JP2000196129A - Roof material integrated with solar cell, roof employing the material, photovoltaic power generation system, and manufacture and installation thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roof material integrated with solar cell which can be handled well and installed easily without causing any damage on a terminal take-out box. SOLUTION: In a roof material integrated with solar cell comprising photovoltaic elements and a roof material body, a step 111 is provided at a part where a photovoltaic element 105 is not present such that the non-light receiving side is recessed and the terminal take-out part (a terminal take-out box 102, an electrical connector 106) of photovoltaic element 105 is formed in the step 111.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell integrated roofing material, a roof and a solar power generation system using the solar cell integrated roofing material, and a method of manufacturing and installing the solar cell integrated roofing material. The workability has been improved.

[0002]

2. Description of the Related Art In recent years, awareness of environmental problems has been increasing worldwide. Above all,
The concern about the global warming phenomenon associated with CO ₂ emission is serious, and the demand for clean energy is increasing more and more. In response to such demands, especially solar cells are expected to be a clean energy source due to their safety and ease of handling.

Conventionally, various types of solar cells, that is, solar power generation devices have been proposed. Among them, from the viewpoint of emphasizing higher ease of installation, economy, and design, we departed from the method of installing on the existing roof,
Technical developments on so-called solar cell-integrated roofing materials in which solar cells are incorporated into building materials themselves are being carried out.

A conventional solar cell integrated roof material will be described with reference to FIG.

FIG. 16 is a schematic view of a conventional solar cell integrated roofing material. FIG. 16 (a) is a schematic view of an installation sectional structure, and FIG. 16 (b) is an overall solar cell integrated roofing material. It is a schematic diagram.

A conventional solar cell integrated roofing material has a structure as shown in FIG. In FIG. 16, 160
1 is a solar cell integrated roof material, 1602 is a terminal extraction box, 1603 is a terminal extraction cable, 1604 is a roof material holding member, 1605 is a screw for fixing a roof material holding member, 1606 is a cover member, and 1607 is a small member. wood,
Reference numeral 1608 denotes a field board, 1609 denotes a general roofing material, 1610 denotes a photovoltaic element, and 1611 denotes an electrical connector.

[0007] As shown in FIG. 16, a solar cell integrated roofing material 1601 integrally molded with a roofing material is a general roofing material 16.
It is bent to the same shape as that of the conventional roofing material 09, and can be laid in the same manner as the conventional general roofing material 1609 so that the solar cell integrated roofing material can be laid.

[0008] Conventional solar cell integrated roofing materials include:
Some had other forms. A conventional solar cell integrated roofing material having another embodiment will be described with reference to FIG.

FIG. 17 is a schematic view of a conventional solar cell-integrated roofing material having another embodiment. FIG. 17 (a) is a schematic view of an installation sectional structure, and FIG. 17 (b) is a solar cell. It is the whole schematic of an integrated roofing material.

A conventional solar cell integrated roofing material having another form has a structure as shown in FIG. FIG.
, 1701 is a solar cell integrated roof material, 1702
Is a terminal extraction box, 1703 is a terminal extraction cable, 1704 is a roof material holding member, 1705 is a screw for fixing a roof material holding member, 1706 is a cover member, 1
Reference numeral 707 denotes a cutting board, 1708 denotes a base plate, 1709 denotes a general roofing material, 1710 denotes a photovoltaic element, and 1711 denotes an electrical connector.

A solar cell integrated roofing material 170 shown in FIG.
In order to double the number of series in comparison with the solar cell integrated roofing material 1601 shown in FIG. 16, the solar cell integrated roofing material 1 shown in FIG.
The number of photovoltaic elements 1710 that is twice as large as that of the photovoltaic element 601 is connected in series. For this purpose, the solar cell integrated roofing material 17
01 has a large width.

As described above, when a photovoltaic element 1710 twice as large as a normal photovoltaic element 1710 is disposed in one solar cell integrated roofing material 1701, a terminal extraction box 170 for electrical connection is provided.
2. It is only necessary to use one set of the cable 1703 for extracting the terminal and the connector 1711 for the electrical connection, so that the manufacturing cost can be reduced.

[0013]

However, when the above-described conventional solar cell integrated roofing material 1601 shown in FIG. 16 is installed, the terminal extraction box 1602 of the photovoltaic element 1610 is replaced by the solar cell integrated type roofing material 1601. Of the solar cell-integrated roofing material 1 so as to face the non-light-receiving surface side of the
601 could not be installed.

For this reason, it is necessary to arrange the cutting board 1607 on the base plate 1608 in advance so that the base plate 1608 and the terminal take-out box 1602 do not interfere with each other. The height of the tree 1607 should be equal to or greater than the thickness of the terminal box 1602, and the pitch of the tree 1607 should be as shown in FIG.
As shown in (a), the roof material holding member 1604 for holding the solar cell integrated roof material 1601 needs to be arranged at such a pitch that the roof material can be fixed.

Further, the field plate 1608 and the terminal take-out box 1
As another method for preventing the interference with the terminal 602, not shown, a notch is provided in the base plate 1608 without using the sanki 1607, and the terminal extraction box 16 is provided in the notch.
02, and a time-consuming operation such as arranging the solar cell integrated roofing material 1601 on the field plate 1608 was required.

Further, as shown in FIG. 16, in the conventional solar cell integrated roofing material 1601, a terminal extraction box 160 is provided on the non-light receiving surface side of the solar cell integrated type roofing material 1601.
2 is mounted in a protruding state. Therefore, when the solar cell integrated roofing material 1601 is laid, the terminal extraction box 1602 may be hit against surrounding building materials or tools, and the terminal extraction box 1602 may be damaged.

In the conventional solar cell-integrated roofing material 1701 shown in FIG. 17, the rigidity of the solar cell-integrated roofing material 1701 is reduced due to an increase in the width thereof. Was.

Further, in the solar cell integrated roofing material 1701, since the solar cell integrated roofing material 1701 becomes wider,
In some cases, work cannot be performed unless the operator steps on the solar cell integrated roofing material 1701 during construction. When the photovoltaic element unit 1710 is trampled, long-term reliability may be reduced due to the pressure history.

Furthermore, the conventional solar cell integrated roofing material 17
01, similarly to the conventional solar cell integrated roofing material 1601 shown in FIG.
When installing a terminal extraction box 1702 on the non-light receiving surface side
In addition, since a protrusion such as a cable 1703 for extracting a terminal is present, the sanki 1707 is previously placed on the base plate 1708.
It was necessary to fix it on the top or to make a cutout in the base plate 1708.

Further, when the solar cell integrated roofing material 1701 is laid, the terminal take-out box 1702 may be hit against surrounding building materials and tools to be damaged.

On the other hand, Japanese Utility Model Publication No. Sho 63-21628 discloses that a flat valley portion and a flat ridge portion are alternately provided in a roof using a thin solar cell plate so as to be inclined in the length direction. A roof is disclosed in which the part is formed of a solar cell plate.

However, this publication describes improvement in workability by increasing the strength, but does not make any description about preventing damage to the terminal take-out box.

In Japanese Utility Model Laid-Open Publication No. 1-80963,
A solar cell device for roof installation in which photovoltaic elements are provided on all surfaces of a solar cell integrated roof material having a step is disclosed.

However, this publication does not describe not only preventing damage to the terminal extraction portion of the photovoltaic element on each surface but also taking measures against a case where an operator steps on the surface during construction. Is not described.

The solar cell-integrated roofing material according to the present invention has been proposed in view of the above-mentioned circumstances, has good handling, is easy to install, and has no danger of damaging the terminal box during installation. An object is to provide a battery-integrated roofing material.

It is another object of the present invention to provide a roof and a photovoltaic power generation system using such a solar cell integrated roof material, and a method of manufacturing and installing such a solar cell integrated roof material.

[0027]

In order to achieve the above-mentioned object, a solar cell integrated roofing material according to the present invention is a solar cell integrated roofing material comprising at least a photovoltaic element and a roofing material main body. The solar cell integrated roof material has a step at which a non-light receiving surface side is concave at least in a portion where no photovoltaic element is present, and a terminal extraction portion of the photovoltaic element is formed in the step. It is characterized by having.

The step is convex on the light-receiving surface side of the solar cell integrated roof material, or
The step is formed within the interval between the photovoltaic element groups of the solar cell integrated roof material, and the shape of the step is one solar cell integrated roof material and another solar cell adjacent to the solar cell integrated roof material. It is preferable that the shape of the joint between the battery-integrated roof material and the roof material is substantially the same.

The roofing material body is a metal plate,
The light-receiving surface side of the photovoltaic element is coated with a resin, and the solar cell-integrated roofing material preferably has an outermost surface coating material made of a weather-resistant transparent resin.

