JP3005123B2 - Installation method of roof and solar panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell and a method of installing the same, and more particularly to a structure of a solar cell panel array fixed to a roof.

[0002]

2. Description of the Related Art In recent years, it has been predicted that global warming will occur due to a greenhouse effect due to an increase in CO ₂ , and the demand for clean energy is increasing more and more. Also, nuclear power generation that does not emit CO ₂ has not solved the problem of radioactive waste disposal, and clean energy with higher safety is desired.

[0003] Among clean energy expected in the future, solar cells are particularly expected to be clean, safe and easy to handle.

Among various solar cells, compound semiconductors such as polycrystalline silicon, amorphous silicon, and copper indium selenide, thin-film crystalline silicon, and the like have been enthusiastically studied.

[0005] Among solar cells, monocrystalline and polycrystalline silicon wafer solar cell modules are vulnerable to impact, and are protected by a thick glass plate using EVA (ethylene-vinyl acetate copolymer) as an adhesive and filler. And is held by a frame made of aluminum or the like. The surface of an amorphous silicon solar cell formed on a glass substrate is protected by a thick glass plate similarly to the crystalline silicon module. Conventionally, such a solar cell module weighs 13 to 15 kg per square meter area, and when installed on a roof, it is not easy to handle due to its heavy weight. The solar cell module had to be installed on the roof. For this reason, installation time, installation cost, and gantry cost are required.

Further, among solar cells, a metal substrate such as stainless steel is sometimes used as a substrate material because of its excellent weather resistance, impact resistance, and flexibility. Solar cell modules using metal substrates have the advantage of being resistant to impact and having a very low weight per unit area and a very low weight per generated power. Also, the method of installing the module on a gantry has been adopted, and the original light weight of the metal substrate module has not been utilized.

Accordingly, there has been a strong demand for the development of a panel array of a roof-mounted solar cell module that is lightweight, has good installation workability, and is inexpensive to install.

[0008]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional disadvantages, and provides a roof-mounted solar panel array that is lightweight, has good installation workability, and is inexpensive to install. Aim.

[0009]

SUMMARY OF THE INVENTION A roof according to the present invention is provided on an insulated metal reinforcement having two opposing sides bent.
A solar cell panel in which a solar cell having a conductive substrate is covered with a translucent material, a metal roofing material, and a pair of fixing members having different heights with respect to the metal roofing material surface. The fixing member is directly fixed to the metal roof material, and the bent portion of the metal reinforcing member of the solar cell panel is fixed to the pair of fixing members, so that the solar cell panel and the metal roof material are fixed. And a wiring space is formed between the solar cell panel and the solar cell panel. In the method for installing a solar cell panel according to the present invention, there is provided an insulated panel having two opposite sides bent.
Fixing the bent portion of the solar cell panel, in which the solar cell having the conductive substrate on the provided metal reinforcing material is coated with a translucent material, to a pair of fixing members; Fixing the solar cell panel, wherein the pair of fixing members comprises a plurality of members having different heights from each other with respect to the metal roofing material surface, and the pair of fixing members. Thus, a wiring space is formed between the solar cell panel and the metal roof material, and electric wiring of the solar cell panel is arranged in the wiring space.

[0010]

According to the present invention, a light-weight solar cell panel array can be installed by using a projection of a member forming a roof and can simultaneously fix a plurality of solar cell panels. It can be manufactured, and the work of installing the solar cell panel on the roof becomes easy.

[0011]

FIG. 4 is a schematic view of a solar cell panel array according to a reference example , in which (a) is a sectional view, and (b) and (c) are perspective views. In FIG. 4, reference numeral 400 denotes a protrusion on the roof,
Reference numeral 401 denotes a fixing frame on which a plurality of solar cell panels constituting the solar cell panel array of the reference example are mounted and can be fixed to a projection on a roof. Reference numeral 402 denotes a solar cell panel. The installation strength of the protruding portion 400 of the roof is sufficiently higher if it is a part of the roof material constituting the roof or a member for fixing the roof material.

