JP2002188247A - Solar cell integral type monolithic roof member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell integral type monolithic roof member excellent in workability and sealing performance against the incursion of water, having a drainage mechanism of water and high water proofing property even if the incursion of water occurs by breathing an open air and preventing the accumulation of dust on the solar cell light receiving surface. SOLUTION: A solar cell module 11 formed by sealing a solar cell 1 with a resin sealing compound 40 between the surface protection member 2 and the back protection member 3 is placed to the inside of a recess section 20a provided on the surface of a roof member body 20 through an adhesive sheet 30 having a predetermined thickness, a gap between the bottom and the sides of the solar cell module and the inside of the recess section of the roof member body is filled with a liquid foamable sealing compound 50 to foamingly solidify, the solar cell module and the roof member body are monolithically formed, weep holes 21 passing through the bottom of the tile from the bottom of the recess section are provided to the recess section, and weep hole cover members 22 for preventing the drainage incapability by blocking the weep holes with foamable are arranged to the bottom of the recess section.

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 roof member, and more particularly to a sealing structure of a solar cell module having improved waterproofness.

[0002]

2. Description of the Related Art At present, research and development of clean energy are being promoted from the standpoint of environmental protection. Above all, solar cells are attracting attention because of their infinite resources (solar rays) and no pollution. A typical example of a solar cell (photoelectric conversion device) in which a plurality of solar cell elements formed on the same substrate are connected in series is a thin-film solar cell.

Thin-film solar cells are considered to be the mainstream of solar cells in the future because of their thinness, light weight, low production cost, and easy area enlargement. Demand is expanding for business use and general residential use, which are used for such purposes. Roof tiles with solar cells have also been developed for general residential use.

In recent years, research and development of a flexible solar cell using a plastic film has been promoted, and by utilizing this flexibility, mass production can be performed by a roll-to-roll method or a step-roll method. I have.

In order to seal a solar cell formed on an electrically insulating film substrate with an electrically insulating protective material, the light receiving surface side and the non-light receiving surface side of the solar cell are used as the thin film solar cell module. Both are provided with a protective layer.

FIG. 3 is a side sectional view showing an example of a schematic structure of a conventional solar cell module. In FIG. 3, one or a plurality of solar cell elements are connected in series or in parallel, and a solar cell 1 has a surface protection member 2 such as a glass plate on its light receiving surface side, and one side on an aluminum foil side on its back side. A back surface protection member 3 to which ethylene fluoride is adhered is provided, and is thermally sealed by an adhesive resin sealing material 40 such as EVA (ethylene-vinyl acetate copolymer resin) which is excellent in adhesive sealing property and inexpensive. I have.

In the solar cell 1, internal lead wires 5 and 6 are electrically connected to the positive (+) and negative (−) poles, and the internal leads 5 and 6 are connected to the back surface protective member 3. The connection terminal box 70, which is bonded and fixed, is guided through the back surface protection member 3, and is electrically connected to the core wires 9 and 10 of the cable 8 as external lead wires inside the connection terminal box 70, and these are entirely solar cells. A module 11 is formed.

As the surface protective member 2, an organic material such as a transparent acrylic plate may be used in addition to an inorganic material such as a glass plate. In addition to the above-mentioned resin containing a metal foil, the backside protective member 3 may be an organic film alone such as a fluorine-based film, a composite material obtained by laminating an organic film and a metal foil, or a metal such as a metal plate or a glass plate.・ Inorganic materials may be used.

Further, as described above, roof tiles with solar cells and the like have been developed.
717 and JP-A-2000-226909.

In the roof tile with a solar cell described in the above-mentioned Japanese Patent Application Laid-Open No. 2000-204717, the solar cell is disposed in a concave portion provided on the surface of a tile base made of a hydraulic inorganic material, for example, lightweight concrete. It has a structure and describes an invention relating to the thickness and shape of the concave portion. As the solar cell, a solar cell module having the above-described configuration is used.However, in the roof tile with a solar cell described in the above publication, if the end seal of the solar cell module is insufficient, light-weight concrete is used. There is a problem that the solar cell module is corroded by the eluted alkali component.

