JP2006140420A - Solar cell module and installation structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar cell module which can be laid according to the shape of a substrate for the solar cell module, can be installed with excellent appearance, and can realize weight reduction as a whole and reduction of manufacturing costs; and to provide an installation structure for the solar cell module. <P>SOLUTION: The solar cell module is composed by sealing a solar cell sub-module group constituted by connecting a plurality of solar cells in series and/or in parallel by a rear face protection material 122, insulating sealing materials 123, 124, and a surface protection material 121. A thin plate made of metal or plastic is used for the rear face protection material 122. Bending is not executed to the periphery of the solar cell module, namely, the four sides in the case of the rectangular solar cell module. The solar cell module is formed into a flat plate shape and made flexible. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a long solar cell module and a solar cell module installation structure.

  A solar cell is a power generation device that directly obtains electrical energy from solar light energy. As global environmental issues are highlighted, solar cells have been attracting attention as a clean energy source and gradually being introduced.

Here, as a structure of a conventional solar cell module, for example, as shown in FIGS. 9 to 11, a structure in which a frame is attached to the periphery (Japanese Patent Laid-Open No. 2002-115375, Patent Document 1) is generally employed. .
As shown in FIGS. 9A to 9D, the solar battery panel 20 includes a solar battery panel main body 24 in which a plurality of solar battery cells 23 are arranged in a panel shape, and a frame 25 as shown in FIG. The terminal protection cover 26 and the output lead wires 27 and 28 as shown in FIG. 9D are provided on the back surface of the solar cell panel body 24.
Moreover, the solar cell panel 20 is attached to flat roofs, such as the folded-plate roof 31 of a unit building, as FIG. 11 shows.
The folded plate roof 31 is formed by forming a plurality of substantially mountain-shaped protrusions 33 in parallel at a constant interval 34.

Then, as shown in FIG. 9A, the substantially rectangular solar cell panel 20 intersects with the extending direction 15 of the ridge 33 (usually orthogonal but may not be orthogonal) ( It is attached to the folded plate roof 31 via the fixture 21 with its one side 17 and the opposite side 18 directed in the crossing direction 16). The solar cell panel 20 is arranged in an inclined manner as a whole by fixing one side 17 side in a substantially grounded state and fixing the opposite side 18 side in a floating state.
In addition, the solar cell panel body generally uses glass as a protective material on the light receiving surface side.

  In addition, as shown in FIG. 12, it has a structure using a translucent film as a protective material on the light receiving surface side of the solar cell module 200 and a steel plate material subjected to bending processing on the back surface protective material 201, and can be reduced in weight and size. Solar cell modules have also been developed. FIG. 12 shows a state in which the solar cell module 200 is mounted on the folded plate roof 202.

  In any of the conventional solar cell modules, in the case of the roof material separation type, the frame is fixed to a metal fitting attached to the tile roof or the folded plate roof, and the solar cell module is fixed to the frame with screws. It is. Also, in an outdoor installation type solar cell power generation facility that is not related to a roof structure, a solar cell module having the same structure as described above is installed on a mount.

On the other hand, in an outdoor installation type solar cell power generation facility unrelated to the roof structure, there is a case where a solar cell module is installed on a curved surface with an emphasis on aesthetics.
Here, as shown in FIG. 9 to FIG. 11, a conventional solar cell panel having a general size (about 1 m square) having a structure in which a frame is attached to the periphery using a protective material on the light receiving surface side of the related art. Assume that they are mounted side by side on a curved surface. If it does so, since a solar cell module is planar shape, it becomes polygonal shape and it cannot be called a curved surface, and the beauty | look is impaired. If the solar cell panel is reduced in size and arranged in a large number, it can be brought close to a curved shape. However, since the number of installations increases, the installation cost also increases. Moreover, since the solar cell panel of the structure of FIGS. 9-11 uses glass as a structural member, mass is heavy and the intensity | strength of a mount frame is required, and there also exists a problem that mount manufacturing cost increases.
Such a situation is not solved even by the solar cell module as shown in FIG.
JP 2002-115375 A

  With respect to the above circumstances, the present invention can be laid along the shape of the foundation of the solar cell module, can be installed with an excellent aesthetic appearance, and can achieve overall weight reduction and production cost reduction. An object of the present invention is to provide a solar cell module and a solar cell module installation structure.

