阅读说明：本技术 太阳能电池模块的设置方法 (Method for installing solar cell module ) 是由 藤野刚明 前田大辅 坂本浩行 今村隆大 田中聪一郎 于 2018-09-14 设计创作，主要内容包括：提供一种太阳能电池模块的设置方法,其能够容易地进行太阳能电池模块向支架的设置,即使作业者不登上屋顶也能够进行太阳能电池模块的安装作业。本发明将太阳能电池模块(16)设置于安装在屋顶(22)上的支架(20)。太阳能电池模块(16)在外周的至少一部分具备由包含树脂的材料形成的框架(14)。支架(20)具备形成有槽部(19)的多个导轨(18),并且配置形成为一对导轨(18)彼此的槽部(19)对置。该方法具备：通过将太阳能电池模块(16)的框架(14)嵌入槽部(19),从而使太阳能电池模块(16)保持于一对导轨(18)的工序；以及为了防止太阳能电池模块(16)从槽部(19)脱落而使太阳能电池模块(16)固定于一对导轨(18)的工序。(Provided is a method for installing a solar cell module, which can easily install the solar cell module on a rack and can install the solar cell module without a worker climbing on a roof. A solar cell module (16) is provided to a bracket (20) mounted on a roof (22). The solar cell module (16) is provided with a frame (14) formed of a material containing a resin at least in a part of the outer periphery thereof. The bracket (20) is provided with a plurality of guide rails (18) formed with groove sections (19), and the groove sections (19) formed as a pair of the guide rails (18) are arranged to face each other. The method comprises: a step of fitting the frame (14) of the solar cell module (16) into the groove (19) to thereby hold the solar cell module (16) on the pair of rails (18); and a step of fixing the solar cell module (16) to the pair of guide rails (18) in order to prevent the solar cell module (16) from falling off the groove (19).)

1. A method for installing a solar cell module in a rack installed on a roof, wherein,

the solar cell module is provided with a frame formed of a material containing a resin at least in a part of the outer periphery,

the holder includes a plurality of guide rails having groove portions formed therein, and the groove portions of the pair of guide rails are arranged to face each other,

the setting method comprises:

fitting the frame of the solar cell module into the groove portion, thereby holding the solar cell module on the pair of rails; and

and a step of fixing the solar cell module to the pair of guide rails in order to prevent the solar cell module from falling off the groove portion.

2. The setting method according to claim 1,

the bracket is further provided with a cross member that spans the pair of guide rails, the cross member being interposed between the pair of guide rails and the roof.

3. The setting method according to claim 1 or 2,

the method includes a step of providing a locking member for locking the solar cell module at least one end of the guide rail.

4. The setting method according to any one of claims 1 to 3,

the guide rail is also formed with a groove portion on a surface opposite to the surface on which the groove portion is formed.

Technical Field

The present invention relates to a method for installing a solar cell module.

Background

Conventionally, a solar cell module is constructed on a roof of a building such as a house or a carport. As a method of installing a solar cell module on a roof, for example, a construction method is known in which: a bracket is formed on the roof in advance, and the solar cell module is mounted and fixed on the bracket.

A solar cell module generally has a structure in which the edges thereof are surrounded by a frame (frame material) made of aluminum. The following methods have been used in many cases: such solar cell modules are fixed to angle bars assembled in a lattice shape by a jig, a bolt, or the like, and are installed on a roof. For example, patent document 1 discloses a support structure in which a bracket in which a plurality of longitudinal members and cross members are combined is assembled by using bolts or the like.

Disclosure of Invention

Technical problem to be solved

However, the conventional method of installing the solar cell module on the roof of a house, a carport, or the like using a bracket requires, for example, an operator to install the solar cell module on the roof and fix the solar cell module using a fixing member such as a bolt or a jig. In this case, if the roof cannot be secured with sufficient strength, the following danger may occur: when a worker steps on the roof while holding the solar cell module, the roof is damaged and the worker falls due to the weight of the worker and the solar cell module. Further, since the installation work is performed at a high place, there is also a limit to the skill level of the operator.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a method of installing a solar cell module, which can easily install the solar cell module on a rack, suppress a load on a roof due to a light weight, and enable an operator to perform an operation of installing the solar cell module without climbing up the roof.

(II) technical scheme

The present inventors have conducted intensive studies to achieve the above object, and as a result, have found that: the above object can be achieved by providing a solar cell module protected by a frame formed of a material containing a resin using a rail having a specific shape, and the present invention is achieved.

That is, the present invention includes, for example, the inventions described in the following embodiments.

Technical solution 1

A method for installing a solar cell module in a rack installed on a roof, wherein,

the solar cell module is provided with a frame formed of a material containing a resin at least in a part of the outer periphery,

the holder includes a plurality of guide rails having groove portions formed therein, and the groove portions of the pair of guide rails are arranged to face each other,

the setting method comprises:

fitting the frame of the solar cell module into the groove portion, thereby holding the solar cell module on the pair of rails; and

and a step of fixing the solar cell module to the pair of guide rails in order to prevent the solar cell module from falling off the groove portion.

