Solar cell module

Abstract

The invention provides a solar cell module which is high in rigidity and capable of suppressing manufacturing cost. A solar cell module (1) is provided with a front panel (2) and a rear panel (3) which are disposed on the light-receiving surface side of a solar cell (4) and on the opposite side of the light-receiving surface side (the opposite side of the light-receiving surface) with a sealing material (6) interposed therebetween, and the rear panel (3) is provided with a woven metal plate (30) formed by weaving a metal band plate having a predetermined band width (W).

Description

Technical Field

[0001] This invention relates to solar cell modules. Background Technology

[0002] Patent Document 1 discloses a solar cell module with a metal foil, metal mesh, or the like on the back panel opposite to the incident light side. This solar cell module, in a flexible solar cell module comprising solar cell units and a resin film laminated with a sealing material separating the light-receiving side and the opposite side of the solar cell units, further includes a burn-prevention sheet bonded to the opposite side of the light-receiving side of the solar cell units via the resin film. The burn-prevention sheet is composed of a flexible sheet comprising any one of metal foil, metal mesh, or inorganic fiber cloth. Therefore, it is described that in addition to suppressing the spread of combustion from the module surface to the inner side (building side), the module's flame retardancy can be improved by suppressing the module's own temperature rise.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2013-004835 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In automotive solar cell modules, for example, when mounted under an engine hood, a glass back panel fails to meet regulations from a head protection perspective in the event of a collision. Furthermore, if the back panel is made of polycarbonate resin, the engine is located under the hood, presenting a high-temperature component, raising concerns about reduced rigidity at high temperatures. Using a metal plate for the back panel can alleviate these two problems, but it increases manufacturing costs. While using a metal mesh for the back panel in the prior art may reduce manufacturing costs, a small wire diameter results in a lack of rigidity, raising concerns about reduced rigidity at high temperatures when mounted under an engine hood. Additionally, increasing the wire diameter to improve rigidity may prevent three-dimensional shaping.

[0008] The present invention was made in view of the above-mentioned problems, and its object is to provide a solar cell module with high rigidity and the ability to suppress manufacturing costs.

[0009] Methods for solving problems

[0010] To address the aforementioned issues, the solar cell module of the present invention is characterized by comprising: a solar cell array including at least one solar cell unit; and a surface plate and a back plate disposed on the light-receiving side and the opposite side of the light-receiving side of the solar cell array, separated by a sealing material, wherein a woven metal plate is provided on the back plate, the woven metal plate being woven from a metal strip having a predetermined bandwidth.

[0011] Invention Effects

[0012] According to the present invention, by providing a fabric-like metal plate as a structure on the back panel, a solar cell module with high rigidity and the ability to suppress manufacturing costs can be provided. Attached Figure Description

[0013] Figure 1 This is an enlarged cross-sectional view schematically showing the configuration of the solar cell module of this embodiment.

[0014] Figure 2 This is a plan view schematically illustrating the structure of the fabric-like metal plate of the solar cell module according to this embodiment (schematically showing along...). Figure 1 (A sectional view of the section cut by line AA).

[0015] Figure 3 This is a schematic plan view illustrating the fabric-like metal plate structure of a solar cell module in variant 1 (schematically representing the structure along...). Figure 1 (A sectional view of the section cut by line AA).

[0016] Figure 4 This is an enlarged cross-sectional view schematically showing the structure of the solar cell module in variant 2.

[0017] Explanation of reference numerals in the attached figures

[0018] 1: Solar cell module, 2: Surface panel, 3: Back panel, 30: Fabric-like metal plate, 31: Sealing material, 32: Insulating layer, 33: Resin layer, 4: Solar cell array, 5: Solar cell unit, 6: Sealing material, W: Bandwidth, θ: Cross angle. Detailed Implementation

[0019] The following is for reference Figures 1 to 4 The accompanying drawings illustrate embodiments of the present invention in detail. Furthermore, the embodiments shown below are one aspect of the present invention and do not limit the technical scope of the invention.

[0020] In the following embodiment, an example of mounting the solar cell module 1 of this embodiment on the engine hood of a vehicle is described. The solar cell module 1 has a curved, plate-like shape. Therefore, it can be mounted on the engine hood in accordance with the similarly curved shape of the vehicle's engine hood.

[0021] The solar cell module 1 has a surface plate 2 made of light-transmitting plate-like components on the uppermost layer of the engine hood. Figure 1 When sunlight or other light shines on the solar cell module 1, the light passes through the surface plate 2 and reaches the interior of the solar cell module 1. As a result, an electromotive force is generated between the positive and negative terminals of the solar cell module 1, which can supply the generated electricity to vehicles, etc.

