U.S. patent application number 14/927187 was filed with the patent office on 2016-02-18 for solar cell module and solar cell array.
The applicant listed for this patent is KANEKA CORPORATION. Invention is credited to Kensuke Ishida, Takeharu Nakajima, Tadashi Obayashi, Yasuhiro Ueda, Takeharu Yamawaki.
Application Number | 20160049537 14/927187 |
Document ID | / |
Family ID | 42005140 |
Filed Date | 2016-02-18 |
United States Patent
Application |
20160049537 |
Kind Code |
A1 |
Ueda; Yasuhiro ; et
al. |
February 18, 2016 |
SOLAR CELL MODULE AND SOLAR CELL ARRAY
Abstract
It is an object to provide a solar cell module having a uniform
configuration, presenting stable output characteristics, and having
a size enabling easy wiring in arrangement and a solar cell array
presenting stable output characteristics by employment of said
solar cell modules. A solar cell module 10 has a solar cell panel
12 having a length of its longer edges of 900 to 1100 mm. The solar
cell panel 12 is constituted by a number of unit solar cells 100
connected in series and has an open-circuit voltage of 100 to 180
volts. The unit solar cell 100 is of a strip-like shape with a
length of its shorter edges of 7 to 12 mm and arranged in a
longer-edge direction of the panel 12 so that its longer edges
extend in a shorter-edge direction of the panel 12 and its shorter
edges extend in the longer-edge direction of the panel 12.
Inventors: |
Ueda; Yasuhiro; (Osaka,
JP) ; Yamawaki; Takeharu; (Moriyama-shi, JP) ;
Ishida; Kensuke; (Yasu-shi, JP) ; Nakajima;
Takeharu; (Osaka, JP) ; Obayashi; Tadashi;
(Otsu-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KANEKA CORPORATION |
Osaka |
|
JP |
|
|
Family ID: |
42005140 |
Appl. No.: |
14/927187 |
Filed: |
October 29, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13063201 |
Mar 10, 2011 |
|
|
|
PCT/JP2009/065368 |
Sep 2, 2009 |
|
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14927187 |
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Current U.S.
Class: |
136/244 |
Current CPC
Class: |
H01L 31/0504 20130101;
H02S 40/36 20141201; H02S 20/23 20141201; Y02E 10/50 20130101; Y02B
10/10 20130101; H02S 40/34 20141201 |
International
Class: |
H01L 31/05 20060101
H01L031/05; H02S 40/34 20060101 H02S040/34; H02S 40/36 20060101
H02S040/36; H02S 20/23 20060101 H02S020/23 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 10, 2008 |
JP |
2008-232221 |
Sep 10, 2008 |
JP |
2008-232223 |
Sep 16, 2008 |
JP |
2008-236527 |
Sep 30, 2008 |
JP |
2008-253483 |
Claims
1-11. (canceled)
12. A solar cell module to constitute a solar cell array formed by
electrically connecting in series a plurality of solar cell blocks
formed by electrically connecting a plurality of the solar cell
modules in parallel, the module arranged so that a eaves side of
one of the modules are placed onto a ridge side of another of the
modules on a inclined roof, the module comprising a solar cell
panel, the solar cell panel being formed in a substantially
rectangular plane with longer edges and shorter edge, and being
arranged so that the longer edges of the panel extend in a ridge
direction of a house and the shorter edges of the panel extend in a
direction perpendicular to the ridge direction of a house, wherein
the solar cell panel comprises a plurality of unit solar cells and
is formed by electrically connecting the unit solar cells in
series, wherein the unit solar cells each are of a strip-like shape
with longer edges and shorter edges, and are arranged in lines in a
longer-edge direction of the panel so that the longer edges extend
in a shorter-edge direction of the panel and the shorter edges
extend in the longer-edge direction of the panel, wherein the solar
cell panel has one or more dividing lines extending in a
longer-edge direction of the module and dividing an effective
electricity-generating area of the unit solar cell, at least one of
the dividing lines eccentrically located toward a ridge side in a
shorter-edge direction of the module, and wherein a ridge side area
of the unit solar cells formed by the dividing lines is smaller
than a half of the largest area of the unit solar cells formed by
the dividing lines.
13. The solar cell module as defined in claim 12, the module having
substantially the same size as or slightly larger than the panel,
wherein the dividing line prevents deterioration or failure of the
module caused by a hot spot phenomenon in a ridge side section of
the module, the ridge side section being in shade due to at least
one of the other modules.
14. The solar cell module as defined in claim 12, wherein the
dividing line is eccentrically located toward the eaves side in the
short-edge direction of the module, and the area of the unit solar
cells formed by the dividing line and the edge of the unit solar
cell in the eaves side is smaller than the area of the unit solar
cells formed by the dividing line and the edge of the unit solar
cell in the ridge side, and wherein the area of the unit solar
cells formed by the dividing line nearest the edge of the unit
solar cell in the eaves side is smaller than a half of the largest
area formed by any one of the dividing line, and any other of the
dividing line or the edge of the unit solar cell in the ridge side,
excluding an area having another of the dividing lines in the
area.
15. The solar cell module as defined in claim 12, the module having
longer edges and shorter edges with a total length of each of the
longer edges of 920 to 1200 mm and a total length of each of the
shorter edges of 240 to 700 mm, wherein the solar cell panel is
formed in a substantially rectangular plane with longer edges and
shorter edges and having a length of the longer edges of 900 to
1200 mm and a length of the shorter edges of 230 to 650 mm, and
being arranged so that the longer edges of the panel extend in a
ridge direction of the house and the shorter edges of the panel
extend in a direction perpendicular to the ridge direction of the
house, wherein the solar cell panel comprises a plurality of the
unit solar cells and is formed by electrically connecting the unit
solar cells in series so as to have an open-circuit voltage of 100
to 180 volts, wherein the unit solar cells each are of a strip-like
shape with longer edges and shorter edges, the shorter edges having
a length of 7 to 12 mm, and are arranged in lines in the
longer-edge direction of the panel so that the longer edges extend
in the shorter-edge direction of the panel and the shorter edges
extend in the longer-edge direction of the panel, the module
further comprising two positive conducting wires in electrical
connection with a positive electrode of the solar cell panel and
two negative conducting wires in electrical connection with a
negative electrode of the solar cell panel, wherein the two
positive conducting wires and the two negative conducting wires
each are pulled out from one of the longer edges of the module, the
module having a space for accommodating the two positive conducting
wires and the two negative conducting wires of another panel in a
back of the module, and the module having an overlapping portion
for overlapping a part of another module on its top face.
16. The solar cell module as defined in claim 12, wherein the unit
solar cells each have the open-circuit voltage of 1.2 to 1.5
volt.
17. The solar cell module as defined in claim 12, wherein the
overlapping portion is formed on a part except a top face of the
solar cell panel.
18. The solar cell module as defined in claim 12, wherein the unit
solar cells each are of a tandem type.
19. The solar cell module as defined in claim 12, wherein the solar
cell panel has a short-circuit current of 9 to 15 mA/cm.sup.2.
20. The solar cell module as defined in claim 12, having grooves
through which a cable is inserted in the shorter-edge direction in
the back of the module.
21. The solar cell module as defined in claim 12, wherein the solar
cell module constitutes a solar cell as a whole and comprises two
connectors and cables, the cables each having more than one
conducting wire and pulled out from a center part of a longer edge
of the module, the connectors being connected to the respective
cables, wherein the cable connected to the one connector is shorter
than the cable connected to the other connector, wherein, when the
modules are arranged in a row, the cables have a length
relationship in which the connectors connected to the short cables
are unconnectable to each other because the cables are not long
enough.
22. A solar cell array being formed by serially connecting two
solar cell blocks, the solar cell blocks each being formed by
electrically connecting in parallel a plurality of the solar cell
modules as defined in claim 12.
23. The solar cell array as defined in claim 22, wherein the solar
cell blocks each are formed by electrically connecting twenty or
more of the solar cell modules in parallel.
24. A solar cell array being formed by electrically connecting in
parallel a plurality of the solar cell modules as defined in claim
12. wherein the module further comprises: two positive conducting
wires in electrical connection with a positive electrode of the
solar cell panel and two negative conducting wires in electrical
connection with a negative electrode of the solar cell panel; and a
space for accommodating the two positive conducting wires and the
two negative conducting wires of another panel in a back of the
module, wherein a plurality of the modules are arranged in a plane
in a plurality of rows each consisting of the modules, and wherein
the positive conducting wire of one of adjacent modules and the
negative conducting wire of the other of the adjacent modules are
connected to each other with the connected conducting wires housed
in the space of the module in an adjacent row.
25. The solar cell array as defined in claim 24, the one positive
conducting wire and the one negative conducting wire of the module
located at an end of one row and the one positive conducting wire
and the one negative conducting wire of the module located at an
end of its adjacent row being connected to each other and housed in
the space of the module of the next row but one.
26. A solar cell module to constitute a solar cell array formed by
electrically connecting in series a plurality of solar cell blocks
formed by electrically connecting a plurality of the solar cell
modules in parallel, the module comprising a solar cell panel, the
solar cell panel being formed in a substantially rectangular plane
with longer edges and shorter edges and having a length of the
longer edges of 900 to 1100 mm, and being arranged so that the
longer edges of the panel extend in a ridge direction of a house
and the shorter edges of the panel extend in a direction
perpendicular to the ridge direction of the house, wherein the
solar cell panel comprises a plurality of unit solar cells and is
formed by electrically connecting the cells in series so as to have
an open-circuit voltage of 100 to 180 volts, wherein the unit solar
cells each are of a strip-like shape with longer edges and shorter
edges, the shorter edges having a length of 7 to 12 mm, and are
arranged in lines in a longer-edge direction of the panel so that
the longer edges extend in a shorter-edge direction of the panel
and the shorter edges extend in the longer-edge direction of the
panel, wherein the unit solar cells each have an effective
electricity-generating area where electricity is generated upon
reception of light, wherein the solar cell panel has one or more
dividing lines extending in a longer-edge direction of the module
and dividing the effective electricity-generating area of the unit
solar cell, at least one of the dividing line at a position
eccentrically located toward one of edges in a short-edge direction
of the module.
27. A solar cell panel being formed in a rectangle and electrically
connecting a plurality of unit solar cells, the solar cell panel
comprising first edges and second edges intersecting therewith,
wherein the unit solar cells each are of a strip-like shape with
longer edges and shorter edges, and are arranged so that the longer
edges extend in a first-edge direction of the panel and the shorter
edges extend in a second-edge direction of the panel, wherein the
module has one or more dividing lines, at least one of the dividing
lines dividing an effective electricity-generating area of the unit
cell and eccentrically located toward one of the second edges of
the panel, and wherein the most eccentrically located area of the
unit solar cells formed by the dividing line is smaller than a half
of the largest area formed by the dividing line.
28. The solar cell panel as defined in claim 27, wherein the unit
solar cells each are of a strip-like shape with longer edges and
shorter edges, the shorter edges having a length of 7 to 12 mm, and
are arranged in lines in a longer-edge direction of the panel so
that the longer edges extend in a shorter-edge direction of the
panel and the shorter edges extend in the longer-edge direction of
the panel.