Japanese Patent Application Laid-Open No. 2000-226909 describes an invention relating to an end sealing structure of a solar cell module for a solar cell storage tile. JP 200
The roof tile with a solar cell described in Japanese Patent Publication No. 0-226909 is composed of a roof tile main body and a solar cell structure (solar cell module), and the roof tile main body is formed by pressing a cement composition. A concave portion for inserting the solar cell structure is provided substantially at the center of the upper surface of the roof tile body, and eight nailing pedestals are provided on the water side, and a nail hole is provided substantially at the center of the nailing pedestal. Is formed so that it can be fixed to the roof.

FIG. 4 shows an example of an enlarged cross-sectional structure of a peripheral portion of a solar cell structure described in Japanese Patent Application Laid-Open No. 2000-226909. The solar cell structure 62 shown in FIG.
The periphery of the solar cell laminate (solar cell module) 62a is covered with an elastic sealing material or an adhesive tape 7, and the laminate 6 on which the elastic sealing material or the adhesive tape 7 is stuck.
The peripheral portion 2a is press-fitted into the opening of the frame 4 having a U-shaped cross section. This solar cell structure 62
Is inserted into the concave portion of the roof tile body to obtain a roof tile with solar cells.

The adhesive tape 7 is, for example, a tape-like sheet of EPDM (ethylene propylene terpolymer) having a width of about 9 mm and a thickness of about 5 mm provided with a butyl rubber-based pressure-sensitive adhesive layer on one surface. Tape 7 is laminated 62
After affixing the adhesive tape 7 to the peripheral edge of the frame 4, the peripheral edge of the laminated body 62a to which the adhesive tape 7 is adhered is inserted into the U-shaped opening of the frame 4 while compressing the adhesive tape 7.

In this case, the adhesive tape 7 having a thickness of about 5 mm is inserted in a compressed state into a gap of about 1 mm between the peripheral portion of the laminate 62a and the inner surface of the flange of the frame 4. Therefore, the solar cell structure 62 can be easily manufactured simply by inserting the adhesive tape 7 into the opening having the U-shaped cross section while compressing the same, and the manufactured solar cell structure 62 can be easily manufactured.
Since the compressed adhesive tape 7 is attached to the peripheral portion of the laminated body 62a, the compressed adhesive tape 7 tries to return to the original shape, and the inner surface of the flange of the frame 4 and the peripheral edge of the laminated body 62a. As a result of pressing the portion, the space between the adhesive tape 7 and the peripheral portion of the laminate 62a becomes watertight, and rainwater does not enter from this portion to the internal solar cell.

The above publication also discloses an embodiment in which a silicone rubber molded body is used instead of the adhesive tape 7.

Furthermore, as a method of joining the solar cell module and the roof of a house (including tiles), a method using a modified silicone-based elastic adhesive is also known (Japanese Patent Laid-Open No. 10-1).
No. 76158).

[0017]

However, the conventional solar cell integrated roof member and the adhesive sealing method described in the above publications have the following problems.

When the elastic sealing material to be inserted into the U-shaped frame described in JP-A-2000-226909 is a moisture-cured modified silicone-based material, there is a disadvantage that it takes 1 hour or more to cure. Also, if the elastic sealing material is putty-like butyl rubber, it has a high viscosity,
There is a disadvantage that a special device is required for filling the U-shaped frame and press-fitting the module. Furthermore, when a sheet-like foam is used as a sealant to be inserted into a U-shaped frame, it is necessary to take a sufficient compression allowance in order for the sheet-like foamer to exhibit good sealing properties. However, there is a disadvantage that the thickness of the glass plate becomes large and the accumulation of dust on the surface of the glass plate increases.

