JPH09331079A - Frameless solar cell module - Google Patents

Abstract

(57) Abstract: To realize excellent reliability and high module rigidity at low cost without using a conventional frame. SOLUTION: The thin film solar cell layer is formed on one surface and an insulating layer side surface of a first transparent substrate having an insulating layer provided on the entire surface of the thin film solar cell layer, and a first transparent substrate. And a second light-transmissive substrate having at least the same size as that of the first resin, the second light-transmissive substrate having the same size, and the first light-transmissive substrate having the same size. It may be on the light incident side.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell module using a thin film semiconductor material such as amorphous silicon, and can realize excellent reliability and high module rigidity at low cost without using a conventional frame. It relates to the structural technology that can be done.

[0002]

2. Description of the Related Art In recent years, a solar cell as an alternative energy, as represented by a solar cell for a house, has been in the spotlight. At the same time, there is a great demand for cost reduction, and in particular, solar cells using thin film semiconductor materials such as amorphous silicon are attracting attention. In this amorphous silicon solar cell, an amorphous silicon solar cell layer 32 is formed on a glass substrate 30 as shown in FIG.
It is common to take in sunlight from the side. further,
In order to protect the amorphous silicon solar cell layer 32,
An adhesive layer 34 of ethylene vinyl acetate is provided and back coated with a Tedlar film 36. In addition, a frame 38 extending from the glass surface to the Tedlar film surface is fitted and installed on the end surface of the glass substrate 30 via an adhesive 40 made of butyl rubber to form a solar cell module 42. Here, the adhesive 40 prevents water from entering from the end surface, and the frame 38 ensures the rigidity of the solar cell module 42. When the solar cell module 42 is installed outdoors, a method of screwing the frame 38 to a separately installed array frame is used.

In such a thin film solar cell module 42, since the frame 38 is used, the cost is high. Therefore, recently, a laminated glass module 44 as shown in FIG. 6 has been proposed. As shown in the drawing, while omitting the frame 38, a glass substrate 30a on which the amorphous silicon solar cell layer 32 is formed and another glass substrate 30b having the same size are attached by an adhesive layer 34 of ethylene vinyl acetate. It is bonded to form a laminated glass structure.

[0004]

However, such a conventional solar cell module has the following problems. The laminated glass system shown in FIG. 6 was originally designed to solve the problems of the framed device shown in FIG. 5, but there is a concern that new problems will occur. Specifically, water may enter between the laminated glasses of the solar cell module 44 and cause a short circuit between the front and back of the amorphous silicon solar cell layer 32, that is, between the positive and negative electrodes, which greatly affects the reliability of the product. It is a point. Therefore, even if it is effective in arid areas such as deserts, it can be a problem in rainy areas such as Japan. In addition, for safety reasons, it is considered to use the conventional framed one shown in Fig. 5 in a rainy area such as Japan, but this not only leads to an increase in product cost and the weight of the solar cell module, but also Butyl rubber (adhesive 40) flows down in a high temperature environment in the summer, and the glass surface is contaminated, so that the power generation amount is reduced.

As described above, the conventional thin film solar cell module technology has not been able to achieve both high reliability and high rigidity at low cost, and to solve other problems of conventional solar cell modules.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention not only to achieve both high reliability and high rigidity at low cost, but also to solve various problems of the solar cell module. Such the present invention, the thin film solar cell layer is formed on one side and the insulating layer side surface of the first translucent substrate provided with an insulating layer on the entire surface of the thin film solar cell layer,
This can be realized by forming a frameless solar cell module in which a first translucent substrate and a second translucent substrate having at least the same dimensions are bonded by a synthetic resin layer. Also,
The first and second transparent substrates may have the same size and the first transparent substrate side may be the light incident side.
The operation of the present invention will be described below. In the frameless solar cell module of the present invention, even if water enters from the mating portion of the two translucent substrates, that is, the end surface,
Since the thin film solar cell layer is covered with the insulator layer, water does not come into direct contact with the solar cell layer. When the first light-transmissive substrate side on which the thin-film solar cell layer is formed is the light incident side, the electrode located on the insulator layer side becomes the back electrode, so the electrode is made of a light-shielding material such as aluminum. Since it can be configured, even if water enters from the end surface and reaches between the insulator layer and the synthetic resin layer or between the synthetic resin layer and the second transparent substrate, the appearance such as discoloration from the light receiving surface side. It is not observed as anomalous and does not adversely affect the solar cell characteristics. Here, the electrode material of the thin-film solar cell layer that is in contact with the insulator layer is a metal such as aluminum or silver as described above, or a metal oxide conductor such as tin oxide or indium tin oxide. It is a conductive material for semiconductors. It is known that these conductive materials for semiconductors have good adhesion performance with insulating materials such as silicon oxide and silicon nitride. Therefore, in the structure of the present invention, if water enters from the end face, it is either between the insulator layer and the synthetic resin layer, or between the synthetic resin layer and the second light-transmissive substrate. It is possible to secure high reliability. As described above, the present invention is based on the idea of assuming that water will intrude from one end surface and realizing a structure in which the characteristics of the solar cell do not change even if infiltration of water occurs.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, the details of the present invention will be described with reference to the drawings showing specific embodiments. FIG. 1 shows a cross-sectional structure of a frameless solar cell module of the present invention. This is because the thin-film solar cell layer 1 is formed on one side and the insulating layer 3 is provided on the entire surface of the thin-film solar cell layer 1, and the side surface of the insulating layer 3 of the first translucent substrate 5 A second transparent substrate 7 having at least the same size as the transparent substrate 5,
A frameless solar cell module 11 adhered by a synthetic resin layer 9, in particular, the first and second translucent substrates 5 and 7 have the same size, and light is incident on the first translucent substrate 5 side. It is the side.