29. The solar cell panel as defined in claim 27, the solar cell
panel being arranged so that a eaves side of one of the modules are
placed onto a ridge side of another of the modules on a inclined
roof, the solar cell panel being formed in a substantially
rectangular plane, and being arranged so that the longer edges of
the panel extend in a ridge direction of the house and the shorter
edges of the panel extend in a direction perpendicular to the ridge
direction of the house, wherein the unit solar cells each are
arranged in lines in a longer-edge direction of the panel so that
the longer edges extend in a shorter-edge direction of the panel
and the shorter edges extend in the longer-edge direction of the
panel, and wherein the dividing line prevents deterioration or
failure of the module caused by a hot spot phenomenon in a ridge
side portion of the module, the ridge side portion being in shade
due to at least one of the other modules.
30. The solar cell panel as defined in claim 27, wherein the unit
solar cells each are of a tandem type.
31. The solar cell panel as defined in claim 27, wherein the unit
solar cells each have the open-circuit voltage of 1.2 to 1.5 volt,
and wherein the solar cell panel has a short-circuit current of 9
to 15 mA/cm.sup.2.
Description
TECHNICAL FIELD
[0001] The present invention relates to a solar cell module for
constituting a solar cell array arranged on a house and to a solar
cell array constituted by the solar cell modules.
BACKGROUND ART
[0002] Recently, a photovoltaic system with solar cell modules
having solar cell panels arranged on a place such as a roof of a
house has increased for covering electricity consumed at the house
and simultaneously selling surplus electricity to an electric power
company. A solar cell panel is an integrated solar cell, which is
formed by laminating a film such as a conducting film and a
semiconductor film on a glass substrate, cutting a plurality of
grooves on the laminated layer so as to form a predetermined number
of one-cell batteries (unit solar cells), and electrically
connecting the unit solar cells in series. It is known that some
panels generate a voltage of 100 volts or more. The Patent Document
1 specified below discloses a method for manufacturing such a solar
cell panel.
[0003] The solar cell module as described above can generate a
desired voltage by adjusting the number of serially-connected unit
solar cells. However, in view of convenience of arrangement or
manufacture, there is a limit to a size of the module and also some
limits to the number of and an output voltage of the unit solar
cells being connectable in series in the sole module. Further, the
sole module can generate much less large output current. Thus, in
the conventional art, a plurality of solar cell modules are
electrically connected in parallel so as to form a solar cell
block, a plurality of which are connected in series so as to form a
solar cell array, and whereby an output voltage and an output
current are adjusted to be a practical level.
[0004] As described above, when the solar cell modules are
electrically connected in parallel so as to form the solar cell
block and the solar cell array is constituted by the solar cell
blocks formed in this way, an output power generated by the whole
solar cell array is not much reduced even if power reduction would
be caused by a reason such that a part of the modules is placed in
shade, if the serially-connected modules respectively generate the
same level of output power.
[0005] Though mentioning a size or the like of a solar cell panel,
the Patent Document 2 specified below has little notion that the
panels are placed on a roof and further that the panels are
overlapped.
[0006] Further, the known arts relating to the present invention
include the Patent Documents 3 to 9 specified below.
[0007] In FIG. 25 in the Patent Document 3, such a configuration
that conducting wires are pulled out from a longer edge of a solar
cell panel is disclosed. However, the conducting wires of a solar
cell module described in the Patent Document 3 are short and are
not pulled out from the module, judging from a positional
relationship of the solar cell panel and a base member 62.
[0008] The solar cell module in the Patent Document 3 has two
conducting wires, one being a positive wire and the other being a
negative wire.
[0009] The Patent Documents 4 and 5 each disclose such a
configuration that two cables are pulled out from an eaves side of
a solar cell module. In the configurations disclosed in the Patent
Documents 4 and 5, each of the two cables has only one core and
connects the solar cell modules in series.
[0010] Also in the configuration described in the Patent Document
4, as disclosed in FIGS. 20 and 21 in the document, the connected
cables are housed in a back of the solar cell module from which
said cables are pulled out or in a back of the solar cell module in
the same level (same row).
[0011] In the Patent Document 5, the solar cell modules are placed
flat and not placed one above the other. Also in the Patent
Document 5, most of the cables are housed in a back of the solar
cell module from which said cables are pulled out.
[0012] The Patent Document 6 discloses such a configuration that
two cables are pulled out from a ridge side of a solar cell module.
In the configuration disclosed in the Patent Document 6, the cables
are wired at a part separate from a part where the solar cell
modules are arranged.
[0013] The Patent Document 7 has such a configuration that two
cables are pulled out from a ridge side of a solar cell module, the
cables being connected at a back side of a solar cell module
belonging to an adjacent row. In the configuration disclosed in the
Patent Document 8, each of the two cables has only one core and
connects the solar cell modules in series. The invention described
in the Patent Document 7 is characterized in that flat connectors
are used. The solar cell module in the Patent Document 7 has a flat
main body, at the bottom of which the flat connectors are
arranged.
[0014] The module in the Patent document 7 is of a rectangular
shape with the two cables pulled out from a shorter edge of the
module.
[0015] The inventions using cables or the like disclosed in the
Patent Documents 8 and 9 specified below are disclosed as a method
for connecting a plurality of solar cell modules.
[0016] The Patent Document 8 discloses such a configuration that
four cables are connected to a solar cell module, and further, such
a configuration that a plurality of solar cell modules connected in
parallel are connected in series. In the Patent Document 8, a
plurality of modules are connected in parallel by directly
connecting adjacent cables. In the configurations described in the
Patent Document 8 as disclosed in FIG. 8 in the document, the
connected cables are housed in a back of the solar cell module from
which said cables are pulled out or in a back of the solar cell
module in the same level (same row).
[0017] The Patent Document 9 discloses such a configuration that
four cables are connected to a solar cell module, further, that the
cables includes a long one and a short one, and further, that the
cables are different in color.
[0018] Also in the configurations described in the Patent Document
9, as disclosed in FIG. 7 in the document, the connected cables are
housed in a back of the solar cell module from which said cables
are pulled out or in a back of the solar cell module in the same
level (same row).
[0019] [Patent Document 1] JP H11-298017 A
[0020] [Patent Document 2] WO 2007/074683 A1
[0021] [Patent Document 3] WO 2003/029577 A1
[0022] [Patent Document 4] JP 2000-282647 A
[0023] [Patent Document 5] JP 2002-329881 A
[0024] [Patent Document 6] JP 2002-83991 A
[0025] [Patent Document 7] JP 2004-14920 A
[0026] [Patent Document 8] JP 2004-349507 A
[0027] [Patent Document 9] JP 2008-130902 A
DISCLOSURE OF INVENTION
Technical Problem
[0028] In a case where a solar cell array is constituted by the
above-mentioned connecting structure, an output power generated by
the whole solar cell array is not much reduced even if the modules
have individual difference in output performances, if the solar
cell blocks respectively generate the same level of output power,
as well as the case where power reduction would be caused by a
reason such that a part of the modules is placed in shade. However,
the combined effect of various conditions such as variability in
output performances of the solar cell modules and insolation
condition of the installation site might cause variability in
output characteristics among the modules and fail in effective
utilization of an output power of the modules normally operating,
resulting in failure in outputting an expected power of the whole
solar cell array. Thus, in view of potential for unexpected
temporary power reduction caused by a reason such that the modules
are arranged in shade, there has been a desire to minimize
individual difference in output performances of the modules.
Meanwhile, in view of easy manufacture and easy arrangement on a
house of the modules, it is impractical to finely adjust output
performances by changing a configuration or a size for each module.
Therefore, it has been desired to provide a solar cell module
having a uniform configuration and a size enabling easy wiring in
arrangement.
[0029] The present invention therefore aims to provide a solar cell
module having a uniform configuration, presenting stable output
characteristics, and having a size enabling easy wiring in
arrangement and a solar cell array presenting stable output
characteristics by employment of said solar cell module.
Solution to Problem
[0030] In order to solve the above-mentioned problem, an aspect of
the present invention provided herein is a solar cell module to be
arranged on a roof of a house and to constitute a solar cell array
formed by electrically connecting in series a plurality of solar
cell blocks formed by electrically connecting a plurality of the
solar cell modules in parallel.
[0031] The module in this aspect has longer edges and shorter edges
with a total length of each of the longer edges of 920 to 1200 mm
and a total length of each of the shorter edges of 240 to 700
mm.
[0032] The module includes a solar cell panel, the solar cell panel
being formed in a substantially rectangular plane with longer edges
and shorter edges and having a length of the longer edges of 900 to
1200 mm and a length of the shorter edges of 230 to 650 mm, and is
arranged so that the longer edges of the panel extend in a ridge
direction of the house and the shorter edges of the panel extend in
a direction perpendicular to the ridge direction of the house.
[0033] The solar cell panel includes a plurality of unit solar
cells and is formed by electrically connecting the cells in series
so as to have an open-circuit voltage of 100 to 180 volts.
[0034] The unit solar cells each are of a strip-like shape with
longer edges and shorter edges, the shorter edges having a length
of 7 to 12 mm, and are arranged in lines in a longer-edge direction
of the panel so that the longer edges extend in a shorter-edge
direction of the panel and the shorter edges extend in the
longer-edge direction of the panel.
[0035] The module further includes two positive conducting wires in
electrical connection with a positive electrode of the solar cell
panel and two negative conducting wires in electrical connection
with a negative electrode of the solar cell panel.
[0036] The two positive conducting wires and the two negative
conducting wires each are pulled out from one of the longer edge of
the module.
[0037] The module has a space for accommodating the two positive
conducting wires and the two negative conducting wires of another
panel in a back of the module.
[0038] The module has an overlapping portion for overlapping a part
of another module on its top face.
[0039] The solar cell module in this aspect incorporates the solar
cell panel having the length of the longer edges of 900 to 1200 mm,
so as to be easily carried in and arranged at a place such as a
roof of a house, where the arrangement work is difficult. Further,
the module has the total length of the longer edge of 920 to 1200
mm and the total length of the shorter edge of 240 to 700 mm. Thus,
the solar cell module in this aspect has the length of the longer
edges being about twice a size of a common roof tile, so as to be
arranged on a house with a working efficiency not much different
from tiling.
[0040] Herein, the total length of the module excludes the length
of the cables.
[0041] The solar cell panel constituting the solar cell module in
this aspect includes a plurality of strip-like unit solar cells
each having the width of 7 to 12 mm electrically connected in
series and aligned in the longer-edge direction of the panel, so
that the modules have the uniform configuration. Further, the
above-mentioned uniform configuration employed in the modules in
this aspect minimizes output variability. Still further, the cell
panel constituting the module in this aspect has the open-circuit
current of 100 to 180 volts, so that the solar cell array capable
of outputting a voltage suitable to be inputted in a device such as
the known AC power conditioner is constructed by electrically
connecting a plurality of the panels in parallel so as to form a
solar cell block and connecting a plurality of solar cell blocks in
series.
[0042] In the module in this aspect, the unit cells are arranged in
lines in the longer-edge direction of the panel so that the longer
edges extend in the shorter-edge direction of the panel and the
shorter edges extend in the longer-edge direction of the panel.
Further, the modules in this aspect are arranged so that the longer
edges of the panel extend in the ridge direction of the house and
the shorter edges of the panel extend in the direction
perpendicular to the ridge direction of the house. Herein, when the
modules are arranged on a house in a similar manner as common
tiling, some modules might be hidden behind another module above in
the direction perpendicular to the ridge depending on insolation
conditions or overlapped with another module at a portion below in
the direction perpendicular to the ridge, resulting in formation of
some portion unable to generate electricity or having considerable
output reduction, which may cause electric resistance. However,
even if such a portion is formed, the unit cells normally operate
at other portions, so that all the unit cells are maintained in
electrical connection with one another. Consequently, the solar
cell module in this aspect minimizes an effect on power reduction
of the entire solar cell array even if output power is reduced
because of the insolation conditions or the like.