In the case of the method using the U-shaped frame, the U-shaped part is more or less higher than the glass surface, so that dust or the like accumulates on the glass surface of the solar cell, and the power generation efficiency is reduced. .

Further, when the modified silicone-based elastic adhesive described in Japanese Patent Application Laid-Open No. 10-176158 is used as the adhesive between the tile and the solar cell module, the elastic adhesive has insufficient weather resistance. Because of the long-term use, the adhesive surface peeled off, and water from the peeled surface entered the gap in the solar cell module storage section of the tile due to surface tension, and if water was not well drained, water eventually penetrated into the module, There is a problem that causes the failure of the.

The elastic seal adhesive has a high viscosity, and it is difficult to uniformly apply the adhesive to the surface of the concave portion of the roof tile or the back of the solar cell module. It is necessary to extrude the sealing adhesive from the gap between the roof tile and the solar cell module. At this time, the glass surface of the solar cell module is often contaminated. As described above, the elastic seal adhesive has a disadvantage of poor workability.

The moisture that has penetrated into the module penetrates into the inside of the adhesive resin sealing material 40 from the end surface of the adhesive resin sealing material 40 at the periphery of the solar cell module located on the side surface around the solar cell module 11. Eventually, it reaches the solar cell 1, the internal lead wires 5, 6 and their connection parts to cause corrosion. In particular, the adhesive resin sealing material 40
When EVA (ethylene-vinyl acetate copolymer resin) is used for EVA, EVA is hydrolyzed with water to generate acetic acid, which further accelerates corrosion.

When the solar cell 1 or the like is corroded, not only does the power generation characteristic decrease, but also the conductor cross-sectional area of the internal leads 5 and 6 decreases, the wire breaks, and further, the contact portion with the solar cell 1 has poor contact. In the worst case, the output cannot be taken out to the outside.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide an excellent workability and a sealing property against water intrusion, and to provide water invasion by breathing with outside air. The present invention is to provide a solar cell integrated roof member having a function of preventing puddles in the module storage concave portion and a high waterproof property even in the case of occurrence of dust, and preventing the accumulation of dust on the solar cell light receiving surface. .

[0025]

In order to solve the above-mentioned problems, according to the present invention, a solar cell is sealed between a translucent surface protection member and a back surface protection member with an adhesive resin sealing material. Solar cell module, a solar cell integrated roof member disposed via a pressure-sensitive adhesive sheet having a predetermined thickness in a recess provided on the surface of the roof member body, the bottom surface of the solar cell module and The gap between the side surface and the inner surface of the concave portion of the roof member main body is filled with a liquid foaming sealing material and foam-hardened to integrate the solar cell module and the roof member main body (the invention of claim 1). .

According to the above configuration, the periphery of the solar cell module serving as a moisture intrusion path can be covered with the foamable sealing material, so that moisture intrusion can be blocked and workability is improved.

In the above structure, the liquid foaming sealing material is formed by inserting a part of a thin needle-like injection port into the gap, and moving the injection port around the module to form a closed-cell type liquid foaming sealing material. Inject all around the module. The liquid foamable sealing material is foamed and cured after being filled in the gap by the action of gravity and surface tension.

In order to efficiently inject the liquid foamable sealing material and increase the internal pressure to cure and enhance the sealing property, it is necessary to use a light-transmitting surface protection member (for example, a glass plate) used in the solar cell module. It is desirable to take a sufficient R at the end, widen the injection port of the liquid foaming sealing material, and gradually narrow the injection port to provide a narrowed portion for the flow of the liquid foaming sealing material in the gap. .

Further, when water invades into the concave portion provided on the surface of the roof member main body due to breathing with the outside air, it is preferable that the water is easily discharged from the concave portion.
It is desirable that the solar cell module has a structure having high waterproofness. From this viewpoint, the following claim 2
And inventions 3 are preferred.

