Environmental power generation module and method for manufacturing the same
The environmental power generation module employs a snap-fitting frame structure to simplify the manufacturing process and enhance fitting strength, addressing the complexity of traditional frame connections.
Patent Information
- Application Number
- JP2022538652
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2020-07-22
- Filing Date
- 2021-06-22
- Publication Date
- 2025-06-18
- Estimated Expiration
- 2041-06-22
AI Technical Summary
The manufacturing process of environmental power generation modules is complicated due to the need to connect adjacent partial frames with fixtures like screws.
An environmental power generation module with a frame structure that includes a plate-shaped power generation element and partial frames with alternating snap-fitting outer and inner peripheral walls, simplifying the attachment process by eliminating the need for screws.
The snap-fitting mechanism simplifies the manufacturing process and ensures strong fitting strength between the frames, securely supporting the power generation element.
Smart Images

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Abstract
Description
Technical Field
[0001] The present invention relates to an environmental power generation module and a method for manufacturing the same.
Background Art
[0002] There is known an environmental power generation module having an environmental power generation element such as a solar cell element and a frame attached to the outer peripheral edge thereof, and the frame is composed of a plurality of partial frames. For example, Patent Document 1 describes an environmental power generation module in which a frame is constituted by partial frames respectively attached along four sides of a rectangular flat solar cell element.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, in the environmental power generation module as described in Patent Document 1, since it is necessary to connect adjacent partial frames to each other by a fixture such as a screw, the manufacturing process is complicated.
[0005] Therefore, an object of the present invention is to provide an environmental power generation module and a method for manufacturing the same that can simplify the manufacturing process.
Means for Solving the Problems
[0006] An environmental power generation module as one aspect of the present invention includes a plate-shaped environmental power generation element having a first main surface, a second main surface located on the back side of the first main surface, and a first side forming corner portions at both ends, a first partial frame configured to support the outer peripheral edge of the first main surface, and a second partial frame configured to support the outer peripheral edge of the second main surface. The first partial frame has a first outer peripheral wall that extends along the outer peripheral edge of the environmental power generation element and extends from the side of the first main surface toward the side of the second main surface. The second partial frame has a second outer peripheral wall configured to radially overlap the first outer peripheral wall. The frame has an alternating arrangement structure in which a second outer peripheral wall outer structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially outer side and snap-fits therewith and a second outer peripheral wall inner structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially inner side and snap-fits therewith are alternately arranged along the outer peripheral edge of the environmental power generation element, with respect to the first side. According to such a configuration, by snap-fitting the first outer peripheral wall and the second outer peripheral wall with each other in the alternating arrangement structure, the first partial frame and the second partial frame can be attached to the outer peripheral edge of the environmental power generation element. Therefore, the manufacturing process of the environmental power generation module can be simplified. Further, at the first side, the elastic deformation of the first partial frame relative to the second partial frame in the radially outer direction is suppressed by the second outer peripheral wall outer structure, and the elastic deformation of the first partial frame relative to the second partial frame in the radially inner direction is suppressed by the second outer peripheral wall inner structure. Therefore, good fitting strength between the first frame and the second partial frame can be ensured at the first side.
[0007] As one embodiment of the present invention, the first partial frame is configured to support the outer peripheral edge of the first main surface at the first side, and the second partial frame is configured to support the outer peripheral edge of the second main surface at the first side. According to such a configuration, the environmental power generation element can be firmly supported by the frame at the first side.
[0008] As one embodiment of the present invention, the first partial frame and the second partial frame are configured to cooperate to sandwich the environmental power generation element on the first side. According to such a configuration, the environmental power generation element can be more firmly supported by the frame on the first side.
[0009] As one embodiment of the present invention, the environmental power generation element has a second side and a third side located on both adjacent sides of the first side, and a fourth side located on the opposite side of the first side, and has a rectangular plate shape, and the frame has the alternating arrangement structure for each of the second side, the third side, and the fourth side. According to such a configuration, the environmental power generation element can be firmly supported by the frame.
