Solar battery module device and method of installing the same

A solar battery module device (14), wherein an bottom-side end part (22) is fixed onto a placing surface (23) by fitting the top-side end part (19) as one-side of a rectangular shape of a rectangular flat plate-like solar battery module (16) to the engagement part (20) of an upper frame (21) forming a frame (17) from the lower side of a roofer and by fitting a fixing cover (27) to a lower frame (24) in a state in which the bottom-side end part (22) as the opposite-side of the rectangular shape of the solar battery module (16) is placed on the placing surface (23) of the lower frame (24) forming the frame (17). According to the solar battery module device of the present invention, operations such as installation work and maintenance and inspections for the device can be easily and safely performed without damaging the solar battery module (16).

TECHNICAL FIELD

The present invention relates to a solar battery module device for installing a solar battery module on a roof that generates power utilizing solar energy and a method of installing the same.

RELATED ART

By recent rise in environmental consciousness, photovoltaic power generating systems for generating power by installing solar battery modules on roofs of general housings and public buildings have been attracting attention to as clean energy. Example of a photovoltaic power generating system installed on an sloping roof of a general housing or the like include a roof-placement type system for installing a mount on the existing roof and mounting a solar battery module thereon and a roof-integration type system in which a roof is thatched with a roofing material such as a roof tile or a slate having a solar battery incorporated therein in place of or together with a normal roofing material.

The latter photovoltaic power generating system of a roof-integration type can be constructed when a general housing is newly built or renovated and has the advantage in that an appearance harmonized with a roof is more beautiful than that in the roof-placement type system.FIG. 53is a perspective view showing a state where a conventional roof-integration type photovoltaic power generating system1is installed on a roof3of a general housing2,FIG. 54is a cross-sectional view showing a state where a roofer7of a roof is thatched with roofing materials5serving as solar battery modules having solar batteries4incorporated therein that constitutes the photovoltaic power generating system1and normal roofing materials6, andFIGS. 55 and 56are perspective views each showing an example of the shapes of the roofing materials5and6constituting the photovoltaic power generating system1.

Referring to the figures, used as the rooting material5constituting the roof-integration type photovoltaic power generating system1is one each having the solar battery4incorporated into a main body8having substantially the same shape as that of the normal roofing material6. Referring toFIG. 55, for example, the roofing materials5as illustrated are each formed in a rectangular flat plate shape and have the same shape as the roofing materials6having a configuration in which the adjacent ones in a direction parallel to a ridge of the roof are meshed with and connected to each other by an upper protruding part9projected downward and a lower protruding part10projected upward. The roofing materials are also each formed by forming the main body8having a recess part11formed on its upper surface (light receiving surface) of ceramic or the like, similarly to the roofing materials6, and embedding the solar battery4formed by affixing a translucent substrate composed of a translucent body such as glass or resin and a solar battery cell, for example, in the recess part11of the main body8to integrate with adhesives, for example.

Referring toFIG. 56, the roofing materials5as illustrated have the same shape as the roofing materials6in a Japanese style formed in a curved shape, and are each formed by forming a main body8having a recess part11on its upper surface (light receiving surface) of ceramic or the like, similarly to the above-mentioned roofing materials6, and embedding the solar battery4in the recess part11of the main body8to integrate with adhesives, for example.

Since both the roofing materials5are entirely the same in shape as the normal roofing material6having no solar battery, the installation thereof on the roof can be performed in the same manner as that in construction of the normal roofing material6. That is, referring toFIG. 54, the roof can be thatched with the roofing materials5and6while overlapping them in order from an edge of eaves to a ridge of the roof with crosspieces12equally spaced on the roofer7used as a reference.

In the example shown inFIG. 55, for example, the roofing materials5and6are first successively installed rightward along the right side of the roofing materials5and6installed at left front in the figure while meshing the upper protruding part9and the lower protruding part10with each other with the first crosspiece from the edge of eaves used as a reference. Then, on the roofing materials5and6installed in one line, the roofing materials5and6in the subsequent line are similarly installed while being connected thereto such that ends closer to the edge of eaves of the roofing materials5and6to be newly installed are respectively overlapped with ends closer to the ridge of the roofing materials5and6previously installed with the second crosspiece from the edge of eaves used as a reference. This operation is repeated up to the ridge of the roof, so that the roof can be thatched with the roofing materials5and6while overlapping them with one another in order from the edge of eaves to the ridge of the roof.

