JP2928099B2 - Manufacturing method of photovoltaic roofing material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a photovoltaic roofing material which can be installed in an upper part of a house or the like to obtain electric power.

[0002]

2. Description of the Related Art There is great expectation for solar cells as a source of clean energy. Since the amount of power obtained by a solar cell is proportional to the area of the solar cell, a large solar cell installation site is required to obtain a large amount of power. Utilizing a roof such as a house as such an installation location is also suitable in that it is close to a power consumption location.

[0003] The simplest method for installing a solar cell on a roof of a house or the like is to install the base on a roof tile by fixing it to a roof structural member with a metal fitting or the like, and to mount a plurality of solar cell elements on the base. This is a method of installing a module consisting of However, in this case, the gantry and the module become structures independent of the roof, and not only are large strengths required, but also the gantry and the solar cell module impair the aesthetics of the house. Was.

Therefore, solar cell tiles have been developed as an alternative method. The solar cell tile is formed by directly forming a solar cell element on a tile base material, or by attaching or embedding a solar cell element to a tile base material.

[0005]

However, in addition to the problem of high cost per se, such a solar cell tile has a serious practical problem that the installation work is extremely complicated. . That is, each solar cell tile is provided with two positive and negative output terminals, and when laying the tile, wiring work to connect these output terminals in series or parallel as appropriate so as not to block the solar cell surface is extremely required. It is complicated and the installation cost is high.

[0006] It is an object of the present invention to solve these problems and to provide a low-cost manufacturing method of a photovoltaic roofing material that can be easily installed.

[0007]

According to the present invention, there is provided, in accordance with the present invention, a plurality of photovoltaic cells arranged on one surface in a longitudinal direction at equal intervals and having the same polarity as each cell. A band-shaped moisture-proof material and a band-shaped peelable material adhered on the band-shaped moisture-proof material on the solar cell mounting side of the insulative flexible substrate having the terminal conductors connecting the respective terminals on the same surface in the longitudinal direction. A method for manufacturing a photovoltaic roof, comprising laminating a band-like base material on the opposite side via a sealant layer, and heating and pressing the laminated body between elastic rolls. After passing between the rolls, apply a roughening process to the moisture-proof material so that the peelable material on the moisture-proof material has irregularities on the surface, and the smooth surface roll is in contact with the base material on the opposite side. And Also, a plurality of solar cells are arranged on one surface in the longitudinal direction at equal intervals, and an insulating flexible member having terminal conductors for connecting terminals of the same polarity of each cell in the longitudinal direction on the same surface. On the solar cell mounting side of the conductive substrate, a band-shaped moisture-proof material and a band-shaped peelable material to be adhered thereon are laminated via a sealant layer, and on the opposite side, a band-shaped base material is laminated via a sealant layer. A method for manufacturing a photovoltaic roof in which the laminate is heated and pressed through elastic rolls, wherein the moisture-proof material and the base material are bonded between the sealant layer and the moisture-proof material and the base material, respectively. Materials are to be inserted. Also, a plurality of solar cells are arranged on one surface in the longitudinal direction at equal intervals, and an insulating flexible member having terminal conductors for connecting terminals of the same polarity of each cell in the longitudinal direction on the same surface. After covering both sides of the functional substrate with a sealant layer and temporarily crosslinking the sealant, a band-shaped moisture-proof material is applied on the sealant layer covering the solar cells on the substrate, and a band-shaped exfoliation is applied thereon. Laminate possible materials,
A belt-like base material is laminated on the sealant layer covering the opposite side of the substrate, and the laminate is heated and pressed through an elastic roll, and then the sealant is fully crosslinked. here,
A strip-shaped strippable material is applied on the sealant layer covering both sides of the flexible substrate on which the solar cell is mounted, and the strippable material is removed before laminating the moisture-proof material and the base material. After passing through a certain roll, the surface of the peelable material on the moisture-proof material has unevenness, and the smooth surface of the roll is in contact with the base material on the opposite side, and the unevenness is applied to the moisture-proof material through the two rolls. It is effective to insert a moisture proof material and a moisture proof material adhered to the base material between the sealant layer and the moisture proof material and the base material, respectively.