The roof on which the solar cell panel array of the present invention is installed is preferably a roof having projections, particularly a metal roof having high strength. Types of metal roofs include folded plates, tile rods,
Corrugated sheets, seam welding, etc. are suitable. Further, as the folded plate, goby fastening, bolt fastening, fitting type, and the like are appropriate. FIG. 9 shows a typical roof shape. In FIG. 9, (a) is a folded plate goby fastening type,
(B) is a folded plate bolt tightening type, (c) is a seam welding type, and (d) is a roof type roof.

The present invention provides a solar cell having a structure in which a solar cell panel is mounted on a fixing frame having a shape that can be fixed to a protrusion of a member forming the roof, for example, a goby-tightened goby or a bolted-type bolt. It is a battery panel array.

FIGS. 5 (a), 5 (b), 5 (c), and 5 (c) show examples in which the reference example is applied to the various roof shapes shown in FIG.
(D). In FIG. 5, 500, 501, 50
2, and 503 are roofing materials, 504, 505, 506,
Reference numerals 507 and 507 denote fixing frames for fixing to a projection of a roofing material, which is a main component of the reference example , and 508 denotes a solar cell panel.

(Fixed Frame) In the present invention, a fixed frame that can be fixed to a projection on a roof and to which an end of a solar cell panel can be attached is used.

In this fixed frame, for example, a space having substantially the same shape as a roof projection that opens downward is formed, and the fixed frame is fixed to the roof by fitting the roof projection into this space. be able to.

Further, the fixed frame may be an integral body or a separate body. That is, the portion to be fixed to the projection of the roof and the portion to which the end of the solar cell panel is attached may be formed integrally or separately.

In the case of an integral body, a groove may be formed on the side surface of the fixed frame so that the end of the solar cell panel can be inserted into the groove.

In the case of a separate object, it may be combined with a pressing member (lid-like member) separately from a portion for fixing to the roof (see FIGS. 2 and 3). In this case, replacement of the solar cell panel becomes easy.

As the material of the fixed frame, aluminum, aluminum alloy, stainless steel, iron, plated steel, glass fiber reinforced plastic, carbon fiber and the like are used.

It is preferable that the rust-prone portion is covered with a paint or the like.

(Mounting of Solar Cell Panel on Fixed Frame) According to the method for fixing the main components of the present invention to the roof member and mounting the solar cell panel to the fixed frame, grooves are formed on the side surfaces of the fixed frame. In the case where it is formed, it may be performed by inserting the end of the solar cell panel into the groove. Further, a screw or the like may be used.

When the fixing frame is a separate object, that is, when the fixing frame can be separated into a part for fixing to the roof and a holding member (lid-like member), the end of the solar cell panel is placed on the upper surface of the fixing part. Portion, and the lid-like portion may be mechanically mounted by tightening a screw and a gasket or the like from above (FIG. 2,
(See FIG. 3). In any case, it is preferable to use an adhesive or a sealant in combination.

(Shape and Installation Angle of Solar Cell Panel) The solar cell used in the present invention has a shape along the roof shape.
A flat shape may be used. When a solar cell panel having a shape conforming to the roof shape is used, the area of the solar cell panel per unit area of the roof can be increased, so that there is an advantage that power generation efficiency is increased.

[0025]

FIG. 6C shows an installation example of the solar cell panel array according to the present invention . Reference numerals 601 , 602, and 603 fix the solar cell panel and fix it to the projection of the roof material. fixed frame, 606 is a solar panel.

(Procedure for Installation on Roof) In the procedure for installing the solar cell of the present invention on a roof, a plurality of solar cell panels whose surfaces are covered are mounted on a fixed frame constituting a solar cell panel array of the present invention in advance. The fixing frame may be fixed to the projection of the roof member later, or a plurality of solar cell panel arrays whose surface is coated after fixing the fixing frame to the projection of the roof member may be attached.

(Electrical connection between solar cell panels)
The perspective view of FIG. 7 shows an example of a method of electrically connecting the solar cell panels to make a series-parallel connection. (A) is an example in which electrical connection of the solar cell panel is performed using a waterproof connector or the like on the back side of the panel, and (b) is an example in which electrical connection is performed on the surface of the solar cell panel. In FIG.
701 is a fixing frame for fixing the solar cell panel, 702 is a member made of rubber or metal for connecting the solar cell panels, 703 and 705 are waterproof connectors, 704 are output terminals and connectors , 706 is a solar panel, and 707 is the sun. Although a member for connecting the panel 702 is not always necessary, by providing the member, the end of the solar cell panel can be protected. 702 may not be used, and only the ends of the solar cell panels may be overlapped.

