JP2000145074A - Solar cell integrated roof material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roof member integrated with solar cells, free from any load on a roof surface, excellent in execution, and excellent in durability and weathering. SOLUTION: A sheet-like flexible solar cell module 2 is integrated with a joining surface 3 of a ceramic roof base material 4 with an adhesive or the like. The solar cell module 2 consists of an organic material, in particular, an aromatic polyamide film material. A power lead part 5 is formed of a flat metallic sheet, and extended to a back surface side part of the roof material 1 integrated with a solar cell which is located thereabove, or extended to a space 10 formed between a roof member 1 and a sheathing roof board 8.

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 that can be laid on a roof of a house or the like to obtain power using sunlight.

[0002]

2. Description of the Related Art At present, the use of inexhaustible and clean solar energy as an alternative to fossil fuel has been attracting attention in order to save resources and solve environmental problems on a global scale. Install solar cells on the roof,
Attempts to save energy have been implemented by supplying power from solar cells to houses.

In mounting a solar cell on a roof,
A method in which a gantry is fixed to a roof structural member on an existing roof tile with metal fittings and the like, and a panel-shaped solar cell unit is installed on this gantry, or a roof tile having a flat surface such as a slate tile or a metal tile In this method, a so-called solar cell integrated roof tile in which a solar cell is bonded to the surface of a base material is directly laid on a field board.

[0004]

A method of fixing a gantry to a roof structural member on an existing roof tile with metal fittings and the like, and installing a panel-shaped solar cell unit on the gantry includes wiring and connectors for solar cells. Since it is exposed to the outside, it is susceptible to the direct effects of wind, rain, and sunlight, has a problem in durability, and has a problem that it is difficult to finish rain. Also,
The gantry and the solar cell unit are positioned as structures independent of the roof, are required to have the same strength as roof tiles against external forces such as wind resistance and snow load, and naturally increase in weight. For this reason, there is a problem that a great amount of weight is loaded on the roof surface, which is not preferable in terms of earthquake resistance, and that the work of installing the gantry is extremely complicated and expensive.

Further, a so-called solar cell integrated roofing material in which a solar cell is integrated with a base material surface of a roofing material having at least a partly flat surface such as a slate tile, a cement tile, and a metal tile, is directly mounted on a field board. A roofing method has also been proposed. In this method, the solar cell integrated roofing material generally protects the solar cell by arranging a highly rigid material such as glass or tempered glass on the upper surface of the solar cell. The light receiving surface of such a solar cell integrated roofing material is limited to a substantially flat surface, and the roofing material for integration is at least partially using a roofing material having a substantially flat surface, and the design is extremely extremely. It had to be monotonous. In addition, when the solar cell is integrated with the surface of the roofing material having at least a partly substantially flat surface, the light receiving area of the solar cell with respect to the working area of the roofing material is limited to a substantially flat surface portion. The number of solar cell-integrated roofing materials used increases, and the construction work is complicated and expensive. Furthermore, due to the roof area and roof shape of the building, there has been a very fatal problem that the light receiving area of the solar cell required to obtain a desired amount of power cannot be secured.

[0006] As a solar cell integrated with a roofing material, for example, as disclosed in Japanese Patent Application Laid-Open No. 10-93127, a concave portion is provided in the central portion on the front side of a flat tile, and the solar cell is mounted. Things have been suggested. Such a solar cell integrated roofing material generally protects the solar cell by disposing a highly rigid material such as glass or tempered glass on the upper surface of the solar cell. Such a roofing material, in order to mount a solar cell, it is necessary to form a recess in the center of the front side of the flat tile, compared to a normal roofing material that does not form a recessed foot crack strength is insufficient, There is a problem that the solar cell may be damaged during construction or the like. In addition, if the thickness of the roofing material is increased in order to improve the step cracking strength, the weight of the solar cell-integrated roofing material increases, which not only makes the construction difficult, but also places a burden on the building frame and lowers the earthquake resistance. There is such a problem.

[0007] Further, as for a method of taking out a connection cord of a solar cell of a solar cell integrated roof material according to the above-mentioned Japanese Patent Laid-Open No.
As disclosed in JP-93127A, a concave portion is provided in the central portion on the front side of the flat tile, and a concave groove communicating outside from the upper periphery orthogonal to the flow direction of the flat tile is provided. A method in which a waterproof rib is erected on the edge, the connection cord of the solar cell is inserted through the concave groove, and is pulled out over the waterproof rib,
As shown in Japanese Patent Application Laid-Open No. 10-102687, ribs are arranged side by side at intervals in a flow gradient direction of a flat portion on the back surface of a flat tile, and a through hole penetrating the surface is provided in a part between the ribs. A method has been proposed in which a connection cord and a plug of a solar cell are inserted through the through hole and pulled out.

[0008] In such a method of taking out the connection cord of the solar cell, it is necessary to provide a concave groove on the surface of the roof material or to provide a through hole from the front surface to the back surface. In addition, there are problems in terms of waterproofing and durability.

[0009]

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention is excellent in durability, rain-repelling, light weight without imposing a burden on a roof surface, excellent in workability, inexpensive and excellent in design. Another object of the present invention is to provide a roofing material with a solar cell that can obtain electric power using sunlight by laying it on a roof of a house or the like.