[0008]

[Function] A solar power generation roof in which a flexible substrate on which solar cells are mounted is sealed between a moisture-proof surface material and a waterproof, heat-insulating, and fire-resistant underlying roofing material using a sealant. The material can be continuously mass-produced by forming the material by hot pressing through an elastic roll. Rolling this long roof material in a roll shape on the roof board on the roof while rolling, and connecting the terminal conductors of both poles exposed at the cut end greatly reduces the laying time and wiring time it can. Alternatively, by temporarily crosslinking the sealant with both sides of the flexible substrate on which the solar cells are mounted covered with the sealant, the sealant is cured and the surface of the solar cell module during work can be protected. If the sealant is then fully cross-linked after being heat-pressed between the moisture-proof material and the base material through a roll, a moisture-proof film for protecting the solar cell during the sealing step becomes unnecessary.

Further, if a peelable material is applied on the surface of the moisture-proof material, laid on the roof, and then peeled off, the surface of the roof material does not become stained or damaged during the work. Further, the unevenness of the moisture-proof material together with the release material thereon can prevent the worker from slipping during the roofing work. Improving the moisture resistance can be achieved without significantly impairing the flexibility by bonding and laminating another moisture-proof layer on the inner surfaces of the moisture-proof material and the base material.

[0010]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing an embodiment of the present invention; FIGS. 2 to 4 show the construction of roofing a photovoltaic roofing material according to an embodiment of the present invention. A solar roofing 11 which is a photovoltaic roofing material having a solar cell module on the surface is shown in FIG. As shown in the figure, the frame is laid on the field board 12 with the edges overlapping from the eave to the ridge, and fixed by hitting a screw called a tucker (FIG. 2). Next, solar roofing 11
A tempered glass 13 is tightened as a roof finishing material on the top and fixed using a mounting member 14 (FIG. 3).

FIG. 5 is a sectional view of a solar roofing manufactured according to an embodiment of the present invention. Each layer of the solar cell 2 is laminated on the flexible film substrate 1. As the film substrate 1, a plastic film such as polyimide, aramid, polyethersulfone, or polyethylene terephthalate is used. A film substrate on which such a solar cell 2 is mounted has a lower surface thickness of 80 μm.
Are laminated via a sealant 5 between a base material 3 and a moisture-proof material 4 having a thickness of 50 to 100 μm on the upper surface. As the base material 3 requiring waterproofness, heat insulation, fire resistance, or the like, an asphalt roofing material, a rubberized asphalt roofing material, a roofing material with a butyl adhesive on the back surface, or the like used for ordinary roof construction is used. The moisture-proof material 4 has a release film 6 on one side. A plastic film that is transparent and has a low moisture permeability is used for the moisture proof material 4. Fluorine-based, polymethyl methacrylate, polyarylate, polyethylene naphthalate, polysulfone, polyethersulfone, polyvinyl chloride, polycarbonate, polyphenylene Films such as sulfide are exemplified.

As shown in FIG. 6, a solar cell 2 has a metal electrode layer and an amorphous semiconductor layer having a pin junction on a flexible substrate 1 having a positive terminal lead 31 and a negative terminal lead 32 attached on the surface. , A transparent electrode layer, and a back electrode layer or the like connected to the front electrode layer through a through hole of the substrate 1.
It is formed by forming it at predetermined intervals by a predetermined device such as a VD method or a sputtering method, and has a total thickness of 5 mm.
It is wound on a core 21 in a roll form at 0 to 60 μm.

FIG. 1 shows an apparatus according to an embodiment of the present invention for laminating a flexible substrate 1 having solar cells on such a surface.
Sheet-like sealant 5 pulled out from above core 22 on both surfaces of
The moisture-proof film 41 in which the release film pulled out from above the core 23 is bonded to the surface on the side of the solar cell 2 and the core 24
The sheet-like base material 3 pulled out from above is overlapped.
These laminates are passed between a pair of rubber rolls 7 at a temperature of 80 ° C., a traveling speed of 20 mm / min, and a pressure of 1 kg / c.
The thermocompression bonding, that is, lamination, is continuously performed under the condition of m ² . Then, immediately after lamination, a roll 81 having an uneven surface
The embossing process is continuously performed on the surface of the moisture-proof film 41 with the release film through the space between the film and the smooth roll 82. Thereafter, the sealing agent 5 is crosslinked at a temperature of 130 ° C. in the heating zone 27, and the completed solar roofing 11 is wound on the core 25.

