Solar battery module and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-9960313-B2
Application number	US-201715603452-A
Country	US
Kind code	B2
Filing date	May 24, 2017
Priority date	Jan 31, 2011
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

A solar battery module and manufacturing method for a solar battery module having improved output are provided. The solar battery module 1 is a transparent substrate 10 , transparent resin layer 13 b , solar battery cell 12 , colored resin layer 13 a and back sheet 11 laminated in this order. The light-receiving surface 12 a of the solar battery cell 12 faces the transparent resin layer 13 b side. The backside 12 b of the solar battery cell faces the colored resin layer 13 a . The MFR [melt flow rate] of the transparent resin layer 13 b is lower than the MFR of the colored resin layer 13 a.

First claim

What is claimed is:

1. A manufacturing method for a solar battery module, the method comprising:
forming a laminate of a transparent substrate, a transparent resin sheet, a solar battery cell unit, a colored resin sheet, and a back sheet in this order a light receiving surface of the solar battery cell unit facing the transparent resin sheet; and
heating the laminate, wherein
a melt flow rate, MFR, of the transparent resin sheet is lower than an MFR of the colored resin sheet,
a resin of the transparent resin sheet consists of copolymers of ethylenically unsaturated silane compounds and α-olefins, and
a resin of the colored resin sheet consists of at least one selected from the group consisting of ethylene-vinyl acetate copolymers, ethylene-ethyl acrylate copolymers, silicone resins, epoxy resins, polyvinyl butyral, ethylene vinyl alcohol copolymers, acrylic resins, polyethylene, and polypropylene.

2. The manufacturing method for a solar battery module according to claim 1 , wherein the MFR of the transparent resin sheet is lower than the MFR of the colored resin sheet by 0.7 g/10 min. or more.

3. The manufacturing method for a solar battery module according to claim 1 , wherein the MFR of the transparent resin sheet is lower than the MFR of the colored resin sheet by 1.0 g/10 min. or more.

4. The manufacturing method for a solar battery module according to claim 1 , wherein
the transparent substrate is a glass plate or a resin sheet, and
the back sheet is a resin sheet having a thickness that ranges between 150 μm and 300 μm.

5. The manufacturing method for a solar battery module according to claim 1 , wherein
the heating the laminate comprises:
deforming the transparent resin sheet such that a thickness of the transparent resin sheet at each of edges thereof is smaller than a thickness of the transparent resin sheet at a center portion thereof by causing the resin of the transparent resin sheet at the each of edges thereof to flow towards the center portion thereof; and
deforming the colored resin sheet such that a thickness of the colored resin sheet at each of edges thereof is smaller than a thickness of the colored resin sheet at a center portion thereof by causing the resin of the colored resin sheet at the each of edges thereof to flow towards the center portion thereof.

6. The manufacturing method for a solar battery module according to claim 1 , wherein
in the forming the laminate, the solar battery cell unit comprises solar battery cell strings that are electrically connected to each other, each solar battery cell string comprising solar battery cells that are electrically connected by wiring material.

7. The manufacturing method for a solar battery module according to claim 1 , wherein the colored resin sheet comprises at least one colorant selected from the group consisting of titanium oxide particles, calcium carbonate particles, ultramarine, carbon black, and light-scattering material.

8. The manufacturing method for a solar battery module according to claim 7 , wherein the light-scattering material comprises glass beads.

9. A manufacturing method for a solar battery module, the method comprising:
forming a laminate of a transparent substrate, a transparent resin sheet, a solar battery cell unit, a colored resin sheet, and a back sheet in this order a light receiving surface of the solar battery cell unit facing the transparent resin sheet; and
heating the laminate, wherein
in the heating the laminate, a viscosity of the colored resin sheet is lower than a viscosity of the transparent resin sheet,
a resin of the transparent resin sheet consists of copolymers of ethylenically unsaturated silane compounds and α-olefins, and
a resin of the colored resin sheet consists of at least one selected from the group consisting of ethylene-vinyl acetate copolymers, ethylene-ethyl acrylate copolymers, silicone resins, epoxy resins, polyvinyl butyral, ethylene vinyl alcohol copolymers, acrylic resins, polyethylene, and polypropylene.

10. The manufacturing method for a solar battery module according to claim 9 , wherein
the transparent substrate is a glass plate or a resin sheet, and
the back sheet is a resin sheet having a thickness that ranges between 150 μm and 300 μm.

11. The manufacturing method for a solar battery module according to claim 9 , wherein
the heating the laminate comprises:
deforming the transparent resin sheet such that a thickness of the transparent resin sheet at each of edges thereof is smaller than a thickness of the transparent resin sheet at a center portion thereof by causing the resin of the transparent resin sheet at the each of edges thereof to flow towards the center portion thereof; and
deforming the colored resin sheet such that a thickness of the colored resin sheet at each of edges thereof is smaller than a thickness of the colored resin sheet at a center portion thereof by causing the resin of the colored resin sheet at the each of edges thereof to flow towards the center portion thereof.

12. The manufacturing method for a solar battery module according to claim 9 , wherein
in the forming the laminate, the solar battery cell unit comprises solar battery cell strings that are electrically connected to each other, each solar battery cell string comprising solar battery cells that are electrically connected by wiring material.

13. The manufacturing method for a solar battery module according to claim 9 , wherein the colored resin sheet comprises at least one colorant selected from the group consisting of titanium oxide particles, calcium carbonate particles, ultramarine, carbon black, and light-scattering material.

14. The manufacturing method for a solar battery module according to claim 13 , wherein the light-scattering material comprises glass beads.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Maeda Masanori

Classifications

• B32B17/10798

  containing silicone · CPC title

• B32B17/10761

  containing vinyl acetal · CPC title

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• B32B17/10651

  comprising colorants, e.g. dyes or pigments · CPC title

• B32B17/10018

  comprising only one glass sheet · CPC title