Frame for wall-mounted solar cell module and installation method for wall-mounted solar cell module

Abstract

Wall-mounted solar cell modules are installed by a small team of people. [Solution] A frame body for a solar cell module to be mounted on a wall, comprising a pair of first support parts that extend in a first direction and face each other, and a pair of second support parts that extend in a second direction that intersects the first direction and face each other, wherein the first support parts have first side parts that are long in the first direction and extend in a third direction that intersects both the first and second directions, a solar cell panel is supported on one end side of the first side parts, and the flange parts of each of the pair of first support parts have openings through which a fixing device to be attached to the wall surface can be inserted, and by sliding the relative position of the fixing device within the opening of one of the flange parts in a predetermined fourth direction, one of the flange parts and the fixing device engage with each other, and the opening of the other flange part can engage with the flange part of another module.

Description

[Technical Field]

[0001] The present disclosure relates to a frame that holds the peripheral edge of a solar cell panel in a solar cell module for wall mounting, and to a method for installing a solar cell module for wall mounting that has the frame. [Background technology]

[0002] In recent years, solar power generation systems have been installed widely as a form of renewable energy, and in addition to being installed on roofs of buildings, wall installation is becoming an increasingly common installation location. For example, solar cell modules are currently being installed on walls using a method such as that shown in Patent Document 1.

[0003] When installing solar panels on a structure, construction is generally carried out to install a mount (for example, the horizontal beam R in Patent Document 1) at the installation location for the solar panel to secure the solar panel. The solar panel is then installed on the mount. In the case of Patent Document 1, first, multiple horizontal beams R are fixed to a wall surface W in a generally horizontal orientation, arranged in upper and lower rows. Next, each locking portion of the panel body P is hooked onto each locking portion receiving portion of the horizontal beam R (

[0021] to

[0022] ). Each locking portion of the panel body P is provided on a frame body that secures the periphery of the solar panel. Because each locking portion of the panel body is formed inward, the panel body can be installed regardless of its upside down orientation (

[0008] ).

[0004] In order to increase the effective area of ​​the solar cell module and install more solar cell panels on the wall of a building, it is common for each locking part to be formed inward and located on the underside of the back surface of the solar cell panel. Because of this shape, when fixing a solar cell module to a wall of a building using the locking parts, as described in Patent Document 1, the solar cell module must be fixed to the building via a mount or the like, and it is not possible to fix the locking parts directly to the building from the front side of the solar cell module. For this reason, wall-mounted solar cell modules tend to be more expensive to install than roof-mounted solar cell modules.

[0005] In response to this, Patent Document 2 proposes a solar cell module in which the holding portion of the frame that holds the solar cell panel has a flange on the end opposite the solar cell panel that faces outward parallel to the solar cell panel, and the flange is installed directly on the wall. This eliminates the two-step installation process of installing a mounting base, such as a horizontal beam, on the wall and then mounting the solar cell module. This reduces the design weight in structural calculations for buildings that use wall installation, and enables installation in a single step, saving time and effort. It also reduces the number of mounting parts, lowering installation costs and improving cost-effectiveness. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2019-183458 [Patent Document 2] International Publication No. 2024 / 053723 Summary of the Invention [Problem to be solved by the invention]

[0007] To directly install the solar cell module described in Patent Document 2 on a wall, the installation requires drilling holes in the wall and fastening them with screws while supporting the solar cell module, or drilling pilot holes first and then fastening the solar cell module to the wall with screws while supporting the module. However, the larger the solar cell module, the heavier it is, making it difficult to install it alone. In addition, from the perspective of ensuring safety, it is preferable for the installation work to be performed by two or more people, with at least one person supporting the module and another person drilling pilot holes and fastening the screws, which increases the installation cost.

[0008] In view of the above, the present disclosure aims to provide a frame body for a solar cell module that can reduce the number of workers required when attaching a solar cell module to a wall surface of a building and can be installed by a small number of people (for example, even by one person), and a method for installing a solar cell module using the frame body. [Means for solving the problem]

[0009] One aspect of the present disclosure relates to a wall-mounted solar cell module, comprising a frame body that holds peripheral portions of solar cell panels used corresponding to each of a plurality of solar cell panels so that the plurality of solar cell panels can be mounted on a wall surface, the frame body including a pair of first support portions that extend in a first direction and face each other, and a pair of second support portions that extend in a second direction that intersects with the first direction and face each other, the first support portions and the second support portions each having a first side portion that is elongated in the first direction and a second side portion that is elongated in the second direction, the first support portions and the second support portions each extending in a third direction that intersects with both the first direction and the second direction, the solar cell panels being supported on one end side of the first side portion and one end side of the second side portion, and the first support portions supporting the solar cell panels on the other end side of the first side portion. the first flange of one of the pair of first supports has two or more first openings through which a fastener to be attached to the wall surface is inserted, and the second flange of the other of the pair of first supports has two or more second openings at positions corresponding to the first openings of the second flange of the first support, the first flange being the flange of the other of the pair of first supports; and the first flange and the fastener can be engaged with each other by sliding the relative position of the fastener within the first opening in a predetermined fourth direction intersecting the third direction, and the second flange can be engaged with the first flange of another of the wall-mounted solar cell modules at the second opening.

[0010] Another aspect of the present disclosure is a method for installing a plurality of wall-mounted solar cell modules on a wall, the method including: (a) preparing a first wall-mounted solar cell module and a second wall-mounted solar cell module, each having a frame body of the wall-mounted solar cell module; (b) drilling, on the wall surface, two or more first pilot holes corresponding to the first opening, on a reference line of a planned installation position of the first flange portion of the one first support portion of the first wall-mounted solar cell module; (c) inserting first screws into the first pilot holes and temporarily fixing the first wall-mounted solar cell module in a state where a head of the first screw is raised above the wall surface by at least a thickness of the first flange portion; (d) positioning the first wall-mounted solar cell module so that a part of the first opening of the first wall-mounted solar cell module and a head of the first screw overlap, and then sliding the first wall-mounted solar cell module in the fourth direction to fix the first flange portion and the first first flange portion together; (e) a step of finally tightening the first screw; (f) a step of drilling two or more second pilot holes in the second opening of the second flange of the other first support part of the first wall-mounted solar cell module on the wall surface; (g) a step of inserting second screws into the second pilot holes and temporarily fastening the second screws in a state in which the heads of the second screws are raised above the wall surface by at least the sum of the thicknesses of the first flange and the second flange; (h) a step of positioning the second wall-mounted solar cell module so that the first openings of the second wall-mounted solar cell module overlap the heads of the second screws, and then sliding the second wall-mounted solar cell module in the fourth direction to engage the first flange of the second wall-mounted solar cell module with the second flange of the first wall-mounted solar cell module and the second screw; and (i) a step of finally tightening the second screws. [Effects of the Invention]

[0011] According to the present disclosure, when installing a wall-mounted solar cell module on the wall of a building, there is no need to attach a mount to the wall, and the number of parts and construction costs can be significantly reduced, while the design weight in the structural calculations for the building can be reduced and the installation work can be carried out by a small number of people. [Brief explanation of the drawings]

[0012] [Figure 1A] 1A is a plan view of a wall-mounted solar cell module according to an embodiment of the present disclosure installed on the wall of a building, FIG. 1B is a cross-sectional view taken along line B-B', and FIG. 1C is a cross-sectional view taken along line CC'. [Figure 1B] FIG. 1B is a rear view of the wall-mounted solar cell module shown in FIG. 1A. [Figure 2A] FIG. 1B is an enlarged view of region A in FIG. 1A(b). [Figure 2B] FIG. 1B is an enlarged view of region B in FIG. 1A(b). [Figure 3] 3 is an enlarged view of a cross section perpendicular to the first direction of an end portion of a first support part in a solar cell module for wall installation according to an embodiment of the present disclosure. FIG. [Figure 4] 1A(a) is an enlarged view of a partial region of a first flange (region R in FIG. 1A(a)) showing an example of a first opening provided in the first flange in a solar cell module for wall installation according to an embodiment of the present disclosure. FIG. [Figure 5A] FIG. 10 is a plan view of a solar cell module for wall installation according to an embodiment of the present disclosure, showing an example of a second opening provided in a second flange portion. [Figure 5B] 5B is a partial perspective view of the wall-mounted solar cell module showing an enlarged view of a part of the second flange portion corresponding to region R in FIG. 5A. FIG. [Figure 6A] FIG. 1 is a plan view of a solar cell module for wall mounting according to an embodiment of the present disclosure, showing an example of a first opening provided in a first flange portion and a second opening provided in a second flange portion. [Figure 6B] 6B is a partial plan view of the wall-mounted solar cell module, showing an enlarged view of a part of the first flange portion corresponding to region R1 in FIG. 6A. FIG. [Figure 6C] 6B is a partial plan view of the wall-mounted solar cell module, showing an enlarged view of a part of the second flange portion corresponding to region R2 in FIG. 6A. FIG. [Figure 7] 10 is a view illustrating step (d) of engaging a first flange portion of the solar cell module with a screw in the method for installing a solar cell module for wall surface installation according to an embodiment of the present disclosure. FIG. [Figure 8] 10 is a view illustrating step (g) of inserting a screw into the second opening of the second flange of the solar cell module in the method for installing a solar cell module for wall surface installation according to an embodiment of the present disclosure. FIG. [Figure 9] FIG. 10 is a diagram illustrating step (g) of engaging the first flange of the solar cell module with the second flange and screw of the solar cell module located below in the installation method for a wall-mounted solar cell module according to one embodiment of the present disclosure. [Figure 10] 10 is a view illustrating the state of the second flange portion of the solar cell module in step (d) of engaging the first flange portion with a screw in the method for installing a solar cell module for wall surface installation according to another embodiment of the present disclosure. FIG. [Figure 11] FIG. 10 is a view illustrating step (d) of engaging a first flange portion of the solar cell module with a screw in the method for installing a solar cell module for wall surface installation according to another embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0013] The following describes embodiments of the present disclosure using examples, but the present disclosure is not limited to the examples described below. In the following description, specific numerical values ​​and materials may be exemplified, but other numerical values ​​and materials may be applied as long as the effects of the present disclosure are obtained. In this specification, the expression "numerical value A to numerical value B" includes numerical value A and numerical value B and can be read as "numerical value A or more and numerical value B or less." When multiple materials are exemplified, one may be selected from them and used alone, or two or more may be used in combination.

