JP2013168518A - Solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thin solar cell module having rigidity, thinner, and high in flexibility allowing the solar cell module to follow a three dimensional curved surface according to an installing/mounting place for a vehicle or the like.SOLUTION: In a thin solar cell module having a thickness of 100-600 μm, a photoelectric conversion layer is included by a sealing material layer present between a front face protection layer and a rear face protection layer each of which comprises a hard resin having a thickness of 1-100 μm and a glass transition temperature of 20-200°C.

Description

  The present invention relates to a method for manufacturing a solar cell module.

As a solar cell, for example, a solar cell using single crystal silicon or polycrystalline silicon is known.
These solar cells normally constitute a solar cell module in a state of being sealed between protective members (protective layer) with a sealing material such as EVA resin. Specifically, these solar cell modules sandwich a photoelectric conversion layer in which a plurality of solar cells are connected with an electric wire or the like between protective layers such as a surface protective layer and a back surface protective layer, wrapped in an EVA resin film, Generally, the entire module is vacuum-produced by heating and pressing with a vacuum laminator.

  As a thin solar cell module aiming at weight reduction and thinning of the solar cell module and capable of being formed by a simpler process, for example, Patent Document 1 discloses a synthetic resin plate and a sealant material having a thickness of 1 mm or less. Using an adhesive synthetic resin sheet having a thickness of 0.6 mm or less, a thin solar cell module having a thickness of 3.0 mm or less as a whole module with the same material and the same thickness as the surface protection member and the back surface protection member. Have been described.

JP 2007-242777 A

  The thin solar cell module described in Patent Document 1 can be molded by a single vacuum lamination, and the obtained thin solar cell module can be obtained without warping or deformation, but is mounted for a vehicle. Like such a solar cell module, there was not enough flexibility to follow a three-dimensional curved surface.

  The present invention solves the above-described problems, and provides a highly flexible thin solar cell module that has rigidity, is thinner, and can follow a three-dimensional curved surface in accordance with an installation / mounting place for vehicles or the like. The purpose is to do.

  As a result of intensive studies to solve the above-mentioned problems, the inventors of the present invention have used a sealing material layer existing between a surface protective layer and a back surface protective layer made of a hard resin having a specific thickness and a glass transition temperature. It has been found that the above problem can be solved by including a conversion layer in a thin solar cell module having a thickness of 100 to 600 μm, and the present invention has been completed. Conventionally, when trying to manufacture a thin solar cell module having a thickness of 100 to 600 μm, there is a problem in sealing performance and sealing performance, such as a void formed at the interface between the cell and the sealing material. In the present invention, a solar cell module that has excellent sealing properties and can be bent by using a specific hard resin has been conceived.

The gist of the present invention is a thin solar cell module having a thickness of 100 to 600 μm formed by laminating a sealing material layer, a photoelectric conversion layer, and a sealing material layer in this order between a surface protective layer and a back surface protective layer. The surface protective layer and the back surface protective layer are each a hard resin having a thickness of 1 to 100 μm and a glass transition temperature of 20 to 200 ° C. The photoelectric conversion layer is included in the sealing material layer. Each of the sealing material layers has a thickness of 1 to 100 μm.

Moreover, it is preferable to have an outermost layer with a thickness of 1 to 100 μm outside the surface protective layer, and it is preferable to further have an adhesive layer between the surface protective layer and the outermost layer.
The thin solar cell module of the present invention is laminated in the order of the outermost layer, the adhesive layer, the surface protective layer, the sealing material layer, the photoelectric conversion layer, the sealing material layer, and the back surface protective layer from the sunlight receiving surface side. It can also be produced.

The thin solar cell module of the present invention can be bent in the biaxial direction with a minimum curvature radius R of 10,000 mm or less.
Moreover, a reinforcing layer having a thickness of 0.1 to 4 mm can be further provided outside the back surface protective layer.
The thin solar cell module of the present invention can be placed, installed or mounted on a vehicle.

  According to the present invention, by using a hard resin, it is possible to provide a thin solar cell module having high long-term reliability and high flexibility that can follow a three-dimensional curved surface.