That is, in the solar cell integrated roof member according to claim 1, the roof member body is a lightweight concrete roof tile, and the recess has a drainage hole penetrating from the bottom of the recess to the bottom of the tile. A lid member for a drain hole for preventing the drain hole from being closed by a foaming sealing material and preventing water from being drained is provided on the bottom surface of the concave portion. 2).

Furthermore, in the solar cell integrated roof member according to claim 1 or 2, the back surface protection member of the solar cell module is a sheet in which a resin film is laminated on both surfaces of a metal foil (the invention of claim 3). ). According to this invention, even if water infiltrates the solar cell module from the bottom surface of the concave portion, water does not enter the inside from the metal foil (for example, aluminum foil), so that the safety of the solar cell module can be ensured.

The liquid foamable sealing material includes:
The invention of the following claim 4 is preferable. That is, in the solar cell integrated roof member according to any one of claims 1 to 3, the liquid foamable sealing material is any one of a silicone-based, a modified silicone-based, a urethane-based, and a phenol-based foamable resin. .

[0033]

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

FIG. 1 is a schematic sectional view of a solar cell integrated roof member according to the present invention, and is a sectional view taken along line AA in FIG. FIG. 2 is a schematic cross-sectional view showing a state where the solar cell integrated roof member is attached to the roof.

In FIG. 1, the solar cell module 11
Is the same as the conventional structure shown in FIG. 3, and the same functional members are denoted by the same reference numerals and are partially simplified. The solar cell module 11 used in the present invention is formed by sealing the solar cell 1 between the translucent surface protection member 2 and the back surface protection member 3 with an adhesive resin sealing material 40.

As the translucent surface protection member 2, a glass plate, a polycarbonate resin plate, an acrylic resin plate or the like can be used, but a glass plate is most preferable. In the case where a glass plate is used, it is desirable that the R at the end of the glass plate be sufficiently set as described above.

As the resin sealing material 40, the above-mentioned EVA (ethylene-vinyl acetate copolymer), ethylene-acrylate copolymer resin, urethane resin, silicone resin, tetrafluoroethylene-6-fluoropropylene -A vinylidene fluoride copolymer or the like is used. The form of use of the resin is preferably sheet-like.

As the solar cell 1, known solar cells such as a crystalline Si-based solar cell, a polycrystalline Si-based solar cell, and an a-Si solar cell using various substrates can be used.

As the back surface protection member 3, an aluminum foil in which ethylene monofluoride (trade name: Tedlar, manufactured by DuPont) whose surface is corona-treated is laminated on both sides with an adhesive material is preferable. In addition, instead of the above-mentioned ethylene monofluoride, tetrafluoroethylene-ethylene copolymer (ETF)
E), tetrafluoroethylene-6-fluoropropylene copolymer (FEP), polyethylene terephthalate (PET),
Plastic sheets such as polyethylene terephthalate (PEN) and modified polyphenyl ether can be used. Further, instead of the aluminum foil, an iron foil or the like whose surface is treated with a zinc alloy can be used.

The above solar cell module is laminated at a module temperature of 150 ° C. by a known method. EVA protruding from the end of the solar cell module 11 is removed by a cutter or the like. Thereafter, a terminal box for drawing out the lead wire to the outside is adhesively fixed to a predetermined position.

The adhesive sheet 3 having a predetermined thickness is placed in the concave portion 20a provided on the surface of the roof member body 20 made of, for example, a lightweight concrete tile.
And a gap between the bottom and side surfaces of the solar cell module and the inner surface of the concave portion of the roof member main body is filled with a liquid foamable sealing material 50 and foam-hardened, and the solar cell module 11 and the roof member main body 20 are bonded together. Are integrated.

An integrated solar cell integrated roof member 100
As shown in FIG. 2, a plurality of are arranged along a slope of a roof on a roof base plate 60 having a roofing material 61 disposed on a surface thereof. Here, the roof member main body 20 is formed so as to form a cavity along the slope of the roof between the surface facing the roof and the roof, for example, as shown in FIG.
A wiring portion indicated by reference numeral 80 in the figure is provided in this hollow portion.

