JP5722596B2 - Solar cell integrated roofing material - Google Patents

Description

  The present invention relates to a solar cell integrated roof material in which solar cells are integrally attached to a roof material without using mechanical fixing means such as bolts and fixing metal fittings.

  The spread of solar cells is strongly desired in order to contribute to the saving of petroleum resources and the reduction of carbon dioxide emissions. In order to widely spread solar cells in general, cost reduction including installation costs becomes an issue. Therefore, development of the installation method which can install a solar cell cheaply and simply is desired strongly.

  It is most reasonable from the viewpoint of space efficiency and power transmission efficiency to install solar cells on the roof of a building that uses generated electric power. Therefore, development of an installation structure that can easily and inexpensively install solar cells on the roof of a building is desired.

  When installing a solar cell on an existing roof, it is necessary to fix the paneled solar cell to the roof using a fixing bracket or the like. Since such a solar cell panel requires a certain amount of rigidity, it is necessary to include a metal plate or a glass plate, which increases cost and weight. In addition, the fixing brackets and the like require attachment strength that prevents the solar cell panel from being blown by strong winds. Accordingly, the fixing brackets and the like have a considerable weight, which increases the weight of the roof and the installation cost.

  On the other hand, when the solar cell integrated roof material in which the solar cell is integrally attached to the base material is used, there is no need to use a fixing bracket or the like, and an increase in the roof weight can be easily suppressed. Furthermore, the process for installing the solar cell can be incorporated into the process for forming the roof. For this reason, the installation cost of a solar cell can be reduced.

  In order to produce such a solar cell integrated roof material, in Patent Document 1, a film type amorphous solar cell is joined to a roof material such as a galvanium steel plate to form a solar cell integrated roof material. . Here, the film-type solar battery cell is obtained by forming a solar battery on a plastic film. In patent document 1, it does not describe about the waterproofing of a film type photovoltaic cell.

  In patent document 2, it is affixed on the roofing materials, such as a stainless steel plate, in the state which sealed the photovoltaic cell with transparent weather resistant resin. In Patent Document 3, amorphous silicon solar cells using a polyimide film as a substrate are provided on a roof material such as a galvanium steel plate, and the solar cells are sealed with an ethylene-vinyl acetate copolymer (EVA). Furthermore, a surface protective material of ethylene-tetrafluoroethylene copolymer (ETFE) is provided on the outermost surface of the light receiving surface of the solar battery cell.

  In patent document 4, as shown in FIG. 5, the film module 53 which sealed the photovoltaic cell 52 between the two film materials 51 which consist of EVA, for example is affixed on the roof base material 54, ETFE etc. on it. The surface protection layer 55 is provided, and the end portions of the film module 53 and the roof base material 54 are sealed with a packing 56.

JP 2009-127327 A Japanese Patent Laid-Open No. 11-4010 JP 2006-249877 A JP 2009-76692 A

  A normal steel plate (galvanium steel plate or the like) used as a roofing material is said to have a life of about 10 years. On the other hand, in the solar cell-integrated roof material, it is possible to expect a life that is twice or three times as long as the steel plate is protected by solar cells or a covering material.

  However, when the solar cell is provided on the roofing material, if the solar cell of the power generation unit comes into contact with water, the life may be shortened due to an increase in the electrical resistance of the electrode unit or the like. If the solar cell is shortened due to contact with water, the solar cell-integrated roofing material can fully perform the basic function as a roofing material, and only the power generation function is lost early. It can happen.

  In relation to this point, in Patent Documents 2 and 3, the solar battery cell is waterproofed by sealing the solar battery cell with EVA or a fluororesin. However, since most of the resins cannot completely block the permeation of water vapor, none of the conventional waterproof structures can sufficiently prevent the solar cells from coming into contact with water.

  Furthermore, moisture penetrates not only from the upper surface of the film covering the solar battery cells but also from the gap between the end portions where the films are bonded together, and comes into contact with the solar battery cells sealed between the films. Therefore, in order to maintain the power generation capacity of the solar cell integrated roof material for a long period of time, it is necessary to sufficiently waterproof not only the upper surface of the solar battery cell but also the end portion where the films are joined together.