The schematic diagram of one embodiment of the solar cell module of this invention. The schematic diagram of one embodiment of the solar cell module of this invention. The schematic diagram of one embodiment of the solar cell module of this invention. The schematic diagram of one embodiment of the solar cell module of this invention. The schematic diagram of one embodiment of the solar cell module of this invention. The schematic diagram of one embodiment of the solar cell module of a comparative example.

Embodiments of the solar cell module of the present invention will be specifically described below.
The solar cell module of the present invention has a photoelectric conversion layer sequentially laminated between a front surface protective layer and a back surface protective layer. The solar cell module can be provided at a low cost by using a resin substrate instead of a glass substrate as the surface protective layer and the back surface protective layer. A solar cell module using such a resin substrate is generally manufactured by thermal lamination. In the solar cell module of the present invention, the surface protective layer and the back surface protective layer, which are resin substrates having a specific range of thickness, and the sealing material layer having a specific thickness are rigid and have high sealing performance, In addition, a highly flexible thin solar cell module capable of maintaining a shape such as a three-dimensional curved surface can be provided.

<Surface protective layer>
The surface protective layer of the present invention is a layer for imparting mechanical strength, weather resistance, scratch resistance, chemical resistance, gas barrier properties and the like to the solar cell module. A hard resin is used as the surface protective layer. In general, reducing the thickness of the entire solar cell module causes a problem of a decrease in hermeticity. However, in the present invention, a hard resin having a glass transition temperature of 20 to 200 ° C. is used for the surface protective layer, and the flexibility is high. A solar cell module with high strength can be obtained. In the present invention, the hard resin refers to a resin having a tensile elastic modulus (JIS K7161,7162: 1994) of 0.5 GPa or more, preferably 1 GPa or more. In addition, although the upper limit of the said tensile elasticity modulus is not specifically limited, Usually, it is 50 GPa or less, Preferably it is 10 GPa or less. From the viewpoint of supplying a large amount of sunlight to the photoelectric conversion layer, the total light transmittance of the surface protective layer is 80% or more, preferably 90% or more. The measuring method of a total light transmittance is based on JISK7361-1, for example.

  Examples of the hard resin used for the surface protective layer include polycarbonate (PC), polymethyl methacrylate (PMMA), cyclic polyolefin, polystyrene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyvinyl chloride, and ethylene-tetrafluoro. Examples thereof include ethylene copolymer (ETFE), polytetrafluoroethylene (PTFE), polypropylene (PP), and polyethylene (PE). Preferably, polyethylene terephthalate (PET), polyethylene (PE), polycarbonate (PC) resin, polymethyl methacrylate (PMMA), ethylene-tetrafluoroethylene copolymer (ETFE), etc. are mentioned.

  In the surface protective layer of the present invention, the hard resin can be used alone, but two or more resins can be laminated and used. When two or more resins are laminated and used, any hard resin can be selected. However, when two or more hard resins are laminated, an adhesive layer (primer layer) is used between the resins. Is preferred. For example, it can be used by laminating from the surface like a polyethylene terephthalate (PET) layer, a primer layer, and a polyethylene (PE) layer. The material of the adhesive layer (primer layer) is not particularly limited, but usually, for example, an ethylene-vinyl acetate copolymer (EVA) resin, a polyvinyl butyral (PVB) resin, a modified polyethylene resin modified with maleic acid or silane, etc. A light transmissive material such as a polypropylene resin, an acrylic adhesive, an epoxy adhesive, or a urethane adhesive is used. The primer layer preferably has a sheet shape of 1 to 50 μm.

The method for obtaining these resins is not particularly limited, and commercially available products can be used. For example, polyethylene terephthalate (PET) includes Novapex manufactured by Mitsubishi Chemical Corporation, and polyethylene (PE) includes Novatec, kernel manufactured by Nippon Polyethylene Co., Ltd. Examples of polycarbonate include polycarbonate plates manufactured by Takiron Co., Ltd., Iupilon manufactured by Mitsubishi Engineering Plastics Co., Ltd., and polymethyl methacrylate such as acrylite manufactured by Mitsubishi Rayon Co., Ltd. and Sumipex manufactured by Sumitomo Chemical Co., Ltd. Examples of the resin in which polyethylene terephthalate (PET), a primer layer, and polyethylene (PE) are laminated include a hot laminate film GOLI FILM manufactured by Lamy Corporation.

