Solar cell modules
The solar cell module with deformable gas chambers and communication passages addresses the challenge of insufficient heat insulation in conventional designs, achieving enhanced thermal performance and reduced thickness for flexible applications.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-02-23
- Publication Date
- 2026-03-31
AI Technical Summary
Conventional solar cell modules combining solar cells and heat insulation means face the challenge of insufficient heat insulation effect while maintaining a small thickness.
A solar cell module design featuring deformable gas chambers and communication passages in cover materials that protrude in opposite directions to the solar cell, enhancing thermal insulation during use and allowing for reduced thickness during storage.
The design increases thermal insulation effect during use and reduces module thickness, enabling flexible application in various structures and materials.
Smart Images
Figure 2026055761000001_ABST
Abstract
Description
Technical Field
[0005] , , , ,
[0001] The present invention relates to a solar cell module.
Background Art
[0002] Conventionally, a solar cell module combining a solar cell and heat insulation means is known. For example, Patent Document 1 discloses a structure in which heat insulation means (heat shielding member) is arranged at a position adjacent to the solar cell.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, in the above structure, in a solar cell module combining a solar cell and heat insulation means, although it is possible to reduce the thickness of the solar cell module, there is a risk that the heat insulation effect is insufficient in order to make the solar cell module function as a heat insulation member. An object of the present invention is to provide a solar cell module that has a small thickness during storage and a large heat insulation effect during use in a solar cell module combining a solar cell and heat insulation means.
Means for Solving the Problems
[0005] The present invention relates to a solar cell module comprising: a sheet-like substrate; a solar cell provided on one side of the substrate; a first cover material bonded in a pattern to the side of the substrate opposite to the side on which the solar cell is provided; a region of the first cover material not bonded to the substrate and a plurality of first gas chambers in contact with the substrate; a first gas communication passage connecting the first gas chambers; and a gas inlet communicating with the first gas chambers, wherein the region of the first cover material in contact with the first gas chambers is deformable into a first curved shape that protrudes in the direction opposite to the direction in which the solar cell is located and a second curved shape different from the first curved shape, and the amount of protrusion of the second curved shape in the direction opposite to the direction in which the solar cell is located is smaller than the amount of protrusion of the first curved shape in the direction opposite to the direction in which the solar cell is located. [Effects of the Invention]
[0006] According to an aspect of the present invention, in a solar cell module combining a solar cell and a heat insulating means, the thickness during storage can be reduced and the heat insulating effect during use can be increased. [Brief explanation of the drawing]
[0007] [Figure 1] This is a perspective view showing the overall structure of the solar cell module according to the first embodiment. [Figure 2] This is a plan view showing the overall structure of the solar cell module according to the first embodiment. [Figure 3] This is a plan view showing the overall structure of the thermal insulation means of the solar cell module according to the first embodiment. [Figure 4] This is a plan view showing the overall structure of the thermal insulation means of the solar cell module according to the first embodiment. [Figure 5] This is a plan view showing the internal structure of the thermal insulation means of the solar cell module according to the first embodiment. [Figure 6] This is a cross-sectional view showing the internal structure of the thermal insulation means of the solar cell module of the first embodiment during use and storage. [Figure 7] This is a perspective view showing the overall structure of the solar cell module according to the second embodiment. [Figure 8] This is a plan view showing the overall structure of the thermal insulation means for the solar cell module of the second embodiment. [Figure 9] This is a plan view showing the overall structure of the thermal insulation means for the solar cell module of the second embodiment. [Figure 10] This is a plan view showing the internal structure of the thermal insulation means of the solar cell module according to the second embodiment. [Figure 11] This is a cross-sectional view showing the internal structure of the heat insulating means of the solar cell module of the second embodiment during use and storage. [Figure 12] This is a perspective view showing the overall structure of the solar cell module according to the third embodiment. [Modes for carrying out the invention]
[0008] [First Embodiment] The solar cell module of the first embodiment of the present invention will be described below with reference to Figures 1 to 6.
[0009] Figure 1 is a perspective view showing the overall structure of the solar cell module 10. As shown in Figure 1, the solar cell module 10 comprises a substrate 11, a solar cell 12, a first cover material 13, an adhesive layer 14, a second cover material 17, and an adhesive layer 18. In Figure 1, the substrate 11 and the adhesive layer 14 are shown separated for clarity, but in reality, the substrate 11 and the adhesive layer 14 are in close contact. Similarly, the first cover material 13 and the adhesive layer 18 are shown separated, but in reality, the first cover material 13 and the adhesive layer 18 are in close contact.
[0010] Figure 2 is a plan view showing the overall structure of the solar cell module 10. As shown in Figures 1 and 2, the base material 11 is a sheet-like component made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, and polycarbonate, metal materials such as stainless steel and titanium, and glass materials. On one surface of the base material 11, a solar cell 12 such as a perovskite solar cell, a dye-sensitized solar cell, or an organic thin-film solar cell is formed. The solar cell 12 is connected to a terminal 121. When sunlight irradiates the surface of the solar cell 12, a potential difference is generated between the terminals 121, and power can be supplied from the terminals 121 to the outside.
[0011] FIG. 3 is a plan view when looking at the side of the adhesive layer 14 from the interface between the base material 11 and the adhesive layer 14, showing the overall structure of the heat insulation means of the solar cell module 10. As shown in FIGS. 1 and 3, the first cover material 13 is a sheet-like member made of a resin material such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, fluororesin, etc.