For the electrical connection between the panels, there is a simple method of crimping the wiring material of the current terminal cable, and then covering the wiring material with a material such as butyl rubber or silicon rubber which is self-fused and has both insulation and waterproofness. .

(Solar Cell Panel) The thickness of the end portion of the solar cell panel is preferably 5 mm or less, more preferably 4 mm or less, in order to make the fixed frame lightweight and reduce the load on the roof. Thickness of the solar cell panel means that the weight increases, and therefore, a fixed frame and a roof having a thickness and width sufficient to withstand the load of the solar cell panel are required. Further, the fixing frame of the solar cell panel array of the present invention is not suitable for a solar cell panel using a glass plate or the like that is easily damaged to the end in order to mechanically fix the solar cell panel.

For this reason, as a solar cell panel used in the present invention, a conductive substrate having excellent mechanical strength is provided on a conductive substrate.
A solar cell having a thin film semiconductor layer as a photoelectric conversion member is preferable, and a solar cell having a back reinforcing plate as a reinforcing material is more preferable. Further, at least the surface layer on the light incident side is covered with a weather-resistant translucent material. FIG. 8A shows an example of a schematic cross-sectional view of a solar cell panel used for the solar cell panel array of the present invention. A solar cell panel is composed of at least one or more photovoltaic elements. 8A, reference numeral 800 denotes an insulated back reinforcing plate, 801 denotes a solar cell formed by connecting one or more photovoltaic elements in series or parallel, and 802 denotes a front surface for protecting the front surface. It is a covering material.

The surface protective layer 802 needs to have translucency and stable weather resistance to ultraviolet rays and ozone, and has a double structure of a fluororesin film / ethylene-vinyl acetate copolymer (light incidence). Side is a fluororesin film), silicone resin, fluororesin paint, and the like.

The reinforcing member 800 on the back surface of the solar cell panel is formed in a film or plate shape, and the material is made of insulated metal such as painted zinc steel plate, carbon fiber, glass fiber reinforced plastic, ceramic, or the like. , the like glass.

(Photovoltaic Element) A solar cell panel used in the solar cell panel array of the present invention is composed of at least one or more photovoltaic elements, and is schematically shown in FIG. 8B as an example. It has a configuration. In FIG. 8B, reference numeral 803 denotes a conductive substrate;
Reference numeral 4 denotes a back reflection layer, 805 denotes a semiconductor layer as a photoelectric conversion member, 806 denotes a transparent conductive layer, and 807 denotes a current collecting electrode. 8
The back reflection layer 04 can also serve as the conductive substrate 803. As the conductive substrate 803, stainless steel,
Aluminum, copper, titanium, carbon sheet, galvanized steel plate, and the like.

As the thin film semiconductor layer 805, a compound semiconductor such as amorphous silicon, crystalline silicon, and copper indium selenide is suitable.

In the case of amorphous silicon, it is formed by plasma CVD using silane gas or the like . In the case of polycrystalline silicon, it is formed by sheeting molten silicon or heat-treating amorphous silicon . In the case of CuInSe ₂ / Cd S , it is formed by a method such as electron beam evaporation, sputtering, or electrodeposition (deposition by electrolysis of an electrolytic solution). The structure of the semiconductor layer, pin junction, pn junction, is tio Ttoki junction used. The semiconductor layer has a structure sandwiched between at least the back electrode layer 804 and the transparent conductive layer 806.

As the back electrode layer 804, a metal layer or a metal oxide, or a composite layer of a metal layer and a metal oxide layer is used. As the material of the metal layer, Ti, Cr,
Mo, W, Al, Ag, Ni, or the like is used, and ZnO, TiO ₂ , SnO _2, or the like is used as the metal oxide layer. Examples of the method for forming the metal layer and the metal oxide layer include resistance heating evaporation, electron beam evaporation, and sputtering.