  The thickness of the surface protective layer is 1 to 100 μm. Preferably it is 10-80 micrometers, More preferably, it is 20-50 micrometers. If the thickness is less than 1 μm, the tear strength tends to decrease, and if it exceeds 100 μm, the flexibility tends to decrease. If the surface protective layer becomes too thick, it is not preferable because the flexibility of the resin layer is reduced and the weight of the module is increased.

  Moreover, the magnitude | size of the laminated surface of a surface protective layer should just have an area larger than the laminated surface of the photoelectric converting layer which has the photovoltaic cell mentioned later normally. The area of the lamination surface here means the area of the surface perpendicular to the thickness direction of the surface protective layer. A photoelectric conversion layer can fully be protected because the area of the lamination surface of a surface protective layer is larger than the area of the lamination surface of a photoelectric conversion layer.

  The hard resin used for the surface protective layer has a glass transition temperature (Tg) of 20 to 200 ° C, preferably 40 to 170 ° C, more preferably 60 to 150 ° C. When Tg is in the above range, the solar cell module has an appropriate flexibility during lamination and excellent workability. The glass transition point Tg is measured by DSC measurement.

The hard resin used for the surface protective layer usually has a weight average molecular weight (Mw) of 10,000 or more. The upper limit is 70,000 or less, and preferably 20,000 or less. The weight average molecular weight in the present invention is determined by SEC (size exclusion chromatography) measurement. In SEC measurement, the elution time is shorter for higher molecular weight components and the elution time is longer for lower molecular weight components, but using the calibration curve calculated from the elution time of polystyrene (standard sample) with a known molecular weight, the elution time of the sample is changed to the molecular weight. The weight average molecular weight is calculated by conversion.

In the case where the surface protective layer is used by laminating resins, it is preferable that all of the resins used satisfy the conditions of the glass transition temperature (Tg) and the weight average molecular weight (Mw).
Moreover, it is preferable that the whole surface protective layer formed by lamination satisfies the condition of the tensile elastic modulus.

  Moreover, in the solar cell module of this invention, it is preferable to have an outermost layer further on the outer side (sunlight side) of a surface protective layer. In the present invention, it is preferable to provide the outermost layer in order to suppress damage and deterioration of the surface protective layer and maintain the total light transmittance. The material constituting the outermost layer is preferably a weather-resistant film containing a UV absorber, a radical scavenger, an antioxidant and the like, and commonly used known materials can be used.

  Examples of the resin used as a material for the weather resistant film include polyvinyl chloride, polyolefin, ethylene-tetrafluoroethylene copolymer, silicone, polyethylene terephthalate, weather resistant polyethylene terephthalate, and polyamide. Among these, polyvinyl chloride, polyolefin, and weather resistant polyethylene terephthalate are preferable.

  The thickness of the outermost layer is usually 1 to 100 μm, preferably 5 to 70 μm, and more preferably 10 to 50 μm.

  Moreover, since a solar cell module is heated by sunlight, it is preferable that the outermost layer has heat resistance. Therefore, the constituent material of the outermost layer preferably has a melting point of 100 ° C. or higher, and more preferably 120 ° C. or higher. On the other hand, the upper limit of the melting point is preferably 320 ° C. or lower.

  An adhesive layer (primer layer) may be provided between the outermost layer and the surface protective layer. The material of the adhesive layer (primer layer) is not particularly limited, but usually, for example, an ethylene-vinyl acetate copolymer (EVA) resin, a polyvinyl butyral (PVB) resin, a modified polyethylene resin modified with maleic acid or silane, etc. A light transmissive material such as a polypropylene resin, an acrylic adhesive, an epoxy adhesive, or a urethane adhesive is used. The primer layer preferably has a sheet shape of 1 to 50 μm.

