JP2005123370A - Power converter integrated type solar battery module and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a power converter integrated type solar battery module which has such a structure that allows easy dissipation of heat generated from a power converter and hence can reduce a power loss, and which can reduce the number of constituent members of the power converter, resulting in improving the assembling workability in manufacturing. <P>SOLUTION: A metal plate 102 is integrally formed in at least a part on a non-light receiving face side of the solar battery module. The metal plate 102 is partially bent into having a U-shaped portion 104, and a power conversion substrate 105 is located in the U-shaped portion 104. The electrode connection member 107 of a photovoltaic element is electrically connected to the power conversion substrate 105. The power conversion substrate 105 is resin-sealed inside the U-shaped portion 104. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a solar cell module having a power converter.

The awareness of environmental issues has been increasing worldwide. Above all, the fear of global warming due to CO ₂ emissions is serious, and the demand for clean energy is increasing. Solar cells are currently expected to be clean energy sources because of their safety and ease of handling.

  In recent years, various types of solar cell devices have been proposed. In addition to the conventional ground-mounted mounting system, technical development is also underway for a system that builds a mounting on the roof and fixes the solar cell panel, and a building material integrated solar cell that incorporates solar cells into the building material itself. .

  FIG. 16 is an example of a solar cell mounting frame using a block body, FIG. 16 (a) is an overall perspective view, and FIG. 16 (b) is a cross-sectional view. In the figure, reference numeral 1601 denotes an inclined material block, 1602 denotes a pillow material block, 1603 denotes a solar cell module, and 1604 denotes an abutting portion.

  As shown in the figure, the base block is formed by combining the pillow block 1602 and the inclined block 1601. If heavy objects such as concrete are used as the inclined material block and the pillow material block, the placement of the gantry is completed only by the placement. The solar cell array 160 can be formed by fixing the solar cell module 1603 to the inclined surface. When a heavy object is used for the block body, it is difficult to be blown by strong winds, and it is difficult to shift due to vibration. As shown in FIG. 16B, the inclined material block and the pillow material block are brought into contact with each other (1604) to form a gantry, whereby durability against wind and vibration can be further improved.

  On the other hand, the currently popularized photovoltaic power generation system has a configuration in which a plurality of solar cell modules are connected in series and parallel to form a solar cell array, and these powers are collected and then converted into electric power. FIG. 17 is a schematic diagram for explaining power conversion of a conventional solar power generation system. In the figure, 1701 is a solar cell module, 1702 is an inverter, and 1703 is a system line. In this way, a plurality of solar cells 1701 are connected in series and parallel, then DC / AC converted by the power converter 1702 and then connected to the AC line 1703.

  In addition, a power converter integrated solar cell module with a power converter attached has been developed. This power converter integrated solar cell module has the following advantages over the conventional solar power generation system.

  When a DC / DC converter or DC / AC converter is used as the power converter, the current can be reduced and the wire can be made narrower by boosting (increasing the voltage), so wiring work between the solar cell module and the inverter Can be simplified, the construction period can be shortened, and the cost can be reduced.

  By integrating the power converter with the solar cell module, the power converter can be expected to reduce costs due to the mass production effect.

  When a DC / AC converter is used as the power converter, the maximum power point control is performed for each solar cell module, so that the power imbalance generated in the array circuit can be minimized.

  FIG. 18 shows an example in which the power converter 1801 integrated with the solar cell module is a DC / DC converter. In the figure, 1801 is a power converter, 1802 is a solar cell module, 1803 is an inverter, and 1804 is a system line. In this example, a grid interconnection inverter (DC / AC converter) 1803 is used.

  Moreover, the example in case the power converter united with a solar cell is a DC / AC converter is shown in FIG. In FIG. 19, 1901 is a power converter, 1902 is a solar cell module, and 1903 is a system line. When the power converter 1901 in the solar cell module 1902 is a DC / AC converter as shown in the figure, the output from the solar cell module can be connected to the system line 1903 as it is. In this case, each power converter 1901 needs a function such as synchronization with AC on the system side.

  Furthermore, the temperature of the surface of the solar cell module reaches 70 ° C. to 80 ° C. in midsummer, and the heat is transmitted to the back surface of the solar cell module, so that the entire solar cell module becomes high temperature. For this reason, when the power converter is integrally formed with the solar cell module, the power converter body is heated by the heat absorbed by the solar cell module by light irradiation, and the conversion efficiency is lowered. In addition, since the power converter itself generates heat when energized, in the worst case, the mounted components inside the power converter may be destroyed.

  Therefore, the power converter of the power converter integrated solar cell module is mounted in consideration of heat dissipation. For example, Patent Document 1 discloses a solar cell module in which a power converter is in contact with a thermally conductive back reinforcing material on the non-light-receiving surface side of the solar cell module. According to this, the power converter is radiated through the back surface reinforcing material, and the power conversion efficiency reduction can be suppressed.

  Patent Document 2 discloses a solar cell module in which a power converter is disposed on a frame member of the solar cell module with improved heat dissipation.