Technical solution 2

According to the setting method described in claim 1,

the bracket is further provided with a cross member that spans the pair of guide rails, the cross member being interposed between the pair of guide rails and the roof.

Technical solution 3

According to the setting method described in claim 1 or 2,

the method includes a step of providing a locking member for locking the solar cell module at least one end of the guide rail.

Technical solution 4

The setting method according to any one of claims 1 to 3,

the guide rail is also formed with a groove portion on a surface opposite to the surface on which the groove portion is formed.

(III) advantageous effects

According to the method for installing a solar cell module of the present invention, the solar cell module can be easily installed on the bracket, the load on the roof is suppressed due to the light weight, and the installation work of the solar cell module can be performed without the worker climbing up the roof.

Drawings

Fig. 1 is a perspective view illustrating an example of an embodiment of a method of installing a solar cell module according to the present invention, (a) is a perspective view illustrating an example of a solar cell module to be installed, (b) is a perspective view illustrating a pair of guide rails installed on a roof, (c) is a perspective view illustrating a state in which the solar cell module is fitted into the pair of guide rails, and (d) is a perspective view illustrating a state in which the solar cell module is fitted into the pair of guide rails.

Fig. 2 is a perspective view showing an example of the embodiment of the holder including the locking member that can be used in the method of installing the solar cell module according to the present invention.

Fig. 3 is a perspective view showing a state in which the solar cell module is fitted in a guide rail of a bracket provided with a locking member.

Fig. 4 is a perspective view showing another example of a holder that can be used in the method of installing a solar cell module according to the present invention.

Fig. 5 is a perspective view showing another example of a holder that can be used in the method for installing a solar cell module according to the present invention.

Fig. 6 is a perspective view showing another example of a holder that can be used in the method for installing a solar cell module according to the present invention.

Fig. 7 is a perspective view showing another example of a holder that can be used in the method of installing a solar cell module according to the present invention.

Fig. 8 is a perspective view showing another example of a holder that can be used in the method for installing a solar cell module according to the present invention.

Fig. 9 is a plan view showing an example of a solar cell module provided on a holder by the method for installing a solar cell module according to the present invention, wherein (a) is a plan view seen from a light receiving surface side of the solar cell module, and (b) is a plan view seen from a direction opposite to the light receiving surface side of the solar cell module.

Fig. 10 shows a solar cell module provided by the method for providing a solar cell module according to the present invention, wherein (a) is a sectional view taken along line a-a of fig. 9 (a), and (B) is a sectional view taken along line B-B of fig. 9 (a).

Fig. 11 is a plan view showing another example of the solar cell module provided on the holder by the method for installing the solar cell module according to the present invention, wherein (a) is a plan view seen from the light receiving surface side of the solar cell module, and (b) is a plan view seen from the opposite direction of the light receiving surface side of the solar cell module.

Fig. 12 shows a solar cell module provided by the method for providing a solar cell module according to the present invention, wherein (a) is a sectional view taken along the line C-C in fig. 10 (a), and (b) is a sectional view taken along the line D-D in fig. 10 (a).

Fig. 13 is an example of a solar cell module that can be mounted by the installation method of the present invention, and shows a cross-sectional view of a solar cell element included in the solar cell module.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail.

Fig. 1 is a perspective view illustrating an example of an embodiment of a method of installing a solar cell module according to the present invention. Hereinafter, a method of installing a solar cell module will be described by taking the embodiment shown in fig. 1 as an example.

In the method of installing the solar cell module of the present embodiment (hereinafter simply referred to as "the installation method of the present embodiment"), the solar cell module 16 is installed on the rack 20 mounted on the roof 22.

As shown in fig. 1 (a), in the installation method of the present embodiment, the solar cell module 16 includes a frame 14 formed of a material containing a resin at least in a part of the outer periphery thereof. As shown in fig. 1 (b), the holder 20 includes a plurality of guide rails 18 each having a groove 19, and the grooves 19 of the pair of guide rails 18a and 18b are arranged to face each other.

The frame 14 is provided to cover the entire periphery or a part of the periphery of the solar cell element 10. As described below (see fig. 1 (c) and (d)), since at least one pair of side ends of the solar cell module 16 are fitted into the grooves 19, the frame 14 is preferably provided on at least one pair of side ends of four sides of the solar cell element 10, and the frame 14 is preferably provided on all four sides (i.e., the entire peripheral edge) of the solar cell element 10.

The type, size, and the like of the solar cell element 10 are not particularly limited, and a known solar cell element can be widely used. The solar cell element 10 is generally formed in a rectangular shape in a plan view.

As an example of the solar cell element 10, there is a structure including glass, an element sealed with a sealing material, a back sheet, and the like in this order from the light receiving surface side. In addition, a preferable mode of the solar cell element 10 used in the installation method of the present embodiment will be described below (fig. 13).

