Flexible solar cell sheet and method for manufacturing same

Abstract

To provide a flexible solar cell sheet which can be stably and surely bonded to an installation surface of a structure.SOLUTION: A flexible solar cell sheet 1 includes a flexible solar cell module 2 provided with a bonding thermoplastic resin layer 221 composed of a part of a sealing material 22 for sealing a solar cell 21 and the like, and a laminated material 3 in which a first fabric layer 32 and a second fabric layer 33 are respectively laminated and fixed to both surfaces of an edge cutting film 31, wherein at least a part of the bonding thermoplastic resin layer 221 enters gaps between fibers of the first fabric layer 32 to bond the flexible solar cell module 2 and the laminated material 3.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a flexible solar cell sheet that can be adhered to conform to the shapes of various structures, and a method for manufacturing the same. [Background technology]

[0002] Conventionally, flexible solar cell sheets that can be adhered to conform to the shapes of various structures are disclosed in Patent Documents 1 and 2. In the flexible solar cell sheets of Patent Documents 1 and 2, a fabric layer is adhered to one side of a flexible solar cell module with an adhesive, and the fabric layer on the flexible solar cell module side is hardened with the adhesive that has soaked into it, while the fabric layer on the side opposite the flexible solar cell module is left in a state where the adhesive does not reach it, so that when the sheet is adhered to the installation surface of the structure with the adhesive, the adhesive soaks into the fabric layer on the opposite side, enabling a strong bond. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-67622 [Patent Document 2] Japanese Patent Application Laid-Open No. 2011-124320 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the flexible solar cell sheets of Patent Documents 1 and 2, the adhesive penetrates into the interior of the fabric layer on the flexible solar cell module side, but does not reach the interior on the opposite side, so during production, it is necessary to apply the adhesive while accurately and uniformly controlling the amount of adhesive applied to bond the fabric layers. Such application of adhesive while accurately and uniformly controlling the amount applied is usually performed using a roll coater.

[0005] However, because the objects onto which adhesive can be applied using a roll coater are limited to flat, wide and long objects, e.g., lengths of 20 meters or more, it is difficult to apply adhesive to sheet-form flexible solar cell modules using a roll coater. Furthermore, when the adhesive used to bond the fabric layers is applied using a bar coater, it can sometimes reach the inside of the fabric layer on the opposite side of the flexible solar cell module, making it impossible for the adhesive to penetrate into the fabric layer on the opposite side when bonding the flexible solar cell sheet to the installation surface of a structure. Therefore, there is a demand for a flexible solar cell sheet that can be stably and reliably attached to the installation surface of a structure.

[0006] The present invention has been proposed in view of the above problems, and has an object to provide a flexible solar cell sheet that can be stably and reliably adhered to the installation surface of a structure, and a method for manufacturing the same. [Means for solving the problem]

[0007] The flexible solar cell sheet of the present invention comprises a flexible solar cell module provided with an adhesive thermoplastic resin layer, and a laminate material in which a first fabric layer and a second fabric layer are respectively laminated and fixed to both sides of an edge-cutting film, and is characterized in that at least a portion of the adhesive thermoplastic resin layer penetrates into the gaps between the fibers of the first fabric layer to adhere the flexible solar cell module and the laminate material. According to this, by allowing the adhesive thermoplastic resin to penetrate the gaps between the fibers of the first fabric layer to bond the flexible solar cell module and the laminate material, a flexible solar cell sheet can be obtained in which the flexible solar cell module and the laminate material are firmly bonded together. Furthermore, the second fabric layer used for bonding to the installation surface of the structure has an edge-cutting film, which prevents the adhesive thermoplastic resin from seeping out during manufacturing. Therefore, when bonding the flexible solar cell sheet to the installation surface of the structure, the second fabric layer can be impregnated with the installation adhesive, allowing the flexible solar cell sheet to be firmly and reliably bonded to the installation surface of the structure.

[0008] The flexible solar cell sheet of the present invention is characterized in that the edge-cutting film is a film formed from a material having a melting point higher than that of the adhesive thermoplastic resin layer. This ensures that the edge-cutting film is prevented from melting and being damaged when the adhesive thermoplastic resin is melted and allowed to penetrate into the gaps between the fibers of the first fabric layer to bond the flexible solar cell module and the laminate, thereby increasing the yield of flexible solar cell sheets during the manufacturing process.