  FIG. 20 is a diagram for explaining the power converter integrated solar cell module described in Patent Document 2. FIG. FIG. 20A is an overall view of the solar cell module, and FIG. 20B is a cross-sectional view of the solar cell module. In the figure, 2001 is a photovoltaic element, 2002 is a frame member, and 2003 is a power converter.

  In FIG. 20, the power converter 2003 is arranged on the frame member 2002 and has a structure that promotes heat dissipation by forming a gap between the solar cell module non-light-receiving surface and the power converter. In addition, heat is radiated more effectively by using a metal material as the frame member 2002.

  FIG. 21 is a diagram for explaining the power converter of the solar cell module described in Patent Document 2. In the figure, reference numeral 2101 denotes a power converter housing, 2102 denotes a power conversion board, 2103 denotes a resin sealing material, 2104 denotes an adhesive, 2105 denotes a solar cell module frame material, and 2106 denotes a photovoltaic element. As shown in the figure, the power conversion board 2102 is disposed inside the housing 2101 and the inside of the housing is sealed with resin 2103. The power converter is fixed to the frame member 2105 using an adhesive 2104.

JP 2002-141539 A Japanese Patent Laid-Open No. 9-271179

  However, the structure described in Patent Document 2 has a complicated structure. That is, in the above-described power converter integrated solar cell module, the power conversion board 2102 is disposed in the housing 2101 and is resin-sealed 2103, and is further fixed to the frame member 2105. As described above, the manufacture of the solar cell module integrated with a power converter has problems that workability is poor, the structure is complicated, and the cost is increased because of the large number of components.

  Therefore, as a result of intensive research and development to solve the above problems, the present inventor has found that the following power converter integrated solar cell module is the best.

That is, the present invention is a solar cell module having at least one photovoltaic element and one power conversion substrate, and a metal plate is integrally formed on at least a part of the non-light-receiving surface side of the solar cell module. The metal plate has a U-shaped part that is partially bent, and the power conversion substrate is disposed in the U-shaped part, and the electrode connecting member of the photovoltaic element is the power. A power converter integrated solar cell module, wherein the solar cell module is electrically connected to a conversion board, and the power conversion board is resin-sealed in the U-shaped portion.
In the power converter integrated solar cell module of the present invention, it is preferable that the power conversion board is composed of at least an insulating transformer, a switching element, and a circuit board.
Moreover, it is preferable that any one surface of the power conversion board in the thickness direction is in contact with the metal plate.
Moreover, it is preferable that the cushion material is arrange | positioned between the surface which is not contacting the said metal plate of the said power conversion board | substrate, and the said metal plate.
Moreover, it is preferable that the thickness of the said power conversion board | substrate is the same as the clearance gap between the metal plates in the said U-shaped part.
Moreover, it is preferable that the insulating material is arrange | positioned at the contact part of the said power conversion board | substrate and the said metal plate.
The U-shaped portion of the metal plate is preferably formed at the end of the solar cell module so as to protrude toward the non-light-receiving surface.

  Further, as a result of intensive research and development to solve the above problems, the present inventor has found that the following method for manufacturing a power converter integrated solar cell module is the best.

That is, the present invention is a method for manufacturing a solar cell module having at least one photovoltaic element and one power conversion substrate, the step of integrally forming at least the photovoltaic element and a metal plate, from the photovoltaic element A step of extending and removing the electrode connection member so as to penetrate the metal plate, a step of bending the metal plate to form a U-shaped portion, and electrically connecting the extended electrode connection member to the power conversion board A power converter integrated type, comprising: a step of storing the power conversion board in the U-shaped portion; and a step of resin-sealing the inside of the U-shaped portion. It is a manufacturing method of a solar cell module.
In the manufacturing method of the power converter integrated solar cell module of the present invention, it is preferable that the metal plate of the electrode connecting member extraction portion from the photovoltaic element is punched before integral molding.

  According to the present invention, since the metal plate integrally formed with the solar cell module can be used as the outer casing of the power converter, the number of members constituting the power converter can be reduced, and the assembly workability at the time of manufacture is improved. improves.

  In addition, since the power conversion board is placed inside the metal plate, the heat in the power conversion board is transferred to the metal plate, and heat dissipation is promoted, so the temperature rise of the power conversion board is suppressed and damage to the power conversion board is suppressed. And power conversion loss can be reduced.

  FIG. 1 is a view for explaining a power converter integrated solar cell module of the present invention. FIG. 1 is a view showing a state where a U-shaped portion is formed by forming a metal plate on the entire surface of the non-light-receiving surface of a solar cell module, and a power conversion substrate is arranged in the U-shaped portion. In the figure, 101 is a photovoltaic element, 102 is a metal plate, 103 is a solar cell module coating material, 104 is a U-shaped portion of the metal plate, 105 is a power conversion substrate, 106 is a resin sealing material, and 107 is an electrode. It is a connection member.