[0022] Furthermore, the solar cell module 1 is thin and lightweight. Taking advantage of this characteristic, in addition to the engine hood of the aforementioned vehicle, the solar cell module 1 can be mounted on various other objects such as the roof, fenders, doors, trunk, and the outer panels or walls of buildings other than vehicles.

[0023] Figure 1 This is an enlarged cross-sectional view schematically illustrating the configuration of the solar cell module 1 according to this embodiment. Additionally, Figure 2 This is a plan view schematically illustrating the structure of the fabric-like metal plate of the solar cell module according to this embodiment; that is, it schematically illustrates the structure along... Figure 1 The cross-sectional view is taken along line AA. Furthermore, the solar cell module 1 is a vehicle-mounted component, curved to correspond to the shape of the vehicle's hood, but for ease of explanation in the cross-sectional view, it is shown as a flat plate. The solar cell module 1 includes a surface plate 2, a back panel 3, a solar cell array 4 disposed between the surface plate 2 and the back panel 3, and a sealing material 6 sealing the solar cell array 4. In other words, the solar cell module 1 has the surface plate 2 and the back panel 3 disposed on the light-receiving side of the solar cell array 4 and on the opposite side (opposite side of the light-receiving side) separated by the sealing material 6.

[0024] The solar cell array 4 has multiple solar cell units 5 in a generally rectangular shape. When viewed in planar view, the solar cell units 5 are slightly separated from each other and arranged in a matrix. Each solar cell unit 5 has a power generation element, electrodes, etc., and is curved accordingly to the curved shape of the solar cell module 1.

[0025] As described above, the irradiated light passes through the surface plate 2 and reaches the interior of the solar cell module 1. The irradiated light reaches the power generation element (solar cell unit 5) and is absorbed, thereby converting the energy of the irradiated light into electrical energy. In addition, each power generation element (solar cell unit 5) is electrically connected through an interconnect (not shown), and current flows through the entire solar cell array 4 via the interconnect.

[0026] Furthermore, the configuration of the solar cell array, which is the power generation unit of solar cell module 1, is not limited to the configuration shown in the figure. For example, in this embodiment, a configuration in which the power generation unit is composed of a single solar cell array is illustrated, but a series configuration in which the first and second solar cell arrays are arranged vertically can also be used. In addition, there is no particular limitation on the solar cell unit constituting the solar cell array, and any conventionally known solar cell unit can be used.

[0027] The feature of this embodiment is the construction of the back panel 3 of the solar cell module 1, which is equipped with a structure that has high rigidity and can suppress manufacturing costs.

[0028] The general manufacturing process of solar cell module 1 includes a lay-up process that stacks the components, followed by a lamination process that uses a vacuum laminator (also called a laminator) for vacuum degassing and hot pressing. Additionally, flat-panel products for residential and industrial use are widely used in manufacturing, enabling cost reduction through mass production and automated production lines.

[0029] On the other hand, automotive products are three-dimensional products, and the aforementioned solar cell manufacturing equipment for residential and industrial use cannot be used. Therefore, manual labor is required, resulting in high manufacturing costs.

[0030] In addition, the lamination process for three-dimensional products is prone to problems such as battery cell breakage, resulting in a high defect rate and high cost due to low yield during manufacturing.

[0031] Therefore, by laminating in a flat shape, it is possible to manufacture high-quality products at low cost.

[0032] Based on the above, this embodiment proposes a structure for a solar cell module 1 (back panel 3) that can be thermally bent (shaped) in three dimensions after being laminated in a flat plate shape.

[0033] In detail, the back panel 3 includes a fabric-like metal plate 30 and a sealing material 31 for sealing the fabric-like metal plate 30. That is, the back panel 3 is a laminated member formed by sandwiching the fabric-like metal plate 30, which serves as a structural element, in the middle with the sealing material 31. In addition, the back panel 3 has a plate-shaped insulating layer 32 on the solar cell array 4 side (upper side) of the sealing material 31, in other words, between the fabric-like metal plate 30 and the solar cell array 4, and a plate-shaped resin layer 33 on the side of the sealing material 31 opposite to the solar cell array 4 side (lower side). The back panel 3 (the sealing material 31 constituting the back panel 3) is bonded to the upper sealing material 6 via the insulating layer 32. That is, in this embodiment, the back panel 3 is constructed by providing a fabric-like metal plate 30 as a structural element, and bonding the plate-shaped insulating layer 32 and resin layer 33 to the side of the fabric-like metal plate 30 on the solar cell array 4 side (sealing material 6 side) and the side opposite to the solar cell array 4 side (sealing material 6 side) via the sealing material 31.

[0034] like Figure 2 As shown, the fabric-like metal plate 30 is a strip of metal (metal plate) with a predetermined bandwidth W, arranged at a predetermined cross angle θ. Figure 2 It is made by weaving in a cross pattern (approximately 90°). The fabric-like metal plate 30 is three-dimensionally curved in accordance with the curved shape of the solar cell module 1.

