Solar cell module

Abstract

The solar cell module (1) has a three-dimensional shape and can be easily manufactured. The solar cell module (1) comprises a plurality of solar cell units (10); a single front surface protection member (20) which covers the light-receiving surface side of the plurality of solar cell units (10), and the surface (21) of which facing the plurality of solar cell units (10) is a three-dimensional curved surface; a single back sheet (30) which covers the back surface sides of the plurality of solar cell units (10), in which one or more cutouts (31) extending from the outer edge are formed, and which is shaped to imitate the shape of the facing surface (21); a sealing material (40) filled between the front protective member (20) and the back plate (30); and one or more patches (50) that cover the light-receiving surface side or the back surface side of the cutout (31).

Description

Technical Field

[0001] The utility model relates to a solar cell module. Background Art

[0002] Solar cell modules formed by sealing a plurality of solar cell units inside a protective member have been widely used. As the use of solar cell modules expands, for example, there has been a demand for solar cell modules with a three-dimensional curved surface shape that can be installed on the roof of a car, etc. Such a solar cell module is formed using a flat glass formed into a desired curved surface shape as a front protective member for protecting the light-receiving side. As a back protective member for protecting the back side, a back plate for lightweighting is mostly used, but it is difficult to form a flat back plate into a three-dimensional shape. That is, a general back plate cannot follow the three-dimensional shape of the front protective member, and may cause wrinkles or floating. Therefore, a scheme has been proposed to divide the back plate into a plurality of parts so that the back plate is set to a three-dimensional shape that matches the shape of the front protective member (for example, refer to patent document 1).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: International Publication No. WO2018 / 150794 Utility Model Content

[0006] Problems to be solved by utility models

[0007] If the back sheet is divided into a plurality of parts, the plurality of back sheets need to be positioned and arranged, and the modularization operation becomes complicated. Therefore, an object of the present invention is to provide a solar cell module that has a three-dimensional shape and can be easily manufactured.

[0008] Solutions for solving problems

[0009] A solar cell module of one embodiment of the present invention comprises: a plurality of solar cell units; a single front protection member, which covers the light-receiving side of the plurality of solar cell units, and whose opposite surface facing the plurality of solar cell units is a three-dimensional curved surface; a single back plate, which covers the back side of the plurality of solar cell units and is formed with one or more cutouts extending from the outer edge, and the back plate is formed to imitate the shape of the opposite surface; a sealing material filled between the front protection member and the back plate; and one or more patches, which cover the light-receiving side or the back side of the cutout.

[0010] Utility Model Effect

[0011] According to the present invention, it is possible to provide a solar cell module which has a three-dimensional shape and can be easily manufactured. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a perspective view showing a solar cell module according to the first embodiment of the present invention.

[0013] Figure 2 yes Figure 1 Rear view of a solar cell module.

[0014] Figure 3 yes Figure 2 XX line cross-sectional view of a solar cell module.

[0015] Figure 4 yes Figure 2 An expanded view of the back sheet of a solar cell module.

[0016] Figure 5 It is a rear view of the solar cell module according to the second embodiment of the present invention.

[0017] Figure 6 yes Figure 5 YY line cross-sectional view of a solar cell module.

[0018] Figure 7 yes Figure 5 An expanded view of the back sheet of a solar cell module.

[0019] Figure 8 This is a development view of a back sheet of a solar cell module according to a modified example of the present invention.

[0020] Fig. 9 This is a development view of a back sheet of a solar cell module according to another modified example of the present invention.

[0021] Fig.10 This is a development view of a back sheet of a solar cell module according to yet another modified example of the present invention. DETAILED DESCRIPTION

[0022] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. In addition, in each of the drawings, the same or equivalent parts are marked with the same reference numerals. In addition, for the sake of simplicity, the illustration of components, reference numerals, etc. are sometimes omitted, but in this case, it is assumed that other drawings are referred to. In addition, for the sake of convenience, the shapes and sizes of various components in the drawings are adjusted to be easy to see.

[0023] Figure 1 It is a perspective view showing the solar cell module 1 according to the first embodiment of the present invention. Figure 2 It is a rear view of the solar cell module 1 . Figure 3 is a cross-sectional view of the solar cell module 1 .

[0024] The solar cell module 1 includes: a plurality of solar cell units (cells) 10; a single front protection member 20, which covers the light-receiving side of the plurality of solar cell units 10; a single back sheet 30, which covers the back side of the plurality of solar cell units 10; a sealing material 40, which is filled between the front protection member 20 and the back sheet 30; and a single patch sheet 50, which is stacked on the light-receiving side of the back sheet 30.