  In relation to this point, in Patent Document 4, the film module is bonded to the roof material so that the outer periphery of the roof material and the end of the film module are aligned, and the roof material is covered over the entire outer periphery of the roof material. The packing is attached so that the end of the film module is sandwiched from above and below. Thereby, it is going to prevent the penetration | invasion of the water from the edge part of a roof material and a film module.

  However, in the structure of Patent Document 4, the outer peripheral portion of the solar cell integrated roof material is entirely covered with the packing, and the connection between the end of the roof material and other members (the ends of the roof material, and another Including connection with members).

  The most basic function of the roofing material is to prevent rainwater from passing behind it. Therefore, the connection between the end portion of the roofing material and the other member is very important. However, if the outer periphery of the roofing material is completely surrounded by, for example, rubber packing as in Patent Document 4, an existing connecting member that is generally used is used, and the end of the roofing material is connected to the other member. It becomes impossible to connect. Therefore, it is necessary to manufacture a special connection member or the like for connecting the end portions. As a result, the cost increases.

  Then, this invention aims at providing the solar cell integrated roof material which can prolong the lifetime of the electric power generation capability of a solar cell, without producing difficulty in the connection with the other member in an edge part.

The present invention includes a metal plate-like base material having a first main surface and a second main surface opposite to the first main surface ;
A first sheet containing an electrically insulating resin-containing resin disposed on the first main surface of the base material, a sheet-like solar battery cell disposed on the first sheet, and the solar battery cell A laminated body including a second sheet containing a resin having electrical insulation and translucency, and a moisture-proof layer having a translucency arranged on the second sheet. And
The first sheet and the second sheet sandwich the solar battery cell between their central parts, and the peripheral parts thereof are joined to each other to hold the solar battery cell,
From the moisture-proof layer, the gap between the end portions of the first sheet and the second sheet, and the gap between the end portion of the first sheet and the substrate, the first sheet and the second sheet. A connecting portion for connecting the base material to another member from the end waterproofing portion toward the outer peripheral portion of the base material. Extended ,
The end waterproof part is
A first folded portion that is folded back so as to face the moisture-proof layer at a first fold outside the outer peripheral portion of the laminate;
A first sealing material that seals a gap between the first folded portion and the moisture-proof layer;
The present invention relates to a solar cell integrated roof material including a second sealing material that seals a gap between an outer peripheral portion of the laminate and the first folded portion .

  According to the solar cell integrated roof material of the present invention, the power generation capacity of the solar cell can be extended without difficulty in connection with other members at the end.

It is a top view of the solar cell integrated roof material which concerns on one Embodiment of this invention. FIG. 2 is an enlarged cross-sectional view taken along the line II-II in FIG. 1. It is an expanded sectional view of an edge part waterproof part. It is an expanded sectional view of a moisture-proof layer. It is an expanded sectional view of the edge part of the conventional solar cell integrated roof material.

The solar cell integrated roof material of the present invention includes a metal plate-like base material having two main surfaces (that is, a first main surface and a second main surface opposite to the first main surface) , and a base material Of the first sheet containing resin, which is disposed on one main surface (first main surface) , and which has an electrical insulating property, on the first sheet, A second sheet including a resin having electrical insulation and translucency disposed thereon, and a laminate including a moisture-proof layer having a translucency disposed on the second sheet. . The first sheet and the second sheet hold the solar battery cell by sandwiching the solar battery cell between the central parts thereof, and the peripheral parts thereof are joined to each other.

  And the roofing material of the present invention includes the first sheet and the second sheet from the moisture-proof layer, the gap between the end portions of the first sheet and the second sheet, and the gap between the end portion of the first sheet and the substrate. In addition, an end waterproof part that prevents water from entering between is provided, and a connecting part for connecting the base material to another member is extended from the end waterproof part toward the outer peripheral part of the base material. ing.

  As described above, the moisture-proof layer is disposed on the second sheet including the resin, which is electrically insulating and translucent, disposed on the solar cell, and the solar cell and the resin sheet are laminated. By disposing the end waterproof portion at the end of the body, water can be almost completely prevented from entering between the first sheet and the second sheet. Thereby, it can prevent that a photovoltaic cell shortens life by contact with water. Therefore, it is possible to solve the problem that the solar cell integrated roof material loses the power generation function at a much earlier stage than the basic function of the roof material is lost. Therefore, the lifetime of the solar cell integrated roof material can be extended as a whole.