  In order to solve the above problems, a solar cell module according to the present invention is a solar cell module in which a plurality of solar cells are connected in series and / or in parallel to form a solar cell submodule group. A thin plate is used as the back surface protective material, the periphery is not bent, a flat plate shape is formed, and flexibility is provided. Here, the periphery means four sides in a rectangular solar cell module. Moreover, the solar cell module is formed by sealing a solar cell sub-module group with a back surface protective material, an insulating sealing material, and a surface protective material as a general configuration, as long as it meets the purpose of the present invention. It is not limited to such a thing. It is preferable to use a thin plate made of metal or plastic for the back surface protective material, but in short, any material that gives the flexibility of the solar cell module can be used as long as it is not contrary to the object of the present invention.

  In the solar cell module of this configuration, it becomes possible to lay along the shape of the base on which the solar cell module is installed, and even if the base shape is convex upward and convex downward, it has a sense of unity with the base and is aesthetically pleasing. Excellent installation. Furthermore, the solar cell module can be reduced in weight and the manufacturing cost can be reduced by not bending the periphery.

  In one embodiment, the solar cell module according to the present invention is preferably provided with a mounting hole in the back surface protective material. In this way, by providing the mounting holes in the back surface protective material in advance, the dimensions of the screw pitch can be determined without performing inking work during construction. As a result, when a plurality of solar cell modules are installed adjacent to each other, it is possible to prevent the positions where the drill screws are attached from becoming uneven and impair the aesthetic appearance, and to reduce the number of construction steps.

  In another embodiment, the solar cell module according to the present invention is a terminal box for connecting the output of the solar cell submodule group to the back surface protective material side, a cable for connecting adjacent solar cell modules, and a waterproof connector. It is preferable to comprise. The terminal box is generally a positive or negative terminal box.

  In this embodiment, the terminal box / wiring material is not visible from the appearance, and the light-receiving surface side is flattened, so that the appearance is excellent.

  In addition, the present invention is a solar cell module installation structure according to another aspect, wherein the installation structure is a long trapezoidal corrugated folded plate formed by alternately and continuously forming peaks and valleys in parallel to the roof gradient. The solar cell module according to the present invention is arranged so that the back surface protective material of the solar cell module and the peak portion of the trapezoidal corrugated folded plate are in close contact with each other, The solar cell module is attached. In general, it is preferable that the solar cell module is attached by tapping the solar cell module to the peak portion of the trapezoidal corrugated folded plate using a drill screw.

  According to the installation structure of the solar cell module having this configuration, the back surface of the flat solar cell module is supported by the mountain portion of the long trapezoidal corrugated folded plate, thereby giving strength to the wind load due to the wind pressure. be able to. Furthermore, when tapping is applied to the peak portion of the trapezoidal corrugated folded plate using a drill screw, the installation man-hour can be significantly reduced as compared with the case of using a screw and a nut.

  The installation structure of the solar cell module according to the present invention is, in the embodiment, the terminal box and the adjacent solar cell module in the space on the back surface protective material side of the solar cell module and the valley portion of the trapezoidal corrugated folded plate. It is preferable to store a cable to be connected and a waterproof connector.

  In this embodiment, the space in the valley portion of the trapezoidal corrugated folded plate can be used as a rainwater distribution path and a wiring space for the solar cell module from above the water to below the water. Therefore, the light-receiving surface side of the solar cell module is flattened, and the solar cell module excellent in aesthetics can be installed.

  The installation structure of the solar cell module according to the present invention is another embodiment, in which the above (long) trapezoidal corrugated folded plate protrudes upward and protrudes downward in a direction in which peaks and valleys are alternately continued. The solar cell module is laid so that the back surface protective material and the peak portion of the trapezoidal corrugated folded plate are in close contact with the peak portion of the curved trapezoidal corrugated folded plate. Is preferred.