[0010] In the solar cell integrated roofing material according to the first aspect, a solar cell module having a sheet-like bendability on the surface of a ceramic roof substrate having at least a curved surface and / or a flat surface. It is characterized by being joined and integrated.

The sheet-shaped flexible solar cell module of the present invention comprises a solar cell portion, a material for sealing and protecting the solar cell portion, and an insulating-coated connection conductor.
The thickness of the solar cell module is 3 mm or less. In particular, the thickness of the solar cell module is preferably about 1 mm. The bendability means that the power generation characteristics do not substantially change even when the solar cell portion is bent to a radius of curvature of 100 mm or less. Even if it is bent to a radius of curvature of 50 mm or less, it is preferable that the power generation characteristic does not substantially change.

As the solar cell of the present invention, any of known crystalline silicon, polycrystalline silicon and amorphous silicon solar cells may be used. Solar cells are preferred.

In the present invention, the ceramic roofing base material is composed of a hydraulic raw material, other inorganic raw materials, and water for kneading, which are kneaded, formed, and cured, or kneaded, formed, and fired using clay as a main raw material. It refers to glaze tiles and anthracite tiles. As the hydraulic raw material, for example, commercially available ordinary portland cement, alumina cement, blast furnace cement, gypsum and the like can be used. The hydraulic raw material is used in an amount of 10 parts by weight to 70 parts by weight based on 100 parts by weight of the solid content mainly composed of a cement raw material and other inorganic raw materials.

Other inorganic raw materials include quartzite, feldspar,
River sand, viscosity, alunite, zeolite, diatomaceous earth, glass powder, fly ash, blast furnace slag, and the like are used. The water for kneading is added in an amount of 10 to 50 parts by weight, preferably 20 to 40 parts by weight, based on 100 parts by weight of the solid content.

In the production of the roof substrate of the present invention, it is possible to add reinforcing fibers to other inorganic raw materials. As the reinforcing fibers, for example, organic fibers such as polypropylene, vinylon, polyethylene, polyester, aramid, polyamide, nylon, and pulp and inorganic fibers such as asbestos, wollastonite, glass, and steel can be used. The synthetic fiber is preferably added in an amount of 0.1 part by weight to 10 parts by weight based on 100 parts by weight of a solid content mainly composed of a cement raw material and other inorganic raw materials. The diameter of the synthetic fiber is preferably 1 μm to 1 mm, particularly preferably 20 μm to 0.5 mm.

In the production of the roof substrate according to the present invention, a water-soluble polymer may be added as required. As the water-soluble polymer, for example, methyl cellulose, polyvinyl alcohol, carboxymethyl cellulose, hydroxyl cellulose, sodium polyacrylate, polyacrylamide and the like can be used.

In the production of the roof substrate according to the present invention, an inorganic filler may be further added as required. Examples of the inorganic filler include silica sand, river sand, fly ash, blast furnace slag, clay, bentonite, calcium carbonate, silica fume, and the like.

In the present invention, a pigment can be added as required. As a raw material to be added, pigments such as Gunjo, Cadmium Yellow, Bengala, Chrome Yellow, Lead White, Titanium White, Carbon Black, Iron Oxide Black and Iron Oxide Brown can be used.

The ceramic-based roof substrate used in the present invention has a curved surface and / or a flat surface, and it is possible to bond a sheet-like curable solar cell module to these surfaces. is there. For example, as shown in FIG. 2, when the solar cell module is arranged on the exposed surface of the roofing material regardless of the flat surface portion or the curved surface portion of the roof base material, the power generation amount of the solar cell alone is increased. be able to. As described above, the surface of the ceramic roof substrate may be flat or curved, or may have both flat and curved surfaces. still,
In order to make the back surface of the solar cell module having a sheet-shaped bendable and the surface of the roof substrate conform, if the ceramic-based roof substrate has a curved surface, the curved surface is a substantially parallel straight line. It is preferably a curved surface composed of continuous,
Further, when the ceramic-based roof substrate has a curved surface, the curved surface preferably has a radius of curvature larger than the minimum bendable radius of curvature of the solar cell module having a sheet-like bendability. It should be noted that specific examples of the curved surface formed by the continuation of the substantially parallel straight lines include a wavy shape, an S-shaped shape, and a semi-cylindrical shape.

In the roof material in which the solar cell module of the present invention is integrated, the solar cell module having a sheet-like bendability and the surface of the ceramic roof substrate are bonded to the surface of the ceramic roof substrate. Place a flexible solar cell module in the shape of a circle, place an elongated metal plate or frame on its surface, and use the metal screws or metal screws to ceramically plate the metal plate or frame. The method of joining a sheet-shaped bendable solar cell module to the surface of a ceramic roofing base by fixing it to a roofing base of a ceramic type also uses a metal-shaped U-shaped material to form a sheet-shaped A method may be used in which the edge of the solar cell module having the above is sandwiched, and the metal material is joined to the surface of the ceramic roof substrate, and the solar cell module is bonded and fixed to the roof substrate using an adhesive. Method is fine,
A fixing method combining these methods may be used. still,
The metal material is preferably a non-rusting metal such as aluminum, stainless steel, and galtite.