[0025] The solar cell module 1 is manufactured (assembled) by stacking a front protection member 20, a sheet of material forming the light-receiving side portion of the sealing material 40, a plurality of solar cell units 10, a sheet of material forming the back side portion of the sealing material 40, a patch 50, and a back sheet 30 in this order, and melting the material of the sealing material 40 by hot pressing to form the sealing material 40 that tightly holds the other components.

[0026] The plurality of solar cell units 10 are arranged in a vertical and horizontal arrangement. The plurality of solar cell units 10 may also be arranged on substantially the entire surface of the solar cell module 1 by forming a plurality of strings 11. Each string 11 is formed by arranging and connecting a certain number of solar cell units 10 in a row.

[0027] There is no particular limitation on the solar cell unit 10, and any structure of solar cell can be used. For example, by using a back electrode type solar cell having an electrode only on the back side as the solar cell unit 10, a relatively high photoelectric conversion efficiency can be achieved, and the color of the solar cell module 1 when viewed from the front side can be made black as a whole to improve the aesthetics.

[0028] In front protection member 20, at least its facing surface 21 facing the plurality of solar cells 10 is a three-dimensional curved surface. Front protection member 20 generally has a certain thickness, and the surface opposite to solar cell 10 is also formed into a three-dimensional curved surface similar to facing surface 21.

[0029] The front protection member 20 covers the plurality of solar cell units 10 via the sealing material 40. The front protection member 20 is a structural member that protects the plurality of solar cell units 10 and determines the overall shape of the solar cell module 1. Therefore, as the front protection member 20, a front protection member 20 formed of a material having sufficient mechanical strength and excellent light transmittance and weather resistance is formed. As specific materials, for example, transparent resins such as acrylic resins or polycarbonate resins, glass, and laminates thereof can be cited. In addition, in order to suppress the reflection of light, the surface of the front protection member 20 can also be processed into a concave-convex shape or covered with an anti-reflection coating.

[0030] The back sheet 30 protects the solar cell 10 by covering the plurality of solar cell 10 via the sealing material 40. The back sheet 30 is a flexible sheet and is pressed toward the front protection member 20 when the solar cell module 1 is manufactured to be formed into a shape similar to the opposite surface 21 of the front protection member 20.

[0031] As the back sheet 30, for example, a resin film such as polyethylene terephthalate (PET), polyethylene (PE), fluorine-containing resin, silicone resin, or a laminate of these resin films and metal foils such as aluminum foil can be used. On the light-receiving side of the back sheet 30, an easy-adhesive layer that can be bonded to the sealing material 40 and the back side of the back sheet 30 can also be included. The back sheet 30 can also contain a black coloring material, etc., so that the gap between the solar cell units 10 is not easily conspicuous.

[0032] The back sheet 30 has a plurality of cutouts 31. The plurality of cutouts 31 facilitates deformation of the back sheet 30 into a shape that mimics the shape of the opposite surface 21 when manufacturing the solar cell module 1. Therefore, the number, size, and arrangement of the cutouts 31 can be selected to match the shape of the front protection member 20. However, in order to prevent the cutouts 31 from being visually recognized from the light-receiving side, the cutouts 31 are preferably arranged so that a portion thereof overlaps with the solar cell unit 10. That is, the cutouts 31 are preferably not arranged in the gaps between the strings 11. The outer shape of the back sheet 30 can be formed so that a desired planar shape can be formed when incorporated into the solar cell module.

[0033] like Figure 4 As shown, the cutout 31 of the present embodiment can be formed into a triangle or wedge shape defined by two cutting lines 32 extending from two points of the outer edge of the back sheet 30 and having the same top point when the back sheet 30 is unfolded into a plane. In the solar cell module 1, the top angle of the cutout 31 (the angle of the vertices formed by the two cutting lines) is preferably designed so that a small gap remains between the two cutting lines 32. In this way, it is possible to prevent the end faces of the two cutting lines 32 from abutting against each other and hindering the deformation of the back sheet 30.

[0034] The sealing material 40 is a member that seals the solar cell 10 between the front protection member 20 and the back sheet 30 for protection, and in particular prevents moisture from coming into contact with the solar cell 10. Therefore, the sealing material 40 is interposed between the light-receiving surface of the solar cell 10 and the front protection member 20, between the back surface of the solar cell 10 and the back sheet 30, and also fills the gaps between the solar cell 10.

