JP2014037685A - Metal fitting for photovoltaic power generation module, and method for installing photovoltaic power generation module onto architectural structure - Google Patents

Metal fitting for photovoltaic power generation module, and method for installing photovoltaic power generation module onto architectural structure Download PDF

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JP2014037685A
JP2014037685A JP2012179158A JP2012179158A JP2014037685A JP 2014037685 A JP2014037685 A JP 2014037685A JP 2012179158 A JP2012179158 A JP 2012179158A JP 2012179158 A JP2012179158 A JP 2012179158A JP 2014037685 A JP2014037685 A JP 2014037685A
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power generation
generation module
cover member
photovoltaic power
frame
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JP6088175B2 (en
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Susumu Ueno
晋 上野
Akio Omuro
彰男 大室
Yugo Ota
祐吾 太田
Takeshi Shimizu
剛 清水
Fukio Yoshizaki
布貴男 吉崎
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Nippon Steel Nisshin Co Ltd
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Abstract

PROBLEM TO BE SOLVED: To provide an installation method of a photovoltaic power generation module by which reliability of corrosion resistance is remarkably improved as entire support members by using members of high productivity.SOLUTION: When installing a photovoltaic power generation module including framework onto an architectural structure through support members made of a steel material, some of the support members are covered with a cover member which has a flange width of 5 mm or more for each crosspiece side width and is obtained by hat-shaped bending, such that rainwater from the photovoltaic power generation module flows down to a surface of the cover member. The cover member is obtained by bending a hot dip aluminized steel sheet in which an Al-based plating layer is formed with an adhesion amount of 20 g/mor more for each side, by passing a base stainless steel sheet through a bath of molten Al containing 0-12 mass% Si.

Description

本発明は、金属製等のフレーム枠を持つ太陽光発電モジュールの金具並びに太陽光発電モジュールの建築物への設置方法に関する。   The present invention relates to a metal fitting for a solar power generation module having a frame frame made of metal or the like and a method for installing the solar power generation module in a building.

近年、住宅やビルなどの建築物の屋上に太陽光発電モジュールを設置した発電システムを採用するケースが増えている。図1、3に(財)新エネルギー財団によりまとめられた「住宅用太陽光発電システム設計・施工指針」に示されている太陽光発電モジュールを建築物の屋根面に設置する場合の部材構成の一例を模式的に示す。太陽光発電モジュール(以下、単に「モジュール」ということがある)12は、多結晶シリコンなどの太陽電池セルを配置したパネルであり、周囲にフレーム枠11を有している。フレーム枠11はAl合金部材で構成されることが多く、通常、その表面には陽極酸化皮膜、あるいはさらに塗膜が形成されている。モジュール12を建築物に設置する際には、建築物とモジュール12の間に金属製の架台を介在させ、その架台を介してモジュール12を建築物に固定するのが一般的である。   In recent years, an increasing number of cases employ a power generation system in which a photovoltaic power generation module is installed on the rooftop of a building such as a house or a building. Fig. 1 and Fig. 3 shows the component structure when installing the photovoltaic module shown in the "Residential photovoltaic system design and construction guidelines" compiled by the New Energy Foundation. An example is shown schematically. A photovoltaic power generation module (hereinafter, simply referred to as “module”) 12 is a panel in which solar cells such as polycrystalline silicon are arranged, and has a frame frame 11 around it. The frame 11 is often made of an Al alloy member, and usually has an anodized film or a coating film formed on the surface thereof. When installing the module 12 in a building, it is common to interpose a metal mount between the building and the module 12 and fix the module 12 to the building via the mount.

図3の例では、太陽光発電モジュール12が、横桟21と縦桟22を結合してなる架台を介して傾斜した屋根面10に設置されている。この場合、モジュール12は横桟21と横桟21の間に挟まれて配置され、モジュール間カバー32と締結金具31を用いて固定されている。本明細書では、端部に配置されるモジュール12に取り付けられ、モジュール12どうしの間にないカバーも便宜上モジュール間カバー32と称している。横桟21は締結金具31によって縦桟22に固定されている。そして縦桟22は屋根面10に支持金具33を用いて固定されている。また、図1の例では、ほとんど勾配の無い陸屋根に勾配を付けた架台を介してモジュールが設置されている。この場合、架台は横桟21あるいは縦桟22に相当する部材の他にステー23や、必要に応じて筋交い等の補強部材が取り付けられて構築されている。   In the example of FIG. 3, the photovoltaic power generation module 12 is installed on the inclined roof surface 10 via a gantry formed by connecting a horizontal beam 21 and a vertical beam 22. In this case, the module 12 is disposed between the horizontal rail 21 and the horizontal rail 21, and is fixed by using the inter-module cover 32 and the fastening bracket 31. In the present specification, a cover that is attached to the module 12 disposed at the end and is not between the modules 12 is also referred to as an inter-module cover 32 for convenience. The horizontal beam 21 is fixed to the vertical beam 22 by a fastening bracket 31. The vertical rail 22 is fixed to the roof surface 10 with a support metal fitting 33. Moreover, in the example of FIG. 1, the module is installed through the mount frame which attached the slope to the land roof with almost no inclination. In this case, the gantry is constructed by attaching a stay 23 and reinforcing members such as braces as needed in addition to members corresponding to the horizontal beam 21 or the vertical beam 22.

架台は、横桟21や縦桟22のように太陽光発電モジュールの荷重を受け持つ部材が、締結金具、ボルト、ナット、座金などによって結合された構造を有する。架台を構成する部材の中でも、横桟21、縦桟22、ステー23、支持金具33は、モジュールの荷重を受け持つ部材である。このような部材を本明細書では「支持部材」と呼び、締結金具、ボルト、ナット、座金などの結合部材や、筋交いなどの補強部材と区別している。一般的に太陽光発電モジュールの架台を構成する支持部材は、支持金具を除き、長手方向に一定の断面形状を持つ加工部材からなる。   The gantry has a structure in which members that handle the load of the photovoltaic power generation module, such as the horizontal beam 21 and the vertical beam 22, are coupled by a fastener, a bolt, a nut, a washer, and the like. Among the members constituting the gantry, the horizontal beam 21, the vertical beam 22, the stay 23, and the support fitting 33 are members responsible for the module load. Such a member is referred to as a “support member” in this specification, and is distinguished from a coupling member such as a fastening bracket, a bolt, a nut, and a washer, and a reinforcing member such as a brace. In general, the support member that constitutes the base of the photovoltaic power generation module is formed of a processed member having a constant cross-sectional shape in the longitudinal direction, excluding the support fitting.