[0014] The present disclosure also encompasses combinations of two or more features arbitrarily selected from the appended claims, i.e., two or more features arbitrarily selected from the appended claims can be combined unless a technical contradiction arises.

[0015] The frame body (hereinafter also referred to as "Frame (F)") according to the present disclosure holds the peripheral portions of the solar cell panels used corresponding to each of the multiple solar cell panels in a wall-mounted solar cell module, so that the multiple solar cell panels can be attached to a wall surface. Hereinafter, the wall-mounted solar cell module according to the present disclosure will also be referred to as a "solar cell module (SCM)."

[0016] The frame (F) includes a pair of first support portions that extend in a first direction and face each other, and a pair of second support portions that extend in a second direction that intersects the first direction and face each other. The overall outer shape of the frame (F) is a rectangle. The pair of first support portions correspond to two of the four sides of the rectangle that face each other. The pair of second support portions correspond to the remaining two sides that face each other.

[0017] It is desirable that the first direction and the second direction are perpendicular to each other, taking into consideration the strength of the frame body (F), the manufacturing process of the frame body (F), ease of incorporation into a solar cell module (SCM), ease of installation on a wall material, etc. In other words, it is desirable that the outer shape of the frame body (F) is rectangular. However, the angle formed by the first direction and the second direction does not necessarily have to be 90°. For example, the outer shape of the frame body (F) may be a trapezoid or a parallelogram.

[0018] The first support portion and the second support portion each have a first side portion elongated in a first direction and a second side portion elongated in a second direction, and the first side portion and the second side portion extend in a third direction that intersects both the first direction and the second direction.

[0019] Considering the strength of the frame body (F), the manufacturing process of the frame body (F), ease of incorporation into the solar cell module (SCM), ease of installation on the wall material W, etc., it is desirable that the third direction be perpendicular to the first direction and the second direction. However, the angle between the third direction and the first direction and the angle between the third direction and the second direction do not necessarily have to be 90°.

[0020] The first side surface portion is preferably formed over the entire length of the first support portion, but may be partially cut out. The second side surface portion is preferably formed over the entire length of the second support portion, but may be partially cut out.

[0021] A solar cell panel is supported on one end of the first side surface portion and one end of the second side surface portion. Hereinafter, for convenience, the end on which the solar cell panel is supported will also be referred to as the "upper end."

[0022] A solar cell panel support portion is provided flush with the upper end of the first side surface portion and the upper end of the second side surface portion. The solar cell panel support portion may have, for example, a groove structure that holds the peripheral edge of the solar cell panel, and the groove structure may be provided with holes for fastening the peripheral edge with screws.

[0023] A flange is provided on the other end of the first side surface portion of the first support portion. Hereinafter, the other end continuous with the flange will also be referred to as the "lower end" for convenience.

[0024] The flange protrudes outward, away from the solar panel. The flange may be referred to as a "flange." Hereinafter, for convenience, the end of the flange that is not continuous with the first side surface may be referred to as the "end of the flange." It is desirable that the flange protrudes uniformly throughout, taking into account strength and other factors. The flange protrudes by a width of, for example, 20 mm or more, and may be 25 mm or more when workability is taken into account. However, the flange protrudes by a width that is appropriately designed taking into account the weight and strength of the solar cell module, the installation area, and other factors.

[0025] Considering the strength of the frame body (F), the manufacturing process of the frame body (F), ease of incorporation into the solar cell module (SCM), ease of installation on a wall surface, etc., it is desirable that the flange portion and the first side surface portion are perpendicular to each other. However, the angle formed by the flange portion and the first side surface portion does not necessarily have to be 90°. When the heights of a pair of first side surface portions are equal and the flange portion and the first side surface portion are perpendicular to each other, the flange portion and the surface direction of the solar cell panel will be parallel.

[0026] The flange is preferably formed over the entire length of the first support part, but may be partially cut out. The flange may be formed uniformly over the entire length of the first support part. From the viewpoint of reducing the weight and cost of the frame body (F), the flange may be provided only on the part that is fixed to the wall material of the structure.

[0027] The length of the first side surface portion in the third direction is longer than the length of the second side surface portion in the same direction. This ensures a gap between the wall surface and the lower end of the second side surface portion when the solar cell module (SCM) is installed on a wall material of a building. The width of the gap may be, for example, at least as wide as the width through which a power cable can pass. If the diameter of the power cable joint is, for example, 15 mm to 20 mm, the width of the gap is preferably 20 mm to 25 mm, taking workability into consideration. If the joint is made smaller through improvements, the width of the gap may be reduced accordingly. However, the width of the gap required to pass the power cable is preferably 10 mm or more. In other words, the length of the first side surface portion is preferably 10 mm to 25 mm longer than the second side surface portion.

[0028] The pair of first support parts may be placed above and below the wall material of the building, and the pair of second support parts may be placed on the left and right sides, thereby preventing rain and dew from entering the gap between the wall material and the lower end of the second side surface part.

[0029] The pair of first support members may have the same structure as each other. The pair of second support members may also have the same structure as each other. This allows the solar cell module (SCM) to be installed on the wall material of a building without considering the top and bottom and left and right of the frame body (F).

[0030] The pair of first support members may have different structures. For example, the length of one of the pair of first support members in the third direction may be different from the length of the other first side face member. In this case, the shorter one in the third direction is fixed to the upper part of the wall material of the building, and the longer one is fixed to the lower part of the wall material of the building. With this arrangement, the solar panel is tilted so that it faces upward at an angle rather than parallel to the wall surface. This allows more sunlight to be irradiated onto the solar panel.

[0031] Each of the pair of first support parts has a flange that bends from the first side surface and protrudes outward. Here, the flange provided on one of the pair of first support parts is referred to as the first flange. The flange provided on the other of the pair of first support parts is referred to as the second flange. One of the first support parts (or first flange) is located on the lower side when the solar cell module is placed on a wall surface. The other first support part (or second flange) is located on the upper side when the solar cell module is placed on a wall surface.

[0032] The first flange has two or more first openings for inserting fasteners to be attached to the wall surface of the building. Similarly, the second flange has two or more second openings for inserting fasteners. That is, the flange has holes for fixing the flange to the wall material of the building with fasteners such as screws. The fasteners may be used to fix the flange to an internal structure of the wall material of the building through the openings (holes). When the frame is directly fixed to the wall material of the building using the flange, no mounting frame is required, thereby reducing installation costs. The second opening may be provided in the second flange at a position corresponding to the first opening provided in the first flange (for example, directly above the first opening when the solar cell module is placed on the wall). Note that the mounting position of the fastener is determined taking into account the spacing of the base of the building to which the module is to be installed, so multiple openings (holes) may be provided in the flange in advance. Taking into consideration the condition of the building's base, some of the openings (holes) may be selected and used to attach the fasteners.

[0033] The area of ​​the first opening is sufficiently larger than the area (cross-sectional area) of the insertion portion of the fixture. In other words, when the fixture is inserted into the first opening and the first flange (and solar cell module) is not fixed to a predetermined position on the wall by the fixture, the position of the first flange (and solar cell module) can be changed and adjusted within the range of the first opening, and the relative position of the first flange (and solar cell module) with respect to the fixture can be changed and adjusted. The frame (F) is configured so that the relative position of the fixture within the first opening can be slid in a predetermined fourth direction that intersects with the third direction.

[0034] The sliding engages the first flange with the fastener, and in this engaged state, the solar cell module is fixed at a desired position on the wall surface. At this time, the second flange can be engaged (via another fastener) with the first flange of another solar cell module having a frame body (F) at its second opening. This allows multiple solar cell modules to be arranged side by side on a wall surface using a common solar cell module, making it possible to install a large-area solar cell system with a small number of workers and low labor costs. The fourth direction may be parallel to the first direction or may be a direction along the second direction. The fourth direction may be horizontal or vertical.

