 19 of the translucent substrate or the angle a formed by the C-surface treatment portion and the non-light-receiving surface side plane of the translucent substrate is less than 120 degrees, Although the strength does not decrease, the effect of protection along the outer peripheral end shape of the translucent substrate is reduced.

  3A shows a perspective view of the translucent substrate 10 subjected to the R surface treatment, and FIG. 3B shows an enlarged cross-sectional view of a main part of the translucent substrate 10 subjected to the R surface treatment. . In FIGS. 3A and 3B, 20 indicates a portion subjected to the R surface treatment, r indicates the size of the R surface processed portion (the radius of the R surface portion), and 19 indicates the thickness of the translucent substrate 10.

  As shown in FIG. 3A, the R surface treatment is performed in advance before the lamination over almost the entire side of the corner portion on the non-light-receiving surface side of the translucent substrate 10.

  In addition, in the R surface processing unit 20, in a test repeatedly performed by the present inventors, it is desirable that the radius r is 1 mm or more and not more than the thickness of the substrate.

  That is, if the radius r of the R-surface treatment part 20 is increased beyond the thickness of the substrate, the effect of protecting the outer peripheral edge of the translucent substrate along the shape can be increased, but the R-surface treatment part 20 There is a problem that the strength of the glass is lowered.

  Conversely, if the radius r of the R-surface treatment unit 20 is reduced to less than 1 mm, the strength does not decrease, but the effect of protection along the outer peripheral end shape of the translucent substrate is reduced.

  FIG. 4 is an enlarged cross-sectional view of a main part showing a state of an end portion of the solar cell module according to the present invention using the translucent substrate 10 subjected to the C-plane treatment or the R-plane treatment.

  As shown in FIG. 4, the outer periphery of the translucent substrate 10 is subjected to C surface treatment or R surface treatment so that the filler and back surface material can be easily covered along the shape of the outer peripheral edge of the translucent substrate. Since the outer peripheral edge of the translucent substrate is not exposed by covering the outer periphery of the translucent substrate with at least one of the back material and the filler, the solar cell module end surface portion is It is possible to protect easily and inexpensively without using a module frame or the like.

  Such C surface treatment 17 or R surface treatment 20 can be performed by grinding and polishing with a diamond wheel if the light-transmitting substrate 10 is glass as described above. It can be manufactured by cutting by processing or the like.

  In addition, as described above, the C surface treatment or the R surface treatment is performed, and at least one of the back material and the filler covers at least one side of the outer periphery of the translucent substrate. The entire periphery may be sufficient, or only the portion that hits the outside may be considered in consideration of the state of being installed after completion.

  FIG. 5 is a cross-sectional view showing the state of the end portion of the solar cell module according to the present invention, in which only the fillers 11 and 13 are previously made larger in size than the size of the translucent substrate 10 and laminated.

  That is, in order to improve the weather resistance performance of the solar cell module, etc., the thickness of the back material 14 is increased and its flexibility is deteriorated, or the back material is flexible such as a metal plate such as a stainless steel plate or an aluminum plate. Even when a bad back surface material is used, the end surfaces of the solar cell module can be protected by increasing the size of only the fillers 11 and 13.

  FIG. 6 is a cross-sectional view showing a state in which a high-viscosity resin material is applied to the outer peripheral end of the frameless solar cell module according to the present invention. In FIG. 6, reference numeral 23 denotes a high viscosity resin material.

  As shown in FIG. 6, the outer periphery of the translucent substrate 10 is subjected to C surface treatment or R surface treatment, and at least one of the back material 14 and the fillers 11 and 13 is disposed around the outer periphery of the translucent substrate. Covering and applying a high-viscosity resin material such as silicone resin to this part can further improve the effect of protecting the end face of the solar cell module, and it is also difficult to pass humidity. Is possible.

  In addition, this invention is not limited to the said embodiment, Many corrections and changes can be added within the scope of the present invention. For example, the solar cell element can be applied not only to single crystal silicon or polycrystalline silicon but also to a thin film solar cell element. Further, the shape of the frameless solar cell module according to the present invention is not limited to a square or a rectangle. For example, a frameless solar cell module having a trapezoidal shape or a triangular shape can be applied.

It is sectional drawing of the structure of the frameless solar cell module which concerns on this invention. (A) It is a perspective view of the translucent board | substrate which performed the C surface process based on this invention. (B) It is sectional drawing of the translucent board | substrate which performed the C surface process based on this invention. (A) It is a perspective view of the translucent board | substrate which performed the R surface process based on this invention. (B) It is a principal part expanded sectional view of the translucent board | substrate which performed the R surface process based on this invention. It is a principal part expanded sectional view which shows the state of the edge part of the solar cell module which concerns on this invention using the translucent board | substrate which performed C surface process or R surface process. It is a principal part expanded sectional view which shows the mode of the edge part of the solar cell module which concerns on this invention which enlarged only the filler from the magnitude | size of the translucent board | substrate. It is sectional drawing which shows the state which applied the high-viscosity resin material to the outer peripheral edge part of the flameless solar cell module which concerns on this invention. It is the schematic which shows an example in the case of installing a frameless solar cell module in the outdoors.

Explanation of symbols

1: Foundation 2: Stand 3: Frameless solar cell module 4: Fastener 10: Translucent substrate 11: Light receiving surface side filler 12: Solar cell element 13: Back surface side filler 14: Back surface material 15: Connection Tab 17: C surface treated portion 18: Size (length) of C surface treated portion
19: Thickness of translucent substrate 20: Part subjected to R surface treatment 23: High-viscosity resin material a: Angle r formed between C surface treated part and non-light-receiving surface side plane of translucent substrate is R surface treatment Size of the part (radius of the R surface)

Claims (3)

A frameless solar cell module comprising a light-transmitting substrate, a light-receiving surface side filler, a solar cell element, a back surface side filler, and a back material, which are arranged so as to sequentially overlap,
While having a chamfered portion only on the outer peripheral portion on the non-light-receiving surface side of the translucent substrate,
A frameless, characterized in that at least one of the back surface material, the light receiving surface side filler, and the back surface side filler covers an outer peripheral portion so as to be flush with the light receiving surface of the translucent substrate. Solar cell module. The chamfered portion is a C-plane, and the length of the chamfered portion in a cross section perpendicular to the main surface and the side surface of the translucent substrate is substantially the same as the thickness of the translucent substrate, and the chamfered portion and the chamfered portion 2. The frameless solar cell module according to claim 1, wherein an angle formed by the non-light-receiving surface side main surface of the translucent substrate is 120 degrees or more and 150 degrees or less. The chamfered portion is formed of an R surface, and a radius r of the R surface in a cross section perpendicular to a main surface and a side surface of the translucent substrate is 1 mm or more and less than a thickness of the substrate. Item 2. A frameless solar cell module according to Item 1.

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