[0010] As a manufacturing method of an environmental power generation module according to an aspect of the present invention, the environmental power generation module includes a plate-shaped environmental power generation element having a first main surface, a second main surface located on the back side of the first main surface, and a first side forming corner portions at both ends, a first partial frame configured to support an outer peripheral edge of the first main surface, and a second partial frame configured to support an outer peripheral edge of the second main surface, and the frame has an alternating arrangement structure in which a second outer peripheral wall outer structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially outer side and snap-fits therewith and a second outer peripheral wall inner structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially inner side and snap-fits therewith are alternately arranged along the outer peripheral edge of the environmental power generation element, with respect to the first side, and the manufacturing method includes a frame attachment step of attaching the first partial frame and the second partial frame to the outer peripheral edge of the environmental power generation element by snap-fitting the first outer peripheral wall and the second outer peripheral wall to each other in the alternating arrangement structure. According to such a configuration, the manufacturing process of the environmental power generation module can be simplified by the frame attachment step using snap-fitting. Further, the alternating arrangement structure can ensure good fitting strength between the first frame and the second partial frame at the first side.
Effect of the Invention
[0011] According to the present invention, it is possible to provide an environmental power generation module and a manufacturing method thereof that can simplify the manufacturing process.
Brief Description of the Drawings
[0012]
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Mode for Carrying Out the Invention
[0013] Hereinafter, with reference to the drawings, the environmental power generation module 1 according to an embodiment of the present invention and its manufacturing method will be exemplified and described in detail.
[0014] The environmental power generation module 1 of the present embodiment shown in FIGS. 1 to 2 has an environmental power generation element 2, a terminal member 3, and a frame 4. The frame 4 has a first partial frame 5 and a second partial frame 6. The environmental power generation element 2 is a solar cell element configured to convert light energy such as sunlight and indoor light into electrical energy. Note that the environmental power generation element 2 is not limited to a solar cell element, and may be, for example, a thermoelectric conversion element configured to convert thermal energy such as geothermal energy into electrical energy.
[0015] The environmental power generation element 2 has a rectangular flat plate shape, and the outer peripheral edge of the environmental power generation element 2 has a first side 2a, a second side 2b, a third side 2c, and a fourth side 2d. A first corner 2e is formed by the first side 2a and the second side 2b, a second corner 2f is formed by the first side 2a and the third side 2c, a third corner 2g is formed by the second side 2b and the fourth side 2d, and a fourth corner 2h is formed. The second side 2b and the third side 2c are located on both adjacent sides of the first side 2a, and the fourth side 2d is located on the opposite side of the first side 2a. A terminal convex portion 2i protruding radially outward is provided on the fourth side 2d. The first side 2a, the second side 2b, and the third side 2c are straight.
[0016] Further, the ambient power generation element 2 has a first main surface 2j and a second main surface 2k located on the back side of the first main surface 2j. In the present embodiment, for convenience of explanation, the direction perpendicular to the ambient power generation element 2, that is, the thickness direction of the ambient power generation element 2 is referred to as the vertical direction, the direction from the side of the second main surface 2k toward the side of the first main surface 2j is referred to as the upward direction, the direction from the side of the first main surface 2j toward the side of the second main surface 2k is referred to as the downward direction, the direction from the inside to the outside of the ambient power generation element 2 within a plane perpendicular to the vertical direction is referred to as the radially outward direction, the direction from the outside to the inside of the ambient power generation element 2 within a plane perpendicular to the vertical direction is referred to as the radially inward direction, and the direction that circulates around the ambient power generation element 2 within a plane perpendicular to the vertical direction is referred to as the circumferential direction.
[0017] The terminal member 3 has a terminal 3a for taking out the power generated by the ambient power generation element 2 to the outside. The terminal member 3 is disposed on the terminal projection 2i and is configured to be held by the frame 4 in a state where the frame 4 is attached to the outer peripheral edge of the ambient power generation element 2.