The approximate dimensions of the lightweight concrete tile 20 are as follows.
The length is 900 mm and the width is 300 mm to 500 mm. A concave portion 20a for accommodating the solar cell module is provided on the tile.
The recess 20a is provided with a drain hole 21 for discharging water that enters by breathing with the outside air to the outside of the roof tile. The drain hole 21 is formed at the lowest part of the roof tile. Further, it is preferable to lay a plastic or inorganic fiber non-woven fabric as the cover member 22 so that the entrance of the drain hole 21 is not closed by the liquid foam sealing material 50.

Side gap D between the recess and the solar cell module
Is preferably 1 mm or more, and as small as possible. In consideration of the size due to temperature change, 0.5 mm or more is sufficient, but a minimum of 1 mm is required as a dimensional tolerance and a size required for injecting the liquid foamable sealing material. If the gap is 1 mm or less, there is a problem that the liquid foaming sealing material starts foaming before reaching the bottom of the tile.

For adhesion between the solar cell module and the roof tile, a double-sided adhesive sheet 30 having a minimum thickness of 1 mm or more and about 2 mm is preferable. As this adhesive sheet,
Acrylic, silicone, butyl, and polyester adhesive sheets can be used. When the thickness is 1 mm or less, it becomes difficult for liquid moisture invaded by breathing with the outside air to flow down, and the invaded moisture stays between the roof tile and the solar cell module for a long time, and the water infiltrates the solar cell module. Might be.

As the liquid foamable sealing material 50, as described above, foamable resins such as silicone-based, modified silicone-based, urethane-based, phenol-based foamable resin, silicone-based, and urethane-based resins are used. Among them, a silicone resin is most preferable, particularly from the viewpoint of weather resistance.

The expansion ratio of the liquid foamable sealing material 50 is 2
The range is preferably from 10 to 10 times. When the expansion ratio is high, the sealing property is poor, and when the expansion ratio is low, a large amount of liquid is required, and there is a disadvantage that the injection time is long. The viscosity of the liquid foamable sealing material is preferably in the range of 1 to 200 poise (P).
More preferably, it is 10-50P.

After the solar cell module is bonded to the roof tile, the liquid foamable sealing material 50 is injected by an injection device whose injection port can move around the module. When the liquid foaming sealing material reaches the bottom of the concave portion of the tile due to gravity, foaming starts and hardens. The liquid foaming sealing material partially rises from the tile surface due to foam hardening. The raised portion is cut out with a knife or the like.

[0049]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIG.

The solar cell module 11 includes a glass plate having a thickness of 3 mm as the surface protection member 2, a sheet-shaped EVA having a thickness of 0.4 mm as the resin sealing material 40, and a 200 mm × 800 mm sheet as the solar cell 1. As the plastic film substrate a-Si solar cell and the back surface protection member 3, an aluminum foil laminated on both surfaces with an adhesive material on both surfaces of corona-treated ethylene monofluoride (trade name: Tedlar, manufactured by DuPont) was used. The solar cell module is laminated at a module temperature of 150 ° C. by a known method,
EVA protruding from the end of the solar cell module 11 was removed by a cutter.

The lightweight concrete roof tile 20 was manufactured using a mold. The tile is provided with a concave portion 20a for accommodating a solar cell module, and the concave portion has a drain hole 21 for discharging water invading by breathing with the outside air to the outside of the tile.
Was provided at the lowest part of the tile. In addition, the nonwoven fabric 22 made of glass fiber was filled into the drain hole entrance so as not to be closed by the liquid foamable sealing material 50.