  On the other hand, FIG. 8 is a figure for demonstrating the manufacturing method of the power converter integrated solar cell module of this invention. FIG. 8A is a view for explaining a state where a photovoltaic element and a metal plate are integrally formed and an electrode connecting member is taken out from a hole (not shown) of the metal plate, and FIG. FIG. 8 (c) is a diagram for explaining the electrical connection between the electrode connecting member and the power conversion board, and FIG. 8 (c). d) is a figure for demonstrating the place which arrange | positioned the power conversion board | substrate in the U-shaped part, and was resin-sealed.

  In the figure, 801 is a photovoltaic element, 802 is a metal plate, 803 is a covering material, 804 is a U-shaped portion, 805 is a power conversion substrate, 806 is a resin sealing material, 807 is an electrode connecting member, and 808 is a photovoltaic device. It is an electrical connection between the power element and the power converter.

  First, as shown in FIG. 8A, a photovoltaic element 801 is laminated with a covering material 803 and formed integrally with a metal plate 802. At this time, the metal plate 802 is wider than the photovoltaic element 801 so that the end of the metal plate protrudes beyond the photovoltaic element. Then, the electrode connecting member 807 connected to the positive and negative electrodes of the photovoltaic element is taken out from a hole (not shown) of the metal plate 802. Next, as shown in FIG. 8B, the end of the metal plate 802 protruding from the photovoltaic element is bent to form a U-shaped portion 804. Then, as shown in FIG. 8C, the power conversion substrate 805 and the photovoltaic element are electrically connected 808 by the electrode connecting member 807. Finally, as shown in FIG. 8D, the power conversion board is inserted into the U-shaped portion, and the resin sealing 806 is performed.

  By manufacturing in this way, the metal plate 802 can be used as the casing of the power conversion board 805, and the cost of the exterior casing can be reduced compared to the conventional power converter, so that the cost can be reduced. . Also, the assembly workability is improved. Furthermore, the heat generated in the power conversion board is transferred to the metal plate of the outer casing and can be effectively dissipated, thereby reducing power conversion loss.

  FIG. 8C shows the power conversion board 805 being inserted into the U-shaped part 804. However, if the power conversion board 805 is fixed at the U-shaped part, it becomes easier to seal the resin. Improves.

  Furthermore, if the thickness of the power conversion substrate 805 is the same as the gap between the metal plates in the U-shaped portion 804, it is preferable from the viewpoint of improving workability during manufacturing and preventing temperature rise of the mounted components.

  When the power conversion board 805 is inserted into the U-shaped portion 804 and the metal plate 802 and the mounting component or circuit board of the power conversion board are in contact with each other, heat generated by the mounting component is effectively transferred to the metal plate and mounted. The temperature rise of components can be suppressed. At this time, if the circuit board comes into contact, the pattern circuit on the circuit board may come into contact with the metal plate. Needless to say, the circuit board / metal plate must be insulated.

  Below, each member which comprises the power converter integrated solar cell module of this invention is demonstrated in detail.

[Power conversion board]
It is used to convert the power output from the photovoltaic element into alternating current power or to convert it into boosted direct current power. It is composed of a circuit board and mounting components, and is generally composed of a booster circuit, a control circuit, a power converter circuit, and the like.

  Each electric circuit is formed on the circuit board, and a mounting component is formed on each electric circuit. A mounting component having a switching function such as an IGBT or a MOSFET is used for the power converter circuit. In the booster circuit, it is converted into high voltage power by an insulating transformer. A desired output power can be obtained by controlling the switching element by a control signal from the control circuit.

  However, it is known that the above-described insulating transformer, switching elements such as IGBT and MOSFET have power loss during operation and generate heat. When heat dissipation is insufficient and the temperature rises, the power loss is further increased, and in the worst case, the mounted components may be damaged.

  The solar cell module of the present invention is improved not only to efficiently dissipate this heat generation, but also to prevent damage to the mounted components, as well as to efficiently convert power.

  In addition, the thickness of the power conversion board | substrate of the solar cell module used by this invention is a total thickness of the mounting component which has the maximum height with a circuit board. The power conversion substrate can efficiently dissipate heat by contacting the metal plate of the solar cell module.

[Power converter integrated solar cell module]
The power converter integrated solar cell module of the present invention includes a photovoltaic element, a metal plate, a power conversion substrate, and a resin sealing material, and is configured using a cushion material or an insulating material as necessary.

  Since the voltage increases after power conversion, the current decreases and power loss is less likely to occur, so a relatively thin wire can be used. However, the electrode connecting member between the photovoltaic element and the power conversion substrate needs to be made of a conductive material that is as short as possible and has a large cross-sectional area in order to minimize power loss.

[Photovoltaic element]
The photovoltaic element used in the present invention is not particularly limited. For example, a photovoltaic element such as a crystal system, an amorphous system, or a compound semiconductor system can be used.