[0018] The outer peripheral edge of the ambient power generation element 2 is covered by the frame 4 over the entire circumference and is thereby protected. The frame 4 is composed of a first partial frame 5 and a second partial frame 6 which are two partial frames configured to be snap-fitted to each other in the vertical direction, that is, the stepped portions elastically deform to overcome each other in the vertical direction and fit together.
[0019] The first partial frame 5 and the second partial frame 6 are each made of a synthetic resin such as a polycarbonate resin. Note that the first partial frame 5 and the second partial frame 6 are not limited to being made of a synthetic resin. Further, the first partial frame 5 and the second partial frame 6 are each integrally formed by injection molding. Note that the first partial frame 5 and the second partial frame 6 may each be configured by assembling a plurality of members using a fixture such as a screw or by adhesion or fitting. Also, the vertical thickness of the frame 4 in the assembled state can be, for example, about 3 mm.
[0020] As shown in FIGS. 3 to 6, the first partial frame 5 has a first support surface 5a configured to support the outer peripheral edge of the first main surface 2j on the first side 2a. Further, the first partial frame 5 has a first outer peripheral wall 5b that extends along the first side 2a and extends in the vertical direction from the side of the first main surface 2j toward the side of the second main surface 2k. That is, the first outer peripheral wall 5b is configured as a wall perpendicular to the radial direction. The first partial frame 5 has a first main wall 5c having the first support surface 5a as a lower surface, and the first outer peripheral wall 5b extends downward from the first main wall 5c along the vertical direction.
[0021] The second partial frame 6 has a second support surface 6a configured to support the outer peripheral edge of the second main surface 2k on the first side 2a. Further, the second partial frame 6 has a second outer peripheral wall 6b that extends along the first side 2a and extends in the vertical direction from the side of the second main surface 2k toward the side of the first main surface 2j. That is, the second outer peripheral wall 6b is configured as a wall perpendicular to the radial direction. The second outer peripheral wall 6b is configured to overlap the first outer peripheral wall 5b in the radial direction. The second partial frame 6 has a second main wall 6c having the second support surface 6a as an upper surface, and the second outer peripheral wall 6b extends upward from the second main wall 6c along the vertical direction.
[0022] It is preferable that the first support surface 5a of the first partial frame 5 and the second support surface 6a of the second partial frame 6 cooperate to sandwich the environmental power generation element 2 on the first side 2a in order to firmly support the environmental power generation element 2 by the frame 4 on the first side 2a.
[0023] In addition, the frame 4 has an alternating arrangement structure 7 in which a second outer peripheral wall outer structure 7a, configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the radially outer side and snap-fits in the vertical direction, and a second outer peripheral wall inner structure 7b, configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the radially inner side and snap-fits in the vertical direction, are alternately arranged along the outer peripheral edge of the environmental power generation element 2, with respect to the first side 2a. Note that FIGS. 3 to 4 show only one second outer peripheral wall outer structure 7a and one second outer peripheral wall inner structure 7b, but the number of the second outer peripheral wall outer structures 7a and the second outer peripheral wall inner structures 7b included in the alternating arrangement structure 7 can be set as appropriate.
[0024] On one side 2a, the portion of the first outer peripheral wall 5b that constitutes the second outer peripheral wall outer structure 7a and the portion of the second outer peripheral wall 6b that constitutes the second outer peripheral wall inner structure 7b are aligned in the circumferential direction, and the portion of the second outer peripheral wall 6b that constitutes the second outer peripheral wall outer structure 7a and the portion of the first outer peripheral wall 5b that constitutes the second outer peripheral wall inner structure 7b are aligned in the circumferential direction.
[0025] In the second outer peripheral wall outer structure 7a, the second outer peripheral wall 6b has a convex portion 8 as a stepped portion, and the first outer peripheral wall 5b has a concave portion 9 as a stepped portion, but a configuration in which the convex portion 8 and the concave portion 9 are interchanged may also be used. That is, the second outer peripheral wall 6b may have a concave portion 9 as a stepped portion, and the first outer peripheral wall 5b may have a convex portion 8 as a stepped portion.