  Here, the trapezoidal corrugated folded plate is long, and for example, an inexpensive keystone plate having a pitch of 90 mm, a height of 25 mm, and a thickness of about 1.2 mm can be used. It is possible to form a shape in which convexities are alternately curved upward and downward, and can be integrated with the gantry by a welding structure or the like.

  The solar cell used in the present invention is not particularly limited. For example, the solar cell is made of a material such as a silicon-based semiconductor or a compound-based semiconductor, and examples thereof include a single crystal system, a polycrystalline crystal semiconductor, and an amorphous semiconductor. It is done. Among these solar cells, crystalline silicon solar cells, in particular, are suitably used in outdoor applications as building material-integrated solar cells due to high reliability, energy conversion efficiency, and the like. Amorphous silicon solar cells are expected as low-cost thin-film solar cells, although the energy conversion efficiency and the like are currently lower than those of the crystalline silicon solar cells. As the solar cell, a module in which a large number of elements composed of a crystalline semiconductor, a compound semiconductor, or a cell having a stacked structure of these semiconductors and an amorphous semiconductor are integrated on a single substrate is used. Further, a module composed of one amorphous silicon solar cell element having a large area may be used. In addition, these solar cells may have a highly transparent surface protective material such as normal or tempered glass, an acrylic resin plate, or a Teflon-based thin film laminated on the surface thereof.

  The back surface protective material on which the solar cell is disposed is not particularly limited. For example, a metal material such as aluminum or steel, an organic material such as polycarbonate or fiber reinforced plastic, or a composite of these materials. The thing which consists of the board | substrate which did is mentioned.

  According to the present invention, in particular, when a solar cell module is installed in a curved surface, even if the base shape is convex upward and the convex shape is downward, it is possible to have a sense of unity with the base and provide an excellent aesthetic appearance. The number of installation steps can be significantly reduced, and the solar cell power generation cost can be greatly reduced.

  Hereinafter, the solar cell module and the installation structure thereof according to the present invention will be described in more detail with reference to the embodiments. However, the present invention is not limited to these embodiments.

First Embodiment First, a first embodiment will be described with reference to FIGS. 1 and 3 to 6.
FIG. 1 is a plan view schematically showing the internal connection structure of the solar cell module according to the first embodiment. FIG. 1 shows a configuration in which an a-Si solar cell sub-module 2 having a size of 20 cm × 90 cm has a total of eight solar cell sub-modules 2 arranged in four rows. Connections between the solar cell sub-modules 2 arranged side by side are connected in series by a serial connection wiring material 3. And the output of the solar cell submodule 2 is made to the non-light-receiving surface side through the through-hole which is provided in the back surface protective material 122 (FIG. 3) mentioned later by the parallel lead wire 4 in the plus side end and the minus side end. They are taken out and connected to the plus parallel line 9 and the minus parallel line 10, respectively.

  On the other hand, the terminal box 5 is provided at each of the plus side end and the minus side end, and guides the output of the solar cell submodule 2 drawn from a through hole (not shown) into the terminal box 5. The plus and minus terminal boxes 5 are integrated by a terminal crossing cable 8. The terminal crossing cable 8 is a pair of positive and negative two-core cables in which the plus parallel line 9 and the minus parallel line 10 are unified in a state of being insulated from each other. The plus parallel line 9 and the minus parallel line 10 penetrate the terminal box 5 with a single line. Thereafter, the plus parallel line 9 and the minus parallel line 10 are connected to an output take-out cable 6 that is a pair of positive and negative two-core cables that are insulated from each other. Further, a pair of positive and negative two-pole waterproof connectors 110 are provided at the tip of the output take-out cable 6 so as to be insulated from each other. From the positive connection part 110 a and the negative connection part 110 b of the two-pole waterproof connector 110, the power generation output of the solar cell submodule is taken out at both ends in the longitudinal direction of the solar cell module 1.