The roofing material in which the solar cell module of the present invention is integrated uses a ceramic roofing substrate having a curved surface and / or a flat surface, and a sheet-shaped bendable solar cell module on the surface. Therefore, there is no need to form a recess for embedding solar cells in the surface of the roofing material, and the roofing material has the same stepping strength as a normal roofing material that does not form a recess. can do. Since there is no need to form recesses in this way, it can be manufactured with ordinary roofing material thickness, the weight of the solar cell integrated roofing material does not increase, and the roofing work can be facilitated, as well as the building. No load is applied to the skeleton of the building, and it is possible to prevent the seismic resistance from being lowered as in the case where a load is applied to the skeleton of the building.

In the solar cell integrated roofing material of the present invention, a sheet-shaped bendable solar cell module is integrated with a ceramic roof substrate. For this reason, the solar cell portion can be arranged regardless of the flat portion and the curved surface portion of the roof base material, so that the light receiving area is not limited to the flat portion, and the exposed surface of the roofing material of the solar cell integrated roofing material is not limited. The solar cell unit can be effectively arranged. For this reason, the roofing material with a solar cell of the present invention can reduce the number of sheets used, and can effectively use a limited roof area as a light receiving area of the solar cell.

Further, regardless of the angle of the sun and the inclination of the roof, the entire exposed surface of the roofing material can be irradiated with sunlight and the sunlight can be effectively converted into electricity.

The roofing material with solar cells of the present invention comprises a ceramic roofing material. Ceramic roof substrates are generally inexpensive and nonflammable. It has a larger heat capacity than metal-based roofing materials, and can alleviate the rise in temperature of solar cells when installed on a roof surface, effectively reducing the deterioration of solar cell characteristics due to thermal degradation. In addition, the ceramic roofing base material has high insulation properties, and can effectively prevent electric leakage due to destruction or deterioration of the solar cell module and wiring.

According to a second aspect of the present invention, in the solar cell integrated roof material, the substrate of the solar cell section of the solar cell module having flexibility is made of an organic material.

Organic materials have higher bendability than inorganic materials such as stainless steel, and as a result, it is possible to produce a solar cell module having excellent bendability. Since it has higher bendability, the solar cell unit can be effectively arranged on the exposed exposed surface of the solar cell integrated roof material. For this reason, the roofing material with a solar cell according to the present invention can reduce the number of sheets used, and the limited roof area can be effectively used for the light receiving area of the solar cell.

[0027] Irrespective of the angle of the sun and the inclination of the roof, all the exposed surfaces of the roofing material can be irradiated with sunlight, and the sunlight can be effectively converted into electricity.

According to a third aspect of the present invention, in the solar cell integrated roof material, the substrate of the solar cell section of the solar cell module having flexibility is made of an aromatic polyamide film material.

The aromatic polyamide film has high bendability, high heat resistance and high dimensional stability, so that the long-term reliability of the solar cell integrated roofing material can be improved. The thermal expansion coefficient of the aromatic polyamide film is 10 ppm
/ ° C or lower is preferred. As the aromatic polyamide film, a colored one can also be used. The thickness of the aromatic polyamide film is preferably from 20 to 50 μm.

According to a fourth aspect of the present invention, there is provided a solar cell integrated roofing material, wherein when the solar cell integrated roofing material is laid on a roof, a space formed between the roofing material and a base plate, or a roof that overlaps the roofing material. It is characterized in that a space formed between the material and the material substantially forms a space in which a wiring, a connection terminal, a power cable, and the like of the power extraction unit can be laid.

The wiring, connection terminal, power cable, etc. of the power extraction section can be substantially laid. The wiring of the power extraction section of the solar cell module, the connection terminal connected to the wiring, the power cable connecting the connection terminal. Means that they can be laid so that they are not exposed on the roof surface in the state where they are connected.

In the solar cell integrated roofing material according to the present invention, when the solar cell integrated roofing material is laid on a roof, a space formed between the roofing material and a base plate, or a roof material overlapping therewith. Since the space formed between them can substantially form a space in which wiring, connection terminals, power cables, and the like of the power extraction unit can be laid, the wiring of the power extraction unit of the solar cell module and the connection connected to the wiring With the power cables and the like connected to the terminals and the connection terminals connected, the cables can be laid so as not to be exposed on the roof surface, and a beautifully designed roof surface can be formed.

In addition, the rise in temperature of the solar cell is reduced by the air layer in the space, and it is possible to effectively suppress a decrease in efficiency at high temperatures.

In the solar cell integrated roof material according to the fifth aspect, the wiring of the power draw-out portion of the solar cell module is made of a strip-shaped flat metal plate, and is connected to the anode and the cathode of the solar cell. It is characterized in that it is connected and is integrally formed with the solar cell with a weather-resistant protective material having electrical insulation that covers the solar cell from both sides.

The strip-shaped metal thin film of the present invention is made of aluminum, copper,
It is preferable to use a highly conductive metal such as gold or silver. The weather-resistant protective material with electrical insulation covering the solar cell sandwiched from the front and back, first seals the solar cell from the front and back with a resin such as ethylene-vinyl acetate copolymer, and the front and back are even more weather resistant It is possible to use a film of an ethylene / tetrafluoroethylene copolymer, polyethylene, polyester or the like.