[0012] The adhesive layer 14 is a sheet-like adhesive made of a polyamide-based adhesive, a polyester-based adhesive, a polyolefin-based adhesive, an epoxy-based adhesive, a polyimide-based adhesive, etc., or a cured liquid adhesive such as an epoxy-based adhesive or an acrylic-based adhesive. The adhesive layer 14 is formed in a pattern on the outer peripheral portion and inside of the base material 11 and the first cover material 13. By joining the base material 11 and the first cover material 13 with the adhesive layer 14, a region where the base material 11 and the first cover material 13 are joined and a region where the base material 11 and the first cover material 13 are not joined are formed in a pattern.
[0013] In a region where the base material 11 and the first cover material 13 are not joined by the adhesive layer 14, a first gas chamber 151, a first gas communication path 152, and a first gas introduction path 153 are formed. Further, in the first cover material 13, a third gas communication path 154 that penetrates the first cover material 13 and communicates with the first gas introduction path 153 is provided.
[0014] The first gas chamber 151 is a space sandwiched between the base material 11 and the first cover material 13 and partitioned by the adhesive layer 14. A plurality of first gas chambers 151 are provided, and the plurality of first gas chambers 151 are arranged in the X direction, which is a first direction parallel to the in-plane direction of the base material 11, and the Y direction, which is a second direction parallel to the in-plane direction of the base material 11 and intersects the X direction. At least a part of the first gas chamber 151 is located at a position facing the solar cell 12 with the base material 11 interposed therebetween.
[0015] A first gas communication path 152 is provided between adjacent first gas chambers 151. The first gas communication path 152 may communicate the first gas chambers 151 arranged in the X direction with each other, or may communicate the first gas chambers 151 arranged in the Y direction with each other. The first gas chamber 151 communicates with the third gas communication path 154 via the first gas communication path 152 and the first gas introduction path 153.
[0016] FIG. 4 is a plan view when viewed from the side of the adhesive layer 18 from the interface between the first cover material 13 and the adhesive layer 18, showing the overall structure of the heat insulation means of the solar cell module 10. As shown in FIGS. 1 and 4, the second cover material 17 is a sheet-like member made of a resin material such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, fluororesin, etc.
[0017] The adhesive layer 18 is a sheet-like adhesive made of a polyamide-based adhesive, a polyester-based adhesive, a polyolefin-based adhesive, an epoxy-based adhesive, a polyimide-based adhesive, etc., or a cured product of a liquid adhesive such as an epoxy-based adhesive or an acrylic-based adhesive. The adhesive layer 18 is formed in a pattern on the outer peripheral portion and the inside of the first cover material 13 and the second cover material 17. By joining the first cover material 13 and the second cover material 17 with the adhesive layer 18, a region where the first cover material 13 and the second cover material 17 are joined and a region where the first cover material 13 and the second cover material 17 are not joined are formed in a pattern.
[0018] In the region where the first cover material 13 and the second cover material 17 are not joined by the adhesive layer 18, a second gas chamber 191, a second gas communication passage 192, and a second gas introduction passage 193 are formed. In addition, the second cover material 17 is provided with a gas inlet 194 that penetrates the second cover material 17 and communicates with the second gas introduction passage 193 and the third gas communication passage 154 (Figure 3).
[0019] The second gas chamber 191 is a space sandwiched between the first cover material 13 and the second cover material 17 and partitioned by the adhesive layer 18. Multiple second gas chambers 191 are provided, and multiple second gas chambers 191 are arranged in the X and Y directions. At least a portion of the second gas chamber 191 is located opposite the solar cell 12, with the first cover material 13 and the substrate 11 in between.
[0020] A second gas connecting passage 192 is provided between adjacent second gas chambers 191. The second gas connecting passage 192 may connect second gas chambers 191 arranged in the X direction, or it may connect second gas chambers 191 arranged in the Y direction. The second gas chamber 191 communicates with the gas inlet 194 via the second gas communication passage 192 and the second gas introduction passage 193.
[0021] By introducing a gas such as air or argon through the gas inlet 194, the gas is introduced into each of the second gas chambers 191 via the second gas inlet passage 193 and the second gas connecting passage 192. In addition, the gas is introduced into each of the first gas chambers 151 via the third gas connecting passage 154, the first gas inlet passage 153, and the first gas connecting passage 152.
[0022] In the solar cell module 10, the first gas chamber 151, the first gas connection passage 152, the first gas introduction passage 153, and the third gas connection passage 154, as well as the first cover material 13 and adhesive layer 14 that constitute them, constitute the thermal insulation means. In addition, the second gas chamber 191, the second gas connection passage 192, the second gas introduction passage 193, and the gas inlet 194, as well as the second cover material 17 and adhesive layer 18 that constitute them, also constitute the thermal insulation means.
[0023] Figure 5 is a plan view of the internal structure of the heat insulating means of the solar cell module 10, looking from the interface between the substrate 11 and the adhesive layer 14 towards the adhesive layer 14, and is an enlarged view of region L in Figures 3 and 4. As shown in Figure 5, the second gas chamber 191 (hatched area) is located at a position offset in the X and Y directions relative to the first gas chamber 151 (hatched area).
[0024] Figure 6 is a cross-sectional view of the solar cell module 10 at cross-section JJ (Figure 5), showing the internal structure of the heat insulation means of the solar cell module 10. Figure 6(a) shows the state during use, and Figure 6(b) shows the state during storage.