[0026] In the second outer peripheral wall inner structure 7b, the second outer peripheral wall 6b has a concave portion 9 as a stepped portion, and the first outer peripheral wall 5b has a convex portion 8 as a stepped portion, but a configuration in which the concave portion 9 and the convex portion 8 are interchanged may also be used. That is, the second outer peripheral wall 6b may have a convex portion 8 as a stepped portion, and the first outer peripheral wall 5b may have a concave portion 9 as a stepped portion.
[0027] In the second outer peripheral wall outer structure 7a, it is preferable that the outer peripheral surface of the first outer peripheral wall 5b and the inner peripheral surface of the second outer peripheral wall 6b are in contact with each other in order to ensure the fitting strength. Also, in the second outer peripheral wall inner structure 7b, it is preferable that the inner peripheral surface of the first outer peripheral wall 5b and the outer peripheral surface of the second outer peripheral wall 6b are in contact with each other in order to ensure the fitting strength.
[0028] Note that in each of the second outer peripheral wall outer structure 7a and the second outer peripheral wall inner structure 7b, there may or may not be a gap between the lower surface of the first outer peripheral wall 5b and the upper surface of the second main wall 6c, and there may or may not be a gap between the upper surface of the second outer peripheral wall 6b and the lower surface of the first main wall 5c. In the second outer peripheral wall outer structure 7a, the outer peripheral surfaces of the first main wall 5c and the second outer peripheral wall 6b may or may not be flush. In the second outer peripheral wall inner structure 7b, the outer peripheral surfaces of the second main wall 6c and the first outer peripheral wall 5b may or may not be flush.
[0029] Also, in the second outer peripheral wall outer structure 7a, it may be configured such that there is no first main wall 5c above the second outer peripheral wall 6b, and the second outer peripheral wall 6b is extended upward so that the upper surface of the second outer peripheral wall 6b and the upper surface of the first main wall 5c are flush. In the second outer peripheral wall inner structure 7b, it may be configured such that there is no second main wall 6c below the first outer peripheral wall 5b, and the first outer peripheral wall 5b is extended downward so that the lower surface of the first outer peripheral wall 5b and the lower surface of the second main wall 6c are flush.
[0030] Note that in the second outer peripheral wall outer structure 7a, in order to facilitate snap fitting, the corner between the upper surface and the tip surface of the convex portion 8 may be chamfered, or the corner between the lower surface and the outer peripheral surface of the first outer peripheral wall 5b may be chamfered. Also, in the second outer peripheral wall inner structure 7b, in order to facilitate snap fitting, the corner between the lower surface and the tip surface of the convex portion 8 may be chamfered, or the corner between the upper surface and the outer peripheral surface of the second outer peripheral wall 6b may be chamfered.
[0031] Frame 4 has an alternating arrangement structure 7 with the above configuration not only for the first side 2a but also for each of the second side 2b, the third side 2c, and the fourth side 2d. Further, the first support surface 5a of the first partial frame 5 is configured to support the outer peripheral edge of the first main surface 2j not only at the first side 2a but also at each of the second side 2b, the third side 2c, and the fourth side 2d. Also, the second support surface 6a of the second partial frame 6 is configured to support the outer peripheral edge of the second main surface 2k not only at the first side 2a but also at each of the second side 2b, the third side 2c, and the fourth side 2d.
[0032] The environmental power generation module 1 of the present embodiment can be easily manufactured by undergoing a frame attachment process of attaching the first partial frame 5 and the second partial frame 6 to the outer peripheral edge of the environmental power generation element 2 by snap-fitting the first outer peripheral wall 5b and the second outer peripheral wall 6b vertically with each other in the alternating arrangement structure 7.
[0033] Also, at the first side 2a, the elastic deformation of the first partial frame 5 radially outward relative to the second partial frame 6 is suppressed by the second outer peripheral wall outer structure 7a, and the elastic deformation of the first partial frame 5 radially inward relative to the second partial frame 6 is suppressed by the second outer peripheral wall inner structure 7b. Therefore, good fitting strength between the first partial frame 5 and the second partial frame 6 can be ensured at the first side 2a.