太陽光発電モジュールのフレーム枠(以下、単に「フレーム枠」ということがある)、
および架台を構成する支持部材(以下、単に「支持部材」ということがある)はアース線によって接地される。したがって、フレーム枠と支持部材は電気的に接続された状態となるが、Al合金製のフレーム枠は通常、陽極酸化皮膜や塗膜で被覆されて表面が絶縁状態となっているので、フレーム枠のAl合金素地と、支持部材の金属とをケーブルで接続することによって導通を確保するのが一般的である。
Photovoltaic module frame (hereinafter sometimes simply referred to as “frame”),
A support member constituting the gantry (hereinafter also simply referred to as “support member”) is grounded by a ground wire. Therefore, although the frame frame and the support member are in an electrically connected state, the frame frame made of Al alloy is usually covered with an anodized film or a coating and the surface is in an insulating state. In general, electrical connection is ensured by connecting the Al alloy substrate and the metal of the support member with a cable.

従来、太陽光発電モジュールの周辺部材(支持部材、モジュール間カバー、締結金具など)の材料としては、ドブ漬けZnめっき鋼材、ステンレス鋼材、Al合金材などが使われている。ドブ漬けZnめっき鋼材の場合、成形加工した後の部材を溶融Znめっき浴に浸漬することによりZnめっきを施したものであるから、例えば図3の符号40に示されるような切断端面にもめっき層が形成されている。   Conventionally, as materials for peripheral members (support members, cover between modules, fastening brackets, etc.) of a photovoltaic power generation module, doub-zipped Zn-plated steel material, stainless steel material, Al alloy material or the like has been used. In the case of the dobbed Zn-plated steel material, since the member after the forming process is subjected to Zn plating by immersing it in a hot-dip Zn plating bath, for example, it is also plated on the cut end face as shown by reference numeral 40 in FIG. A layer is formed.

一方、Znめっき鋼板に代わる高耐食材料として、昨今、Zn−Al−Mg系めっき鋼板(例えば特許文献1、2)が種々の分野で使用されている。また、排ガス経路部材などの用途では耐熱性・耐食性に優れたAl系めっきステンレス鋼板が使用されている(例えば特許文献3、4)。   On the other hand, Zn—Al—Mg based plated steel sheets (for example, Patent Documents 1 and 2) have been used in various fields as high corrosion resistance materials instead of Zn plated steel sheets. Further, in applications such as exhaust gas passage members, Al-based plated stainless steel plates having excellent heat resistance and corrosion resistance are used (for example, Patent Documents 3 and 4).

本発明者は、特許文献5に記載の通り、基材が7質量%以上のCrを含有する鋼板であってAl−3〜12質量%Si組成のAl系めっき層が片面あたり20g/m2以上の付着量で形成された溶融Al系めっき鋼板を、前記支持部材として用いる発明を行った。 As described in Patent Document 5, the present inventor is a steel sheet containing 7 mass% or more of Cr, and an Al-based plating layer having an Al-3 to 12 mass% Si composition is 20 g / m 2 per side. An invention was carried out in which a hot-dip Al-based plated steel sheet formed with the above adhesion amount was used as the support member.

特許第3179401号公報Japanese Patent No. 3179401 特許第3149129号公報Japanese Patent No. 3149129 特許第2132539号公報Japanese Patent No. 2132539 特開平07−233451号公報Japanese Patent Application Laid-Open No. 07-233451 特開2009−33066号公報JP 2009-33066 A

上記従来の支持部材には、以下のような問題点がある。   The conventional support member has the following problems.

〔ドブ漬けZnめっき鋼材の問題点〕
太陽光発電モジュールは勾配を付けた状態で設置される。モジュール面に降った雨はその勾配にしたがってモジュールの表面やモジュール間カバーの表面を流れ、一部は支持部材の表面や、締結金具の表面を伝って流れ落ちる。そのため、これら部材には雨水が集中して流れる流路ができる。これらの部位ではドブ漬けZnめっき材のめっき層の消耗は一般の暴露環境に比べると著しく速く、耐久性が不十分となることが多い。これは、一般の暴露環境ではめっき層の表面に生成した腐食生成物が保護皮膜となってその後の腐食を抑制するのに対し、雨水の流路となる箇所では生成した腐食生成物が流失して保護皮膜を形成できないことによるものと考えられる。
[Problems of Dobbed Zn-plated steel]
The photovoltaic power generation module is installed with a gradient. The rain that has fallen on the module surface flows along the surface of the module and the cover of the module according to the gradient, and a part of the rain flows down along the surface of the support member and the surface of the fastener. Therefore, a flow path in which rainwater concentrates is formed in these members. In these parts, the consumption of the plated layer of the zinc-plated Zn plating material is significantly faster than the general exposure environment, and the durability is often insufficient. This is because, in a general exposure environment, the corrosion product generated on the surface of the plating layer becomes a protective film to suppress the subsequent corrosion, whereas the generated corrosion product is washed away at the location where it becomes a rainwater flow path. This is probably because the protective film cannot be formed.

また、これらの部材表面に雨水が滞留する箇所ができると夏季にはこの滞留水は熱せられ50〜60℃の温水となることもある。特にフレーム枠と支持部材との接触部には隙間が形成されて雨水が滞留しやすく、温水との接触により腐食が促進される。   In addition, if there is a place where rainwater stays on the surface of these members, the staying water may be heated in the summer to become hot water of 50 to 60 ° C. In particular, a gap is formed at the contact portion between the frame frame and the support member so that rainwater tends to stay, and corrosion is accelerated by contact with hot water.

