JP2002061355A - Solar battery module integral type roof panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery module integral type roof panel excellent in waterproofing, soundproofing and heat insulating properties by simple construction to set it on a roof of a building by manufacturing it in a factory. SOLUTION: The solar battery module integral type roof panel to be laid at least on a part of a roof structural member constitutes its characteristic feature of furnishing a lattice skeleton member 1 made of a vertical frame bar 2 and a lateral frame bar 3, a pan 7 fixed in a state to cover an opening part of this skeleton member 1 and a solar battery sub-module 12 mounted on an upper part of this pan 7.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roof panel integrated with a solar cell module, which is laid on at least a part of a roof structural member of a house or the like and converts solar energy into electricity for use.

[0002]

2. Description of the Related Art A technique of mounting a solar cell panel on a roof of a building such as a house and converting solar energy into electricity for use is disclosed in, for example, Japanese Patent Application Laid-Open Nos.
-72910 and the like.

Japanese Patent Application Laid-Open No. Hei 10-46770 discloses that a plurality of solar cell panels are laid on a roof base material via a support frame or a heat insulating material, and the outer peripheral edges of these solar cell panels are fixed to the roof base material. It was fixed with a solar cell panel mounting bracket.

[0004] In Japanese Patent Application Laid-Open No. Hei 10-72910, a solar cell panel is composed of a base material, a solar cell element mounted on the base material, and a sealing material. Then, an engaging portion and an engaging receiving portion are integrally provided on an outer peripheral edge portion of the base material of the solar cell panel, and the engaging portion and the engaging receiving portion are engaged with each other to couple the solar cell panel. The solar cell panels are laid on a roof base material.

Further, as shown in Japanese Utility Model Laid-Open Publication No. Sho 62-52610, a concave portion having a shape suitable for a solar cell module is provided on the upper surface of a roof tile or an exterior material intended for an outer wall, and the solar cell is formed in the concave portion. Some are equipped with a module.

On the other hand, solar cell modules are roughly classified into crystal modules and thin film modules. In a crystalline solar cell module, solar cells formed using a small-area single-crystal semiconductor wafer on a plate glass (front cover glass) of the size of the module are 20 to
About 30 sheets are arranged and interconnected. The back surfaces of these single crystal cells are sealed and protected using a well-known filler such as EVA and a well-known protective film such as Tedra (registered trademark).

In a thin-film solar cell module (module integrated with a substrate), a transparent electrode layer, a semiconductor thin-film photoelectric conversion layer, and a back surface are directly formed on a glass plate having the size of the module and also serving as a front cover glass. The electrode layers are sequentially stacked. These layers are divided into a plurality of cells and electrically interconnected (integrated) using vapor deposition and patterning by laser scribing, etc., so that the desired voltage and current output can be obtained. can get. For the back surface protection of the thin-film solar cell module, the same filler and protective film as in the case of the crystalline solar cell module can be used.

The thin-film solar cell module has an advantage that it can be easily formed in a larger area and can be manufactured at low cost, as compared with a crystalline solar cell module. For example, the dimensions and shape of a large-area thin-film solar cell module in recent years can be manufactured, for example, with a rectangular planar shape of about 90 cm × 45 cm and a thickness of about 6 to 8 mm.

When arranging a solar cell panel including a solar cell module on a roof, a predetermined frame is installed on a partial area of the roof on which a tile, a slate, or the like is installed, and a plurality of solar cell panels are mounted on the frame. Conventionally, a method of fixing an array has been used.

[0010]

However, in order to lay a solar cell panel on the roof of a building, a plurality of solar cell panels are placed on the roof to be laid, and the solar cell panels are mounted one by one. This is a so-called on-site construction in which the base member of the solar cell panel is fixed to the base material or the engaging portion provided on the base material of the solar cell panel and the engaging receiving portion are engaged and fixed. Also, in the case of a solar cell module tile in which a solar cell module is mounted on a roof tile, the construction is performed on site as in the case of ordinary roofing work.

In addition, it is necessary to take a waterproof structure while laying the solar cell panel on the roof, and it is difficult to construct the solar cell panel, and much time is required for the construction.

The present invention has been made in view of the above circumstances, and has as its object the simple construction of manufacturing at a factory and installing it on the roof of a building, and is excellent in waterproofness, soundproofing and heat insulation. A roof panel integrated with a solar cell module.