[0035] In one embodiment of the frame (F) having the first and second openings, the first opening may be a notch extending from the end of the first flange toward the first side surface. The notch includes a portion extending along the fourth direction. In this case, the fourth direction may be a direction along the second direction or a vertical direction.

[0036] The notch has, for example, a semicircular or semioval oval portion. The connecting portion between the semicircular or semioval shape and the end of the first flange portion may be chamfered to form a guide portion that connects the end of the first flange portion to the semicircular or semioval shape. The connecting portion may be C-chamfered or R-chamfered. When the connecting portion is C-chamfered, the guide portion has a tapered shape in which the width in the first direction decreases as it approaches the first side portion from the end of the first flange portion. Alternatively, the guide portion may have a shape in which the connecting portion is R-chamfered.

[0037] In this case, for example, with the screw (first screw) temporarily fastened to the wall surface, the frame body (F) can be slid in the fourth direction (for example, downward) so that the screw passes through the oval portion via the guide portion. This allows gravity to easily position the frame body (F) (and the solar cell module) on the wall surface.

[0038] The guide portion preferably has a rounded chamfered shape. When the guide portion has a rounded chamfered shape at the connection portion, the absence of corners allows the screws to pass through the guide portion smoothly, making it easy to install the frame body (F) (and solar cell module) on the wall surface. In addition, it is possible to prevent damage to the screws when they come into contact with the cutout portion, improving installation performance and the quality of the solar cell module installation. It is also possible to prevent injuries to workers caused by the cutout portion.

[0039] An "oval" is a non-intersecting, convex, closed curve in a plane, including an egg, an ellipse, and an ellipse. For example, an "oval" includes a semicircle connected to a portion of an ellipse, a shape formed by connecting multiple arcs of different diameters to form a closed curve, two semicircles connected by a line segment, such as an athletics track, a rounded rectangle, a Cassini oval, an elliptic curve, and a superellipse. An "oval" is a differentiable (smooth), convex, closed curve that has a line symmetry and is not significantly different from a circle or an ellipse. A "semi-oval" is an open curve obtained by cutting out a portion of an oval (for example, one of the open curves obtained by bisecting an oval with a line perpendicular to its axis of symmetry).

[0040] In another embodiment of the frame (F) having the first opening and the second opening, the second opening may be a notch extending from the boundary between the second flange and the first side surface of the other first support (i.e., the protruding position of the second flange on the first side surface) in a direction approaching the end of the second flange. A third opening is formed in the first side surface of the other first support, extending in a direction approaching the second flange, and the third opening is connected to the notch.

[0041] A fastener (e.g., a second screw) that engages with the second flange is placed within the second opening, and the frame (F) is positioned and fixed on the wall surface. By providing a third opening in the first side surface that is connected to the second opening, the frame (F) can be slid in a fourth direction (e.g., downward) to engage the first flange within the first opening, without the head of the second screw interfering with the sliding, making it easy to position the frame (F) on the wall surface. In this case, the fourth direction may be a direction along the second direction or a vertical direction.

[0042] In this case, the first screw can be temporarily fastened at a position on the wall corresponding to the first opening, the second screw can be temporarily fastened at a position on the wall corresponding to the second opening, and then the frame (F) can be slid to position it on the wall. However, it is also possible to temporarily fasten the first screw at a position on the wall corresponding to the first opening, slide the frame (F) to position it on the wall, and then temporarily fasten the second screw at a position on the wall corresponding to the second opening.

[0043] The cutout portion may have, for example, a semicircular or semioval shape. Similar to the cutout portion described above, the connection between the semicircular or semioval shape and the boundary of the second flange portion may be chamfered to form a guide portion connecting the boundary to the semicircular or semioval shape. However, at the point where the cutout portion (guide portion) connects to the third opening, the width of the third opening in the first direction is greater than the diameter of the head of the second screw. Meanwhile, the width of the cutout portion in the first direction only needs to be greater than the diameter of the threaded portion of the second screw, but less than the diameter of the head of the second screw and smaller than the width of the third opening in the first direction.

[0044] In another embodiment of the frame (F) having the first and second openings, the first and second openings may each be a cutout having a substantially circular or elliptical first portion and a second portion extending at least along the fourth direction and connecting to the first portion, wherein the diameter of the first portion is greater than the width of the portion of the second portion extending along the fourth direction.

[0045] In this case, the first screw is temporarily fixed at a position corresponding to the first opening in the wall surface, and then the frame body (F) is placed so that it passes through the first part, and then the frame body (F) is slid so that the first screw is aligned with the second part, thereby positioning the frame body (F) on the wall surface.

[0046] In this case, the first screw can be temporarily fastened in a position corresponding to the first opening on the wall surface, the second screw can be temporarily fastened in a position corresponding to the second opening, and then the frame body (F) can be slid to position it on the wall surface. In this case, when the frame body (F) is positioned so that the first screw passes through the first portion of the first opening, the second screw passes through the first portion of the second opening. When the frame body (F) is slid so that the first screw follows the second portion of the first opening, the relative position of the second screw moves so that it follows the second portion of the second opening. However, it is also possible to temporarily fasten the first screw in a position corresponding to the first opening on the wall surface, slide the frame body (F) to position it on the wall, and then temporarily fasten the second screw in a position corresponding to the second opening.

[0047] The second portion may have a semicircular portion having a substantially semicircular shape and a square portion having a side the diameter of the semicircle, and the square portion may be shaped to be connected to the first portion.

[0048] At least two cutouts, notches, and / or cutouts may be provided along the first direction of the flange, and preferably at least two are provided equidistant from both ends of the flange in the longitudinal direction. The cutouts may be located at positions corresponding to the first opening of the first flange, but may be located elsewhere.

[0049] The present disclosure also relates to a method for installing a solar cell module (SCM) in a wall material of a building. The method for installing a solar cell module (SCM) in a wall material of a building includes a step of fixing a flange of a frame body (F) to a structure inside the wall material. The structure inside the wall material may be, for example, a furring strip.

[0050] In a typical steel-framed building, the furring strips are fixed to the beams with metal fittings, and the wall materials are fixed to the furring strips with metal fittings. In steel-framed buildings, the furring strips are made of lip-channel steel (C-shaped steel), while in wooden buildings, the wall materials are fixed to the furring strips or directly to wooden timbers such as pillars, studs, and beams.

[0051] Solar cell modules may be attached to the wall surface of a building using screws. In this case, it is preferable to use self-drilling screws, which have a drill-shaped tip. Generally, when fastening a mounting member to a steel substrate, the steps of drilling a pilot hole, tapping, and tightening are required. However, when using self-drilling screws, the cutting edge (drill shape) at the tip of the screw drills a pilot hole in the steel substrate, the threads of the self-drilling screw bite into the substrate to create a female thread, and the mounting member is fastened to the steel substrate. These steps can be performed in one step, greatly improving the ease of fastening.

[0052] The method according to the present disclosure is a method for installing solar cell modules for wall mounting, in which a plurality of solar cell modules for wall mounting are attached to a wall surface, and includes the following steps (a) to (g).

[0053] (a) preparing a first wall-mounted solar cell module and a second wall-mounted solar cell module, each of which has the frame body (F) of the wall-mounted solar cell module described above; (b) drilling two or more first pilot holes corresponding to the first openings on the wall surface on a reference line of a planned installation position of the first flange portion of one of the first support portions of the first wall-mounted solar cell module; (c) inserting a first screw into the first pilot hole and temporarily fastening the first screw in a state where the head of the first screw is raised above the wall surface by at least the thickness of the first flange portion; (d) positioning the first wall-mounted solar cell module so that a portion of the first opening of the first wall-mounted solar cell module overlaps with the head of the first screw, and then sliding the first wall-mounted solar cell module in the fourth direction to engage the first flange with the first screw; (e) a step of fully tightening the first screw; (f) drilling two or more second pilot holes in the wall surface within the second opening of the second flange portion of the other first support portion of the first wall-mounted solar cell module; (g) inserting a second screw into the second pilot hole and temporarily fixing the second screw in a state where the head of the second screw is raised above the wall surface by at least the sum of the thicknesses of the first flange and the second flange; (h) positioning the second wall-mounted solar cell module so that a portion of the first opening of the second wall-mounted solar cell module overlaps with the head of the second screw temporarily fastened to the first wall-mounted solar cell module, and then sliding the second wall-mounted solar cell module in the fourth direction to engage the first flange of the second wall-mounted solar cell module with the second flange of the first wall-mounted solar cell module and the second screw; and (i) A step of tightening the second screw.

[0054] By overlapping and fastening the first and second flanges of adjacent solar cell modules, multiple solar cell modules can be installed on the wall material of a building. Adjacent solar cell modules are fastened by overlapping the flanges so that a portion of the first opening of one solar cell module overlaps a portion of the second opening of the other solar cell module, and inserting a fastener (e.g., a screw) into the overlapping portion of the first and second openings. Overlapping the flanges reduces the installation area of ​​the solar cell modules (SCM). This increases the efficiency of wall surface utilization. Furthermore, the gap between the first flange of one solar cell module and the wall surface is covered by the second flange of the other solar cell module, preventing water from entering through this gap. Furthermore, because the flanges can be used to directly fasten the frame to the wall material of a building, no mounting frame is required. This reduces the design weight in structural calculations for wall installation and reduces installation costs.