A detailed description will be given below. On one surface of the first transparent substrate 5 such as white plate glass, a transparent conductive film such as tin oxide, an amorphous silicon layer having a single or multi-junction structure including a pin junction, and an electrode layer such as aluminum are sequentially formed. A laminated thin film solar cell layer 1 is formed. An insulating layer 3 of silicon oxide or the like is provided over the entire surface of the first translucent substrate 5 so as to cover the entire surface of the thin film solar cell layer 1. This insulator layer 3 is
Considering workability when forming, liquid raw material is desirable,
For example, it is possible to exemplify a method in which an organometallic compound as a main component and a reaction catalyst which causes hydrolysis and dehydration condensation reaction at room temperature are formed by coating. On the other hand, a thin film of silicon oxide or silicon nitride can be formed by CVD or sputtering. In contrast to the first light-transmissive substrate 5 on which the insulating layer 3 is formed, the second light-transmissive substrate 7 such as white plate glass having the same shape and the same size as the first light-transmissive substrate 5 has ethylene vinyl acetate or polyvinyl butyral. The frameless solar cell module 11 having a laminated glass structure is configured by being adhered by a synthetic resin layer 9 such as.

The frameless solar cell module 11 of the present invention as described above is manufactured, for example, by the following manufacturing method. First, a transparent conductive film to be one electrode of the thin film solar cell layer 1 is formed on the white plate glass (first transparent substrate 5) by thermal CVD or the like. Next, this transparent conductive film is laser patterned to be divided into a plurality of regions corresponding to the respective power generation regions. Then, by plasma CVD or the like, p-i-
An amorphous silicon layer having an n-junction is formed, and laser patterning is performed in the same manner as the transparent conductive film to divide into a plurality of regions corresponding to each power generation region. Further on this,
A thin metal film to be the other electrode is formed by sputtering or the like, and similarly, laser patterning is performed to divide into a plurality of regions corresponding to each power generation region, and the thin film solar cell layer 1 is completed. The method for forming the thin-film solar cell layer 1 is conventionally known, and the detailed description thereof is omitted here. Then, liquid glass containing the above-mentioned organometallic compound as a main component is applied to the entire surface of the white plate glass (first transparent substrate 5) by a roll coater or the like so as to cover the entire surface of the thin film solar cell layer 1 and dried. Then, the insulator layer 3 is formed. Then, the white plate glass (first light-transmissive substrate 5) on which the insulating layer 3 is formed, and the ethylene vinyl acetate sheet (which becomes the synthetic resin layer 9) having substantially the same size as the white plate glass (first transparent substrate 5).
And another white plate glass (second transparent substrate 7) having the same shape and size as the first transparent substrate 5 are stacked and heated and pressed by a vacuum laminating device. Are integrally laminated and bonded to complete the frameless solar cell module 11 of the present invention. Although not shown here, the output lead wire from the solar cell may be taken out from, for example, the thin-film solar cell layer 1 and taken out through a hole provided in the second light-transmissive substrate 7.

At this time, as shown in FIG. 2, the synthetic resin layer 9 is made to wrap around the end face portion where the two transparent substrates 5 and 7 are joined to protect the overlapping portion, so that the intrusion of water is more reliable. Can also be prevented. To this end, the above-mentioned ethylene vinyl acetate sheet is made larger than the two translucent substrates 5 and 7, and is made to protrude from the end portions of the translucent substrates 5 and 7 at the time of superposition before laminating and bonding. As a result, it can be softened by the action of heat and pressure during lamination, and can be wrapped around the end face as shown in the figure. Here, as described above, the insulator layer 3 can be formed by plasma CVD or sputtering in addition to applying the liquid material.
Since the film thickness can be made thicker by coating,
Especially when applying to a place where the humidity conditions are severe, it is applied, and when the place is relatively dry, plasma C is used.
It is also effective to use VD or sputtering to form each.

The present invention is characterized in that the second light transmissive substrate 7 has at least the same size as the first light transmissive substrate 5, that is, the same size or larger.
The above embodiment is the case where the same size is used. The purpose of using the second light-transmissive substrate 7 having at least the same size as that of the first light-transmissive substrate 5 is to ensure that the surface of the insulator layer 3 having a relatively thin film thickness is covered with the synthetic resin layer 9. This is to cover.