[0013]

According to the present invention, in order to achieve the above object, a first aspect of the present invention is a roof panel integrated with a solar cell module laid on at least a part of a roof structural member. Characterized by comprising a skeletal member of (1), a base material fixed to cover an opening of the skeletal member, and a solar cell sub-module mounted on an upper portion of the base material. It is a panel.

According to a second aspect, the skeletal member of the first aspect is
It has a supporting portion for supporting at least a part of the outer peripheral edge of the base material.

A third aspect of the present invention is characterized in that the base material of the first aspect is a non-combustible material such as a metal which has been subjected to a rust-proof treatment.

A fourth aspect of the present invention is characterized in that the base material of the first aspect has a recess for accommodating a heat insulating material and a solar cell submodule.

According to a fifth aspect of the present invention, the heat insulating material and the solar cell submodule housed in the concave portion of the base material of the fourth aspect are bonded and fixed.

According to a sixth aspect of the present invention, the waterproof sealing material is filled between the outer peripheral surface of the solar cell submodule housed in the concave portion of the base material and the inner peripheral surface of the concave portion. It is characterized by.

According to a seventh aspect of the present invention, the heat insulating material and the solar cell submodule housed in the concave portion of the base material of the fourth aspect are fixed by a cover member fixed to the frame member. .

An eighth aspect of the present invention is characterized in that the outer peripheral edge of the base material according to the first aspect is fixed to the skeleton member by a pressing member having a waterproof gasket.

According to a ninth aspect of the present invention, the gap between the adjacent outer peripheral edges of the respective substrates provided at the opening of the skeleton member of the first aspect is a cover member having a waterproof gasket fixed to the skeleton member. It is characterized by being covered.

According to a tenth aspect, in the solar cell module according to the first aspect, a base material, a heat insulating material provided on the base material,
And a solar cell sub-module fixed to the heat insulating material.

According to the above construction, an integrated roof panel can be manufactured in a factory, and it is excellent in productivity. In addition, since each solar cell module is supported by a lattice-like frame member, it is rigid and durable. And a highly reliable waterproof structure can be obtained. Further, the solar cell module is supported on the skeleton member, and when any one of the solar cell modules is damaged, only the solar cell module can be easily replaced.

Further, by providing the solar cell sub-module via the heat insulating material on the base material, the solar cell sub-module has a heat insulating effect and a soundproof effect, so that energy saving and a comfortable living space can be configured. further,
Since the holding member having the water-stop gasket and the cover member having the water-stop gasket are provided on the skeleton member and the solar cell module is fixed by the mounting structure, a waterproof structure can be obtained simultaneously with the fixing.

[0025]

Embodiments of the present invention will be described below with reference to the drawings.

1 to 3 show a first embodiment of a roof panel integrated with a solar cell module. FIG. 1 is a plan view and FIG.
1 is a cross-sectional view taken along the line AA of FIG. 1, and FIG. 3 is a cross-sectional view taken along the line BB of FIG.

As shown in FIGS. 1 to 3, the skeletal member 1 is formed of a wooden vertical bar 2 and a horizontal bar 3 in a lattice shape. The skeletal member 1 corresponds to a roof structural member, for example, in the case of a wooden building, a rafter spanned from the ridge to the eaves with a roof gradient. In the present embodiment, the vertical beam 2 and the horizontal beam 3 are used in the horizontal direction. Are provided with ten long rectangular openings 4.

A support bar 5 protrudes from the inner surface of the horizontal rail 3 (on the side of the opening 4) at a substantially middle portion in the vertical direction over the longitudinal direction thereof, and supports a solar cell module M described later. Unit. Further, concave portions 2a and 3a are provided in the widthwise middle portions of the upper surfaces of the vertical bar 2 and the horizontal bar 3 in a long direction. 3a communicates.

Each opening 4 of the skeleton member 1 is provided with a receiving tray 7 as a base material so as to cover the opening. The receiving tray 7 is a rectangular plate with a shallow bottom made of an iron plate or stainless steel, aluminum, or the like that has been subjected to a rust-proofing process. An outer peripheral wall 9 is provided on the outer peripheral edge of the bottom surface 8 of the receiving tray 7.
Is provided with a flange portion 10 integrally therewith. The height of the bottom surface 8 of the tray 7 and the height of the flange 10 are substantially the same as the height of the upper surface of the support bar 5 of the horizontal rail 3 and the upper surface of the horizontal bar 3, and the outer peripheral portion of the bottom surface 8 of the tray 3 is supported The flange 10 is supported by the bar 5
And is supported by the upper surface of the horizontal rail 3. At this time, the flange 10 is formed to have a small width so as not to cover the concave grooves 2a and 3a.