Further, it is preferable that the photovoltaic element is a thin film semiconductor formed on a stainless steel substrate, and the solar cell integrated roof material has flexibility.

The solar cell-integrated roofing material can constitute a roof or a solar power generation system.

Further, the method for manufacturing a solar cell integrated roofing material comprises manufacturing a flat solar cell integrated roofing material constituting at least a photovoltaic element and a roofing material main body, and then manufacturing the flat solar cell integrated roofing material. Forming the integral roofing material at least in a portion where the photovoltaic element does not exist to form a step that is concave on the non-light receiving surface side, and then forming a terminal extraction portion of the photovoltaic element in the step. It is characterized by the following.

Further, it is preferable that the roof material main body is a metal plate.

Another method of manufacturing the solar cell integrated roofing material is to manufacture at least a sheet-like solar cell constituting a photovoltaic element, and then to make the sheet-like solar cell at least concave on the non-light-receiving surface side. And fixing the terminal of the sheet-shaped solar cell to the step of the roof material main body in the step of the roof material main body.

[0035] The method of installing the solar cell integrated roofing material is a solar cell integrated roofing material constituted by at least a photovoltaic element and a roofing material main body. Using a solar cell integrated roofing material having a step that is concave on the non-light receiving surface side in a portion without a photovoltaic element, and a terminal extraction portion of the photovoltaic element is formed in the step. The non-light receiving surface side is installed facing a flat roof installation surface having substantially no irregularities.

Further, in the solar cell integrated roof material, it is preferable that an electrical connection member at a connection portion of the solar cell integrated roof material is housed and installed in the step.

The roofing material integrated with a solar cell according to the present invention has the above-described structure, and thus can exert the following effects.

Since the rigidity of the solar cell-integrated roofing material is improved, handling is improved and work efficiency is improved.

Further, since there is no protrusion on the non-light-receiving surface side of the solar cell integrated roof material, the back surface side of the solar cell integrated roof material can be directly stuck and fixed on the field board.

Further, since the terminal take-out portion is housed in the step, it is difficult to hit the terminal take-out box during the installation work, and the terminal take-out box can be prevented from being damaged.

[0041]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an embodiment of a solar cell integrated roofing material according to the present invention will be described with reference to the drawings.

FIG. 1 is a schematic view for explaining a solar cell integrated roof material according to the present invention. FIG. 1 (a) shows a solar cell integrated roof material according to the present invention installed on a field board. 1 (b) is a schematic cross-sectional view of a solar cell integrated roofing material according to the present invention, and FIG. 1 (c) is a schematic cross-sectional view of a solar cell integrated roofing material according to the present invention. The figures are shown respectively.

The solar cell integrated roofing material according to the present invention has a structure as shown in FIG. In FIG. 1, 10
1 is a solar cell integrated roofing material, 102 is a cable for terminal extraction, 103 is a screw for fixing the solar cell integrated roofing material and a general roofing material, 104 is a field plate, 105 is a photovoltaic element, and 106 is electricity. Connector for connection, 107: terminal extraction box, 108: outermost surface covering material, 109: filler, 110: outermost surface covering material (roof material main body), 111: step of solar cell integrated roof material, 112, 113 adjacent 2 shows a joint portion between the solar cell integrated roof material and the roof material.

The solar cell integrated roofing material 101 according to the present invention
As shown in FIG. 1, a concave step 11 is provided on the non-light receiving surface side.
1 and the terminal take-out box 107, the terminal take-out cable 102, and the connector 106 for electric connection are placed in the step, so that the solar cell integrated roofing material 10 is provided.
No. 1 has no protrusion on the non-light receiving surface side. With such a structure, the back side (non-light-receiving surface side) of the solar cell integrated roofing material 101 can be placed on the roof installation surface without arranging trees or providing cutouts in the base plate 105. It can be arranged as follows.

Next, the above-described solar cell integrated roof material 10
1 will be described.

FIG. 4 is a schematic diagram for explaining a method of manufacturing a solar cell integrated roofing material according to the present invention.
(A) is a schematic diagram showing a state in which the materials constituting the solar cell integrated roof material are stacked, and FIG. 4 (b) is a schematic cross-sectional view of a flat solar cell integrated roof material after integrally molding. FIG.
(C) is a schematic cross-sectional view of the solar cell integrated roof material after bending, and FIG. 4 (d) is a schematic cross-sectional view of the solar cell integrated roof material after attaching a terminal take-out box and a terminal take-out cable. It is.

In FIG. 4, reference numeral 401 denotes a photovoltaic element group;
402 is a filler, 403 is a top surface coating material, 404 is an insulating film, 405 is a top surface coating material, 406 is a terminal extraction hole, 407 is a copper foil for extracting electrode terminals, 408 is a terminal extraction box, and 409 is a terminal extraction box. Cable, 410
Indicates a step, respectively.

To manufacture the solar cell integrated roofing material 101, first, the flat roofing material body 40, which is the outermost backing material, is used.
5, a filler 402, an insulating film 404, a filler 402, a photovoltaic element group 401, a filler 402, and a top surface covering material 403 are laminated in this order (FIG. 4A). Then, by performing vacuum evacuation and heat processing,
The filler 402 is cross-linked and integrally molded to produce a flat solar cell integrated roofing material (FIG. 4B).

Further, in order to carry out the terminal take-out operation in a later step, the material on the non-light receiving surface side of the photovoltaic element group 401, that is, the flat roof material 405, the filler material 402,
A terminal extraction hole 406 is formed in the insulating film 404 and the filler 402 so as to face the position of the electrode terminal extraction copper foil 407. If a plug (not shown) made of, for example, silicon is attached to the perforated portion, the plug can be easily removed after integral molding, and the electrical connection operation can be easily performed.

Next, the flat solar cell integrated roofing material 10
1 is formed to form a step 410 having a concave shape on the non-light receiving surface side (FIG. 4C). At this time, the step 410 is formed so that the terminal take-out hole 406 is accommodated in the step 410, and when the terminal take-out box 408 and the terminal take-out cable 409 are attached in a later step, the terminal take-out hole 406 fits in the step 410, respectively. Keep it.

After that, the terminal extraction hole 4 in the step 410
A terminal takeout cable 409 and a terminal takeout box 408 are attached to 06 (FIG. 4D). At this time, the terminal extraction box 4 is
08 is attached, and the terminal extracting cable 409 is attached so that the conductor of the terminal extracting cable 409 is electrically connected to the electrode terminal extracting copper foil 407 in the terminal extracting hole 406 therein.

Next, each material constituting the solar cell integrated roofing material 101 according to the present invention will be described.

[Photovoltaic Element] The photovoltaic element used for the solar cell integrated roofing material 101 according to the present invention is not particularly limited, but is preferably a flexible photovoltaic element. As such a photovoltaic element, for example, there is an element in which a semiconductor photoactive layer as a light conversion member is formed on a conductive substrate.

FIG. 2 is a schematic diagram showing an example of a photovoltaic element.
Shown in 2, reference numeral 201 denotes a conductive base, 202 denotes a metal electrode layer, 203 denotes a semiconductor photoactive layer, 204 denotes a transparent conductive layer, and 205 denotes a current collecting electrode.

The conductive base 201 serves as a base for the photovoltaic element and also serves as a lower electrode.
As the material of the conductive substrate 201, silicon, tantalum, molybdenum, tungsten, stainless steel, aluminum, copper, titanium, a carbon sheet, a lead plating copper plate, a resin film having a conductive layer formed thereon, ceramics, and the like can be used. .

On the conductive substrate 201, the metal electrode layer 20
Second, a metal layer, a metal oxide layer, a metal layer and a metal oxide layer, or the like may be formed. As the material of the metal layer, for example, Ti, Cr, Mo, W , A1, Ag, can be used Ni, etc., as the material of the metal oxide layer, for example, ZnO, and TiO _2, SnO _2, etc. Can be used. The metal layer and the metal oxide layer are formed by a resistance heating evaporation method, an electron beam evaporation method, a sputtering method, or the like.

The semiconductor photoactive layer 203 is a part for performing photoelectric conversion. As a material of the semiconductor photoactive layer 203, for example, pn junction type polycrystalline silicon, pin junction type amorphous silicon, CulnSe ₂ , CulnS ₂ , GaAs, C
dS / Cu ₂ S, CdS / CdTe, CdS / InP,
Compound semiconductors such as CdTe / Cu ₂ Te can be used.

In the case of polycrystalline silicon, this semiconductor photoactive layer 203 is formed by sheeting molten silicon or by heat treatment of amorphous silicon, and in the case of amorphous silicon, it is formed by plasma CVD using silane gas or the like as a raw material. In the case of a compound semiconductor, it is formed by ion plating, ion beam deposition, vacuum deposition, sputtering, electrodeposition, or the like.

