Point support method for solar module using re-adhesive elastic material

Abstract

To provide a flexible solar panel that can be installed by a non-destructive and simple construction method. [Solution] This flexible solar panel has multiple adhesive materials distributed on its back surface, and is configured to create an air gap between the flexible solar panel and the installation surface, allowing it to be fixed non-destructively to the roof or wall of a building. Because it does not use metal parts, there is no need to worry about corrosion or a decrease in waterproofing, and no processing of the roof or other surfaces is required. In addition to improving heat dissipation and power generation efficiency, the panel can also be easily removed and reused.

Description

[Technical Field]

[0001] This invention relates to a method for easily and reliably installing solar panels without using mounting brackets or curing adhesives, using a re-adhesive elastic material, without destructive force. This invention is particularly suitable for solar modules such as thin, lightweight flexible solar panels (hereinafter referred to as flexible solar panels). [Background technology]

[0002] The installation of solar panels, particularly flexible solar panels, has recently become more common, and the most widely used installation methods are to fasten the panels to a mounting frame on a structure with screws or bolts, or to attach them directly to the structure with adhesive or double-sided tape, which is time-consuming and labor-intensive. These methods have various problems, including the need to drill holes in the roof or wall when installing on a mounting frame, and the difficulty of installing with adhesive, which takes time for the adhesive to harden.

[0003] Conventional installation methods can damage the substrate when removing panels for restoration or due to malfunctions, so there is a growing need for simple, non-destructive installation methods for flexible solar panels.

[0004] When installed using a curing adhesive method, there is no gap between the solar panel and the installation surface (roof or wall), which makes it impossible to avoid the temperature of the panel rising, leading to a decrease in power generation. Summary of the Invention [Problem to be solved by the invention]

[0005] Conventional flexible solar panel installation methods all place physical and chemical burdens on the installation surface, and have inherent issues such as the following:

[0006] When fixing to a mounting frame, holes must be drilled in the roof or wall, which requires additional work such as waterproofing, and compromises the non-destructive nature of the installation surface.

[0007] Fixing with adhesive is difficult to remove, and in many cases it is virtually impossible to restore the original condition, which has limited its use, particularly in rental properties and temporary properties.

[0008] Construction takes time and effort, and there is also the need to wait for the adhesive to harden, making work inefficient.

[0009] Panels that are directly attached with adhesive or double-sided tape cannot dissipate heat and are prone to temperature increases, resulting in reduced power generation efficiency.

[0010] Structures that use mounting frames and metal parts are at high risk of corrosion and deterioration in salt-damaged or humid environments, and require regular maintenance.

[0011] In some cases, it was difficult to provide evidence of the strength of the construction work against external forces such as strong winds and gusts of wind. [Effects of the Invention]

[0012] As shown in Figure 1, it can be installed using only re-adhesive elastic material, which allows for non-destructive installation and removal, and construction is simple and can be completed in a short time.

[0013] As shown in Figure 2, the thickness of the re-adhesive elastic material, which is 1mm to 5mm, creates a structure in which an air layer naturally forms between the substrate and the solar panel. This creates an air layer between the installation surface and the panel, so the flexible solar panel does not retain heat and ensures stable power generation efficiency. Figure 3 shows the disadvantage of the curing adhesive method, which is that no air layer is created and heat is generated.

[0014] Figure 4 shows the load in the direction of wind pressure, and the "vertical adhesive force, N," which is an indicator for preventing panels from rolling up or peeling off, especially during typhoons, shows that the adhesive elastic material of this invention exerts a holding force of approximately 652 N per 50 mm square panel. For example, the wind pressure acting on a panel in a strong wind with a wind speed (V) of 50 m / s can be calculated using the wind pressure calculation coefficient (0.613) using the following formula.

[0015] The holding power against wind pressure during strong winds (wind speed 50 m / s) can be expressed by the following formula. 1 Wind pressure calculation formula: P = 0.613 × V 2 2 Wind pressure at a wind speed of 50 m / s: 0.613 × 50 2 = 1532.5N / sqm 3 Panel area: Approximately 2 square meters → Estimated wind pressure: 3065N 4 Total holding force of 20 adhesive units: 13,040N 5 Safety factor: 13,040N ÷ 3065N ≒ approximately 4.2 times From the above, sufficient safety can be ensured even against peeling due to being rolled up in strong winds.

[0016] Figure 5 shows that the unit can be safely installed on a vertical wall against vertical loads. This is indicated as "180-degree peel strength (N / 25 mm)" by the JIS Z 0237 standard, and indicates the wall mounting retention strength of re-adhesive elastic materials.

[0017] Assuming the weight of the panel is approximately 3 kg / m², the conversion to physical load (N) is calculated using the Earth's gravitational acceleration g = 9.8 m / s 2 is used. Vertical load (N) = Mass (kg) × Gravitational acceleration (g) = 3kg × 9.8 m / s 2 = 29.4N. The adhesive elastic material of this invention has a 180-degree peel strength of 25.4N / 25mm, which means that it can exert a holding force equivalent to a vertical load of approximately 29.4N per 25mm width panel. Therefore, while theoretically one panel could support a panel weighing approximately 3kg per panel, in actual design, taking into account wind pressure and safety factors, we recommend installing 10 panels per square meter. The total holding force in this case is 25.4N x 10 panels x 2 (50mm width) = 508N, which is more than 17 times the static load (29.4N) and can prevent panels from falling or peeling with an extremely high safety factor.