[0035] For example, when the solar cell module 1 is applied to the hood of a vehicle, the curvature of the hood's exterior design surface is determined by the vehicle's design, but the bandwidth W of the strip constituting the fabric-like metal plate 30 is set to match the curvature of the hood's exterior design surface. Therefore, the bandwidth W of the strip constituting the fabric-like metal plate 30 can, for example, be as follows: Figure 3 As shown, the width W of the strip can be changed to match the curvature of the surface of the mounting destination. For example, the width W of the strip can be reduced (narrowed) in areas with low curvature and increased (widened) in areas with high curvature. Similarly, the cross angle θ of the strips constituting the fabric-like metal plate 30 can be changed to match the curvature of the surface of the mounting destination.

[0036] Hereinafter, preferred examples of the material or raw material and thickness of each component constituting the stacked structure of the solar cell module 1 of this embodiment will be shown sequentially from the side of sunlight incident. However, the material or raw material and thickness of each component are not limited to the following.

[0037] Layer 1: Surface Panel 2

[0038] Materials: PC (polycarbonate) resin, acrylic resin, ETFE (ethylene-tetrafluoroethylene copolymer) film, etc. (preferably PC resin)

[0039] Thickness: 0.1–2 mm (preferably 1 mm)

[0040] Second layer: Sealing material 6 (sealing material sheet on the upper part of solar cell unit 5)

[0041] Materials: EVA (ethylene vinyl acetate copolymer), polyolefins, ionomers, PVB (polyvinyl butyral), etc. (preferably polyolefins)

[0042] Thickness: 0.4–1 mm (preferably 0.5 mm)

[0043] Layer 3: Solar cell unit 5

[0044] Raw materials: silicon (Si) units, perovskite elements, etc. (preferably Si units)

[0045] Thickness: 0.1~0.2mm (preferably 0.18mm)

[0046] 4th layer: Sealing material 6 (sealing material sheet on the lower part of solar cell unit 5)

[0047] Materials: EVA, polyolefins, ionomers, PVB, etc. (preferred: polyolefins)

[0048] Thickness: 0.4–1 mm (preferably 0.5 mm)

[0049] 5th layer: Insulation layer 32

[0050] Materials: PC resin, acrylic resin, ETFE film, PET (polyethylene terephthalate) resin (preferred: PET resin)

[0051] Thickness: 0.1–2 mm (preferably 0.5 mm)

[0052] 6th layer: Sealing material 31 (sealing material sheet on the upper part of the fabric-like metal plate 30)

[0053] Materials: EVA, polyolefins, ionomers, PVB, etc. (preferred: ionomers)

[0054] Thickness: 0.1–2 mm (preferably 0.5 mm)

[0055] Layer 7: Fabric-like metal plate 30

[0056] Raw materials: steel plates, aluminum plates, titanium plates, etc. (preferred: steel plates, aluminum plates)

[0057] Thickness: 0.1–1 mm (preferably 0.2 mm)

[0058] 8th layer: Sealing material 31 (sealing material sheet on the lower part of the fabric-like metal plate 30)

[0059] Materials: EVA, polyolefins, ionomers, PVB, etc. (preferred: ionomers)

[0060] Thickness: 0.1–2 mm (preferably 0.5 mm)

[0061] 9th layer: Resin layer 33

[0062] Materials: PC resin, acrylic resin, ETFE film, PET resin (preferred: PET resin)

[0063] Thickness: 0.1–2 mm (preferably 0.2 mm)

[0064] The aforementioned components are stacked, and a solar cell module 1 is fabricated in a flat state using a vacuum laminating apparatus (laminator). At this time, a commonly used glass module manufacturing apparatus can be used. After fabricating the solar cell module 1 in a flat state, the solar cell module 1 is shaped (thermally bent) into the shape of an engine hood using a three-dimensional mold. At this time, the strips of the fabric-like metal plate 30, which constitute the structural body within the back panel 3, are shaped (thermally bent) with slight offsets from each other, thereby enabling the fabrication of a three-dimensionally bent solar cell module 1.

[0065] It should be noted that in the above embodiment, only one fabric-like metal plate 30 is used to fabricate the solar cell module 1, but for example, as Figure 4 As shown, by dividing the fabric-like metal plate into two sections (upper fabric-like metal plate 30A and lower fabric-like metal plate 30B) and setting the sealing material 31 in between to a hard ionomer resin or PVB resin with a Young's modulus of about 200 MPa, shear deformation during module bending can be suppressed, thus achieving a commonly known honeycomb structure. Therefore, lightweighting can be achieved while improving bending rigidity.