[0035] As the sealing material 40, for example, it is suitable to use a light-transmitting thermoplastic resin such as ethylene / vinyl acetate copolymer (EVA), ethylene / α-olefin copolymer, ethylene / vinyl acetate / triallyl isocyanurate (EVAT), polyvinyl butyral (PVB), acrylic resin, urethane resin or silicone resin.

[0036] The patch 50 covers the light-receiving side of the cutout 31 in the solar cell module 1. The patch 50 has a plurality of cover portions 51 that cover each cutout 31 individually and a connection portion 52 that connects the plurality of cover portions 51. Thus, all the cutouts 31 are covered by a single patch 50. The patch 50 may be made of any material that can protect the solar cell unit 10 as the back sheet 30, and may be formed of the same material as the back sheet 30. In order to make the patch 50 less visually recognizable, the patch 50 preferably has the same color as the back sheet 30.

[0037] The cover 51 can prevent the fluidized sealing material 40 from leaking from the cutout 31 to the back side of the back sheet 30 when assembling the solar cell module 1, and can inhibit the intrusion of moisture from the cutout, thereby improving moisture resistance. Considering the configuration error of the patch 50 and the back sheet 30, the position deviation of the patch 50 and the back sheet 30 caused by the unpredictable flow of the sealing material 40 during assembly, etc., the cover 51 is formed to a size that does not expose the cutout 31. Therefore, the cover 51 is preferably formed in a strip shape with a certain width.

[0038] The connection part 52 holds the covers 51 together when assembling the solar cell module 1, especially when stacking the patch 50 and the back sheet 30, making it easy to place the covers 51 in appropriate positions. The connection part 52 is formed into a shape that can exert a degree of rigidity that can position the covers 51.

[0039] As described above, the solar cell module 1 is easy to manufacture because it uses a single back sheet 30 that can be easily deformed into a three-dimensional shape that imitates the opposite surface 21 of the front protection member 20 by having the cutout 31. In addition, since the solar cell module 1 includes the patch 50 having the cover portion 51 that covers the cutout 31 of the back sheet 30, it is possible to prevent the sealing material 40 from overflowing to the back side even if the solar cell module 1 is assembled by conventional hot pressing. Therefore, the solar cell module 1 has a three-dimensional shape and can be easily manufactured.

[0040] Next, a solar cell module 1A according to a second embodiment of the present invention will be described. Figure 5 It is a rear view of the solar cell module 1A according to the second embodiment of the present invention. Figure 6 It is a cross-sectional view of the solar cell module 1A. In the following embodiments, the same components as those in the previously described embodiments are denoted by the same reference numerals and the duplicated description may be omitted.

[0041] The solar cell module 1A comprises: a plurality of solar cell units 10; a single front protection member 20, which covers the light-receiving side of the plurality of solar cell units 10; a single back plate 30A, which covers the back side of the plurality of solar cell units 10; a sealing material 40, which is filled between the front protection member 20 and the back plate 30A; and a single patch 50A, which is stacked on the back side of the back plate 30A.

[0042] The back sheet 30A protects the solar cell 10 by covering the plurality of solar cell 10 via the sealing material 40. The back sheet 30A has a plurality of cutouts 31A. Figure 5 The materials of the back sheet 30A of the solar cell module 1A are Figure 2 The back sheet 30 of the solar cell module 1 is similar.

[0043] like Figure 7 As shown, the cutout 31A has: a separation portion 33, which is a slit-shaped portion extending from the outer edge of the back sheet 30A (it may be a single cut line without removing material, or a slit-shaped portion with a small width of material removed) when the back sheet 30A is unfolded into a plane; and an opening portion 34, which is continuous with the top end of the separation portion 33 (the end on the side opposite to the outer edge of the back sheet 30A). In the solar cell module 1A, the back sheet 30A is formed into a three-dimensional shape that imitates the opposite surface 21 of the front protection member 20 by overlapping the two side portions of the separation portion 33. The opening portion 34 is provided to facilitate deformation of the back sheet 30A when the thickness of the back sheet 30A is large or the elastic modulus of the back sheet 30A is large.