A heat insulating material 11 such as, for example, styrofoam is accommodated in the tray 7 and is adhered to the bottom surface 8 with an adhesive or a double-sided adhesive tape. A waterproof sealing material 11a is filled between the module 12 and the outer peripheral surface. A solar cell sub-module 12 is adhered to the upper surface of the heat insulating material 11 with an adhesive or a double-sided adhesive tape. A terminal box (not shown) is fixed to a part of the lower surface of the solar cell submodule 12, and an output cable (not shown) led out of the terminal box passes through the heat insulating material 11 and is led out from the bottom surface 8 of the tray 7. ing.

The solar cell module M is constituted by the tray 7, the heat insulating material 11, the solar cell sub-module 12, and the terminal box. As shown in FIG. Is set with a solar cell module M. The upper surface of the solar cell sub-module 12 of the solar cell module M, that is, the glass surface is substantially flush with the flange 10 of the tray 7.

This solar cell module M is, for example, 1
Transparent electrode layer, amorphous semiconductor layer,
A back surface electrode layer is formed, and the back surface has a rectangular thin panel structure sealed with a sealing material for protecting the semiconductor layer and the back surface electrode layer. Note that the present invention is not limited to the amorphous semiconductor layer, and may be single crystal, polycrystal, microcrystal, Si-based, or compound-based.

FIG. 1 shows a ridge-side panel installed on the ridge side of the roof. In the figure, the left-side vertical bar 2b is formed to have a width of 1/2 so as to be connected to the eave-side panel.
“b” is formed to have a half width so as to be connected to the right ridge side panel.

FIG. 4 is an enlarged sectional view showing a fixing structure between the vertical rail 2 and the solar cell module M, and FIG. 5 is a sectional view of a pressing member and a cover member. As shown in FIG. 5, the holding member 15 is formed in a substantially T-shape by, for example, extrusion molding of aluminum, and its head 16 has substantially the same width as the vertical rail 2 and water-stop gaskets 17 are adhered to both sides of the lower surface. Have been. Further, a pair of L-shaped engaging portions 18 are integrally provided at an intermediate portion of the head 16 in the width direction.

The leg portion 19 of the holding member 15 is formed by two insertion plate portions 20 which are set at an interval capable of being inserted into the concave groove 2a of the vertical rail 2, and the two insertion plate portions 20 The water stop gasket 21 is fixed.

The cover member 22 is formed in a belt shape by extrusion molding of aluminum, for example, and is wider than the pressing member 15 and extends outward from the vertical bar 2. The gasket 23 is fixed, and an engaging claw 24 that is elastically engageable with the engaging portion 18 of the pressing member 15 is provided integrally at an intermediate portion.

The holding member 15 is provided with the concave groove 2a of the vertical rail 2.
Into the groove 2a.
The watertight gasket 17 of the head 16 is fixed to the longitudinal bar 2 by a fixing member 25 such as a wood screw or a nail while being in close contact with the flange 10 of the receiving tray 7 while being in close contact with the inner bottom portion. Therefore, the flange portion 10 of the receiving tray 7 is fixed to the vertical rail 2, and the solar cell module M is fixed to the vertical rail 2, and the water stopping gasket 17 presses the holding member 1.
5 and the flange 10 are sealed watertight.

In this state, when the pressing member 15 is covered with the cover member 22 from the upper surface thereof and the cover member 22 is pressed against the pressing member 15 or struck by a wooden hammer, the engaging claw 24 is engaged with the engaging portion 18. And holding member 15
, The cover member 22 is fixed. Then, the waterproof gasket 23 is in close contact with the upper surface of the outer peripheral edge of the solar cell module M, and the cover member 22 and the solar cell module M are sealed in a watertight manner. Therefore, the waterproof gasket 23
And 17, a double seal structure is provided, and it is possible to prevent rainwater on the upper surface of the solar cell module M from penetrating in the vertical rail 2 direction.