It is preferable that the wiring of the power extraction section of the present invention has substantially the same thickness as the solar cell module. Also,
It is preferable to have a bendability equal to or higher than that of the solar cell module.

In the present invention, the wiring of the power extraction section of the solar cell module is formed of a strip-shaped flat thin metal plate, is connected to the anode section and the cathode section of the solar cell, and sandwiches the solar cell from both sides. It is possible to improve the reliability at the connection point between the anode and cathode of the solar cell because it is formed integrally with the solar cell with an electrically insulating weather-resistant protective material covered with It is. Further, in order to insert the connection cord of the solar cell, or to provide a concave groove in the ceramic roof base material, wiring of the power extraction unit in the ceramic roof base material,
There is no need to provide through holes for passing connection terminals, power cables, and the like through the back surface or side surface, and the labor involved in processing the roof material can be omitted, and the waterproofness and durability of the roof material can be improved. It is possible.

The installed houses and buildings can be maintained in a comfortable and safe state without impairing the functions of the roofing material such as waterproofness and fireproofing.

In the solar cell integrated roofing material according to the sixth aspect, the wiring of the power draw-out portion of the solar cell module is formed of a strip-shaped flat thin metal plate, and is connected to the anode part and the cathode part of the solar cell. While being connected, the solar cell is covered integrally with the solar cell with a weatherproof protective material having electrical insulation covering the solar cell from both sides, and when at least the ceramic-based roof base material is laid on the roof It is characterized by being extended and formed up to the space created between the roof material and the ground board that overlaps.

In the above-mentioned solar cell integrated roofing material, the wiring of the power draw-out portion is extended and formed at least to a space formed between the ceramics-based roofing base material and the roofing material that is superimposed when the ceramics-based roofing material is laid on the roof. Therefore, the wiring of the power draw-out section is arranged in a space formed between the roof material and the baseboard that overlap in the roofing direction. For this reason, the wiring of the power draw-out portion, which is insulated and coated, of the solar cell module is not directly exposed to wind, rain, and ultraviolet rays, and furthermore, the temperature change is greatly reduced by the air layer in the space, and the long-term power It is possible to effectively prevent disconnection, electric leakage, and the like due to deterioration of the wiring of the lead portion, and improve long-term durability.

In addition, when the roof material with solar cells is constructed, when the roof surface is walked, the wiring of the power draw-out section does not become cluttered, and the work can be carried out safely, and the work efficiency can be improved. improves. Even after construction of the roofing material with solar cells, when walking on the roof surface for maintenance or the like, since the wiring of the power draw-out portion is not exposed on the roof surface, work can be safely advanced, and work efficiency can be improved. improves. Furthermore, since the wiring of the power draw-out part is not exposed on the roof surface, it is possible to finish the roof surface excellent in design.

The roofing material integrated with a solar cell according to claim 7 is
The upper edge of the solar cell module is arranged up to the overlapping portion with the roof material that overlaps when roofing, and the lower edge of the solar cell module is arranged up to the overlapping portion with the roof material that overlaps when roofing. Have been.

The overlapping margin of the solar cell module is preferably 5 mm or more, more preferably 10 mm or more.
There may be a gap of about 5 mm between the roof material and the roof material that overlaps in the direction of the roofing foot due to unevenness with the ground plate and the dimensional accuracy of the roof material.

The upper edge and the lower edge of the solar cell module are not directly exposed to the wind and rain, and the durability of the solar cell can be improved. Furthermore, even if the solar cell module and the roofing material may be partially peeled off, the solar cell module and the roof material are overlapped in the direction of the roof, so that the progress of the peeling can be prevented well, and the solar cell module is scattered in a strong wind. Can be prevented.

In the solar cell integrated roofing material according to claim 8, the joint surface between the ceramic roof substrate and the solar cell module is a curved surface and a flat surface obtained by moving a substantially straight line in parallel. , A step is provided besides the joining surface and the joining surface,
At the roof foot direction upper part of the roofing material, there is no step at the junction between the upper edge upper surface of the solar cell module and the roof substrate upper surface, or that the solar cell module upper surface is lower than the roof substrate surface. Features. In the present invention, at the upper part of the roofing material in the direction of the roofing foot, the joint between the upper surface of the solar cell module and the upper surface of the roof substrate can be subjected to waterproofing by applying caulking or sealing, or applying an adhesive tape.

In the upper part of the roofing material in the direction of the roofing foot, the joint between the upper surface of the solar cell module and the upper surface of the roofing base material is not exposed to the roof surface when the roofing is performed.
Rainwater blowing, rainwater flow, etc., may make contact with rainwater and accumulate dust and dirt. In the upper part in the roofing direction of the roofing material, there is no step at the junction between the upper surface of the solar cell module and the upper surface of the roof substrate, or the upper surface of the solar cell module is lower than the roof substrate surface, so that Rainwater and dusty soil are discharged, effectively preventing water from entering through the mouth of the solar cell module, propagation of microorganisms, fungi, mold, moss, etc. into the dusty soil, and the durability of the roofing material with solar cells. It is possible to improve.

According to a ninth aspect of the present invention, there is provided a roofing material integrated with a solar cell, wherein a roofing foot can be adjusted at the time of construction.