また、Al合金製のフレーム枠は一般に塗膜等により表面が絶縁されているが、支持部材への取り付け箇所などでは据付時に表面疵が生じてAl合金が露出した状態となることがある。アース用ケーブル接続箇所でも、Al合金がわずかに露出することがある。Al合金が露出した箇所が雨水で濡れ、フレーム枠を取り付けた支持部材のZnめっき層との間に雨水を介して電気的な回路が形成されると、自然電位がAlに対して「卑」であるZnめっき層において腐食が促進されることになる(異種金属接触腐食)。   Further, although the surface of the frame frame made of Al alloy is generally insulated by a coating film or the like, surface flaws may occur at the installation position on the support member or the like, and the Al alloy may be exposed. The Al alloy may be slightly exposed even at the ground cable connection point. When the Al alloy is exposed to the rainwater and an electrical circuit is formed through the rainwater between the Zn plating layer of the support member to which the frame frame is attached, the natural potential is “base” against Al. Corrosion is promoted in the Zn plating layer (dissimilar metal contact corrosion).

さらに、ドブ漬けZnめっき鋼材は成形加工後の部材を高温のめっき浴に浸漬することにより製造されるため熱歪の影響が出やすく、支持部材に用いる「桟」などの長尺材では高い寸法精度を得ることが難しい。成形加工後のめっき作業は生産性が悪いという問題もある。   In addition, the dobbed Zn-plated steel material is manufactured by immersing the molded member in a high-temperature plating bath, so it is easily affected by thermal strain. For long materials such as “bars” used as support members, the dimensions are high. It is difficult to obtain accuracy. There is also a problem that the plating work after the forming process has poor productivity.

特許文献1、2に示される耐食性に優れたZn−Al−Mg系めっき鋼材で代替すれば、耐久性を確保・向上させた上で高い寸法精度を持つ部材を作製できる。しかし、Zn−Al−Mg系めっき層はAlに対して「卑」であることに変わりはなく、異種金属接触腐食に関しては抜本的な対策にならない。   If the Zn—Al—Mg based plated steel material having excellent corrosion resistance shown in Patent Documents 1 and 2 is substituted, a member having high dimensional accuracy can be manufactured while ensuring and improving durability. However, the Zn—Al—Mg-based plating layer is still “base” with respect to Al, and is not a drastic measure for dissimilar metal contact corrosion.

〔ステンレス鋼材の問題点〕
太陽光発電モジュールの支持部材や締結金具は、上述のように、雨水に曝され、場合によっては高温の滞留水に接触する。このような用途にステンレス鋼材を適用することによって十分な耐食性を確保するためには、Cr含有量の高い鋼種、NiやMoを含有する鋼種など、比較的耐食性グレードの高いステンレス鋼を適用する必要がある。そのため、必然的に部材コストが高くなる。
[Problems with stainless steel]
As described above, the support member and the fastening member of the photovoltaic power generation module are exposed to rainwater and, in some cases, come into contact with high-temperature stagnant water. In order to ensure sufficient corrosion resistance by applying stainless steel materials for such applications, it is necessary to apply stainless steels with relatively high corrosion resistance grades, such as steel types with a high Cr content and steel types containing Ni and Mo. There is. Therefore, the member cost is inevitably increased.

また、ステンレス鋼製の支持部材や締結金具を使用した場合は、フレーム枠の疵つき箇所などに生じたAl合金素地露出部との間に上記のような雨水を介した回路が形成されると、ステンレス鋼に対し電位的に「卑」となるAl合金の方で異種金属接触腐食が生じる。   In addition, when a stainless steel support member or fastener is used, a circuit through rainwater such as that described above is formed between the exposed portion of the Al alloy substrate that is generated at a spotted portion of the frame frame, etc. Different metal contact corrosion occurs in the Al alloy which is “base” in terms of potential with respect to stainless steel.

〔Al系合金材の問題点〕
支持部材や、モジュール間カバーをAl合金製とすれば、上記のような雨水の流路での腐食や異種金属接触腐食の問題は回避される。しかし、これらの部材をAl合金で構成するには、強度の観点から厚肉化する必要があり、コストが高くなる。また、このようなAl合金部材は一般に押出し成形により作られるため、設計自由度がかなり制約されてしまう。
[Problems of Al-based alloy materials]
If the support member and the cover between modules are made of an Al alloy, the above-described problems of corrosion in the rainwater flow path and contact corrosion of dissimilar metals can be avoided. However, in order to configure these members with an Al alloy, it is necessary to increase the thickness from the viewpoint of strength, and the cost increases. Moreover, since such an Al alloy member is generally made by extrusion molding, the degree of design freedom is considerably limited.

〔Al−Si系めっきCr含有鋼材の問題点〕
前記のAl−Si系めっきCr含有鋼材を支持部材として用いることによって、上記のドブ漬けZnめっき鋼材、ステンレス鋼材、Al系合金材等を支持部材等として用いた場合の耐食性に関する問題点(雨水の流路、滞留部の腐食、異種金属接触腐食)や設計自由度は一掃された。しかしながら、ドブ漬けZnめっき鋼材やステンレス鋼材を使った支持部材において耐食性に問題の発生する箇所はフレーム枠と接触する箇所やモジュール面からの雨水が集中する流路などに限られ、このような箇所が支持部材全体に占める割合は僅かである。このような箇所の耐食性確保のためだけにAl−Si系めっきCr含有鋼材を適用することは支持部材の大部分の箇所では必要以上の過剰品質となることを意味しており、部材のコストアップに繋がるものであった。
[Problems of Al-Si plating Cr-containing steel]
By using the Al-Si-plated Cr-containing steel material as a support member, there are problems related to corrosion resistance when the above-described doubly-zipped Zn-plated steel material, stainless steel material, Al-based alloy material, etc. are used as a support member. Corrosion of flow path and staying part, contact corrosion of dissimilar metals) and design freedom have been wiped out. However, locations where corrosion resistance problems occur in support members using dobbing Zn-plated steel materials or stainless steel materials are limited to locations where they come into contact with the frame frame or channels where rainwater from the module surface concentrates. Is a small proportion of the entire support member. Applying Al-Si-plated Cr-containing steel just to ensure corrosion resistance in such locations means that the majority of the support members will have excessive quality beyond what is needed, increasing the cost of the components It was connected to.