[Metal plate]
It is configured integrally with the power converter integrated solar cell module and is used as an outer casing of the power conversion board. By storing the power conversion board in the U-shaped portion formed of this metal plate, the heat generated in the power conversion board can be radiated efficiently, and damage to the mounted components can be suppressed.

  The properties required for the metal plate include thermal conductivity and corrosion resistance. As a material, stainless steel, a plated steel plate, an insulation-treated resin-coated steel plate, or the like can be used.

  In addition, the U-shaped part formed by bending a metal plate is a U-shaped cross section in the example of FIG. 8, but if it is a shape that can be bent to place the power conversion board inside, Any cross-sectional shape similar to a U-shape can be used.

  Further, the metal plate is not necessarily formed integrally on the entire surface of the solar cell module on the non-light-receiving surface side. For example, as shown in the cross-sectional view of FIG. It may be formed. Depending on the form, the U-shaped portion (bending portion) may be formed on the light receiving surface of the solar cell module.

[Resin encapsulant]
When the power conversion substrate is left as it is, the electric circuit is exposed, and thus the resin is completely sealed in the U-shaped portion of the metal plate to improve the durability of the power conversion substrate. Properties required for the resin sealing material include heat resistance, electrical insulation, moisture resistance, and thermal conductivity. Examples of usable materials include epoxy resins and silicone resins.

[Cushion material]
In general, solar cell modules are considered to be bent or twisted during handling or during construction. Therefore, in the power converter integrated solar cell module of the present invention, when both sides in the thickness direction of the power conversion board 405 are in contact with the metal plate 402 as shown in FIG. The substrate may be damaged.

  FIG. 6 is an end cross-sectional view of a power converter integrated solar cell module in which a cushion material is disposed in a U-shaped portion. FIG. 6A is a view showing a place where a cushion material and a power conversion board are inserted, and FIG. 6B is a view showing a place where a U-shaped portion is resin-sealed. In the figure, 601 is a photovoltaic element, 602 is a metal plate, 603 is a solar cell module covering material, 605 is a power conversion substrate, 606 is a resin sealing material, 607 is an electrode connecting member, and 608 is a cushioning material. As described above, the cushion material 608 is disposed on any surface in the thickness direction of the power conversion board, so that damage to the power conversion board can be suppressed.

  Properties required for the cushion material include electrical insulation, moisture resistance, flexibility, heat resistance, and the like. As a material, urethane resin, silicon resin, acrylic resin, or the like can be used.

〔Insulating material〕
In the power conversion board, an electric circuit is formed on the circuit board, and the electric circuit is exposed. The mounted component may be fixed by soldering on the circuit board. If such a circuit board is disposed so as to be in contact with the metal plate, in the worst case, there is a possibility of short-circuiting through the metal plate. In order to suppress this, an insulating material is used.

  FIG. 7 is an end cross-sectional view of a power converter integrated solar cell module in which an insulating material is disposed in a U-shaped portion. In the figure, 701 is a photovoltaic element, 702 is a metal plate, 703 is a covering material for a solar cell module, 705 is a power conversion substrate, 706 is a resin sealing material, 707 is an electrode connecting member, and 709 is an insulating material. In this manner, the insulating material 709 can be prevented from being short-circuited by disposing the insulating material 709 in advance on the metal plate surface in contact with the circuit board and then disposing the power conversion board.

  In the manufacturing procedure, the photovoltaic element 701 and the metal plate 702 are integrally formed, and the metal plate is bent to form a U-shaped portion. Thereafter, an insulating material 709 is disposed inside the U-shaped portion, and the power conversion board 705 is inserted to temporarily fix the power conversion board. The insulating material is preferably in the form of a thin sheet in order to facilitate insertion of the power conversion board and to efficiently dissipate heat generated in the power conversion board to the metal plate.

Hereinafter, the present invention will be described in detail based on examples.

(Example 1)
This example is a power converter integrated solar cell module in which the thickness of the power conversion board is the same as the gap between the metal plates at the U-shaped portion of the metal plate, and the metal plate is not receiving light. It is an example formed in a part on the surface side.

  FIG. 4 is a cross-sectional view for explaining the power converter integrated solar cell module of this embodiment. In the figure, 401 is a photovoltaic element, 402 is a metal plate, 403 is a covering material for the solar cell module, 405 is a power conversion substrate, 406 is a resin sealing material, and 407 is an electrode connecting member.

  FIG. 5 is a diagram for explaining the power converter integrated solar cell module of FIG. 4 in detail. 5 (a) is an enlarged cross-sectional view of the power converter, FIG. 5 (b) is a diagram showing a power conversion board inserted into a U-shaped portion, and FIG. 5 (c) is a resin-sealed place. FIG. In the figure, 501 is a circuit board, and 502 is a mounted component.