[0055] When three or more solar cell modules are to be installed on the wall material of a building, a step of installing a third wall-mounted solar cell module is carried out in addition to the first and second wall-mounted solar cell modules. After step (h), steps (f) to (i) can be carried out by replacing the "first wall-mounted solar cell module" with the "second wall-mounted solar cell module," the "second wall-mounted solar cell module" with the "third wall-mounted solar cell module," and the "second screw" and "second pilot hole" with the "third screw" and "third pilot hole," respectively.

[0056] In step (d), engaging the first flange of the first wall-mounted solar cell module with the first screw, the second pilot holes may or may not be drilled. In other words, step (f) may be performed before or after step (d). When step (f) is performed before step (d), drilling all necessary pilot holes prior to fixing the wall-mounted solar cell module to the wall surface eliminates the need to drill pilot holes during installation, allowing the worker to focus on sequentially installing the solar cell module and improve work efficiency. However, precision is required in the positioning of the initial pilot holes, making installation accuracy important. On the other hand, when step (f) is performed after step (d), drilling pilot holes within the second opening of the second flange after fixing the first wall-mounted solar cell module allows the solar cell module to be fixed to the wall surface without considering errors that may occur during the installation process. However, work efficiency is reduced because drilling pilot holes and fixing the wall-mounted solar cell module to the wall surface must be alternated. The order of steps (d) and (f) can be selected depending on the location and situation of the work.

[0057] Similarly, in step (d) of engaging the first flange of the first wall-mounted solar cell module with the first screw, the second screw may or may not already be attached, depending on the shape of the frame body (F) (particularly the shape of the second opening). In other words, step (g) may be performed before step (d) or after step (d).

[0058] When the drill screw is used for the first screw, steps (b) and (c) are performed approximately simultaneously. When the drill screw is used for the second screw, steps (f) and (g) are performed approximately simultaneously. When a drill screw is used, steps (f) and (g) may be performed prior to step (d) in order to improve work efficiency. On the other hand, steps (f) and (g) may be performed after step (d) in order to fix the solar cell module to the wall surface without considering errors that may occur in the installation step. The order of steps (d) and (f) and (g) may be selected according to the location and circumstances of the work.

[0059] It is desirable to interpose a sealant between the periphery of the opening (hole) in the flange and the corresponding part of the wall material. By interposing a sealant between the periphery of the opening and the wall material, the gap between the periphery of the opening and the wall material is filled, making it possible to prevent moisture (rain and humidity) from entering the interior of the building.

[0060] As the sealing material, silicone resin, epoxy resin, butyl rubber, EVA (ethylene vinyl acetate copolymer resin), adhesive, etc. can be used.

[0061] In addition, after the step (c) of temporarily fixing the lower first flange with screws or the step (c), the back surface of the upper second flange and the wall surface may be temporarily fixed with an adhesive to prevent the upper second flange from tilting. Double-sided butyl adhesive tape or the like can be used as the adhesive.

[0062] The material of the frame (F) is not particularly limited as long as it can ensure a predetermined strength. Currently, aluminum is mainly used for the frame (F) of a solar cell module, but the frame may also be made of other metals, FRP (fiber reinforced plastic), etc.

[0063] It is preferable to form the flange of the frame (F) as an integral part of the first support part, as this provides high strength and simplifies the manufacturing process for the frame, but a separate flange may also be attached to the first support part. The thickness of the material for the frame and flange can be selected by calculating the strength based on the size and weight of the solar panel.

[0064] The installation surface (wall surface) of the solar cell module (SCM) is not limited to a surface perpendicular to the ground (a vertical surface), but may be an inclined surface forming an angle with the vertical direction.

[0065] The type of solar cell is not particularly limited. For example, it may be a crystalline silicon solar cell using single crystal silicon or polycrystalline silicon, an amorphous silicon solar cell, or a compound solar cell such as CdTe, CIS, or GaAs. It is also possible to use next-generation solar cells such as dye-sensitized solar cells, organic thin films, and perovskite solar cells.

[0066] The surface of a solar cell panel is coated with a glass coating that allows sunlight to pass through, allowing irradiated sunlight to reach the solar cell. However, some sunlight is reflected from the surface and emitted as reflected light in the opposite direction to the incident sunlight. In the case of rooftop installation, the reflected light is directed upward from the roof, so the impact on the surrounding area can be adjusted by adjusting the installation angle and method. However, in the case of wall installation, sunlight is reflected downward, which can have a significant impact on nearby buildings. In particular, in the wall-mounted solar cell module disclosed herein, the frame is installed directly on the wall, making it difficult to change the angle to adjust the reflected light. For this reason, it is preferable to reduce reflected light by using an anti-glare layer on the surface glass of the solar cell panel. The anti-glare layer is film- or plate-shaped and forms irregularities on the surface onto which sunlight enters, scattering and diffusely reflecting visible light through the irregularities. This disperses reflected light and reduces glare.

[0067] The structure and installation method of the frame body (F) and the solar cell module (SCM) will be described below with reference to the drawings, although the present disclosure is not limited to the following embodiments.

[0068] FIG. 1A shows a plan view (a), a cross-sectional view (b) taken along line B-B', and a cross-sectional view (c) taken along line C-C' of a solar cell module (SCM) installed on the wall surface of a building. FIG. 1B shows a rear view of the solar cell module (SCM) shown in FIG. 1A. FIG. 2A is an enlarged view of region A in FIG. 1A(b), and FIG. 2B is an enlarged view of region B in FIG. 1A(b). In FIG. 2B, the flanges of the frame bodies (F) of adjacent solar cell modules (SCM) in the vertical direction overlap each other.

[0069] The solar cell module 1 comprises a solar cell panel 2. The solar cell panel 2 is made by sealing connected solar cells with a surface material, a filler, and a back surface material. The peripheral edge of the solar cell panel 2 is held by a frame 4, with the light-receiving surfaces of the solar cells facing the front surface. The back surface, opposite the light-receiving surface, faces the wall surface (exterior wall surface) of the building's wall material.

[0070] The frame 4 includes a pair of first support portions 41 that extend in a first direction (here, the horizontal direction) and face each other, and a pair of second support portions 42 that extend in a second direction (here, the vertical direction) that is perpendicular to the first direction and face each other. The first support portions 41 and the second support portions 42 each have a first side surface portion 411 and a second side surface portion 421 that hang down in a third direction (the normal direction to the wall surface) that is perpendicular to both the first and second directions. The first side surface portion 411 is elongated in the first direction, and the second side surface portion 421 is elongated in the second direction.

[0071] The first side surface portion 411 and the second side surface portion 421 may have a single-layer structure or a multi-layer structure, and may be provided with various reinforcing processed portions 413. It is desirable to apply fastening processing to the corner portions of the frame body 4 in order to ensure mechanical strength and improve the finish.

[0072] The solar cell panel 2 is supported on the upper end side of the first side surface portion 411 and the upper end side of the second side surface portion 421. A solar cell panel support portion 43 is provided flush with the upper end side of the first side surface portion and the upper end side of the second side surface portion. The solar cell panel support portion 43 has a groove structure that holds the peripheral edge of the solar cell panel 2. The groove structure may be provided with holes for fastening the peripheral edge with screws.

[0073] The upper and lower ends of the first side surface portion 411 and the upper and lower ends of the second side surface portion 421 are parallel to the surface direction of the solar cell panel 2. The space (hollow portion) surrounded by the solar cell panel 2, the frame body 4, and the wall surface of the building is used as a space for passing the power cable 6.

[0074] In the pair of first support parts 41, a flange part (first flange part) 4121 is provided on the lower end side of the first side surface part 411 of one first support part 41, the flange part (first flange part) 4121 being continuous with the lower end and protruding in a flange shape so as to move away from the solar cell panel 2. In the pair of first support parts 41, a flange part (second flange part) 4122 is provided on the lower end side of the first side surface part 411 of the other first support part 41, the flange part (second flange part) 4122 being continuous with the lower end and protruding in a flange shape so as to move away from the solar cell panel 2.

[0075] The length of the second side surface portion 421 in the third direction (hereinafter also referred to as the "height of the second side surface portion 421") is preferably 25 mm to 35 mm in consideration of components to be installed on the rear surface of the solar cell panel 2. The length of the first side surface portion 411 in the third direction (hereinafter also referred to as the "height of the first side surface portion 411") is configured to be longer than the length of the second side surface portion 421. The height of the first side surface portion 411 is preferably 10 mm to 30 mm higher than the height of the second side surface portion 421. This increases the space (hollow portion) enclosed by the solar cell panel 2, the frame body 4, and the wall surface of the building, allowing for more space to install the power cable 6. Furthermore, the gap S between the wall surface and the lower end of the second side surface portion 421 makes it easier to pass the power cable 6 through. Furthermore, the gap S allows air to pass through, making it less likely for air and moisture to become trapped.