本発明はこのような現状に鑑み、耐食性向上が必要とされる箇所の耐食性をピンポイントで向上させ、支持部材全体として耐食性に対する信頼性が顕著に改善される太陽光発電モジュールの金具並びに太陽光発電モジュールの建築物への設置方法を提供することを目的とする。   In view of such a current situation, the present invention improves the corrosion resistance of places where improvement in corrosion resistance is necessary, and improves the reliability of the corrosion resistance of the support member as a whole, and the photovoltaic module bracket and solar light It aims at providing the installation method to the building of a power generation module.

上記目的を達成するために、本発明は、フレーム枠を持つ太陽光発電モジュールを、鋼材からなる支持部材を介して建築物に設置するに際し、該支持部材および縦桟あるいは横桟の一部を、桟の片側幅当たり5mm以上の鍔幅をもつハット加工よりなるカバー部材で覆うことによって前記太陽光発電モジュールからの雨水の流れを該カバー部材の表面に流れ落ちるようにする、太陽光発電モジュールの架台への設置において、流水カバーを兼ね備えた取付け金具並びに太陽光発電モジュールの建築物への設置方法を提供する。
また、カバー部材の材料はAl−0〜12質量%Si組成のAl系めっき層が片面あたり20g/m2以上の付着量で形成された溶融Al系めっきステンレス鋼板が最良である。
In order to achieve the above-described object, the present invention provides a solar power generation module having a frame frame in a building through a support member made of steel. The solar power generation module is configured to cover the surface of the cover member with rainwater from the solar power generation module by covering the cover member with a cover member made of a hat having a ridge width of 5 mm or more per side width of the crosspiece. In installation on a gantry, a mounting bracket having a running water cover and a method for installing a photovoltaic power generation module on a building are provided.
The cover member is preferably a hot-dip Al-plated stainless steel sheet in which an Al-plated layer having an Al-0 to 12% by mass Si composition is formed with an adhesion amount of 20 g / m 2 or more per side.

上記のカバー部材は桟にボルト等によって取り付けられるが、桟と接触していなくてもよい。ただし、この場合、フレーム枠、カバー部材、支持部材がボルト等により相互に電気的接続を形成することがさらに好ましい。 The above cover member is attached to the crosspiece with a bolt or the like, but may not be in contact with the crosspiece. However, in this case, it is more preferable that the frame frame, the cover member, and the support member form an electrical connection with each other by bolts or the like.

ここで、「建築物」は土地に定着する構造物をいうが、地面に太陽光発電モジュールを設置する場合の土台もここでは建築物として扱う。「Al合金」は少なくともAlが90質量%以上を占める合金であり、具体的にはJIS
H4000に規定される範囲の合金を選択することができる。前記の「溶融Al系めっき鋼板」には、溶融めっき後に化成処理や塗装を施した状態のものも含まれる。
Here, “building” means a structure that is fixed on the land, but the foundation in the case of installing a photovoltaic power generation module on the ground is also treated as a building here. “Al alloy” is an alloy in which at least Al occupies 90% by mass or more.
An alloy in the range defined by H4000 can be selected. The “hot-dip Al-based plated steel sheet” includes a state in which chemical conversion treatment or coating is performed after the hot-dip plating.

前記カバー部材は、基材にステンレス鋼板として、一般的なSUS304、SUS430等でよいが、より低級なステンレス鋼板、例えばSUH409、NSS409M1、NCR−M等でも十分対応できる。これらのステンレス鋼板をベースに、Al−0〜12質量%Si組成のAl系めっき層を有する溶融めっきを施す。   The cover member may be a general stainless steel plate such as SUS304, SUS430 or the like as a stainless steel plate for the base material, but a lower-grade stainless steel plate such as SUH409, NSS409M1, NCR-M, or the like can be sufficiently used. On the basis of these stainless steel plates, hot dip plating having an Al-based plating layer having an Al-0 to 12% by mass Si composition is performed.

本発明によれば、フレーム枠を持つ太陽光発電モジュールを降雨に曝される環境に設置することにより生じていた耐食性に関わる問題(保護性の腐食生成物が生成されないために促進されるZnめっき部材の腐食、Al合金との異種金属接触腐食)が解消する。すなわち、モジュールのフレーム枠を上記カバー部材と架台の縦桟あるいは横桟とではさみこむことでモジュールを固定する。このとき、縦桟あるいは横桟よりもカバー部材の方が大きいため、雨水がモジュールにより集められて流れてきても、カバー部材に流れた後、カバー部材を伝い、縦桟あるいは横桟を避けて流れ落ちるため、架台に流れることがなく、架台の耐久性を確保できる。
したがって、本発明は、カバー部材を兼ねた取付金具を使用するだけで、既存の太陽光発電モジュールを使用した太陽光発電システムにおいて、コスト増を抑えながら全体としての顕著な耐久性向上をもたらすものである。
また、金具としては、モジュールを架台と金具とで挟み込む形状になっているため、片側施工も可能となり、施工性にも優れる。
According to the present invention, the problem related to corrosion resistance caused by installing a photovoltaic power generation module having a frame in an environment exposed to rain (Zn plating promoted because a protective corrosion product is not generated) Corrosion of members, contact corrosion of dissimilar metals with Al alloy) is eliminated. That is, the module frame is fixed by sandwiching the frame of the module between the cover member and the vertical or horizontal beam of the frame. At this time, since the cover member is larger than the vertical beam or horizontal beam, even if rainwater collects and flows through the module, it flows through the cover member and avoids the vertical beam or horizontal beam. Since it flows down, it does not flow to the gantry, and the durability of the gantry can be secured.
Therefore, the present invention brings about a significant improvement in durability as a whole while suppressing an increase in cost in a photovoltaic power generation system using an existing photovoltaic power generation module only by using a mounting bracket that also serves as a cover member. It is.
In addition, the metal fitting has a shape in which the module is sandwiched between the gantry and the metal fitting, so that one-side construction is possible and the workability is excellent.