  On the other hand, FIG. 3 is a YY cross-sectional view of FIG. 1 showing a module laminated structure with respect to the solar cell module of the embodiment of FIG. As shown in FIG. 3, the solar cell module 1 includes a surface protection material 121, a surface insulating sealing material 123, a solar cell submodule 2, a back surface insulating sealing material 124, and a back surface protection material 122 in this order from the light receiving surface side. Laminated and configured.

The surface protective material 121 is a Teflon-based thin film sheet of several tens of microns, the surface insulating sealing material 123 and the back surface insulating sealing material 124 are thermoplastic resins, for example, a sheet-like EVA (ethylene-ethylene, about 0.4 mm). Vinyl acetate copolymer) is used.
Further, the solar cell submodule 2 is an amorphous silicon solar cell formed on a film substrate of several tens of microns, and the back surface protection member 122 is a steel plate or aluminum plate of 1 mm or less used as a roofing material, or a plastic. Use a board.

  As a manufacturing process of the solar cell module as shown in FIG. 3, each material of the surface protection material 121, the surface insulating sealing material 123, the solar cell submodule 2, the back surface insulating sealing material 124, and the back surface protection material 122 is used. A laminate manufacturing process in which the layers are heated and heated to about 150 ° C. to bring the front surface insulating sealing material 123 and the rear surface insulating sealing material 124 to the crosslinking temperature and adhere is preferable.

  A mounting hole 11 is processed in advance in the steel plate as the back surface protective material 122 before the laminate manufacturing process, and the front surface insulating sealing material 123 and the back surface insulating sealing material 124 are melted during the manufacturing process of the laminate. Is buried and cross-linked. The front surface insulating sealing material 123 and the back surface insulating sealing material 124 use a transparent color so that the mounting hole 11 can be seen from the light receiving surface side even after the laminate manufacturing process.

  When the solar cell module 1 is fixed to the trapezoidal corrugated folded plate 130, the center of the drill screw 131 is aligned with the center of the mounting hole 11 of the back surface protective material 122, and the surface protective material 121, surface insulation is formed by the drill tip of the drill screw 131. The sealing material 123, the back surface insulating sealing material 124, and the trapezoidal corrugated folded plate 130 having a plate thickness of about 1.2 mm are fixed while being processed.

  4 shows a cross-sectional installation structure of the solar cell module of the first embodiment, and is a view seen from the X direction of FIG. As shown in FIG. 4, a trapezoidal corrugated folded plate 130 is fixed with a welded structure on a pedestal 132 formed by bending a steel material such as I-shaped steel or C-shaped steel with a welded structure.

  The trapezoidal corrugated folded plate 130 is, for example, a commercially available inexpensive iron folded plate material (keystone plate) having a plate thickness of about 1.2 mm, a height of 25 mm, and a pitch of the crests 130a and crests 130a being alternately 90 mm. use. The solar cell module 1 is installed such that the center of the valley wiring space 130c of the trapezoidal corrugated folded plate 130 and the center of the terminal box 5 of the solar cell module 1 coincide with each other, and the back surface protective material 122 on the back surface of the solar cell module 1. It is preferable that the trapezoidal corrugated plate 130 be installed so that the crests 130a are in close contact with each other. In this way, the output extraction cable 7, the terminal crossing cable 8, and the two-pole waterproof connector 110 of the solar cell module 1 of FIG. 1 can be accommodated in the valley wiring space 130 c of the trapezoidal corrugated plate 130.

  Moreover, since the valley part 130b and the wiring space 130c have a gradient from the water surface to the water surface, they also serve as rainwater distribution channels. Moreover, since the solar cell module 1 is installed in close contact with the peak portion 130a of the trapezoidal corrugated folded plate 130, the solar cell module 1 has sufficient strength against wind load due to wind pressure.

  5 is a perspective view showing a state before the solar cell module according to the first embodiment is laid, and FIG. 6 is a perspective view showing a state after the solar cell module is laid.