[0043] The module further includes the two positive conducting
wires in electrical connection with a positive electrode of the
solar cell panel and the two negative conducting wires in
electrical connection with a negative electrode of the solar cell
panel, both which are pulled out from the longer edge of the
module.
[0044] In this aspect, the module is of a substantially rectangular
shape with the four conducting wires pulled out from the longer
edge of the module. That allows connection of the cables outside a
body of the module. Further, the module in this aspect has the
overlapping portion for overlapping a part of another module on its
top face.
[0045] The modules belonging to an adjacent row are arranged on the
previously-connected cables by placing said modules after the
connection of the cables.
[0046] Further, in the present aspect, arrangement of the modules
belonging to an adjacent row after the connection of the cables
allows the previously-connected cables to be housed in the spaces
of the modules belonging to the adjacent row.
[0047] In the module in this aspect described above, the unit solar
cells each preferably have the open-circuit voltage of 1.2 to 1.5
volt.
[0048] By this configuration, there is provided the solar cell
module capable of outputting the open-circuit voltage required for
construction of the solar cell array.
[0049] The overlapping portion is preferably formed on a part
except a top face of the solar cell panel.
[0050] In the solar cell module in this aspect described above, the
unit solar cell may be of a tandem type.
[0051] This configuration utilizes energy contained in incident
light to the maximum, so as to provide the solar cell module having
a high energy conversion efficiency.
[0052] In the solar cell module in this aspect described above, the
solar cell panel preferably has a short-circuit current of 9 to 15
mA/cm.sup.2.
[0053] As described above, in the solar cell module constituted by
a number of the unit cells connected in series, failure of
electricity generation by a part of a specific unit cell due to a
reason such as being in shade might cause a hot spot phenomenon in
which heat is generated because the electric resistance is
increased at the part. Such a hot spot phenomenon might cause a
problem such as deterioration or breaking of the module and reduce
specific output of the module as subsequent events. That might
cause output variability of the modules constituting the solar cell
array or the solar cell blocks, resulting in failure in utilizing a
part of electric energy generated in the other modules.
[0054] In view of such a drawback, the solar cell module in this
aspect described above is therefore preferably configured in such a
manner that the unit solar cells each have an effective
electricity-generating area where electricity is generated upon
reception of light and that the module has at least one dividing
line extending in the longer-edge direction of the module and
dividing the effective electricity-generating area of the unit
solar cell.
[0055] Even if a part of a specific module would fails to generate
electricity due to a reason such as being in shade, this
configuration protects the part from being subjected to
considerably large electric resistance, thereby preventing
deterioration or breaking of the module caused by such a hot spot
phenomenon. Consequently, the above-mentioned configuration
minimizes individual difference in output performances of the solar
cell modules due to a hot spot phenomenon after arrangement of the
solar cell array.
[0056] The solar cell module preferably has grooves through which a
cable is inserted in the shorter-edge direction in the back of the
module.
[0057] A solar cell array in another aspect of the present
invention is formed by serially connecting two solar cell blocks,
the solar cell blocks each being formed by electrically connecting
in parallel a plurality of the solar cell modules in the
above-mentioned aspect.
[0058] The present aspect employs the solar cell modules in the
foregoing aspect, which has small individual difference in output
performances of the modules. Further, the array in this aspect is
formed by serially connecting a plurality of solar cell blocks,
each of which is formed by connecting the modules in parallel.
Thus, even if a part of the solar cell module would cause power
reduction, it is possible to minimize energy loss resulting from
the power reduction and present stable output performances.
[0059] In the solar cell array in this aspect described above, the
solar cell blocks each are preferably formed by electrically
connecting twenty or more of the solar cell modules in
parallel.
[0060] In the above-mentioned array, it is preferable that a
plurality of the modules are arranged in a plane in a plurality of
rows each consisting of the modules and that the positive
conducting wire of one of adjacent modules and the negative
conducting wire of the other of the adjacent modules are connected
to each other with the connected conducting wires housed in the
space of the module in an adjacent row.
[0061] This configuration makes the connected cables to fit into
place, thereby facilitating the arrangement work.
[0062] In the above-mentioned array, the one positive conducting
wire and the one negative conducting wire of the module located at
an end of one row and the one positive conducting wire and the one
negative conducting wire of the module located at an end of its
adjacent row are preferably connected to each other and housed in
the space of the module of the next row but one.
[0063] In an arrangement structure of solar cell modules using the
modules each being of a substantially rectangular shape and having
a plurality of unit solar cells formed inside thereof so as to
constitute a solar cell as a whole and arranging the modules on a
structural object, the solar cell modules each may include two
connectors and cables, the cables each having more than one
conducting wire and pulled out from a center part of a longer edge
of the module, the two connectors each having more than one
individual terminal and being connected to the respective cables,
wherein the one terminal of each connector is a positive terminal
connected to a positive electrode of the solar cell and the other
terminal of each connector is a negative terminal connected to a
negative electrode of the solar cell, wherein the cable connected
to the one connector is shorter than the cable connected to the
other connector, wherein, when a plurality of the modules are
arranged in a row, the cables have a length relationship in which
the connectors connected to the short cables are unconnectable to
each other because the cables are not long enough, and wherein the
modules are arranged in a row on the structural object so that the
connector connected to the long cable of one of adjacent modules
and the connector connected to the short cable of the other of the
adjacent modules are connected to each other with the positive
terminals of the both connectors connected to each other and with
the negative terminals of the both connectors connected to each
other, and whereby a plurality of the modules electrically
connected in parallel.
[0064] In the above-mentioned arrangement structure of the modules,
the connectors of the adjacent module are connected in such a
manner that the connector connected to the long cable and the
connector connected to the short cable are connected to each other.
In the arrangement structure described above, it is normal that the
connector connected to the long cable and the connector connected
to the short cable are connected to each other in this way.
According to the arrangement structure described above, connection
of the connector connected to the long cable and the connector
connected to the short cable in connection of adjacent modules in
this way achieves connection of the positive terminals and
connection of the negative terminals of the both connectors. That
electrically connects a plurality of the modules in parallel.
[0065] Further, the arrangement structure described above prevents
workers from improper connection of the connectors. Since the
arrangement structure described above has the long and short cables
in this way, the connectors connected to the short cables are
unconnectable to each other because of lack of length when arranged
with the other modules in a row. Therefore, when the modules are
arranged on a structural object such as a roof, the short cables of
adjacent modules are physically unconnectable to each other. That
prevents workers from improper connection of the connectors.
Advantageous Effect of Invention
[0066] The present invention provides a solar cell module having a
uniform configuration, presenting stable output performances, and
having a size enabling easy wiring in arrangement and a solar cell
array presenting stable output performances by employment of said
solar cell modules.
BRIEF DESCRIPTION OF DRAWINGS
[0067] FIG. 1A is a perspective view of a solar cell module
embodying the present invention and FIGS. 1B and 1C each are a
cross-section of a connector in the solar cell module;
[0068] FIG. 2 is a perspective view showing a structure of a back
of the module in FIG. 1;
[0069] FIG. 3 is a cross section of a solar cell panel employed in
the solar cell module shown in FIG. 1;
[0070] FIG. 4 is another cross-section of the connector of the
module in FIG. 1;
[0071] FIG. 5 is a flow chart showing a work procedure of
arrangement of the solar cell modules;
[0072] FIG. 6A is a view illustrating a roof of a house and FIG. 6B
is a view illustrating the roof of the house arranged with the
solar cell modules;
[0073] FIG. 7 is a conceptual diagram showing a module row in which
the solar cell modules are properly connected;
[0074] FIG. 8 is a conceptual diagram showing a module row in which
the solar cell modules are improperly connected;
[0075] FIG. 9 is a circuit diagram of wiring in which the solar
cell modules are properly connected;
[0076] FIG. 10 is a conceptual diagram showing a solar cell
array;
[0077] FIG. 11A is a front view of a service cable and FIG. 11B is
a cross-section of a molded portion of the service cable;
[0078] FIG. 12 is a plan view of a terminal protector;
[0079] FIG. 13A is a plan view of a connector with male portions at
both electrodes and FIG. 13B is a plan view of a connector with
female portions at both electrodes;
[0080] FIG. 14 is a perspective view of a modified embodiment of
the solar cell module shown in FIG. 1;
[0081] FIG. 15 is a front view of a cable for voltage test;
[0082] FIG. 16 is an exploded perspective view of the solar cell
module in FIG. 1;
[0083] FIG. 17 is a cross section showing the solar cell module in
FIG. 1 arranged adjacent to the eaves on a top face of a house;
[0084] FIGS. 18A and 18B each are a perspective view illustrating
arrangement of the solar cell module adjacent to the eaves of a
house having a roof structure in the present embodiment. FIG. 18A
shows a state before the arrangement and FIG. 18B shows a state
after the arrangement;
[0085] FIG. 19 is a perspective view illustrating arrangement of
the solar cell modules after the first module row in the roof
structure in the present embodiment;
[0086] FIG. 20 is a partial cross-section illustrating arrangement
of the solar cell module after the first module row in the roof
structure in the present invention;
[0087] FIG. 21 is a perspective view illustrating a cable wiring of
the solar cell modules in the roof structure in the present
embodiment;
[0088] FIG. 22 is a perspective view illustrating a relationship
between a cable connection of the solar cell modules belonging to a
specific module row in the roof structure in the present embodiment
and the solar cell modules belonging to an adjacent module row;
[0089] FIG. 23 is a perspective view showing a cable wiring of the
solar cell modules in the roof structure in the present embodiment
observed from a back of the modules;
[0090] FIG. 24 is a perspective view showing the cable wiring of
the solar cell modules at a portion adjacent to the end of the row
in the roof structure in the present embodiment observed from the
back of the modules;
[0091] FIG. 25 is a view illustrating sizes of the modules and
lengths of the cables when the modules are arranged on a roof with
rows and columns justified;
[0092] FIG. 26 is a view illustrating sizes of the modules and
lengths of the cables when the modules are arranged on a roof with
upper and lower rows shifted by a quarter of the length;
[0093] FIG. 27 is a view illustrating sizes of the modules and
lengths of the cables when the modules are arranged on a roof with
upper and lower rows shifted by a half of the length; and
[0094] FIG. 28 is a view illustrating sizes of the modules and
lengths of the cables when the modules are arranged on a roof with
upper and lower rows shifted by three quarters of the length.
DESCRIPTION OF EMBODIMENTS
[0095] Now, a solar cell module 10 and a solar cell array 1
relating to an embodiment of the present invention will be
described in detail below, making reference to the accompanying
drawings.
[0096] In the descriptions below, a vertical positional
relationship is based on a positional relationship shown in FIG.
1.
[0097] As shown in FIGS. 1A and 14, the solar cell module 10
consists mainly of a base 82 constituted by a base member 70
attached with a reinforcing heat insulator 90 and other members
such as a solar cell panel 12, a front cover 102, and hooking
brackets 84 mounted on the base 82.