[0034] Also, the environmental power generation module 1 of the present embodiment can ensure good fitting strength between the first partial frame 5 and the second partial frame 6 by the alternating arrangement structure 7 not only at the first side 2a but also at each of the second side 2b, the third side 2c, and the fourth side 2d. Therefore, the environmental power generation element 2 can be firmly supported by the frame 4.
[0035] The above-described embodiments are merely examples of the embodiments of the present invention, and various modifications can be made without departing from the gist of the invention.
[0036] Therefore, the environmental power generation module 1 and its manufacturing method of the above-described embodiment can be variously modified as described below, for example.
[0037] The environmental power generation module 1 includes a plate-shaped environmental power generation element 2 having a first main surface 2j, a second main surface 2k located on the back side of the first main surface 2j, and a first side 2a forming corner portions (a first corner portion 2e and a second corner portion 2f) at both ends, a first partial frame 5 configured to support the outer peripheral edge of the first main surface 2j, and a second partial frame 6 configured to support the outer peripheral edge of the second main surface 2k. The frame 4 has a first outer peripheral wall 5b that extends along the outer peripheral edge of the environmental power generation element 2 and extends from the side of the first main surface 2j toward the side of the second main surface 2k. The second partial frame 6 has a second outer peripheral wall 6b configured to overlap the first outer peripheral wall 5b in the radial direction. The frame 4 has a second outer peripheral wall outer structure 7a configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the radially outer side and snaps into place, and a second outer peripheral wall inner structure 7b configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the radially inner side and snaps into place. As long as the alternating arrangement structure 7 in which the second outer peripheral wall outer structure 7a and the second outer peripheral wall inner structure 7b are alternately arranged along the outer peripheral edge of the environmental power generation element 2 is provided with respect to the first side 2a, various modifications are possible.
[0038] However, in the environmental power generation module 1, it is preferable that the first partial frame 5 is configured to support the outer peripheral edge of the first main surface 2j at the first side 2a, and the second partial frame 6 is configured to support the outer peripheral edge of the second main surface 2k at the first side 2a.
[0039] Further, in the environmental power generation module 1, it is preferable that the first partial frame 5 and the second partial frame 6 are configured to cooperate to sandwich the environmental power generation element 2 at the first side 2a.
[0040] Further, in the environmental power generation module 1, the environmental power generation element 2 has a second side 2b and a third side 2c located on both sides adjacent to the first side 2a, and a fourth side 2d located on the opposite side of the first side 2a, and has a rectangular plate shape. It is preferable that the frame 4 has an alternating arrangement structure 7 for each of the second side 2b, the third side 2c, and the fourth side 2d.
[0041] The manufacturing method of the environmental power generation module 1 includes a plate-shaped environmental power generation element 2 in which the environmental power generation module 1 includes a first main surface 2j, a second main surface 2k located on the back side of the first main surface 2j, and a first side 2a forming corner portions (first corner portion 2e, second corner portion 2f) at both ends, a first partial frame 5 configured to support the outer peripheral edge of the first main surface 2j, and a second partial frame 6 configured to support the outer peripheral edge of the second main surface 2k. The frame 4 has a first outer peripheral wall 5b that extends along the outer peripheral edge of the environmental power generation element 2 and extends from the side of the first main surface 2j toward the side of the second main surface 2k. The second partial frame 6 has a second outer peripheral wall 6b configured to overlap the first outer peripheral wall 5b in the radial direction. The frame 4 has a second outer peripheral wall outer structure 7a configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the outside in the radial direction and snaps into place, and a second outer peripheral wall inner structure 7b configured such that the second outer peripheral wall 6b overlaps the first outer peripheral wall 5b from the inside in the radial direction and snaps into place. The alternating arrangement structure 7 in which the second outer peripheral wall outer structure 7a and the second outer peripheral wall inner structure 7b are alternately arranged along the outer peripheral edge of the environmental power generation element 2 is provided with respect to the first side 2a. As long as the manufacturing method has a frame attachment step of attaching the first partial frame 5 and the second partial frame 6 to the outer peripheral edge of the environmental power generation element 2 by snap-fitting the first outer peripheral wall 5b and the second outer peripheral wall 6b to each other in the alternating arrangement structure 7, various modifications are possible.