The transparent conductive layer 204 functions as an upper electrode of the photovoltaic device. As a material of the transparent conductive layer 204, for example, In ₂ O ₃ , SnO ₂ , 1n ₂ O ₃ —Sn
O ₂ (ITO), ZnO, may be used TiO _2, Cd ₂ SnO _4, a crystalline semiconductor layer or the like high-concentration impurity-doped.

This transparent conductive layer 204 is formed by resistance heating evaporation,
It is formed by a sputtering method, a spray method, a CVD method, an impurity diffusion method, or the like.

A grid-like current collecting electrode 205 (grid) may be provided on the transparent conductive layer 204 in order to efficiently collect current. As a material of the collecting electrode 205,
For example, Ti, Cr, Mo, W, A1, Ag, Ni, C
u, Sn, or a conductive paste such as a silver paste can be used.

The current collecting electrode 205 is directly collected by sputtering using a mask pattern, resistance heating, a CVD method, a method in which an unnecessary portion is removed by etching after depositing a metal film on the entire surface and patterning, or a photo-CVD method. It is formed by a method of forming a current collector electrode pattern, a method of forming a mask of a negative pattern of a current collector electrode pattern and then plating, a method of printing a conductive paste, or the like.

As the conductive paste, for example, a paste in which silver, gold, copper, nickel, carbon or the like in the form of fine powder is dispersed in a binder polymer can be used.
As the binder polymer, for example, polyester,
Resins such as epoxy, acrylic, alkyd, polyvinyl acetate, rubber, urethane, and phenol can be used.

Next, the wide solar cell-integrated roofing material according to the present invention will be described. In a wide solar cell-integrated roof material, photovoltaic elements are serialized in a wide size in order to increase the number of series.

FIG. 3 is a schematic diagram for explaining a procedure for serializing photovoltaic elements to produce a group of photovoltaic elements, and thereafter producing a group of photovoltaic elements serialized to have a wide size. FIG. 3A is a schematic diagram of a photovoltaic element before serialization, FIG. 3B is a schematic cross-sectional view for explaining a procedure for serializing the photovoltaic element, and FIG. (C) is a schematic view of a wide serialized photovoltaic element group.

In FIG. 3, reference numeral 301 denotes a collecting electrode;
Is a copper foil for serial connection, 303 is a SUS substrate, 304 is a copper foil for extracting a negative electrode, 305 is a copper foil for extracting a positive electrode, 306 is a copper foil for serializing into a wide size, 30
Reference numeral 7 denotes a photovoltaic element group.

As shown in FIG. 3, the series-connecting copper foil 302 is in an electrically conductive state with the collecting electrode 301 of each photovoltaic element. The lower side of the adjacent photovoltaic element to which the series-connected copper foil 302 is connected in series, that is, the SUS substrate 303
The photovoltaic element is serialized by being electrically connected to the back side of the photovoltaic device. (FIG. 3 (b)). By repeating such connection work, a photovoltaic element group (a plurality of photovoltaic elements in series) 307 is manufactured.

In order to manufacture a wide group of photovoltaic elements for use in the wide solar cell-integrated roofing material according to the present invention, the same serialization is performed by using the copper foil 306 for wide serialization. Do the work. Then, a copper foil for extracting a terminal, that is, a copper foil 304 for extracting a negative electrode and a copper foil 305 for extracting a positive electrode are attached to manufacture a wide photovoltaic element group. (FIG. 3 (c)) In general, when a solar cell is used as a roof material, it is preferable to be lightweight from the viewpoint of workability. In recent years, there has been an increasing need for a solar cell integrated with a roof material and a solar cell installed on an outer wall of a building, for example, in order to bend a solar cell or install it on a curved surface. In addition, solar cells are required to be flexible.

For these requirements, a thin-film semiconductor photovoltaic element formed on a stainless steel substrate is very suitable. That is, since such a photovoltaic element can be thinned to a thickness of about 0.1 mm including the substrate by thinning the photovoltaic element itself, the filling for sealing the photovoltaic element is performed. This is because the amount of the material can be reduced.

As a result, the weight of the solar cell can be reduced, and the thickness of the solar cell can be reduced. Further, if the thickness of the solar cell can be reduced, the stress applied to the surface coating material when the solar cell is bent can be reduced. Furthermore, it is possible to suppress cracking of the coating material with respect to the tensile force, and to suppress the coating material with respect to the contraction force. In addition, since the solar cell is formed on a stainless steel substrate, the solar cell has flexibility and does not require more rigidity than necessary, so that the thickness of the filler or the covering material can be reduced. From such a viewpoint, the weight of the solar cell can be reduced, and the solar cell can be made flexible and suitable for bending.

Therefore, as described above, the photovoltaic element is optimally a thin film semiconductor formed on a stainless steel substrate.

[Outermost surface coating material] The outermost surface coating material is required not only to be light-transmitting and weather-resistant, but also to be hardly contaminated. As the material of the outermost surface covering material, glass, a light-transmitting resin film, or the like can be used. However, in order to treat a solar cell in the same way as a general roofing material, it is necessary to bend the solar cell itself, and it is convenient if the outermost surface covering material is a flexible material.

For the reasons described above, a weather-resistant transparent resin is preferably used as the outermost surface coating material, and a weather-resistant transparent film is more preferably used. By using the weather-resistant transparent film, the filling property is improved, the weight can be reduced, the strength against impact is increased, and the film can be used as a roofing material by bending. Further, by performing the embossing treatment on the film surface, there is also an effect that the surface reflection of sunlight is not dazzling.

As the material of the outermost surface coating material, for example, a fluororesin film such as polyethylene tetrafluoroethylene (ETFE), polytrifluoroethylene, polyvinyl fluoride, or the like can be used, but is not limited thereto. is not. A surface treatment such as a corona discharge treatment can be applied to the surface to be bonded with the filler so that the filler is easily bonded.

[Filler] The filler is used for sealing the photovoltaic element and bonding and fixing the photovoltaic element on the outermost surface coating material or the outermost surface coating material.

The filler is required to have thermoplasticity, weather resistance, heat adhesion, and light transmittance. As the material of the filler, for example, EVA (vinyl acetate-ethylene copolymer), butyral resin, silicone resin, fluororesin, EEA (ethylene ethyl acrylate), EMA (ethylene methyl acrylate), EBA (ethylene butyl acrylate), A transparent resin such as an acrylic resin or a urethane resin PVA (polyvinyl alcohol) can be used, but is not limited thereto. Further, in order to suppress light deterioration, it is preferable that an ultraviolet absorber is contained.

[Coating Material on the Backmost Side] The covering material on the rearmost side of the solar cell integrated roofing material functions as a reinforcing material for the solar cell integrated roofing material. In the solar cell integrated roofing material according to the present invention, the roofing material itself can be used as the outermost covering material. As the material of the outermost backing material, a material capable of imparting moisture resistance and rigidity, for example, a metal material such as an aluminum plate, a stainless steel plate, and a galvanized copper plate, a galvanium copper plate, or another plated copper plate is used. can do. In addition, a tile, a slate material, or the like can be used as the outermost covering material.

By folding the outermost backing material, a step of the solar cell integrated roof material can be formed, and the solar cell integrated roof material can be handled in the same manner as a general roof material.

[Step] In the solar cell integrated roof material according to the present invention, a step is formed by processing the non-light receiving surface side so as to be concave. For example, a step can be formed by directly forming and processing a solar cell integrated roof material integrally formed with the roof material body. The step can be formed by, for example, a bender, a press, a roller former, or the like, but is not particularly limited to these forming methods.

In the solar cell integrated roofing material according to the present invention,
An electric connection member, that is, a terminal take-out box, a terminal take-out cable, and an electric connection connector are accommodated in this step, so that no protrusion is present on the non-light-receiving surface side of the solar cell integrated roof material. .

Therefore, it is necessary that the size of the step has a cross-sectional shape and a size in which the electric connection member is accommodated. The height of the step that is concave toward the non-light-receiving surface side can be made in a range where the electric connection member can be accommodated so that a shadow is not formed on the photovoltaic element when the incident light is inclined. It is preferably as low as possible.

Further, the solar cell integrated roofing material has such a step, whereby the rigidity is increased, the handling during installation work is improved, and the workability is improved. Further, it is preferable that the step is formed in a portion where the photovoltaic element does not exist.

That is, since the step formed by molding and processing the solar cell integrated roofing material has strength, the workability is greatly improved if an operator can step on the step during construction. For this reason, it is better not to have a photovoltaic element in the step portion to which pressure is applied by stepping on the operator. In the case where a step is formed on the photovoltaic element, if the step is bent at a small radius, the reliability of the photovoltaic element may be reduced.