[0025] The internal structure of the solar cell module 10 during use will be described. As shown in Figure 6(a), the first cover material 13 has a plurality of curved sections formed along the Y direction. These curved sections consist of a curved section 131 that protrudes in the direction in which the solar cell 12 is installed, and a curved section 132 that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The adhesive layer 14 is formed on the convex side of the curved portion 131, and the adhesive layer 14 joins the substrate 11 to the curved portion 131 of the first cover material 13. This forms a first gas chamber 151 between the substrate 11 and the first cover material 13. The shape of the region of the first cover material 13 that is in contact with the first gas chamber 151 is a first curved shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The amount of protrusion when the shape of the first cover material 13 is the first curved shape is h1.
[0026] The second cover material 17 has multiple curved sections formed along the Y direction. These curved sections consist of a curved section 171 that protrudes in the direction in which the solar cell 12 is installed, and a curved section 172 that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The adhesive layer 18 is formed on the convex side of the curved portion 171, and the curved portion 132 of the first cover material 13 and the curved portion 171 of the second cover material 17 are joined by the adhesive layer 18. As a result, a second gas chamber 191 is formed between the first cover material 13 and the second cover material 17. The shape of the region of the second cover material 17 that is in contact with the second gas chamber 191 is a third curved shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The amount of protrusion when the shape of the second cover material 17 is the third curved shape is h3.
[0027] The curved portions 131 and 132 may be created by embossing, laser forming, or the like on the planar first cover material 13 before joining the first cover material 13 to the base material 11 with the adhesive layer 14. Alternatively, when joining the planar first cover material 13 to the base material 11 with the adhesive layer 14, wrinkles may be created in the area of the first cover material 13 that is not joined to the base material 11, and the pressure of the gas introduced into the first gas chamber 151 may be used to curve the area of the first cover material 13 that is in contact with the first gas chamber 151 into a shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located.
[0028] The curved portions 171 and 172 may be created by embossing or laser forming the planar second cover material 17 before joining the second cover material 17 to the first cover material 13 with the adhesive layer 18. Alternatively, when joining the planar second cover material 17 to the first cover material 13 with the adhesive layer 18, wrinkles may be created in the area of the second cover material 17 that is not joined to the first cover material 13, and the pressure of the gas introduced into the second gas chamber 191 may be used to curve the area of the second cover material 17 that is in contact with the second gas chamber 191 into a shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located.
[0029] The mechanism of the thermal insulation effect when the solar cell module 10 is in use will be explained. When sunlight shines on the surface of the solar cell 12 and the solar cell 12 generates electricity, the temperature of the solar cell 12 rises due to radiant heat from the sun. This temperature rise of the solar cell 12 propagates through the inside of the solar cell module 10, warming the air in the indoor space that is in contact with the second cover material 17. At this time, the first cover material 13 and the second cover material 17 are extended in the direction opposite to the direction in which the solar cell 12 is located, and the volume of gas such as air and argon filled inside the first gas chamber 151 and the second gas chamber 191 is large. As a result, the proportion of the heat conduction path from the substrate 11, through the adhesive layer 14, the first cover material 13, and the adhesive layer 18, to the second cover material 17 is large in the heat transfer path propagating inside the solar cell module 10.
[0030] As shown in Figure 6(a), the first cover material 13 includes a region P that is joined to the base material 11 but not to the second cover material 17, and a region R that is joined to the second cover material 17 but not to the base material 11, with a region Q that is not joined to either the base material 11 or the second cover material 17. Therefore, the heat conduction path within the first cover material 13 includes an in-plane path of the sheet-like first cover material 13, as indicated by arrow 161, resulting in increased thermal resistance. This reduces heat conduction from the solar cell 12 to the air in the indoor space in contact with the second cover material 17, thereby increasing the thermal insulation effect of the solar cell module 10. As shown in Figure 5, in the first cover material 13, region P is surrounded by region Q. Also, in the first cover material 13, region R is surrounded by region Q. In each case, heat conduction from the solar cell 12 to the air in the indoor space in contact with the second cover material 17 is further reduced, and the thermal insulation effect of the solar cell module 10 is further increased.
[0031] The internal structure of the solar cell module 10 during storage will be described. The first cover material 13 is deformable into a first curved shape and a second curved shape different from the first curved shape in the region in contact with the first gas chamber 151, and the amount of overhang in the direction opposite to the direction in which the solar cell 12 is located is smaller in the second curved shape than in the first curved shape. Furthermore, the second cover material 17 can be deformed into a third curved shape and a fourth curved shape different from the third curved shape in the region in contact with the second gas chamber 191, and the amount of overhang in the direction opposite to the direction in which the solar cell 12 is located is smaller in the fourth curved shape than in the third curved shape.
[0032] As shown in Figure 6(b), the second curved shape of the first cover material 13 may be a shape in which a curved portion 134 extending in the direction opposite to the direction in which the solar cell 12 is located and a curved portion 133 extending in the direction in which the solar cell 12 is installed are continuous in the Y direction. The amount of extension h2 of the first cover material 13 in the direction opposite to the direction in which the solar cell 12 is located in the second curved shape is smaller than the amount of extension h1 of the first cover material 13 in the direction opposite to the direction in which the solar cell 12 is located in the first curved shape (Figure 6(a)). With the second curved shape, the thickness of the solar cell module 10 can be reduced compared to the first curved shape.