<Photoelectric conversion layer>
The photoelectric conversion layer is a layer having solar cells that can directly convert light energy into electric power, and is usually formed by connecting a plurality of solar cells with a collector line or the like. Electricity generated in the solar battery cell can be taken out via an external converter through a collector line.

  As a solar cell element, a silicon solar cell element such as a single crystal silicon solar cell element, a polycrystalline silicon solar cell element, an amorphous silicon solar cell element, a microcrystalline silicon solar cell element, a spherical silicon solar cell element, or the like is used. Can do. Moreover, compound solar cell elements, such as a CIS type solar cell element, a CIGS type solar cell element, and a GaAs type solar cell element, can also be adopted. Further, a dye-sensitized solar cell element, an organic thin film solar cell element, a multi-junction solar cell element, a HIT solar cell element, or the like may be employed.

  For example, a commercially available silicon-based solar cell element may be used, and examples thereof include solar cells manufactured by Q-Cells, First Solar, Suntech, Sharp, Shinsung, and Gintech.

Each electrode of the element of the solar battery cell can be formed using one or more arbitrary materials having conductivity. Examples of the electrode material (electrode constituent material) include metals such as platinum, gold, silver, aluminum, chromium, nickel, copper, titanium, magnesium, calcium, barium, sodium, and alloys thereof; indium oxide and tin oxide Metal oxides such as, or alloys thereof (ITO: indium tin oxide); conductive polymers such as polyaniline, polypyrrole, polythiophene, polyacetylene; acids such as hydrochloric acid, sulfuric acid, sulfonic acid, Lewis acids such as FeCl ₃ , halogen atoms such as iodine, sodium,
Examples include those containing a dopant such as a metal atom such as potassium; conductive composite materials in which conductive particles such as metal particles, carbon black, fullerene, and carbon nanotubes are dispersed in a matrix such as a polymer binder.
The thickness of each electrode and the thickness of the photoelectric conversion layer can be determined based on the required output and the like.

  Further, an auxiliary electrode may be provided so as to be in contact with the electrode. In particular, it is effective when using a slightly conductive electrode such as ITO. As the auxiliary electrode material, the same material as the above metal material can be used as long as the conductivity is good, but silver, aluminum, and copper are exemplified.

  The linear expansion coefficient at −30 to 30 ° C. of the photoelectric conversion layer is preferably 40 ppm / K or less, more preferably 35 ppm / K or less, and particularly preferably 30 ppm / K or less. The linear expansion coefficient is measured by, for example, ASTM D696. When the linear expansion coefficient exceeds 40 ppm / K, deformation due to temperature change is large, so that it tends to break down under heating / cooling processes or actual use conditions. On the other hand, the lower limit is not particularly limited, but is usually 1 ppm / K or more and preferably 3 ppm / K or more.

<Back side protective layer>
As the back surface protective layer of the solar cell module of the present invention, a hard resin is used similarly to the surface protective layer.
As such hard resin, for example, polycarbonate (PC) resin, polymethyl methacrylate (PMMA), glass epoxy multilayer material, fiber reinforced plastic (FRP), cyclic polyolefin, polyolefin (polyethylene, polypropylene, etc.) or a modified product thereof, Examples include polystyrene, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyimide (PI), and polyamide (PA). Preferred examples include polyethylene terephthalate (PET), polyethylene (PE) or a modified product thereof, polypropylene (PP) or a modified product thereof, polycarbonate (PC) resin, polymethyl methacrylate (PMMA), and a glass epoxy multilayer material.

  The hard resin used for the back surface protective layer may be the same as or different from the resin for the surface protective layer, but it is preferable to use the same resin. The resin used for the back surface protective layer can be used by laminating two or more hard resins, similarly to the resin used for the surface protective layer. Even when two or more hard resins are laminated, the same hard resin as the surface protective layer can be used.