  As shown in FIG. 5A, the power conversion board 405 includes a circuit board 501 and a mounting component 502. The mounted component 502 includes at least an insulating transformer and a switching element, and constitutes a power conversion circuit on the circuit board 501. The thickness d1 of the power conversion board 405 is the total thickness of the circuit board 501 and the mounting component 502 having the maximum height. If the gap d2 between the metal plates in the U-shaped part of FIG. 5B and the thickness d1 of the power conversion board are equal, the power conversion board 405 can be temporarily fixed only by being inserted into the U-shaped part. . If the power conversion substrate 405 can be temporarily fixed in this manner, there is an advantage that workability is improved when the U-shaped portion is sealed with resin 406 in a subsequent process.

  Next, the manufacturing method of the power converter integrated solar cell module of the present embodiment will be described in detail.

  First, the power conversion substrate 405 is manufactured. A power conversion circuit is manufactured by attaching a mounting component 502 such as a switching element or an insulating transformer on the circuit board 501. The thickness d1 of the power conversion board 406 is 15 mm.

  Next, the photovoltaic elements are electrically connected. FIG. 9 is a schematic diagram for explaining the connection of two photovoltaic elements. In the figure, reference numeral 901 denotes a positive electrode connecting member, and reference numeral 902 denotes a negative electrode connecting member. The size of one photovoltaic element is 240 mm × 350 mm, and the positive and negative electrode connection members 901 and 902 of this photovoltaic element are connected to the positive and negative electrodes of the other photovoltaic element. The distance between the photovoltaic elements is 20 mm, and the dimension of the two photovoltaic elements is 500 mm × 350 mm. In addition, since the power conversion board | substrate used by a present Example uses one photovoltaic element 2 parallel x 1 series, the photovoltaic element is made into one set with two sheets.

  Then, the photovoltaic element and the metal plate are integrally formed. FIG. 10 is a schematic view for explaining that the photovoltaic element and the metal plate constituting the solar cell module of the present embodiment are integrally formed. In the figure, reference numeral 1001 denotes two photovoltaic elements, 1002 denotes a filler, 1003 denotes a metal plate, 1004 denotes an outermost covering material, and 1005 denotes an electrode extraction hole. As shown in the figure, the metal plate 1003, the filler 1002, the photovoltaic element 1001, the filler 1002, the outermost surface covering material 1004 are arranged in this order from the non-light-receiving surface side, and heat treatment is performed while evacuating with a vacuum laminator or the like. Integrally formed. Further, in order to facilitate the extraction of the electrode from the photovoltaic element, a hole 1005 is formed in advance in the electrode extraction position in the material on the non-light-receiving surface side from the photovoltaic element. In addition, a padding (not shown) such as silicon rubber is placed in this hole during lamination. By doing so, since the filler does not flow into the hole, it becomes easy to connect the electrode member in a subsequent process.

  Each material is a coated steel plate having a metal plate 1003 of 160 mm × 160 mm, a filler 1002 is EVA of 540 mm × 390 mm, and an outermost coating material 1004 is an ETFE film of 540 mm × 390 mm. Further, at the time of lamination, the metal plate on the electrode take-out side (bending side) is arranged so as to protrude 60 mm from other sealing materials. In this manner, by arranging the metal plate 1003 only at the place where the power conversion board is arranged, the cost can be reduced because the metal plate 1003 can be manufactured with few metal plates.

  Next, the metal plate is bent to integrate the power conversion substrate (the same as the operation in FIG. 8 described above). At this time, the gap d2 between the metal plates is 15 mm.

  Moreover, FIG. 11 is a figure for demonstrating the electric wire accommodation after the power conversion of the power converter integrated solar cell module in a present Example, FIG. 11 (a) is the solar cell module which saw through the U-shaped part. FIG. 11B is a perspective view of the solar cell module viewed from the light receiving surface side. In the figure, reference numeral 1101 denotes an output electric wire after power conversion. As shown in the figure, the output electric wire 1101 from the power conversion board 405 is arranged in the U-shaped portion of the metal plate 402 to fix the output electric wire. The output electric wire 1101 uses an IV electric wire.

  Finally, the power conversion board 405 is inserted into the U-shaped portion of the metal plate 402 and sealed with resin. An epoxy resin is used as the resin. At this time, it is easy to work if the solar cell module is erected, the opening of the U-shaped portion is directed upward, both ends are closed, and the resin is poured.

  The power converter integrated solar cell module shown in FIG. 4 can be manufactured as described above.

  Moreover, FIG. 12 is sectional drawing showing the example which fixed the power converter integrated solar cell module of a present Example on the solar cell stand. In the figure, 1201 is a U-shaped portion, 1202 is an adhesive, 1203 is a frame forming an inclined surface, and 1204 is the above-described power converter integrated solar cell module.

  As shown in FIG. 12, the power converter integrated solar cell module is formed by hanging the U-shaped portion 1201 of the metal plate constituting the power converter integrated solar cell module 1204 on the corner of the gantry 1203 opposite to the water flow. Can be temporarily fixed to the installation surface. Since it can prevent that a power converter integrated solar cell module slips down until the adhesive agent 1202 hardens | cures, it turns out that workability | operativity improves. Moreover, since it becomes a structure where the power converter is not pinched | interposed into the mount frame 1203 and the solar cell module 1204, the heat dissipation of a power converter improves.