The frame 14 may be formed of a material containing a resin, and the type of the resin is not particularly limited. Examples of the resin include: one or more selected from the group consisting of natural rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene propylene rubber, chloroprene rubber, propylene rubber, chlorosulfonated polyethylene rubber, urethane rubber, silicone rubber, fluororubber, olefinic elastomer, ABS, polyethylene, polypropylene, polyvinyl chloride, polycarbonate, polystyrene, and the like. As shown by this exemplary list, the resin in the present specification is not limited to a thermoplastic resin and a thermosetting resin, and includes materials such as rubber and elastomer.

The frame 14 may be formed of only resin, or may include other materials than resin. For example, the frame 14 may be formed of a material containing resin in an amount of 50 mass% or more, preferably 80 mass% or more, and particularly preferably 90 mass% or more.

The frame 14 is not particularly limited as long as it is configured to cover the side end surfaces of the solar cell element 10. The frame 14 is preferably shaped so as to cover the side end of the solar cell element 10 by sandwiching a part of the surface of the solar cell element 10 on the light receiving surface side and a part of the surface on the opposite side of the light receiving surface.

Preferably, when the solar cell module 16 is fitted into the groove 19 of the guide rails 18a and 18b described later, only the frame 14 contacts the groove 19. More specifically, the frame 14 preferably covers a range of 5mm or more, and preferably a range of 20mm or less from the side end of the solar cell element 10. In this case, rainwater can be sufficiently prevented from penetrating into the solar cell element 10.

The thickness of the frame 14 is not particularly limited as long as it can be fitted into the groove 19.

The solar cell module 16 including the frame 14 can be manufactured by fitting the frame 14 into the side end portion of the solar cell element 10, for example. For example, the frame 14 can be fitted to the side end portions of four sides of the solar cell element 10, whereby the solar cell module 16 can be provided with the frame 14 over the entire periphery.

By providing the solar cell module 16 with the frame 14, it is possible to easily prevent the glass of the solar cell element from being broken by, for example, collision impact when the solar cell module 16 is transported. By providing the frame 14 to the solar cell module 16, the strength of the solar cell module can be increased, and the weight of the solar cell module 16 can be reduced as compared with a case where an aluminum frame is conventionally used. Thereby making the installation work of the solar cell module 16 easy.

As shown in fig. 1 (b), the holder 20 is configured to include at least a plurality of guide rails 18. In fig. 1 (b), a bracket 20 for mounting the solar cell module 16 is formed by a pair of rails 18a and 18b composed of two rails 18.

The guide rail 18 is formed with a groove portion 19. The groove 19 is formed so that the frame 14 of the solar cell module 16 can be inserted. The groove 19 is formed along the entire length of the guide rail 18.

The shape of the groove 19 is not particularly limited as long as the solar cell module 16, particularly the frame 14, can be inserted thereinto.

The bracket 20 may be formed by arranging the plurality of guide rails 18 in parallel at a predetermined interval from each other. At least an adjacent pair of the plurality of guide rails 18 are arranged such that the groove portions 19 face each other.

In fig. 1 (b), the bracket 20 includes a pair of guide rails 18a and 18b and is disposed so that the groove portions 19 formed in the pair of guide rails 18a and 18b face each other.

In fig. 1 (b), the guide rail 18 is formed as an elongated member having a substantially U-shaped cross section by bending a flat plate, for example. More specifically, the guide rail 18 shown in fig. 1 (b) is formed in an elongated square column shape and is formed to have an opening on one of four surfaces in the longitudinal direction. The opening corresponds to the groove 19. The guide rail 18 is not limited to the shape shown in fig. 1 (b), and may have another shape as described below.

The material for forming the guide rail 18 is not particularly limited. The material forming the guide rail 18 may be, for example, the same material as that of a conventional rack for arranging solar cell modules. Specifically, the guide rail 18 may be formed of one or two or more materials selected from the group consisting of aluminum and iron. It is preferable that the guide rail 18 is formed of an aluminum material in terms of excellent strength and easy prevention of corrosion by rainwater or the like. When the rail 18 is made of aluminum, the thickness of the aluminum material constituting the rail 18 is preferably 30mm or more and 100mm or less. In this case, it is easy to prevent the deformation of the guide rail 18 or the like due to the solar cell module 16, and to support the solar cell module 16.

The bracket 20 may be formed by mounting a plurality of rails 18 on a roof 22. There is no particular limitation on the method of attaching the bracket 20 to the roof 22, i.e., the method of attaching the plurality of guide rails 18 to the roof 22. For example, the guide rail 18 may be attached to the roof 22 by a known fixing method using a fixing member such as a bolt or a jig.

The bracket 20 may be directly attached to the roof 22, or another bracket may be provided on the roof 22 in advance and the bracket 20 may be provided on the other bracket. The other support may be the same as the existing structure for arranging the solar cell module. For example, other holders may have an inclined surface to make it easy to receive sunlight.