  Furthermore, the connection part for connecting the base material to other members is extended from the end waterproof part toward the outer peripheral part of the base material, so that the presence of the end waterproof part is the end part of the roofing material. Can be prevented from becoming a hindrance when connecting to other members (including the connection between the ends of the roofing material and other members). Therefore, it is possible to connect the roofing material to the other members in a usual manner using an existing connecting member that is generally used. Therefore, a special cost increase due to the provision of the end waterproof portion can be suppressed.

  In the solar cell integrated roof material according to one aspect of the present invention, the end waterproof portion is folded back so that the base material is opposed to the moisture-proof layer at the first fold outside the outer peripheral portion of the laminate. 1 folding | turning part and the 1st sealing material which seals the clearance gap between a 1st folding | turning part and a moisture-proof layer are included.

  If the first folded portion is formed by folding the base material so as to face the moisture-proof layer at the first fold outside the outer peripheral portion of the laminate, the end of the laminate is a first made of a metal material. It is surrounded by the folded part. And if the clearance gap between a 1st folding | turning part and a moisture-proof layer is sealed with the 1st sealing material which consists of resin, for example, the penetration | invasion of the water to the vicinity of the edge part of a laminated body can be suppressed almost completely.

  A butyl hot melt resin can be used for the first sealing material. The first sealing material can be formed by melting the resin, pouring it into the gap between the first folded portion and the moisture-proof layer, and naturally cooling and solidifying the resin. In addition, for example, a simple sealing material such as epoxy putty can be used. Even when such a simple sealing material is used, it is possible to stop the moisture from reaching a slight amount of water vapor in the vicinity of the end of the laminate.

  Since the end portion of the laminated body is an end portion of the layered structure of thin sheets that are in close contact with each other, it is originally a portion that is very difficult for water to enter. Therefore, even if a slight amount of water vapor is present in the vicinity of the end of the stacked body, it does not reach the solar cell from the end of the stacked body. Therefore, the solar battery cell can be almost completely waterproofed without using any other member (for example, rubber packing as described in Patent Document 4).

  Furthermore, the first folded portion is formed so that the substrate is folded at the first fold outside the outer peripheral portion of the laminate. For this reason, when forming a 1st folding | turning part, it can prevent that a moisture-proof layer is bend | folded with a base material and is damaged. Therefore, the moisture-proof property of the moisture-proof layer can be maintained for a long time.

  Here, the first folded portion may be formed so as to be in contact with the moisture-proof layer, or may be formed so as to have a slight gap from the moisture-proof layer. When a slight gap is provided between the first folded portion and the moisture-proof layer, the moisture-proof layer can be prevented from being damaged due to contact with the first folded portion. Therefore, it is possible to prevent the waterproof property of the moisture-proof layer from being impaired, and as a result, it is possible to reliably prevent the life of the solar cell from being shortened.

  In the solar cell integrated roof material according to another aspect of the present invention, the end waterproof portion further includes a second sealing material that seals a gap between the outer peripheral portion of the laminate and the first folded portion.

  By sealing not only the gap between the first folded portion and the moisture-proof layer but also the gap between the outer peripheral portion of the laminate and the first folded portion, water can be more reliably prevented from entering from the end of the laminate. It becomes possible to do.

  In the solar cell-integrated roofing material according to still another embodiment of the present invention, the base material is rectangular, the connection portion is provided at each of the pair of end portions along the longitudinal direction, and the first fold is , And generally parallel to the pair of end portions along the longitudinal direction.

  When connecting a general roofing material which is a rectangle, a pair of edge parts along the longitudinal direction are often connected. This embodiment corresponds to such a case. In this case, by forming the first fold in parallel with the pair of end portions along the longitudinal direction of the rectangular base material, the end waterproof portion can be provided along the longitudinal direction of the base material. It becomes possible. As a result, a longer end waterproof part can be formed as compared with the case where the end waterproof part is provided along the short direction of the substrate. Therefore, it becomes possible to waterproof a photovoltaic cell more effectively.

  In the present invention, the base material is basically a rectangle, a connection portion is provided at each of the pair of end portions along the short direction, and the first fold is a pair of along the short direction. The present invention can also be applied to a case where it is generally parallel to the end portion.