[0018] The calculation of the holding force and safety factor for the point support method can be shown by the following formula. 1 Flexible solar panel weight: 5.8kg x 9.8m / s 2 ≒ 56.8N 2. 180-degree peel strength of one sheet of re-adhesive elastic material (25.4N / 25mm): 50mm square ⇒ 50.8N / sheet 3 Total holding force: 50.8N x 20 sheets = 1016N 4 Safety factor: 1016N ÷ 56.8N ≒ approximately 17.9 times As a result of the above, it has extremely high holding power in the vertical direction (gravity), and it can be installed on a vertical wall using a re-adhesive elastic material without being fixed with bolts or the like.

[0019] It is resistant to corrosive environments, and can be reused or reinstalled after construction. This is a useful new installation method that combines ease of use, convenience, and durability.

[0020] In this way, the point support adhesive construction method of this invention achieves extremely high holding power and safety factor in terms of both self-weight and wind pressure.

[0021] Furthermore, this invention can be flexibly adapted to the size and weight of the flexible solar panel to be installed by adjusting the size (25 to 100 mm square) (1 to 10 mm thick), number of sheets to be installed, and spacing, and can be applied to a variety of substrates such as roofs, walls, slate, and urethane-coated surfaces. [Means for solving the problem]

[0022] The re-adhesive elastic material used in the present invention has the following physical properties:

[0023] Vertical adhesive strength: 26N / cm² or more

[0024] 180° peel strength: 25.4N / 25mm (JIS Z 0237 compliant)

[0025] Peel elongation: 1.92 mm

[0026] The main feature of this invention is the fixing method of flexible solar panels using point support, which uses re-adhesive elastic material and attaches it in a distributed manner. [Brief explanation of the drawings]

[0027] [Figure 1] This is an explanatory diagram of the back of a flexible solar panel, showing a construction method in which re-adhesive elastic material (50 mm square, 5 mm thick) is distributed in dots on the back of the panel and fixed in place non-destructively with point support. A specific example of the material arrangement (5 rows vertically x 4 columns horizontally) is shown. [Figure 2] This is a cross-sectional diagram clearly illustrating how, in the point support method, a natural air layer is formed between the panel and the installation surface due to the thickness of the re-adhesive elastic material (1 to 10 mm), improving heat dissipation performance. [Figure 3] This is a cross-sectional diagram illustrating the problem with conventional curing adhesive construction methods, where the panel and installation surface are in complete contact with each other, preventing the formation of an air layer, which makes it easier for the panel temperature to rise and reduces power generation efficiency. [Figure 4] This is a schematic diagram that visually shows the direction of wind pressure acting on the panel surface and how the load is applied during strong winds (e.g., wind speed equivalent to 50 m / s), and shows that the re-adhesive elastic material used for point support has sufficient holding power against wind pressure. [Figure 5] This is a schematic explanatory diagram showing that re-adhesive elastic material is placed in multiple locations (20 locations in the illustrated example) to effectively and evenly distribute and support vertical loads such as the panel's own weight. DETAILED DESCRIPTION OF THE INVENTION

[0028] As an example of installation of the present invention, a re-adhesive elastic material was attached to a 400-watt flexible solar panel (dimensions: approximately 1000 mm x 2000 mm, weight: approximately 5.8 kg). [Example]

[0029] Figure 1 shows a rear view of the point support method, in which 20 sheets of 50mm square x 5mm thick re-adhesive elastic material are affixed in five vertical rows and four horizontal rows, and directly bonded to a horizontal or vertical surface. This number of sheets and point support locations are just an example, and the number and placement can be flexibly adjusted depending on the installation location and the size and weight of the flexible solar panel. For example, if a flexible solar panel is to be installed on a slate or urethane-coated roof covering an area of ​​approximately 3 square meters (approximately 1500 mm x 2000 mm, weighing approximately 9 kg), a safety factor of more than five times can be ensured by setting the size of the re-adhesive elastic material to 25 mm square and placing 16 pieces per square meter. Furthermore, when installing a small 200-watt panel (approximately 700 mm x 1400 mm, weighing approximately 3 kg) on ​​a vertical wall, placing eight 50 mm square adhesive units can ensure a vertical safety factor of approximately 10 times or more, sufficiently reducing the risk of the panel falling or peeling off. In this way, the present invention has a degree of design freedom that allows it to respond flexibly and safely to installation conditions. [Industrial Applicability]

[0030] This invention provides a completely new method for fixing flexible solar panels that is not only non-destructive, highly durable, easy to install, and reversible, but also does not impair the performance of the solar panels.

Claims

[Claim 1] A point support method characterized by distributing multiple re-adhesive elastic materials in a dot pattern on the back of a flexible solar panel, forming an air layer between the panel and the ground surface, and non-destructively fixing the panel to the roof or wall surface of a building.

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