[0066] As Figure 4 In a preferred embodiment of the method shown, the upper fabric-like metal plate 30A and the lower fabric-like metal plate 30B are formed of thin plates of about 0.1 to 0.5 mm, which are aluminum plates, and the thickness of the sealing material 31 in the middle is preferably about 1 to 2 mm.

[0067] In summary, the solar cell module 1 of this embodiment has a fabric-like metal plate 30 as a structure on the back panel 3, and the fabric-like metal plate 30 is sandwiched in the middle by a sealing material 31 as a laminated component.

[0068] In addition, in process (1), a laminated structure is made using a vacuum lamination device (laminar) in a flat state, and then, as process (2), the laminated structure is shaped using a three-dimensional mold with an engine hood appearance design.

[0069] Preferably, when used for engine hoods, the laminated structure is configured to have a bending stiffness approximately equal to that of the steel plate t0.7.

[0070] In addition, the fabric-like metal plate is constructed as follows: to match the three-dimensional curvature of the engine hood, the bandwidth W of the metal plate is narrowed at small curvatures and increased at large curvatures.

[0071] Although it is a metal sheet, by shaping it into a fabric-like form, a three-dimensionally shaped structure can be achieved. Therefore, after the lamination process in the flat state, three-dimensional processing based on thermal bending can be performed.

[0072] Furthermore, through the above process (1), solar cell modules can be manufactured in a flat (not three-dimensional) state, thus allowing the use of widely available manufacturing equipment. Additionally, only one mold is needed for the above process (2). This results in low manufacturing costs.

[0073] In addition, the vehicle's outer panels are made of steel, but by setting them to have the same bending rigidity, head injuries can be reduced in the event of a collision between a person and the vehicle.

[0074] In addition, for example, the curvature of the engine hood varies depending on the vehicle design, but in the fabric structure described above, it is possible to reduce the stress applied to the power generation elements of the stacked solar cell units.

[0075] The rationale is that, for example, with a large bandwidth and small curvature, the shape becomes such that the bends between the strips become pointed, generating a load on the solar cell. This means that there exists an optimal bandwidth that matches the curvature of the overall design. On the other hand, reducing the bandwidth can reduce the load on the solar cell, but with a small bandwidth, the number of strands increases, which is not a good approach in terms of manufacturing cost. Therefore, while it is desirable to maximize the bandwidth (to reduce cost), there exists an optimal bandwidth in the overall design that minimizes the bandwidth (to reduce the load on the cell) while maintaining a small curvature.

[0076] As described above, the solar cell module 1 of this embodiment includes: a solar cell array 4 including at least one solar cell unit 5; and a (transparent) surface plate 2 and a back plate 3 disposed on the light-receiving side and the side opposite to the light-receiving side (opposite side of the light-receiving side) of the solar cell array 4 separated by a sealing material 6. A fabric-like metal plate 30 is provided on the back plate 3, which is woven from a metal strip having a predetermined bandwidth W.

[0077] The back panel 3 is formed by bonding an insulating layer 32 and a resin layer 33 to the side of the fabric-like metal plate 30 on the side of the solar cell array 4 and the side opposite to the solar cell array 4, separated by a sealing material 31. The insulating layer 32 and the resin layer 33 can be formed of the same resin material.

[0078] The bandwidth W or cross angle θ of the strip is set (or changed) based on the curvature of the destination where the solar cell module 1 is mounted.

[0079] The solar cell module 1 has a curved shape.

[0080] The solar cell module 1 is mounted on the vehicle (e.g., under the hood).

[0081] According to this embodiment, by providing a fabric-like metal plate 30 as a structure on the back panel 3, a solar cell module 1 with high rigidity and the ability to suppress manufacturing costs can be provided.

[0082] Furthermore, the present invention is not limited to the above-described embodiments, and can be appropriately modified and altered without departing from the purpose of the present invention.

Claims

1. A solar cell module, characterized in that, have: A solar cell array comprising at least one solar cell unit; and A surface panel and a back panel are disposed on the light-receiving side and the opposite side of the light-receiving side of the solar cell array, separated by a sealing material. The back panel is provided with a woven metal plate, which is made by weaving together a metal strip with a predetermined bandwidth.

2. The solar cell module according to claim 1, characterized in that, The back panel is formed by bonding an insulating layer and a resin layer on the solar cell assembly side and the opposite side of the fabric-like metal plate, separated by a sealing material.

3. The solar cell module according to claim 1, characterized in that, The bandwidth or cross angle of the strip is set based on the curvature of the destination where the solar cell module is mounted.

4. The solar cell module according to claim 1, characterized in that, The solar cell module has a curved shape.

5. The solar cell module according to claim 1, characterized in that, The solar cell module is mounted on the vehicle.

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