  In the solar cell integrated roof material according to still another embodiment of the present invention, the pair of end portions along the short direction of the base material are installed on the roof so as to face the ridge side and the eave side of the roof.

  This form relates to a case where a rectangular solar cell-integrated roofing material is installed on a roof with a so-called “pipe”. When the roofing material is a vertical wall, the longitudinal direction of the roofing material is parallel to the direction in which water flows along the inclination of the roof. As a result, it is possible to prevent water from staying in a portion where the water in the end waterproof portion provided along the longitudinal direction of the base material easily enters. Therefore, the solar battery cell can be waterproofed more effectively.

  In addition, the present invention is basically a case where the pair of end portions along the longitudinal direction of the base material is installed on the roof so as to face the ridge side and the eave side of the roof, that is, a rectangular roof material, It can also be applied when installing on a roof with a so-called “Yokohama”.

  In the solar cell-integrated roof material according to still another embodiment of the present invention, the connecting portion bends the base material at the end of the second folded portion that is further folded from the first folded portion to the second fold. Is formed.

  The main part of the end waterproof part is composed of a first folded part obtained by folding the base material, and the second folded part is formed by further folding the base material from the first folded part to form a second folded part. It becomes possible to easily form a connecting portion for connecting the roofing material to another member at the end of the roof.

  Here, the first sheet or the second sheet is at least one selected from the group consisting of a copolymer of ethylene and vinyl acetate, an ionomer resin, polyvinyl butyral, a styrene thermoplastic elastomer, a polyolefin resin, and a silicone resin. It can include seeds.

  These resins have excellent insulating properties and are excellent as heat-welding adhesives. Therefore, a solar cell can be firmly fixed to the upper surface of the base material by using these resins as the first sheet.

  The first sheet and the second sheet may have a single layer structure or a multilayer structure. The sheet having a multilayer structure may be multilayered by combining sheets made of a resin selected from the above resin group, or a sheet made of another resin, for example.

  A solar battery cell includes a semiconductor element that contributes to photoelectric conversion, an electrode that extracts current from the element, a substrate that supports the element, and the like. An antireflection film can be formed on the element surface as needed. In the present invention, a single solar cell or a plurality of electrically connected solar cell groups can be sandwiched between the first sheet and the second sheet to form a laminate.

  A back sheet having waterproofness can be bonded to the surface of the first sheet that contacts the substrate. This back sheet can be produced, for example, by forming a resin layer such as polyethylene naphthalate resin on both surfaces of an aluminum foil and coating a fluororesin on the surface in contact with the substrate. As described above, the above back sheet can be included as a component of the first sheet having a multilayer structure in the present invention.

  In the solar cell integrated roof material according to still another embodiment of the present invention, the moisture-proof layer has a multilayer structure including a surface layer, an ultraviolet absorption layer, and a barrier layer. Here, the surface layer includes at least one selected from the group consisting of a fluororesin, an acrylic resin, a polycarbonate resin, and a polyethylene naphthalate resin. The barrier layer has a base portion including at least one selected from the group consisting of polyethylene terephthalate resin, acrylic resin, polyethylene naphthalate resin, and polycarbonate resin, and a coating layer that includes silicon oxide or aluminum oxide and covers the base portion. .

  If the moisture-proof layer is formed of glass, for example, there will be no moisture that permeates the moisture-proof layer. The present invention includes the case where the moisture-proof layer is glass. However, when the moisture-proof layer is formed of glass, the moisture-proof layer lacks flexibility. Therefore, it is necessary to increase the thickness of the moisture-proof layer to some extent in order to prevent the moisture-proof layer from being damaged by deformation of the roof material made of thin steel plates and bending of the base material when forming the end waterproof portion. Arise. As a result, the weight increases.

In this embodiment, the moisture-proof layer is mainly formed of a resin, thereby providing the moisture-proof layer with flexibility and reducing the thickness, while providing a barrier layer with a silicon oxide or aluminum oxide coating layer, It is possible to achieve. For example, according to JIS K 7129: 2008, high moisture resistance is achieved such that the water vapor transmission rate measured at a temperature of 40 ° C. and a relative humidity of 90% is 0.10 g / m ² · 24 h or less. Thereby, it becomes possible to extend the life of the solar battery cells while reducing the weight of the roofing material.