[0098] The module 10 in the present embodiment is a
roof-tile-shaped solar cell module applied to a roof R of a
newly-built or already-built house. As shown in FIGS. 1A to 1C and
2, the solar cell module 10 is provided with the solar cell panel
12, a terminal box 14 attached to a back of the panel 12, two
cables 16 and 18 pulled from the terminal box 14, and connectors 20
and 22 connected to the respective cables 16 and 18.
[0099] It is necessary that the module 10 has a total length of a
longer edge of 920 to 1200 mm and a total length of a shorter edge
of 240 to 700 mm.
[0100] It is necessary that the panel 12 mounted on the module 10
has a length of a longer edge of 900 to 1200 mm and a length of a
shorter edge of 230 to 650 mm.
[0101] Next, recommendable sizes of the module 10 and the panel 12
will be described below, each being a size in the embodiment shown
in FIG. 1A and the followings.
[0102] The solar cell module 10 is formed in a substantially
rectangular plane as shown in FIGS. 1A and 2. In the module 10,
most of area exposed outside when the module 10 is arranged is
occupied by the panel 12. Therefore, the module 10 has
substantially the same size as or slightly larger than the panel
12. In this embodiment, a total length LT of the module 10 is
longer than a total length L1 of the panel 12 by a width of a
trough-like gutter 80.
[0103] The module 10 in this embodiment has the total length LT of
the longer edge smaller than 1200 mm in view of ensuring output and
simultaneously workability in arrangement work on a house. Herein,
the total length LT of the module 10 excludes lengths of the cables
16 and 18.
[0104] In this embodiment, the panel 12 has the total length L1 in
a range of 900 to 1100 mm in view of intervals of common scaffolds
laid in arrangement of the modules 10 and easy handling by
workers.
[0105] The panel 12 has a length (width) L4 of its shorter edge in
a range of 250 to 320 mm.
[0106] Further, the solar cell module 10 has a length L2 of its
shorter edge in a range of 240 to 480 mm in view of a size of a
common flat roof tile. In this embodiment, the module 10 is
adjusted to have the length L2 in a range of 280 to 360 mm in view
of improvement of incident phonon-to-current conversion efficiency
by minimizing a part hidden behind depending on an insolation
condition with an effective width no less than the common flat
roof-tile.
[0107] The panel 12 is formed in a substantially rectangular plane
as shown in FIGS. 1A and 2. The solar cell panel 12 is arranged
with its longer edges extending in a ridge direction (direction
parallel to the ridge) of a house and its shorter edges extending
in a direction perpendicular to the ridge of the house. The panel
12 is formed by arranging a number of unit solar cells 100
(hereinafter referred to as a unit cell 100), each being of a
strip-like shape, in a longer-edge direction of the panel 12 so as
to be electrically connected in series. One panel generates a
voltage of about 100 volts.
[0108] The panel 12 is a combination of more than one photoelectric
conversion layer or a so-called tandem solar cell, having high
incident photon-to-current conversion efficiency. This embodiment
employs a hybrid solar cell of one-body system of a tandem type as
the solar cell panel 12. More specifically, as shown in FIG. 3, the
panel 12 is a so-called hybrid solar cell by sequentially
laminating a transparent front electrode layer 104, a first and
second thin film photoelectric conversion units 106a, 106b
(hereinafter also referred to as an amorphous photoelectric
conversion unit 106a and a crystalline photoelectric conversion
unit 106b), a metal back electrode layer 108, an encapsulation
resin layer 110, an organic protection layer 112 on a transparent
substrate 102. The transparent substrate 102 is made of a material
having translucency such as a glass plate and a transparent resin
film and constitutes a face closest to incident light when the
modules 10 are arranged.
[0109] The transparent front electrode layer 104 is a layer having
a single layer structure or a multilayer structure arranged at a
position next to the transparent substrate 102. The electrode layer
104 is formed by laminating an oxide having transparency and
electric conductivity, such as an ITO film, a SnO.sub.2 film, and a
ZnO film, on the transparent substrate 102 in laminae. The
electrode layer 104 is formed by a method such as the known vapor
deposition method as typified by an evaporation method, a CVD
(Chemical Vapor Deposition) method, an EVD (Electrochemical Vapor
Deposition) method, and a sputtering method.
[0110] The thin film photoelectric conversion unit 106a has an
amorphous photoelectric conversion layer and is arranged at a
position next to the transparent front electrode layer 104 in a
direction of incident light (from below in FIG. 3). The
photoelectric conversion unit 106a may have a laminated
configuration in which a p-type silicon semiconductor layer, an
i-type silicon amorphous photoelectric conversion layer, and an
n-type silicon semiconductor layer are laminated in this order from
a side of the layer 104. These p-type silicon semiconductor layer,
i-type silicon amorphous photoelectric conversion layer, and n-type
silicon semiconductor layer are also formed by an appropriate
method such as a plasma CVD method as well as the above-mentioned
layer 104. The photoelectric conversion unit 106a preferably has a
thickness of 0.01 .mu.m to 0.5 .mu.m and more preferably has a
thickness of 0.1 m to 0.3 .mu.m.
[0111] The thin film photoelectric conversion unit 106b has a
crystalline photoelectric conversion layer and is arranged at a
position next to the photoelectric conversion unit 106a in the
direction of incident light. The photoelectric conversion unit 106b
may have a laminated configuration in which a p-type silicon
semiconductor layer, an i-type silicon crystalline photoelectric
conversion layer, and an n-type silicon semiconductor layer are
laminated in this order from a side of the unit 106a. These p-type
silicon semiconductor layer, i-type silicon crystalline
photoelectric conversion layer, and n-type silicon semiconductor
layer constituting the unit 106b are also formed by a method such
as a plasma CVD method as well as the above-mentioned unit
106a.
[0112] The crystalline photoelectric conversion layer constituting
the unit 106b has a light absorption coefficient lower than the
above-mentioned amorphous photoelectric conversion layer
constituting the unit 106a. Therefore, the photoelectric conversion
unit 106b is preferably several times to ten times thicker than the
unit 106a. Specifically, the unit 106b preferably has a thickness
of 0.1 .mu.m to 10 .mu.m and more preferably has a thickness of 0.1
.mu.m to 5 .mu.m.
[0113] The p-type semiconductor layer constituting the
photoelectric conversion units 106a, 106b described above is formed
by doping p-type conductivity-determining impurity atoms such as
boron and aluminum into silicon, silicon carbide, or
silicon-containing alloy such as silicon-germanium alloy. The
amorphous photoelectric conversion layer and the crystalline
photoelectric conversion layer are formed by an amorphous silicon
semiconducting material and a crystalline silicon semiconducting
material respectively. Specifically, the amorphous photoelectric
conversion layer and the crystalline photoelectric conversion layer
are constituted by an intrinsic semiconductor such as silicon
(hydrogenated silicon or the like), silicon carbide, and
silicon-containing alloy such as silicon-germanium alloy. Further,
the amorphous photoelectric conversion layer and the crystalline
photoelectric conversion layer require only a photoelectric
conversion function and may be constituted by using a weak p-type
or a weak n-type silicon semiconducting materials containing trace
conductivity-determining impurity, for example. The n-type
semiconductor layer constituting the amorphous photoelectric
conversion layer and the crystalline photoelectric conversion layer
is formed by doping n-type conductivity-determining impurity atoms
such as phosphorus and nitrogen into silicon, silicon carbide, or
silicon-containing alloy such as silicon-germanium alloy.
[0114] Further, the above-mentioned photoelectric conversion units
106a, 106b are different in absorption wavelength ranges.
Specifically, the photoelectric conversion layer of the unit 106a
constituted by the amorphous silicon most effectively absorbs an
optic element of about 550 nm, while the photoelectric conversion
layer of the unit 106b constituted by the crystalline silicon most
effectively absorbs an optic element of about 900 nm.
[0115] The metal back electrode layer 108 is arranged at a position
next to the thin film photoelectric conversion unit 106b in the
direction of incident light. The electrode layer 108 is constituted
by a material such as silver and aluminum and formed to have a
thickness of about 200 nm to 400 nm by a method such as the known
evaporation and a sputtering method. Between the metal back
electrode layer 108 and the photoelectric conversion unit 106b, a
transparent electroconductive thin film (not shown) made of a
nonmetal material such as ZnO may be appropriately provided in view
of improvement of adhesion between those. The layer 108 has a
function as a reflecting layer for reflecting light, which incomes
through the transparent substrate 102 and passes through the units
106a, 106b, so as to make the light to enter the units 106a, 106b
again in addition to a function as an electrode of the cell panel
12.
[0116] The module 10 has the organic protection layer 112 via the
encapsulation resin layer 110 at a position next to the metal back
electrode layer 108 in the direction of incident light, that is, at
a position coming to a back of the module 10 when the module 10 is
arranged on a house. The encapsulation resin layer 110 bonds the
organic protection layer 112 and the metal back electrode layer 108
and is formed by a material such as EVA (ethylene vinyl acetate
copolymer), PVB (polyvinyl butyral), PIB (polyisobutylene), and
silicone resin. The organic protection layer 112 encapsulates the
back face of the module 10. The organic protection layer 112 may
suitably employ an insulation film having high resistance to
humidity and water like a fluorine resin film such as a polyvinyl
fluoride film and a PET (polyethylene terephthalate) film, a film
formed by lamination of those films, or a film formed by
sandwiching a metal foil made of aluminum or the like by those
films.
[0117] As shown in FIG. 3, in the solar cell module 10, a plurality
of unit cells 100 are defined by dividing the resulting thin films
laminated as described above by a first and a second dividing
grooves 114a, 114b and a connecting groove 116. In other words, the
first and the second dividing grooves 114a, 114b and the connecting
groove 116 each are formed between adjacent unit cells 100 so as to
divide the thin films constituting the layers such as the
transparent front electrode layer 104, the thin film photoelectric
conversion units 106a, 106b, and the metal back electrode layer 108
into a plurality of cells. The first and the second grooves 114a,
114b and the connecting groove 116 each have a linear shape and are
formed so as to extend in a direction perpendicular to the plane of
paper in FIG. 3, that is, along the shorter edges of the module 10
and in parallel with respect to one another.
[0118] The first dividing groove 114a divides the transparent front
electrode layer 104 into unit cells 100. The first dividing groove
114a has an opening at a boundary between the transparent front
electrode layer 104 and the photoelectric conversion unit 106a and
its bottom at a surface of the transparent substrate 102. The
groove 114a is filled with a material such as amorphous silicon
constituting the unit 106a. Thus, the transparent front electrode
layer 104 of the unit cell 100 is electrically insulated from the
transparent front electrode layer 104 of another unit cell 100
adjacently located in the longer-edge direction of the module 10 by
the material such as amorphous silicon filled in the first dividing
groove 114a.
[0119] The second dividing groove 114b defines a boundary between
adjacent unit cells 100. The second dividing groove 114b is formed
at a position shifted relative to the first dividing groove 114a in
the longer-edge direction of the module 10. The second dividing
groove 114b is formed so as to divide the photoelectric conversion
units 106a, 106b and the metal back electrode layer 108 into unit
cells 100. The groove 114b has an opening at a boundary between the
metal back electrode layer 108 and the encapsulation resin layer
110 and its bottom at a surface of the transparent front electrode
layer 104. The groove 114b is filled with resin such as the
above-mentioned EVA (ethylene vinyl acetate copolymer) constituting
the layer 110. Thus, the metal back electrode layer 108 of the unit
cell 100 is electrically insulated from the metal back electrode
layer 108 of another unit cell 100 adjacently located by the resin
filled in the second dividing groove 114b.