[0009] The flexible solar cell sheet of the present invention is characterized in that the adhesive thermoplastic resin layer is formed as part of a sealing material that seals the solar cells of the flexible solar cell module. According to this, by using part of the sealing material that seals the solar cells of the flexible solar cell module as an adhesive thermoplastic resin layer, there is no need to form a separate adhesive thermoplastic resin layer on the flexible solar cell module, which makes it possible to make the manufacturing process of the flexible solar cell sheet more efficient and reduce manufacturing costs.

[0010] The manufacturing method of the flexible solar cell sheet of the present invention is characterized by using a flexible solar cell module provided with an adhesive thermoplastic resin layer and a laminate material in which a first fabric layer and a second fabric layer are respectively laminated and fixed to both sides of an edge-cutting film, and including an integration process in which the flexible solar cell module and the laminate material are bonded together by melting at least a portion of the adhesive thermoplastic resin layer, allowing it to penetrate into the gaps between the fibers of the first fabric layer, and hardening it. According to this, by allowing the adhesive thermoplastic resin to penetrate the gaps between the fibers of the first fabric layer to bond the flexible solar cell module and the laminate material, a flexible solar cell sheet can be obtained in which the flexible solar cell module and the laminate material are firmly bonded together. Furthermore, the second fabric layer used for bonding to the installation surface of the structure has an edge-cutting film, which prevents the adhesive thermoplastic resin from seeping out during manufacturing. Therefore, when bonding the flexible solar cell sheet to the installation surface of the structure, the second fabric layer can be impregnated with the installation adhesive, allowing the flexible solar cell sheet to be firmly and reliably bonded to the installation surface of the structure.

[0011] The manufacturing method of the flexible solar cell sheet of the present invention is characterized in that, before the integration process, a process of forming the laminated material is carried out by applying adhesive to one side and the other side of the edge-cutting film using a roll coater, adhering the first fabric layer to the one side, and adhering the second fabric layer to the other side. This allows the adhesive to be applied to one side and the other side of the edge-cutting film using a roll coater, ensuring a uniform amount of adhesive without variation. This makes it possible to form the first and second fabric layers that can reliably absorb and bond the thermoplastic resin layer for adhesive of the flexible solar cell module and the installation adhesive applied to the installation surface of the structure, ensuring stable product quality of the flexible solar cell sheet.

[0012] The method for laying a flexible solar cell sheet of the present invention comprises a flexible solar cell module provided with an adhesive thermoplastic resin layer, and a laminate material in which a first fabric layer and a second fabric layer are laminated and fixed to both sides of an edge-cutting film, with at least a portion of the adhesive thermoplastic resin layer penetrating into the gaps between the fibers of the first fabric layer to bond the flexible solar cell module to the laminate material, and is characterized by comprising the steps of applying an installation adhesive to the installation surface of a structure, pressing the second fabric layer of the flexible solar cell sheet against the installation adhesive to allow the installation adhesive to penetrate into the second fabric layer, and hardening the installation adhesive that has penetrated into the second fabric layer to adhere the flexible solar cell sheet to the installation surface of the structure. This allows the adhesive thermoplastic resin to penetrate into the gaps between the fibers of the first fabric layer, bonding the flexible solar cell module and the laminate, and the flexible solar cell sheet, in which the flexible solar cell module and the laminate are firmly fixed and integrated, can be installed on the installation surface of a structure. Furthermore, the second fabric layer used for bonding to the installation surface of the structure has an edge cutting film that prevents the adhesive thermoplastic resin from seeping out during manufacturing, so the installation adhesive can be impregnated into the second fabric layer to firmly and reliably bond the flexible solar cell sheet to the installation surface of the structure. [Effects of the Invention]

[0013] According to the present invention, a flexible solar cell sheet can be stably and reliably adhered to the installation surface of a structure. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a plan view of an embodiment of a flexible solar cell sheet according to the present invention. [Figure 2] FIG. 2 is a perspective view of the flexible solar cell sheet according to the embodiment in a rolled state. [Figure 3] 1 is a schematic longitudinal cross-sectional view of a flexible solar cell sheet according to an embodiment. [Figure 4]5A and 5B are process explanatory diagrams illustrating a manufacturing process of a flexible solar cell sheet according to an embodiment. [Figure 5] 5A and 5B are process explanatory views illustrating a laying process for laying a flexible solar cell sheet according to an embodiment on an installation surface of a structure. DETAILED DESCRIPTION OF THE INVENTION

[0015] [Flexible solar cell sheet according to an embodiment] 1 to 3, a flexible solar cell sheet 1 according to an embodiment of the present invention includes a flexible, sheet-like flexible solar cell module 2, a flexible, sheet-like laminate material 3, and terminals 4 and 4 of the flexible solar cell module 2. The flexible solar cell module 2 and the laminate material 3 are stacked and fixed to each other to form an integrated structure, thereby forming a flexible flexible solar cell sheet 1 as a whole.