  In the solar cell integrated roofing material according to still another embodiment of the present invention, the solar cell has an amorphous silicon type or spherical silicon type photoelectric conversion element.

  The present invention basically includes the case where the solar battery cell is a wafer-like solar battery cell. However, since the wafer-like solar cell has a low mechanical strength and is easily broken, it is necessary to reinforce the surface with glass or the like in order to install it on the surface of the roof. Therefore, the weight increases. In addition, when the roof base material made of thin steel plate is bent, it is difficult to attach the solar cell to such a base material because the wafer-like solar cells are not flexible. Become.

  On the other hand, a solar battery cell (hereinafter referred to as an amorphous silicon solar battery cell or a spherical silicon solar battery cell) incorporating an amorphous silicon type or a spherical silicon type photoelectric conversion element has flexibility and has a roof base. Even when the material is bent, it can be easily attached without damaging the solar battery cell. Moreover, even if the roof base material is deformed after being attached to the roof base material, it is difficult to be damaged.

  Therefore, it is easy to reduce the weight by using amorphous silicon solar cells or spherical silicon solar cells. In particular, the spherical silicon solar cell is preferable to the amorphous silicon solar cell in that the energy conversion efficiency can be increased relatively easily.

  Here, the spherical silicon solar cell refers to a solar cell formed by mounting a large number of spherical silicon solar cell elements (for example, a diameter of about 1 mm) one by one in a hole provided in a substrate (for example, JP 2010-126428). Since the spherical silicon solar cell has a thin plate made of a metal such as aluminum (for example, a thickness of about 0.1 mm), the spherical silicon solar cell has flexibility to be installed on a curved surface.

  In a spherical silicon solar cell, a higher conversion efficiency than that of an amorphous silicon solar cell can be expected with a silicon usage amount of about 1/5 of a general wafer type silicon solar cell. The spherical silicon particles that are the precursors of the spherical silicon solar cell elements are obtained, for example, by continuously dropping a silicon melt placed in a crucible from a nozzle hole at the bottom of the crucible, and the droplets that have become spherical due to surface tension are contained in the cooling tower. It is manufactured by solidifying while falling.

  In addition, this invention is a photovoltaic cell in which a photovoltaic cell has flexibility other than an amorphous silicon type solar cell or a spherical silicon type, for example, a compound semiconductor thin film photovoltaic cell, a dye-sensitized photovoltaic cell, etc. It can be preferably applied to cases.

Embodiments of the present invention will be described below with reference to the drawings.
(Embodiment 1)
In FIG. 1, the top view of the solar cell integrated roof material which concerns on one Embodiment of this invention is shown. FIG. 2 shows an enlarged cross-sectional view taken along the line II-II of the roofing material of FIG. FIG. 3 is an enlarged sectional view of the end waterproof portion. In FIGS. 2 and 3, the thickness and dimensions of each member do not reflect the actual thickness and dimensions of the members in order to improve visibility. 2 and 3 mainly show the approximate shape and positional relationship of each member.

  The roofing material 10 includes a base material 12 made of a rectangular metal plate (for example, a galvanium steel plate) and a laminate 14 disposed on one main surface of the base material 12. The thickness of the base material 12 is 0.4-0.6 mm as an example.

  The laminated body 14 is disposed so as to come into contact with one main surface of the substrate 12, and the resin-made first sheet 18 and a predetermined number disposed on the upper surface of the first sheet 18 (eight in the illustrated example). Solar cell 16, a translucent resin-made second sheet 20 disposed on the upper surface of solar cell 16, and a translucent moisture-proof layer 22 disposed on the upper surface of second sheet 20. Including. The outer peripheral ends of the first sheet 18, the second sheet 20, and the moisture-proof layer 22 are all aligned.

  The laminate 14 has a rectangular shape with a length almost the same as the longitudinal direction of the base material 12 and a width smaller than the length of the base material 12 in the short direction, and the longitudinal direction is parallel to the longitudinal direction of the base material 12. It is arranged to be. Further, in the laminate 14, the center in the short direction coincides with the center in the short direction of the substrate 12.