[0120] The connecting groove 116 is formed between the first and
the second dividing grooves 114a, 114b. The connecting groove 116
divides the photoelectric conversion units 106a, 106b into unit
cells 100. The groove 116 has an opening at a boundary between the
photoelectric conversion unit 106b and the metal back electrode
layer 108 and its bottom at a surface of the transparent front
electrode layer 104. The groove 116 is filled with a metal material
such as silver and aluminum constituting the layer 108, so as to
electrically connect the layer 108 of one of adjacent unit cells
100 and the layer 104 of the other of the adjacent unit cells 100.
In other words, a number of the unit cells 100 formed in the module
10 are electrically connected to the respective adjacent unit cells
100 in series by the metal material filled in the groove 116.
[0121] Each of the unit cells 100 is preferably formed so as to
have a width (shorter edges) L3 of 7 to 12 mm and more preferably
of 8 to 10 mm in view of a balance between an
electricity-generating area and an electrode resistance, accuracy
and easiness of manufacture, minimization of output variability, or
the like. Each of the unit cells 100 has a length of the longer
edges slightly shorter than the length L4 of the shorter edges of
the cell panel 12 and of about three quarters of the length L2 of
the module 10. Therefore, each of the unit cells 100 is of a
strip-like configuration from a side of the transparent substrate
102. The unit cell 100 is a tandem (hybrid) solar cell provided
with the thin film photoelectric conversion units 106a, 106b and
obtains an open-circuit voltage in a range of 1.2 to 1.5 volts by
the added open-circuit voltage of the two units, which is higher
than the voltage obtained by a solar cell constituted by one unit.
The cell panel 12 is formed by the serially-connected 50 to 150
cell units 100, so as to be configured to output the open-circuit
voltage of 100 to 180 volts as a whole. In the cell panel 12 in
this embodiment, a number of cell units 100 are serially connected
so as to output the open-circuit voltage of about 100 volts as a
whole. The cell panel 12 is preferably formed to have a
short-circuit current value in a range of 9 to 15 mA/cm.sup.2 and
more preferably of 10 to 15 mA/cm.sup.2.
[0122] The longer edges of each of the cell units 100 extend in the
shorter-edge direction of the cell panel 12 and the shorter edges
thereof extend in the longer-edge direction of the cell panel 12.
Thus, in the cell panel 12, an area of a portion functioning as a
connecting part of the cell units 100, that is, an area of the
first and the second dividing grooves 114a, 114b and the connecting
groove 16 is minimized. Further, arrangement of the cell units 100
in the cell panel 12 as described above prevents a so-called hot
spot phenomenon even when a part of the cell panel 12 is located in
shade or dust and trash are accumulated around the bottom (an
eaves-side edge) of the cell panel 12.
[0123] As shown in FIG. 2, the solar cell module 10 is provided
with the terminal box 14 at the back of the panel 12 and the first
and the second cables 16, 18 pulled out from the terminal box 14.
The terminal box 14 has inside a plus electrode-connecting terminal
(not shown) connected to a positive electrode of the panel 12 and a
minus electrode-connecting terminal (not shown) connected to a
negative electrode of the panel 12. Within the terminal box 14,
there are provided two positive inner wires 24, which are black
coated wires, connected to the plus electrode-connecting terminal
and two negative inner wires 26, which are white coated wires,
connected to the minus electrode-connecting terminal.
[0124] The first and the second cables 16, 18 are used for
electrically connecting a plurality of the solar cell modules 10 to
one another when the solar cell array 1 is constructed by arranging
the modules 10. As shown in FIG. 1, the first cable 16 is formed by
bundling one wire 24 of the positive inner wires 24, 24 and one
wire 26 of the negative inner wires 26, 26. The second cable 18 is
formed by bundling the other wire 24 of the positive inner wires
24, 24 and the other wire 26 of the negative inner wires 26,
26.
[0125] As shown in FIGS. 1B and 1C, the first cable 16 and the
second cable 18 are different in color, the first cable 16 having
the positive inner wire 24 and the negative inner wire 26 put
together in a white insulation tube 16a and the second cable 18
having the positive inner wire 24 and the negative inner wire 26
put together in a black insulation tube 18a.
[0126] Further, the first cable 16 and the second cable 18 are
different in length, one being longer than the other. Specifically,
the first cable 16 is shorter than the second cable 18. The first
cable 16 has a total length of less than 50% of the length L1 of
the longer edges of the rectangular panel 12, while the second
cable 18 has a total length of 50% or more of the length L1.
[0127] Herein, a sum of the lengths of the first cable 16 and the
second cable 18 is longer than the length L1.
[0128] More specifically, the second cable 18 is, as shown in FIG.
1A, pulled out from a longer edge (upper side edge) 150 of a ridge
side of the module 10 toward the ridge side (upper side), having a
length X of a part pulled out from the longer edge 150 to the
connector 22 without a length of the connector 22, the length X
being 50% or more of the length L1 of the panel 12 of the module
10.
[0129] The more recommended length X is 50% or more of the length
L1 and simultaneously longer than the length L4 of the shorter
edges of the panel 12 and shorter than the length L1.
[0130] Specifically, the length X of the second cable 18 is longer
than (L1/2) and longer than L4 when the length of the longer edges
of the panel 12 is designated as L1 and the length of the shorter
edges of the panel 12 is designated as L4. The more recommended
length X is longer than a sum of (L1/4) and L4 and shorter than a
sum of ((L1/4).times.3) and L4.
[0131] Further, the length X of the second cable 18 may be of a
length obtained by the above-mentioned formulae using L2 instead of
L4 in view of flexibility for connection. That is, the length X of
the second cable 18 is longer than (L1/2) and longer than L2 when
the length of the longer edges of the panel 12 is designated as L1
and the length of the shorter edges of the module 10 is designated
as L2. The more recommended length X is longer than a sum of (L1/4)
and L2 and shorter than a sum of ((L1/4.times.3) and L2.
[0132] Meanwhile, the first cable 16 has a length Y of a part
pulled out from the longer edge 150 is shorter than the length X of
the second cable 18 and shorter than (L1/2).
[0133] Further, the length Y is shorter than the length L4 of the
shorter edges of the panel 12.
[0134] The length X of the first cable 16 may be of a length
obtained by the above-mentioned formulae using L2 instead of L4 in
view of flexibility for connection. That is, the length Y of the
first cable 16 is shorter than L2 of the shorter edges of the
module 10.
[0135] As shown in FIG. 1A to 1C, the first cable 16 and the second
cable 18 have the first connector 20 and the second connector 22
respectively attached to the respective ends. The first connector
20 and the second connector 22 have the same configuration though
being different in color. In this embodiment, the first connector
20 is white, while the second connector 22 is black.
[0136] As shown in FIG. 4, the first connector 20 and the second
connector 22 each are provided with a pin terminal 28 and a socket
terminal 30. The first and the second connectors 20 and 22 each are
provided with a female portion 32 and a male portion 34 with the
pin terminal 28 being within the female portion 32 and the socket
terminal 30 being within the male portion 34.
[0137] As shown in FIGS. 1B and 1C, in this embodiment, the
positive inner wire 24 is connected to the pin terminal 28 of the
first connector 20, while the negative inner wire 26 is connected
to the socket terminal 30 of the first connector 20. In contrast,
the negative inner wire 26 is connected to the pin terminal 28 of
the second connector 22, while the positive inner wire 24 is
connected to the socket terminal 30 of the second connector 22.
That is, in the first connector 20, the pin terminal 28 is a
positive electrode and the socket terminal 30 is a negative
electrode. In contrast, in the second connector 22, the pin
terminal 28 is a negative electrode and the socket terminal 30 is a
positive electrode. Therefore, in the first connector 20 and the
second connector 22, the female portion 32 of one of the connectors
20, 22 is engaged with the mail portion 34 of the other of the
connectors 20, 22 and whereby the pin terminal 28 of the one of the
connectors 20 and 22 is connected to the socket terminal 30 of the
other of the connectors 20 and 22, so that electrodes having the
same polarity are electrically connected in parallel.
[0138] As shown in FIG. 16, the base member 70 is made of a plate
of a substantially rectangular shape, which is formed into a
predetermined shape by bending a piece of metal plate or a
plurality of metal plates. Production of the base member 70 by a
piece of metal plate is easily worked, reduces production costs,
and further allows a configuration without a connected portion,
thereby adding the advantage of strength. Thus, the base member 70
is preferably made by bending a piece of metal plate in view of
those advantages.
[0139] On the base member 70 produced as described above, a cover
attaching portion 72, a solar-cell arranging portion 74, a
ridge-side fixing portion 76, and an overlapping portion 78 are
formed in this order from the eaves side, the ridge-side fixing
portion 76 being for fixing a ridge side of the solar cell panel 12
arranged on the solar-cell arranging portion 74 and the overlapping
portion 78 being for being overlapped with an eave-side end portion
of the solar cell module 10 or of a common roof tile adjacently
arranged on the ridge side (upper row). The base member 70 has the
trough-like gutter 80 formed at its side. The base member 70 is
preferably made of a metal plate such as a steel plate, an aluminum
plate, and a stainless steel plate, and in this embodiment, a
Galvalume steel plate is used.
[0140] As shown in FIG. 17, the cover attaching portion 72, which
is formed by an eave-side end of the base member 70 bent to the
back at a substantially right angle, is a portion to which the
front cover 102 described below is attached.
[0141] The solar-cell arranging portion 74, which is formed in the
substantially same size as the panel 12, is a planate portion on
which the solar cell panel 12 is arranged. As shown in FIG. 16, the
solar-cell arranging portion 74 has an opening 74a in which the
terminal box 14 of the panel 12 is inserted at its substantial
center part. In the solar cell module 10 in this embodiment, the
solar cell panel 12 is mounted on the base member 70 from its front
face, so that the terminal box 14, the cables 16, 18, and the
connectors 20, 22 come to the back of the base member 70 through
the opening 74a, as shown in FIG. 2.
[0142] As shown in FIG. 17, the ridge-side fixing portion 76 is a
portion for fixing the ridge side of the solar cell panel 12
arranged on the solar cell arranging portion 74. The fixing portion
76 has a rising portion 76a and a surface holding portion 76b, the
rising portion 76a being formed by bending the base member 70 to
the front face at a substantially right angle at a predetermined
position and the surface holding portion 76b being formed by
bending the base member 70 to the eaves side at a predetermined
position from a proximal end of the rising portion 76a. The rising
portion 76a has a contact with a ridge-side end face of the panel
12 and the holding portion 76b covers a part of a surface
(light-receiving face) of the panel 12 and puts a pressing force
from the surface side.
[0143] The overlapping portion 78 is a planate portion formed by
bending the base member 70 to the ridge side at a predetermined
position from a proximal end of the holding portion 76b of the
fixing portion 76. As shown in FIG. 16, the overlapping portion 78
has throughholes 78a at predetermined positions and throughholes
78b at predetermined positions nearer to the ridge side than the
throughholes 78a, the throughholes 78a being for securing the
hooking brackets 84 described below and the throughholes 78b being
for driving in screws therethrough to fix the module 10 to a
house.
[0144] The overlapping portion 78 is located at an area except an
upper face of the solar cell panel 12.