The roofing foot in the present invention means the length of the roofing material in the direction of the roofing foot that is exposed on the roof surface of the roofing material when the roofing material is roofed. The adjustable length of thatched feet is 5m
m to 100 mm is preferable, and 10 to 50 mm is more preferable.

Because the roof can be adjusted, the solar cell unit can be effectively disposed not only on the gable roof but also on a complicated roof surface such as a ridged house, a purlin roof, or a combination of these roofs. It is possible.

In the solar cell integrated roofing material according to the tenth aspect, in the joint surface of the ceramic type three-dimensional roofing material with the solar cell module, air is transmitted from the joint surface to the ceramic type roof base material. It is characterized in that at least a part is formed.

In the present invention, the part at least partially permeable to the surface of the roofing material is defined as having a permeability of 20 × in the thickness direction of the roofing material.
10 ^-6 [cm ³ · cm / (sec · cm ² · g / c
m ² )].

The entrainment of air bubbles during the application and bonding steps of the adhesive used in integrating the solar cell module and the roofing material, and the heat generated during the production, construction, and post-construction of the solar cell integrated roofing material In addition to preventing swelling due to expansion, the curing reaction by-product of the adhesive used in the roofing material with a solar cell of the present invention is dissipated into the atmosphere through the roof base material. It is possible to prevent swelling due to thermal expansion after the construction and construction of the integrated roofing material.

In the solar cell integrated roofing material according to the eleventh aspect, the solar cell module and the ceramic roof substrate are joined with an adhesive, and the adhesive is colored. And

In the present invention, the adhesive is an elastic adhesive,
Reactive resin adhesives, instant adhesives, rubber solvent adhesives, emulsion / latex adhesives, hot melt adhesives, resin solvent adhesives, and the like can be used. Preferably, the adhesive of the present invention generally contains at least one of silicone having high weather resistance and modified silicone. Silicone adhesives are of one-component condensation reaction type,
A component addition reaction type, a two-component condensation type, a two-component addition reaction type, and the like can be used. The modified silicone adhesive is
One-component condensation reaction type, two-component condensation type, two-component addition reaction type and the like can be used. It is also possible to use an adhesive mainly composed of a specially modified silicone polymer and epoxy.

The adhesive is preferably what is called an elastic adhesive. Since the roofing material with a solar cell can be repeatedly loaded with a temperature difference of several tens of degrees Celsius every day for a day, an adhesive that absorbs a dimensional change due to a difference in linear expansion coefficient between the solar cell module and the roofing material is preferable. Prior to bonding, a suitable primer can be used.

The adhesive used in the roofing material with a solar cell of the present invention is characterized in that it is colored. The adhesive used for integrating the solar cell module and the roof material of the present invention may be colored by changing the composition of the polymer, a pigment,
It may be colored by adding a filler, or by combining these. The pigment to be added may be an inorganic pigment such as gunjo, cadmium yellow, red iron, chrome yellow, lead white, titanium white, carbon black, or an organic pigment such as azo, triphenylmethane, quinoline, anthraquinone, phthalocyanine, and the like. May be used, but inorganic pigments are preferably used. As a filler to be added, mica, silica, calcium carbonate, or the like can be used.

In the solar cell integrated roofing material according to the present invention, the solar cell module and the ceramic roof substrate are bonded with an adhesive, and the adhesive is colored. It is possible to easily match colors with roof materials that are not integrated with the roof, and it is possible to construct a beautiful roof in design.

According to a twelfth aspect of the present invention, there is provided a solar cell integrated roofing material, wherein the solar cell module and the ceramic roofing base material are bonded with an adhesive, and the adhesive is volatile at a high temperature. Characterized in that they do not substantially contain or volatilize at high temperatures.

[0059] In the adhesive content and curing reaction by-product used in the roofing material with a solar cell of the present invention, the component having a boiling point of 85 ° C or less is preferably less than 1% by weight of the adhesive weight before curing.

Since the roofing material with solar cell of the present invention is used on a roof surface, its temperature may rise to about 85 degrees during the daytime in summer.

In the curing reaction by-product of the adhesive used in the roofing material with a solar cell according to the present invention, if the component having a boiling point of 85 ° C. or less is less than 1% by weight of the weight of the adhesive before curing, the roofing with a solar cell is required. Bulging does not occur on the surface of the solar cell module of the material, and it is possible to prevent performance degradation, peeling, and damage to the solar cell module. In addition, it is possible to prevent the solar cell module from scattering in a strong wind.

[0062] In the solar cell integrated roofing material according to claim 13, the solar cell module and the ceramic roofing base material are:
The bonding surface is bonded with an adhesive, and a substantially air-permeable portion is formed in the adhesive layer.

The substantially air-permeable portion in the present invention is
The solar cell-integrated roofing material is laid on the roof surface by air bubbles contained in the adhesive layer, an air layer, or a component that volatilizes at a high temperature contained in the adhesive or a component that volatilizes at a high temperature generated by the adhesive. Means a portion where a gas passage is formed, which is quickly released into the atmosphere when heated to a high temperature by the sun.

In the present invention, there are a method of bonding only the periphery around which a part of the solar cell module is released, a method of applying spot bonding to the entire bonding surface of the solar cell, and a method of bonding almost the entire bonding surface in a bead shape. Can be used.