Industrial Applicability
[0042] According to the present invention, it is possible to provide an environmental power generation module and a manufacturing method thereof that can simplify the manufacturing process.
Explanation of Reference Numerals
[0043] 1 Environmental power generation module 2 Environmental power generation element 2a First side 2b Second side 2c Third side 2d Fourth side 2e First corner 2f Second corner 2g Third corner 2h Fourth corner 2i Protrusion for terminal 2j First main surface 2k Second main surface 3 Terminal member 4 Frame 5 First partial frame 5a First support surface 5b First outer peripheral wall 5c First main wall 6 Second partial frame 6a Second support surface 6b Second outer peripheral wall 6c Second main wall 7 Alternating arrangement structure 7a Structure outside the second outer peripheral wall 7b Structure inside the second outer peripheral wall 8 Protrusion 9 Recess
Claims
1. A plate-shaped environmental power generation element that includes a first main surface, a second main surface located on the back side of the first main surface, and a first side that forms corner portions at both ends, and is configured to convert light energy into electrical energy or a thermoelectric conversion element configured to convert thermal energy into electrical energy, and A frame including a first partial frame configured to support the outer peripheral edge of the first main surface and a second partial frame configured to support the outer peripheral edge of the second main surface. The first partial frame has a first outer peripheral wall that extends along the outer peripheral edge of the environmental power generation element and extends from the side of the first main surface toward the side of the second main surface. The second partial frame has a second outer peripheral wall configured to radially overlap the first outer peripheral wall. The frame has an alternating arrangement structure in which a second outer peripheral wall outer structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially outer side and snap-fits, and a second outer peripheral wall inner structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially inner side and snap-fits are alternately arranged along the outer peripheral edge of the environmental power generation element, with respect to the first side. An environmental power generation module.
2. The first partial frame is configured to support the outer peripheral edge of the first main surface at the first side. The second partial frame is configured to support the outer peripheral edge of the second main surface at the first side. The environmental power generation module according to claim 1.
3. The first partial frame and the second partial frame are configured to cooperate to sandwich the environmental power generation element at the first side. The environmental power generation module according to claim 1 or 2.
4. The environmental power generation element has a second side and a third side located on both sides adjacent to the first side, and a fourth side located on the opposite side of the first side, and has a rectangular plate shape. The environmental power generation module according to any one of claims 1 to 3, wherein the frame has the alternating arrangement structure with respect to each of the second side, the third side, and the fourth side.
5. A method for manufacturing an environmental power generation module, wherein the environmental power generation module includes a first main surface, a second main surface located on the back side of the first main surface, and a first side forming corner portions at both ends, and a plate-shaped environmental power generation element that is configured to convert light energy into electrical energy or a thermoelectric conversion element that is configured to convert thermal energy into electrical energy, and a frame including a first partial frame configured to support an outer peripheral edge of the first main surface and a second partial frame configured to support an outer peripheral edge of the second main surface, wherein the first partial frame has a first outer peripheral wall that extends along an outer peripheral edge of the environmental power generation element and extends from the side of the first main surface toward the side of the second main surface, the second partial frame has a second outer peripheral wall configured to overlap the first outer peripheral wall in the radial direction, and the frame has an alternating arrangement structure in which a second outer peripheral wall outer structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially outer side and snap-fits therewith and a second outer peripheral wall inner structure configured such that the second outer peripheral wall overlaps the first outer peripheral wall from the radially inner side and snap-fits therewith are alternately arranged along the outer peripheral edge of the environmental power generation element, with respect to the first side, the manufacturing method including a frame attachment step of attaching the first partial frame and the second partial frame to the outer peripheral edge of the environmental power generation element by snap-fitting the first outer peripheral wall and the second outer peripheral wall with each other in the alternating arrangement structure, in the method for manufacturing an environmental power generation module.
Citation Information
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