[0145] Next, the reinforcing heat insulator 90 will be described,
making reference to FIG. 16. The reinforcing heat insulator 90 is a
member made of foamed resin attached to the back of the base member
70 for keeping strength and heat insulation of the solar cell
module 10. The heat insulator 90 has a ridge-direction reinforcing
portion 92 extending in a ridge direction along the ridge-side
longer edge of the base member 70 and an inclining-direction
reinforcing portion 94 extending in a direction toward eaves
(perpendicular to the ridge) along the shorter edges of the base
member 70 from the both ends of the ridge-direction reinforcing
portion 92. The inclining-direction reinforcing portion 94 is a
portion to be overlapped on the overlapping portion 78 of the solar
cell module 10 or on a common roof tile adjacently arranged on the
eaves side (lower row) and is formed to have a thickness thinner
than the ridge-direction reinforcing portion 92.
[0146] The heat insulator 90 is arranged along a peripheral part of
the base member 70 instead of being arranged on the entire back of
the base member 70. Thus, the base member 70 has at its back an
accommodation space (gap portion) 96 surrounded by the heat
insulator 90 and opening at the eaves side. The terminal box 14 is
housed at a substantial center part of the space 96. Further, the
wired cables 16, 18 are accommodated in the space 96.
[0147] In this embodiment, the cables 16, 18 are pulled out from
the longer edge 150 of the ridge side of the solar cell module 10,
so that the solar cell modules 10 are connected in parallel by
connecting the connectors 20, 22 of the cables 16, 18 of the
modules 10 adjacently located on the right and left hands in the
same row as described below. The cables 16, 18 are pulled out from
the longer edge 150 of the module 10 as described above, so that
the connectors 20, 22 are connected above and outside the modules
10. When the modules in an upper row are arranged as described
below, the wired cables 16, 18 (including the connectors 20, 22)
are housed in the space 96 of the modules in the upper row.
[0148] Further, there is a gap between the inclining-direction
reinforcing portion 94 and a house, through which gap the cables
16, 18 are inserted.
[0149] The ridge-direction reinforcing portion 92 of the heat
insulator 90 has three cable grooves 98, as shown in FIG. 2, at a
face opposite to the face with which the base member 70 contacts.
The cable grooves 98 communicate from the ridge side to the eaves
side, so as to connect inside and outside of the space 96. The
cable grooves 98 consist of a center groove 98a located at a
substantial center part of the reinforcing portion 92 and side
grooves 98b, 98b located at right and left of the center groove 98a
at predetermined intervals from the center groove 98a. In the solar
cell module 10, the center groove 98a and the terminal box 14 are
located on the substantially same line, so that the cables 16, 18
pulled out from the terminal box 14 are pulled from the space 96
through the center groove 98a to an outside of the ridge side. The
side grooves 98b, 98b are used for wiring with the other solar cell
modules 10 arranged in the upper row and the lower row.
[0150] Now, the solar cell array 1 constructed by the
above-mentioned solar cell modules 10 will be described in detail,
making reference to a work procedure of arrangement on the roof R
of the house shown in FIG. 6. For arrangement of the solar cell
modules 10, a drip at the eaves and a predetermined roofing member
are firstly attached to the roof R of the house on which the
modules 10 are arranged. At the step 1, markings indicating lines,
shapes, and sizes on the roof R required to proceed with the work
are carried out. At the next step 2, counter-battens are mounted at
predetermined intervals. At the step 3, tilting fillets (eaves
boards) and battens (gauge laths) are mounted. The battens are
mounted at predetermined intervals toward the ridge. At the step 4,
fixtures for preventing blow-off of the solar cell modules 10 are
mounted on predetermined positions, and then the procedure proceeds
to the step 5.
[0151] At the step 5, the solar cell modules 10 are sequentially
arranged from the eaves side to the ridge side of the roof R with
the adjacent solar cell modules 10, 10 connected by the first and
the second cables 16, 18. More specifically, the modules 10 are
arranged, as shown in FIGS. 6A and 6B, in such a manner that the
shorter edges of a plurality of modules 10 are put together side by
side with each other in a row so as to form a module row 36 and
that the modules 10 are fixed to the roof R by means such as
screws. In this embodiment, even number of the module rows 36
(fourteen rows 36 in FIG. 6B) are arranged on the roof R.
[0152] Specifically, after engagement of the modules 10 with the
fixtures 110 for preventing blow-off of the modules 10, the modules
10, as shown in FIG. 18B, are fixed to the house by driving
construction screws 152 into the throughholes 78b of the
overlapping portion 78. At this time, the cables 16, 18 of the
modules 10 are pulled out toward the ridge side.
[0153] As shown in FIG. 7, during formation of the module row 36,
the first connector 20 of one of the adjacent modules 10, 10 is
connected to the second connector 22 of the other of the adjacent
modules 10, 10, and whereby the adjacent modules 10, 10 are
electrically connected in parallel. Specifically, connection of the
first connector 20 in white attached to the first cable 16 in white
to the second connector 22 in black attached to the second cable 18
in black allows parallel connection of the adjacent modules 10, 10.
Therefore, in the modules 10 in this embodiment, connection of the
adjacent modules 10, 10 on the right and left hands by the first
and the second cables 16, 18 enables sequential parallel connection
of all the modules 10 belonging to the module row 36 (FIG. 10).
[0154] Herein, in the module 10 in this embodiment, the first cable
16 is shorter than the second cable 18 as described above.
Therefore, according to the module 10, workers immediately
determine whether the connector attached to the cable 16, 18 is the
first connector 20 or the second connector 22 by confirming a
length of said cable.
[0155] In the module 10 in this embodiment, the first cable 16 has
the total length of less than 50% of the length of the longer edges
of the rectangular panel 12, while the second cable 18 has the
total length of 50% or more of the length of the longer edges of
the panel 12. Therefore, as shown in FIG. 8, the first connectors
20, 20 of the respective first cables 16, 16 of the adjacent
modules 10, 10 with their shorter edges adjacently put together are
unconnectable to each other. Consequently, the solar cell module 10
of this embodiment surely prevents improper connection of the first
connectors 20, 20 of the adjacent modules 10, 10.
[0156] The module 10 in this embodiment makes the first cable 16
white and the second cable 18 black. Therefore, workers easily
determine the kinds of the connectors 20, 22 attached to the cables
16, 18 by confirming colors of the cables 16, 18.
[0157] The module 10 makes the first connector 20 white and the
second connector 22 black. That is, the first connector 20 and the
second connector 22 are different in color from each other.
Therefore, in the module 10 in this embodiment, workers rapidly
determine the kinds of the connectors 20, 22 by confirming colors
of the connectors 20 and 22. Consequently, the solar cell module 10
in this embodiment allows workers rapid and appropriate selection
of a connector and reduces improper wiring, thereby giving high
working efficiency.
[0158] Further, in the module 10, the first cable 16 and the second
cable 18 each are pulled out from a center part of the ridge side
of the module 10 as shown in FIG. 1A, so as to be connected to each
other with the module 10 fixed to the roof. That is, even when the
module 10 is fixed to the roof by means such as nails, the first
cable 16 and the second cable 18 are, as shown in FIGS. 19 and 22,
located outside of the main body of the module 10. Consequently, in
this embodiment, the connection of the cables 16, 18 can be carried
out after fixation of the module 10 to the roof by means such as
nails.
[0159] The connection of the cables 16, 18 is carried out one row
by one row. In this embodiment, the modules 10 are arranged from
the eaves side and thus, all the modules 10 belonging to one row
(first row) are firstly arranged at the eaves or near the eaves.
Then, the cables 16, 18 pulled out toward the ridge side of the
modules 10 are sequentially connected. The connection in one row is
carried out adjacent to an upper row of the modules 10 having been
arranged in the row in question. The connected cables 16, 18 are
placed, as shown in FIG. 22, adjacent to the upper row of the
modules 10 having been arranged in the row in question.
[0160] Subsequently, the modules 10 in the second row are fixed.
Herein, the modules 10 in the second row are arranged so that the
eaves sides of the modules 10 are placed on the overlapping
portions 78 of the modules 10 in the first row. Therefore, the
modules 10 in the second row overlap, as shown in FIG. 22, on the
cables 16, 18 of the modules 10 in the first row, the cables 16, 18
in the first row being housed in the spaces 96 of the modules 10 in
the second row.
[0161] The modules 10 in the module rows 36 that follow the first
row are arranged in the following way as shown in FIGS. 19 and 20.
The front covers 102 of the modules 10C to be arranged in an upper
row are arranged on the eaves side with stoppers 108 of the covers
102 inserted into gaps 156 between the engaging portion 88 of the
hooking brackets 84 and the surface of the overlapping portions 78
of the bases 70 of the modules 10D. The modules 10C are pulled up
overall toward the ridge side, so as to be engaged with the modules
10D. Herein, the stopper 108 of the module 10C is provided with a
seal 154, which is arranged without space in the gap 156 when the
stopper 108 is inserted into the gap 156 between the engaging
portion 88 of the hooking bracket 84 and the base member 70. That
avoids slip at an engaged portion of the module 10C and the module
10D.
[0162] When the modules 10C are arranged at predetermined positions
by engagement of the modules 10C with the modules 10D, the cables
16, 18 of the modules 10D in the lower row are orderly housed in
the spaces 96 in the modules 10D in the upper row (FIG. 23).
[0163] After engagement of the stoppers 108 of the modules 10C in
the upper row with the hooking brackets 84 of the modules 10D in
the lower row respectively, the modules 10C in the upper row are
fixed to the house by driving the screws 152 in the throughholes
78b of the overlapping portion 78 with the cables 16, 18 pulled out
to the ridge side. Also as for the module rows 36 that follow the
first row arranged in this way, all the modules 10 belonging to the
module row 36 are connected in parallel by connecting the adjacent
modules 10, 10 on the right and left hands by the cables 16, 18 in
the same procedure as in the module row 36 in the first row.
[0164] As shown in FIG. 10, in the solar cell array 1 formed by a
number of solar cell modules 10, connection orders of the first and
second cables 16, 18 of the module rows 36a, 36c in the
odd-numbered rows from the eaves side (from the bottom) and those
of the module rows 36b, 36d in the even-numbered rows therefrom are
different in direction. Specifically, in the module rows 36a, 36c
in the odd-numbered rows, the second connector 22 in the right
module 10 and the first connector 20 in the left module 10 are
connected, so as to connect the second cable 18 and the first cable
16. In contrast, in the module rows 36b, 36d in the even-numbered
rows, the first connector 20 in the right module 10 and the second
connector 22 in the left module 10 are connected, so as to connect
the first cable 16 and the second cable 18.
[0165] When all the modules 10 constituting the module row 36 are
connected by the first and the second cables 16, 18, as shown in
FIG. 7, among the modules 10, 10 arranged at either side of a
plurality of modules 10 constituting the module row 36, the first
connector 20 of the module 10 situated at one end and the second
connector 22 of the module 10 situated at the other end are unused
(unconnected). These unused first and second connectors 20 and 22
are used for an electrical connection of the module rows 36, 36
arranged in an upper and lower rows.
[0166] In the array 1 shown in FIG. 10, for example, the module
rows 36a, 36c in the odd-numbered rows and the module rows 36b, 36d
in the even-numbered rows are connected respectively, so as to form
solar cell blocks 38a, 38b (hereinafter also referred to as cell
blocks 38a, 38b). Specifically, the second cables 18 of the modules
10a, 10c arranged at the left ends of the module rows 36a, 36c in
the odd-numbered rows pass through the respective backs of the
solar cell panels 12 of the modules 10b, 10d arranged at the left
ends of the module rows 36b, 36d in the even-numbered rows, so as
to connect the second connectors 22 of the modules 10a, 10c to the
respective first connectors 20 of the modules 10b, 10d.