[0076] The protruding width of the first flange 4121 and the second flange 4122 is uniform overall, for example, 20 mm or more. By making the protruding width 20 mm or more, the strength of the frame body 4 is improved, and the stability of the solar cell module 1 installed on the wall surface is ensured. Furthermore, by making the protruding width of the flange 25 mm or more, it becomes easier to fix the solar cell module 1 to the wall material of a building using a jig or the like, and the workability of installing the solar cell module 1 is improved even when multiple solar cell modules are installed on a wall by stacking the flanges. However, if the protruding width of the flange is large, not only will the solar cell module become heavy, but the installation area on the wall surface will also increase, resulting in poor area efficiency. Therefore, it is not preferable to make it larger than necessary.

[0077] The first flange 4121 has a plurality of first openings 51 formed at equal intervals. Similarly, the second flange 4122 has a plurality of second openings 52 formed at equal intervals at positions corresponding to the first openings 51. When installing the solar cell module 1 on the wall surface of the wall material W, two or more first openings 51 and two or more second openings 52 are positioned and arranged at positions corresponding to lip channel steel (C-shaped steel) L, which is a structure inside the wall material W of the building. Of the plurality of first openings 51 and the plurality of second openings 52, two or more are selected and used to fix the solar cell module 1 to the wall surface. There may be first openings 51 and second openings 52 that are not used to fix the solar cell module 1 to the wall surface.

[0078] The lip channel steel L of this embodiment has a first portion L1 extending along the wall material W, a second portion L2 extending from the first portion L1 toward the inside of the building, and a third portion L3 extending from an end of the second portion L2 in parallel to the first portion L1. Then, a fastener (e.g., a drill screw) 5 is passed through the first opening 51 and / or the second opening 52 into the inside of the wall material W, and the first flange portion 4121 and the second flange portion 4122 are fixed to the lip channel steel L (specifically, the first portion L1 of the lip channel steel L) (see FIG. 2A).

[0079] When installing multiple solar cell modules 1 on the wall surface of a building, they can be installed in order from bottom to top. For vertically adjacent solar cell modules 1, the first flange 4121 of the frame 4 of the upper solar cell module 1 is overlapped with the second flange 4122 of the frame 4 of the lower solar cell module 1, and these are fixed together to the structure inside the wall material W with drill screws. As shown in FIG. 2B, overlapping the flanges of adjacent solar cell modules 1 can reduce the installation area of ​​the solar cell modules 1. Specific examples of installation methods in which flanges overlap will be described later.

[0080] Furthermore, by overlapping the first flange 4121 of the frame body 4 of the solar cell module 1 located above with the second flange 4122 of the frame body 4 of the solar cell module 1 located below, the contact surface between the second flange 4122 and the wall surface can be covered by the first flange 4121 on the lower edge of the frame body 4 of the solar cell module 1 located further above, effectively preventing water from entering through gaps.

[0081] Three reinforcing members 45 are provided between a pair of second supports 42, bridging the first supports 41. The reinforcing members 45 are in contact with the rear surface of the solar cell panel 2. In FIG. 1B, the reinforcing members 45 are attached at positions that divide the solar cell module 1 at equal intervals. When installing the solar cell module 1 on the wall surface of the wall material W, the reinforcing members 45 may be positioned at positions corresponding to the lip channel steel L inside the wall material W of the building. This improves the structural stability of the solar cell module 1 installed on the wall surface. The number and spacing of the reinforcing members 45 can be selected as desired depending on the area, strength, and installation location of the solar cell module 1, etc.

[0082] A sealant may be sandwiched between the periphery of the first opening 51 and the second opening 52 and the wall material W. A doughnut-shaped silicone resin sheet, for example, is preferable as the sealant in terms of sealing properties and workability, but is not particularly limited. The sealant fills the gap between the flange around the fastener 5, such as a screw, and the wall material W, thereby preventing water and other contaminants from entering the building through the openings and around the fastener 5.

[0083] The first support member 41 may have an outward step between the upper and lower ends of the first side surface portion 411. FIG. 3 is an enlarged view of a cross section perpendicular to the first direction at an end of the first support member 41 in a solar cell module according to an embodiment of the present disclosure. The first side surface portion 411 has an outward step 415 between the upper and lower ends. The step 415 is formed to extend in the first direction of the first side surface portion 411. By providing the step 415, when multiple solar cell modules 1 are stacked, the first flange 4121 or the second flange 4122 of the upper frame body 4 is placed on the step 415 of the lower frame body 4 and fixed in place. This reduces the height of the stack when multiple solar cell modules 1 are stacked and transported, preventing the solar cell modules 1 from shifting relative to each other, making it possible to transport many solar cell modules 1 in a stable state.

[0084] The first side surface portion 411 may have an extension portion 416 extending inward on an inner extension line of the step portion 415. This improves the strength of the frame body 4 to support the solar cell panel 2, thereby improving the stability of the solar cell module 1 when installed on a wall surface.

[0085] 4 is an enlarged view of a partial region of first flange portion 4121 in solar cell module 1 according to an embodiment of the present disclosure, and shows an example of the shape of first opening 51 provided in first flange portion 4121. Fig. 4 is an enlarged plan view of region R shown in Fig. 1A. Fig. 4 shows an example in which first opening 51 is formed as notch 51A extending from the end of first flange portion 4121 in a direction approaching first side surface portion 411.

[0086] Cutout portion 51A has guide portion 51A1 and semicircular or semioval oval portion 51A2 connected to guide portion 51A1 from the end of first flange portion 4121. Guide portion 51A1 is formed by chamfering (here, rounded chamfering) the connection portion between the semicircular or semioval shape and the end of first flange portion 4121. Guide portion 51A1 and oval portion 51A2 form a cut that extends in the vertical direction (fourth direction).

[0087] The diameter of the semicircle or the minor axis of the semioval of the notch 51A may be equal to or greater than the diameter of the threaded portion of the screw used for fastening, but less than the diameter of the screw head. Furthermore, the center X of the semicircle or the minor axis of the semioval of the notch 51A is preferably located at the midpoint in the second direction within the area where the second flange 4122 of the solar cell module to be installed first and the first flange 4121 of the solar cell module to be installed later overlap. The center X is approximately equal to the position where the first screw is inserted when the solar cell module 1 is fixed to the wall surface. If both flanges of the solar cell module have the same width, it is most preferable in terms of both mounting strength and installation area that the center X be located at the midpoint in the second direction of the first flange. However, considering the ease of installation of the screws, the flange width must be large, which increases the weight of the solar cell module. On the other hand, if the center X is located closer to the end of the first flange than the midpoint position of the first flange in the second direction, the overlap between the first flange 4121 and the second flange 4122 will be small, reducing the attachment strength. Conversely, if the center X is located closer to the first side surface 411 than the midpoint position of the first flange in the second direction, it will be difficult to overlap the second flange 4122 beyond the center X to the first side surface side, which may result in unstable fixation. For this reason, it is preferable that the overlap between the second flange 4122 and the first flange 4121 be 60% or more of the width of both flanges in the second direction.

[0088] 5A and 5B are diagrams showing another example of the shape of second opening 52 provided in second flange 4122 in a solar cell module according to an embodiment of the present disclosure. FIG. 5A is a plan view of the solar cell module and corresponds to FIG. 1A(a). FIG. 5B is a partial perspective view of the solar cell module with region R in FIG. 5A enlarged. FIGS. 5A and 5B show an example in which second opening 52 is a notch 52A that extends from the boundary between the second flange and the first side surface portion of the other first support member in a direction approaching the end of the second flange.

[0089] The first side surface portion 411 is formed with a third opening 53 extending toward the second flange portion 4122, and the third opening 53 is connected to the notch portion 52A. The notch portion 52A has a guide portion 52A1 and a semicircular or semioval oval portion 52A2 connected to the guide portion 52A1, and has a shape substantially similar to the notch portion 51A shown in FIG. 4. The guide portion 52A1 is formed by chamfering (here, rounded chamfering) the connection portion between the semicircular or semioval shape and the end of the second flange portion 4121. However, at the point where the guide portion 52A1 and the third opening 53 are connected, the width of the third opening 53 in the first direction is larger than the diameter of the head of the screw used for fastening. On the other hand, the width of the notch portion 52A in the first direction is smaller than the diameter of the head of the screw and smaller than the width of the third opening in the first direction. The width of the notch 52A in the first direction may be larger than the diameter of the threaded portion of the screw used for fixing.

[0090] The diameter of the semicircle or the minor axis of the semioval of cutout portion 52A may be equal to or greater than the diameter of the threaded portion of the screw used for fastening, but less than the diameter of the head of the screw. Furthermore, center Y of the diameter of the semicircle or the minor axis of the semioval of cutout portion 52A is preferably located at the midpoint in the second direction within the area where second flange portion 4122 and first flange portion 4121 overlap when second flange portion 4122 of the solar cell module to be installed first and first flange portion 4121 of the solar cell module to be installed later are overlapped. Center Y is approximately the same as the position where the second screw is inserted when the solar cell module is fixed to the wall surface.