The installation method of the present embodiment includes at least step A, B described below.

Step A: and a step of fitting the frame 14 of the solar cell module 16 into the groove 19, thereby holding the solar cell module 16 on the pair of rails 18(18a, 18 b).

And a step B: and a step of fixing the solar cell module 16 to the pair of guide rails 18a and 18b in order to prevent the solar cell module 16 from falling off the groove 19.

In step a, the solar cell module 16 is fitted into the groove 19 of each of the pair of rails 18a and 18 b. Thereby, the solar cell module 16 can be held by the pair of rails 18a, 18 b.

The method of fitting the solar cell module 16 into the groove portions 19 of the pair of guide rails 18a and 18b is not particularly limited.

As shown in fig. 1 (c), for example, the solar cell module 16 is inserted so as to slide (slide-fit) along the groove 19 from one end portion to the other end portion of the pair of guide rails 18a and 18 b.

As a result, as shown in fig. 1 (d), both side ends of the solar cell module 16 are respectively sandwiched by the groove portions 19 of the pair of guide rails 18a and 18b, and the solar cell module 16 can be held by the guide rails 18. In this case, it is preferable that only the frame 14 in the solar cell module 16 is sandwiched by the groove portions 19 as described above.

As another method of holding the solar cell module 16 on the pair of guide rails 18a, 18b, for example, one end of the solar cell module 16 may be held between the groove portions 19 of one of the pair of guide rails 18a, 18b, and the other end of the solar cell module 16 may be held between the groove portions 19 of the other.

From the viewpoint of facilitating improvement in the workability of the operator, it is preferable to adopt a method of inserting the solar cell module 16 so as to slide along the groove 19 from one end portion to the other end portion of the pair of guide rails 18a and 18b as shown in fig. 1 (c). In this case, for example, even if the worker does not get on the roof but is at a position lower than the roof, for example, under the roof or on the side surface of the roof, the solar cell module 16 can be inserted into the groove 19. Therefore, the danger during the work can be reduced, and the load on the roof can be reduced because the roof does not need to be lifted.

The step a may include a step of preparing the solar cell module 16 having the frame 14. That is, the step a may include a step of mounting the frame 14 to the solar cell element 10. Alternatively, a step of preparing the solar cell module 16 having the frame 14 may be provided before the step a, and the solar cell module 16 obtained in this step may be used in the step a.

The step a may include a step of attaching the bracket 20 to the roof 22 or a step of attaching the bracket 20 to another bracket provided in advance on the roof 22 (hereinafter, simply referred to as "bracket installation step"). That is, the step a may include a rack setting step. Alternatively, a rack setting step may be provided before step a, and the rack 20 formed in this rack setting step may be used in step a.

The process of preparing the solar cell module 16 having the frame 14 is preferably performed before the process a. The rack setting step is preferably performed after the step of preparing the solar cell module 16 having the frame 14. In this case, a bracket 20 sized to fit the dimensions of the solar module 16 can be provided on the roof 22.

In step B, the solar cell module 16 is fixed to the pair of rails 18a and 18B. For example, in a state where the solar cell module 16 is inserted into the guide rail 18, at least one of the end portions of the solar cell module 16 perpendicular to the guide rail 18 is engaged, whereby the solar cell module 16 can be fixed to the pair of guide rails 18a and 18 b. In the step B, the solar cell module 16 can be fixed to the holder 20, and the solar cell module 16 can be prevented from slipping off the groove 19.

In the step B, a method of fixing the solar cell module 16 to the holder 20 is not particularly limited. For example, a method of fixing the solar cell module 16 to the holder 20 by a locking member (for example, a locking member 30 described later) is given.

Fig. 2 is a perspective view of the bracket 20 including the locking member 30, and is a perspective view in which the locking member 30 for locking the solar cell module 16 is provided at the end (short side) of the guide rail 18. In this embodiment, the locking member 30 is provided across one end of each of the pair of guide rails 18a and 18 b. The locking member 30 may be provided so as to be sandwiched between the end portions of the pair of guide rails 18a, 18 b.

The shape of the locking member 30 is not particularly limited. For example, the same member as the guide rail 18 can be used as the locking member 30. When the same member as the guide rail 18 is used as the locking member 30, the groove 19 is also formed in the locking member 30, and therefore, as shown in fig. 2, the locking member 30 can be disposed so that the groove 19 faces between the pair of guide rails 18a and 18 b. When the solar cell module 16 is inserted between the pair of rails 18a and 18b by using the bracket 20 formed in this manner, the end of the solar cell module 16 on the insertion side can be fitted into the groove 19 of the locking member 30. In this case, the frame 14 is preferably provided also at the end of the solar cell module 16 on the insertion side.

When the locking member 30 is provided, the solar cell module 16 can be prevented from coming off the pair of guide rails 18a and 18b, and the solar cell module 16 can be prevented from slipping off the groove 19. In addition, even when the solar cell module 16 is fixed by the locking member 30, the strength of the solar cell module 16 in the lateral direction can be increased.