[0016] The flexible solar cell module 2 has solar cells 21 arranged in parallel, and a sealing material 22 that is provided so as to surround the solar cells 21 and seals the solar cells 21, the sealing material 22 being made of a thermoplastic resin. The layer of the sealing material 22 on the laminate material 3 side is an adhesive thermoplastic resin layer 221, and in this embodiment, the adhesive thermoplastic resin layer 221 is made up of a part of the sealing material 22. It is also possible to configure the module such that an adhesive thermoplastic resin layer, separate from the sealing material 22, is laminated and fixed on the outer surface of the sealing material 22 on the laminate material 3 side.

[0017] The thermoplastic resin used for the sealing material 22 or the adhesive thermoplastic resin layer may be any suitable thermoplastic resin within the spirit and scope of the present invention, such as polyethylene (PE), polyvinyl chloride (PVC), polypropylene (PP), polystyrene (PS), acrylonitrile butadiene styrene (ABS), acrylonitrile styrene (AS), acrylic (PMMA), polybutylene terephthalate (PBT), or polyethylene terephthalate (PET), or a combination of two or more of these thermoplastic resins. From the perspective of reducing manufacturing costs, it is particularly preferable to use a polyethylene-based resin such as polyethylene, a polypropylene-based resin such as polypropylene, a styrene-based resin such as polystyrene, or a general-purpose resin such as polyvinyl chloride. Furthermore, from the perspective of reducing manufacturing costs and improving processability, it is even more preferable to use a polyethylene-based resin such as polyethylene.

[0018] The laminated material 3 has an edge-cutting film 31 and a first cloth layer 32 and a second cloth layer 33 respectively laminated on both sides of the edge-cutting film 31, with the first cloth layer 32 laminated on one side of the edge-cutting film 31 and fixed to one side by an adhesive layer 321, and the second cloth layer 33 laminated on the other side of the edge-cutting film 31 and fixed to the other side by an adhesive layer 331.

[0019] The edge cutting film 31 can be made of any suitable material within the spirit and scope of the present invention, but from the standpoint of preventing damage to the edge cutting film 31 during manufacturing and improving the yield of the flexible solar cell sheet 1, it is preferable to use a film made of a material with a higher melting point than adhesive thermoplastic resin layers such as the adhesive thermoplastic resin layer 221, and it is preferable to use a resin film such as a polyester film. It is also preferable to use a laminated film in which an anti-rust metal foil such as stainless steel is bonded to a resin film for the edge cutting film 31, as this makes it possible to easily adjust the shape retention of the flexible solar cell sheet 1.

[0020] The first fabric layer 32 and the second fabric layer 33 can each be formed from an appropriate fiber material within the scope of the present invention, and can be formed from, for example, woven fabric, knitted fabric, nonwoven fabric, etc. Furthermore, the first fabric layer 32 and the second fabric layer 33 may both be formed from the same type of fiber material, such as from woven fabric, or the first fabric layer 32 and the second fabric layer 33 may be formed from different types of fiber materials.

[0021] The flexible solar cell module 2 and the laminated material 3 are bonded together so that at least a portion of the adhesive thermoplastic resin layer 221 of the flexible solar cell module 2 penetrates into the gaps between the fibers of the first fabric layer 32 of the laminated material 3, and are integrated as a flexible solar cell sheet 1.

[0022] When manufacturing the flexible solar cell sheet 1 of this embodiment, as shown in Figure 4, a flexible solar cell module 2 provided with an adhesive thermoplastic resin layer 221 and a laminated material 3 in which a first fabric layer 32 and a second fabric layer 33 are laminated and fixed to both sides of an edge-cutting film 31 are used, and at least a portion of the adhesive thermoplastic resin layer 221 is melted and allowed to penetrate into the gaps between the fibers of the first fabric layer 32 and hardened, thereby bonding and integrating the flexible solar cell module 2 and the laminated material 3 to obtain the flexible solar cell sheet 1.

