Solar cell module

• US 6,323,416 B1
• Filed: 09/10/1997
• Issued: 11/27/2001
• Est. Priority Date: 09/12/1996
• Status: Expired due to Fees

• Current Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Original Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Inventors: Mori, Takahiro, Yamada, Satoru, Shiotsuka, Hidenori, Kataoka, Ichiro, Komori, Ayako
• Primary Examiner(s): Dye, Rena L.
• Assistant Examiner(s): Miggins, Michael C.
• Application Number:
  US08/926,937
• Publication Number:
  US 20010054437A1
• Time in Patent Office: 1,539 Days
• Field of Search: 136/251, 136/256, 136/259, 126/705, 126/706, 126/621, 126/622, 521/733, 438/64, 454/900
• US Class Current: 136/259
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: E04D 2001/3447 the fastening means being integral or premounted to the roof covering
• CPC Class Codes: E04D 3/366 by closing the space between the slabs or sheets by gutters, bulges, or bridging elements, e.g. strips
• CPC Class Codes: F24D 5/005 combined with solar energy
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• 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
• CPC Class Codes: Y10S 454/90 Ventilator using solar power

Abstract

A solar cell module includes a substrate, a photo-electricity generating device (i.e., a solar cell or a block of solar cells), a filler resin sealing the photo-electricity (generating device on the substrate, and a surface film covering the filler resin. An insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside the substrate, and an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside the insulating film. The substrate is befit at a portion thereof free from the insulating film. The solar cell member thus provided can exhibit a long-term reliability for outdoor use because the moisture is affectively prevented from penetrating the solar cell.

Claims

1. A solar cell module, comprising:

a substrate, a photo-electricity generating device, a filler resin sealing the photo-electricity generating device on the substrate, and a surface film covering the filler resin;

wherein

an insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside all edges of the substrate,

an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside all edges of the insulating film, and

the module is bent at a portion thereof which includes three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, and said portion is free from the insulating film and therefore is also free from the inorganic fibrous sheet.

2. A solar cell module according to claim 1, wherein the inorganic fibrous sheet is disposed to cover an entire area of the photo-electricity generating device.

3. A solar cell module according to claim 1, wherein the filler resin and/or the surface film are disposed in a larger area than the substrate.

4. A solar cell module according to claim 1, wherein the inorganic fibrous sheet comprises non-woven glass fiber cloth.

5. A solar cell module according to claim 1, wherein the insulating film comprises a member selected from the group consisting of polycarbonate, polyethylene terephthalate, and nylon.

6. A solar cell module according to claim 1, wherein an adhesive layer is inserted between the photo-electricity generating device and the insulating film, and/or between the insulating film and the substrate, and the adhesive layer is disposed in an area smaller than that of the filler resins.

7. A solar cell module according to claim 1, wherein said insulating film is provided with adhesive layers on both surfaces thereof to form an integrated laminate film before its insertion between the photo-electricity generating device and the substrate.

8. A solar cell module according to claim 1, wherein another inorganic fibrous sheet is inserted between the photo-electricity generating device and the insulating film so as to be inside all the edges of the insulating film.

9. A roofing member, comprising:

a substrate, a photo-electricity generating device, a filler resin sealing the photo-electricity generating device on the substrate, and a surface film covering the filler resin;

wherein

an insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside all edges of the substrate,

an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside all edges of the insulating film, and

the module is bent at a portion thereof which includes three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, and said portion is free from the insulating film and therefore is also free from the inorganic fibrous sheet.

10. A roofing member according to claim 9, wherein the inorganic fibrous sheet is disposed to cover an entire area of the photo-electricity generating device.

11. A roofing member according to claim 9, wherein the filler resin and/or the surface film are disposed in a larger area than the substrate.

12. A roofing member according to claim 9, wherein the inorganic fibrous sheet comprises non-woven glass fiber cloth.

13. A roofing member according to claim 9, wherein the insulating film comprises a member selected from the group consisting of polycarbonate, polyethylene terephthalate, and nylon.

14. A roofing member according to claim 9, wherein an adhesive layer is inserted between the photo-electricity generating device and the insulating film, and/or between the insulating film and the substrate, and the adhesive layer is disposed in an area smaller than that of the filler resins.

15. A roofing member according to claim 9, wherein said insulating film is provided with adhesive layers on both surfaces thereof to form an integrated laminate film before its insertion between the photo-electricity generating device and the substrate.

16. A process for producing a solar cell module, comprising:

stacking a substrate, an insulating film, a solar cell, an inorganic fibrous sheet, a filler resin layer and a surface film in this order to form a stacked body, wherein said insulating film is disposed inside all edges of the substrate, and the inorganic fibrous sheet is disposed inside all edges of the insulating film,

heating and pressing the stacked body to form a module in the form of an integral laminate sheet having an edge, and

bending a portion of the module along the edge, said portion including three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, which is free from the insulating film of the laminate sheet and therefore said portion is also free from the inorganic fibrous sheet.

17. A process according to claim 16, wherein an adhesive layer is included in the stacked body so as to be inserted between the photo-electricity generating device and the insulating film, and/or between the insulating film and the substrate, and the adhesive layer is disposed in an area smaller than that of the filler resin layer.

18. A process for producing a roofing member, comprising:

stacking a substrate, an insulating film, a solar cell, an inorganic fibrous sheet, a filler resin layer and a surface film in this order to form a stacked body, wherein said insulating film is disposed inside all edges of the substrate, and the inorganic fibrous sheet is disposed inside all edges of the insulating film,

heating and pressing the stacked body to form a module in the form of an integral laminate sheet having an edge, and

bending a portion of the module along the edge, said portion including three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, which is free from the insulating film of the laminate sheet and therefore said portion is also free from the inorganic fibrous sheet.

19. An electricity generating apparatus, comprising a solar cell module and an inverter for converting an output of the solar cell module;

wherein the solar cell module comprises a substrate, a photo-electricity generating device, a filler resin sealing the photo-electricity generating device on the substrate, and a surface film covering the filler resin;

wherein

an insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside all edges of the substrate,

an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside all edges of the insulating film, and

the module is bent at a portion thereof which includes three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, and said portion is free from the insulating film and therefore is also free from the inorganic fibrous sheet.

20. A roofing method, comprising:

fixing a plurality of roofing members onto a roof sheathing by fixing means, and connecting a pair of mutually adjacent roofing members;

wherein each roofing member comprises a substrate, a photo-electricity generating device, a filler resin sealing the photo-electricity generating device on the substrate, and a surface film covering the filler resin;

wherein

an insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside all edges of the substrate,

an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside all edges of the insulating film, and

the roofing member is bent at a portion thereof which includes three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, and said portion is free from the insulating film and therefore is also free from the inorganic fibrous sheet.

21. A ventilating apparatus, including a roof sheathing, and a plurality of roofing members fixed onto the roof sheathing so as to form a space between the sheathing and the roofing members for introducing external air thereinto, and a path for introducing the air in the space into an inside of a building and/or a path for discharging the air in the space to an outside of the building;

wherein each roofing member comprises a substrate, a photo-electricity generating device, a filler resin sealing the photo-electricity generating device on the substrate, and a surface film covering the filler resin;

wherein

an insulating film is inserted between the photo-electricity generating device and the substrate so as to be inside all edges of the substrate,

an inorganic fibrous sheet is inserted between the photo-electricity generating device and the surface film so as to be disposed inside all edges of the insulating film, and

the roofing member is bent at a portion thereof which includes three laminated layers comprising (i) the surface film, (ii) the filler resin and (iii) the substrate, and said portion is free from the insulating film and therefore is also free from the inorganic fibrous sheet.