Side gap D between the recess and the solar cell module
Is 1 mm, and the adhesion between the solar cell module and the tile is
An acrylic pressure-sensitive adhesive sheet 30 having a thickness of 2 mm was used. As the liquid foamable sealing material 50, a foaming ratio of 3 times, a viscosity of 50
Poise silicone resin was used. After the module and the roof tile were bonded, the liquid foamable sealing material was injected and cured by an injection device capable of moving an injection port around the module. A portion that was partially raised from the tile surface due to foam hardening was cut out with a knife.

It was confirmed that the solar cell integrated roof member produced as described above had the desired effects, such as excellent workability and sealing performance against water intrusion.

[0054]

According to the present invention, as described above, a solar cell module in which a solar cell is sealed between a translucent surface protection member and a back surface protection member with an adhesive resin sealing material is provided.
A solar cell integrated roof member disposed in a concave portion provided on a surface of a roof member main body via an adhesive sheet having a predetermined thickness, wherein a bottom surface and side surfaces of the solar cell module and the roof member main body are provided. A liquid foaming sealing material is filled in the gap between the inner surface of the concave portion and foamed and hardened, and the solar cell module and the roof member body are integrated (invention of claim 1). Is a roof tile made of lightweight concrete, and the recess is provided with a drainage hole penetrating from the bottom of the recess to the bottom of the tile, and the drainage hole is closed by a foaming sealing material on the bottom of the recess, so that drainage is impossible. By providing a cover member for a drain hole for preventing the occurrence of water drainage (the invention of claim 2), the workability and the sealability against water intrusion are excellent, and breathing with outside air is achieved. If water intrusion occurs due to Comprising a protection and high waterproof puddle to Yuru housing recess, and it is possible to provide a solar cell and roof members which aimed at preventing the deposition of dust into the solar cell light-receiving surface.

[Brief description of the drawings]

FIG. 1 is a side sectional view of a schematic configuration of a solar cell integrated roof member according to an embodiment of the present invention.

FIG. 2 is a sectional view showing a state in which a plurality of solar cell integrated roof members of FIG. 1 are attached to a roof;

FIG. 3 is a side sectional view of a schematic configuration showing an example of a conventional solar cell module.

FIG. 4 is a partially enlarged cross-sectional view showing an example of a peripheral portion of a solar cell module attached to a conventional roof tile with solar cells.

[Explanation of symbols]

1: solar cell 2: surface protection member 3: back surface protection member
11: solar cell module, 20: roof member body (lightweight concrete tile), 20a: concave portion, 21: drain hole, 2
2: lid member, 30: adhesive sheet, 40: resin sealing material, 5
0: Liquid foaming sealing material.

Claims (4)

[Claims] 1. A solar cell module in which a solar cell is sealed between a translucent surface protection member and a back surface protection member with an adhesive resin sealing material is provided in a recess provided on a surface of a roof member body. A solar cell integrated roof member disposed via an adhesive sheet having a predetermined thickness, wherein a liquid foaming property is provided in a gap between a bottom surface and side surfaces of the solar cell module and a concave inner surface of the roof member body. A solar cell integrated roof member comprising a sealing material filled and foam-hardened to integrate a solar cell module and a roof member main body. 2. The solar cell-integrated roof member according to claim 1, wherein the roof member body is a lightweight concrete roof tile, and the recess has a drain hole penetrating from the bottom of the recess to the bottom of the tile. A solar cell, wherein a lid member for a drain hole is provided on a bottom surface of the concave portion to prevent the drain hole from being closed by a foamable sealing material to prevent drainage. Integrated roof member. 3. The solar cell integrated roof member according to claim 1, wherein the back surface protection member of the solar cell module is a sheet in which a resin film is laminated on both surfaces of a metal foil. Battery integrated roof member. 4. The solar cell integrated roof member according to claim 1, wherein the liquid foamable sealing material is a silicone-based, a modified silicone-based, a urethane-based sealing material.
A roof member integrated with a solar cell, wherein the roof member is any one of phenolic foamable resins.