[0033] Furthermore, the fourth curved shape of the second cover material 17 may be a shape in which the curved portion 174 extending in the direction opposite to the direction in which the solar cell 12 is located and the curved portion 173 extending in the direction in which the solar cell 12 is installed are continuous in the Y direction. The amount of extension h4 of the second cover material 17 in the direction opposite to the direction in which the solar cell 12 is located in the fourth curved shape is smaller than the amount of extension h3 of the second cover material 17 in the direction opposite to the direction in which the solar cell 12 is located in the first curved shape (Figure 6(a)). In the fourth curved shape, the thickness of the solar cell module 10 can be reduced compared to the third curved shape.
[0034] For example, when stacking multiple solar cell modules 10 for storage after use, the second cover material 17 may be pressed from a direction opposite to the direction in which the solar cells 12 are located, and deform from a third curved shape to a fourth curved shape. Similarly, the first cover material 13 may be pressed from a direction opposite to the direction in which the solar cells 12 are located, and deform from a first curved shape to a second curved shape.
[0035] To complete storage and prepare the solar cell module 10 for use, gas may be introduced through the gas inlet 194, increasing the amount of gas inside the second gas chamber 191, thereby deforming the second cover material 17 from a fourth curved shape to a third curved shape. Alternatively, the first cover material 13 may be deformed from a second curved shape to a first curved shape by increasing the amount of gas inside the first gas chamber 151. To store the solar cell module 10 after its use is complete, the second cover material 17 may deform from a third curved shape to a fourth curved shape by discharging gas from the gas inlet 194 and reducing the amount of gas inside the second gas chamber 191. Alternatively, the first cover material 13 may deform from a first curved shape to a second curved shape by reducing the amount of gas inside the first gas chamber 151.
[0036] The above configuration makes it possible to save space when storing the solar cell module 10. Furthermore, when using flexible solar cells such as perovskite solar cells, dye-sensitized solar cells, or organic thin-film solar cells as the solar cell 12, the solar cell module 10 can be made flexible by reducing its thickness. This makes it possible to wind the solar cell module 10 into a roll shape, enabling further space savings.
[0037] The solar cell module 10 is equipped with multiple first gas chambers 151. This allows the width of the first gas chambers 151 to be kept small, stabilizing the deformation of the first cover material 13 and maintaining a small thickness for the solar cell module 10. The solar cell module 10 is also equipped with multiple second gas chambers 191. This allows the width of the second gas chambers 191 to be kept small, stabilizing the deformation of the second cover material 17 and maintaining a small thickness for the solar cell module 10.
[0038] In the solar cell module 10, the first gas communication passage 152 connects multiple first gas chambers 151. This equalizes the gas pressure inside the multiple first gas chambers 151, stabilizing the deformation of the first cover material 13 and allowing the solar cell module 10 to be kept at a small thickness. In addition, in the solar cell module 10, the second gas communication passage 192 connects multiple second gas chambers 191. This equalizes the gas pressure inside the multiple second gas chambers 191, stabilizing the deformation of the second cover material 17 and allowing the solar cell module 10 to be kept at a small thickness.
[0039] As described above, the solar cell module 10, in a solar cell module that combines solar cells and heat insulation means, can reduce the thickness of the solar cell module during storage and increase the heat insulation effect during use. As a result, the solar cell module 10 can be applied to the walls and roofs of membrane structures, the walls and roofs of houses, and other similar materials.
[0040] The solar cell module 10 may have a light-transmitting structure.
[0041] The base material 11 may be a sheet-like, light-transmitting member made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, or polycarbonate, or glass materials. The solar cell 12 may be a perovskite solar cell, a dye-sensitized solar cell, an organic thin-film solar cell, or the like, and may have a light-transmitting structure. Furthermore, the first cover material 13 and the second cover material 17 may be sheet-like, light-transmitting members made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, or fluororesin. The adhesive layers 14 and 18 may be sheet-like adhesives made from polyamide adhesives, polyester adhesives, polyolefin adhesives, epoxy adhesives, polyimide adhesives, etc., or cured liquid adhesives such as epoxy adhesives and acrylic adhesives, and may be translucent members.
[0042] As described above, the solar cell module 10, in addition to being a solar cell module that combines solar cells and heat insulation means, can also be made light-transmitting. As a result, the solar cell module 10 can be applied to the sun-diving parts of the walls and roofs of membrane structures, as well as to heat insulation materials for windows of houses and vehicles.
[0043] [Second Embodiment] Hereinafter, a solar cell module according to a second embodiment of the present invention will be described with reference to Figures 7 to 11. However, components having the same configuration as those in the first embodiment will be denoted by the same reference numerals, and their descriptions will be omitted as appropriate.
[0044] Figure 7 is a perspective view showing the overall structure of the solar cell module 20. As shown in Figure 7, the solar cell module 20 comprises a substrate 11, a solar cell 12, a first cover material 23, an adhesive 24, a second cover material 27, and an adhesive 28. In Figure 7, the substrate 11 and adhesive 24 are shown separated for clarity, but in reality, the substrate 11 and adhesive 24 are in close contact. Similarly, the first cover material 23 and adhesive 28 are shown separated, but in reality, the first cover material 23 and adhesive 28 are in close contact.
[0045] Figure 8 is a plan view showing the overall structure of the heat insulation means of the solar cell module 20, as seen from the interface between the substrate 11 and the adhesive layer 24, looking towards the adhesive layer 24. As shown in Figures 7 and 8, the first cover material 23 is a sheet-like member made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, and fluororesin.