Therefore, as shown in FIG. 1, in the case of a wide solar cell-integrated roof material, it is preferable to form a step between the photovoltaic element groups serialized.

When a step is formed, the shape of the step should be substantially the same as the shape of the joint between the solar cell integrated roof material and another adjacent solar cell integrated roof material. preferable. By forming the steps in this manner, when the solar cell integrated roofing material is roofed on a roof having a shape such as a ridge, the filling rate of the solar cells with respect to the roof can be increased, and the maximum solar cell The loadable power generation amount can be increased.

Next, the filling rate of the solar cell with respect to the roof will be described with reference to FIG.

FIG. 5 is a schematic diagram for explaining the filling rate of the solar cell with respect to the roof. FIG. 5 (a) shows that the shape of the step is different from that of the joint between the adjacent solar cell-integrated roof material. FIG. 5 (b) is a schematic view of a case where the entire surface of the roof is different from that of FIG. 5, and FIG. 5 (b) shows that the shape of the step is substantially the same as the shape of the joint between the adjacent solar cell integrated roof material and
It is a schematic diagram in the case where the step and the joint of the roof material on the ridge side are respectively overlapped with the joint and the step of the roof material on the eaves front side, and the roofing is performed.

In FIG. 5, reference numeral 501 denotes a step of the solar cell integrated roof material, 502 denotes a joint between adjacent solar cell integrated roof materials, and 503 denotes a non-power generation area of the roof.

As shown in FIG. 5, the shape of the step 501 is
Joint 5 between adjacent solar cell integrated roofing material
In the case where the shape is substantially the same as the shape of No. 02 (FIG. 5B), the step 501 and the joint 502 of the solar cell integrated roof material on the eaves side are used.
Then, the solar cell integrated roof material can be roofed such that the joint 502 of the solar cell integrated roof material on the ridge side and the step 501 are overlapped with each other. By repeating this for each stage, the filling rate of the solar cell with respect to the roof surface can be increased, that is, the non-power generation area 503 of the roof can be reduced.

In the example shown in FIG. 5A, as compared with the example shown in FIG. 5B, the shape of the step 501 is different from the shape of the joining portion 502 between the adjacent solar cell integrated roof material. Therefore, it is necessary to align the step 501 and the joint 502 of the solar cell integrated roof material from the eave to the ridge. Therefore, in the example shown in FIG. 5A, it can be seen that the non-power generation area 503 of the roof is large.

As described above, when the shape of the step 501 is substantially the same as the shape of the joint portion 502 between the adjacent solar cell integrated roof material, the non-power generation area 503 can be reduced, and the solar cell By increasing the filling rate of, the maximum loadable power generation amount of the solar cell can be increased.

[Terminal Extraction Box] The terminal extraction box used in the solar cell integrated roofing material according to the present invention protects the electrical junction between the terminal extraction cable and the photovoltaic element from mechanical external force, It has the function of protecting it from foreign substances such as water and dust. For this reason, it is preferable that the terminal take-out box be excellent in impact resistance, flame retardancy, heat resistance, cold resistance, and oil resistance in addition to mechanical strength, water resistance, and electrical insulation. When the inside of the terminal take-out box is sealed with a filler, it is preferable that the terminal take-out box be made of a material having good adhesiveness to the filler.

Therefore, the material of the terminal take-out box is preferably made of plastic, and considering the flame retardancy,
Flame-retardant plastics and ceramics are preferred.

As a material of the terminal take-out box, for example,
Noryl, polycarbonate, polyamide, polyacetal, modified PPE, polyester, polyarylate, unsaturated polyester, phenol resin, epoxy resin and the like can be used.

[Terminal Extraction Cable] The terminal extraction cable is used for connecting the electricity generated by the photovoltaic element in series or in parallel, or for electrically connecting the electricity to a junction box or an inverter. It is preferable to use a cable having a cable structure for the terminal extraction cable, but it is also possible to use an insulated wire. The cable for terminal extraction is required to have heat resistance, cold resistance, mechanical strength, electrical insulation, water resistance, oil resistance, abrasion resistance, acid resistance, and alkali resistance.

As a material of the cable for taking out the terminal, for example, a 600 V polyethylene cable (EV, EE, CV, CE) of JIS-C3605 standard, JIS-C3605, etc.
C3621 standard 600VEP rubber insulated cable (P
N, PV), 600V vinyl insulated vinyl sheath (flat) cable (VVR, VVF) of Jls-C3342 standard
Etc. can be used.

[Electrical Connection Connector] The material of the electrical connection connector is not particularly limited, but is, similarly to the terminal take-out box, mechanical strength, water resistance, electric insulation, impact resistance, flame retardancy, heat resistance. Those excellent in heat resistance, cold resistance and oil resistance are preferred.

The material of the electrical connection connector is, for example, vinyl chloride, polyethylene resin, polyamide resin,
Pinylidene fluoride resin, chloroprene rubber, ethylene propylene rubber, polycarbonate, polybutylene terephthalate, polypropylene and the like can be used.

[Bending] To form a step, a flat solar cell-integrated roofing material in which a roofing material main body and a photovoltaic element are integrally formed is bent as it is. The bending method is not particularly limited, and for example, a roller former, a press, and a bender can be used. That is, a machine in which a conventional general roofing material is bent can be used as it is.

[0100]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a solar cell integrated roofing material according to the present invention will be specifically described based on Examples 1 to 7.

Example 1 The solar cell integrated roofing material of Example 1 uses a solar cell module as a roofing material.

In Example 1, first, the thin film semiconductor (a
-Si) was manufactured. The manufacturing procedure of this photovoltaic element will be described with reference to FIG.

In FIG. 2, reference numeral 201 denotes a stainless steel substrate serving as a conductive substrate, 202 denotes a metal electrode layer, 203 denotes a semiconductor photoactive layer, 204 denotes a transparent conductive layer, and 205 denotes a current collecting electrode.

In order to manufacture a photovoltaic element, first, an Al layer (thickness 5000 °) and a ZnO layer were formed as a back metal electrode layer 202 on a cleaned stainless steel substrate 201 by sputtering.
Layers (thickness 5000 °) are sequentially formed. Then, by plasma CVD, an n-type a-Si layer was formed from a gas mixture of SiH ₄ and PH ₃ and H _2, to form an i-type a-Si layer from a gas mixture of SiH ₄ and H _2, SiH ₄ A p-type microcrystalline μc-Si layer is formed from a mixed gas of BF ₅ and H ₂ , and an n-layer thickness of 150 ° / i-layer thickness of 4000 ° / p-layer thickness of 100 ° / n
Layer thickness 100 ° / i-layer thickness 800 ° / p-layer thickness 100 °
The tandem a-Si-based photoelectric conversion semiconductor layer 203 having the layer structure described above was formed. Next, as the transparent conductive layer 204, I
An n ₂ O ₃ thin film (thickness: 700 °) was formed by depositing In by a resistance heating method in an O ₂ atmosphere.

On this, the current collecting electrode 205 was formed by pattern-printing a silver paste with a screen printing machine and drying it.

Next, the photovoltaic elements produced as described above were connected in series to produce a photovoltaic element group.

The method of manufacturing the photovoltaic element group by serializing the photovoltaic elements is as outlined in the description of the photovoltaic element described above with reference to FIG.

That is, first, electrical conduction is established on the current collecting electrode 301 at the end of the photovoltaic element.
The copper foil 302 for series connection is fixed. This copper foil 302 for series connection was electrically connected to the back side of the adjacent photovoltaic element to perform series connection (FIG. 3).
(B)). According to the same procedure, two photovoltaic element groups 307 were manufactured by connecting the photovoltaic elements in series.

Next, the copper foil 306 is used to electrically connect the series-connected copper foil 302 of one of the photovoltaic element groups to the back side of the other photovoltaic element group. Two photovoltaic element groups were connected in series. Then, the copper foil 304 for taking out the positive electrode and the copper foil 305 for taking out the negative electrode were attached to manufacture a wide-sized photovoltaic element group.

The steps of integrally forming the above-described manufactured photovoltaic element and then bending the same are as outlined in the above-described method for manufacturing the solar cell integrated roofing material 101 with reference to FIG.

That is, first, in order to perform the integral molding process, the materials constituting the solar cell module were laminated. The laminating order is, from the bottom, the outermost back surface covering material 405, the filler 402, the insulating film 404, the filler 402, the wide-sized photovoltaic element group 401 manufactured as described above,
The order of the filler 402 and the outermost covering material 403 is as follows.

