JPH1146007A - Solar battery mounting structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable mounting of a solar battery in a manner so as to realize ease and a good design characteristic along the surface of a film constituting a curved surface and provide durability by welding a peripheral edge of a thermoplastic resin film on the film surface and housing a flexible solar battery module inside thereof. SOLUTION: A film cover is welded to the surface of a film member, having one long side 10d left as an open side and having three sides 10a to 10c cut into a predetermined shape to form a U-shape, in advance at factory. The film member having the film cover welded thereon is transported to the spot and is expanded between frames constructed in advance as a structure member such as a roof member. In the state where the film member is expanded as a body film surface 1 of a predetermined shape, a flexible solar battery module 20 is inserted from the one side 10d as the open side housed in the film cover. Then, the open side is welded to the surface of the body film surface 1 with a predetermined welding width by a welding machine.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a solar cell mounting structure, in which a solar cell module is mounted on a film structure constituting a building roof or the like so that a high effect can be obtained easily and in design, and a high durability can be obtained. A solar cell mounting structure.

[0002]

2. Description of the Related Art Conventionally, solar cell modules for electric power have
In general, it is designed to be durable enough to withstand wind and rain, sunshine, temperature changes, etc., for use outdoors. For this reason, conventionally, a plate-shaped solar cell module is supported by a rigid resin or metal support plate or the like, and the entire solar cell module is installed on a stable place such as a building roof via the support plate. It has become. As the supporting plate, FRP (fiber reinforced plastic) or the like is used, and a plurality of these solar cell modules are arranged on an appropriate scale to secure a predetermined power.

In a so-called membrane structure in which a membrane material is stretched to form a roof or the like, the developed membrane surface has a curved surface shape subjected to a predetermined tension. It is difficult to attach a highly rigid solar cell module directly to a curved surface. In consideration of such problems, there is an idea to use a flexible solar cell as a solar cell module for electric power. This flexible solar cell is obtained by forming an alpha-mos-silicon (a-Si) solar cell on a thin substrate made of stainless steel or synthetic resin. This flexible solar cell is a lightweight product having a very small thickness of 1 mm or less and can be rolled or bent at a predetermined curvature. Since the flexible solar cell can be bent into an arbitrary curved shape, it can be easily attached to the curved surface. Conventionally,
In mounting a flexible solar cell, a method has been adopted in which a protective film on the back surface of the module is bonded to a curved surface to be mounted using a suitable adhesive or the like.

[0004]

By the way, a film surface constituting a roof or the like of a building where a solar cell is installed is exposed to direct sunlight of the sun for a long time. At this time, it is known that the film material made of synthetic resin changes its temperature under the influence of sunlight and expands and contracts accordingly. As described above, when the flexible solar cell is bonded to the surface of the film surface, the shape change due to the thermal expansion of the flexible solar cell cannot follow the change in the expansion and contraction of the film material, and the bonded surface may be broken. Further, the film surface vibrates minutely under the influence of wind or the like. For this reason, a repeated load is applied to the bonding surface, and the bonding surface between the solar cell module and the film surface is in a state where the bonding surface is easily peeled, and there is a problem in durability.

Accordingly, an object of the present invention is to solve the above-mentioned problems of the prior art, and to provide a solar cell which is easily and easily designed along the surface of a film surface constituting a curved surface and has durability. It is an object of the present invention to provide a solar cell mounting structure capable of mounting a solar cell.

[0006]

In order to achieve the above object, the present invention relates to a method of forming a flexible resin cell module on a stretched film surface by covering the periphery of a thermoplastic resin film with the film. The flexible solar cell module is attached to the film surface by welding to the surface and housing the flexible solar cell module therein.

On the stretched film surface, a prepacked module containing a flexible solar cell module is placed between a thermoplastic resin film and a base film material whose peripheral edge is welded in advance, and the base film material The flexible solar cell module is mounted on the film surface by welding a peripheral edge of the flexible solar cell module to the film surface.