[0044] The patch 50A includes a plurality of cover portions 51 that cover the respective incisions 31A and a connection portion 52A that connects the plurality of cover portions 51 . Figure 5 The material of the patch 50A of the solar cell module 1A is Figure 2 The same is true for the patch 50 of the solar cell module 1. When the curvature of the opposite surface 21 of the front protection member 20 at the portion where the connecting portion 52A is arranged is small, it can also have a relatively large area as in the present embodiment. In addition, the connecting portion 52A can also be reduced in width so that it is easy to be partially bent according to the shape of the opposite surface 21.

[0045] The patch 50A of the present embodiment is formed of a sheet-shaped material having a base layer 53 and an adhesive layer 54 . The base layer 53 is formed of the same material as the back plate 30A, and the adhesive layer 54 is laminated on the surface facing the back plate 30A.

[0046] The adhesive layer 54 may be formed of, for example, ethylene / vinyl acetate copolymer (EVA), ethylene / α-olefin copolymer, ethylene / vinyl acetate / triallyl isocyanurate (EVAT), polyvinyl butyral (PVB), acrylic resin, urethane resin, silicone resin, or the like.

[0047] In this way, by covering the cutout 31A with the patch 50A having the adhesive layer 54 , it is possible to prevent the sealing material 40 from leaking out from the opening 34 to the back side, and to prevent the overlapping portion of the back sheet 30A from curling up to the back side.

[0048] The above describes the various embodiments of the present invention, but the present invention is not limited to the above embodiments, and various changes and deformations can be made. As an example, in the solar cell module of the present invention, according to the configuration of the cutout of the back plate, a part or all of the cover parts in the patch can also be directly connected to each other, and the connecting part is not necessary. In addition, in the solar cell module of the present invention, the patch can also be divided into multiple parts. Moreover, in the solar cell module of the present invention, an adhesive layer can also be provided on the surface of the patch arranged on the light-receiving side of the back plate that is opposite to the back plate.

[0049] In the solar cell module of the present invention, the back plate may also be Figure 8 As shown, the cutouts may be arranged on the diagonal line. Fig. 9 As shown, only parallel cuts are provided, but also Fig.10 As shown in the figure, it has a plurality of cutouts arranged asymmetrically with respect to the center line, such as in a windmill shape. In addition, the solar cell module of the utility model may have only a single cutout and be formed, for example, in an umbrella shape. In addition, for example, an opening may be formed at the top of a cutout formed by cutting a large notch in a triangular shape in the back sheet.

[0050] The solar cell module of the present invention may also include further components such as a member that provides a fixing structure to a frame, etc. In addition, in the solar cell module of the present invention, in order to provide a fixing structure to a frame, etc., the front protection member may also be formed larger than other components in a plan view.

[0051] Description of Reference Numerals

[0052] 1. 1A solar cell module

[0053] 10 Solar Cells

[0054] 11 skewers

[0055] 20 Front protection member

[0056] 21 Opposite side

[0057] 30, 30A backplane

[0058] 31, 31A incision

[0059] 32 Cut Line

[0060] 33 Separation

[0061] 34 Opening

[0062] 40 Sealing material

[0063] 50, 50A patch

[0064] 51 Hood

[0065] 52 Connection

[0066] 53 substrate layer

[0067] 54 Adhesive layer.

Claims

1. A solar cell module, characterized in that: have: a plurality of solar cell units; a single front protection member, which covers the light-receiving side of the plurality of solar cell units, and whose opposite surface facing the plurality of solar cell units is a three-dimensional curved surface; a single back sheet covering the back side of the plurality of solar cell units and formed with one or more cutouts extending from an outer edge, the back sheet being shaped to follow the shape of the opposing faces; A sealing material filled between the front protection member and the back plate; as well as One or more patches covering the light-receiving side or the back side of the incision.

2. The solar cell module according to claim 1, wherein: The back plate has a plurality of cutouts. A single patch covers all of the incisions.

3. The solar cell module according to claim 2, wherein: The patch has a plurality of cover portions covering the respective incisions.

4. The solar cell module according to any one of claims 1 to 3, wherein: The incision has an opening at the top end.

5. The solar cell module according to any one of claims 1 to 3, wherein: The patch has an adhesive layer on a surface opposite to the back plate.

6. The solar cell module according to claim 4, wherein: The patch has an adhesive layer on a surface opposite to the back plate.

7. The solar cell module according to any one of claims 1 to 3 and 6, wherein: A portion of the cutout is arranged to overlap with the solar cell unit.

8. The solar cell module according to claim 4, wherein: A portion of the cutout is arranged to overlap with the solar cell unit.

9. The solar cell module according to claim 5, wherein: A portion of the cutout is arranged to overlap with the solar cell.

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