[0167] As described above, in order to connect the second cables 18
of the modules 10a, 10c in the lower rows to the respective first
cables 16 of the modules 10b, 10d in the upper rows, the second
cables 18 in the lower rows pass through the respective backs of
the panels 12. At this time, each of the second cables 18, as shown
in FIGS. 23 and 24, passes through either of the side grooves 98b,
98b via the space 96 of the module 10b, 10d. Then, a distal end of
the second cable 18 is pulled out further upwardly than the modules
10b, 10d in the upper row, so as to be connected to the first cable
16 of the module 10b, 10d in the upper row.
[0168] In this embodiment, in a case where the modules 10
constituting the solar cell block 38 are arranged in a plurality
rows, the longer cables (second cables 18) among the two cables 16,
18 connect the modules 10 in parallel.
[0169] Herein, in the module 10 in this embodiment, if the length X
of the long cable (second cable 18) is longer than the length L4 of
the shorter edges of the panel 12, the second cable 18 passes under
and comes further above the module 10 belonging to the module row
36 in the upper row.
[0170] In view of margin for connection, if the length X of the
long cable (second cable 18) is longer than the length L2 of the
shorter edges of the module 10, the second cable 18 passes under
and comes further above the module 10 belonging to the module row
36 in the upper row, so as to be easily connected to the other
cable.
[0171] Practically, as shown in FIG. 22, the length X of the second
cable 18 is necessarily to be made longer to some extent than the
length L2 of the shorter edges of the module 10 because the space
through which the cable 18 is inserted is confined and the modules
10 are arranged in a staggered manner.
[0172] In the configuration shown in FIG. 22, the cable 18 passes
under the module 10 via the side groove 98b in the heat insulator
90. The solar cell modules 10 belonging to the adjacent row are
arranged with a shift by a length (a).
[0173] A portion overlapped with the overlapping portion 78 of the
module 10 in the upper row has a length (b).
[0174] To describe by an example shown in FIG. 22, the second cable
18 has a length extended in a horizontal direction of ((L1/4)+(a))
and a length required in a vertical direction of (L2-(b)).
[0175] Therefore, the second cable 18 needs a length of
((L1/4)+(a))+(L2-(b)).
[0176] In this embodiment, the length (L2-(b)) substantially equals
to the length L4 of the shorter edges of the panel 12.
Consequently, the second cable 18 needs a length
(((L1/4)+(a))+L4).
[0177] FIGS. 26 to 28 each show an illustration of a considerable
length of the cable 18 required by changing a shift length of the
modules 10 belonging to adjacent rows. By FIGS. 26 to 28, the more
the shift length (a) is, the longer the cable 18 is required. When
the shift length becomes three quarters of the total length L1 of
the panel 12, the cable 18 is required to be longest, the length
being a sum of ((L1/4).times.3) and L4. In consideration of the
margin of connection, it is a sum of ((L1/4).times.3) and L2.
[0178] Consequently, the length of the cable 18 is less than or
equal to a sum of ((L1/4).times.3) and L4 and preferably less than
or equal to a sum of ((L1/4).times.3) and L2 in consideration of
the margin.
[0179] The pulled-out length Y of the first cable 16 is shorter
than the length X of the second cable 18 and shorter than a length
(L1/2).
[0180] Further, the length Y is shorter than the length L4 of the
shorter edges of the panel 12. Thus, the first cable 16 is
prevented from passing under the module 10 in the upper row, so as
to have no possibility of improper connection.
[0181] When the length Y is shorter than the length L2 of the
shorter edges of the module 10, there is no possibility of improper
connection because a margin for connection is practically
needed.
[0182] The connection of the two cables 16, 18, in a case where the
modules 10 constituting the solar cell block 38 are arranged in a
plurality rows, is also carried out at outside of the modules 10.
That achieves high workability. The connected cables 16, 18 are
housed in the spaces 96 of the modules 10 in the next row but one
as shown in FIG. 24.
[0183] Thereby, all the modules 10 belonging to the module rows 36a
and 36b are connected in parallel, so as to form the cell block
38a. All the modules 10 belonging to the module rows 36c and 36d
are also connected in parallel, so as to form the cell block 38b.
The cell blocks 38a, 38b each are made up of twenty or more of the
modules 10 electrically connected in parallel. Further, the cell
blocks 38a, 38b are made up of the same number of the modules 10.
The cell blocks 38a, 38b having been formed as described above are
electrically connected in series by a service cable 40, and whereby
the solar cell array 1 is constructed.
[0184] As shown in FIG. 11A, the service cable 40 consists mainly
of a first serial connector 42, a second serial connector 44, an
output connector 46, a first outdoor cable 48, a second outdoor
cable 50, an indoor cable 52, and a molded portion 54. The first
serial connector 42 is to be connected to the first connector 20 of
the module 10. The second serial connector 44 is to be connected to
the second connector 22 of the module 10. The output connector 46
is to be connected to an indoor power conductor (not shown) so as
to output electric power converted in the panel 12 of the module
10. The first outdoor cable 48 is to be connected to the first
serial connector 42. The second outdoor cable 50 is to be connected
to the second serial connector 44. The indoor cable 52 is to be
connected to the output connector 46.
[0185] The first serial connector 42, the second serial connector
44, and the output connector 46 have the same configuration as the
first connector 20 and the second connector 22 of the module 10.
The first serial connector 42 and the output connector 46 are
black, while the second serial connector 44 is white.
[0186] The first outdoor cable 48, the second outdoor cable 50, and
the indoor cable 52 each have one positive inner wire 24 and one
negative inner wire 26 in respective insulation tubes 48a, 50a, 52a
as well as the first cable 16 and the second cable 18 of the module
10. The insulation tubes 48a, 52a of the first outdoor cable 48 and
the indoor cable 52 are black, while the insulation tube 50a of the
second outdoor cable 50 is white.
[0187] A white vinyl tape 56 is wound around a part adjacent to the
output connector 46 of the indoor cable 52, thereby enabling
immediate determination of the indoor cable 52 and the output
connector 46.
[0188] As shown in FIG. 11B, the first outdoor cable 48, the second
outdoor cable 50, and the indoor cable 52 are connected within the
molded portion 54. To put it more specifically, the positive inner
wire 24 of the first outdoor cable 48 is electrically connected to
the negative inner wire 26 of the second outdoor cable 50, while
the negative inner wire 26 of the first outdoor cable 48 is
electrically connected to the negative inner wire 26 of the indoor
cable 52, and while the positive inner wire 24 of the second
outdoor cable 50 is electrically connected to the positive inner
wire 24 of the indoor cable 52.
[0189] As shown in FIG. 10, when the cell block 38a and the cell
block 38b are connected in series by the service cable 40, the
second serial connector 44 (white) of the service cable 40 is
connected to the second connector 22 (black) of the rightmost solar
cell module 10f in the module row 36b constituting the cell block
38a. Meanwhile, the first serial connector 42 (black) of the
service cable 40 is connected to the first connector 20 (white) of
the rightmost solar cell module 10g in the module row 36c
constituting the cell block 38b.
[0190] In short, the connections of the service cable 40 to the
cell blocks 38a, 38b are done only by connecting the connectors
being different in color as well as the connection of the adjacent
modules 10, 10. That reduces improper connection of wiring.
Further, as described above, the service cable 40 is connected to
the cell blocks 38a, 38b only by the connections of predetermined
combinations between the connectors 44, 22, 42, 20. That allows
easy working on the roof R.
[0191] Herein, the cell blocks 38a, 38b in this embodiment are
constituted by a plurality of the solar cell modules 10, one module
generating a voltage of about 100 volts, connected in parallel. The
cell blocks 38a, 38b also generate a voltage of about 100 volts in
total. The solar cell array 1 is constituted by the two cell blocks
38a, 38b serially connected by the service cable 40, thereby
outputting a voltage of about 200 volts, which is a rated voltage
of various devices.
[0192] As described above, the solar cell modules 10 defined in
this application are connected by the first cables 16 and the
second cables 18 and further a plurality of the modules 10
connected in parallel constitute the solar cell blocks 38a, 38b,
which are connected in series by the service cable 40. The
above-mentioned work is easy and simple without improver wiring,
thereby arranging a number of modules 10 on the roof. And an output
voltage of substantially 200 volts is obtained from the output
cable 52 of the service cable 40.
[0193] Therefore, according to this invention, a wiring work can be
done by anyone even if being not a skilled electrician. For
example, skilled workers in high places such as a roof tiler and a
carpenter can easily finish a wiring work.
[0194] Further, the way such as increasing of the number of unit
solar cells 100 of the solar cell panel 12 of the solar cell module
10 can generate a voltage of 200 volts or more. For example, it is
possible to generate a voltage of 200 volts to 360 volts.
[0195] As shown in FIG. 10, the first connector 20 of the rightmost
module 10e in the module row 36a and the second connector 22 of the
rightmost module 10h in the module row 36d are unused (unconnected)
with the cell blocks 38a, 38b serially connected. According to the
array 1 of the modules 10 in this embodiment, the first and second
connectors 20, 22 each are attached with the terminal protector 58
shown in FIG. 12. The terminal protector 58 has the substantially
same configuration with the first connector 20 and the second
connector 22 of the module 10 except that no cable is connected. In
the array 1 of the modules 10 in this embodiment, the terminal
protectors 58 attached to the unused connectors 20, 22 protect the
terminals 28, 30 of the unused first and second connectors 20, 22
from adhering of dust or water.
[0196] When the arrangement work of the array 1 of the modules 10
carried out as described above is interrupted, the terminals 28, 30
of the connectors 20, 22 are protected from adhering of dust or
water by attaching the terminal protectors 58 to the unconnected
first or second connector 20 or 22.
[0197] After completion of the work in the step 5 in FIG. 5 as
described above, workers pull the indoor cable 52 of the service
cable 40 within the house at the step 6. Thereafter, trim tiles are
arranged (step 7), the roof R is cleaned (step 8), an inspection is
given (step 9), the service cables 40 are banded in the house (step
10), and then the output connector 46 is connected to a splice box
(not shown) of the power conductor (step 11). Thus, a series of
procedure is completed.
[0198] As described above, the solar cell module 10 in this
embodiment includes the solar cell panel 12, the panel 12 having
the length L1 of its longer edges of 900 to 1100 mm and the module
10 having the length L2 of its shorter edges of 240 to 480 mm.
[0199] More specifically, the solar cell module 10 has a whole
length WL of its longer edges of 920 to 1200 mm and the length L2
of its shorter edges of 240 to 480 mm, while the solar cell panel
12 has the length L1 of its longer edges of 900 to 1100 mm and the
length L4 of its shorter edges of 230 to 320 mm.
[0200] By this configuration, the modules 10 are easily carried in
and arranged at a place such as a roof of a house, where the
arrangement work is difficult. Further, the module 10 in this
embodiment has the length of its longer edges being about twice a
size of a common roof tile and the length of its shorter edges
being substantially the same as that. Thus, the modules 10
described above are arranged by the similar working method as
common tiling arranged sequentially in a horizontal direction by
orienting those on a roof so that they are wider than they are tall
(elongated in the ridge direction), thus being suitable to
arrangement on a roof.