In the example shown inFIG. 56, the roofing materials5and6are first successively installed along the right side of the roofing materials5and6installed at left front in the figure with the first crosspiece from the edge of eaves used as a reference such that left ends of the roofing materials5and6to be newly installed are respectively overlapped with right ends of the roofing materials5and6previously installed. Then, on the roofing materials5and6installed in one line, the roofing materials5and6in the subsequent line are similarly installed while being overlapped therewith such that ends closer to the edge of eaves of the roofing materials5and6to be newly installed are respectively overlapped with ends closer to the ridge of the roofing materials5and6previously installed with the second crosspiece from the edge of eaves used as a reference. This operation is repeated up to the ridge of the roof, so that the roof can be thatched with the roofing materials5and6while overlapping with one another in order from the edge of eaves to the ridge of the roof.

In the conventional roofing material5, however, the recess part11for which the solar battery4is embedded in and a through hole (not shown), for example, penetrating to a reverse surface of the main body8from the recess part11for passing an output wiring13connected to the solar battery4must be formed. Therefore, the shape of the main body8becomes complicated, so that there lies a problem that producing the main body is not easy. The strength and the durability of the main body8having the complicated shape must be ensured. Therefore, the size of the recess part11is restricted. Correspondingly, the area of the solar battery4to be embedded into the recess part11is restricted, so that electricity generated per unit area by the roofing material5cannot be increased.

Referring toFIG. 54, the output wiring13is generally passed through a clearance, produced by overlapping of the roofing materials5and6, between the roofing materials and the roofer7. Every time the one roofing material5is installed, wiring operations for connecting the output wiring13to a bus line (not shown) must be performed. Accordingly, at the time when the installation of all the roofing materials5is completed, operations for wiring to the solar battery4incorporated in each of the roofing materials5must be also completed. Therefore, there also lies a problem that installation work is complicated because it involves a large number of man-hours, so that misconnection may happen.

Japanese Unexamined Patent Publication No. 2003-347576 A describes a solar battery module device in which a solar battery module having a rectangular flat plate shape and having a shape and a size substantially equal to those corresponding to one conventional roofing material or a plurality of (two or more) conventional roofing materials, which is formed by holding a solar battery having a translucent body such as glass or resin and a solar battery cell affixed to each other in a frame made of a metal such as an aluminum alloy is held in a casing formed by assembling a frame made of a metal such as an aluminum alloy or stainless steel. In the invention described in Japanese Unexamined Patent Publication No. 2003-347576 A, a main body having a complicated shape and difficulty in production is useless, and the casing can be formed by only assembling the metal frame. Therefore, it is possible to improve the productivity of the solar battery module device and to reduce the manufacturing cost thereof.

Since the size of the solar battery module is not restricted by the main body, electricity generated per unit area by the solar battery module device can be also increased. Further, when the solar battery module device is combined with the conventional roofing material, the metal frame forming the casing may be one corresponding to a connection structure with the roofing material to be combined. Only by replacing the frame, the roof can be thatched with the solar battery module device together with roofing materials having various shapes.

DISCLOSURE OF INVENTION

However, the solar battery module devices described above must be installed on a roofer while being overlapped with each other in order from an edge of eaves to a ridge of a roof, similarly to conventional roofing materials incorporating solar batteries therein. Every time one solar battery module device is installed, operations for wiring to a solar battery module must be performed as in the conventional example. Therefore, installation work is complicated because it involves a large number of man-hours. Thus, the problem that misconnection may happen is not still solved.

When misconnection is found during installation or in a test after installation, for example, the roofing materials and the solar battery module devices must be successively removed from the ridge in order, so that there lies a problem that large-scale operations for reconnection are required. When a failure or the like is found in maintenance and inspection operations of a photovoltaic power generating system, the roofing materials and the solar battery module devices must be also similarly removed in order from the ridge. Therefore, there lies a problem that large-scale operations are required for replacing and repairing the failed solar battery module device.

Furthermore, in the case of the installation work, a worker necessarily gets on the previously installed solar battery module device closer to the edge of eaves in order to install the roofing material and the solar battery module device closer to the ridge to perform operations. However, a surface of the solar battery module is covered with glass or the like and is slippery, as previously described, so that there lies a problem that the operations cannot be performed safely. Further, the solar battery module may be damaged by the worker getting thereon.

An object of the present invention is to provide a solar battery module device capable of performing installation work and maintenance and inspection operations more simply and safely than before without damaging a solar battery module, and a method of installing the same.