[0023] The bonding or welding of the adhesive thermoplastic resin layer 221 to the first fabric layer 32 by melting it can be performed using various welding equipment within an applicable range. For example, the bonding or welding of the adhesive thermoplastic resin layer 221 to the first fabric layer 32 can be performed by using a vacuum laminator, which is part of the manufacturing equipment for the flexible solar cell module 2, and operating the vacuum laminator while maintaining a predetermined temperature suitable for melting the adhesive thermoplastic resin layer 221. This is advantageous because it makes effective use of the manufacturing equipment for the flexible solar cell module 2 and allows the bonding or welding of the adhesive thermoplastic resin layer 221 to the first fabric layer 32 without the need for new manufacturing equipment.

[0024] Furthermore, when performing the process of forming the laminated material 3 before the process of integrating the flexible solar cell module 2 and the laminated material 3, it is preferable to form the laminated material 3 by applying adhesive to one side and the other side of the edge-cutting film 31 using a roll coater, adhering the first fabric layer 32 to one side with an adhesive layer 321, and adhering the second fabric layer 33 to the other side with an adhesive layer 331.

[0025] In this case, it is possible to use a roll coater to apply adhesive to one side of the edge-cutting film 31, adhere the first fabric layer 32 to one side, and then use a roll coater to apply adhesive to the other side of the edge-cutting film 31 and adhere the second fabric layer 33 to the other side, or conversely, adhere the second fabric layer 33 first and then adhere the first fabric layer 32, or use a double roll coater to apply adhesive to both one and the other sides of the edge-cutting film 31 and adhere the first fabric layer 32 and the second fabric layer 33. In other words, the laminate 3 can be formed into a long roll in advance and then cut to fit the size of the solar cell module 2 or the installation surface, allowing for efficient and high-quality production.

[0026] 5 , when the flexible solar cell sheet 1 of this embodiment is fixed to an installation surface 101 such as a wall of a structure 100, for example, a primer 102 is applied to the installation surface 101, and then an installation adhesive 103 is applied as a top coat on the primer 102. The second fabric layer 33 of the flexible solar cell sheet 1 is pressed against the installation adhesive 103 to allow the installation adhesive 103 to penetrate into the second fabric layer 33. The installation adhesive 103 that has penetrated into the second fabric layer 33 then hardens, thereby fixing or adhering the flexible solar cell sheet 1 to the installation surface 101 of the structure 100.

[0027] According to this embodiment, by allowing the adhesive thermoplastic resin 221 to penetrate into gaps between the fibers of the first fabric layer 32 to bond the flexible solar cell module 2 and the laminate material 3, it is possible to obtain a flexible solar cell sheet 1 in which the flexible solar cell module 2 and the laminate material 3 are firmly bonded and integrated. Furthermore, the second fabric layer 33 used for bonding to the installation surface 101 of the structure 100 has an edge cutting film 31, which prevents the adhesive thermoplastic resin 221 from seeping out during manufacturing. Therefore, when bonding the flexible solar cell sheet 1 to the installation surface 101 of the structure 100, the installation adhesive 103 is impregnated into the second fabric layer 33, allowing the flexible solar cell sheet 1 to be firmly and reliably bonded to the installation surface 101 of the structure 100.

[0028] Furthermore, if the edge-cutting film 31 is made of a material having a higher melting point than the adhesive thermoplastic resin layer 221, when the adhesive thermoplastic resin is melted and allowed to penetrate into the gaps between the fibers of the first fabric layer 32 to bond the flexible solar cell module 2 and the laminated material 3, it is possible to reliably prevent the edge-cutting film 31 from melting and being damaged, thereby increasing the yield of the flexible solar cell sheet 1 in the manufacturing process.

[0029] Furthermore, by forming the adhesive thermoplastic resin layer 221 from part of the sealing material 22 that seals the solar cells 21 of the flexible solar cell module 2, there is no need to form a separate adhesive thermoplastic resin layer on the flexible solar cell module 2, which makes it possible to make the manufacturing process of the flexible solar cell sheet 1 more efficient and reduce manufacturing costs.