[0201] As described above, the cell panels 12 each are formed by
lining up a plurality of the strip-like unit cells 100 having the
width of 7 to 12 mm and electrically connecting those in series,
thereby ensuring the uniform configuration. Further, being formed
in this way, the cell panels 12 have little individual difference
in output power. Therefore, the solar cell array 1 constructed as
described above minimizes power reduction of the entire array 1
caused by the individual difference in output power of the cell
panels 12.
[0202] As described above, the unit cells 100 constituting the cell
panel 12 each have the width of 7 to 12 mm and the open-circuit
voltage of 1.2 to 1.5 volts. Therefore, the cell panel 12 and the
module 10 having the above-mentioned sizes generate an output
voltage suitable to construct the solar cell array 1.
[0203] The above-mentioned unit cell 100 is of a tandem type formed
by lamination of the photoelectric conversion units 106a, 106b,
thereby utilizing energy contained in incident light to the
maximum. The above-mentioned embodiment illustrates an example
employing the unit cell 100 of the two-layered tandem type (hybrid)
with the laminated units 106a, 106b, but the present invention is
not limited thereto and may be that of an n-layered tandem type
(n=an integer more than two). Further, the unit cell 100 is not
limited to be of the tandem type and may be of a type of a single
layer having either one of the units 106a, 106b.
[0204] The above-mentioned embodiment illustrates an example
employing the solar cell panel 12 capable of outputting the
short-circuit current in a range of 9 to 15 mA/cm.sup.2, but the
present invention is not limited thereto and may be that capable of
outputting the short-circuit current beyond the above-mentioned
range.
[0205] As described above, in the above-mentioned embodiment, the
cell blocks 38a, 38b each are configured by twenty or more of the
modules 10 electrically connected in parallel, so as to have a
small effect on power reduction of the entire array 1 even with
power reduction of a part of the modules 10. Thus, the
above-mentioned array 1 achieves stable output performances with
less effect by power reduction of a part of the modules 10 even if
the power reduction would happen. The above-mentioned embodiment
illustrates an example in which the cell blocks 38a, 38b each are
configured by connecting twenty or more of the modules 10 in
parallel, but the present invention is not limited thereto and may
have the cell blocks 38a, 38b each configured by less than twenty
modules 10.
[0206] The solar cell array 1 described above is formed by
connecting the two cell blocks 38 in series, but the present
invention is not limited thereto and may be formed by constructing
more than two cell blocks 38 and connecting those in series.
[0207] The module 10 described above dispenses with a dividing line
dividing an area of the unit cell 100 that generates electricity
(effective electricity-generating area) upon reception of light
into sections electrically insulated from each other, but the
present invention is not limited thereto and may have a
configuration with at least one dividing line 118, as shown in FIG.
14, extending in the longer-edge direction of the module 10. By
this configuration, even if a part of a specific unit cell 100
would fail to generate electricity because of being in shade, the
module 10 is protected from deterioration or breaking due to a hot
spot phenomenon. Further, provision of the dividing line 118
prevents generation of individual difference in output performances
of the modules 10 due to a hot spot phenomenon and an imbalance of
output of the cell blocks 38a, 38b resulting from the individual
difference after arrangement of the array 1, thereby utilizing
output power generated by the normally-operating modules 10 to the
maximum.
[0208] The dividing line 118 may be formed so as to pass through
any position in the unit cell 100, but is preferably formed at an
upper end portion (ridge side) of the module 10 and/or at a lower
end portion (eaves side), that is, at a position eccentrically
located toward the upper end and/or the lower end in the
shorter-edge direction of the module 10, when the modules 10 are
arranged on a house. This configuration prevents a hot spot
phenomenon at a ridge-side portion hidden behind another module 10
or a roof tile arranged above and an eaves-side portion easily
collecting dust and trash.
[0209] Further, the solar cell modules 10 in this embodiment are
arranged with the cables 16, 18 pulled toward the ridge side. Thus,
as well as the general manner to tile a house, the modules 10 are
readily arranged from the eaves side to the ridge side of a house.
Consequently, even workers being inexperienced in electric work for
example readily and orderly wire the cables 16, 18 and arrange the
modules 10.
[0210] Further, the array 100 in this embodiment employs the
above-mentioned solar cell modules 10, thereby facilitating wiring
of the cables 16, 18 in arrangement and reducing the possibility of
breaking of wire caused by twisting of the cables 16, 18 or the
like. Still further, the array 100 in this embodiment are arranged
with the cables 16, 18 of the module 10 pulled toward the ridge
side without especial wiring of the cables 16, 17. Therefore, as
well as the general manner to tile a house, the array 100 in this
embodiment facilitates works such as connection of the cables 16,
18 by arranging the modules 10 from the eaves side to the ridge
side of a house.
[0211] In the solar cell modules 10 in this embodiment, the
accommodation space 96 formed on the base 82 is enclosed by the
ridge-direction reinforcing portion 92 and the inclining-direction
reinforcing portions 94, 94 of the reinforcing heat insulator 90 on
three sides. Therefore, the space 96 keeps out air and water from
its upper side (ridge side) or its right and left sides when the
modules 10 are arranged on a house, so that the terminal box 14 is
protected from being wet.
[0212] In the solar cell module 10 in this embodiment, the
accommodation space 96 is open toward an eaves-side edge 162, so as
to be ventilated through the opened part. Therefore, even if the
terminal box 14 is subjected to high temperature resulting from
power distribution, heat is prevented from accumulating in the
space 96, so that a suitable temperature condition is maintained in
the space 96.
[0213] The solar cell module 10 in this embodiment, as shown in
FIG. 2, has a gap 168 around the terminal box 14 in the space 96.
That surely prevents heat generated in the terminal box 14 from
accumulating in the space 96 and a trouble, such as failure and
break of the terminal box 14 caused by the heat, from
occurring.
[0214] In the solar cell module 10 in this embodiment, the
ridge-direction reinforcing portion 92 of the reinforcing heat
insulator 90 is made of formed resin. That protects the cables 16,
18 from being subjected to an excess load even if the cables 16, 18
fail to pass through the cable grooves 98 formed in the portion 92
and happen to get stuck in between a top surface of a house and the
portion 92. Consequently, the solar cell module 10 surely avoids
inconvenience such as breaking of the cables 16, 18.
EXAMPLES
[0215] Now, examples of the present invention will be described in
detail below.
[0216] FIG. 1A is a perspective view of the roof-tile shaped solar
cell module employed in the embodiment of the present invention.
FIG. 4 is a cross section of the connector of the solar cell module
shown in FIG. 1.
[0217] The roof-tile shaped solar cell module 10 is an integrated
solar cell, in which a plurality of unit solar cells are formed so
as to constitute a solar cell as a whole.
[0218] Specifically, the module 10 is formed by laminating a film
such as a conducting film and a semiconductor film on a glass
substrate, cutting a plurality of grooves on the laminated layer so
that the layer is divided into a number of one-cell batteries (unit
solar cells), and electrically connecting the unit solar cells in
series.
[0219] The module 10 is of a rectangular shape as shown in figures
with the two cables 16, 18 pulled out from a center part of its
longer edge.
[0220] Further, the cables 16, 18 are connected to the connectors
20, 22 respectively.
[0221] The cables 16, 18 are different in length, one being long
and one being short. Specifically, the long cable 18 has a total
length of 50% or more of a total length of the module 10, while the
short cable 16 has a total length of less than 50% of the total
length of the module 10.
[0222] Further, the cables 16, 18 are different in color. The
cables 16, 18 each have two electrically-insulated conducting wires
24, 26 (the positive inner wire 24 and the negative inner wire 26).
More specifically, the cables 16, 18 each are a cable with the two
covered conducting wires 24, 26 arranged in one insulation
tube.
[0223] The cables 16, 18 are connected to the connectors 20, 22
respectively. The connectors 20, 22 are different in color but have
the same configuration in which the two terminals 28, 30 (the pin
terminal 28 and the socket terminal 30) are provided as shown in
FIG. 4.
[0224] The pin terminal 28 is of a pin shape and the socket
terminal 30 is of a socket shape.
[0225] Further, the connectors 20, 22 each have the female portion
32 and the male portion 34, the pin terminal 28 being formed in the
female portion 32 and the socket terminal 30 being formed in the
male portion 34.
[0226] The connectors 20, 22 are connectable to each other with the
female portion 32 of one of the connectors 20, 22 and the male
portion 34 of the other thereof connected. When one pair of the
female portion 32 and the male portion 34 is connected, the pin
terminal 28 of the female portion 32 and the socket terminal 30 of
the male portion 34 are connected inside the portions.
[0227] In this embodiment, the two covered conducting wires 24, 26
of each of the two cables 16, 18 are connected to the positive
electrode and the negative electrode of the solar cell in the
module 10 respectively. Specifically, the coated conducting wire 24
in the cable 18 is connected to the positive electrode of the solar
cell, while the coated conducting wire 26 therein is connected to
the negative electrode of the solar cell. Similarly, the coated
conducting wire 24 in the cable 16 is connected to the positive
electrode of the solar cell, while the coated conducting wire 26
therein is connected to the negative electrode of the solar
cell.
[0228] Consequently, one of the two terminals 28, 30 of the
connector 22 is connected to the positive electrode of the solar
cell, while the other thereof is connected to the negative
electrode of the solar cell. Similarly, one of the terminal 28, 30
of the connector 20 is connected to the positive electrode of the
solar cell, while the other thereof is connected to the negative
electrode of the solar cell.
[0229] Herein, the two terminals 28, 30 of the connectors 20, 22
have reverse polarities. Specifically, in the connector 20, the pin
terminal 28 has the positive electrode and the socket terminal 30
has the negative electrode. In contrast, in the connector 22, the
pin terminal 28 has the negative electrode and the socket terminal
30 has the positive electrode.
[0230] Now, an arrangement structure of the roof-tile shaped solar
cell module 10 described above will be described in detail
below.
[0231] FIG. 7 is a conceptual diagram showing the modules 10
properly connected. FIG. 8 is a conceptual diagram showing the
modules 10 improperly connected. FIG. 9 is a circuit diagram of
wiring in which the modules 10 are properly connected.
[0232] The above-mentioned modules 10 are, as shown in FIGS. 5 and
7, are arranged on a structural subject such as a roof by lining up
in one row sideways.
[0233] Then, the connectors 20, 22 of adjacent modules 10 are
connected. Looking at one module 10, the connector 22 of said
module 10 is connected the connector 20 of the module 10 located to
its immediate left. The connector 20 of said module 10 is connected
to the connector 22 of the module 10 located to its immediate
right.
[0234] To explain with focusing on the lengths of the cables, the
connector 22 of the long cable 18 of said module 10 is connected to
the connector 20 of the short cable 16 of the module 10 located to
its immediate left. The connector 20 of the short cable 16 of said
module 10 is connected to the connector 22 of the long cable 18 of
the module 10 located to its immediate right.
[0235] As a result, as shown in FIG. 7, the solar cells are
connected in parallel.
[0236] In contrast, because of improper connection, as shown in
FIG. 8, connection of the connectors 22 of the long cables 18
renders the other connectors 20 physically unable to connect, and
whereby workers notice the improper connection. That is because the
connector 20 is connected to the short cable 16, which has a length
less than a half of the total length of the module 10. Further,
since the cables 16, 18 each are pulled out from the center part of
the module 10, the short cables 16 lacks length, thus being
unconnectable to each other.
[0237] Consequently, the roof-tile shaped solar cell modules 10 in
this embodiment are never wired improperly.
* * * * *