FIG. 6 is an enlarged sectional view showing a fixing structure between the horizontal rail 3 and the solar cell module M, and FIG. 7 is a sectional view of a cover member. As shown in FIG. 6, the pressing member 15 has the same structure as the pressing member 15 of the vertical bar 2, and thus the description thereof is omitted, but the leg 19 of the pressing member 15 is formed by the concave groove 3 a of the horizontal bar 3.
Plugged in.

As shown in FIG. 7, the cover member 26 is formed in a strip shape by, for example, extrusion molding of aluminum, and has a downwardly inclined surface 26a formed on both sides of the upper surface so that rainwater can easily flow. Further, the cover member 26 is wider than the holding member 15 and extends outward from the cross rail 3. Water blocking gaskets 27 are fixed to both sides of the lower surface, and the holding member 15 An engagement claw 28 that can be elastically engaged with the joint portion 18 is provided integrally.

The holding member 15 is provided with the groove 3a of the horizontal rail 3.
Into the groove 2a.
The watertight gasket 17 of the head 16 is fixed to the horizontal bar 3 by a fixing member 25 such as a wood screw or a nail in a state in which the gasket 17 of the head 16 is in close contact with the flange 10 of the tray 7. Therefore, the flange 10 of the receiving tray 7 is fixed to the horizontal rail 3, and the solar cell module M is fixed to the horizontal rail 3.
5 and the flange 10 are sealed watertight.

In this state, when the pressing member 15 is covered from above by the cover member 26 and the cover member 26 is pressed against the pressing member 15 or struck by a wooden hammer, the engaging claw 28 engages with the engaging portion 18. And holding member 15
, The cover member 26 is fixed. Then, the water stop gasket 27 is in close contact with the upper surface of the outer peripheral edge of the solar cell module M, and the cover member 26 and the solar cell module M are sealed in a watertight manner. Therefore, the waterproof gasket 27
And 17, a double seal structure is provided, and it is possible to prevent rainwater on the upper surface of the solar cell module M from entering the horizontal rail 3 direction.

Further, as shown in FIGS. 8 and 9, in the solar cell module-integrated roof panel 30, the pressing member 15 of the vertical bar 2 is one continuous over the entire length in the longitudinal direction of the vertical bar 2. The holding member 15 of the cross bar 3 is divided into a plurality of pieces that abut against the vertical side surface of the vertical bar 2 at the crossing portion 6, and the end of the horizontal bar 3 at the crossing portion 6 is filled with a caulking material 29 to be watertight. Sealed.

The solar cell module integrated roof panel 30 thus configured is manufactured by a factory and is, for example, an integrated panel having a vertical dimension of 2700 mm and a horizontal dimension of 2014 mm. Basically, a solar cell module integrated roof panel 30 having the same structure is manufactured, and as shown in FIG. 8, a plurality of sheets (four sheets in this embodiment) are connected at a construction site.

When connecting a plurality of solar cell module-integrated roof panels 30, as shown in FIGS. 10 and 11, the vertical rails 2b and the horizontal rails 3b having a half width are connected to each other. The fixing of the holding member 15 and the fixing of the cover members 22 and 26 at the joint are performed at the construction site.
The fixing structure of the holding member 15 and the cover members 22 and 26 is the same as the assembly at the factory described above, and thus the description is omitted.

Cover members 22 and 26 in a state where a plurality of solar cell module integrated roof panels 30 are connected.
A joint cap 32 filled with a caulking material on the back surface is attached to the crossing portion 31 to close the gap in the connecting portion, thereby preventing the invasion of wind and rain and improving the aesthetic appearance.

According to the first embodiment described above, the solar cell module M is composed of the tray 7, the heat insulating material 11 provided therein, and the solar cell submodule 12 provided on the upper surface of the heat insulating material 11. It is configured. Therefore, the solar cell module M is excellent in the heat insulation effect and the soundproof effect, and since each solar cell module M is supported by the lattice-shaped skeleton member 1, the rigidity is excellent and the durability can be improved.

In the first embodiment, the solar cell sub-module 12 is fixed on the upper surface of the heat insulating material 11 with an adhesive or a double-sided adhesive tape. However, the cover members 22, 26 are provided via the waterproof gaskets 23, 27. The solar cell sub-module 12 can be pressed and fixed to the heat insulating material 11 from above by the
2 need not be adhered to the heat insulating material 11. With such a configuration, there is an effect that replacement work, repair, and the like when the solar cell submodule 12 is damaged can be easily performed.