From the above viewpoint, the installation method of the present embodiment preferably includes a step of installing the locking member 30 for locking the solar cell module 16 at least one end portion (at least one end portion on the short side) of the guide rail 18. This step may be performed in either of the steps a and B, or may be performed between the steps a and B.

The locking member 30 may be a member other than the guide rail 18, and for example, a flat plate-shaped or curved metal plate may be used. The locking member 30 does not necessarily have to extend between the guide rails 18, and the shape thereof is not particularly limited as long as it is configured to prevent the solar cell module 16 from coming out of the guide rails 18.

The method of attaching the locking member 30 to the guide rail 18 is not particularly limited. For example, the locking part 30 may be attached to the rail 18 by a fastener such as a bolt or a coupling member. Alternatively, the locking member 30 may be attached to the roof 20.

As shown in fig. 3, the locking member 30 may be provided on the insertion side of the solar cell module 16 of the pair of guide rails 18a and 18 b. In other words, the locking members 30 may be provided at both side end portions of the solar cell module 16 perpendicular to the guide rail 18. This prevents the solar cell module 16 from coming off the guide rail 18 and slipping off. From this viewpoint, it is preferable to provide the locking members 30 on both the insertion side and the distal end side of the pair of guide rails 18a and 18b into which the solar cell module 16 is inserted. The locking member 30 provided on the insertion side of the solar cell module 16 may be the same as the rail 18. The groove 19 of the locking member 30 may be provided to face the insertion direction of the solar cell module 16. In this case, the frame 14 is preferably provided on all four sides (i.e., the entire periphery) of the solar cell module 16.

The method of providing the locking member 30 on the insertion side of the solar cell module 16 is not particularly limited, and for example, the locking member 30 may be fixed to the insertion side of the solar cell module 16 after the solar cell module 16 is held on the pair of rails 18a and 18b in the step a. The fixing method of the locking part 30 is not particularly limited, and for example, the locking part may be attached to the rail 18 or the roof 20 by a fixing member such as a bolt or a coupling member. The locking member 30 may be provided so as to be sandwiched between the end portions of the pair of guide rails 18a and 18 b.

As described above, according to the installation method of the present embodiment, the solar cell module can be easily installed on the rack, the load on the roof is suppressed due to the light weight, and the installation work of the solar cell module can be performed without the worker climbing up the roof.

Fig. 4 shows another example of the guide rail 18 that can be used in the installation method of the present embodiment, in this embodiment, the guide rail 18 is formed to be elongated and L-shaped in cross section, and the groove portion 19 is formed in the guide rail 18 so as to be surrounded by both sides of the guide rail 18.

Fig. 5 shows another example of the guide rail 18 that can be used in the installation method of the present embodiment. In this embodiment, the guide rail 18 is provided with a roller portion 24. The roller portion 24 enables the solar cell module 16 to slide more easily in the groove portion 19.

As shown in fig. 5, the roller portion 24 may be provided on the bottom surface of the groove portion 19. The roller portion 24 may be provided on the side surface of the groove portion 19. The roller portion 24 may be provided in plurality at intervals, for example, on the guide rail 18. The method of attaching the roller portion 24 to the groove portion 19 is not particularly limited. The material for forming the roller portion 24 is also not particularly limited.

Fig. 6 shows another example of the guide rail 18 that can be used in the installation method of the present embodiment. In this embodiment, the guide rail 18 includes a water passage 26. The water passage 26 can discharge rainwater and the like that have entered the guide rail to the outside of the guide rail. The water passage 26 may be a through hole or a notch, and the shape thereof is not particularly limited. The water passage portion 26 may be provided in plurality at intervals, for example, in the guide rail 18. The method for forming water passage 26 in groove 19 is not particularly limited. The guide rail 18 may have both the water passage portion 26 and the roller portion 24.

In the present invention, the guide rail 18 is preferably configured in an elongated square column shape as shown in fig. 1 (b), and is formed to have an opening on one of four surfaces in the longitudinal direction. When the guide rail 18 is used, it is easy to suppress floating of the solar cell module 16 due to strong wind or the like.

The guide rail 18 described above includes one groove portion 19, but a plurality of groove portions 19 may be provided in the guide rail 18.

Fig. 7 shows another example of the guide rail 18 that can be used in the installation method of the present embodiment. In this embodiment, the guide rail 18 is provided with a plurality of groove portions 19. Specifically, the guide rail 18 of this embodiment is formed in an elongated square column shape, and has a groove 19 formed on the entire surface. When this guide rail 18 is used, the pair of guide rails 18a and 18b can be arranged such that the groove portions 19 face each other regardless of which surface of the guide rail 18 faces the other guide rail 18.

Even if three or more guide rails 18 are arranged in parallel in the embodiment of fig. 7, the pair of guide rails 18 can be arranged such that all the groove portions 19 face each other, and thus the plurality of solar cell modules 16 can be provided on the rack 20.