  As shown in FIGS. 5 and 6, the pedestal 132 has a support column 133 standing on the ground (not shown), and is fixed thereon by a welding structure or with a bolt and nut. The gantry 132 has a structure in which a curved shape convex upward and convex downward is continuously repeated, and a water flow gradient is formed by giving an inclination in a direction orthogonal to the repeating direction. The trapezoidal corrugated folded plate 130 has a mountain portion 130a and a trough portion 130b of the trapezoidal corrugated folded plate 130 extending in parallel with the direction from the water to the water direction, and the mountain in the direction perpendicular to the water direction from the water. The part 130a and the valley part 130b are continuously arranged at equal intervals.

  The solar cell module 1 is installed in such a manner that the long direction of the solar cell module 1 is parallel to the direction from the water to the water, and the trapezoidal corrugated folded plate 130 is processed with the drill screw 131. Fix the surrounding area. When fixing, it is preferable to use an electric impact driver in consideration of workability. Eight adjacent solar cell modules are sequentially laid in the short direction of the solar cell module 1.

  The wiring of the solar cell module 1 is drawn out to the water side of the trapezoidal corrugated folded plate 130, and all the solar cell modules are connected in parallel by a parallel wiring material (not shown), and further connected by a power conditioner via a connection box. After conversion, power is supplied to the grid. In FIGS. 5 and 6, eight solar cell modules are illustrated, but in the case of a large-scale power generation facility of 10 kW, if the output of one solar cell module is DC 200 V, 100 W, 100 units are required to obtain an output of 10 kW. It becomes.

Second Embodiment Next, a second embodiment will be described with reference to FIGS. 2 to 4, 7, and 8.
FIG. 2 is a plan view schematically showing the internal connection structure of the solar cell module according to the second embodiment. FIG. 2 shows a configuration in which a total of eight solar cell submodules 2 are arranged in two rows of four a-Si solar cell submodules 2 having a size of 20 cm × 90 cm. Connections between the solar cell sub-modules 2 arranged side by side are connected in series by a serial connection wiring material 3. Then, the output of the solar cell submodule 2 is passed through a through hole (not shown) provided in the back surface protective material 122 (FIG. 3) by the parallel lead wires 4 at the positive side end and the negative side end, and the terminal box on the non-light-receiving surface side 5 and connected to the plus parallel line 9 and the minus parallel line 10 respectively.

  The plus parallel line 9 and the minus parallel line 10 are single-core insulated cables, and are drawn out at both ends in a direction orthogonal to the longitudinal direction of the solar cell module 1. At the tips of the plus parallel line 9 and the minus parallel line 10, a plus connection part 111a and a minus connection part 111b of a one-pole waterproof connector 111 are provided, respectively, from which the power generation output of the solar cell submodule is taken out.

  Also in the second embodiment, the structure of FIGS. 3 and 4 described for the first embodiment described above is employed. Here, the description is omitted to avoid duplication.

  Further, FIG. 7 is a perspective view showing a state before the solar cell module according to the second embodiment is laid, and FIG. 8 is a perspective view showing a state after the solar cell module is laid.

As shown in FIGS. 7 and 8, the structure of the pedestal 132 and the trapezoidal corrugated folded plate 130 is the same as that shown in FIGS. 5 and 6 employed in the first embodiment, and a description thereof will be omitted.
The solar cell module 1 is installed so that the lengthwise direction of the solar cell module 1 is orthogonal to the direction from the water to the water, and the periphery of the solar cell module 1 is processed while processing the trapezoidal corrugated folded plate 130 with the drill screw 131. Fix the four sides. When fixing, use an electric impact driver in consideration of workability. Adjacent solar cell modules are laid in a total of 8 modules, 4 rows in the direction from the water to the bottom and 2 rows in the direction perpendicular to the water.

  The wiring of the solar cell module 1 is connected to the positive connection portion 111a and the negative connection portion 111b of the one-pole waterproof connector 111 drawn in a direction orthogonal to the longitudinal direction of the adjacent solar cell module 1 from the water side toward the water side. The solar cell modules are connected to each other, drawn out to the water side of the trapezoidal corrugated folded plate 130, and all solar cell modules are connected in parallel with a parallel wiring material (not shown). Furthermore, it is connected by a power conditioner through a connection box, and after being converted from DC to AC, power is supplied to the system.