FIG. 12 shows a second embodiment of the solar cell module M, in which a corrugated uneven portion 37 is integrally provided on a bottom surface 36 of a tray 35 made of an iron plate or aluminum. The convex portion 37a of the concave / convex portion 37 is formed on the support surface, and the solar cell sub-module 12
Is provided.

According to the above configuration, an air layer is formed by the concave and convex portions 37, which has a heat insulating effect and a soundproofing effect, and eliminates the need for a heat insulating material. Therefore, weight reduction and cost reduction can be achieved. Of course, also in this embodiment, the solar cell sub-module 12 may or may not be adhered to the support surface.
The shape of the uneven portion 37 is not limited.

[0051]

As described above, according to the present invention, a roof panel integrated with a solar cell module can be produced in a factory and installed on the roof of a building.
A highly reliable waterproof structure can be obtained. Moreover, it has excellent soundproofing and heat insulating properties, and has an effect that the solar cell module can be easily replaced or the like.

[Brief description of the drawings]

FIG. 1 is a plan view showing a roof panel integrated with a solar cell module according to a first embodiment of the present invention.

FIG. 2 is a sectional view of the embodiment, taken along line AA of FIG. 1;

FIG. 3 is a sectional view of the same embodiment, taken along line BB of FIG. 1;

FIG. 4 is an enlarged cross-sectional view showing the embodiment and showing a fixing structure of the vertical rail and the solar cell module.

FIG. 5 is a sectional view of the pressing member and the cover member, showing the same embodiment.

FIG. 6 is an enlarged cross-sectional view showing the same embodiment and showing a fixing structure between the horizontal rail and the solar cell module.

FIG. 7 shows the same embodiment, and is a cross-sectional view of a cover member.

FIG. 8 is a perspective view of the same embodiment, in which four solar cell module integrated roof panels are combined.

FIG. 9 shows the same embodiment, and is a partial plan view and a cross-sectional view in a state where a roof panel integrated with a solar cell module is connected.

FIG. 10 is a cross-sectional view illustrating the same embodiment and enlarging a portion C in FIG. 9;

FIG. 11 is an exemplary sectional view showing the same embodiment and enlarging a portion D in FIG. 9;

FIG. 12 shows a second embodiment of the present invention, and is a cross-sectional view of a roof panel integrated with a solar cell module.

[Description of Signs] 1… Frame member M… Solar cell module 2… Vertical rail 3… Horizontal rail 7… Receiving plate (base material) 11… Insulation material 12… Solar cell submodule 15… Holding member 22, 26… Cover member

Claims (10)

[Claims] 1. A solar cell module-integrated roof panel laid on at least a part of a roof structural member, comprising: a lattice-shaped skeleton member; and a base material fixed to cover an opening of the skeleton member. A solar cell module-integrated roof panel, comprising: a solar cell sub-module mounted on an upper portion of the substrate. 2. The solar cell module-integrated roof panel according to claim 1, wherein the skeleton member has a support portion that supports at least a part of an outer peripheral edge of the base material. 3. The solar cell module-integrated roof panel according to claim 1, wherein the base material is a non-combustible material such as a metal that has been subjected to a rust-proof treatment. 4. The solar cell module-integrated roof panel according to claim 1, wherein the substrate has a recess for accommodating a heat insulating material and a solar cell submodule. 5. The solar cell module-integrated roof panel according to claim 4, wherein the heat insulating material and the solar cell submodule housed in the concave portion of the base material are adhered and fixed. 6. A waterproof sealing material is filled between an outer peripheral surface of the solar cell submodule housed in the concave portion of the base material and an inner peripheral surface of the concave portion.
The roof panel integrated with the solar cell module described in the above. 7. The solar cell according to claim 4, wherein the heat insulating material and the solar cell submodule housed in the concave portion of the base material are pressed and fixed by a cover member fixed to the skeleton member. Module integrated roof panel. 8. The solar cell module-integrated roof panel according to claim 1, wherein an outer peripheral edge of the base material is fixed to the skeleton member by a pressing member having a waterproof gasket. 9. A gap between adjacent outer peripheral edges of each base material provided in an opening of the skeleton member is covered with a cover member having a waterproof gasket fixed to the skeleton member. The roof panel integrated with a solar cell module according to claim 1. 10. The solar cell module, comprising: a base material;
The solar cell module integrated roof panel according to claim 1, comprising a heat insulating material provided on the base material and a solar cell submodule fixed to the heat insulating material.