The outermost coating 405 is made of a coated steel plate (manufactured by Nisshin Steel, trade name: Galbuster, 0.4 mm thick), and the filler 402 is EVA (ethylene-vinyl acetate copolymer-weather resistance). Grade, Bridgestone, 46
0 μm), and the outermost surface covering material 403 is made of a fluororesin film (ethylene tetrafluoroethylene, 50 μm
Atsushi, manufactured by Daikin, product name: NEOFLON EF-0050
SB1) was used.

For the material on the back surface covering material side of the photovoltaic element, the electrode extracting copper foil 407 composed of the positive electrode extracting copper foil and the negative electrode extracting copper foil of the photovoltaic element group is used. Position the terminal extraction hole 40
6 were provided. The positioning of the terminal extraction hole 406 was performed so as to be included in the step 410 after the forming process in a later step. At the time of the integral molding process, a silicon stopper (not shown) was attached to the terminal extraction hole 406.

Next, the material laminated as described above is heated to 160 ° C. in a vacuum state,
Heat was applied to 2 to crosslink it, and an integral molding process was performed. Thereafter, cooling was performed to produce a flat solar cell integrated roofing material as shown in FIG. 4B.

Then, as shown in FIG. 4 (c), the solar cell integrated roofing material is bent using a bender, and a central portion of the solar cell integrated roofing material has a concave shape on the non-light receiving image side. Step 410 was formed. At this time, the step of the solar cell integrated roof material was large enough to accommodate a terminal extraction box, a terminal extraction cable, and an electrical connection connector in a later process. Also, the shape and size of the joint between the solar cell integrated roof material and the adjacent roof material at both ends were formed so as to be substantially the same as the shape and size of the step at the center of the solar cell integrated roof material. .

Then, as shown in FIG. 4 (d), the terminal take-out box 408 and the terminal take-out cable 409 were attached so as to fit inside the step of the solar cell integrated roof material. Further, at the time of the above-described integral molding process, the silicon plug (not shown) filled in the terminal extraction hole 406 in the step is removed, and the terminal extraction copper foil 407 in the solar cell integrated roofing material is removed. Cable 40
9 were fixed so that the conducting wire portions were electrically connected.
At this time, in order to secure the mechanical strength of the electrical connection portion, electrical connection is performed via the terminal extraction box 408, and in order to ensure insulation of the electrical connection portion, the inside of the terminal extraction box 408 is insulated with an insulating sealant ( (Not shown).

Next, the solar cell integrated roof material manufactured as described above was installed on the roof surface.

FIG. 6 is a schematic diagram of the solar cell integrated roof material of Example 1 installed on the roof surface. In FIG. 6, 60
1 is a solar cell integrated roofing material, 602 is a general roofing material, 60
3 is a cable for taking out a terminal, 604 is a down ridge cover,
605 indicates the main building cover.

The arrangement of the solar cell module of Example 1 is as follows.
As shown in FIG. 5B, the shape of the step of the solar cell integrated roofing material is substantially the same as the shape of the joint between the adjacent solar cell integrated roofing material. By installing it, the roof filling rate of solar cells is increased.

The installation of the solar cell integrated roof material shown in FIG. 6 will be described in more detail with reference to FIG.

FIG. 7A is a schematic cross-sectional view showing a state in which the solar cell integrated roof material of Example 1 is installed on a roof.
FIG. 7B is a schematic cross-sectional view of the installation of the cable connection portion on the eaves side, and FIG. 7C illustrates the superposition of the solar cell integrated roof material on the eaves side and the solar cell integrated roof material on the ridge side. FIG. In FIG. 7, 701 is a photovoltaic element, 702 is a cable for taking out a terminal, 703 is a screw for fixing a roof material, 704 is a connector for electrical connection, 705 is a drainage member for eaves disposal, and 706 is a solar cell on the ridge side Integral roof material, 707 is a solar cell integrated roof material on the eaves side, 708 is a step of the solar cell integrated roof material, 709 is a junction between adjacent solar cell integrated roof materials, 710
Denotes a ground board, 711 denotes a waterproof sheet, and 712 denotes a roofing material.

As shown in FIG. 7A, the joining portions 709 at both ends of the adjacent solar cell integrated roof material are overlapped with each other, and the back side (non-light receiving surface side) of the solar cell integrated roof material is directly , And fixed on a roof installation surface, that is, on a field board 710.
Also, as shown in FIG. 7C, the roof-side solar cell-integrated roofing material 706 is overlaid on the eaves-side solar cell-integrated roofing material 707, so that the roof surface can be installed in the flow direction. Done. At this time, the construction was performed such that the joint 709 and the step 708 of the solar cell integrated roof material 706 on the ridge side were respectively superimposed on the step 708 and the joint 709 of the solar cell integrated roof material 707 on the eaves side.

Then, in the overlapping portion of the roof material,
A waterproof sheet 711 (butyl tape) was provided. Terminal extraction cable 702 and electrical connection connector 7
No. 04 was installed in the flow direction of the roof surface so as to be accommodated in the steps of the solar cell integrated roof materials 706 and 707. The fixing of the solar cell integrated roofing materials 706 and 707 is
Was fixed on a base plate 710.

The electrical connector 70 on the eaves side
4 is connected to the base plate 7 as shown in FIG.
A cable 702 for extracting a terminal is provided in a portion where 10 is notched
And electrical connection was made under the ground plate 710. Then, after the eaves draining member 705 was fixed from above, the solar cell integrated roof material was fixed.

The general roofing material (indicated by reference numeral 602 in FIG. 6) has the same shape and size as the solar cell-integrated roofing material. It was attached in the same way.

The installation and electrical connection in the above-described procedure were repeated, and a solar cell integrated roof material as shown in FIG. 6 was arranged on the roof surface. Finally, by fixing the down ridge cover 604 and the main ridge cover 605 at predetermined positions, a roof in which the solar cells were integrated was formed.

In the solar cell-integrated roofing material of Example 1, by providing a step in the solar cell-integrated roofing material, the rigidity of the roofing material was increased, handling was facilitated, and work efficiency was improved.

Further, by forming a step so as to be concave on the non-light receiving surface side, the terminal take-out box, the terminal take-out cable 702, and the electrical connection connector 704 can be accommodated in the step 708. For this reason, the protrusion on the back surface side of the roof material can be eliminated, and the roof material can be installed facing the roof installation surface. Further, since the terminal take-out box can be accommodated in the step, the terminal take-out box is not damaged during the construction work.

Further, since a step is provided in the solar cell integrated roof material, the worker can step on the step during the construction work, and the workability is greatly improved.

Also, the shape of the joint between the central step of the solar cell integrated roof material and the adjacent roof material is substantially the same, and the ridge side roof material is placed on the step and the joint of the eaves-side roof material. By overlapping the joint and the step of
The filling rate of the solar cell part on the roof surface could be improved.

Example 2 The solar cell integrated roof material of Example 2 is different from the solar cell integrated roof material of Example 1 in that
A joining member is used at a lateral joint between roofing materials, and the shape and size of the joining member are substantially the same as the shape and size of the step of the solar cell integrated roofing material.

FIG. 8 is a schematic view showing a state where the solar cell integrated roof material of Example 2 is fixed on the roof surface.
FIG. 8A is a schematic sectional view, and FIG. 8B is a schematic view for explaining a procedure of arranging a ridge-side roofing material on an eaves-side roofing material. In FIG. 8, reference numeral 801 denotes a photovoltaic element;
Is a cable for taking out a terminal, 803 is a screw for fixing a roof material, 804 is a joint member for a roof material, 805 is a field board, 806.
Is a roof material integrated with solar cells on the ridge side, 807 is a roof material integrated with solar cells on the eaves side, 808 is a connector for electrical connection, 8
Reference numeral 09 denotes a waterproof sheet, and reference numeral 810 denotes a roofing material.

In the solar cell integrated roof material of Example 2, the joint member 804 was bent into a U-shape so that the shape and size of the joining member 804 were substantially the same as the steps of the solar cell integrated roof material.

As a joining member, a coated steel plate (manufactured by Nisshin Steel, trade name: Galbuster, 0.4 mm thick) was used. Further, in the solar cell integrated roof material, the lateral joining portions at both ends are bent 90 ° toward the light receiving surface side, and the size of the bent portion is combined with the joining member.

The roofing material integrated with the solar cell of Example 2 is different from the roofing material integrated with the solar cell of Example 1 in the shape of the joint in the horizontal direction. The size of the material used in the solar cell integrated roof material of Example 1 was changed and used.

The arrangement of the solar cell integrated roof material on the roof surface is performed in the same manner as the solar cell integrated roof material of the first embodiment. The joining member 804 is put between the roof materials in the horizontal direction, and the screw 803 is mounted. On the roof surface.