  The thickness of the back surface protective layer is 1 to 100 μm. Preferably it is 10-80 micrometers, More preferably, it is 20-50 micrometers. When the thickness is less than 1 μm, the moisture permeability tends to be lowered and the durability as a module tends to be lowered. When the thickness exceeds 100 μm, the flexibility as a module tends to be lowered. If the back surface protective layer is too thick, the flexibility of the resin layer is reduced and the weight of the module is increased.

The thickness of the back surface protective layer is preferably the same as that of the front surface protective layer. The preferred ranges of the glass transition temperature (Tg), weight average molecular weight, and tensile elastic modulus of the hard resin of the back surface protective layer are the same as those of the hard resin of the surface protective layer.

  In the back surface protective layer, the conditions of the glass transition temperature (Tg), the weight average molecular weight (Mw), and the tensile elastic modulus when the hard resin is laminated and used are the same as those of the surface protective layer.

<Reinforcing layer>
The solar cell module of this invention can provide a reinforcement layer in the outer side of a back surface protective layer. The thickness of the reinforcing layer is usually 0.1 to 4 mm, preferably 0.2 to 2 mm. As the material of such a reinforcing layer, a galvalume steel plate, an aluminum plate, a glass plate, glass fiber reinforced epoxy resin (GFRP), carbon fiber reinforced epoxy resin (CFRP), or the like can be used. A normal adhesive can be used for adhesion between the back surface protective layer and the reinforcing layer.

<Encapsulant layer>
The photoelectric conversion layer in the solar cell module is usually provided with a sealing material layer so as to cover the photoelectric conversion layer for the purpose of sealing the photoelectric conversion layer and the like. Since the sealing material layer is disposed so as to cover the photoelectric conversion layer, it is disposed between the surface protective layer and the photoelectric conversion layer and between the back surface protective layer and the photoelectric conversion layer. When forming a battery module, it is preferable that a sealing material layer is provided so that the said photoelectric converting layer may be included. Here, the inclusion means that the end portion of the photoelectric conversion layer is not exposed from the end portion of the sealing material layer in the solar cell module.

  The material of these sealing material layers is not particularly limited as long as it is a synthetic resin material that transmits sunlight, and a known and commonly used material can be used. For example, ethylene-vinyl acetate copolymer (EVA) resin, polyvinyl butyral (PVB) resin, modified polyethylene resin modified with maleic acid or silane, modified polypropylene resin, epoxy adhesive, urethane adhesive, etc. are used. be able to.

  The thickness of the sealing material layer is 1 to 100 μm, preferably 5 to 80 μm, and more preferably 10 to 60 μm. By setting the thickness of the sealing material layer within the above range, moderate impact resistance can be obtained, which is preferable from the viewpoint of cost and weight, and power generation characteristics can be sufficiently exhibited.

<Electrical insulation layer>
The solar cell module of the present invention can further be provided with an electrical insulating layer. The electrical insulating layer is not particularly limited as long as it is a material that is difficult to conduct electricity. By providing such an electrical insulating layer, it is possible to prevent electricity generated in the photoelectric conversion layer from escaping from the outside of the collector line, so that the power generation efficiency of the solar cell is improved.

  As the electrical insulating layer, for example, a fluorine resin such as ETFE (a copolymer of tetrafluoroethylene and ethylene), PET, or the like can be used. Note that the arrangement position of the electrical insulating layer is not particularly limited, but in the case where the electric insulating layer is arranged on the light receiving surface side with respect to the photoelectric conversion layer, it is necessary to use a material having high light transmittance.

The thickness of the electrical insulating layer is not particularly limited, but is usually 10 μm or more, preferably 25 μm or more, more preferably 50 μm or more. On the other hand, the upper limit is usually 500 μm or less, preferably 300 μm or less.
In addition to these layers, a gas barrier layer, an ultraviolet cut layer, a weather resistant protective layer, a scratch resistant layer, an antifouling layer, and other known constituent members may be laminated.