[0091] If both flanges of the solar cell module have the same width, it is most preferable for the center Y to be located at the midpoint of the second flange in the second direction, both in terms of mounting strength and installation area. However, considering the ease of screw installation, the flange width must be made larger, which increases the weight of the solar cell module. On the other hand, if the center Y is located closer to the end of the flange than the midpoint of the second flange in the second direction, the overlap between the first flange 4121 and the second flange 4122 will be smaller, reducing mounting strength. Conversely, if the center Y is located closer to the first side surface portion than the midpoint of the second flange in the second direction, it will be difficult to overlap the second flange 4122 with the first flange 4121 beyond the center Y and all the way to the first side surface portion, which may result in unstable fixation. For this reason, it is preferable that the overlap between second flange portion 4122 and first flange portion 4121 be 60% or more of the width of both flange portions in the second direction.

[0092] 6A to 6C are diagrams illustrating another example of a first opening 51 provided in a first flange 4121 and a second opening 52 provided in a second flange 4122 in a solar cell module according to an embodiment of the present disclosure. FIG. 6A is a plan view of the solar cell module and corresponds to FIG. 1A(a). FIG. 6B is a partial plan view of the solar cell module in which a partial region R1 of the first flange 4121 in FIG. 6A is enlarged. FIG. 6C is a partial plan view of the solar cell module in which a partial region R2 of the second flange 4122 in FIG. 6A is enlarged. FIGS. 6A to 6C illustrate an example in which the first opening 51 is a cutout 51B having a substantially circular or elliptical first portion 51B1 and a second portion 51B2 extending in a direction along the first direction (fourth direction) and connected to the first portion 51B1.

[0093] The second portion 51B2 has a semicircular portion 51B3 having a substantially semicircular shape and a square portion 51B4 having a side equal to the diameter of the semicircle, and the square portion 51B4 is connected to the first portion 51B1. The diameter of the first portion 51B1 is larger than the width of the portion of the second portion 51B2 extending in the fourth direction (i.e., the length of one side of the square portion 51B4, which is equal to the diameter of the semicircular portion 51B3).

[0094] The diameter of the first portion 51B1 is larger than the diameter of the head of the screw used for fixing, and the diameter of the semicircular portion 51B3 is larger than the diameter of the threaded portion of the screw used for fixing but smaller than the diameter of the head of the screw.

[0095] The second opening 52 provided in the second flange 4122 may have a cutout having a shape similar to that of the cutout 51B shown in Fig. 6C. In Fig. 6C, the second opening 52 is cutout 52B having a substantially circular or elliptical first portion 52B1 and a second portion 52B2 extending in the first direction (the fourth direction) and connected to the first portion 52B1. The second portion 52B2 has a substantially semicircular portion 52B3 and a square portion 52B4 whose side is the diameter of the semicircle, and square portion 52B4 is connected to the first portion 52B1.

[0096] The diameter of semicircle of semicircle portions 51B3, 52B3 may be equal to or greater than the diameter of the threaded portion of the screw used for fastening, but less than the diameter of the head of the screw. Furthermore, center Z of semicircle of semicircle portions 51B3, 52B3 is preferably located at the midpoint in the second direction within the region where second flange portion 4122 and first flange portion 4121 overlap when second flange portion 4122 of the solar cell module to be installed first and first flange portion 4121 of the solar cell module to be installed later are overlapped. Center Z is approximately the same as the position where the first or second screw is inserted when solar cell module 1 is fixed to the wall surface.

[0097] If both flanges of the solar cell module have the same width, if center Z is located closer to the end than the midpoint of the flange in the second direction, the overlap between first flange 4121 and second flange 4122 will be small, resulting in a lower attachment strength. On the other hand, if center Z is located closer to first side surface 411 than the midpoint of the flange in the second direction, it will be difficult to overlap second flange 4122 beyond center Z to the first side surface, which may result in unstable fixation. For this reason, the overlap between second flange 4122 and first flange 4121 is preferably 60% or more of the width of both flanges in the second direction.

[0098] (How to install a wall-mounted solar module) A detailed description will be given below of an installation method for mounting a solar cell module (SCM) having a frame body (F) with the notch 51A, cutout 52A, or cutouts 51B, 52B provided in the flange on a wall.

[0099] First, a first solar cell module 1A and a second solar cell module 1B are prepared (step (a)). The first solar cell module 1A and the second solar cell module 1B each have a frame body (F) with the above-mentioned characteristics and have the same structure. Here, the frame body (F) of the first solar cell module 1A and the second solar cell module 1B has the configuration shown in FIG. 1A, and the first flange portion 4121 of the frame body (F) is provided with a notch portion 51A shown in FIG. 4.

[0100] Next, in one of the pair of first supports 41 of the first solar cell module 1A that is located on the lower side, two or more pilot holes (first pilot holes) corresponding to the first opening are drilled on a reference line of the planned installation position of the first flange 4121 of the first side surface 411 (step (b)). Subsequently, screws 5a (first screws) are inserted into these pilot holes. However, the screws 5a are not inserted all the way in, but are temporarily fixed in a state where the heads of the screws 5a are raised above the wall surface by at least the thickness of the first flange 4121 (step (c)).

[0101] A drill screw may be used as the screw 5a (first screw). In this case, the step of drilling a pilot hole in the wall surface and the step of inserting the screw can be performed simultaneously, and steps (b) and (c) can be performed approximately simultaneously.

[0102] Next, the solar cell module 1A is positioned on the wall surface. After the solar cell module 1A is positioned horizontally so that the guide portion 51A1 of the notch 51A of the first flange portion 4121 overlaps with the screw 5a, the solar cell module 1A is slid downward (in the fourth direction) along the oval portion 51A2 (step (d)). This engages the first flange portion 4121 with the screw 5a. Gravity can be used to easily position the solar cell module 1A on the wall surface. The state of engagement between the first flange portion 4121 and the screw 5a at this time is shown in Figure 7.

[0103] Next, the screws 5a are fully tightened to fix the solar cell module 1A to the wall surface (step (e)).

[0104] Next, in the other first support portion 41 located on the upper side of the pair of first support portions 41 in the first solar cell module 1A, two or more pilot holes (second pilot holes) are drilled in the second opening 52 of the second flange portion 4122 of the first side surface portion (step (f)). Next, screws 5b (second screws) are inserted into these pilot holes. However, the screws 5b are not inserted all the way in, but are temporarily fastened in a state where the heads of the screws 5b are raised above the wall surface by at least the combined thickness of the first flange portion 4121 and the second flange portion 4122 (step (g)). The state of the second flange portion 4122 and the screws 5b at this time is shown in FIG. 8.

[0105] A drill screw may be used as the screw 5b (second screw). In this case, the step of drilling a pilot hole in the wall surface and the step of inserting the screw can be performed simultaneously, and steps (f) and (g) can be performed approximately simultaneously.

[0106] Next, the solar cell module 1B is positioned on the wall surface. After the solar cell module 1B is positioned horizontally so that the guide portion 51A1 of the notch 51A of the first flange portion 4121 overlaps with the screw 5b, the solar cell module 1B is slid downward (in the fourth direction) along the oval portion 51A2 (step (h)). This causes the first flange 4121 of the solar cell module 1B to engage with the screw 5b and the second flange 4122 of the solar cell module 1A. Gravity can be used to easily position the solar cell module 1A on the wall surface. The engaged state of the first flange 4121 of the solar cell module 1B, the second flange 4122 of the solar cell module 1A, and the screw 5b at this time is shown in Figure 9.

[0107] Next, the screws 5b are fully tightened to fix the solar cell module 1B to the wall surface (step (i)).

[0108] Thereafter, two or more pilot holes (third pilot holes) are drilled in the second opening 52 of the second flange 4122 of the solar cell module 1B, and the screws 5c (third screws) are inserted into the pilot holes and finally tightened. At this time, the engagement state between the second flange 4122 of the solar cell module 1B and the screws 5c is such that, in FIG. 8, the solar cell module 1A is tightened to the solar cell module 1B, and the screws 5b are tightened to the screws 5c. This results in a large-area solar cell module for wall installation that includes the solar cell modules 1A and 1B.

[0109] The screws may be fully tightened all at once after the positioning of all the solar cell modules is completed.

[0110] In this installation method, in step (b), only the first pilot hole is drilled, and in step (d), after the solar cell module 1A is positioned at the first flange portion 4121, a second pilot hole is drilled in the second opening 52 of the solar cell module 1A and the installation work is performed, so that the solar cell module can be fixed to the wall surface without considering errors that may occur during the installation process.

[0111] Alternatively, all necessary pilot holes may be drilled first. In other words, step (f) may be performed before step (d). In this case, since there is no need to drill pilot holes in between, it is possible to concentrate on the task of sequentially installing the solar cell modules, which improves work efficiency. However, precision is required in the positioning of the initial pilot holes.

[0112] The solar cell modules 1A and 1B may have a notch 52A as shown in FIG. 5B as the shape of the second opening 52 provided in the second flange 4122 of the frame body (F). In this case, the installation method is the same as the method described above. In this case, even if the screw (second screw) 5b is already inserted, when sliding the solar cell module 1A downward (in the fourth direction) in step (d), the head of the screw 5b does not obstruct the sliding due to the presence of the third opening 53 (see FIG. 5B). Therefore, steps (f) and (g) can be performed before step (d). In this case, the state of the second flange 4121 and the screw 5b in step (d) is shown in FIG. 10.