[0046] The adhesive 24 is a sheet-like adhesive made of polyamide adhesive, polyester adhesive, polyolefin adhesive, epoxy adhesive, polyimide adhesive, etc., or a cured liquid adhesive such as epoxy adhesive or acrylic adhesive. The adhesive 24 is formed in a pattern on the outer periphery and interior of the base material 11 and the first cover material 23. When the base material 11 and the first cover material 23 are joined by the adhesive 24, areas where the base material 11 and the first cover material 23 are joined and areas where the base material 11 and the first cover material 23 are not joined are formed in a pattern.
[0047] In the region where the base material 11 and the first cover material 23 are not joined by the adhesive 24, a first gas chamber 251, a first gas communication passage 252, and a first gas introduction passage 253 are formed. In addition, the first cover material 23 is provided with a third gas communication passage 254 that penetrates the first cover material 23 and communicates with the first gas introduction passage 253.
[0048] The first gas chamber 251 is a space sandwiched between the substrate 11 and the first cover material 23 and partitioned by adhesive 24. The first gas chamber 251 has a shape that extends in the X direction, which is a third direction parallel to the in-plane direction of the substrate 11. Multiple first gas chambers 251 are provided, and the multiple first gas chambers 251 are arranged in the Y direction, which is a fourth direction parallel to the in-plane direction of the substrate 11 and intersects the X direction. At least a portion of the first gas chamber 251 is located opposite the solar cell 12 across the substrate 11.
[0049] A first gas connecting passage 252 is provided between the adjacent first gas chambers 251. The first gas chamber 251 is connected to the third gas communication passage 254 via the first gas communication passage 252 and the first gas introduction passage 253.
[0050] Figure 9 is a plan view showing the overall structure of the thermal insulation means of the solar cell module 20, as seen from the interface between the first cover material 23 and the adhesive layer 28, looking towards the adhesive layer 28. As shown in Figures 7 and 9, the second cover material 27 is a sheet-like member made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, and fluororesin.
[0051] The adhesive 28 is a sheet-like adhesive made of polyamide adhesive, polyester adhesive, polyolefin adhesive, epoxy adhesive, polyimide adhesive, etc., or a liquid adhesive such as epoxy adhesive or acrylic adhesive that has been cured. The adhesive layer 28 is formed in a pattern on the outer periphery and interior of the first cover material 23 and the second cover material 27. When the first cover material 23 and the second cover material 27 are joined by the adhesive layer 28, a pattern is formed in which the areas where the first cover material 23 and the second cover material 27 are joined and areas where the first cover material 23 and the second cover material 27 are not joined.
[0052] In the region where the first cover material 23 and the second cover material 27 are not joined by the adhesive layer 28, a second gas chamber 291, a second gas communication passage 292, and a second gas introduction passage 293 are formed. In addition, the second cover material 27 is provided with a gas inlet 294 that penetrates the second cover material 27 and communicates with the second gas introduction passage 293 and the third gas communication passage 254 (Figure 8).
[0053] The second gas chamber 291 is a space sandwiched between the first cover material 23 and the second cover material 27 and partitioned by the adhesive layer 28. The second gas chamber 291 has a shape that extends in the X direction. Multiple second gas chambers 291 are provided, and multiple second gas chambers 291 are arranged in the Y direction. At least a portion of the second gas chamber 291 is located opposite the solar cell 12, with the first cover material 23 and the substrate 11 in between.
[0054] A second gas connecting passage 292 is provided between the adjacent second gas chamber 291. The second gas chamber 291 communicates with the gas inlet 294 via the second gas communication passage 292 and the second gas introduction passage 293.
[0055] By introducing a gas such as air or argon through the gas inlet 294, the gas is introduced into each of the second gas chambers 291 via the second gas inlet passage 293 and the second gas connecting passage 292. In addition, the gas is introduced into each of the first gas chambers 251 via the third gas connecting passage 254, the first gas inlet passage 253, and the first gas connecting passage 252.
[0056] In the solar cell module 20, the first gas chamber 251, the first gas communication passage 252, the first gas introduction passage 253, and the third gas communication passage 254, as well as the first cover material 23 and adhesive layer 24 that constitute them, constitute the thermal insulation means. In addition, the second gas chamber 291, the second gas communication passage 292, the second gas introduction passage 293, and the gas inlet 294, as well as the second cover material 27 and adhesive layer 28 that constitute them, also constitute the thermal insulation means.
[0057] Figure 10 is a plan view showing the internal structure of the heat insulating means of the solar cell module 20, viewed from the interface between the substrate 11 and the adhesive layer 24, looking towards the adhesive layer 24 side. It is an enlarged view of region M in Figures 8 and 9. As shown in Figure 10, the second gas chamber 291 (hatched area) is located at a position shifted in the Y direction relative to the first gas chamber 251 (hatched area).
[0058] Figure 11 is a cross-sectional view of the solar cell module 20 at cross-section KK (Figure 10), showing the internal structure of the heat insulation means of the solar cell module 20. Figure 11(a) shows the state during use, and Figure 11(b) shows the state during storage.