カバー部材の材料は、ステンレスやAl合金、Al系めっきステンレスが考えられる。
その中でも、Al系めっきステンレスが最良である。ステンレスは前述の架台、支持金具と同じの理由から、コスト増になりやすい。
Al合金は本発明の材料としては最も近しいものであるが、固定金具を兼ねており、強度が必要であるため、Al合金を採用すると、板厚が厚くなってしまう。これをカバー部材に適用すると、高コストとなる。また、積雪地域では雪だまりの原因となり、太陽光発電効率に影響する。積雪地域でなくとも、降り積もった埃やゴミなどがたまりやすくなり、洗浄回数を増やすこととなる。このため、板厚は薄い方がよく、強度が高い本発明で採用した材料が最良である。また、カバー部材の取付は一般的にステンレスボルトを使用することが多いが、Al合金製のものを用いると、異種金属接触腐食により、カバー部材そのものが腐食してしまい、最悪モジュールがはずれてしまうことになる。一方、本発明で採用したAl系めっきステンレスの場合は、仮にめっき層が異種金属接触腐食で消失したとしても、母材にステンレスを用いているため、モジュールがはずれてしまうことはない。
As the material of the cover member, stainless steel, Al alloy, and Al-plated stainless steel are considered.
Among them, Al-based plated stainless steel is the best. Stainless steel tends to increase in cost for the same reason as the above-mentioned frame and support bracket.
Although the Al alloy is the closest to the material of the present invention, it also serves as a fixing metal and requires strength, so if an Al alloy is used, the plate thickness will be increased. When this is applied to the cover member, the cost becomes high. In addition, in snowy areas, it causes snow accumulation and affects photovoltaic power generation efficiency. Even if it is not in a snowy area, the accumulated dust and debris are likely to collect, and the number of cleanings is increased. For this reason, it is preferable that the plate thickness is thin, and the material employed in the present invention having high strength is the best. In addition, stainless steel bolts are generally used for mounting the cover member, but if an Al alloy one is used, the cover member itself corrodes due to the contact corrosion of dissimilar metals, and the worst module comes off. It will be. On the other hand, in the case of the Al-based plated stainless steel used in the present invention, even if the plating layer disappears due to the contact corrosion of different metals, the stainless steel is used as the base material, so that the module does not come off.

太陽光発電モジュールを陸屋根面に設置する場合の部材構成の一例を模式的に示した図。The figure which showed typically an example of the member structure in the case of installing a solar power generation module in a flat roof surface. 図1の構成に本発明を適用した場合であって、縦桟に取り付けるカバー部材の取り付け位置とカバー部材の形状の一例を模式的に示した図。The figure which is a case where this invention is applied to the structure of FIG. 1, Comprising: The figure which showed typically an example of the attachment position of the cover member attached to a vertical cross, and the shape of a cover member. 太陽光発電モジュールを建築物の傾斜屋根面に設置する場合の部材構成の一例を模式的に示した図。The figure which showed typically an example of the member structure in the case of installing a photovoltaic power generation module in the inclined roof surface of a building. 図3の構成に本発明を適用した場合であって、横桟に取り付けるカバー部材の取り付け位置とカバー部材の形状の一例を模式的に示した図(a)。カバー部材を取付けた状態の断面図(b)。FIG. 4A is a diagram schematically showing an example of the attachment position of the cover member attached to the cross rail and the shape of the cover member when the present invention is applied to the configuration of FIG. 3. Sectional drawing (b) of the state which attached the cover member.

カバー部材は、さらに縦桟および横桟の片側幅当たり5mm以上の鍔幅をもつハット加工によって作製する。鍔幅が縦桟や横桟の幅より短いと縦桟や横桟が当然露出し、縦桟や横桟がモジュールで集められた雨水などが流れてきて直接接触することになり、腐食を促進させるもとになる。
実際のモニター試験などから当該カバーは、縦桟や横桟の片側当たり5mm以上の鍔幅を有するハット加工したものを、フレーム枠とフレーム枠の間にハット加工の凸部を下にして、カバー部材および縦桟や横桟との締結部に、ボルト・ナットで締結することにより完成する。締結部は、カバー部材の頂部および縦桟や横桟のフレーム枠上部(搭載側)のそれぞれにボルト孔を予め適切な位置に設けておく必要がある。このボルト孔はボルト締結の際のワッシャーで覆い隠される大きさでなくてはならない。覆い隠されなければ、ボルト孔から水が流れ込んで桟に伝うため、カバーとしての機能が低下してしまう。
さらにカバー部材の角部分を曲げて爪状のものを作り、取り付ける際に、モジュールのフレーム枠のアルマイト皮膜(不導体)を傷つける構造にしておくことが好ましい。こうすることで、モジュールのアース線の取り付けを省くことができる。さらにこの爪状のものはアースのためにつけるものであり、縦桟に取り付ける場合はパネルの傾斜の低い側のみにあればよい。高い側に爪が付いている場合は、爪がつぶれない可能性があれば、フレーム枠とカバー部材との間に隙間を作ることになり、モジュールから流れた雨水がその隙間を通って縦桟に流れてしまい、カバーの役目を果たさなくなる。
The cover member is further manufactured by a hat process having a ridge width of 5 mm or more per one side width of the vertical beam and the horizontal beam. If the ridge width is shorter than the width of the vertical or horizontal beam, the vertical beam or horizontal beam will naturally be exposed, and the vertical beam or horizontal beam will come into direct contact with the rainwater collected by the module and promote corrosion. It will be the basis.
From actual monitor tests, the cover is a hat with a ridge width of 5 mm or more per side of the vertical or horizontal beam, with the hat-shaped convex part between the frame frame and the cover. It is completed by fastening with bolts and nuts to the members and fastening parts with the vertical and horizontal bars. The fastening portion needs to be provided with bolt holes at appropriate positions in advance at the top portion of the cover member and the frame frame upper portion (mounting side) of the vertical beam and the horizontal beam. The bolt hole must be sized to be covered with a washer when fastening the bolt. If it is not covered, water flows from the bolt hole and is transmitted to the crosspiece, so that the function as a cover is deteriorated.
Further, it is preferable to make a structure that damages the anodized film (non-conductor) of the frame of the module when the corner portion of the cover member is bent to make a nail-like one and attached. By doing so, it is possible to omit the installation of the ground wire of the module. Furthermore, this claw-shaped object is attached for grounding, and when it is attached to a vertical rail, it is only necessary to be provided on the side of the panel having a low inclination. If there is a claw on the high side, if there is a possibility that the claw will not collapse, a gap will be created between the frame frame and the cover member. Will no longer serve as a cover.