The roofing material integrated with a solar cell of Example 2 was installed in the same manner as the roofing material integrated with a solar cell of Example 1, except for the matters described above.

In the solar cell integrated roofing material of Example 2, by providing the solar cell integrated roofing material with a step, the rigidity of the roofing material was increased, the handling was facilitated, and the working efficiency was improved.

Further, by forming a step so as to be concave on the non-light receiving surface side, the terminal take-out box, the terminal take-out cable 802, and the electrical connection connector 808 can be accommodated in the step. For this reason, the protrusion on the back surface side of the roof material can be eliminated, and the roof material can be installed facing the roof installation surface. Further, since the terminal take-out box can be accommodated in the step, the terminal take-out box is not damaged during the construction work.

Further, since the step is provided on the solar cell integrated roof material, the worker can step on the step during the construction work, and the workability is greatly improved.

Further, the step at the center of the solar cell-integrated roofing material and the shape of the lateral joint member used between the adjacent roofing material are made substantially the same, and the step of the eaves-side roofing material and the upper part of the joint are formed. In addition, the overlapping rate of the solar cell part on the roof surface could be improved by overlapping the joint and the step of the ridge side roof material.

Embodiment 3 The solar cell integrated roofing material of Example 3 is different from the solar cell integrated roofing material of Example 1 in that
The shape of the step at the center is changed.

FIG. 9 is a schematic view showing a state where the solar cell integrated roof material of Example 3 is fixed on the roof surface.
9A is a schematic cross-sectional view, and FIG. 9B is a schematic view for explaining a procedure for arranging a ridge-side roofing material on an eaves-side roofing material. In FIG. 9, reference numeral 901 denotes a photovoltaic element;
Is a cable for taking out terminals, 903 is a screw for fixing a roof material, 904 is a base plate, 905 is a roof material integrated with a solar cell on the ridge side, 906 is a roof material integrated with a solar cell on the eaves side, 907
Is a connector for electrical connection, 908 is a waterproof sheet, 909
Indicates underlaying materials, respectively.

In the solar cell integrated roofing material of the third embodiment, as shown in FIG. 3, the central step of the solar cell integrated roofing material has a triangular shape, and the joint between the solar cell integrated roofing material and the adjacent horizontal roofing material is formed. In the combined state, the solar cell integrated roof material was bent so that the shape was substantially the same as the step shape at the center. Along with this shape change, the material used in the integral molding process of the solar cell integrated roof material of Example 3 was used by changing the size of the material used for the solar cell integrated roof material of Example 1.

The roofing material integrated with a solar cell of Example 3 was installed in the same manner as the roofing material integrated with a solar cell of Example 1, except for the matters described above.

In the solar cell integrated roofing material of the third embodiment, by providing a step on the solar cell integrated roofing material, the rigidity of the roofing material was increased, the handling was facilitated, and the working efficiency was improved.

Further, by forming a step so as to be concave on the non-light receiving surface side, the terminal take-out box, the terminal take-out cable 902, and the electrical connector 907 can be accommodated in the step. For this reason, the protrusion on the back surface side of the roof material can be eliminated, and the roof material can be installed facing the roof installation surface. Further, since the terminal take-out box can be accommodated in the step, the terminal take-out box is not damaged during the construction work.

Further, since a step is provided in the solar cell integrated roof material, an operator can step on the step during the construction work, and workability is greatly improved.

Further, the step at the center of the solar cell-integrated roofing material and the shape of the lateral joining member used between the adjacent roofing material are set to be substantially the same, and the step of the eaves-side roofing material and the joining In addition, the overlapping rate of the solar cell part on the roof surface could be improved by overlapping the joint and the step of the ridge side roof material.

Embodiment 4 The solar cell integrated roof material of Example 4 is different from the solar cell integrated roof material of Example 1 in that
The size is a standard size (narrow).

FIG. 10 is a schematic view showing a state in which the solar cell integrated roof material of Example 4 is fixed on the roof surface.
10A is a schematic cross-sectional view, and FIG. 10B is a schematic view for explaining a procedure of arranging a ridge-side roofing material on an eaves-side roofing material. In FIG. 10, reference numeral 1001 denotes a photovoltaic element;
002 is a cable for taking out a terminal, 1003 is a screw for fixing a roof material, 1004 is a ground plane, 1005 is a roof material integrated with a solar cell on the ridge side, 1006 is a roof material integrated with a solar cell on the eaves side, 1007 is an electrical connection A connector, 1008 indicates a waterproof sheet, and 1009 indicates an underlaying material.

The solar cell-integrated roofing material of Example 4 was manufactured by manufacturing the same size as the standard size, forming the step by integral molding, bending, and mounting a terminal take-out box in the step. It is.

FIG. 11 is a schematic diagram for explaining the procedure for manufacturing the solar cell integrated roof material of Example 4, and FIG.
1 (a) is a schematic view of a photovoltaic element group of a standard size, and FIG. 11 (b) is a schematic view of a solar cell integrated roof material after finishing. In FIG. 11, reference numeral 1101 denotes a photovoltaic element group; 1102, a copper foil for taking out a positive electrode terminal;
Is a copper foil for extracting a negative terminal, 1104 is a cable for extracting a terminal, 1105 is a connector for electrical connection, 11
Reference numeral 06 denotes a terminal extraction box.

In the solar cell integrated roofing material of Example 4, as shown in FIG. 11, a photovoltaic element group 1101 was set as a standard size, and a copper foil 1102 for taking out a positive pole terminal and a negative Copper foil for pole terminal extraction 11
03 is taken out. Then, it was integrally formed in the same manner as the roofing material integrated with the solar cell of Example 1, and then bent to form a step, and a terminal extraction box 1106 and an electric connection cable 1104 were attached inside the step. In the solar cell integrated roofing material of Example 4, since the material used in the integral molding process is a standard size, a material different from the solar cell integrated roofing material of Example 1 was used.

In the solar cell integrated roof material of Example 4, as shown in FIG. 10, the solar cell integrated roof material manufactured by the above-described procedure was installed on the roof surface.

The roofing material integrated with a solar cell of Example 4 was installed in the same manner as the roofing material integrated with a solar cell of Example 1, except for the matters described above.

In the solar cell-integrated roofing material of Example 4, by providing a step in the solar cell-integrated roofing material, the rigidity of the roofing material was increased, handling was facilitated, and work efficiency was improved.

Further, by forming a step so as to be concave on the non-light receiving surface side, the terminal take-out box 1106, the terminal take-out cable 1002, and the electrical connection connector 1
007 can be stored in the step. For this reason, the protrusion on the back surface side of the roof material can be eliminated, and the roof material can be installed facing the roof installation surface.

Further, since the terminal take-out box 1106 can be accommodated in the step, the terminal take-out box 1106 is not damaged during the construction work.

Example 5 The solar cell-integrated roofing material of Example 5 was obtained by sandwiching a photovoltaic element with a film instead of being integrally formed with the roofing material body into a sheet shape, and then forming a concave shape on the back surface side. It is attached and fixed on a roofing material main body having a step.

FIG. 12 is a schematic diagram for explaining a procedure for manufacturing a sheet-like solar cell used for the solar cell-integrated roofing material of Example 5, and FIG. 12 (a) is a photovoltaic element. FIG. 12B is a schematic cross-sectional view for explaining a material configuration to be integrally molded, and FIG. 12C is a schematic diagram of a sheet-shaped solar cell after the integral molding. In FIG. 12, reference numeral 1201 denotes a photovoltaic element group, 1202 denotes a positive electrode extraction wire, 1203 denotes a negative electrode extraction wire, 1204 denotes an outermost surface covering material, 1205 denotes a filler, 1
Reference numeral 206 denotes an insulating film.

In the solar cell integrated roof material of Example 5, the photovoltaic element groups were connected in series in the same manner as in the solar cell integrated roof material of Example 1, but instead of the terminal extraction copper foil, an electric wire was used. 1202 and 1203 were used. The integral molding process includes the insulating film 1206, the filler 1205, the photovoltaic element group 1201, the filler 1205, and the outermost covering material 120.
4 were laminated in this order (FIG. 12 (b)), and the same procedure was carried out as for the solar cell integrated roof material of Example 1. Each of the materials was the same as the solar cell integrated roofing material of Example 1 to manufacture a sheet-like solar cell (FIG. 12).
(C)).

FIG. 13 is a schematic diagram for explaining a procedure for manufacturing the solar cell integrated roof material of Example 5, and FIG.
3 (a) is a schematic view of a roofing material main body having a step that is concave on the back side, and FIG. 13 (b) is a sheet-like solar cell stuck thereon to form a terminal extraction portion within the step on the back side. It is the schematic of the solar cell integrated roof material showing the state which carried out. FIG.
, 1301 is a roofing material main body, 1302 is a wire drawing hole at a step portion of the roofing material main body, 1303 is a sheet-like solar cell, 1304 is a photovoltaic element group, 1305 is a terminal extraction cable, and 1306 is a terminal extraction box. Shown respectively.