[0113] When using a frame body (F) having the cutout portion 52A shown in Fig. 5B, all necessary pilot holes are drilled first, and after screws are temporarily fastened in the pilot holes, the positioning and fixing of the solar cell modules 1A and 1B can be performed sequentially, improving work efficiency. Furthermore, when positioning the solar cell module 1A (step (d)), the first flange portion 4121 of the solar cell module 1A engages with the screw 5a, and the second flange portion 4122 of the solar cell module 1A engages with the screw 5b. This makes it difficult for the solar cell module 1A to fall off the wall surface, stabilizing the installation work.

[0114] As another example of the shape of the first opening 51 provided in the first flange 4121 of the frame body (F) and the shape of the second opening 52 provided in the second flange 4122, the solar cell modules 1A and 1B may have the cutout 51B shown in FIG. 6B and the cutout 52B shown in FIG. 6C. In this case, in step (d), the solar cell module 1A is positioned horizontally so that the first portion 51B1 of the cutout 51B of the first flange 4121 overlaps with the screw 5a, and then the solar cell module 1A is slid horizontally to the right (fourth direction) along the second portion 51B2. This engages the first flange 4121 with the screw 5a. The state of engagement between the first flange 4121 and the screw 5a at this time is shown in FIG. 11.

[0115] At this time, steps (f) and (g) may be performed before step (d), and screws (second screws) 5b may be inserted. In this case, in step (d), solar cell module 1A is positioned so that first portion 51B1 of cutout portion 51B of first flange portion 4121 overlaps with screw 5a, and first portion 52B1 of cutout portion 52B of second flange portion 4122 overlaps with screw 5b. Thereafter, solar cell module 1A can be slid to the right (fourth direction) along second portions 51B2 and 52B2. This engages first flange portion 4121 with screw 5a, and second flange portion 4122 with screw 5b. This makes solar cell module 1A less likely to tip over from the wall surface, stabilizing the installation process.

[0116] Although the present invention has been described with reference to a currently preferred embodiment, such disclosure should not be construed as limiting. For example, in the case of installation on a reinforced concrete wall, instead of using sealed stainless steel head screws for steel frame construction, a method of drilling pilot holes into the concrete frame, installing 6 mm diameter SUS anchors (effectively embedded to the frame at least 40 mm deep), and then waterproofing the space between the solar cell module flange and the wall surface can be substituted. Furthermore, in the case of installation on a wooden building, a method of drilling pilot holes in the surface finish material, waterproofing the space between the solar cell module flange and the wall surface, and directly attaching the posts to structural members such as studs with wood screws can be substituted. Various modifications and variations will no doubt become apparent to those skilled in the art from reading the above disclosure. Accordingly, the appended claims should be construed to embrace all modifications and variations that do not depart from the true spirit and scope of the present invention.

[0117] (Addendum) The above description of the embodiments discloses the following techniques. (Technology 1) In a solar cell module for wall installation, a frame body is provided which holds peripheral portions of solar cell panels used in correspondence with each of the plurality of solar cell panels so that the plurality of solar cell panels can be attached to a wall surface, The frame body is a pair of first support portions extending in a first direction and facing each other; a pair of second support portions extending in a second direction intersecting the first direction and facing each other, the first support portion and the second support portion each extend in a third direction intersecting both the first direction and the second direction, and each have a first side surface portion elongated in the first direction and a second side surface portion elongated in the second direction; the solar cell panel is supported on one end side of the first side surface portion and one end side of the second side surface portion; the first support portion has a flange portion on the other end side of the first side surface portion that protrudes away from the solar cell panel, The length of the first side surface portion in the third direction is longer than the length of the second side surface portion, a first flange portion of one of the pair of first support portions has two or more first openings through which a fixing tool to be attached to the wall surface is inserted, two or more second openings are provided at positions corresponding to the first openings of a second flange portion that is the flange portion of the other of the pair of first support portions, A frame body for a wall-mounted solar cell module, in which the first flange portion and the fixing device engage with each other by sliding the relative position of the fixing device within the first opening in a predetermined fourth direction that intersects with the third direction, and the second flange portion is capable of engaging with the first flange portion of another wall-mounted solar cell module in the second opening. (Technology 2) the first opening is a notch extending from an end of the first flange portion toward the first side surface portion, The frame body of the solar cell module for wall surface installation according to Technical 1, wherein the cutout portion includes a portion extending along the fourth direction. (Technology 3) The cutout has a semicircular or semioval shape, The frame body of the wall-mounted solar cell module described in Technology 2, wherein the connection portion between the semicircular or semioval shape and the end of the first flange portion is chamfered, and a guide portion connecting the end of the first flange portion and the semicircular or semioval shape is formed. (Technology 4) The frame body of the solar cell module for wall surface installation described in Technology 3, wherein the guide portion has a tapered shape in which the width in the first direction becomes smaller as it approaches the first side surface portion from the end of the first flange portion, or a shape in which the connection portion has an R-chamfered shape. (Technology 5) the second opening is a notch extending from a boundary between the second flange portion and the first side surface portion of the other first support portion in a direction approaching an end of the second flange portion, A frame body for a wall-mounted solar cell module described in any one of techniques 1 to 4, wherein a third opening extending in a direction approaching the second flange portion is formed in the first side portion of the other first support portion, and the third opening is connected to the cutout portion. (Technology 6) The cutout portion has a semicircular or semioval shape, A frame body for a wall-mounted solar cell module described in Technology 5, wherein the width of the third opening in the first direction is larger than the width of the cutout in the first direction at the point where the cutout and the third opening are connected. (Technology 7) The frame body of the solar cell module for wall installation described in Technology 6, wherein the connection portion between the semicircular or semioval shape and the boundary is chamfered, and a guide portion connecting the boundary and the semicircular or semioval shape is formed. (Technology 8) the first opening and the second opening are cutouts having a first portion that is substantially circular or elliptical and a second portion that extends at least along the fourth direction and is connected to the first portion; The frame of the solar cell module for wall installation according to technique 1, wherein the diameter of the first portion is larger than the width of the portion of the second portion extending along the fourth direction. (Technology 9) The frame body of the wall-mounted solar cell module described in Technology 8, wherein the second part has a semicircular part that is approximately semicircular and a square part whose one side is the diameter of the semicircle, and the square part is connected to the first part. (Technology 10) 5. The frame body of the solar cell module for wall installation according to any one of techniques 1 to 4, wherein the fourth direction is a direction along the first direction or the second direction. (Technology 11) 8. The frame body of the solar cell module for wall installation according to any one of techniques 5 to 7, wherein the fourth direction is a direction along the second direction. (Technology 12) 10. The frame of the solar cell module for wall installation according to claim 8 or 9, wherein the fourth direction is a direction along the first direction.

[0118] (Technology 13) A method for installing solar cell modules for wall mounting, comprising: attaching a plurality of solar cell modules for wall mounting to a wall surface; (a) preparing a first wall-mounted solar cell module and a second wall-mounted solar cell module, each of which has a frame body for the wall-mounted solar cell module according to the first technique; (b) drilling two or more first pilot holes corresponding to the first opening on the wall surface on a reference line of a planned installation position of the first flange portion of the one first support portion of the first wall-mounted solar cell module; (c) inserting a first screw into the first pilot hole and temporarily fastening the first screw in a state where the head of the first screw is raised above the wall surface by at least the thickness of the first flange portion; (d) positioning the first wall-mounted solar cell module so that a portion of the first opening of the first wall-mounted solar cell module overlaps with a head of the first screw, and then sliding the module in the fourth direction to engage the first flange with the first screw; (e) a step of fully tightening the first screw; (f) drilling two or more second pilot holes in the wall surface within the second opening of the second flange portion of the other first support portion of the first wall-mounted solar cell module; (g) inserting a second screw into the second pilot hole and temporarily fastening the second screw in a state where the head of the second screw is raised from the wall surface by at least the sum of the thicknesses of the first flange portion and the second flange portion; (h) positioning the second wall-mounted solar cell module so that the first opening of the second wall-mounted solar cell module overlaps with the head of the second screw, and then sliding the second wall-mounted solar cell module in the fourth direction to engage the first flange of the second wall-mounted solar cell module with the second flange of the first wall-mounted solar cell module and the second screw; and (i) a step of fully tightening the second screw; A method for installing a wall-mounted solar cell module, comprising: (Technology 14) the first opening is a notch extending from an end of the first flange portion toward the first side surface portion, the notch includes a portion extending along the fourth direction, The method for installing a wall-mounted solar cell module described in Technology 13, wherein in step (d), the first wall-mounted solar cell module is slid along the notch portion to engage the first flange portion with the first screw. (Technology 15) the second opening is a notch extending from a boundary between the second flange portion and the first side surface portion of the other first support portion in a direction approaching an end of the second flange portion, a third opening extending in a direction approaching the second flange portion is formed in the first side surface portion of the other first support portion, and the third opening is connected to the notch portion; The installation method for a wall-mounted solar cell module according to technology 13 or 14, wherein the width in the first direction of the third opening at the point where the cutout and the third opening are connected is larger than the width in the first direction of the cutout and is also larger than the diameter of the head of the second screw. (Technology 16) 16. The method for installing a solar cell module for wall installation according to any one of techniques 13 to 15, wherein the fourth direction is a direction along the second direction. (Technology 17) the first opening and the second opening are cutouts having a first portion that is substantially circular or elliptical and a second portion that extends at least along the fourth direction and is connected to the first portion; The diameter of the first portion is larger than the diameter of the head of the first screw, The method for installing a wall-mounted solar cell module described in Technology 13, wherein in step (d), the first screw is inserted into the first portion of the first opening in the first wall-mounted solar cell module, and then the first wall-mounted solar cell module is slid in the fourth direction along the second portion to engage the first flange portion with the first screw. (Technology 18) The method for installing a solar cell module for wall surface installation according to technique 17, wherein the fourth direction is a direction along the first direction. (Technology 19) The method for installing a solar cell module for wall mounting according to any one of techniques 15 to 18, wherein after steps (c) and (g), the first solar cell module for wall mounting is positioned on the wall surface and slid in the fourth direction to perform step (d). [Industrial Applicability]