カバー部材の板厚は必要な強度から算出すればよい。厚くなりすぎると、雪や埃のたまる原因となるため、2mm〜3mmが好ましい。 The plate thickness of the cover member may be calculated from the required strength. If it becomes too thick, it may cause snow and dust to accumulate, so 2 mm to 3 mm is preferable.

〔溶融Al系めっき層〕
Al系めっき層を施したカバー部材を用いることで、モジュール面に降った雨が集中して流れる箇所や雨水が滞留する箇所におけるめっき面の耐食性を良好なものとすることができる。これは、めっき表面に生成する酸化物皮膜がこれらの環境において、安定に保護皮膜として存在するからであると考えられる。さらに、カバー部材にAl系めっきを用いると、フレーム枠のAl合金との間での異種金属接触腐食を防止できる。
[Fused Al-based plating layer]
By using the cover member to which the Al-based plating layer is applied, the corrosion resistance of the plating surface can be improved at a location where the rain that has fallen on the module surface is concentrated and where rainwater stays. This is presumably because the oxide film formed on the plating surface stably exists as a protective film in these environments. Further, when Al-based plating is used for the cover member, it is possible to prevent dissimilar metal contact corrosion with the Al alloy of the frame frame.

本発明では、カバー部材としてAl−0〜12質量%Si組成のAl系めっき層が片面あたり20g/m2以上の付着量で形成された溶融Al系めっきステンレス鋼板を使用する。「Al−0〜12質量%Si組成」とは、基材ステンレス鋼板をSi含有量が0〜12質量%の溶融Alめっき浴中に通板することによって形成されるめっき層である。 In the present invention, a hot-dip Al-based plated stainless steel sheet in which an Al-based plating layer having an Al-0 to 12% by mass Si composition is formed with an adhesion amount of 20 g / m 2 or more per side is used as the cover member. “Al-0-12 mass% Si composition” is a plating layer formed by passing a base stainless steel plate through a molten Al plating bath having an Si content of 0-12 mass%.

Siを添加する理由は、主として(i)融点を低下させることによってめっき浴の温度を下げること、および(ii)Alめっき層と鋼素地の間に形成される脆い合金層の生成を抑制することである。このメリットを生じさせるにはAl浴中のSi含有量が3質量%以上であることが好ましい。また、Si含有量が12質量%付近で共晶組成となり、融点が最も低下する。したがって、それより多量のSiを添加しても浴温を下げる上で有効でない。むしろSi含有量が増加するとめっき層の耐食性低下につながるので注意が必要である。すなわち、Siを含有したAl系めっき層の流水中や滞留水中における腐食は、めっき層表面に存在するSi析出物の周囲のAlから進行する。12質量%を超えてSiを過剰に含有させると表面に存在するSi析出物が多くなり、腐食の起点が増え、耐食性が低下するようになる。耐食性の観点からもめっき浴中のSi含有量は12質量%以下の範囲とすることが望ましく、11質量%以下とすることがより好ましい。また、Si含有量が12質量%を超えると塊状の析出物が析出し加工性を阻害するようになるので、加工性の面からもSi含有量は12質量%以下の範囲とすることが望ましい。 The reasons for adding Si are mainly (i) to lower the temperature of the plating bath by lowering the melting point, and (ii) to suppress the formation of a brittle alloy layer formed between the Al plating layer and the steel substrate. It is. In order to produce this merit, the Si content in the Al bath is preferably 3% by mass or more. Moreover, it becomes a eutectic composition when the Si content is around 12% by mass, and the melting point is most lowered. Therefore, adding a larger amount of Si is not effective in lowering the bath temperature. Rather, increasing the Si content leads to a decrease in the corrosion resistance of the plating layer, so care must be taken. That is, corrosion of the Al-based plating layer containing Si in flowing water or staying water proceeds from Al around the Si precipitates present on the surface of the plating layer. When Si is excessively contained exceeding 12% by mass, Si precipitates existing on the surface increase, the starting point of corrosion increases, and the corrosion resistance decreases. From the viewpoint of corrosion resistance, the Si content in the plating bath is desirably in the range of 12% by mass or less, and more preferably 11% by mass or less. Further, if the Si content exceeds 12% by mass, massive precipitates are deposited and the workability is impaired. Therefore, from the viewpoint of workability, the Si content is preferably within the range of 12% by mass or less. .