Therefore, as in the embodiment of fig. 7, the groove 19 is preferably formed also in the guide rail 18 on the surface opposite to the surface on which the groove 19 is formed. Even if three or more guide rails 18 are arranged in parallel, the groove portions 19 of the pair of guide rails 18 can be arranged to face each other, and the plurality of solar cell modules 16 can be mounted on the rack 20. As described below (see fig. 9 and 10), the guide rail 18 preferably has two grooves 19 on the same surface in order to provide a back sheet of the solar cell module 16.

Fig. 8 is a perspective view showing another embodiment of a holder that can be used in the method for installing a solar cell module according to the present invention. The bracket 20 of this embodiment further includes a cross member 28 that spans the pair of guide rails 18a, 18b, and the cross member 28 is interposed between the pair of guide rails 18a, 18b and the roof 22. For example, the cross member 28 is configured to be orthogonal to the rail 18.

The cross member 28 may be provided on both short sides of the pair of guide rails 18a, 18b as in the manner of fig. 8.

The material forming the cross member 28 is not particularly limited. For example, a square member made of metal such as aluminum material can be suitably used as the cross member 28.

The method of attaching the cross member 28 to the roof 22 side surface of the guide rail 18 is not particularly limited, and a known method, for example, attachment using a fastener such as a bolt, may be employed.

The method of attaching the cross member 28 to the roof 22 or another previously provided bracket is also not particularly limited. For example, fasteners such as bolts may be used to mount the cross member 28 to the roof 22 or other brackets provided previously. The cross member 28 may be installed on the roof 22 after being attached to the guide rail 18, or the bracket 20 may be formed after only the cross member 28 is previously attached to the roof 22. As an example of a method of attaching the cross member 28 to the guide rail 18, a pair of guide rails 18a and 18b may be arranged in parallel with each other, and the cross member 28 may be attached and fixed to the surface of the guide rail 18 on the roof 22 side so as to be orthogonal to the guide rail 18.

The cross member 28 may be installed in step a or may be installed in advance on the roof 22 before step a.

In the installation method of the present invention, when the bracket 20 includes the cross member 28, there is an advantage that a back sheet for shielding the junction box, the wiring, and the like included in the solar cell module 16 can be installed as described below. The following describes in detail a method of installing a solar cell module that can also shield a junction box, wiring, and the like.

Fig. 9 and 10 show an installation example of a solar cell module installed on a rack by the installation method of a solar cell module according to the present invention. Fig. 9 (a) is a plan view when viewed from the light-receiving surface side of the solar cell module 16, and fig. 9 (b) is a plan view when viewed from the surface opposite to fig. 9 (a), that is, the back surface side of the solar cell module 16. Fig. 10 (a) is a sectional view taken along line a-a of fig. 9 (a), and fig. 10 (B) is a sectional view taken along line B-B of fig. 9 (a).

As shown in fig. 9 (a) and (b), the solar cell module installation structure of this embodiment is formed such that the rack 20 includes the rails 18a and 18b and the cross member 28, which form a pair with each other. The cross member 28 is attached to the roof 22 (not shown), and is provided at both end portions on the short sides of the pair of guide rails 18a, 18b so as to straddle the pair of guide rails 18a, 18 b. The solar cell module 16 is fitted into and held by the groove portions 19 of the pair of guide rails 18a, 18b, and locking members 30 are attached to both ends of the pair of guide rails 18a, 18 b. Thereby, the solar cell module 16 is fixed to the bracket 20.

As shown in fig. 10 (a), the pair of guide rails 18a and 18b each have two groove portions 19 formed on the same surface. The two groove portions 19 are formed in parallel along the longitudinal direction of the guide rail 18, and the two groove portions 19 are formed at intervals. The solar cell module 16 is fitted into the groove 19 on the light receiving surface side, and the back sheet 46 is fitted into the groove 19 on the back surface side. In the embodiment of fig. 10, the guide rail 18 has two groove portions 19 formed on all four sides of the square columnar guide rail 18. The locking member 30 in the embodiment of fig. 9 and 10 may be the same as the guide rail 18, and the solar cell module 16 may be fitted into the groove 19 on the light receiving surface side of the locking member 30, and the back plate 46 may be fitted into the groove 19 on the back surface side of the locking member 30.

The back sheet 46 is a plate material for shielding the junction box 50, wiring (not shown), and the like provided in the solar cell module 16. By providing the back sheet 46, the junction box 50 and the wiring can be prevented from being seen when the solar cell module 16 is seen from the bottom of the roof, resulting in improved appearance. Especially, in the case where the roof has high transparency for a carport or the like, it is effective to provide the back plate 46. Further, even if the junction box 50 is separated from the solar cell module 16, it can be received by the back sheet 46, thereby also improving safety.

From the above viewpoint, the installation method of the present invention preferably further includes a step of attaching the back sheet 46 to the back surface side of the solar cell module 16. As described above, the back plate 46 is fitted into the groove 19 of the guide rail 18.

The size, material, and the like of the back plate 46 are not particularly limited. For example, the back sheet 46 may be formed to be the same size as the solar cell module 16. The back plate 46 may be formed of a metal plate such as an aluminum material, a resin plate, or the like.

The installation structure of the embodiment of fig. 9 and 10 can be formed by the same method as described above, that is, by a method including at least the step a and the step B. The back sheet 46 may be inserted between the pair of guide rails 18a, 18b in the same step as when the solar cell module 16 is inserted between the pair of guide rails 18a, 18 b. The order of inserting the solar cell module 16 and the back sheet 46 is not particularly limited. The embedding of the backing plate 46 may be performed prior to process a or during process a.

Fig. 11 and 12 show another installation example of the solar cell module installed on the rack by the installation method of the solar cell module according to the present invention. Fig. 11 (a) is a plan view when viewed from the light-receiving surface side of the solar cell module 16, and fig. 11 (b) is a plan view when viewed from the surface opposite to fig. 11 (a), that is, the back surface side of the solar cell module 16. Fig. 12 (a) is a sectional view taken along the line C-C of fig. 11 (a), and fig. 12 (b) is a sectional view taken along the line D-D of fig. 11 (a).

As shown in fig. 11 (a) and (b), the solar cell module installation structure of this embodiment is formed such that the rack 20 includes the rails 18a and 18b and the cross member 28, which form a pair with each other. The cross member 28 is mounted to the roof 22 (not shown) and is disposed across the pair of rails 18a, 18 b. The solar cell module 16 is fitted into and held by the groove portions 19 of the pair of guide rails 18a, 18b, and the solar cell module 16 is fixed to the bracket 20 by attaching the locking members 30 to the both ends of the solar cell module 16 of the pair of guide rails 18a, 18b, respectively.

As shown in fig. 12 (a), the pair of guide rails 18a and 18b each have a single groove 19 formed in the same surface. The pair of rails 18a, 18b are both rails in the same manner as shown in fig. 7.

The locking member 30 in the embodiment of fig. 11 and 12 has the same shape as the guide rail 18 and is formed to have a smaller size than the guide rail 18. The locking member 30 is also formed with a groove 19, and the solar cell module 16 is fitted into the groove 19.

In the embodiment of fig. 11 and 12, the locking member 30 is also provided on the back side of the pair of guide rails 18a and 18b (fig. 12 (a)). A back plate 46 is fitted into the groove 19 of the locking member 30 disposed on the back side of the pair of guide rails 18a, 18 b. The back plate 46 may be the same as the back plate 46 of the embodiment of fig. 9 and 10.

In the embodiment of fig. 11 and 12, a groove 19 is formed in the cross member 28, and a back plate 46 is fitted into the groove 19 (see fig. 11 (b) and 12 (b)). Similarly to the locking member 30, the cross member 28 has the same shape as the rail 18 on the back surface side of the pair of rails 18a and 18b, and is formed to have a smaller size than the rail 18.

That is, in the embodiment of fig. 11 and 12, the back plate 46 is fixed by the groove portion 19 of the cross member 28 and the locking member 30 on the back side of the pair of guide rails 18a and 18 b.

In the embodiments of fig. 11 and 12, the junction box 50 and the wiring can be prevented from being seen from the inner side of the roof when the solar cell module 16 is viewed from below, resulting in improved appearance. In addition, even if the junction box 50 is separated from the solar cell module 16, it can be received by the back sheet 46, thereby also improving safety.

The installation structure of the embodiment of fig. 11 and 12 can be formed by the same method as described above, that is, by a method including at least the step a and the step B. The back sheet 46 may be inserted between the pair of guide rails 18a, 18b in the same step as when the solar cell module 16 is inserted between the pair of guide rails 18a, 18 b. The order of inserting the solar cell module 16 and the back sheet 46 is not particularly limited. The embedding of the backing plate 46 may be performed prior to process a or during process a.

Fig. 13 is a schematic cross-sectional view of an example of the layer structure of the solar cell element 100 included in the solar cell module.

The solar cell element 100 of fig. 13 includes, in order from the light receiving surface side: a surface glass layer 1, a first sealing layer 2, an element 3, a second sealing layer 4, and a back surface protection layer 5. The back surface protection layer 5 includes, in order from the side in contact with the sealing layers (2, 4): a first thermoplastic resin layer 51 and a second thermoplastic resin layer 52.

The surface glass layer 1 can be made of, for example, a known glass used in conventional solar cell elements, the thickness of the surface glass layer 1 can be 0.8mm or more and 1.6mm or less, and the bending stiffness of the surface glass layer, defined by (the third power of the bending elastic modulus × thickness) ÷ 12, can be 3000MPa or more and 25000MPa or less.

The first sealing layer 2 and the second sealing layer 4 are layers for sandwiching the front surface and the back surface of the element, and known sealing materials such as a copolymer of ethylene and vinyl acetate, polyolefin, and the like can be used as the sealing layers, and the first sealing layer 2 and the second sealing layer 4 are not necessarily clearly distinguished, and the first sealing layer 2 and the second sealing layer 4 can be regarded as one sealing layer, and the flexural rigidity defined by (the third power of the flexural elastic modulus × thickness) ÷ 12 of the first sealing layer 2 and the second sealing layer 4 is preferably 1MPa or more and 10MPa or less.

The type of the element 3 is not particularly limited, and may be the same as a known solar cell element.

The back surface protective layer 5 is formed of a first thermoplastic resin layer 51 and a second thermoplastic resin layer 52. The first thermoplastic resin layer 51 may have a flexural modulus of elasticity of 200MPa to 1000MPa and be foamed. The second thermoplastic resin layer may be a layer having a flexural modulus of elasticity of 10000MPa or more and 25000MPa or less and containing glass fibers. By providing the rear surface protective layer 5 having this structure on the rear surface of the solar cell, the rigidity of the solar cell module can be improved.

The back surface protective layer may further include other layers between the layers and the outermost layer in addition to the first thermoplastic resin layer 51 and the second thermoplastic resin layer 52.

The first thermoplastic resin layer 51 may be a foam composed of one or more resins selected from the group consisting of polyethylene, polypropylene, polystyrene, polyurethane, polyethylene terephthalate, polyvinyl chloride, and polymethyl methacrylate, for example. In particular, polypropylene is preferable in view of strength, heat distortion resistance, weather resistance, and the like.

The thickness of the first thermoplastic resin layer 51 is preferably 2mm or more and 6mm or less, and more preferably 3 to 5mm or less. In this case, the rigidity of the solar cell module is improved and warping is less likely to occur. The density of the first thermoplastic resin layer 51 is preferably 100kg/m³Above and 700kg/m³The following. In this case, the solar cell module is less likely to be warped, and the foam is less likely to be broken.

The bending stiffness of the first thermoplastic resin layer 51 defined by (the third power of the bending elastic modulus × thickness) ÷ 12 is preferably 100MPa or more and 20000MPa or less.

Examples of the second thermoplastic resin layer 52 include: and a resin in which glass fibers are further contained in one or more resins selected from the group consisting of polyethylene, polypropylene, polyamide, polyurethane, polycarbonate, polymethyl methacrylate, polyethylene terephthalate, polybutylene terephthalate, an AS resin, an ABS resin, polyoxymethylene, polyphenylene sulfide, polyether sulfone, PEEK, and a fluororesin. For example, a known material can be used for the glass fiber, and specifically, plain woven glass fiber cloth can be used.

In the second thermoplastic resin layer 52, the content ratio of the glass fiber to the resin is arbitrary. For example, the thermoplastic resin is preferably 30 parts by mass or more and 70 parts by mass or less with respect to 100 parts by mass of glass fibers having an average thickness of 1 to 10 μm and an average length of 1 to 20 mm.

The second thermoplastic resin layer 52 has a thickness of, for example, preferably 0.5mm or more and 2.0mm or less, and more preferably 0.5mm to 1.0 mm. In this case, the rigidity of the solar cell module is easily improved and the floating is less likely to occur.

The bending stiffness defined by (the third power of the bending elastic modulus × thickness) ÷ 12 of the second thermoplastic resin layer 52 is preferably 100MPa or more and 20000MPa or less.

In addition, the solar cell element may be provided with an adhesive layer, a weather-resistant layer, a colored layer, and the like. For example, an adhesive layer may be provided between the sealant layer and the first thermoplastic resin layer 51, between the first thermoplastic resin layer 51 and the second thermoplastic resin layer 52, or on at least one of the surfaces of the second thermoplastic resin layer 52 opposite to the surface on which the first thermoplastic resin layer 51 is laminated. The weathering layer may be disposed on the opposite side of the second thermoplastic resin layer 52 from the first thermoplastic resin layer 51. The colored layer may be provided on the surface of the first thermoplastic resin layer 51 on the side bonded to the sealing layer. The adhesive layer, the weather-resistant layer and the colored layer may be formed of any known materials.

The sum of the bending rigidity defined by the pass (the third power of the bending elastic modulus × thickness) ÷ 12 of the front glass layer 1, the first sealing layer 2, the second sealing layer 4, and the back surface protective layer 5 of the solar cell element is preferably 4000MPa or more.

The solar cell module including the solar cell element 100 shown in fig. 13 is light in weight and is less likely to be broken. Therefore, by applying such a solar cell module to the installation method of the present invention, the workability can be further improved, and the installation of the solar cell module can be easily and safely performed. In particular, since the solar cell module is less likely to be broken, even a solar cell module having a larger size than the conventional one is less likely to be broken at the time of installation and has excellent durability even after installation.

Description of the reference numerals

14-a frame; 16-a solar cell module; 18-a guide rail; 19-a trough portion; 20-a scaffold; 22-roof top; 28-a cross member; 30-a locking member.