[0008] The flexible solar cell module housed between the thermoplastic resin films via a fastener attached so as to penetrate the stretched membrane surface, is mounted on the membrane surface. I do.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the solar cell mounting structure of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 shows a main body membrane surface 1 made of a membrane material stretched between frame frames (not shown). In this embodiment, the material of the film surface is made of a type A film material. Class A membrane material is a material in which PTFE (polytetrafluoroethylene, tetrafluoroethylene resin) is coated on the surface of a glass fiber woven fabric and has excellent durability, strength, and fire prevention performance. A transparent FEP (ethylene tetrafluoride / propylene hexafluoride copolymer resin) film cover 10 is provided at a predetermined position on the film surface.
A flexible solar cell is attached so as to be covered by the cover. As shown in FIG. 1, this FEP film cover 10 (hereinafter, referred to as a film cover 10) has four sides 10a to 10d on the periphery thereof welded to the surface of the main body film surface 1 and a substantially square-shaped weld on the inside. A solar cell module 20 having a predetermined size is accommodated in a part that is not provided. In the present embodiment, a flexible solar cell module 20 having a thickness of about 0.75 to 1.0 mm is used. This flexible solar cell module 20 is made of a known a-Si solar cell, and the surface film is made of PET.
(Polyethylene terephthalate) resin is used. Further, a PET resin film is also used as a substrate film.

At a substantially central position of the solar cell module 20, a central fixing portion 11 to be described later for holding the position of the solar cell module 20 is formed.

As the film cover 10 shown in FIG. 1, a transparent or highly translucent thermoplastic resin is used, but a fluororesin film is preferable in terms of cost, durability and the like. For example, FEP, PCTFE (polychlorotrifluoroethylene), PTFE (polytetrafluoroethylene), PVDF (polyvinylidene fluoride),
PVF (polyvinyl fluoride), PFA (tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer), and ETFE (tetrafluoroethylene / ethylene copolymer).

Other thermoplastic resins include ABS resin, acrylic resin, acetal resin, chlorinated polyether, coumarone-indene resin, regenerated cellulose, petroleum resin, cellulose derivative, polyamide, polyarylate,
Examples include polyolefin, polyethylene, polyethylene terephthalate, polyvinylidene chloride, polyvinyl chloride, polycarbonate, polystyrene, polysulfone, polyvinyl alcohol, polyvinyl ester, polyvinyl ether, polyphenylene oxide, polybutylene terephthalate, polypropylene, and polymethylstyrene.

Here, the installation procedure of the solar cell module 20 shown in FIG. 1 will be described. Film cover 10
In a factory, three sides 10a to 10c are welded to a surface of a film material cut in a predetermined shape so as to form a U-shape, leaving one long side 10d as an open side in advance. Then, the film material to which the film cover 10 is welded is carried into the site, and is developed between frames previously constructed as a structural material such as a roof material. The flexible solar cell module 20 is inserted from the side 10d, which is an open side, in a state where the film material is developed as the main body film surface 1 having a predetermined shape,
It is housed in the film cover 10 and the open side is welded to the surface of the main body film surface 1 by a welding machine (not shown) with a predetermined welding width. At the same time, a lead wire (not shown) derived from the solar cell module 20 is provided with an opening (not shown) formed in the film surface.
And lead it indoors. In order to shorten the work of mounting the flexible solar cell module 20 in the field, the entire flexible solar cell module 20 is covered with the film cover 10 at the manufacturing stage in the factory in advance, and the periphery (4 sides) of the film cover 10 is covered with the main body film surface. 1 and housed in the film cover 10. Thus, the flexible solar cell module is attached to the film material and is carried to the site, and the membrane structure roof provided with the solar cells can be deployed in a short process.

FIG. 3A is a sectional view taken along a sectional line of the solar cell mounting structure shown in FIG. As shown in FIG. 3 (a), a solar cell module 20 is housed on the surface of the main body film surface 1 made of PTFE via a thin layer insulator 2 made of thin EVA (ethylene-vinyl acetate copolymer). I have. Further, peripheral edges 10 a to 1 of FEP film cover 10 are covered so as to cover the surface of solar cell module 20.
0d is attached in a state where it is welded to the main body membrane surface 1. At the left end position of the film cover 10 in the state shown in the figure, an adjustment allowance 13 is provided in consideration of expansion and contraction of the film material due to expansion and contraction of the main body film surface 1. The thin-layer insulator 2 shown in the figure plays a role of absorbing the impact of a flying object colliding with the solar cell module 20, for example, and minimizing damage to the solar cell module 20. . As a material to be used, in addition to EVA, a material having flame retardancy and durability is preferable.

The welding width B between the periphery of the film cover 10 shown in FIG.
Is preferably in the range of about 25 mm to 75 mm, depending on the size and scale of the solar cell module 20 housed in the film cover 10.