めっき浴中には、基材鋼板や、めっき浴の原料から不可避的に混入する元素が含まれるので、めっき浴組成は、「Si:0〜12質量%、残部Alおよび不可避的不純物からなる」と表示することができる。また、めっき浴中にはさらにTi、B、Sr、Cr、Mg、Zr、Ca、Mnの1種以上を合計1%以下の範囲で含有させても構わない。この場合のめっき浴組成は、「Si:0〜12質量%であり、Ti、B、Sr、Cr、Mg、Zr、Ca、Mnの1種以上を合計1%以下の範囲で含有し、残部Alおよび不可避的不純物からなる」と表示することができる。   Since the plating bath contains elements inevitably mixed from the base steel plate and the raw material of the plating bath, the plating bath composition is “Si: 0 to 12% by mass, balance Al and inevitable impurities”. Can be displayed. Further, the plating bath may further contain one or more of Ti, B, Sr, Cr, Mg, Zr, Ca, and Mn in a total range of 1% or less. The plating bath composition in this case is “Si: 0 to 12% by mass, containing one or more of Ti, B, Sr, Cr, Mg, Zr, Ca, and Mn in a total range of 1% or less, and the balance It consists of Al and inevitable impurities ”.

カバー部材のAlめっき層の厚さが薄いとピンホールめっきが発生しやすく、また成形加工時や現場施工時にめっき層に疵が付いた箇所で鋼素地が露出しやすい。普通鋼基材はAlめっき層に対して電位的に「卑」であることからこれら鋼素地露出部で赤錆が発生することになる。これらの不具合を防止するためには、種々検討の結果、カバー部材のAl系めっき層の付着量を片面あたり20g/m2以上確保する必要がある。 If the thickness of the Al plating layer of the cover member is thin, pinhole plating is likely to occur, and the steel substrate is likely to be exposed at places where the plating layer is wrinkled during molding or on-site construction. Since the normal steel base is “base” in terms of potential with respect to the Al plating layer, red rust is generated at the exposed portions of the steel base. In order to prevent these problems, as a result of various studies, it is necessary to secure an adhesion amount of the Al-based plating layer of the cover member of 20 g / m 2 or more per side.

[実施例1]
〔支持部材〕
支持部材(図1の符号21〜23に相当する部材)として、板厚1.6mmで片面あたりのめっき付着量を150g/m2とした溶融Zn−6質量%Al−3質量%Mg組成(Zn−6Al−3Mgと表す。)のめっき普通鋼鋼板に公知の無機系クロムフリー化成処理(Ti−Mg系)を施し、C型チャンネルに加工したものを用いた。
[Example 1]
(Support member)
As a supporting member (a member corresponding to reference numerals 21 to 23 in FIG. 1), a molten Zn-6 mass% Al-3 mass% Mg composition in which the plate thickness is 1.6 mm and the plating adhesion amount per side is 150 g / m 2 ( A known inorganic chromium-free chemical conversion treatment (Ti-Mg system) was applied to a plated plain steel plate of Zn-6Al-3Mg and processed into a C-type channel.

〔カバー部材〕
種々のステンレス鋼板を用意し、これらを基材として表1に示すめっき浴から選ばれためっき浴を用いて、連続式溶融めっきラインにて溶融めっきを行った。溶融めっき層の組成はめっき浴組成をほぼ反映したものとなる。めっき付着量制御は一般的なガスワイピング法(ワイピングガスは空気)で行い、両面とも同じ付着量に調整した。溶融めっき後に公知の有機樹脂被覆を施す後処理を行った。
[Cover member]
Various stainless steel plates were prepared, and using these as base materials, hot dip plating was performed in a continuous hot dip plating line using a plating bath selected from the plating baths shown in Table 1. The composition of the hot dipped layer almost reflects the composition of the plating bath. The plating adhesion amount control was performed by a general gas wiping method (wiping gas was air), and both surfaces were adjusted to the same adhesion amount. After the hot dip plating, a known organic resin coating was applied.

Figure 2014037685
Figure 2014037685

前記の後処理を終えためっき鋼板を加工することによって、図2のような縦桟を覆うカバー部材を作製した。   By processing the plated steel sheet after the post-treatment, a cover member covering the vertical rail as shown in FIG. 2 was produced.

〔太陽光発電モジュール〕
Al合金製のフレーム枠(JIS H8602:陽極酸化塗装複合皮膜)を持つ市販の太陽光発電モジュールを用意した。
〔太陽光発電モジュールの設置〕
モジュールを設置する建築物を陸屋根とした。前記支持部材を用いて図1に相当する架台を作製して陸屋根に固定し、この架台にモジュールをカバー部材により取り付けた。設置場所は大阪府堺市の臨海工業地帯とした。
[Solar power generation module]
A commercially available solar power generation module having an Al alloy frame (JIS H8602: anodized composite film) was prepared.
[Installation of photovoltaic modules]
The building where the module is installed is a flat roof. A gantry corresponding to FIG. 1 was prepared using the support member and fixed to a flat roof, and a module was attached to the gantry with a cover member. The installation location was the coastal industrial area of Sakai City, Osaka Prefecture.

〔耐食性評価〕
雨水の流路および滞留部となる部位に取り付けられたカバー部材について、設置後2年経過した時点での腐食状況と腐食の度合いを評価した。
評価結果の表からわかるように、本発明例では部材の高耐久性が確認された。また、部材の幅は全ての水準で、縦桟と同じサイズの幅のもの、縦桟より両側3mmずつ大きいものと、両側5mmずつ大きいものの3種類で評価している。縦桟と同じサイズのものを用いた場合、縦桟に水が伝った跡のようなめっき層の腐食が見られ、架台としての長期耐久性が期待できない結果となった。3mm大きいものについては腐食は軽微であるものの、縦桟に水濡れ跡が見られ、架台としての長期耐久性に不安がある。5mmのものは水濡れ跡も見られず、雨水の流れが縦桟に達していないことが確認され、架台としての長期耐久性が期待された。
[Corrosion resistance evaluation]
About the cover member attached to the site | part used as a flow path and a retention part of a rainwater, the corrosion condition and the degree of corrosion were evaluated when two years passed after installation.
As can be seen from the table of evaluation results, high durability of the members was confirmed in the examples of the present invention. In addition, the width of the member is evaluated at three levels: a width of the same size as the vertical beam, a width 3 mm larger than the vertical beam, and a width 5 mm larger on both sides. When the same size as the vertical beam was used, corrosion of the plating layer was observed as if water was transmitted to the vertical beam, and the long-term durability of the frame could not be expected. About 3mm larger, although the corrosion is slight, there are traces of water wetting on the vertical rail, and there is concern about the long-term durability as a frame. The 5mm-thickness did not show any traces of water wetting, and it was confirmed that the rainwater flow did not reach the vertical rail, and long-term durability as a gantry was expected.