<Method for manufacturing solar cell module>
The solar cell module production method of the present invention may be a known method. For example, a multilayer sheet including a surface protective layer, a sealing material layer, a photoelectric conversion layer, a sealing material layer, a back surface protective layer, and the like is subjected to vacuum lamination. A solar cell module can be obtained by placing in the apparatus, heating after evacuation, and cooling after elapse of a certain time. Moreover, the solar cell module of the present invention is laminated in the order of, for example, the outermost layer, the adhesive layer, the surface protective layer, the sealing material layer, the photoelectric conversion layer, the sealing material layer, and the back surface protective layer from the sunlight receiving surface side. Can also be obtained as described above.

The heat laminating conditions are not particularly limited, and heat laminating is possible under normal conditions.
It is preferably performed under vacuum conditions, and the degree of vacuum is usually 30 Pa or more, preferably 50 Pa or more, more preferably 80 Pa or more. On the other hand, the upper limit is usually 150 Pa or less, preferably 120 Pa or less, more preferably 100 Pa or less. By setting it as the said range, since generation | occurrence | production of a bubble can be suppressed in each layer in a module, and productivity improves, it is preferable.

  The vacuum time is usually 1 minute or longer, preferably 2 minutes or longer, more preferably 3 minutes or longer. On the other hand, the upper limit is usually 8 minutes or less, preferably 6 minutes or less, more preferably 5 minutes or less. Setting the vacuum time in the above range is preferable because the appearance of the solar cell module after heat lamination becomes good and the generation of bubbles in each layer in the module can be suppressed.

  The pressurizing condition of the thermal laminate is usually a pressure of 50 kPa or more, preferably 70 kPa or more, more preferably 90 kPa or more. On the other hand, the upper limit value is preferably 101 kPa or less. By setting it as the pressurization conditions of the said range, since moderate adhesiveness can be acquired, without damaging a solar cell module, it is preferable also from a durable viewpoint.

  The holding time of the pressure is usually 1 minute or longer, preferably 3 minutes or longer, more preferably 5 minutes or longer. On the other hand, the upper limit is usually 30 minutes or less, preferably 20 minutes or less, more preferably 15 minutes or less. Since the gelling rate of the encapsulant layer can be made appropriate by setting the above holding time, the function of protecting the power generation element of the encapsulant layer can be sufficiently exerted, and sufficient adhesive strength can be obtained. Can be obtained.

The temperature condition of the heat laminate is usually 100 ° C. or higher, preferably 110 ° C. or higher, more preferably 120 ° C. or higher. On the other hand, the upper limit is usually 180 ° C. or lower, preferably 160 ° C. or lower, more preferably 150 ° C. or lower. By setting the temperature range, sufficient adhesive strength can be obtained.
Moreover, the heating time of the said temperature is 10 minutes or more normally, Preferably it is 12 minutes or more, More preferably, it is 15 minutes or more. On the other hand, the upper limit is 60 minutes or less, preferably 45 minutes or less, more preferably 30 minutes or less. By setting it as the said heating time, since durability of a sealing material is bridge | crosslinked moderately and it can have moderate softness | flexibility, it is preferable.

  The solar cell module of the present invention can be used by being curved. Although it does not specifically limit as a method of making it curve, For example, the method of making it curve by heating is mentioned. Further, the solar cell module of the present invention can have a minimum radius of curvature R at the time of bending of 10,000 mm or less, preferably 5,000 mm or less, and can be bent not only in one axis direction but also in two axis directions. Is possible. The lower limit of the minimum curvature radius is not particularly limited, but is usually 50 mm or more, preferably 500 mm or more.

  In order to bend a thick and hard module, it is necessary to bend it at high temperature and high pressure for a long time, and the production efficiency is poor and the shape once formed cannot be held for a long time and gradually flattened. There was a problem of becoming. In the present application, a thin solar cell module having a thickness of 100 to 600 μm that uses a specific hard resin for the front surface protective layer and the back surface protective layer can be easily bent, and the curved shape can be maintained for a long time. It became so.

  The solar cell module of the present invention thus obtained has impact resistance that suppresses the destruction of solar cells despite being thin and lightweight, and also has a function that suppresses deflection and vibration. Therefore, it can be mounted, installed or mounted on a vehicle such as a truck.