The material used for the transparent conductive layer 806 is I
_{n 2 O 3, SnO 2,} In 2 O 2 -SnO 2 (IT
O), ZnO, TiO ₂ , Cd ₂ SnO ₄ , a crystalline semiconductor layer doped with a high concentration of impurities, and the like. Examples of the formation method include resistance heating evaporation, electron beam evaporation, sputtering, spraying, CVD, and impurity diffusion. There is.

The material of the grid-like current collecting electrode 807 for efficiently collecting the current generated by the photovoltaic force on the transparent conductive layer is Ti, C
A conductive paste such as r, Mo, W, Al, Ag, Ni, Cu, Sn, and silver paste is used. The grid electrode can be formed by sputtering using a mask pattern, resistive heating, CVD, or by depositing a metal layer on the entire surface and then etching and patterning, or by directly forming a grid electrode pattern by optical CVD. And a method in which a negative pattern mask of a grid electrode pattern is formed and then formed by plating .
As the conductive paste, one obtained by dispersing silver, gold, copper, nickel, carbon, or the like in a fine powder state with a binder polymer is usually used. Examples of the binder polymer include resins such as polyester, epoxy, acrylic, alkyd, polyvinyl acetate, rubber, urethane, and phenol.

As a material for the bus bar for collecting and transporting the current collected by the grid electrode, tin, solder-coated copper, nickel or the like is used. The connection of the bus bar to the grid electrode is made with a conductive adhesive or solder.

[0041]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on embodiments. Note that the present invention is not limited to these examples.

( Reference Example 1) An example in which the present invention is applied to a roof with a gore-fastening type analysis plate will be described in detail. FIG. 1 is a schematic cross-sectional view of the vicinity of a goby portion of a solar cell panel array fixed to a roof of a panel.

In the solar cell panel 104, a photovoltaic element is adhered on an insulated 0.27 mm thick zinc steel sheet via an adhesive, and then a fluororesin film is applied using EVA as an adhesive layer. A 3 mm thick solar cell panel without a frame, which was manufactured by laminating on the incident side surface, was used.

The photovoltaic element was prepared by the following procedure. Al / ZnO was formed as a back reflection layer on a 0.125 mm thick stainless steel substrate by sputtering, and the n-type a-Si layer was formed by plasma CVD. , I-type a-Si layer,
A semiconductor layer of a p-type microcrystalline Si layer is formed, and In ₂ O ₂ is formed as a transparent conductive layer by vapor deposition of In in a O ₂ atmosphere by a resistance heating method. Was formed to produce an amorphous silicon photovoltaic element.

A plurality of fixed frames 101 made of alumite-treated aluminum having a cross section of 101 shown in FIG. 1 are fixed in parallel to the goby portion of the folded plate roof by bolt screws 102, and then the end portions of the solar cell panel 104 The sealant 105 was injected into the cut grooves of the fixed frame 101 for inserting the solar cell panel, and both ends of a predetermined number of solar cell panels were inserted and fixed with screws 103, and the solar cell panel array was installed on the roof.

( Reference Example 2) The solar cell panel used in Reference Example 1 is made of an insulated painted iron material, and is provided with a fixed frame 201 having a sectional structure shown in FIG. It was installed in.

The installation procedure is as follows. First, the member 201 to be attached to the roofing material is fixed to the goby portion at a plurality of locations with bolt screws 203,
A gasket 205 was attached, both ends of the solar cell panel 206 were inserted into the gasket part, the solar cell panel was pressed by a cover-like member 202, and fixed with bolt screws 204 to install a solar cell panel array.

Reference Example 3 A solar cell panel having a thickness of 2 mm was used in which the surface coating of the solar cell panel used in Reference Example 1 was coated with two layers of a transparent ceramic paint and a fluororesin paint. The frame of the insulated galvanized steel material for fixing the solar cell panel and fixing it to the roof tile roof used the one whose sectional shape is shown in FIG. The installation procedure of the solar cell panel array was as follows.

First, a member 30 for fixing to a roof tile roof
After fixing the solar cell panel 1 with a bolt screw 303, both ends of the solar cell panel are placed on the member 301 and the gasket 30
5 was fitted, and the member 302 for holding the solar cell panel was covered and fixed with bolt screws.