表1からわかるように、Al−0〜12質量%Si組成のAl系めっき鋼板を使用したカバー部材を用いる本発明例では、カバー部材の平坦部だけでなく、平坦部と平坦部の間の曲げ加工部や長手方向の切断端面の折り返しの曲げ加工部の外側面でめっき層が割れておらず良好な耐食性を示した。比較例はカバー部材の片面当たりのめっき付着量が20g/m2未満と少ないためピンホールが発生し、その周辺で白錆が顕著に発生した。また、めっき付着量が多くてもめっき種や母材により錆の発生が著しい。 As can be seen from Table 1, in the example of the present invention using the cover member using the Al-based plated steel sheet of Al-0 to 12% by mass Si, not only the flat part of the cover member but also between the flat part and the flat part. The plating layer was not cracked on the outer surface of the bent portion or the bent portion of the folded end face in the longitudinal direction, and good corrosion resistance was exhibited. In the comparative example, the plating adhesion amount per one side of the cover member was less than 20 g / m 2 , so that pinholes were generated, and white rust was remarkably generated around the pinholes. Moreover, even if there is a large amount of plating, rusting is significant due to the plating type and base material.

10 屋根面
11 フレーム枠
12 太陽光発電モジュール
21 横桟
22 縦桟
23 ステー
31 締結金具
32 モジュール間カバー
33 支持金具
40 切断端面
41 カバー部材
DESCRIPTION OF SYMBOLS 10 Roof surface 11 Frame frame 12 Solar power generation module 21 Horizontal beam 22 Vertical beam 23 Stay 31 Fastening bracket 32 Cover between modules 33 Support metal fitting 40 Cutting end surface 41 Cover member

Claims (4)

フレーム枠を持つ太陽光発電モジュールを、鋼材からなる支持部材を介して建築物に設置するに際し、該支持部材および縦桟あるいは横桟の一部を、桟の片側幅当たり5mm以上の鍔幅をもつハット加工よりなるカバー部材で覆うことによって前記太陽光発電モジュールからの雨水の流れを該カバー部材の表面に流れ落ちるようにする、太陽光発電モジュールの架台への設置において、流水カバーを兼ね備えた取付け金具。   When installing a photovoltaic power generation module having a frame frame on a building through a support member made of steel, the support member and a part of the vertical beam or horizontal beam have a width of 5 mm or more per side width of the beam. Covering with a cover member made of a hat having a flow of rainwater from the photovoltaic module to the surface of the cover member, the installation of the photovoltaic module on a pedestal mounting with a running water cover Hardware. フレーム枠を持つ太陽光発電モジュールを、鋼材からなる支持部材を介して建築物に設置するに際し、該支持部材の一部を、桟の片側幅当たり5mm以上の鍔幅をもつハット加工よりなるカバー部材で覆うことによって前記太陽光発電モジュールからの雨水の流れを該カバー部材の表面に流れ落ちるようにする、太陽光発電モジュールの建築物への設置方法。   When a photovoltaic power generation module having a frame is installed in a building via a support member made of steel, a part of the support member is covered with a hat process having a ridge width of 5 mm or more per side width of the crosspiece A method for installing a photovoltaic module on a building, wherein the photovoltaic module is covered with a member so that a rainwater flow from the photovoltaic module falls on the surface of the cover member. Al−0〜12質量%Si組成のAl系めっき層が片面あたり20g/m2以上の付着量で形成された溶融Al系めっきステンレス鋼板からなる請求項1で規定されるカバー部材。 The cover member prescribed | regulated by Claim 1 which consists of a hot-dip Al type plated stainless steel plate in which the Al type plating layer of Al-0-12 mass% Si composition was formed with the adhesion amount of 20 g / m < 2 > or more per side. Al−0〜12質量%Si組成のAl系めっき層が片面あたり20g/m2以上の付着量で形成された溶融Al系めっきステンレス鋼板からなるカバー部材を用いて施工する請求項2で規定される設置方法。
An Al-based plating layer having an Al-0 to 12% by mass Si composition is constructed using a cover member made of a hot-dip Al-based plated stainless steel plate formed with an adhesion amount of 20 g / m 2 or more per side. Installation method.
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Publication number Priority date Publication date Assignee Title
EP3076103A1 (en) 2015-04-02 2016-10-05 Solibro Hi-Tech GmbH Assembly of parts and assembly for fastening at least one photovoltaic module and method for producing an assembly of parts

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JP2006037545A (en) * 2004-07-28 2006-02-09 Eishin:Kk Mounting holder for solar-cell panel and fixing device for solar-cell panel using its mounting holder
JP2009033066A (en) * 2007-07-30 2009-02-12 Nisshin Steel Co Ltd Method for installing solar power generating module on building
JP2012180662A (en) * 2011-03-01 2012-09-20 Sanyo Industries Ltd Support of roof upper frame

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Publication number Priority date Publication date Assignee Title
JP2006037545A (en) * 2004-07-28 2006-02-09 Eishin:Kk Mounting holder for solar-cell panel and fixing device for solar-cell panel using its mounting holder
JP2009033066A (en) * 2007-07-30 2009-02-12 Nisshin Steel Co Ltd Method for installing solar power generating module on building
JP2012180662A (en) * 2011-03-01 2012-09-20 Sanyo Industries Ltd Support of roof upper frame

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3076103A1 (en) 2015-04-02 2016-10-05 Solibro Hi-Tech GmbH Assembly of parts and assembly for fastening at least one photovoltaic module and method for producing an assembly of parts
DE102015206062A1 (en) 2015-04-02 2016-10-06 Solibro Hi-Tech Gmbh Subassembly and arrangement for mounting at least one photovoltaic module and method for producing a subassembly

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