In the roofing material integrated with a solar cell of Example 5, the steps of the roofing material main body having a concave step on the back side include:
An electric wire lead-in hole 1302 is provided in advance, and the electric wire can be drawn in after the solar cell is attached. Then, the sheet-shaped solar cell manufactured by the above-described procedure was stuck and fixed on the roof material main body using a double-sided tape (not shown).

Each of the electric wires 1202 and 1203 (shown in FIG. 12) is drawn into the step from the electric wire drawing hole 1302, and the electric connection is made. In other words, as shown in FIG. 13B, on one side (rear side in the figure), the photovoltaic element groups are electrically connected as they are, and the photovoltaic element groups are connected in series, and on the other side (front side in the figure).
Then, the terminal extraction box 13 is inserted into each wire entry hole 1302.
06, and the terminal extraction cable 130
5 are electrically connected to electric wires 1202 and 1203 (shown in FIG. 12). Further, the electric wire entry hole 1302 was sealed with a sealing material (RTV silicone sealant) (not shown).

Using the solar cell integrated roof material manufactured as described above, installation was performed in the same manner as the solar cell integrated roof material of Example 1.

In the solar cell integrated roofing material of the fifth embodiment, a sheet-like solar cell is stuck on a roofing material having a concave step on the back side, and a terminal take-out portion is formed in the step. A solar cell integrated roofing material without protrusions on the side could be manufactured. As a result, the roofing material could be installed facing the roof installation surface, and the workability was improved.

Further, since the terminal take-out box can be accommodated in the step, the terminal take-out box is not damaged during the construction work.

Further, since the step is provided on the solar cell integrated roof material, the operator can step on the step during the construction work, and the workability is greatly improved.

Example 6 The solar cell integrated roofing material of Example 6 is different from the solar cell integrated roofing material of Example 1 in that
The solar cell-integrated roof material has a length from the eaves of the roof to the ridge, and is installed on a gable roof.

FIG. 14 is a schematic view for explaining the solar cell-integrated roofing material of the sixth embodiment. FIG. 14A is a schematic view of the solar cell-integrated roofing material, and FIG. It is the schematic which shows the state which installed one solar cell integrated roofing material from the eaves to the ridge on the gable roof. 14, reference numeral 1401 denotes a photovoltaic element; 1402, a cable for extracting a terminal; 1403, a connector for electrical connection;
Numeral 04 denotes a solar cell integrated roof material.

In the solar cell integrated roofing material of Example 6, compared with the solar cell integrated type roofing material of Example 1, the width of the outermost covering material (steel plate) is kept as it is, and The length was changed to match the length from the eaves to the ridge of the gable roof, and a solar cell integrated roofing material 1404 was manufactured. Further, the photovoltaic element 1401 is
The size was changed to a long size, and the size of the filler, the insulating film, and the outermost surface covering material was changed so as to match the size of the outermost surface covering material, and an integral molding process was performed. In addition, a long size bender was used for bending the solar cell integrated roof material. The terminal was taken out in the same manner as in the solar cell integrated roof material of Example 1.

As shown in FIG. 14B, this solar cell integrated roof material was installed on a gable roof. The terminal take-out part was arranged so as to be on the ridge side of the roof, and was installed in the same manner as the solar cell integrated roof material of Example 1. Electrical connection was made on the ridge side, and a ridge cover member (not shown) was fixed so as to cover the ridge side. In addition, a keraba cover member (not shown) was arranged and fixed to the keraba portion.

The solar cell integrated roofing material of Example 6 was installed in the same manner as the solar cell integrated roofing material of Example 1 except for the above.

In the solar cell integrated roofing material of Example 6, the installation work could be simplified by using one roofing material from the eaves to the ridge side.

Further, by providing a step in the solar cell integrated roof material, the rigidity of the roof material was increased, handling was facilitated, and work efficiency was improved.

Further, by forming a step so as to be concave on the non-light receiving surface side, the terminal take-out box, the terminal take-out cable, and the electrical connection connector could be accommodated in the step. For this reason, the protrusion on the back side of the roof material can be eliminated, and the roof material can be installed facing the roof installation surface.

In addition, since the terminal take-out box can be accommodated in the step, the terminal take-out box is not damaged during the construction work.

Further, since the step is provided in the solar cell integrated roof material, the worker can step on the step during the construction work, and the workability is greatly improved.

[Embodiment 7] Embodiment 7 relates to a roof with solar cells manufactured using the solar cell-integrated roofing material of Embodiment 1, wherein the solar cells are connected to a system power circuit, and a solar power generation system is constructed. It was built.

FIG. 15 is a schematic diagram for explaining the photovoltaic power generation system according to the seventh embodiment. In FIG.
01 is a solar cell integrated roof material, 1502 is a connection box, 15
03 denotes an inverter, 1504 denotes a switchboard, 1505 denotes an integrated wattmeter, 1506 denotes a system power circuit, and 1507 denotes home electrical equipment.

FIG. 15 will be described briefly. The electric power generated by the solar cell integrated roofing material 1501 is
02, are converted to cross-current by an inverter 1503, and sent to an electric device 1507 at home via a switchboard 1504. Here, if the amount of generated power is large and there is excess power, the power can be transmitted to the system power circuit 1506 and the power company can purchase the power. Conversely, when the amount of power generation is small or when the power consumption of the electric equipment 1507 in the home is large, the shortage can be supplemented by the system power circuit 1506 and purchased from the power company.

In the solar power generation system according to the seventh embodiment, by connecting to the system power circuit 1506, a system cooperation system can be constructed.

[0184]

The solar cell integrated roofing material according to the present invention comprises:
With the above-described configuration, a roof and a photovoltaic power generation system can be constructed using the solar cell integrated roof material, and the effects described below can be obtained. In addition, by using the solar cell integrated roof material manufacturing method and the installation method according to the present invention, a solar cell capable of obtaining the effects described below can be manufactured and installed.

That is, a solar cell integrated roofing material according to the present invention is a solar cell integrated roofing material comprising at least a photovoltaic element and a roofing material, wherein the solar cell integrated type roofing material is at least a photovoltaic element. The non-light-receiving surface side has a concave portion in a portion where no is present, and a terminal extraction portion of the photovoltaic element is formed in the step.

Therefore, by providing the steps, the rigidity of the roofing material is increased, so that the handling becomes easy and the working efficiency is improved.

Further, by forming the step so as to be concave on the non-light receiving surface side, the terminal take-out box, the terminal take-out cable, and the electrical connection connector can be accommodated in the step. Therefore, the roof material can be directly attached on the roof surface without the protrusion on the back surface side of the roof material, so that the workability is improved.

In addition, since the projections on the back surface side of the roofing material can be eliminated, damage to the terminal take-out box during construction work can be prevented.

Further, when a wide-sized solar cell integrated roof material is used, the following effects can be obtained.

By providing a step at the center of the solar cell integrated roofing material, an operator can step on the step during the construction work, and workability is greatly improved.

Further, the step at the center of the solar cell-integrated roofing material and the shape of the joint between the adjacent roofing material are made substantially the same, and the step on the eaves-side roofing material and the joint on the ridge side roofing material are placed on the joint. By arranging the joining portion of the material and the step so as to overlap each other, the filling rate of the solar cell portion on the roof surface can be improved.

[Brief description of the drawings]

FIG. 1 is a schematic view for explaining a solar cell integrated roofing material according to the present invention, wherein FIG. 1A is a schematic cross-sectional view showing an installed state of a solar cell integrated roofing material, and FIG. FIG. 3C is a schematic cross-sectional view of a roof material integrated with a solar cell, in which FIG.

FIG. 2 is a schematic configuration diagram of a photovoltaic element used in a solar cell integrated roofing material according to the present invention.

3A and 3B are schematic diagrams for explaining a procedure for manufacturing a wide-sized group of photovoltaic elements, in which FIG. 3A is a schematic view of a photovoltaic element before serialization, and FIG. FIG. 3C is a schematic cross-sectional view for explaining a procedure for serializing the photovoltaic devices, and FIG.

4A and 4B are schematic diagrams for explaining a method of manufacturing a solar cell integrated roofing material according to the present invention, wherein FIG. 4A is a schematic diagram for explaining a procedure for laminating each material, and FIG. Schematic cross-sectional view of the solar cell integrated roof material after, (c) is a schematic cross-sectional view of the solar cell integrated roof material after bending, (d) is the sun after attaching a terminal take-out box and a terminal take-out cable FIG. 2 is a schematic sectional view of a battery-integrated roofing material.