FIG. 2 is a perspective view showing a schematic configuration of a solar cell mounting structure according to another embodiment. In this solar cell mounting structure, as shown in FIG. 3B, the solar cell module 20 prepacked in the FEP film cover 10 is welded to a predetermined position on the main body membrane surface 1. Hereinafter, it is referred to as a prepacked module 25. In the prepacked module 25, a highly transmissive FEP film cover 10 is welded on a base film surface 26 made of the same kind of film material (PTFE) as the main body film surface 1, and the solar cell module 20 is accommodated therein. Things.
The prepacked module 25 is disposed at a predetermined position on the main body membrane surface 1 already stretched, and its peripheral edges 26a to
26d can be installed on the main body film surface 1 by welding. In the case of the prepacked module 25 as well, an adjustment margin 27 for compensating for the influence of expansion and contraction of the film material is formed at the joint between the film cover 10 and the base film surface 26.

FIG. 4 is a schematic perspective view of the main body membrane surface 1 as viewed from the inside of the structure (indoor side). As shown in FIG. 4, a lead wire 21 derived from a flexible solar cell module 20 installed on the outer surface of the main body membrane surface 1 passes through a circular opening (not shown) formed at a predetermined position on the main body membrane surface 1. The main body film surface 1 is drawn out inside, and is wired to a predetermined position by the main body film surface reinforcing sheet 30 and the lead wire guide 31 welded along the inner surface of the main body film surface 1.

FIG. 5 shows the lead wire 2 from the film surface shown in FIG.
1 is a partial cross-sectional view showing a cross section of a lead-out portion of a main body film surface, a main body film surface reinforcing sheet welded to the inside of the main body film surface, and a lead wire guide. As shown in the figure, the lead wire 21 led out from the end of the solar cell module 20
Is guided to the inside of the membrane surface through the opening 1A of the main body membrane surface 1 and then folded back at the body membrane surface reinforcing sheet 30 to form the guide hole 3 formed in the lead wire guide 31.
2 to an electric device (not shown).

FIG. 6 shows the structure of the reinforcing film 35 used to guide the lead wire 21 derived from the solar cell module 20 into the inside of the film surface. As shown in FIG. 6, the peripheral edge 35 a of the reinforcing film 35 is welded to the main body film surface 1, and only the portion through which the lead wire 21 passes is not welded. Is to lead to. Further, a backing material 36 of the same material (co-fabric) as the film cover 10 is attached inside the main body membrane surface 1. By using such a reinforcing film 35, it is possible to prevent a decrease in strength due to the formation of the opening 1A in the main body film surface 1.

FIG. 7 shows a large-sized solar cell module 2.
0 is accommodated in the film cover 10 and supported.
2 shows an example of a central fixing unit 11 that holds a central position of a solar cell module 20. In this example, the illustrated central fixing unit 1 is located at the center of the solar cell module 20.
A circular opening 20A having a diameter equal to 1 is provided. A circular patch 4 of the same material as the main body film surface 1 is arranged and welded to the circular opening 20A, and the same material as the film cover 10 is applied to the hollow portions of the main body film surface 1, the patch 4 and the film cover 10 surface. The cloth 12 is welded. By arranging the film material of the same material as that of the main body film surface 1 in the circular opening of the solar cell, even if the welded portion is peeled off, there is no problem in strength.

FIG. 8 is a partial sectional view showing an example of a film sand type in which a film cover and a flexible solar cell module 20 are integrated. As shown in the figure, a flexible solar cell module 20 that is resin-encapsulated between a film cover 10 that covers the outer surface and a back film cover 28 is shown. Film cover 10, 2
EVA resin or the like is suitable as the resin 27 sandwiched between the eight. As the film covers 10 and 28, various materials such as FEP can be used as described above. By welding the end portion 29 of the film cover 10 in a state where the flexible solar cell module 20 is sealed with resin to a predetermined position on the main body film surface 1, a film structure as a solar cell mounting structure can be easily constructed.

FIG. 9 shows an example in which a solar cell module 20 laminated with a thermoplastic resin film 50 is joined to a predetermined position on the main body membrane surface 1 by using a fastener. The joint 40 using a bolt as a fastener used to support the solar cell module 20 has the configuration shown in FIG. To reinforce the bolt holes 41 formed in the main body film surface 1, a backing reinforcing cloth 42 made of a co-fabric with a main body film material having a predetermined diameter is welded. A specially shaped fixing bolt 43 shown in FIG. 10B is inserted into the bolt hole 41. In this embodiment, the fixing bolt 43 is made of an acrylic resin. As shown in FIG. 10B, a thin nut 44 and a butyl rubber-based resin sealing washer 45 are integrally formed at an intermediate position of the screw portion. It is fastened. This fixing bolt 43
By tightening due to the elastic adhesiveness of the hole, a high water stopping property of the hole portion is maintained. Further, the fixing bolt 43 is provided with the film material 1.
A sealing washer 46 and a circular fixing stabilizing plate 47 are attached from the lower surface side of the device, and are fastened to the bolt position by a nut 48 so as to fix them. Above the fixing bolt 43, the solar cell module 20 is fixed by a nut 49. In the present embodiment, the fixing bolt 43 made of acrylic resin is used, but a material such as stainless steel or a normal bolt may be used. Rivets other than bolts may be used. The hole 41 of the film surface 1 for attaching the fixing bolt 43 is set to be larger than the bolt diameter, and a predetermined clearance is provided between the bolt and the film surface 1. Even when the film material expands and contracts due to a change in temperature, no excessive stress is generated in the mounting hole of the solar cell module 20. In addition, hole 4
It is preferable to use a sealing member in order to maintain the water stoppage of (1).