[0119] The wall-mounted solar cell module according to the present disclosure can be installed on a wall material without a mount, significantly reducing the number of parts and construction costs, and enabling installation work to be completed in a short period of time and at low cost. By installing solar cell modules not only on roofs but also on walls, the spread of solar power generation to homes will be promoted. [Explanation of symbols]

[0120] 1, 1A, 1B solar module 2. Solar panels 4 Frame 41 1st support part 411 First side part 4121 First flange 4122 Second flange 413 Reinforcement processing section 415 Multilayered section 416 Extension 42 Second support part 421 Second side part 45 Reinforcement member 51 First opening 51A Notch 51A1 Information section 51A2 Oval section 51B Cutout 51B1 Part 1 51B2 2nd part 52 Second Opening 52A Notch 52A1 Information section 52A2 Oval section 52B Cutout 52B1 Part 1 52B2 2nd part 53 Third Opening 5 Fixtures 5a, 5b, 5c bis 6 Power Cable W wall material L lip channel steel S Gap OP opening

Claims

1. A wall-mounted solar cell module includes a frame that holds peripheral portions of a plurality of solar cell panels, the frame holding the peripheral portions of the plurality of solar cell panels, the frame corresponding to each of the plurality of solar cell panels, so that the plurality of solar cell panels can be mounted on a wall surface, The frame body is a pair of first support portions extending in a first direction and facing each other; a pair of second support portions extending in a second direction intersecting the first direction and facing each other, the first support portion and the second support portion each have a first side surface portion elongated in the first direction and a second side surface portion elongated in the second direction, the first side surface portion and the second side surface portion extending in a third direction intersecting both the first direction and the second direction; the solar cell panel is supported on one end side of the first side surface portion and one end side of the second side surface portion; the first support portion has a flange portion on the other end side of the first side surface portion that protrudes away from the solar cell panel, The length of the first side surface portion in the third direction is longer than the length of the second side surface portion, a first flange portion of one of the pair of first support portions has two or more first openings through which a fastener to be attached to the wall surface is inserted, two or more second openings are provided at positions corresponding to the first openings of a second flange portion that is the flange portion of the other of the pair of first support portions, A frame body for a wall-mounted solar cell module, in which the first flange portion and the fixing device engage with each other by sliding the relative position of the fixing device within the first opening in a predetermined fourth direction that intersects with the third direction, and the second flange portion is capable of engaging with the first flange portion of another wall-mounted solar cell module in the second opening.

2. the first opening is a notch extending from an end of the first flange portion in a direction approaching the first side surface portion, The frame body for a wall-mounted solar cell module according to claim 1 , wherein the notch includes a portion extending along the fourth direction.

3. The cutout has a semicircular or semioval shape, 3. The frame body of a wall-mounted solar cell module according to claim 2, wherein the connection portion between the semicircular or semioval shape and the end of the first flange portion is chamfered, and a guide portion is formed connecting the end of the first flange portion and the semicircular or semioval shape.

4. 4. The frame body of a wall-mounted solar cell module as described in claim 3, wherein the guide portion has a tapered shape in which the width in the first direction becomes smaller as it approaches the first side portion from the end of the first flange portion, or a shape in which the connection portion has an R-chamfered shape.

5. the second opening is a notch extending from a boundary between the second flange portion and the first side surface portion of the other first support portion in a direction approaching an end of the second flange portion, A frame body for a wall-mounted solar cell module described in any one of claims 1 to 4, wherein a third opening extending in a direction approaching the second flange portion is formed in the first side portion of the other first support portion, and the third opening is connected to the cutout portion.

6. The cutout portion has a semicircular or semioval shape, 6. A frame body for a wall-mounted solar cell module as described in claim 5, wherein at the point where the cutout portion and the third opening are connected, the width of the third opening in the first direction is larger than the width of the cutout portion in the first direction.

7. 7. The frame body of a solar cell module for wall installation according to claim 6, wherein a connection portion between the semicircular or semioval shape and the boundary is chamfered, and a guide portion connecting the boundary and the semicircular or semioval shape is formed.

8. the first opening and the second opening are cutouts each having a substantially circular or elliptical first portion and a second portion extending at least along the fourth direction and connected to the first portion; The frame body for a wall-mounted solar cell module according to claim 1 , wherein the diameter of the first portion is larger than the width of the portion of the second portion that extends along the fourth direction.

9. 9. The frame body of a wall-mounted solar cell module according to claim 8, wherein the second portion has a semicircular portion that is approximately semicircular and a square portion whose one side is the diameter of the semicircle, and the square portion is connected to the first portion.

10. 5. The frame body for a solar cell module to be installed on a wall surface according to claim 1, wherein the fourth direction is a direction along the first direction or the second direction.

11. The frame body for a solar cell module to be installed on a wall surface according to claim 5 , wherein the fourth direction is a direction along the second direction.

12. The frame body for a solar cell module to be installed on a wall surface according to claim 8 or 9, wherein the fourth direction is a direction along the first direction.

13. A method for installing solar cell modules for wall mounting, comprising: attaching a plurality of solar cell modules for wall mounting to a wall surface; (a) preparing a first wall-mounted solar cell module and a second wall-mounted solar cell module, each of which has the frame body of the wall-mounted solar cell module according to claim 1; (b) drilling two or more first pilot holes corresponding to the first openings on the wall surface on a reference line of a planned installation position of the first flange portion of the one first support portion of the first wall-mounted solar cell module; (c) inserting a first screw into the first pilot hole and temporarily fastening the first screw in a state where the head of the first screw is raised above the wall surface by at least the thickness of the first flange portion; (d) positioning the first wall-mounted solar cell module so that a portion of the first opening of the first wall-mounted solar cell module overlaps with a head of the first screw, and then sliding the first wall-mounted solar cell module in the fourth direction to engage the first flange with the first screw; (e) a step of fully tightening the first screw; (f) drilling two or more second pilot holes in the wall surface within the second opening of the second flange portion of the other first support portion of the first wall-mounted solar cell module; (g) inserting a second screw into the second pilot hole and temporarily fastening the second screw in a state where the head of the second screw is raised from the wall surface by at least the sum of the thicknesses of the first flange portion and the second flange portion; (h) positioning the second wall-mounted solar cell module so that the first opening of the second wall-mounted solar cell module overlaps with the head of the second screw, and then sliding the second wall-mounted solar cell module in the fourth direction to engage the first flange of the second wall-mounted solar cell module with the second flange of the first wall-mounted solar cell module and the second screw; and (i) a step of fully tightening the second screw; A method for installing a wall-mounted solar cell module, comprising:

14. the first opening is a notch extending from an end of the first flange in a direction approaching the first side surface portion, the notch includes a portion extending along the fourth direction, 14. The method for installing a wall-mounted solar cell module according to claim 13, wherein in step (d), the first wall-mounted solar cell module is slid along the notch portion to engage the first flange portion with the first screw.

15. the second opening is a notch extending from a boundary between the second flange portion and the first side surface portion of the other first support portion in a direction approaching an end of the second flange portion, a third opening extending in a direction approaching the second flange portion is formed in the first side surface portion of the other first support portion, and the third opening is connected to the notch portion; 14. The installation method for a wall-mounted solar cell module according to claim 13, wherein the width in the first direction of the third opening at the point where the cutout and the third opening are connected is larger than the width in the first direction of the cutout and larger than the diameter of the head of the second screw.

16. The method for installing a solar cell module for wall surface installation according to claim 15 , wherein the fourth direction is a direction along the second direction.

17. the first opening and the second opening are cutouts each having a substantially circular or elliptical first portion and a second portion extending at least along the fourth direction and connected to the first portion; The diameter of the first portion is larger than the diameter of the head of the first screw, 14. The method for installing a wall-mounted solar cell module according to claim 13, wherein in step (d), the first screw is inserted into the first portion of the first opening in the first wall-mounted solar cell module, and then the first wall-mounted solar cell module is slid in the fourth direction along the second portion to engage the first flange portion with the first screw.

18. The method for installing a solar cell module for wall surface installation according to claim 17 , wherein the fourth direction is a direction along the first direction.

19. 19. The method for installing a solar cell module for wall mounting according to claim 15, wherein after steps (c) and (g), the first solar cell module for wall mounting is positioned on the wall surface and slid in the fourth direction to perform step (d).

Images