  The solar battery cell 16 is also rectangular, and its longitudinal direction is parallel to the short direction of the laminate 14 and its short direction is parallel to the longitudinal direction of the laminate 14, so that the solar cell 16 extends in the longitudinal direction of the laminate 14. They are arranged in a line. The 1st sheet | seat 18 and the 2nd sheet | seat 20 hold | maintain the photovoltaic cell 16 by sandwiching the photovoltaic cell 16 between those center parts, and the peripheral part is mutually joined. The solar cells 16 in the adjacent stacked body 14 are electrically connected in series, and the solar cells 16 at both ends are provided with connection terminals (not shown). Note that the solar cells 16 can be connected not only in series but also in parallel as necessary, or in combination of series and parallel.

  In the vicinity of a pair of end portions along the longitudinal direction of the substrate 12 (hereinafter, such end portions are referred to as longitudinal end portions) 12a, the longitudinal end portions of the laminate 14 are respectively disposed along the longitudinal end portions 12a. An end waterproof part 24 for waterproofing is provided. In addition, a pair of edge part (henceforth such edge part is called short edge part) along the transversal direction of the laminated body 14 is waterproofed by another method. For example, in the case where the roofing material 10 is installed on a vertical fence, one of the short ends 12b of the laminate 14 is waterproofed by covering one of the short ends 12b of the base 12 with a roof ridge material. (See FIG. 2 of Patent Document 1). The other of the short ends of the laminated body 14 can be waterproofed by covering it with eaves, for example.

  The end waterproof portion 24 includes a first folded portion 26 that is a fold (first fold) 12 c parallel to the longitudinal end portion 12 a of the substrate 12, and the substrate 12 is folded so as to face the moisture-proof layer 22. The first fold line 12 c is located outside the longitudinal end portion of the stacked body 14. Furthermore, the end waterproof part 24 includes a sealing material 28 that seals the gap between the first folded part 26 and the moisture-proof layer 22 and the gap between the first folded part 26 and the end of the laminate 14.

  In addition, in FIG. 3, although the 1st folding | turning part 26 and the moisture-proof layer 22 are spaced apart, you may contact both. Even in that case, since there is a gap between the first folded portion 26 and the moisture-proof layer 22 microscopically, the sealing material 28 is disposed so as to seal the gap.

  The base material 12 is further folded at the fold (second fold) 12d from the first folded portion 26, and a pair of longitudinal ends is folded by folding the end of the folded portion (second folded portion) 30. A connection portion 32 is formed on one side of the portion 12a, and a connection portion 34 is formed on the other side. Thereby, the connection part 32 of the one roofing material 10 and the connection part 34 of the roofing material 10 adjacent to this are connected directly or indirectly using a common existing connection member etc. Thus, a plurality of roofing materials can be connected at each end. Or it is also possible to connect the edge part of the roofing material 10 with another member by either of the connection parts 32 and 34. FIG.

  As described above, the main part of the end waterproof portion is constituted by the first folded portion 26 that is the folded base material 12, and the second folded portion 30 is further folded from the first folded portion 26. By forming, the edge part of the laminated body 14 can be waterproofed without providing packing etc. (refer patent document 4) in the outer peripheral part of the roofing material 10, and forming a connection part in the edge part of a roofing material. Can do. Therefore, the connection between the roof materials and the connection between the roof material and another member are facilitated.

  In addition, the shape of the connection parts 32 and 34 is not limited to the mountain shape of the example of illustration, It is possible to set suitably according to the structure of the connection member used for a connection. For example, the connection portions 32 and 34 can be formed by processing the end portion of the second folded portion 30 into a shape that can be connected with a known connection structure as disclosed in JP-A-10-159271. Is possible.

  The gazette is a connection structure in the case where the roofing material is upright. However, the present invention is not limited to the case where the roofing material is downspreaded, and can be applied to the case where the roofing material is lying down. In the case of lying down on the roofing material, the connecting portions 32 and 34 may be processed into a shape that can be connected with a known connection structure as disclosed in, for example, JP-A-2006-322299.

  The first sheet 18 may be a single layer, but in order to obtain good insulation and adhesion, for example, a sheet made of polyethylene terephthalate (PET) is disposed so as to come into contact with the base material 12, and on top of that, You may make it arrange | position the sheet | seat which consists of EVA. That is, the first sheet 18 can have a multilayer structure. The thickness of the 1st sheet | seat 18 is 0.5-0.7 mm as an example. In addition, ionomer resin, polyvinyl butyral, styrene-based thermoplastic elastomer, silicone-based resin, polyolefin-based resin, and the like can be used as the material for the first sheet 18.