As described above, according to the power converter integrated solar cell module of the present embodiment, the following effects can be expected.
-Since the thickness of the power conversion board is the same as the metal plate gap of the U-shaped portion, the power conversion board can be temporarily fixed in the gap, so that the assembly workability during manufacturing is improved.
-Since any one surface in the thickness direction of the power conversion board is in contact with the metal plate, heat dissipation is further promoted, so that power conversion loss can be reduced.
・ The U-shaped part of the metal plate protrudes toward the non-light-receiving surface side and is formed at the end of the solar cell module. Because it can be fixed, construction workability is improved.
-Since the U-shaped part of the metal plate protrudes toward the non-light-receiving surface and is formed at the end of the solar cell module, the power converter is not sandwiched between the gantry and the solar cell module The heat dissipation of the power converter is improved.

(Example 2)
In this embodiment, two sets of two parallel x one series photovoltaic elements are integrally formed, and a place where a metal plate and a power conversion board are arranged for each set is changed. Other than that is produced like Example 1. FIG.

  FIG. 3 is a perspective view of the power converter integrated solar cell module of this embodiment as seen from the light receiving surface side. In the figure, 301 is a photovoltaic element, 302 is a metal plate, 303 is a covering material, and 305 is a power conversion substrate.

  In this way, three sets of two photovoltaic elements are arranged side by side, and the metal plate 302 is integrally formed in alignment with the place where each power conversion board 305 is disposed. By arranging the metal plate only at the location where the power conversion substrate is arranged, the cost can be reduced because the metal plate can be manufactured with a small number of metal plates.

  Each material at the time of integral formation has the same configuration and changes dimensions as compared to the first embodiment. The filler and the outermost surface covering material are 1540 mm × 390 mm. A metal plate having a size of 160 mm × 160 mm is used. At the time of lamination, the metal plate is disposed so as to protrude 60 mm from the filler or the light receiving surface covering material.

  Then, each metal plate is bent. Bending is performed from the end portions of the outermost surface covering material and the filler, and the gap between the metal plates is 15 mm. The power conversion board is the same as that of the first embodiment, and resin sealing in the U-shaped portion is performed with each metal plate. Other than that, it produces similarly to Example 1. FIG.

  FIG. 13 is a view for explaining the electric wire accommodation after the power conversion of the power converter integrated solar cell module in the present embodiment, and FIG. 13 (a) shows the solar cell module seen through the U-shaped portion. FIG. 13B is a schematic view seen from the light receiving surface side, and FIG. 13B is a perspective view of the solar cell module seen from the non-light receiving surface side. In the figure, 1301 is an output wire after power conversion, and 1302 is a parallel output wire after power conversion.

  As shown in the figure, the output electric wire 1301 from the power conversion board 305 is disposed in the U-shaped portion of the metal plate 302 to fix the output electric wire. Further, parallel output wires 1302 that connect the output wires 1301 in parallel are also housed in a metal plate as shown in the figure. The output electric wire 1301 and the parallel output electric wire 1302 use IV electric wires.

As described above, according to the power converter integrated solar cell module of the present embodiment, the following effects can be expected in addition to the effects of the first embodiment.
・ When multiple power conversion boards are used, the same number of metal plates on the back side of the solar cell module are used to form only the place where the power conversion boards are placed, reducing the amount of metal plates used. The cost of the battery module can be reduced.

(Example 3)
In this embodiment, the point that the cushion material is arranged between the power conversion board and the metal plate in the U-shaped portion of the metal plate is changed. Other than that is produced like Example 2. FIG.

  FIG. 14 is an end cross-sectional view of the power converter integrated solar cell module of the present embodiment, and FIG. 14 (a) is a diagram illustrating a cushion material and a power conversion board inserted into a U-shaped portion; FIG. 14B is a diagram showing the inside of the U-shaped portion sealed with resin. In the figure, 1401 is a photovoltaic element, 1402 is a metal plate, 1403 is a covering material for a solar cell module, 1405 is a power conversion substrate, 1406 is a resin sealing material, 1407 is an electrode connecting member, and 1408 is a cushioning material.

  The manufacturing procedure is to form a photovoltaic element and a metal plate integrally, and after bending the metal plate, place the cushion material 1408 in either one of the gaps in the U-shaped portion of the metal plate, and the rest The power conversion board 1405 can be inserted into the gap to temporarily fix the power conversion board (see FIG. 14A). In this case, if the gap between the metal plates is the same as the sum of the thickness of the power conversion board and the thickness of the cushion material, it is easy to temporarily fix the gap.

  In this embodiment, a metal plate having a size of 160 mm × 165 mm is used at the time of integral molding, and the gap between the metal plates is set to 20 mm after bending. The cushion material 1408 uses a silicon resin having a thickness of 5 mm.

