Solar cell module excelling in reliability

Details Solar cell module excelling in reliability Solar cell module excelling in reliability

1999-04-21

2001-01-16

Dye, Rena L. (Department: 1772)

Batteries: thermoelectric and photoelectric

Photoelectric

Panel or array

C136S244000, C136S259000

Reexamination Certificate

active

06175075

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a highly reliable solar cell module and a process for said solar cell module.
2. Related Background Art
Japanese Unexamined Patent Publication No. 36404/1997 discloses a photovoltaic element having a configuration as shown in FIGS.
2
(
a
) and
2
(
b
) FIG.
2
(
a
) is a schematic plan view, viewed from a light receiving face side of the photovoltaic element, and FIG.
2
(
b
) is a schematic cross-sectional view, taken along the A—A′ line in FIG.
2
(
a
). Particularly, in FIGS.
2
(
a
) and
2
(
b
), reference numeral
201
indicates a semiconductor element (or a photovoltaic element) whose light receiving face side comprises a power generation region with an upper electrode layer
201
′ provided on a semiconductor layer (not shown) and a peripheral non-power generation region which is free of said upper electrode layer. On each of the opposite end portions of the non-power generation region, an insulating adhesive body
202
is arranged while being fixed thereto. Reference numeral
203
indicates a collecting electrode comprising a plurality of wires arranged on the power generation region at an equal interval to extend onto the insulating adhesive bodies
202
in the non-power generation region such that their opposite end portions are situated on the insulating adhesive bodies
202
. Reference numeral
204
indicates a positive electrode terminal member which is contact-bonded on each adhesive body
202
having the extended end portions of the wires as the collecting electrode
203
situated thereon so as to have electrical connection with the wires as the collecting electrode. Reference numeral
205
indicates a negative electrode terminal member which is fixed to the back face of the photovoltaic element so as to have electrical connection by way of soldering, laser beam welding, or ultrasonic welding.
FIG. 3
is a schematic cross-sectional view illustrating an example of a photovoltaic element string comprising a plurality of photovoltaic elements having such configuration as shown in FIGS.
2
(
a
) and
2
(
b
) which are electrically connected with each other in series. Particularly,
FIG. 3
is a schematic cross-sectional view illustrating the constitution of a given, serialized portion of said photovoltaic element string in which a photovoltaic elements
301
(a semiconductor element) and a photovoltaic element
311
(a semiconductor element) are serialized. Specifically, a positive electrode terminal
304
which is electrically connected with a collecting electrode
303
on an insulating adhesive body
302
arranged on a peripheral non-power generation region of a photovoltaic element
301
is extended outside the photovoltaic element
301
and it is electrically connected to a negative electrode terminal
315
arranged at a back face of an adjacent photovoltaic element
311
by means of a solder
306
, whereby the photovoltaic element
301
and the photovoltaic element
311
are connected in series. Reference numeral
307
indicates a filler resin which fills the spaces between the two elements while enclosing them. Reference numeral
305
indicates a negative electrode terminal, reference numeral
312
an insulating adhesive body, reference numeral
313
a collecting electrode, and reference numeral
314
a positive electrode terminal.
FIG. 5
is a schematic view illustrating an embodiment of sealing a photovoltaic element string by laminating a plurality of lamination materials to produce a solar cell module by a vacuum lamination method. In
FIG. 5
, reference numeral
501
indicates a photovoltaic element string comprising a plurality of photovoltaic elements electrically connected with each other, for instance, as shown in FIG.
3
. Reference numeral
502
indicates a back side nonwoven glass fiber member which is arranged on the back face side of the photovoltaic element string
501
, reference numeral
503
is a surface side nonwoven glass fiber member which is arranged on the light receiving face side of the photovoltaic element string
501
, reference numeral
504
is a surface side filler resin, reference numeral
505
is a surface protective film, reference numeral
506
is a back side filler resin, reference numeral
507
is an insulating film, and reference numeral
508
is a back face reinforcing member. The back side nonwoven glass fiber member
502
is used in order to foster deaeration in the back face side of the photovoltaic element string
501
and is also used as a spacer in order to ensure electrical insulation of the photovoltaic element string. The surface side nonwoven glass fiber member
503
is used in order to foster deaeration in the light receiving face side of the photovoltaic element string
501
and also in order to attain an improved surface protective performance in the light receiving face side of the photovoltaic element string.
FIG. 7
[comprising FIGS.
7
(
a
) to
7
(
c
)] and
FIG. 8
[comprising FIGS.
8
(
a
) to
8
(
c
)] are schematic top views respectively illustrating an example of a conventional crystalline series photovoltaic element string comprising a plurality of crystalline series photovoltaic element having a small area which are electrically serialized with each other.
FIG. 7
[FIGS.
7
(
a
) to
7
(
c
)] and
FIG. 8
[FIGS.
8
(
a
) to
8
(
c
)] are top views respectively of a horizontal cross section.
Particularly, FIG.
7
(
a
) shows a crystalline series photovoltaic element
701
shaped as a square 100 mm×100 mm in size, and FIG.
7
(
b
) shows a crystalline series photovoltaic element string comprising a plurality of the photovoltaic elements
701
which are spaced at an equal interval of 1.5 mm while being electrically connected with each other in series. In the case of the photovoltaic element string shown FIG.
7
(
b
), as shown in FIG.
7
(
c
), when the area of a given photovoltaic element (a) is A and a sum of the clearances (hatched by oblique lines) between said photovoltaic element (a) and adjacent photovoltaic elements (b) arranged next to the photovoltaic element (a) is B, the ratio of B/A is about 0.061.
FIG.
8
(
a
) shows a crystalline series photovoltaic element
801
shaped in as a square 100 mm×100 mm in size with four corners cut off, and FIG.
8
(
b
) shows a crystalline series photovoltaic element string comprising a plurality of the photovoltaic elements
801
which are spaced at an equal interval of 2 mm with respect to the lateral arrangement and at an equal interval of 5 mm with respect to the longitudinal arrangement while being electrically connected with each other in series. In the case of the photovoltaic element string shown FIG.
8
(
b
), as shown in FIG.
8
(
c
), when the area of a given photovoltaic element (a) is A and a sum of the clearances (hatched by oblique lines) between said photovoltaic element (a) and adjacent photovoltaic elements (b) arranged next to the photovoltaic element (a) is B, the ratio of B/A is about 0.157.
By the way, a solar cell module is usually prepared by a vacuum lamination method comprising the steps of stacking at least a resin sheet as a lamination material on each of the opposite sides of a given photovoltaic element string to form a stacked body, subjecting the stacked body to vacuum treatment to sufficiently deaerate the inside thereof, and subjecting the stacked body to thermocompression bonding treatment.
FIG.
6
(
a
) is a schematic view illustrating a photovoltaic element string as an example of the above photovoltaic element string, comprising a plurality of relatively small photovoltaic elements
601
of 100 mm×100 mm in size which are spaced at an equal interval (
602
) while connected in a series.
In the case of preparing a solar cell module using the photovoltaic element string shown in FIG.
6
(
a
) in accordance with the above described vacuum lamination method, the deaeration with respect to each of the photovoltaic elements of the photovoltaic element string in the vacu

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