<Example 1>
The solar cell module shown in FIG. 1 was manufactured. In particular,
(1) Sealing film (hot) having a total thickness of 100 μm (sealing material layer thickness 40 μm) composed of polyethylene terephthalate (PET) layer / primer layer / polyethylene (PE) layer / ethylene-vinyl acetate copolymer (EVA) layer Laminated film GOLI FILM, thickness 100μm, manufactured by Lamy Corporation: PET glass transition temperature 69 ° C, tensile modulus 4GPa)
(2) A photoelectric conversion element having a thickness of 50 μm (a polyethylene naphthalate having a thickness of 50 μm (PEN; Young's modulus at 25 ° C. is 1000 MPa) is used as a power generation element substrate, a bottom electrode and an amorphous silicon layer are deposited, and a current collecting electrode is further formed. (3) PET layer / primer layer / PE layer / EVA layer with a current collector (made of 97Sn3Ag coated Cu; with conductive adhesive; total thickness 100 μm) for extracting electric power to the outside (patterned) Sealing film (GOLI FILM, thickness 100μm, manufactured by Lamy Corporation) with a total thickness of 100μm (sealing material layer thickness 40μm)
These are laminated so that the EVA side is in contact with the photoelectric conversion element, and a vacuum laminator (LM-50 × 50-S) manufactured by NPC is used, and heat lamination is performed at 120 ° C. (vacuum degree: 80 Pa, vacuum time: 5). Minutes, pressurization: 100 kPa, pressurization holding time: 5 minutes, heating and holding time: 20 minutes) to produce a solar cell module 1. It was confirmed that the end portion of the photoelectric conversion layer was not exposed from the module and was included in the sealing material layer. The thickness of the solar cell module 1 was 250 μm at the center.

<Example 2>
The solar cell module shown in FIG. 2 was manufactured. Specifically, a weather-resistant film having a total thickness of 110 μm made of polyvinyl chloride (thickness 80 μm) / acrylic adhesive (thickness 30 μm) is further provided on the light-receiving surface side of the solar cell module produced in the same manner as in Example 1. (Cold laminate film: PVG-80G, manufactured by Lamy Corporation) was laminated so that the pressure-sensitive adhesive layer and the light-receiving surface side of the solar cell module were in close contact with each other, thereby producing a solar cell module 2. The thickness of the solar cell module 2 was 360 μm at the center.

<Example 3>
The solar cell module shown in FIG. 3 was manufactured. Specifically, a polyolefin film # 80 (thickness 80 μm) is further formed on the light-receiving surface side of the solar cell module produced in the same manner as in Example 1.
) / Acrylic pressure-sensitive adhesive L-100 (thickness 25 μm) with a total thickness of 105 μm weather resistance film (NE-tak overlaminate film, pure gloss, manufactured by Lamy Corporation), the pressure-sensitive adhesive layer and the light-receiving surface side of the solar cell module The solar cell module 3 was fabricated by stacking so as to be in close contact with each other. The thickness of the solar cell module 3 was 355 μm at the center.

<Example 4>
The solar cell module shown in FIG. 4 was manufactured. Specifically, on the light-receiving surface side of the solar cell module produced in the same manner as in Example 1, a total thickness of 80 μm made of weather resistant polyethylene terephthalate (thickness 50 μm) / acrylic adhesive S-920 (thickness 30 μm) is further provided. The solar cell module 4 was prepared by superimposing the weather-resistant film (NE-tak overlaminate film UTL-50 gloss bias, manufactured by Lamy Corporation) so that the adhesive layer and the light-receiving surface side of the solar cell module were in close contact with each other. The thickness of the solar cell module 4 was 330 μm at the center.

<Example 5>
When the solar cell modules 1 to 4 manufactured in Examples 1 to 4 are heated and curved with a curvature radius of 1,755 mm so that the light receiving surface side is convex, curved solar cell modules 5 to 8 are manufactured. , Both can be curved into a prescribed curvature shape, and the shape was maintained after 6 months.