5A and 5B are schematic diagrams for explaining a filling rate of a solar cell with respect to a roof, where FIG. 5A is a schematic diagram showing one example, and FIG. 5B is a schematic diagram showing another example.

FIG. 6 is a schematic diagram showing a state where the solar cell integrated roof material of Example 1 is installed on a roof surface.

FIGS. 7A and 7B are schematic views for explaining in more detail the installation of the solar cell-integrated roofing material of Example 1, wherein FIG. 7A is a schematic sectional view showing the installation state, and FIG. (C) is a schematic diagram for explaining the superposition with the roofing material integrated with solar cells on the eaves side and the ridge side.

FIG. 8 is a schematic diagram showing a state in which the solar cell integrated roof material of Example 2 is fixed on the roof surface, (a) is a schematic sectional view,
(B) is the schematic for demonstrating the procedure of arrange | positioning the roof material on the ridge side to the roof material on the eaves side.

FIG. 9 is a schematic diagram showing a state in which the solar cell integrated roof material of Example 3 is fixed on the roof surface, (a) is a schematic sectional view,
(B) is the schematic for demonstrating the procedure of arrange | positioning the roof material on the ridge side to the roof material on the eaves side.

FIG. 10 is a schematic view showing a state in which the solar cell integrated roof material of Example 4 is fixed on a roof surface, where (a) is a schematic sectional view,
(B) is the schematic for demonstrating the procedure of arrange | positioning the roof material on the ridge side to the roof material on the eaves side.

FIGS. 11A and 11B are schematic diagrams for explaining a procedure for manufacturing the solar cell integrated roofing material of the fourth embodiment, in which FIG. 11A is a schematic diagram of a standard-sized photovoltaic element group, and FIG. The schematic diagram after the finish of an integrated roofing material.

12A and 12B are schematic diagrams for explaining a procedure for manufacturing the sheet-like solar cell of Example 5, in which FIG. 12A is a schematic diagram of a photovoltaic element group, and FIG. FIG. 2 is a schematic cross-sectional view for explaining, and FIG. 2C is a schematic view of a sheet-like solar cell after an integral molding process.

13A and 13B are schematic diagrams for explaining a procedure for manufacturing the solar cell integrated roof material of Example 5, wherein FIG. 13A is a schematic diagram of the solar cell integrated roof material, and FIG. The schematic diagram of the solar cell integrated roof material which shows the procedure which sticks a battery and forms the terminal extraction part in the step on the back side.

14A and 14B are schematic diagrams for explaining a solar cell integrated roof material according to a sixth embodiment, wherein FIG. 14A is a schematic diagram of a solar cell integrated roof material, and FIG. 14B is a schematic diagram of one solar cell integrated roof material; The schematic diagram which shows the state in which the material was installed.

FIG. 15 is a schematic diagram illustrating a solar power generation system according to a sixth embodiment.

FIG. 16 is a schematic view of a conventional solar cell integrated roof material,
(A) is a schematic diagram of an installation cross-sectional structure, (b) is an overall schematic diagram of a solar cell integrated roof material.

FIG. 17 is a schematic view of a conventional solar cell-integrated roofing material having another embodiment, where (a) is a schematic view of an installation cross-sectional structure, and (b).
1 is an overall schematic view of a solar cell integrated roof material.

[Explanation of symbols]

602, 706, 1301, 1609, 1709 General roofing materials 101, 601, 707, 708, 806, 807, 9
05,906,1005,1006,1404,150
1,1601,1701 Solar cell integrated roof material 102,409,603,702,802,902,1
002, 1104, 1305, 1402, 1603, 1
703 Terminal extraction cable 103, 703, 803, 903, 1003, 160
5,1705 screws 104,710,805,904,1004,160
8,1708 Field board 105,701,801,901,1001,140
1,1610,1710 photovoltaic elements 106,704,808,907,1007,110
5,1403,1611,1711 Electrical connector 107,408,1106,1306,1602,17
02 Terminal take-out box 108, 403, 1204 Top surface covering material 109, 402, 1205 Filling material 110, 405 Top surface covering material 111 410, 501 Step 114, 115, 502, 709 Joint 401, 507, 1101, 1201, 1304 Photovoltaic element group 404, 1206 Insulating film 406 Terminal extraction hole 407 Electrode extraction copper foil 201 Conductive substrate 202 Metal electrode layer 203 Semiconductor photoactive layer 204 Transparent conductive layer 205, 301 Collector electrode 302, 306 Copper for serial connection Foil 303 SUS board 304, 1103 Copper foil for taking out the negative pole 305, 1102 Copper foil for taking out the positive pole 503 Non-power generation area of roof 604 Downing ridge cover 605 Main building cover 705 House draining member 711, 809, 908, 1008 Waterproof sheet 7 14,810,909,1009 Roofing material 804 Roofing material joining member 1502 Junction box 1503 Inverter 1504 Switchboard 1505 Integrating wattmeter 1506 System power circuit 1507 Household electric equipment 1604,1704 Roofing member 1606,1706 Covering member 1607, 1707 Sangi 1202 Positive lead wire 1203 Negative lead wire 1302 Wire lead-in hole 1303 Sheet-shaped solar cell

Continuing on the front page (72) Inventor Hidehisa Makita 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Makoto Sasaoka 3-30-2, Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Tatsuo Fujisaki 3-30-2 Shimomaruko, Ota-ku, Tokyo F-term (reference) 2E108 KK04 LL03 MM03 NN07 5F051 BA03 GA02 JA02 JA04 JA05 JA06 JA08

Claims (16)

[Claims] 1. A solar cell integrated roofing material comprising at least a photovoltaic element and a roofing material main body, wherein the solar cell integrated roofing material has a concave non-light receiving surface at least in a portion where no photovoltaic element is present. The solar cell integrated roof material, wherein the solar cell has a terminal step, and the terminal extraction portion of the photovoltaic element is formed in the step. 2. The solar cell integrated roof material according to claim 1, wherein the step is convex on the light receiving surface side of the solar cell integrated roof material. 3. The solar cell integrated roofing material according to claim 1, wherein the step is formed within a space between the photovoltaic element groups of the solar cell integrated roofing material. 4. The shape of the step is substantially the same as the shape of a joint between one solar cell integrated roof material and another adjacent solar cell integrated roof material adjacent to the solar cell integrated roof material. The solar cell-integrated roofing material according to claim 2, wherein: 5. The solar cell integrated roofing material according to claim 1, wherein the roofing material body is a metal plate. 6. The solar cell integrated roof material according to claim 1, wherein a light receiving surface side of the photovoltaic element is coated with a resin. 7. The solar cell integrated roofing material, wherein the outermost surface coating material is a weather-resistant transparent resin.
7. The solar cell integrated roofing material according to any one of items 6 to 6. 8. The solar cell integrated roofing material according to claim 1, wherein said photovoltaic element is a thin film semiconductor formed on a stainless steel substrate. 9. The solar cell integrated roofing material according to claim 1, wherein the solar cell integrated roofing material has flexibility. 10. A roof comprising a solar cell integrated roofing material according to any one of claims 1 to 9. 11. A solar power generation system comprising a solar cell integrated roofing material according to any one of claims 1 to 9. 12. After manufacturing a flat solar cell integrated roof material constituting at least the photovoltaic element and the roof material main body, at least the photovoltaic element is used to remove the flat solar cell integrated roof material. Forming a step which becomes concave on the non-light receiving surface side by forming at a portion not to be formed, and thereafter forming a terminal extraction portion of the photovoltaic element within the step, manufacturing a solar cell integrated roof material, Method. 13. The method according to claim 12, wherein the roof material body is a metal plate. 14. After manufacturing at least a sheet-like solar cell constituting a photovoltaic element, the sheet-like solar cell is provided with a step of a roof material body having a step that is concave at least on a non-light-receiving image side. A method of manufacturing a roofing material integrated with a solar cell, comprising: fixing the terminal portion of the sheet-shaped solar cell in a step of the roofing material main body; 15. A solar cell integrated roof material comprising at least a photovoltaic element and a roof material body, wherein the solar cell integrated roof material has a non-light-receiving surface at least in a portion where no photovoltaic element is present. The step has a concave side, and the terminal extraction portion of the photovoltaic element uses a solar cell integrated roof material formed in the step, and the non-light receiving surface side has a substantially uneven surface. A method of installing a solar cell-integrated roofing material, which is installed facing a roof-like installation surface. 16. The installation method for a solar cell integrated roofing material according to claim 15, wherein the electric connection member in the connection portion of the solar cell integrated roofing material is housed and installed in the step.