In order to lay the solar roofing 11 thus manufactured on the roof as shown in FIG. 2, the solar roofing is cut at intervals between the solar cells 2 according to the size of the roof. The terminal leads 31 and 32 exposed at the cut ends are connected in parallel by wiring. And the outermost positive and negative terminal leads 3
By connecting 1, 32 to the inverter, the electric power generated by sunlight is put to practical use. The peeling film 6 applied to the moisture-proof film 4 in order to prevent contamination during the work is peeled off after the wiring of the electrodes is completed, and the tempered glass 13 is tightened as a roof finishing material, and is attached by the mounting member 14. During these roofing operations, the surface of the solar roofing 11 made uneven by embossing is
Prevent workers from slipping.

FIG. 7 shows a laminating apparatus according to another embodiment of the present invention. In this case, what is wound on the core 21 is a flexible substrate 1 on which solar cells 2 are provided on the surface as shown in FIG. 6, and a release film on one side as shown in FIG. The sheet-like sealant 5 to which 6 is applied is laminated on both sides and sealed in a temporarily crosslinked state. The peeling film 6 in this case is for preventing the sealing agent 5 from adhering to each other when wound on the core. The moisture-proof film 41 with the release film pulled out from above the core 23 is placed on the side of the solar cell 2 of the temporary laminate from which the release films are removed from both sides of the core 21 and the base material 3 is placed on the side of the substrate film 1. Overlap, and further, sealing agent 5 at the time of subsequent heating
The release film 61 pulled out from the core 26 is overlaid on both sides in order to prevent the leakage from occurring in the lateral direction. Then, these laminates are passed between rubber rolls 7 at a temperature of 100 ° C., a traveling speed of 30 mm / min, and a pressure of 1 kg / c.
The thermocompression lamination is continuously performed under the condition of m ² . FIG.
After the embossing is continuously performed on the surface on the moisture-proof film 41 side using the rolls 81 and 82 in the same manner as in the example of
The cross-linking process is performed in the heating zone 27 at a temperature of 130 ° C. for 30 minutes, and the roll-shaped solar roofing 11 having the structure shown in FIG. The release film 61 may be peeled off before winding on the core 25 or may be peeled off before roofing. In this embodiment, since the substrate 1 and the solar cell 2 wound on the core 21 are sealed with the temporary cross-linking sealant, there is no possibility that the characteristics are deteriorated before the laminating step.

FIGS. 9 and 10 show a manufacturing process of a solar roofing according to still another embodiment of the present invention in a sectional structure. As shown in FIG. 10, both surfaces of a film substrate 1 on which solar cells 2 are mounted on one surface are sealed with moisture-proof films 42 and 43 having a thickness of 50 μm via a layer of a sealing agent 5 made of EVA. . This sealing can also be performed by a laminating apparatus as shown in FIG. As the moisture-proof film 42 on the front side, a film similar to the moisture-proof material 4 in FIG. 5 is used, but the moisture-proof film 43 on the back side is not necessarily transparent, unlike the moisture-proof film 42 on the light incident side. In addition to the film used for the moisture-proof material 4, a material obtained by sandwiching a metal foil such as aluminum with a plastic film can be used. The plastic film itself may have a slightly higher moisture permeability, and the metal film sandwiched by the plastic film may be used. The foil makes it possible to block intruding moisture.

A moisture-proof material 4 having a total thickness of 50 to 100 μm with a release film 6 on the upper part of the structure shown in FIG.
A base material 3 having a thickness of 80 μm is provided at a lower portion, and a thickness of 10 μm
m of the adhesive 9. Thus, by inserting the moisture-proof films 42 and 43 on both sides, the moisture-proof effect is improved. To that extent, the thickness of the solar roofing increases, but the flexibility is rarely impaired because the solar roofing is bonded via a soft adhesive layer.

[0018]

According to the present invention, an integrated structure for sealing a flexible substrate on which solar cells are mounted between a roofing material as a base and a moisture-proof material on the surface is manufactured by heat-pressing between rolls. As a result, continuous work is possible and mass productivity is excellent. By temporarily crosslinking the sealant while the substrate is covered with the sealant during this step, the surface of the solar cell can be protected without the protective film, and the material cost is reduced and the weight is reduced. In addition, by applying a peelable material that can be removed after laying on the roof to the moisture proof material on the surface, the surface can be protected during the laying work, and the surface can be passed between two rolls, one of which has an uneven surface, following heating and pressing. By making the surface uneven, the worker can be prevented from slipping, and safety can be ensured during work on the roof.