  The first sheet 18 and the base material 12 are preferably joined by heat welding. According to the thermal welding, the bonding process is simplified and the gap between the first sheet 18 and the substrate 12 is minimized as compared with the case where the first sheet 18 is bonded to the substrate 12 with an adhesive or the like. Can be suppressed. Therefore, it becomes possible to improve waterproofness more.

  As the solar battery cell 16, it is preferable to use a flexible solar battery cell such as an amorphous silicon solar battery cell or a spherical (crystalline) silicon solar battery cell. Wafer-shaped solar cells need to be reinforced by covering the solar cells with thick glass or the like, which is not preferable because it increases the weight. In this respect, if the solar battery cell 16 has flexibility, it is only necessary to protect the surface with a thin transparent film or the like, and the weight can be easily reduced. A preferable thickness of the solar battery cell 16 is 0.1 to 1.5 mm. The present invention basically includes a case where a wafer-like solar battery cell is used and a case where the solar battery cell is reinforced with glass.

The 2nd sheet | seat 20 is provided in the upper surface of the photovoltaic cell 16 so that the surface of the photovoltaic cell 16 may be protected, and translucent resin, such as EVA, can be formed as a raw material. As the material for the second sheet 20, it is also preferable to use a material having high weather resistance such as a fluororesin. More specifically, in addition to EVA, ionomer resins, polyvinyl butyral, styrene-based thermoplastic elastomers, silicone-based resins, polyolefin-based resins, and the like can be used. Moreover, it is also preferable to use them in combination. That is, the second sheet 20 can also have a multilayer structure. As an example, the thickness of the second sheet 20 is as follows:
0.5 to 0.7 mm.

  The second sheet 20, the solar battery cell 16, and the first sheet 18 are preferably joined to each other by thermal welding from the viewpoint of reducing the gaps between the layers of the stacked body 14. At this time, the area of the first sheet 18 and the second sheet 20 is made larger than that of the solar battery cell 16, the solar battery cell 16 is sandwiched between the central portions of the first sheet 18 and the second sheet 20, The first sheet 18 and the second sheet 20 are welded at the portion. Thereby, the solar battery cell 16 is sealed and held by the first sheet 18 and the second sheet 20.

  Thus, the 1st sheet | seat 18 is set by setting the size and arrangement | positioning of each member so that the edge part of the 1st sheet | seat 18 and the 2nd sheet | seat 20 is located outside the edge part of the photovoltaic cell 16. FIG. And water can be better prevented from entering between the second sheet 20 provided with the moisture-proof layer 22 on the upper surface.

As shown in FIG. 4, the moisture-proof layer 22 may have a multilayer structure including a surface layer 22a, an ultraviolet absorption layer 22b, and a barrier layer 22c. Here, the surface layer 22a can be formed using a fluororesin, an acrylic resin, a polycarbonate resin, a polyethylene naphthalate resin, or the like as a material.
The ultraviolet absorption layer 22b can be formed using, for example, a material obtained by kneading an ultraviolet absorber such as an indole compound in a base material such as an acrylic resin.

The barrier layer 22c includes a base portion 22d made of polyethylene terephthalate resin, acrylic resin, polycarbonate resin, or the like, and a covering layer 22e that covers one surface of the base portion 22d. The coating layer 22e can be formed of silicon dioxide (SiO ₂ , silica) or aluminum oxide (Al ₂ O ₃ ) by a CVD (chemical vapor deposition) method or the like. The covering layer 22e is provided on the surface of the base portion 22d, for example, on the ultraviolet absorbing layer 22b side. The thickness of the moisture-proof layer 22 is preferably 100 to 250 μm.

  If the moisture-proof layer is formed of glass, for example, it is possible to completely prevent the permeation of moisture. The present invention does not exclude the case where the moisture-proof layer is glass. However, when the moisture-proof layer is made of glass, the moisture-proof layer lacks flexibility. Therefore, in order to avoid damage to the moisture-proof layer due to deformation, it is necessary to increase the thickness of the moisture-proof layer. As a result, the weight increases.