  7 and 8 illustrate eight solar cell modules. In the case of a large-scale power generation facility of 10 kW, if the output of one solar cell module is DC 200 V and 100 W, 4 × 25 is required to obtain an output of 10 kW. 100 sheets are required in a row.

It is a top view which shows typically the internal connection structure of the solar cell module which concerns on 1st Embodiment. It is a top view which shows typically the internal connection structure of the solar cell module which concerns on 2nd Embodiment. It is a YY sectional view of Drawing 1 and Drawing 2 showing module lamination structure about a solar cell module concerning the 1st and 2nd embodiments. It is sectional drawing which showed the cross-section installation structure of the solar cell module which concerns on 1st and 2nd embodiment, and was seen from X of FIG. It is a perspective view which shows the state before installation of the solar cell module which concerns on 1st Embodiment. It is a perspective view which shows the state after laying of the solar cell module which concerns on 1st Embodiment. It is a perspective view which shows the state before installation of the solar cell module which concerns on 2nd Embodiment. It is a perspective view which shows the state after laying of the solar cell module which concerns on 2nd Embodiment. The conventional solar cell module is shown, (a) is a top view, (b) is a front view, (c) is a side view, (d) is a rear view. It is sectional drawing which shows the cross-sectional shape seen with the AA line of FIG. 9 with the conventional solar cell module. It is sectional drawing which shows the attachment structure of the solar cell module of FIG. It is sectional drawing which shows the cross-section attachment structure of another conventional solar cell module.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Solar cell submodule 3 Series connection wiring material 4 Parallel lead wire 5 Terminal box 6 Output extraction cable 7 Backflow prevention diode 8 Terminal crossing cable 9 Positive parallel line 10 Negative parallel line 11 Mounting hole 110 Two-pole waterproof connector 110a Positive connection portion 110b Negative connection portion 111 One-pole waterproof connector 111a Positive connection portion 111b Negative connection portion 121 Surface protective material 122 Back surface protective material 123 Surface insulating sealing material 124 Back surface insulating sealing material 130 Trapezoidal corrugated folded plate 130a Mountain portion 130b Valley 130c Wiring space 131 Drill screw 132 Base 133 Prop

Claims (6)

In a solar cell module formed by sealing a solar cell submodule group configured by connecting a plurality of solar cells in series and / or in parallel, a thin plate is used as a back surface protective material, and the surroundings are not bent, A solar cell module having a flat plate shape and flexibility. The solar cell module according to claim 1, wherein an attachment hole is provided in the back surface protective material. The solar cell module according to claim 1, further comprising a terminal box for connecting the output of the solar cell submodule group, a cable for connecting an adjacent solar cell module, and a waterproof connector on the back surface protective material side. A long trapezoidal corrugated folded plate in which peaks and valleys are alternately and continuously formed is installed so as to be parallel to the roof slope, and the solar cell module according to any one of claims 1 to 3 An installation structure of a solar cell module, wherein the back surface protective material of the battery module and the peak portion of the trapezoidal corrugated folded plate are arranged in close contact, and the solar cell module is attached to the peak portion of the trapezoidal corrugated folded plate .   5. The terminal box, a cable connecting adjacent solar cell modules, and a waterproof connector are housed in the space on the back surface protective material side of the solar cell module and in the valley of the trapezoidal corrugated folded plate. The installation structure of the solar cell module described. The above trapezoidal corrugated folded plates are mounted in a curved manner so that they are convex upward and convex downward in the direction in which the peaks and troughs are alternately continued, and are attached to the peaks of the curved trapezoidal corrugated plates 5. The solar cell module installation structure according to claim 4, wherein the solar cell module is laid so that the back surface protective material and the peak portion of the trapezoidal corrugated folded plate are in close contact with each other.

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