On the other hand, as shown in FIG. 3, the second transparent substrate 7 can be made larger than the first transparent substrate 5. In this case, as shown in the figure, an additional component such as a bypass diode or an overcharge prevention circuit, the circuit 13 is attached to the surface of the protruding second light-transmissive substrate 7, and the protective member 15 is further covered thereover. It can be a high value-added solar cell module. As illustrated here, the protection member 1
If 5 is made of a material having high rigidity and the end surface of the solar cell module 5 is in contact with the end surface of the first light-transmissive substrate 5, the solar cell module 11 as a whole can have higher rigidity.

Further, when the frameless solar cell module 11 of the present invention is installed outdoors, as shown in FIG. 4, the frame 17 for outdoor installation is made of, for example, H-shaped rubber or hard material. It can be easily installed via the fixture 19. This is a structure that is substantially equivalent to the relationship between the sash frame and the window glass in the window, and has a proven track record with respect to wind pressure resistance and other environmental conditions.

[0014]

According to the frameless solar cell module of the present invention, the following excellent effects can be obtained by the above operation. In the frameless solar cell module of the present invention, it is assumed that two translucent substrates are joined together,
That is, even if water enters from the end surface, since the thin film solar cell layer is covered with the insulator layer, water does not directly contact the thin film solar cell layer, and the structure is high without using a frame. The reliability can be secured. And since it has a structure in which two substrates are bonded together,
High module rigidity can be obtained without using a frame. When the first light-transmissive substrate side on which the thin-film solar cell layer is formed is the light incident side, the electrode located on the insulator layer side becomes the back electrode, so the electrode is made of a light-shielding material such as aluminum. Since it can be configured, even if water enters from the end surface and reaches between the insulator layer and the synthetic resin layer or between the synthetic resin layer and the second transparent substrate, the appearance such as discoloration from the light receiving surface side. It is never observed as abnormal. Therefore, even if water invades during long-term outdoor use, the reliability of the characteristics will not be affected, and the appearance will not change, and high commercial value can be maintained. Such high reliability can be maintained because the electrode material of the thin-film solar cell layer that is in contact with the insulator layer is a general conductive material for semiconductors. That is, these conductive materials for semiconductors have good adhesion performance with insulating materials such as silicon oxide and silicon nitride, and if water enters from the end face in the structure of the present invention, the insulator layer and the synthetic resin layer Or between the synthetic resin layer and the second light-transmissive substrate. Therefore, the structure of the present invention can secure good reliability.

If a second translucent substrate that is larger than the first translucent substrate is used, a bypass diode and an overcharge prevention circuit can be mounted on the stepped portion at the time of combination, which is an added value. A high solar cell module can be obtained. Further, at this time, if the protective member is made of a material having high rigidity and the end surface of the protective member is in contact with the end surface of the first translucent substrate, the solar cell module as a whole can have higher rigidity. .

Further, when the frameless solar cell module of the present invention is installed outdoors, it is easily installed on the framework for outdoor installation via a fixture made of, for example, H-shaped rubber or hard material. Therefore, the construction cost of the outdoor array can be reduced.

As described above, the present invention is based on the idea of realizing a structure in which the characteristics of the solar cell do not change even if water intrusion occurs, assuming that water will intrude from the end face even if by any chance, As described above, it is an extremely excellent material that solves the problems of the conventional technology and satisfies all of reliability, cost and rigidity (mechanical strength).

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a structural example of a frameless solar cell module of the present invention.

FIG. 2 is an explanatory view showing a structural example of a frameless solar cell module of the present invention.

FIG. 3 is an explanatory view showing a structural example of a frameless solar cell module of the present invention.

FIG. 4 is an explanatory view showing an example of the installation structure of the frameless solar cell module of the present invention to an outdoor frame.

FIG. 5 is an explanatory diagram showing the structure of a conventional typical thin film solar cell module.

FIG. 6 is an explanatory view showing the structure of another conventional thin film solar cell module.

[Explanation of symbols]

1 Thin Film Solar Cell Layer 38 Frame 3 Insulator Layer 40 Adhesive 5 First Transparent Substrate 42 Solar Cell Module 7 Second Transparent Substrate 9 Synthetic Resin Layer 11 Frameless Solar Cell Module 13 Additional Parts, Circuit 15 Protective member 17 Frame 19 Mounting tool 30, 30a, 30b Glass substrate 32 Amorphous silicon solar cell layer 34 Adhesive layer 36 Tedlar film

Claims (2)

[Claims] 1. An insulating layer side surface of a first translucent substrate having a thin film solar cell layer formed on one side and an insulating layer provided on the entire surface of the thin film solar cell layer; and a first translucent layer. A frameless solar cell module in which a second translucent substrate having at least the same dimensions as the substrate is bonded by a synthetic resin layer. 2. The frameless solar cell module according to claim 1, wherein the first and second translucent substrates have the same size, and the first translucent substrate side is the light incident side.