It is understood that the fixing of the solar cell panel and the fixing to the roof material can be easily performed with a small number of members by using the fixing frame having a shape corresponding to the projection of the roof material. Reference is made to the fixing of the solar cell panel. In the case where a structure in which the end of the solar cell panel is mechanically sandwiched and fixed as in Examples 2 and 3 is adopted, repair of the failed solar cell panel is performed. And maintenance that can be removed for replacement becomes very easy.

[0051]

According to the present invention, it is possible to manufacture a solar cell panel array in which a solar cell panel without a frame can be installed on a projection of a roof with a small amount and a lightweight member by a simple operation. This makes it possible to easily install the solar cell panel array on the existing roof without newly processing a roof, reduce the weight of the gantry, and reduce the gantry cost and the installation cost of the solar cell panel array.

[Brief description of the drawings]

FIG. 1 is a partial schematic cross-sectional view of a solar cell panel array installed on a protrusion of a roof in Reference Example 1.

FIG. 2 is a partial schematic cross-sectional view of a solar cell panel array installed on a protrusion of a roof of Reference Example 2.

FIG. 3 is a partial schematic cross-sectional view of a solar cell panel array installed on a protrusion of a roof according to Reference Example 3.

FIG. 4 is a conceptual configuration diagram for explaining a solar cell panel array of a reference example.

FIG. 5 is a partial cross-sectional view when a solar cell panel array of a reference example is installed on various roofs.

6 (a) and (b) are reference examples of the installation mode, and (c)
Is an installation example of the solar cell panel of the present invention.

FIG. 7 is a conceptual diagram showing an example of a method for electrical connection between solar cell panels according to the present invention.

FIG. 8 is a schematic cross-sectional view of a solar cell panel used in the solar cell panel array of the present invention and a photovoltaic element constituting the solar cell.

FIG. 9 shows a typical roof shape.
(A) is a folded plate gouge fastening type, (b) is a folded plate bolt fastening type, (c) is a seam welding type, and (d) is a roof type roof.

[Explanation of symbols]

100, 200, 300, 400, 500, 501, 5
02, 503, 600 Roof projections, 101, 201, 202, 301, 302, 401, 5
04,505,506,507,601,602,60
3 fixed frames, 104, 206, 306, 402, 508, 604, 6
05,606,706 solar cell panel, 105 sealant, 202,302 lid-like member (holding member), 703,705 waterproof connector, 704 cable, 800 back reinforcing plate, 801 photovoltaic element, 802 surface covering material, 803 Conductive substrate, 804 back reflection layer, 805 semiconductor layer, 806 transparent conductive layer, 807 current collecting electrode

Continued on the front page (56) References JP-A-3-200377 (JP, A) JP-A-54-127118 (JP, A) JP-A-61-151353 (JP, U) JP-A-1-173952 (JP) , U) Japanese Utility Model Showa 57-8463 (JP, U)

Claims (3)

(57) [Claims] 1. An insulating process in which two opposing sides are bent.
A solar cell panel having a conductive substrate on a metal reinforcing material coated with a translucent material, a metal roofing material, and a metal roofing material having different heights based on the surface of the metal roofing material. A pair of fixing members, wherein the fixing members are directly fixed to the metal roofing material, and the bent portion of the metal reinforcing material of the solar cell panel is fixed to the pair of fixing members, thereby forming the solar cell. A roof, wherein a wiring space is formed between a battery panel and the metal roof material, and the wiring space has electric wiring of the solar cell panel. 2. The roof according to claim 1, wherein the fixing member is fixed to a projection of the metal roofing material. 3. An insulation treatment in which two opposing sides are bent.
Fixing the bent portion of the solar cell panel, in which the solar cell having the conductive substrate on the metal reinforcing material is coated with a translucent material, to a pair of fixing members, and attaching the fixing member to a metal roofing material. Fixing the solar cell panel, wherein the pair of fixing members comprises a plurality of members having different heights from each other with respect to the metal roofing material surface, and the pair of fixing members. A wiring space is formed between the solar cell panel and the metal roofing material, and an electric wiring of the solar cell panel is arranged in the wiring space.