[0059] The internal structure of the solar cell module 20 when in use will be described. As shown in Figure 11(a), the first cover material 23 has a plurality of curved sections formed along the Y direction. These curved sections consist of a curved section 231 that protrudes in the direction in which the solar cell 12 is installed, and a curved section 232 that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The adhesive layer 24 is formed on the convex side of the curved portion 231, and the adhesive layer 24 joins the substrate 11 to the curved portion 231 of the first cover material 23. This forms a first gas chamber 251 between the substrate 11 and the first cover material 23. The shape of the region of the first cover material 23 that is in contact with the first gas chamber 251 is a fifth curved shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The amount of protrusion when the shape of the first cover material 23 is the fifth curved shape is h5.
[0060] The second cover material 27 has multiple curved sections formed along the Y direction. These curved sections consist of a curved section 271 that protrudes in the direction in which the solar cell 12 is installed, and a curved section 272 that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The adhesive layer 28 is formed on the convex side of the curved portion 271, and the curved portion 232 of the first cover material 23 and the curved portion 271 of the second cover material 27 are joined by the adhesive layer 28. As a result, a second gas chamber 291 is formed between the first cover material 23 and the second cover material 27. The shape of the region of the second cover material 27 that is in contact with the second gas chamber 291 is a seventh curved shape that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The amount of protrusion when the shape of the second cover material 27 is the seventh curved shape is h7.
[0061] The mechanism of the thermal insulation effect when using the solar cell module 20 will be explained. When sunlight shines on the surface of the solar cell 12 and the solar cell 12 generates electricity, the temperature of the solar cell 12 rises due to radiant heat from the sun. This temperature rise in the solar cell 12 propagates through the inside of the solar cell module 20, warming the air in the indoor space that is in contact with the second cover material 27. At this time, the first cover material 23 and the second cover material 27 are extended in the direction opposite to the direction in which the solar cell 12 is located, and the volume of gas such as air and argon filled inside the first gas chamber 251 and the second gas chamber 291 is large. As a result, the proportion of the heat conduction path from the substrate 11, through the adhesive layer 24, the first cover material 23, and the adhesive layer 28, to the second cover material 27 is large in the heat transfer path propagating inside the solar cell module 20.
[0062] As shown in Figure 11(a), the first cover material 23 includes a region P that is joined to the base material 11 but not to the second cover material 27, and a region R that is joined to the second cover material 27 but not to the base material 11, with a region Q that is not joined to either the base material 11 or the second cover material 27. Therefore, the heat conduction path within the first cover material 23 includes an in-plane path of the sheet-like first cover material 23, as indicated by arrow 261, resulting in increased thermal resistance. This reduces heat conduction from the solar cell 12 to the air in the indoor space in contact with the second cover material 27, thereby increasing the thermal insulation effect of the solar cell module 20.
[0063] The internal structure of the solar cell module 20 during storage will be described. The first cover material 23 is deformable into a fifth curved shape and a sixth curved shape different from the fifth curved shape in the region in contact with the first gas chamber 251, and the sixth curved shape has a smaller overhang in the direction opposite to the direction in which the solar cell 12 is located than the fifth curved shape. Furthermore, the second cover material 27 can be deformed into a seventh curved shape and an eighth curved shape different from the seventh curved shape in the region in contact with the second gas chamber 291, and the eighth curved shape has a smaller overhang in the direction opposite to the direction in which the solar cell 12 is located than the seventh curved shape.
[0064] As shown in Figure 11(b), the sixth curved shape of the first cover material 23 may be a shape that includes a curved portion 234 that protrudes in the direction opposite to the direction in which the solar cell 12 is located. The amount of protrusion h6 of the first cover material 23 in the direction opposite to the direction in which the solar cell 12 is located in the sixth curved shape is smaller than the amount of protrusion h5 of the first cover material 23 in the direction opposite to the direction in which the solar cell 12 is located in the first curved shape (Figure 11(a)). In the sixth curved shape, the thickness of the solar cell module 20 can be reduced compared to the fifth curved shape.
[0065] Furthermore, the eighth curved shape of the second cover material 27 may also include a curved portion 274 that extends in the direction opposite to the direction in which the solar cell 12 is located. The amount of extension h8 of the second cover material 27 in the direction opposite to the direction in which the solar cell 12 is located in the eighth curved shape is smaller than the amount of extension h7 of the second cover material 27 in the direction opposite to the direction in which the solar cell 12 is located in the first curved shape (Figure 11(a)). The eighth curved shape allows for a reduction in the thickness of the solar cell module 20 compared to the seventh curved shape.
[0066] The fifth, sixth, seventh, and eighth curved shapes of the solar cell module 20 correspond to the first, second, third, and fourth curved shapes of the solar cell module 10, respectively.
[0067] The second embodiment has the same advantages as the first embodiment.
[0068] In the solar cell module 20, the first gas chamber 251 and the second gas chamber 291 are elongated in the X direction. This allows the width of the first gas chamber 251 and the second gas chamber 291 to be kept small, stabilizing the deformation of the first cover material 23 and the second cover material 27, and allowing the thickness of the solar cell module 20 to be kept small.
[0069] As described above, the solar cell module 20, in a solar cell module that combines solar cells and thermal insulation means, can reduce the thickness of the solar cell module during storage and increase its thermal insulation effect during use. As a result, the solar cell module 20 can be applied to the walls and roofs of membrane structures, the walls and roofs of houses, and other similar materials.
[0070] [Third Embodiment] Hereinafter, a solar cell module according to a third embodiment of the present invention will be described with reference to Figure 12. However, components having the same configuration as those in the first and second embodiments described above will be denoted by the same reference numerals, and their descriptions will be omitted as appropriate.