FIGS. 11 and 12 are partial sectional views showing a modification of the fixing bolt. Of these, the fixing bolt 61 shown in FIG.
2 has a configuration in which a ring-shaped stainless steel fixing plate 63 is fixed. As shown in FIG. 11, the fixing bolt 61 is provided with a resin coating 64 having a predetermined thickness from the bolt head 62 side with the screw portion 61a inserted through the hole 41 of the membrane surface 1. Further, in order to reinforce the resin portion, a ring-shaped reinforcing pad 65 made of the same material as the main body membrane surface 1 is welded. With this structure, the number of component mounting steps can be reduced, and since the structure is simple, the mounting location can be made to look compact in design. Note that FEP is suitable as the resin used for the resin coating.

FIG. 12 shows a fixing plate 68 in which the bolt head has a disk shape.
FIG. 9 is a partial cross-sectional view showing an example of a fixing bolt 66 that is also used as a fixing bolt. The fixing bolt 66 is made of aluminum, and the FEP resin coating 67 is applied to the screw surface 68a of the fixing plate 68 in advance. This fixing bolt 66 is
And heat is applied from the fixing plate 68 side by a not-shown iron or the like as shown in FIG.
The film surface 1 and the fixing plate 68 are adhered via the EP coating 67 layer. Thereby, the fixing bolt 66 is fixed to the film surface.

As is apparent from the above description, according to the present invention, the solar cell module can be securely and reliably designed on the surface of the curved film material, and the mounting can be performed. The effect that the durability of a part can also be expected is produced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a solar cell mounting structure of the present invention.

FIG. 2 is a perspective view showing another embodiment of the solar cell mounting structure of the present invention.

FIG. 3 is a sectional view taken along the line IIIa-IIIa in FIG. 1, and IIIb-III in FIG.
FIG. 4 is a transverse cross-sectional view taken along a cross-section line b.

FIG. 4 is a perspective view showing a state where lead wires derived from the solar cell module are accommodated.

FIG. 5 is a partial cross-sectional view showing a state where the lead wires shown in FIG. 4 are accommodated;

FIG. 6 is a schematic perspective view showing a reinforcing state at an opening in which a lead wire penetrates a main body membrane surface.

FIG. 7 is a partially enlarged cross-sectional view showing details of a central fixing portion of the solar cell module.

FIG. 8 is a sectional view showing an embodiment of a solar cell mounting structure in which a solar cell module is integrated with a film cover.

FIG. 9 is a perspective view showing another embodiment of the solar cell mounting structure of the present invention.

FIG. 10 is an enlarged view of a bolt fixing portion of the solar cell module.

FIG. 11 is an enlarged view showing a modification of the bolt fixing portion.

FIG. 12 is an enlarged view showing another modification of the bolt fixing portion.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Main-body membrane surface 1A Opening 10 Film cover 20 Solar cell module 21 Lead wire 25 Prepacked module 40 Joint 43, 61, 66 Fixing bolt

Claims (4)

[Claims] 1. A peripheral edge of a thermoplastic resin film capable of covering an entire flexible solar cell module provided on a stretched film surface is welded to the film surface, and the flexible solar cell module is accommodated therein. A solar cell mounting structure, wherein the flexible solar cell module is mounted on the film surface. 2. A prepacked module in which a flexible solar cell module is accommodated between a thermoplastic resin film and a base film material whose peripheral edge is welded in advance is placed on the stretched film surface, and A solar cell mounting structure, wherein the flexible solar cell module is mounted on the film surface by welding a peripheral edge of the film material to the film surface. 3. A flexible solar cell module housed between thermoplastic resin films via a fastener attached so as to penetrate the stretched membrane surface, wherein the flexible solar cell module is mounted on the membrane surface. Characteristic solar cell mounting structure. 4. A lead wire led out from the flexible solar cell module is guided to an opposite side to a surface on which the flexible solar cell module is installed, through an opening formed in the film surface. The solar cell mounting structure according to claim 1, wherein: