JP3258942B2 - Exterior material with solar energy converter and exterior structure with solar energy converter - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roofing exterior material integrally provided with a solar energy conversion device such as a solar cell, which is capable of minimizing the amount of water entering a connection portion in the direction of a building eaves, and having been used over time. The present invention also relates to an exterior material with a solar energy conversion device and an exterior structure with a solar energy conversion device, which can exhibit the power generation performance of the solar cell element without deteriorating and maintain its integrity.

[0002]

2. Description of the Related Art In recent years, many proposals have been made in which a solar energy conversion device is integrated with a roofing material. Recently, a solar cell module having a bent portion capable of being bent has been proposed (Japanese Patent Laid-Open No. 7-1995). 297440). The solar cell module described in JP-A-7-297440 discloses a weather-resistant film in order from the surface,
A filler and a back reinforcing plate (roof material) are integrally laminated, and a solar cell element (flexible solar cell) is buried in the layer of the filler. The solar cell had to be integrated with the face plate of the roofing material by bonding or other means.On the other hand, it was possible to perform roll forming after integrating it in a flat plate in advance, so that the productivity of the roofing material was improved. Be expected.

[0003]

However, the solar cell integrated exterior material uses various synthetic resin materials as the filler and various metal materials as the back reinforcing plate (roof material). Since the structure is laminated integrally with adhesive or heat lamination, it is not possible to completely prevent separation at the boundary between the filler and the back reinforcing plate, particularly at the end due to aging thermal expansion and contraction. . When moisture such as rainwater infiltrates into the end peeling portion, the above-mentioned peeling is promoted, a water retention area is formed, the solar cell element is adversely affected, and the power generation performance is deteriorated. Or corrode. Also, the peeling space serves as a flow path for moisture,
If the peeling is further promoted, the filler may separate from the back reinforcing plate, and the solar cell may be scattered around.

[0004] By the way, the conventional roofing exterior material including the solar cell integrated exterior material is connected by mutually engaging a connection receiving portion and a connection portion formed at a ridge end and an eave end. It is important to finish the rain at the connection. Usually, a water return, a capillary phenomenon prevention space, a decompression space, and the like are created in these connection receiving portions and the connecting portions to prevent rainwater from entering the indoor side (water leakage). ) And the shape of the connecting portion are complicated, resulting in problems such as an increase in the number of stages of the roll forming machine and an increase in the development width relative to the effective width. In particular, increasing the number of stages of the roll forming machine is not preferable in the case of a solar cell-integrated exterior material because the solar cell element increases the quality of deformation such as frictional heat accompanying roll pressing and molding.

[0005]

SUMMARY OF THE INVENTION The present invention has been proposed in view of the above circumstances, and has a solar panel and other solar energy converters integrally provided on a face plate, and a resin layer and a back surface in which the solar energy converter is embedded. An exterior material formed by laminating a support plate, wherein the resin layer at the eaves edge of the face plate portion,
The present invention relates to a packaging material with a solar energy conversion device, wherein a water-stopping elastic piece whose lower end is in contact with a resin layer of a packaging material on the lower side is integrally formed.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Although an exterior material 1 shown in FIG. 1 is a horizontal exterior material, it is not a so-called general exterior material, but a solar energy conversion device such as a solar cell (12, FIG. (Not shown), which is integrally provided with a solar energy conversion device, and has a material configuration different from that of a general horizontal roofing exterior material. That is, if the exterior material 1 of FIG. 1 is roughly outlined including its material configuration, a resin layer 15 in which a solar energy conversion device (12) is embedded and a back support plate 16 are laminated, and the resin at the eave end of the face plate portion 11 is formed. The layer 15 has a structure in which a water-stopping elastic piece 17 whose lower end is in contact with the resin layer 15 of the lower packaging material 1 is integrally formed.

The water-stopping elastic piece 17 integrally formed on the eave end of the exterior material 1 is a whisker-like piece made of a resin or the like having excellent elasticity. During the extruding or roll forming step, an integrated means such as heat fusion is provided to integrate with the exterior material. However, the present invention is not limited to this. The shape of the water-stopping elastic piece 17 is not particularly limited, and a plurality of rows may be provided. Further, the ridge end and the eave end of the face plate portion 11 are provided with a connection receiving portion 14 and a connection portion 13 which are engaged or overlapped with each other.

The exterior material 1 (with the solar energy conversion device) is composed of at least a solar energy conversion device 12 such as a solar cell, a resin layer 15 in which the solar energy conversion device 12 is embedded, a back support plate 16, It has a water-stopping elastic piece 17. As for the shape and configuration, the resin layer 15 and the back support plate 16 are integrally laminated with an adhesive or a heat laminator, etc., and have the configuration as the already-described horizontal roofing exterior material. Specifically, the substantially flat face plate portion 1
Connection receiving parts 1 that engage or overlap with each other at the ridge end and eave end
3, a resin layer 15 at the eaves end of the face plate portion 11 is provided with a water-stopping elastic piece 17 whose lower end abuts against the resin layer 15 of the lower exterior material 1. The specific configuration (material, shape) or the configuration other than the above is not particularly limited, and may be designed and implemented in any manner.

The structure of the solar energy converter 12 is not particularly limited, and any structure can be applied. In general, a solar cell is composed of a conductive substrate, a back reflection layer, a semiconductor layer as a photoelectric conversion member, and a transparent conductive layer. Examples of the conductive substrate include steel plates, copper, titanium, aluminum, stainless steel, and carbon sheets. In addition, a resin film such as polyester, polyimide, polyethylene naphthalide, or epoxy provided with a conductive layer, a ceramic, or the like can also be used. The semiconductor layer is not particularly limited, and a compound semiconductor such as an amorphous silicon semiconductor, a polycrystalline silicon semiconductor, a crystalline silicon semiconductor, and copper indium selenide can be used.
Also, the method of embedding in the resin layer is not particularly limited. For example, a recently proposed amorphous silicon solar cell having flexibility is preferable because it is extremely thin and lightweight. The resin layer 15 can be made of ethylene-vinyl acetate copolymer (EVA), polyvinyl butyrol, silicone resin, or the like, but is not limited thereto. The water-stopping elastic piece 17 integrally formed on the eaves end of the exterior material 1 is as described above, but in this exterior material with a solar energy conversion device, the resin layer 15 (more specifically, is laminated on the surface). Weather-resistant film). Specifically, it may be previously integrated with the weather-resistant film by means such as extrusion or heat fusion, or the water-stopping elastic piece 17 may be bonded after being molded as the exterior material 1. Further, the back support plate 16 may be, for example, a rust-preventive steel plate such as a galvanized steel plate or a galvalume steel plate, a special steel and a non-ferrous metal,
A stainless steel plate, a weather-resistant steel plate, a copper plate, an aluminum alloy plate, a lead plate, a zinc plate, a titanium plate, or the like can be used as a material, but is not particularly limited thereto. Further, the existing exterior material may be diverted (reused).

The manner in which these materials are integrated is not particularly limited. For example, the back support plate 1
The surface except for the ridge end and the eaves end of No. 6 is covered with a resin layer 15 in which the solar energy conversion device 12 is embedded, and if necessary, the surface is protected with a transparent weather-resistant film. The connection part 13 and the connection receiving part 14 may be formed. The resin layer 15 in which the solar energy conversion device 12 is embedded and the weather-resistant film may be integrally laminated in advance to form a sheet, and this may be bonded to the back support plate 16 with an adhesive, heat lamination, or the like. . Alternatively, the resin layer 15 may be laminated after the back support plate 16 has been subjected to molding. In addition, as the weather-resistant film, a film that does not break even when walking on the surface is used as a surface protection material.

The exterior material 1 in the embodiment shown in FIG.
2 is an exterior material with a solar energy conversion device made of the composite material shown in FIG. 2, and the solar energy conversion device 12 (1 in FIG.
Reference numeral 21 denotes a configuration in which an electrode is embedded and a weather-resistant film (not shown) is laminated on the surface. Then, the composite material was roll-formed to form the connection receiving portions 14 and the connection portions 13 at the ridge end and the eave end of the face plate portion 11. The connecting portion 13 provided at the eave edge of the face plate portion 11 bends the eave edge of the face plate portion 11 downward,
Subsequently, the structure is bent at a right angle to the ridge side.
The edge of the connecting portion 13 (eave held portion 154) is the eave holding portion 1 extending from the edge of the connecting portion 13 of the back support plate 16.
At 62, it is held and held in an envelope shape. In addition, the resin layer 15 in a horizontal portion below the connection portion 13 includes:
An arc-shaped water-stopping elastic piece 17 having a beard shape, that is, a configuration narrowing toward the tip, is provided.
It is formed to have a length in contact with the resin layer 15 (face plate portion 11) of the lower exterior material 1. The connection receiving portion 14 provided at the ridge end of the face plate portion 11 has a water return portion formed by bending an edge extending from the face plate portion 11 to the ridge side in the same plane toward the eave side slightly obliquely upward,
It has a configuration in which an upper end thereof is folded back toward the eaves, and an engagement portion which is bent obliquely downwardly on the eaves and whose end is folded back. The connection portion 13 and the connection receiving portion 14 are engaged with each other, and have a structure in which rainwater or the like does not easily enter the back surface from the connection portion.

[0012] The exterior material 1 of the present invention having the above-described structure includes a face plate portion 1.
1 is connected to the connecting portion 13 at the eaves end,
Since the water-stopping elastic piece 17 whose lower end abuts on 1 is integrally formed, it is possible to prevent rainwater from being sucked into the connecting portion between the exterior materials 1 and 1 and from being blown during strong wind and rain.
Therefore, since the amount of water that enters the connection portion between the exterior materials 1 and 1 can be extremely reduced, the resin layer 15 and the back support plate 16 are less likely to be separated at the edge. And as a result,
The power generation performance of the solar cell element is maintained without deterioration over time. Further, the development width with respect to the effective width of the back reinforcing plate 16 can be reduced, and the number of roll forming machines can be reduced. Furthermore, it is possible to reduce the deterioration factor of the solar cell element, and as a result, it is possible to provide a more stable exterior material with a solar energy conversion device than before. In addition, the elongation rate of the filler due to bending is suppressed, so that peeling is less likely to occur, cracking of the filler is less likely to occur, and productivity is improved.

In addition, since the exterior material 1 of the present invention has no groove-shaped recessed portion (resistance) in the outer shape from the ridge side to the eaves side, rainwater flows smoothly, and leaves and branches of trees are deposited. This makes it difficult to maintain the appearance of the solar energy conversion device, and it is difficult to cause contamination that reduces the efficiency of the solar energy conversion device.

In the illustrated embodiment, the exterior material 1 comprises a resin layer 1
Since the eaves edge holding portion 154 of No. 5 is physically held by the eaves edge holding portion 162 of the back support plate 16, peeling of the resin layer 15 from the eaves edge with respect to the back support plate 16 is prevented even in use over time. Thus, unlike the conventional case, the resin layer 15 does not separate from the back support plate 16. Also, the eave edge holding unit 162
Does not only prevent the separation by physically pressing the resin layer 15, but also has an effect of preventing rainwater from contacting the boundary end surface between the resin layer 15 and the back support plate 16 and preventing erosion by water. .

The exterior material 1 shown in FIG. 3 includes a resin layer 15 (holding portions 153, 15) at the ridge end and the eave end of the face plate portion 11.
4) is formed to be about twice as thick as the resin layer 15 in the face plate portion 11 and the eave edge (eave edge held portion 1) of the resin layer 15 is formed.
54), the ridge edge (ridge edge held portion 153) is also physically held by (the ridge edge held portion 161 of) the back surface support plate 16. Structures other than these are almost the same as the exterior material 1 of FIG. 1, and thus the same reference numerals are given and the description is omitted. In the exterior material 1, both the ridge edge (ridge edge held portion 153) and the eave edge (eave edge held portion 154) of the resin layer 15 are physically held by the back support plate 16 (holding portions 161 and 162). Therefore, the resin layer 15 is prevented from peeling off from the ridge and eave edges with respect to the back support plate 16 even when used over time. In addition, the ridge edge holding section 161 is also the eave edge holding section 16.
2 not only physically presses the resin layer 15 but also
This has the effect of preventing rainwater from contacting the boundary end surface between the resin layer 15 and the back support plate 16. Further, the exterior material 1 of the illustrated embodiment includes a resin layer 15 at the ridge end and the eave end of the face plate portion 11.
Since the (held portions 153, 154) are formed to be approximately twice the thickness of the face plate portion 11, the holding portions 16
The held portions 153 and 154 of the resin layer 15 can be reliably held even if the bent shapes of the members 1 and 162 are gentle. However, when the eaves edge of the resin layer 15 is formed to be thinner than the face plate portion 11 as in the above-described conventional example, the holding portions 161 and 162 of the back support plate 16 need to be bent deeper.
Molding is difficult, and depending on the material of the back support plate 16, durability may be impaired due to metal deterioration or the like. Therefore, as described above, thickening the resin layer 15 at the ridge end and the eave end of the face plate portion 11 can provide excellent effects in terms of moldability and durability.

The exterior material 1 shown in FIG. 4 has the same thickness as the resin layer 15 in the face plate portion 11 in the eaves edge of the resin layer 15. Structures other than these are almost the same as those of the exterior material 1 of FIG. As in the case of the exterior material 1, the thickness of the resin layer 15 of the exterior material 1 at the ridge end and the eaves end is adjusted by the resin layer 1 in the face plate portion 11.
5, the holding portion 16 of the back support plate 16
1, 162 can be securely held.

The exterior material 1 shown in FIG. 5 is an edge in which the ridge held portion 153 of the resin layer 15 extends from the face plate portion 11 to the ridge side in the same plane. Structures other than these are almost the same as those of the exterior material 1 of FIG. The back support plate 16 as in the case 1
If the ridge held portion 153 held by the ridge is an edge extending from the face plate portion 11 to the ridge side in the same plane, for example, floating occurs between the resin layer 15 and the back surface support plate 16. Also, since the thermal expansion and contraction of the resin layer 15 in the face plate portion 11 directly acts on this ridge, the thermal expansion and contraction of the resin layer 15 can be absorbed in a state where the holding relationship is maintained, and separation can be prevented.

In the exterior material 1 shown in FIG. 6, both the ridge edge held portion 153 and the eave edge held portion 154 of the resin layer 15 are formed in a round cross section having a thickness larger than the thickness. Shape). For other configurations,
Since it is almost the same as the exterior material 1 in FIG. 5, the same reference numerals are given and the description is omitted. When the held portions 153 and 154 of the resin layer 15 are formed to have a round cross section larger than the thickness in this manner, when the holding portions 161 and 162 are formed in combination with the back support plate 16, the molding relationship is such that the holding relationship is impaired. Mistakes are less likely to occur, and it is also easy to grip (engage) the holding portions 161 and 162 of the back support plate 16 in combination after molding.
The shape is not limited to a round cross-section, and if the shape is a bulge larger than the thickness, a similar effect can be obtained even if the cross-section is formed into a polygonal shape.

The exterior structure shown in FIG. 7 uses an exterior material 1 having almost the same configuration as that of FIG. 1, and a back-up material 3 is interposed on the back side of the face plate portion 11. As the backup material 3, a foamed resin material having high heat insulation such as polyurethane, polystyrene, phenol or the like is used, but a wood wool cement board or the like can be used in consideration of fire resistance. Further, the connection receiving portion 14 of the exterior material 1 is held from above by a suspender 6 having an L-shaped cross section. This suspension 6
Is composed of a horizontal strip-shaped base or a fixing portion 61 to the frame 4 and an inclined vertical piece 62 along the ridge side of the water return portion of the connection receiving section 14. 621
Is provided. Therefore, the exterior material 1 is attached to the base 4 by the suspension 6. In the drawing, reference numeral 2 denotes a joint discarding plate used for a connecting portion of the exterior material 1 in the girder direction, reference numeral 11 denotes a receiving plate portion, reference numeral 12 denotes a ridge-side end portion, and reference numeral 13 denotes an eave-side end portion.

On the other hand, in the exterior structure shown in FIG. 8, a backup material 3 formed thicker than that of FIG. 7 is interposed, and a cutout cross section at the eave end of the backup material 3 has a right-angled corner. A polymerization cavity 31 is formed. Further, the suspension 6 has a step 63 between the inclined vertical piece 62 and the fixed part 61. The step 63 of the suspension 6 holds the ridge end of the backup material 3 from above, and the overlapping space 31 of the upper backup material 3 faces from above. As described above, in the exterior structure of FIG. 8, not only the backup material 3 is thick, but also the backup material 3 is arranged without a gap in the ridge direction, so that the heat insulation performance is higher than that of the exterior structure of FIG. 7. Become. Further, in this exterior structure, the exterior material 1 is not in contact with the base 4, and the impact acting on the surface is absorbed by the backup material 3, so that the impact resistance is high. For this reason, the deformation of the suspension 6 and the damage of the solar cell and the like due to the collision of a tree branch in a strong wind or the weight of a construction worker are suppressed.

Although the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the above-described embodiments, but may be modified in any way unless the structure described in the claims is changed. Can be implemented. For example, a cover material is usually provided at the end of the solar energy conversion device butting material of the present invention in the direction of girder, but any other known configuration or structure is used for the configuration that does not mention other configurations. May be applied. Further, when applying (laying) the exterior material with the solar energy conversion device of the present invention, the exterior material may be laid in combination with a general horizontal roofing exterior material having no solar cell. Further, the connection structure may be a conventional structure having a high performance of rain. In this case,
Since it serves as a plurality of infiltration water prevention means, it is possible to further improve the performance of rain.

[0022]

In summary, the exterior material with a solar energy conversion device of the present invention has a water-stopping elastic piece whose lower end abuts against the face plate portion of the lower exterior material at the connection portion at the eaves end of the face plate portion. Because of the formation, the flow of rainwater from the ridge side to the eaves side is smooth, and the amount of infiltration water to the connecting part in the ridge eaves direction can be minimized. Then, the separation between the resin layer and the back support plate is prevented, and as a result, the power generation performance of the solar cell element can be exhibited over a long period of time without deterioration. In addition, when the connection structure of the exterior material is configured to have a conventional structure with a high performance of rain, since it serves as a plurality of means for preventing intrusion of water, the performance of rain is further improved.

Further, the exterior material with the solar energy conversion device of the present invention can reduce the development width with respect to the effective width, the number of roll forming machines can be reduced, and the deterioration factor to the solar cell element can be reduced. As a result, it becomes possible to provide a more stable exterior material with a solar energy conversion device than before.

Further, the exterior material with the solar energy conversion device in which the ridge edge and eave edge of the resin layer are held by the holding portion of the back support plate is prevented from peeling off at least from the edge, and is provided by an adhesive or the like on the face plate portion. Bonding is also maintained stably.

Further, the exterior material with the solar energy conversion device, in which the ridge of the resin layer has an edge extending from the face plate portion to the ridge side in the same plane as the ridge, can maintain the holding relationship with the face plate portion of the resin layer. Can be prevented by absorbing the thermal expansion and contraction of

Further, the exterior material with the solar energy conversion device, in which the ridge edge and eave edge of the resin layer are formed in a bulged shape larger than the thickness, is laminated with the back support plate when the exterior material is manufactured, and the holding portion is formed. Even in the case of bending, a molding error that impairs the holding relationship is unlikely to occur. In addition, it is possible to easily form the holding portion of the back support plate in advance, hold it, and combine it.

[Brief description of the drawings]

FIG. 1 is a side sectional view in which a part of a connection structure of an exterior material with a solar energy conversion device according to one embodiment is enlarged and attached.

FIG. 2 is a plan view showing a material configuration before molding of an exterior material of FIG. 1;

FIG. 3 is a partially enlarged side sectional view showing a connection structure of an exterior material according to another embodiment.

FIG. 4 is a partially enlarged side sectional view showing a connection structure of an exterior material according to another embodiment.

FIG. 5 is a side sectional view in which a part of a connection structure of an exterior material according to another embodiment is enlarged and attached.

FIG. 6 is a partially enlarged side sectional view showing a connection structure of an exterior material according to another embodiment.

7A is a side sectional view showing an exterior structure using the exterior material of FIG. 1, and FIG. 7B is a side view showing a backup material used therefor.

8 (a) is a side sectional view showing an exterior structure using the exterior material of FIG. 1, and FIG. 8 (b) is a side view showing a backup material used therefor.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 exterior material with solar energy conversion device 11 face plate portion 12 solar energy conversion device 121 connection cable 13 connection portion 14 connection receiving portion 15 resin layer 151, 152 thick portion 153 ridge holding portion 154 eave holding portion 16 back support Board 161 Wing edge holding part 162 Eave edge holding part 17 Waterproof elastic piece 2 Joint discard plate 3 Backup material 6 Hanger

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) E04D 13/18 E04D 3/362 E04D 3/40

Claims (5)

(57) [Claims] 1. A solar energy conversion device such as a solar cell on a face plate.
Solar energy converter with integrated converter
Exterior material made by laminating a resin layer embedded with a backing and a back support plate
In the resin layer at the eaves end of the face plate portion, a lower exterior material
The water-stopping elastic piece whose lower end contacts the resin layer of
Solar energy conversion device characterized by being formed
With exterior material. 2. Trees at the ridge end and / or eaves end of the face plate portion
The oil layer is formed to be the same as or thicker than the resin layer on the face plate.
The ridge edge and / or eave edge of the resin layer are provided on the back support plate.
Claims characterized by being held by the formed holding portion
Item 4. An exterior material with a solar energy conversion device according to Item 1. 3. A resin layer held by a holding portion of a back support plate.
Is an edge extending in the same plane from the face plate portion.
The solar energy according to claim 1 or 2, wherein:
-Exterior material with conversion device. 4. A resin layer held by a holding portion of a back support plate.
One or both of the ridge and / or eaves edge of
It is formed in a bulging shape larger than
The solar energy according to claim 1, 2 or 3, wherein
Exterior material with lug conversion device. 5. A solar energy conversion device such as a solar cell on a face plate.
Solar energy converter with integrated converter
Exterior material made by laminating a resin layer embedded with a backing and a back support plate
A sheath structure using a resin layer in Nokiba face plate portion of the outer material is lower stage
The water-stopping elastic piece whose lower end contacts the resin layer of the exterior material
At the ridge end of the lower exterior material that is physically formed and vertically adjacent
The formed connection receiving part and the connection formed at the eaves edge of the upper exterior material
Characterized by mutually engaging or superimposing parts with each other
Exterior structure with energy conversion device.