Solar cell module

• US 6,307,145 B1
• Filed: 10/01/1997
• Issued: 10/23/2001
• Est. Priority Date: 10/08/1996
• Status: Expired due to Term

• Current Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Original Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Inventors: Mori, Takahiro, Yamada, Satoru, Shiotsuka, Hidenori, Kataoka, Ichiro, Shiotsuka, Ayako
• Primary Examiner(s): DIAMOND, ALAN D
• Application Number:
  US08/942,118
• Time in Patent Office: 1,483 Days
• Field of Search: 136/251, 136/258, 136/259, 136/256, 257/433, 257/788, 257/789, 257/790, 257/795, 521/733
• US Class Current: 136/251
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: E04D 13/17 Ventilation of roof coverings not otherwise provided for ventilation of rooms or spaces F24F
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/049 Protective back sheets
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A solar cell module is constructed in such an arrangement that a photovoltaic element is covered by at least a sealant resin and a surface protecting film, wherein the oxygen permeability of the surface protecting film is not less than 1 cc/m²·24 hr·atm and not more than 50 cc/m²·24 hr·atm at 25° C./90% RH, thereby providing the solar cell module with high reliability, free of deterioration of the sealant resin, particularly free of yellowing, in long-term outdoor exposure use.

Claims

1. A solar cell module comprising a photovoltaic element covered at the light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein the use temperature of the solar cell module is 70°

C. or more and wherein the oxygen permeability of said transparent surface protecting film is not less than 1 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH, whereby the drop in output of the solar cell module caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.

2. The solar cell module according to claim 1, wherein the oxygen permeability of said transparent surface protecting film is not less than 10 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH.

3. The solar cell module according to claim 1, wherein the water vapor permeability of said transparent surface protecting film is 20 g/m²·

24 hr or less at 40°

C./90% RH.

4. The solar cell module according to claim 1, wherein said transparent surface protecting film comprises a fluoride polymer.

5. The solar cell module according to claim 4, wherein said fluoride polymer is tetrafluoroethylene-ethylene copolymer resin.

6. The solar cell module according to claim 1, wherein said transparent surface sealant resin layer comprises a crosslinked resin.

7. The solar cell module according to claim 6, wherein said crosslinked resin is ethylene-vinyl acetate copolymer (EVA) resin crosslinked by an organic peroxide.

8. The solar cell module according to claim 1, wherein said transparent surface sealant resin layer contains a nonwoven fabric of glass fiber.

9. The solar cell module according to claim 1, wherein said photovoltaic element comprises a substrate, a non-monocrystalline semiconductor active layer, and a transparent, conductive layer.

10. The solar cell module according to claim 9, wherein said non-monocrystalline semiconductor active layer comprises an amorphous silicon thin film.

11. The solar cell module according to claim 1, further comprising a transparent, rigid, organic resin thin film layer between said transparent surface sealant resin layer and said photovoltaic element, wherein the main component of the resin forming the transparent, rigid, organic resin thin film layer is either an acrylic resin or an acryl silicone resin.

12. A solar cell module comprising a photovoltaic element covered at the light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein the use temperature of the solar cell module is 70°

C. or more and wherein said transparent surface protecting film is sufficiently permeable to oxygen to permit the oxygen to reach said transparent surface sealant resin layer, thereby dissolving any yellow coloration of the transparent surface sealant resin layer, such that the drop in output of the solar cell module caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.

13. A building material comprising a photovoltaic element covered at the light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film, which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, and fixed to a module backing, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein the use temperature of the photovoltaic element is 70°

C. or more and wherein the oxygen permeability of said transparent surface protecting film is not less than 1 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH, whereby the drop in output of the photovoltaic element caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.

14. The building material according to claim 13, wherein the oxygen permeability of said transparent surface protecting film is not less than 10 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH.

15. The building material according to claim 13, wherein the water vapor permeability of said transparent surface protecting film is 20 g/m²·

24 hr or less at 40°

C./90% RH.

16. The building material according to claim 13, wherein said transparent surface protecting film comprises a fluoride polymer.

17. The building material according to claim 16, wherein said fluoride polymer is tetrafluoroethylene-ethylene copolymer resin.

18. The building material according to claim 13, wherein said transparent surface sealant resin layer comprises a crosslinked resin.

19. The building material according to claim 18, wherein said crosslinked resin is ethylene-vinyl acetate copolymer (EVA) resin crosslinked by an organic peroxide.

20. The building material according to claim 13, wherein said transparent surface sealant resin layer contains a nonwoven fabric of glass fiber.

21. The building material according to claim 13, wherein said photovoltaic element comprises a substrate, a non-monocrystalline semiconductor active layer, and a transparent, conductive layer.

22. The building material according to claim 21, wherein said non-monocrystalline semiconductor active layer comprises an amorphous silicon thin film.

23. The building material according to claim 13, further comprising a transparent, rigid, organic resin thin film layer between said transparent surface sealant resin layer and said photovoltaic element, wherein the main component of the resin forming the transparent, rigid, organic resin thin film layer is either an acrylic resin or an acryl silicone resin.

24. A building material comprising a photovoltaic element covered at the light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film, which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, and fixed to a module backing, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein the use temperature of the photovoltaic element is 70°

C. or more and wherein said transparent surface protecting film is sufficiently permeable to oxygen to permit the oxygen to reach said sealant resin, thereby dissolving any yellow coloration of the transparent surface sealant resin layer, such that the drop in output of the photovoltaic element caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.

25. An electric power generation system comprising a solar cell module comprising a photovoltaic element covered at the light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film, which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, and a power converting device connected to said solar cell module, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein the use temperature of the solar cell module is 70°

C. or more and wherein the oxygen permeability of said transparent surface protecting film is not less than 1 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH, whereby the drop in output of the solar cell module caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.

26. An air circulating system comprising a roofing material comprising a photovoltaic element covered at a light incidence side thereof by a surface covering member comprising at least a transparent surface sealant resin layer and a transparent surface protecting film, which is in contact with the transparent surface sealant resin layer and positioned at the outermost surface on the light incidence side thereof, and fixed to a module backing, said roofing material being fixed with a space to a roof underlayment, wherein the transparent surface protecting film has a thickness of from 50 to 100 μ

m, wherein air is introduced into the space and is guided through the space to be discharged outdoors or to be taken indoors, wherein the use temperature of the photovoltaic element is 70°

C. and wherein the oxygen permeability of said transparent surface protecting film is not less than 1 cc/m²·

24 hr·

atm and not more than 50 cc/m²·

24 hr·

atm at 25°

C./90% RH, whereby the drop in output of the photovoltaic element caused by yellowing of the surface covering member when subjected to a thermal degradation test at 150°

C. for 15 hours and then exposed to ultraviolet rays under the output of 100 mW/cm² in the wavelength range of 300 to 400 nm by use of a metal halide lamp is less than 10%.