[0065] Entrapment air bubbles during the application and bonding steps of the adhesive used for integrating the solar cell module and the roofing material during production, construction, and after the production of the solar cell integrated roofing material In addition to successfully preventing blistering due to thermal expansion, the curing reaction by-product of the adhesive used in the roofing material with a solar cell of the present invention is dissipated into the atmosphere, and the blistering due to thermal expansion of the curing reaction by-product is well prevented. It is possible to

[0066]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment FIG. 1 is a plan view showing an example of a solar cell module, FIG. 2 is an exploded perspective view showing an example of a solar cell integrated roofing material, and FIG. 3 is a solar cell shown in FIG. Perspective view of the completed state of the integrated roofing material,
FIG. 4 is a cross-sectional view of the solar cell-integrated roofing material shown in FIG. 3 when it is roofed on the roof surface, and FIG. 5 is a view of the solar cell-integrated roofing material shown in FIG. FIG. 4 is a detailed cross-sectional view of an overlapping solar cell integrated roof material and an overlapping portion.

In FIG. 1, a sheet-shaped bendable solar cell module 2 has a structure in which a wiring 5 of a power lead-out portion of the solar cell module 2 is formed of a strip-shaped flat thin metal plate. The solar cell 7 is connected to the solar cell 7 and the solar cell 7 from the front and the back, and is integrally covered with the solar cell with an electrically insulating weatherproof protective material. Is formed so as to be able to extend to the back surface side of the solar cell integrated roofing material 1 overlapping when it is laid on the roof, or as shown in FIG. It is formed so as to be able to extend to a space 10 formed between it and the ground plate 8, and a connection terminal 6 is connected to the wiring 5 of the power unit.

In FIG. 2, the solar cell integrated roofing material 1 of the present embodiment has a curved surface and a plane formed by a continuous straight line substantially parallel to the sheet-shaped flexible solar cell module 2. This is a structure in which a ceramic roof substrate 4 having at least a part of the surface as a joint surface 3 is integrated.

By bonding the solar cell module 2 to the bonding surface 3 of the ceramic roof substrate 4, the solar cell integrated roof material 1 is in a completed state as shown in FIG.

The solar cell integrated roofing material 1 constructed as described above is laid on the upper surface of the field board 8 in the same manner as a normal roofing material. That is, by laminating the lower end portion of the upper solar cell integrated roofing material 1 on the upper end portion of the solar cell integrated roofing material 1 laid on the lower side, a large number of solar cell integrated roofing materials 1 can be formed. As shown in FIG. 4, a space 10 is formed between the individual solar cell integrated roofing material 1 and the base plate 8.

In FIG. 5, the upper edge of the solar cell module 2 is arranged up to the overlapping portion of the solar cell integrated roof material 1 of the present embodiment, which overlaps with the solar cell integrated roof material 1 when it is roofed. Further, the lower edge of the solar cell module 2 is disposed up to the overlapping portion with the solar cell integrated roofing material 1 that overlaps when roofing.

In the above-mentioned solar cell integrated roofing material 1, the joining surface 3 between the ceramic roof substrate 4 and the solar cell module 2 is
A curved surface and a flat surface obtained by substantially moving a straight line in parallel, a step is provided other than the joining surface 3 and the joining surface, and the upper part of the solar cell module 2 There is no step between the upper edge upper surface and the joint 3 between the upper surface of the roof substrate 4 or the upper surface of the solar cell module 2 is lower than the upper surface of the roof substrate 4.

The roofing material 1 can be adjusted for roofing at the time of construction. In addition, the ceramic-based roof substrate 4 of this embodiment
Is a planar type, but is only an example and is not limited to this embodiment.

Second Embodiment Bonding Surface 3 of Ceramic Roof Base Material 4 to Solar Cell Module 2
In the above, the solar cell integrated roofing material 1 according to claim 10, wherein at least a part of the portion that is permeable from the joint surface 3 to the ceramic roofing base material 4 was formed.

That is, a cement-based roof substrate 4 coated with an acrylic resin is prepared, and an acrylic resin coating film, which is a waterproof layer of the joint surface 3, is formed on the joint surface 3 between the roof substrate 4 and the solar cell module 2. The layer was polished with a # 60 sandpaper, and the resin coating layer was removed almost all over the joint surface 3. The air permeability in the thickness direction of the roof substrate 4 is 15 × 10 ⁻⁶ [cm ³ · c
m / (sec / cm ² · g / cm ² )]. 500 g / m ² of a modified silicone-epoxy adhesive (manufactured by Konishi Corporation, MOS 1008) is applied to the joint surface 3 of the roof substrate 4, and the roof substrate 4 and the solar cell module 2 are adhered to each other, and the room temperature is maintained for one week. And cured to produce a solar cell integrated roofing material 1 according to the claims.

The solar cell integrated roof material 1 prepared as described above was actually applied to the roof surface, and after one week, the occurrence of blisters was visually observed.

Comparative Example 1 A cement-based roof substrate 4 coated with an acrylic resin was prepared. The air permeability in the thickness direction of the roof substrate 4 is 10 × 10
^-7 [cm ³ · cm / (sec / cm ² · g / cm ² ]] A modified silicone-epoxy adhesive (MOS 1008, manufactured by Konishi Co., Ltd.) was applied to the joint surface of the roof base material at 500 g / cm ² .
m ^{2 was} applied, the roof base material and the solar cell module were bonded together, and cured at room temperature for one week to produce a solar cell integrated roof material 1.