[Brief description of the drawings]

FIG. 1 is a side view of a laminating apparatus used for manufacturing a solar roofing according to an embodiment of the present invention.

FIG. 2 is a perspective view of a solar roofing manufactured according to the present invention in an intermediate state of laying work on a roof.

FIG. 3 is a perspective view of the roof after completion of the laying work of FIG. 2;

FIG. 4 is a sectional view conceptually showing the laying structure of FIGS. 2 and 3;

FIG. 5 is a sectional view showing a structure of a solar roofing according to an embodiment of the present invention.

FIG. 6 is a cross-sectional view showing a flexible substrate mounted on a solar cell tower supplied to the apparatus of FIG. 1;

FIG. 7 is a side view of a laminating apparatus used for manufacturing a solar roofing according to another embodiment of the present invention.

FIG. 8 is a sectional view of a temporary laminate supplied to the laminating apparatus of FIG. 7;

FIG. 9 is a cross-sectional view showing a structure during a manufacturing process of a solar roofing according to still another embodiment of the present invention.

10 is a cross-sectional view of the solar roofing shown in FIG. 9 after completion.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Flexible substrate 2 Solar cell 3 Base material 4 Moisture proof material 41 Moisture proof film with release film 42, 43 Moisture proof material film 5 Sealant 6, 61 Release film 7 Rubber roll 81 Uneven roll 82 Smooth roll 9 Adhesive 11 Solar roofing 27 heating zone

Claims (6)

(57) [Claims] A plurality of photovoltaic cells are arranged on one surface in a longitudinal direction at equal intervals, and an insulating material having terminal conductors for connecting terminals of the same polarity of each cell in the longitudinal direction on the same surface. A flexible moisture-proof material and a strip-like peelable material to be adhered thereon are laminated on the solar cell mounting side of the flexible substrate via a sealant layer, and a belt-like base material is laminated on the opposite side via the sealant layer. A method of manufacturing a photovoltaic roof in which the laminate is heated and pressure-bonded through elastic rolls. After passing between the elastic rolls, the surface of the peelable material on the moisture-proof material has irregularities. A method for manufacturing a photovoltaic power generation roof, comprising applying unevenness to a dampproof material between two rolls so that the roll having a smooth surface is in contact with a base material on the opposite side. 2. An insulating material having a plurality of photovoltaic cells arranged on one surface in the longitudinal direction at equal intervals and having terminal conductors for connecting terminals of the same polarity of each cell in the longitudinal direction on the same surface. A flexible moisture-proof material and a strip-like peelable material to be adhered thereon are laminated on the solar cell mounting side of the flexible substrate via a sealant layer, and a belt-like base material is laminated on the opposite side via the sealant layer. A method of manufacturing a photovoltaic roof, in which the laminate is heated and pressed through an elastic roll, and adhered to the moisture-proof material and the base material between the sealant layer and the moisture-proof material and the base material, respectively. A method for manufacturing a solar power generation roof, comprising inserting a moisture-proof material to be used. 3. An insulating material having a plurality of photovoltaic cells arranged on one surface in the longitudinal direction at equal intervals and having terminal conductors connecting the same-polarity terminals of the cells in the longitudinal direction on the same surface. After covering both surfaces of the flexible substrate with the sealant layer and temporarily crosslinking the sealant, the band-shaped moisture-proof material is applied on the sealant layer covering the solar cells on the substrate and adhered thereon. The strip-like peelable material to be laminated is laminated, the belt-like base material is laminated on the sealant layer covering the opposite side of the substrate, and the laminate is heated and pressed through an elastic roll. A method for producing a photovoltaic roof, comprising crosslinking. 4. A strip-shaped peelable material is applied on a sealant layer covering both sides of a flexible substrate on which solar cells are mounted,
The method for manufacturing a photovoltaic power generation roof according to claim 3, wherein the peelable material is removed before laminating the moisture-proof material and the base material. 5. After passing between elastic rolls, a roll having irregularities on the surface of the peelable material on the moisture-proof material and a smooth roll on the opposite side of the base material are passed between the two rolls. The unevenness processing is performed on the moisture-proof material.
The method for manufacturing a photovoltaic roof according to any one of the above. 6. The photovoltaic roof according to claim 3, wherein a moisture proof material and a moisture proof material adhered to the base material are inserted between the sealant layer and the moisture proof material and the base material, respectively. Production method.