[0071] Figure 12 is a perspective view showing the overall structure of the solar cell module 30. As shown in Figure 12, the solar cell module 30 comprises a substrate 11, a solar cell 12, a first cover material 33, an adhesive layer 34, a second cover material 17, and an adhesive layer 18. In Figure 12, the substrate 11 and adhesive 34 are shown separated for clarity, but in reality, the substrate 11 and adhesive 34 are in close contact. Similarly, the first cover material 33 and adhesive 18 are shown separated, but in reality, the first cover material 33 and adhesive 18 are in close contact.
[0072] The first cover material 33 is a sheet-like component made of resin materials such as polyimide, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyethylene, polypropylene, vinyl chloride resin, and fluororesin.
[0073] The adhesive 34 is a sheet-like adhesive made of polyamide adhesive, polyester adhesive, polyolefin adhesive, epoxy adhesive, polyimide adhesive, etc., or a liquid adhesive such as epoxy adhesive or acrylic adhesive that has been cured. The adhesive 34 is formed in a pattern on the outer periphery and interior of the base material 11 and the first cover material 33. When the base material 11 and the first cover material 33 are joined by the adhesive 34, areas where the base material 11 and the first cover material 33 are joined and areas where the base material 11 and the first cover material 33 are not joined are formed in a pattern.
[0074] In the region where the base material 11 and the first cover material 33 are not joined by the adhesive layer 34, a first gas chamber 351 is formed. Furthermore, a third gas communication passage 354 is provided in the first cover material 33 inside the first gas chamber 351, penetrating the first cover material 33. Multiple third gas communication passages 354 are provided corresponding to multiple first gas chambers 351.
[0075] The first gas chamber 351 is a space sandwiched between the base material 11 and the first cover material 33, and partitioned by the adhesive layer 34. The first gas chamber 351 communicates with the third gas passage 354.
[0076] By introducing a gas such as air or argon through the gas inlet 194, the gas is introduced into each of the second gas chambers 191 via the second gas inlet passage 193 and the second gas connecting passage 192. In addition, the gas is introduced into each of the first gas chambers 351 via the third gas connecting passage 354.
[0077] The curved shape of the first cover material 33 of the solar cell module 30 during use and storage is the same as the curved shape of the first cover material 13 of the solar cell module 10 during use and storage. Furthermore, multiple first gas chambers 351 are connected to each other via a third gas connecting passage 354, a second gas chamber 191, and a second gas connecting passage 192. The third gas connecting passage 354, second gas chamber 191, and second gas connecting passage 192 of the solar cell module 30 also serve the function of the first gas connecting passage 152 of the solar cell module 10.
[0078] The third embodiment has the same advantages as the first embodiment.
[0079] As described above, the solar cell module 30, in a solar cell module that combines solar cells and heat insulation means, can reduce the thickness of the solar cell module during storage and increase the heat insulation effect during use. As a result, the solar cell module 30 can be applied to the walls and roofs of membrane structures, the walls and roofs of houses, and other similar materials.
[0080] [Variation] Next, modified examples of each of the above embodiments will be described.
[0081] The solar cell module 10 has a structure in which two layers of gas chambers, a first gas chamber 151 and a second gas chamber 191, are arranged in a direction intersecting the in-plane direction of the substrate 11. However, it may also have a structure in which only one layer of gas chamber, the first gas chamber 151, is arranged. In other words, it may also have a structure in which the second cover material 17, adhesive layer 18, second gas chamber 191, second gas communication passage 192, second gas introduction passage 193, and gas inlet 194 are absent, and the third gas communication passage 154 is used as the gas inlet. This is also true for the solar cell module 20.
[0082] The solar cell module 10 may have a structure in which three or more gas chambers are arranged. That is, one or more additional layers of gas chamber cover material and gas chambers may be provided in the direction opposite to the direction in which the solar cell 12 is located on the second cover material 17. This also applies to solar cell modules 20 and 30.
[0083] The first gas chamber 151 and the second gas chamber 191 of the solar cell module 10 may have a curved shape, a bent shape, or a circular shape, etc. This also applies to solar cell modules 20 and 30.
[0084] In the solar cell module 10, the second gas chamber 191 may be positioned at a location offset only in the X direction or only in the Y direction relative to the first gas chamber 151. Alternatively, when viewed from a direction perpendicular to the in-plane direction of the substrate 11, the positions of the first gas chamber 151 and the second gas chamber 191 may be the same. The same applies to solar cell modules 20 and 30.
[0085] The first, second, third, fourth, fifth, sixth, seventh, and eighth curved shapes can be various shapes other than those described. Any shape is acceptable as long as the overhang amount h2 is smaller than the overhang amount h1, the overhang amount h4 is smaller than the overhang amount h3, the overhang amount h6 is smaller than the overhang amount h5, and the overhang amount h8 is smaller than the overhang amount h7. In addition, the second, fourth, sixth, and eighth curved shapes may be planar shapes or shapes that are close to planar shapes.
[0086] In the solar cell module 10, the gas inlet 194 may be provided penetrating the substrate 11. This also applies to solar cell modules 20 and 30.
[0087] In the solar cell module 10, the adhesive layer 14 is optional, and the substrate 11 and the first cover material 13 may be directly welded or otherwise bonded together. Also, the adhesive 48 is optional, and the first cover material 13 and the second cover material 17 may be directly welded or otherwise bonded together. This also applies to solar cell modules 20 and 30.