The above-mentioned solar cell integrated roof material 1 was actually applied to the roof surface, and after one week, the occurrence of blisters was visually observed.

Example 3 The solar cell module 2 of the ceramic roofing base material 4 was joined to the solar cell module 2 using an adhesive containing a pigment, whereby a solar cell integrated roof material 1 according to claim 11 was prepared.

That is, a cement-based roof substrate 4 coated with black acrylic resin was prepared, and an acrylic resin, which is a waterproof layer of the joint surface 3, was formed on the joint surface 3 between the roof substrate 4 and the solar cell module 2. The coating film layer was polished with a # 60 sandpaper, and the resin coating film layer was removed from almost the entire joint surface 3. Modified silicone / epoxy adhesive (Made by Konishi, MOS1)
008) 1 part by weight of a pigment (manufactured by Konishi Co., Color Master Black) was added to 100 parts by weight to prepare a colored adhesive. The color difference between the adhesive and the paint applied to the roof substrate 4 was 3. 7. An adhesive material is applied to the joint surface 3 of the roof substrate 4 at 500 g / m ² , the roof substrate 4 and the solar cell module 2 are bonded, and cured at room temperature for one week.
Was manufactured.

The above-mentioned solar cell integrated roof material 1 was actually applied to the roof surface, and the external appearance was observed.

Comparative Example 2 That is, a cement-based roof substrate 4 coated with black acrylic resin was prepared, and the roof substrate 4 and the solar cell module 2 were coated.
The acrylic resin coating layer, which is the waterproof layer of the bonding surface 3, was polished with a # 60 sandpaper to remove the resin coating layer from almost the entire bonding surface 3. A modified silicone-epoxy adhesive (MOS1008, manufactured by Konishi Co., Ltd.) is applied to the joint surface of the roof base material at 500 g / m ² , and the roof base material 4 and the solar cell module 2 are bonded and cured at room temperature for one week. Thus, a solar cell integrated roofing material 1 was prepared. The color difference between the adhesive and the paint applied to the roof substrate 4 was 55.

The solar cell integrated roof material 1 was actually applied to the roof surface, and the external appearance was observed.

Embodiment 4 The solar cell module 2 of the ceramic roofing base material 4 was joined to the solar cell module 2 by using an adhesive material which does not substantially contain a material which volatilizes at a high temperature or does not substantially generate a material which volatilizes at a high temperature. A solar cell integrated roofing material 1 according to claim 12 was produced.

That is, a cement-based roof substrate 4 coated with an acrylic resin was prepared, and the roof substrate 4 and the solar cell module 2 were bonded to each other by the total amount of methanol and ethanol, which are by-products of the curing reaction. The solar cell integrated roofing material 1 according to claim 5 or 6 was prepared by bonding using an adhesive of 0.2 parts by weight of the material and curing at room temperature for one week.

Comparative Example 3 A cement-based roof substrate 4 coated with an acrylic resin was prepared, and the roof substrate 4 and the solar cell module 2 were combined with each other so that the total amount of methanol and ethanol, which were by-products of the curing reaction, was completely reduced. Adhesion was performed using 2 parts by weight of the adhesive, and the mixture was cured at room temperature for one week, thereby producing a solar cell integrated roofing material 1.

Example 5 A solar cell module in which the solar cell module 2 and the ceramic roofing base material 4 are bonded together at the bonding surface 3 with an adhesive, and a substantially air-permeable portion is formed in the adhesive layer. The body type roofing material 1 was created.

That is, a cement-based roof base material 4 coated with an acrylic resin was prepared, and the roof base material 4 and the solar cell module 2 were made by using “Super X” manufactured by Cemedine Co., Ltd. with a diameter of 5 mm.
The solar cell-integrated roofing material 1 according to claim 13 was applied and applied in a bead shape at a pitch of 40 mm, and substantially formed with a portion to be ventilated.

The above-mentioned solar cell integrated roof material 1 was actually applied to the roof surface, and after one week, the occurrence of blisters was visually observed.

Comparative Example 4 A cement-based roof base material 4 coated with an acrylic resin was prepared, and the roof base material 4 and the solar cell module 2 were coated with “Super X” manufactured by Cemedine Co., Ltd. In addition, a solar cell integrated roofing material 1 in which substantially no ventilation portion was formed was produced.

The solar cell integrated roofing material 1 was actually applied to the roof surface, and after one week, the occurrence of blisters was visually observed.

Table 1 shows the evaluation results of Example 2 and Comparative Example 1, Table 2 shows the results of Example 3 and Comparative Example 2, Table 3 shows the results of Example 4 and Comparative Example 3, and Example 5 and Comparative Example 4. Table 4 shows the results.

[0093]

[0094]

[0095]

[0096]

[0097]

By laying the roofing material with a solar cell of the present invention on a roof of a house or the like, it is excellent in durability and rain fighting,
Electric power can be obtained using sunlight at low cost, which is lightweight, does not impose a burden on the roof surface, has excellent workability, and is inexpensive.