<Example 6>
The solar cell module shown in FIG. 5 was manufactured. Specifically, the solar cell module 1 produced in Example 1 was adhered to a steel plate having a thickness of 0.6 mm using an adhesive (Cemedine Super X manufactured by Cemedine Co., Ltd.) to produce a solar cell module 9. The steel plate and the solar cell module 1 were firmly integrated, and a lightweight and highly rigid steel plate with solar cells was obtained.

<Example 7>
The solar cell modules 5 to 8 produced in Example 5 were bonded to an aluminum plate having a thickness of 0.4 mm, which was curved in the same manner as the solar cell modules 5 to 8, using an adhesive (Cemedine Super X manufactured by Cemedine). Solar cell modules 10 to 13 were produced. The curved aluminum plate and the solar cell modules 5 to 8 were firmly integrated, and a lightweight and highly rigid aluminum plate with a solar cell was obtained.

<Comparative Example 1>
The solar cell module shown in FIG. 6 was manufactured. In particular,
(1) PET (thickness 100 μm; manufactured by Mitsubishi Plastics, Inc., T680E)
(2) EVA (thickness 300 μm; manufactured by CI Kasei Co., Ltd., UFCCE20)
(3) A photoelectric conversion element having a thickness of 50 μm (a polyethylene naphthalate having a thickness of 50 μm (PEN; Young's modulus at 25 ° C. is 1000 MPa) is used as a power generation element substrate, a bottom electrode and an amorphous silicon layer are deposited, and a current collecting electrode is further formed. (4) EVA (thickness 300 μm; sea eye) with a current collector (solder-covered copper wire; with conductive adhesive (3M # 9703); total thickness 100 μm) for extracting power to the outside (patterned) Kasei Co., Ltd., UFCCE20)
(5) PET (thickness 100 μm; manufactured by Mitsubishi Plastics, T680E)
These are laminated one after another, and an NPC vacuum laminator (LM-50 × 50-S) is used, and heat lamination is performed at 130 ° C. (vacuum degree: 80 Pa, vacuum time: 5 minutes, pressure: 100 kPa, applied) Pressure holding time: 5 minutes, heating holding time: 55 minutes) to produce a solar cell module 14. The thickness of the solar cell module 14 was 750 μm at the center.

<Comparative example 2>
While the solar cell module 14 manufactured in Comparative Example 1 was heated and curved with a curvature radius of 1,755 mm so that the light receiving surface side was convex, the curved solar cell module 15 was manufactured. It could not be formed.

DESCRIPTION OF SYMBOLS 1 PET layer 2 Primer layer 3 PE layer 4 EVA layer 5 Photoelectric conversion layer 6 Acrylic adhesive 71 Polyvinyl chloride layer 72 Polyolefin layer 73 Weatherproof PET layer 8 Adhesive 9 Steel plate

Claims (7)

  A thin solar cell module having a thickness of 100 to 600 μm, which is formed by laminating a sealing material layer, a photoelectric conversion layer, and a sealing material layer in this order between a surface protective layer and a back surface protective layer, the surface protection layer The layer and the back surface protective layer are each a hard resin having a thickness of 1 to 100 μm and a glass transition temperature of 20 to 200 ° C. The photoelectric conversion layer is included in the sealing material layer, and the sealing material A thin solar cell module, wherein each layer has a thickness of 1 to 100 μm.   The thin solar cell module according to claim 1, further comprising an outermost layer having a thickness of 1 to 100 μm outside the surface protective layer.   The thin solar cell module according to claim 2, further comprising an adhesive layer between the surface protective layer and the outermost layer.   The thin solar cell module according to claim 3, wherein the outermost layer, the adhesive layer, the surface protective layer, the sealing material layer, the photoelectric conversion layer, the sealing material layer, and the back surface protective layer are laminated in this order from the sunlight receiving surface side. .   The thin solar cell module according to any one of claims 1 to 4, wherein the minimum curvature radius R is 10,000 mm or less, and the biaxial direction is curved.   The thin solar cell module according to any one of claims 1 to 5, further comprising a reinforcing layer having a thickness of 0.1 to 4 mm outside the back surface protective layer.   A vehicle on which the thin solar cell module according to any one of claims 1 to 6 is mounted, installed, or mounted.