In the present embodiment, the moisture-proof layer 22 is mainly formed of a resin, so that the moisture-proof layer 22 is flexible. On the other hand, the barrier layer 22c is provided with a silicon oxide or aluminum oxide coating layer, thereby providing a high moisture-proof layer. It is possible to achieve. For example, according to JIS K 7129: 2008, it is possible to achieve a high moisture resistance such that the water vapor transmission rate measured at a temperature of 40 ° C. and a relative humidity of 90% is 0.1 g / m ² · 24 h or less.

  According to the solar cell integrated roof material of the present invention, long-term and stable power supply can be ensured, and a low-cost roof facility that is lightweight and highly durable can be formed. Therefore, the present invention is useful for saving earth resources and preserving the living environment.

DESCRIPTION OF SYMBOLS 10 Solar cell integrated roof material 12 Base material 14 Laminated body 16 Solar cell 18 1st sheet 20 2nd sheet 22 Moisture-proof layer 24 End part waterproof part 22a Surface layer 22b Ultraviolet absorption layer 22c Rear layer 22d Base 22e Covering layer 32, 34 joints

Claims (10)

A metal plate-like substrate having a first main surface and a second main surface opposite to the first main surface ;
A first sheet containing an electrically insulating resin-containing resin disposed on the first main surface of the base material, a sheet-like solar battery cell disposed on the first sheet, and the solar battery cell A laminated body including a second sheet containing a resin having electrical insulation and translucency, and a moisture-proof layer having a translucency arranged on the second sheet. And
The first sheet and the second sheet sandwich the solar battery cell between their central parts, and the peripheral parts thereof are joined to each other to hold the solar battery cell,
Between the first sheet and the second sheet from the moisture-proof layer, the gap between the end portions of the first sheet and the second sheet, and the gap between the end portion of the first sheet and the substrate. And an end waterproof portion that prevents water from entering, and a connecting portion for connecting the base material to another member extends from the end waterproof portion toward the outer peripheral portion of the base material. Has been
The end waterproof part is
A first folded portion that is folded back so as to face the moisture-proof layer at a first fold outside the outer peripheral portion of the laminate;
A first sealing material that seals a gap between the first folded portion and the moisture-proof layer;
A solar cell integrated roof material , comprising: a second sealing material that seals a gap between an outer peripheral portion of the laminate and the first folded portion . The base material is rectangular, the connection portion is provided at each of a pair of end portions along the longitudinal direction, and the first fold is generally parallel to the pair of end portions along the longitudinal direction. The solar cell integrated roofing material according to claim 1, wherein The solar cell-integrated roofing material according to claim 2 , wherein the pair of end portions along the short direction of the base material are installed so as to face the ridge side and the eave side of the roof. 4. The connection portion according to claim 1, wherein the connection portion is formed by bending an end portion of a second folded portion obtained by folding the base material at a second fold from the first folded portion into a predetermined shape . 5. 2. The solar cell integrated roof material according to item 1 . The first sheet or the second sheet is at least one selected from the group consisting of a copolymer of ethylene and vinyl acetate, an ionomer resin, polyvinyl butyral, a styrene thermoplastic elastomer, a silicone resin, and a polyolefin resin. The solar cell integrated roofing material according to claim 1, comprising: The solar cell integrated roofing material according to claim 5, wherein at least one of the first sheet and the second sheet has a multilayer structure. The solar cell integrated roof material according to any one of claims 1 to 6 , wherein the moisture-proof layer has a multilayer structure including a surface layer, an ultraviolet absorption layer, and a barrier layer. The surface layer includes at least one selected from the group consisting of a fluororesin, an acrylic resin, a polycarbonate resin, a silicone resin, and a polyethylene naphthalate resin, and the barrier layer includes a polyethylene terephthalate resin, an acrylic resin, and a polyethylene naphthalate. A base including at least one selected from the group consisting of a phthalate resin and a polycarbonate resin;
The solar cell integrated roofing material according to claim 7 , further comprising: a coating layer that includes silicon oxide or aluminum oxide and covers the base. 9. The solar cell-integrated roof according to claim 7 , wherein the moisture-proof layer has a water vapor permeability of 0.10 g / m ² · 24 h or less measured at a temperature of 40 ° C. and a relative humidity of 90% according to JIS K7129: 2008. Wood. The solar cell is a spherical shaped silicon type or has a photoelectric conversion element of a dye-sensitized solar cell and roof member according to any one of claims 1 to 9.

Images