[Brief description of the drawings]

FIG. 1 is a plan view showing an example of a solar cell module.

FIG. 2 is an exploded perspective view showing an example of a solar cell integrated roof material.

FIG. 3 is a perspective view of a completed state of a solar cell integrated roof material.

FIG. 4 is a cross-sectional view of the solar cell integrated roof material when it is laid on the roof surface.

FIG. 5: When the solar cell integrated roof material is laid on the roof surface,
FIG. 4 is a detailed cross-sectional view of a solar cell integrated roof material and an overlapping portion that overlap in a roofing foot direction.

[Description of Signs] 1 Solar cell integrated roofing material 2 Solar cell module 3 Joining surface 4 Ceramics-based roof base material 5 Wiring of power drawer 6 Connection terminal 7 Solar cell 8 Field board 9 Power cable 10 Space

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Tomotoshi Mizota 106, Someya, Sakai-cho, Sarushima-gun, Ibaraki Prefecture Asahi Kasei Corporation (72) Inventor Takufumi Watanabe 106, Someya, Sakai-cho, Sarushima-gun, Ibaraki Pref. Fuji Electric Co., Ltd. (72) Inventor Masahiro Osawa 1-1-1, Tanabe Nitta, Kawasaki-ku, Kawasaki City, Kanagawa Prefecture Inside Fuji Electric Co., Ltd. (72) Inventor Shigeru Maruyama 1-1-1, Tanabe Nitta, Kawasaki-ku, Kawasaki City, Kanagawa Prefecture Fuji Electric Co., Ltd. In-house (72) Inventor Hiroshi Fujii 1-1-1, Tanabe-Shinda, Kawasaki-ku, Kawasaki-shi, Kanagawa F-term (reference) 2E108 GG16 KK04 LL04 MM00 NN07 5F051 BA03 BA18 EA05 EA17 GA05

Claims (13)

[Claims] 1. A solar cell comprising a ceramic roof substrate having at least a curved surface and / or a flat surface, wherein a sheet-shaped curable solar cell module is joined and integrated to the surface. Body type roofing material. 2. A solar cell integrated roof according to claim 1, wherein the substrate of the battery section is made of an organic material in a sheet-shaped flexible solar cell module. Wood. 3. The solar cell integrated roofing material according to claim 2, wherein in the solar cell module having a sheet-like bendability, the substrate of the battery section is an aromatic polyamide film. 4. A space in which power wiring, power cables, connection terminals and the like can be laid substantially between the roof material and the base plate when the roof is laid on the roof. 3. The solar cell integrated roof material described in any one of 3. 5. A wiring of a power extraction portion of the solar cell module is formed of a strip-shaped thin metal plate, is connected to an anode portion and a cathode portion of the solar cell, and covers the solar cell from both sides. The solar cell integrated roof material according to any one of claims 1 to 4, wherein the solar cell integrated roof material is formed so as to be integrally covered with the solar cell with the weather-resistant protective material having electric insulation. 6. A wiring of a power extraction portion of the solar cell module is formed of a strip-shaped flat metal plate, is connected to an anode portion and a cathode portion of the solar cell, and covers the solar cell from both sides. It is covered integrally with the solar cell with a weather-resistant protective material having electrical insulation, and extends at least to the back surface side of the roof material that overlaps at least when the solar cell integrated roof material is laid on the roof. The solar cell integrated roof material according to any one of claims 1 to 4, wherein the roof material is formed. 7. An upper edge of the solar cell module is arranged up to an overlapping portion with a roof material that is overlapped when the roof is covered, and further, the solar cell module is extended to an overlap portion with a roof material that is overlapped when the roof is covered. The solar cell-integrated roofing material according to any one of claims 1 to 6, wherein a lower edge is disposed. 8. The joining surface between the ceramic roof substrate and the solar cell module is a curved surface or a flat surface obtained by substantially moving a straight line in parallel, and a step is provided other than the joining surface and the joining surface. At the roof foot direction upper part of the roofing material, there is no step at the junction between the upper edge upper surface of the solar cell module and the roof substrate upper surface, or that the solar cell module upper surface is lower than the roof substrate surface. 8. The method according to claim 1, wherein
The solar cell integrated roof material described in any one of the above. 9. The solar cell integrated roofing material according to claim 1, wherein the roofing foot can be adjusted at the time of construction. 10. The ceramic roof substrate, wherein at least a part of the joint surface between the ceramic roof substrate and the solar cell module is permeable to air from the joint surface to the ceramic roof substrate. Item 10. A solar cell integrated roofing material according to any one of Items 1 to 9. 11. The solar cell according to claim 1, wherein the solar cell module and the ceramic roof substrate are joined with an adhesive, and the adhesive is colored. Battery-integrated roofing material. 12. The solar cell module and the ceramic roofing base material are bonded on substantially the entire surface of a bonding surface with an adhesive, and the bonding material substantially does not include a material that volatilizes at a high temperature, or has a high temperature. The solar cell-integrated roofing material according to any one of claims 1 to 11, wherein substantially no volatile material is generated. 13. The solar cell module and the ceramic roofing base material are joined at their joint surfaces with an adhesive, and a substantially air-permeable portion is formed in the adhesive layer. The solar cell integrated roof material according to claim 1.