[0030] Furthermore, when adhesive is applied to one side and the other side of edge-cutting film 31 using a roll coater to bond first fabric layer 32 and second fabric layer 33, the adhesive can be applied in a uniform amount without any variation. Therefore, it is possible to form first fabric layer 32 and second fabric layer 33 that can be reliably permeated with mounting adhesive 103 applied to adhesive thermoplastic resin layer 221 of flexible solar cell module 2 and mounting surface 101 of structure 100, thereby ensuring stable product quality of flexible solar cell sheet 1.

[0031] [Scope of the invention disclosed herein] The inventions disclosed in this specification include, in addition to the individual inventions and embodiments listed as inventions, those specified by changing partial contents of these to other contents disclosed in this specification, those specified by adding other contents disclosed in this specification to these contents, or those specified by deleting partial contents of these to the extent that partial effects are obtained and creating a generic concept.The inventions disclosed in this specification also include the following contents and modifications.

[0032] For example, the flexible solar cell module in the flexible solar cell sheet of the present invention can be any suitable flexible solar cell module within the applicable range, and for example, an amorphous silicon solar cell module, a multi-junction solar cell module, or a perovskite solar cell module can be used.

[0033] Furthermore, the manufacturing method or laying method of the flexible solar cell sheet of the present invention is not limited to the examples given in the above embodiments and may be any appropriate method. For example, it is possible to use a configuration in which the flexible solar cell module and the laminated material are bonded together using manufacturing equipment other than the manufacturing equipment for the flexible solar cell module, or a configuration in which the flexible solar cell sheet is bonded to the installation surface of the structure and laid down without applying a primer. [Industrial Applicability]

[0034] The present invention can be used for a flexible solar cell sheet that can be adhered to conform to the shapes of various structures. [Explanation of symbols]

[0035] REFERENCE SIGNS LIST 1...flexible solar cell sheet 2...flexible solar cell module 21...solar cell 22...encapsulant 221...adhesive thermoplastic resin layer 3...laminate material 31...edge cutting film 32...first fabric layer 321...adhesive layer 33...second fabric layer 331...adhesive layer 4...terminal 100...structure 101...installation surface 102...primer 103...installation adhesive

Claims

1. a flexible solar cell module provided with an adhesive thermoplastic resin layer; a laminated material in which a first fabric layer and a second fabric layer are laminated and fixed to both sides of an edge-cutting film, A flexible solar cell sheet characterized in that at least a portion of the adhesive thermoplastic resin layer penetrates into the gaps between the fibers of the first fabric layer, thereby adhering the flexible solar cell module and the laminate material.

2. 2. The flexible solar cell sheet according to claim 1, wherein the edge separation film is a film formed of a material having a melting point higher than that of the adhesive thermoplastic resin layer.

3. 3. The flexible solar cell sheet according to claim 1, wherein the adhesive thermoplastic resin layer is formed as a part of a sealing material that seals the solar cells of the flexible solar cell module.

4. A flexible solar cell module provided with an adhesive thermoplastic resin layer and a laminated material in which a first fabric layer and a second fabric layer are laminated and fixed to both sides of an edge-cutting film are used, a step of melting at least a portion of the adhesive thermoplastic resin layer, allowing it to penetrate into gaps between the fibers of the first fabric layer, and hardening the melted thermoplastic resin layer to bond the flexible solar cell module and the laminated material together;

5. 5. The method for manufacturing a flexible solar cell sheet according to claim 4, wherein, before the integration step, a step of forming the laminated material is carried out by using a roll coater to apply adhesive to one side and the other side of the edge-cutting film, adhering the first fabric layer to the one side, and adhering the second fabric layer to the other side.

6. A method for laying a flexible solar cell sheet, comprising: a flexible solar cell module provided with an adhesive thermoplastic resin layer; and a laminate material in which a first fabric layer and a second fabric layer are laminated and fixed to both sides of an edge-cutting film, wherein at least a portion of the adhesive thermoplastic resin layer penetrates into gaps between fibers of the first fabric layer to bond the flexible solar cell module and the laminate material, applying a mounting adhesive to a mounting surface of a structure and pressing the second fabric layer of the flexible solar cell sheet against the mounting adhesive to allow the mounting adhesive to penetrate the second fabric layer; A method for installing a flexible solar cell sheet, comprising the step of curing the installation adhesive impregnated into the second fabric layer to secure the flexible solar cell sheet to the installation surface of the structure.

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