[0088] In the solar cell module 10, the first cover material 13 and the second cover material 17 do not have to be made of a single material, but may be a laminate of multiple materials with different gas permeability and elastic modulus. For example, they may be members in which a thin film of a metal material, ceramic material, etc., is formed on the surface of a sheet-like member such as a resin material by vapor deposition or the like. This makes it possible to prevent the diffusion of the gas with a layer of material with low gas permeability such as a metal material or ceramic material, while making it possible to easily deform between the first curved shape and the second curved shape, and between the third curved shape and the fourth curved shape, with a layer of material with a low elastic modulus such as a resin material. This also applies to solar cell modules 20 and 30.
[0089] The base material 11 does not have to be a component made of a single material, but may be a laminate of components made of multiple materials.
[0090] The present invention is not limited to the embodiments and modifications described above, and various modifications are possible. [Explanation of Symbols]
[0091] 10 solar modules 11 Base material 12 Solar Cells 13. First cover material 14 Adhesive layer 151 First Gas Chamber 152 First Gas Connection Passage 153 First gas introduction channel 154 Third Gas Linkage 17. Second cover material 18 Adhesive layer 191 Second Gas Chamber 192 Second Gas Connection Passage 193 Second gas introduction channel 194 Gas Inlet h1 Amount of protrusion of the first cover material (when in use) h2 Amount of protrusion of the first cover material (during storage) h3 Amount of protrusion of the second cover material (when in use) h4 Amount of protrusion of the second cover material (during storage)
Claims
1. A sheet-like base material, A solar cell provided on one side of the substrate, A first cover material is bonded in a pattern to the surface of the substrate opposite to the surface on which the solar cell is provided, The first cover material comprises a region not joined to the substrate and a plurality of first gas chambers in contact with the substrate, A first gas communication passage connecting the first gas chambers, The preceding gas chamber is equipped with a gas inlet that communicates with the first gas chamber, The region of the first cover material in contact with the first gas chamber is deformable into a first curved shape that protrudes in the direction opposite to the direction in which the solar cell is located, and a second curved shape different from the first curved shape. A solar cell module in which the amount of overhang in the direction opposite to the direction in which the second curved solar cell is located is smaller than the amount of overhang in the direction opposite to the direction in which the first curved solar cell is located.
2. Furthermore, a second cover material is bonded in a pattern to the surface of the first cover material opposite to the surface on which the base material is located, The region of the second cover material that is not joined to the first cover material and a plurality of second gas chambers that are in contact with the first cover material, A second gas communication passage connecting the two gas chambers, It comprises a third gas communication passage connecting the first gas chamber and the second gas chamber, The region of the second cover material in contact with the second gas chamber is deformable into a third curved shape that protrudes in the direction opposite to the direction in which the solar cell is located, and a fourth curved shape different from the third curved shape. The solar cell module according to claim 1, wherein the amount of overhang in the direction opposite to the direction in which the fourth curved solar cell is located is smaller than the amount of overhang in the direction opposite to the direction in which the third curved solar cell is located.
3. The solar cell module according to claim 2, wherein the first gas chamber and the second gas chamber are arranged in a first direction parallel to the in-plane direction of the substrate and a second direction parallel to the in-plane direction of the substrate and intersecting the first direction, respectively.
4. The solar cell module according to claim 2, wherein the first gas chamber and the second gas chamber are each shaped to extend in a third direction parallel to the in-plane direction of the substrate, and are arranged in a fourth direction parallel to the in-plane direction of the substrate and intersecting the third direction.
5. The solar cell module according to claim 2, wherein the position of the first gas chamber and the position of the second gas chamber are offset when viewed from a direction perpendicular to the in-plane direction of the substrate.
6. The solar cell module according to claim 2, wherein at least a portion of the first cover material comprises a region that is joined to the substrate but not joined to the second cover material, and a region that is joined to the second cover material but not joined to the substrate, between these two regions, the first cover material is further comprising a region that is not joined to either the substrate or the second cover material.
7. The solar cell module according to claim 6, wherein at least a portion of the first cover material is surrounded by a region of the first cover material that is not joined to the substrate and not joined to the second cover material, or a region that is joined to the second cover material and not joined to the substrate.
8. The solar cell module according to claim 1, wherein the second curved shape is a continuous shape consisting of a curved shape extending in the direction opposite to the direction in which the solar cell is located and a curved shape extending in the same direction as the direction in which the solar cell is located.
9. The solar cell module according to claim 2, wherein the second curved shape and the fourth curved shape are a continuous shape consisting of a curved shape extending in the direction opposite to the direction in which the solar cell is located and a curved shape extending in the same direction as the direction in which the solar cell is located.
10. The solar cell module according to claim 1, wherein the substrate, the solar cell, and the first cover material are light-transmitting.
11. The solar cell module according to claim 2, wherein the substrate, the solar cell, the first cover material, and the second cover material are light-transmitting.
12. The solar cell module according to claim 1, wherein the gas inlet is provided in the first cover material.
13. The solar cell module according to claim 2, wherein the gas inlet is provided in the second cover material.
14. The solar cell module according to claim 2, further comprising an adhesive layer at the joint between the substrate and the first cover material, and at the joint between the first cover material and the second cover material.
15. The solar cell module according to claim 2, wherein the first cover material and the second cover material are laminates of members made of a plurality of materials having different gas permeability and elastic modulus.
Citation Information
Patent Citations
Installation method of photovoltaic power generation film, photovoltaic power generation film built-in member, and photovoltaic power generation film
JP2014236212A