  After the power conversion board 1405 is inserted and temporarily fixed in the gap between the U-shaped portions of the metal plate, the sealing resin 1406 is sealed in the U-shaped portions (see FIG. 14B).

  Other than the above-described production contents, the production is performed in the same manner as in Example 2.

As described above, according to the power converter integrated solar cell module of the present embodiment, in addition to the effects of Embodiments 1 and 2, the following effects can be expected.
・ By placing the cushioning material between the surface of the power conversion board that is not in contact with the metal plate and the metal plate, stress due to deflection, twisting, etc. of the solar cell module during handling is absorbed by the cushioning material. Since the power conversion board is not directly applied, damage to the power conversion board can be suppressed.

Example 4
In this embodiment, the point that the insulating material is arranged at the portion where the circuit board of the power converter contacts the metal plate is changed. Other than that is produced like Example 2. FIG.

  FIG. 15 is an end cross-sectional view of the power converter integrated solar cell module of this example, and FIG. 15A shows a state where an insulating material is disposed in the U-shaped portion and a power conversion board is inserted. FIG. 15 (b) is a diagram showing the inside of the U-shaped portion being resin-sealed. In the figure, 1501 is a photovoltaic element, 1502 is a metal plate, 1503 is a solar cell module coating material, 1505 is a power conversion board, 1506 is a resin sealing material, 1507 is an electrode connecting member, and 1509 is an insulating material.

  The power conversion board is formed with an electric circuit patterned on the circuit board, and each electric circuit is exposed. Also, soldering may be performed when mounting components are fixed on a circuit board. When such a circuit board comes into contact with the metal plate, in the worst case, there is a risk of short circuit through the metal plate. Therefore, as shown in FIG. 15, it is possible to suppress short-circuiting by disposing the insulating material 1509 in advance on the metal plate surface in contact with the circuit board and then arranging the power conversion board.

  The manufacturing procedure is as follows. First, a photovoltaic element and a metal plate are integrally formed, and an insulating material 1509 is disposed at a portion where the power conversion substrate contacts. Then, the electrode connecting member 1507 is attached so as to extend from the photovoltaic element so as to penetrate the metal plate. Next, the metal plate 1502 is bent to form a U-shaped portion. The extended electrode connection member 1507 and the power conversion board 1505 are electrically connected, and the power conversion board is inserted into a U-shaped portion and temporarily fixed in a metal plate (see FIG. 15A). Finally, a resin sealing material 1506 is formed (see FIG. 15B).

  Since the insulating material 1509 is formed as described above, it is preferable that the insulating material 1509 has a thin sheet shape in order to facilitate insertion of the power conversion board and to efficiently dissipate heat generated in the power conversion board. In this embodiment, PET is used as the insulating material 1509.

  Other than the above-described production contents, the production is performed in the same manner as in Example 2.

As described above, according to the power converter integrated solar cell module of the present embodiment, in addition to the effects of Embodiments 1 and 2, the following effects can be expected.
-Since the insulating material is arrange | positioned at the contact part of a power conversion board | substrate and a metal plate, it can prevent that the live part on a power conversion board | substrate short-circuits with a metal plate.

It is sectional drawing for demonstrating one Embodiment of the power converter integrated solar cell module of this invention, and is an example by which the metal plate is formed in the whole surface by the side of the non-light-receiving surface of a solar cell module. It is sectional drawing for demonstrating one Embodiment of the power converter integrated solar cell module of this invention, and is an example by which the metal plate is formed in a part by the side of the non-light-receiving surface of a solar cell module. It is a top view of the power converter integrated solar cell module of Example 2 of the present invention. It is sectional drawing of the power converter integrated solar cell module of Example 1 of this invention, and the solar where the thickness of a power conversion board | substrate is the same as the clearance gap between metal plates in the U-shaped part of a metal plate It represents a battery module. It is a figure for demonstrating in detail the solar cell module of FIG. 4, (a) is a cross-sectional enlarged view of a power converter, (b) represents the place which inserted the power conversion board | substrate in the U-shaped part of the metal plate. FIG. 4C is a view showing a resin-sealed place. It is edge part sectional drawing for demonstrating one Embodiment of the power converter integrated solar cell module of this invention, and is the example which has arrange | positioned the cushioning material in the U-shaped part of a metal plate. It is edge part sectional drawing for demonstrating one Embodiment of the power converter integrated solar cell module of this invention, and is the example which has arrange | positioned the insulating material in the U-shaped part of a metal plate. It is a figure for demonstrating the manufacturing method of the solar cell module which has the power conversion board | substrate of this invention. It is the schematic for demonstrating the place which has connected two photovoltaic elements. It is the schematic for demonstrating the place which integrally forms the photovoltaic element and metal plate which comprise the solar cell module of Example 1 of this invention. It is a figure for demonstrating the electric wire accommodation after the power conversion of the solar cell module in Example 1 of this invention, (a) is the outline which looked at the solar cell module which saw through the U-shaped part from the non-light-receiving surface side FIG. 2B is a perspective view of the solar cell module as viewed from the light receiving surface side. It is sectional drawing showing the example which fixed the solar cell module which has the power conversion board | substrate of this invention on a solar cell stand. It is a figure for demonstrating the electric wire accommodation after the power conversion of the solar cell module in Example 2 of this invention, (a) is the outline which looked at the solar cell module which saw through the U-shaped part from the non-light-receiving surface side FIG. 4B is a perspective view of the solar cell module as seen from the non-light-receiving surface side. It is edge part sectional drawing of the power converter integrated solar cell module of Example 3 of this invention, (a) is the figure showing the place which inserted the cushion material and the power conversion board | substrate in the U-shaped part of the metal plate. (B) is a figure showing the place which carried out resin sealing inside the U-shaped part. It is edge part sectional drawing of the power converter integrated solar cell module of Example 4 of this invention, (a) is the figure showing the place which inserted the insulating material and the power conversion board | substrate in the U-shaped part of the metal plate. (B) is a figure showing the place which carried out resin sealing inside the U-shaped part. It is a prior art example of the solar cell mounting stand using a block body, (a) is a whole perspective view, (b) is sectional drawing. It is a schematic diagram for demonstrating the power conversion of the conventional solar power generation system. This is an example in which the power converter integrated with the solar cell module is a DC / DC converter. It is an example in case the power converter united with a solar cell is a DC / AC converter. It is a figure for demonstrating the conventional power converter integrated solar cell module, (a) is a solar cell module whole figure, (b) is sectional drawing of a solar cell module. It is sectional drawing for demonstrating the power converter of the conventional power converter integrated solar cell module.

Explanation of symbols

101, 301, 401, 601, 701, 801, 1001, 1401, 1501, 2001, 2106 Photovoltaic elements 102, 302, 402, 602, 702, 802, 1003, 1402, 1502 Metal plates 103, 303, 403, 603, 703, 803, 1403, 1503 Cover material 104, 804, 1201 U-shaped part 105, 305, 405, 605, 705, 805, 1405, 1505, 2102 Power conversion board 106, 406, 606, 706, 806 1406, 1506, 2103 Resin sealing material 107, 407, 607, 707, 807, 1407, 1507 Electrode connection member 501 Circuit board 502 Mounting component 608, 1408 Cushion material 709, 1509 Insulation material 808 Electrical connection portion 901 Positive electrode connection Element 902 Negative electrode connection member 1002 Filler 1004 Outermost surface covering material 1005 Electrode extraction hole 1101, 1301 Output electric wire 1202, 2104 Adhesive 1203 Mounting frame 1204, 1603, 1701, 1802, 1902 Solar cell module 1302 Parallel output electric wire 1601 Inclined material block 1602 Pillow block 1604 Abutting portion 1702, 1803 Inverter 1703, 1804, 1903 System line 1801, 1901 Power converter 2002, 2105 Frame material 2003 Power converter 2101 Housing

Claims (9)

  A solar cell module having at least one photovoltaic element and one power conversion substrate, wherein a metal plate is integrally formed on at least a part of the non-light-receiving surface side of the solar cell module, and the metal plate is A part of the U-shaped portion is bent, the power conversion board is disposed in the U-shaped part, and an electrode connection member of the photovoltaic element is electrically connected to the power conversion board. A power converter integrated solar cell module, wherein the power conversion substrate is resin-sealed in the U-shaped portion.   The power converter integrated solar cell module according to claim 1, wherein the power conversion board includes at least an insulating transformer, a switching element, and a circuit board.   3. The power converter integrated solar cell module according to claim 1, wherein any one surface in the thickness direction of the power conversion substrate is in contact with the metal plate.   4. The power converter integrated solar cell module according to claim 3, wherein a cushion material is disposed between a surface of the power conversion board that is not in contact with the metal plate and the metal plate.   5. The power converter integrated solar cell module according to claim 1, wherein a thickness of the power conversion board is the same as a gap between the metal plates in the U-shaped portion. .   6. The power converter integrated solar cell module according to claim 3, wherein an insulating material is disposed at a contact portion between the power conversion substrate and the metal plate.   The U-shaped portion of the metal plate is formed at the end of the solar cell module so as to protrude toward the non-light-receiving surface, and according to any one of claims 1 to 6. Power converter integrated solar cell module.   A method of manufacturing a solar cell module having at least one photovoltaic element and one power conversion substrate, wherein at least the photovoltaic element and a metal plate are integrally formed, and an electrode connecting member from the photovoltaic element A step of extending the metal plate so as to penetrate, a step of bending the metal plate to form a U-shaped portion, a step of electrically connecting the extended electrode connection member to a power conversion board, the power A process for housing a conversion substrate in the U-shaped portion and a step of resin-sealing the U-shaped portion in the order of the steps described above. Method. 9. The method of manufacturing a power converter integrated solar cell module according to claim 8, wherein the metal plate of the electrode connecting member extraction portion from the photovoltaic element is punched before integrated molding.

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