In order to attain the above-mentioned object, a solar battery module device according to the present invention comprises a rectangular flat plate-shaped solar battery module and an installing member for installing the solar battery module on a sloping roof, the installing member comprises an upper frame disposed on the roof and having an engagement part in which a top-side end part serving as one side of a rectangular shape of the solar battery module is fitted from the lower side in the sloping direction of the roof, a lower frame disposed below the upper frame in the sloping direction of the roof and having a placing surface on which a bottom-side end part serving as the opposite side of the rectangular shape of the solar battery module is placed with the top-side end part of the solar battery module fitted in the engagement part of the upper frame, and a fixing cover detachably mounted on the lower frame for fixing the bottom-side end part on the placing surface.

In the solar battery module device according to the present invention, it is preferable that the lower frame has a flat plate-shaped extended part extended in a slopingly downward direction of a surface of the solar battery module to be mounted on the lower side in the sloping direction of the roof, and the fixing cover has a flat plate-shaped mounting part overlapped with the extended part and mounted thereon, and a fixing part abutted against an end surface and an upper surface of the bottom-side end part of the solar battery module for fixing the bottom-side end part to the lower frame with the mounting part mounted on the extended part. It is preferable that a projection abutted against the end surface of the bottom-side end part of the solar battery module is formed on the fixing part. Further, it is preferable that the projection has a slant with the end surface of the bottom-side end part of the solar battery module.

It is preferable that a projection abutted against an end surface of the top-side end part fitted in the engagement part of the upper frame of the solar battery module is formed on the engagement part, and it is preferable that the projection has a slant with the end surface of the top-side end part of the solar battery module. Further, it is preferable that a projection for snow stop is formed on an upper surface of the fixing cover.

It is preferable that the engagement part of the upper frame has a supporting part abutted against a lower surface of the top-side end part of the solar battery module for supporting the end part from below, a pressing part located above the supporting part in the sloping direction of the roof and abutted against the upper surface of the end part supported from below by the supporting part, and a groove part located at a position above the supporting part in the sloping direction of the roof and opposite to the pressing part and recessed toward the roof compared with the supporting part. Further, it is preferable that an elastic member is used to stop water between the solar battery module and the upper frame.

It is preferable that at least one of the top-side end part and the bottom-side end part of the solar battery module is mounted on at least one of the upper frame and the lower frame through a conductive fitting integrally formed of a plate material having a plate-shaped upper surface part abutted against the upper surface of the end part, a plate-shaped lower surface part abutted against the lower surface of the end part, claw parts respectively extending upward and downward in the thickness direction of a plate from both the parts, and a connecting part for connecting the upper surface part and the lower surface part. Further, it is preferable that the connecting part is a cushioning part elastically deformable.

It is preferable that the installing member comprises right and left side frames for respectively holding the right and left sides of the rectangular shape of the solar battery module, both the side frames are respectively formed in such shapes that when a plurality of installing members are arranged in a direction perpendicular to the sloping direction of the roof, the right side frame in the left installing member and the left side frame in the right installing member are overlapped with each other, and the installing members are respectively provided with protruding parts that are overlapped with and conductively connected to each other when they arranged in the direction perpendicular to the sloping direction of the roof with both the side frames overlapped with each other.

A method of installing the solar battery module device according to the present invention is a method of installing a solar battery module device on a sloping roof in which an engagement part of an upper frame has a supporting part abutted against a lower surface of a top-side end part of a solar battery module for supporting the end part from below, a pressing part located above the supporting part in the sloping direction of the roof and abutted against an upper surface of the end part supported from below by the supporting part, and a groove part located at a position above the supporting part in the sloping direction of the roof and opposite to the pressing part and recessed toward the roof compared with the supporting part, as previously described, the method preferably comprises the steps of:

(a) fixing an installing member on the roof;

(b) inserting the top-side end part of the solar battery module into the groove part of the engagement part of the upper frame in the fixed installing member through an opening between the supporting part and the pressing part;

(c) rotating the bottom-side end part of the solar battery module downward with the vicinity of the top-side end part used as its support for placing the bottom-side end part on a placing surface of the lower frame, and supporting the top-side end part from below by the supporting part as well as abutting the pressing part against an upper surface of the end part; and

(d) mounting a fixing cover on the lower frame to fix the bottom-side end part of the solar battery module. It is preferable that the installing method according to the present invention comprises the step of inserting an elastic member into an area between the solar battery module and the upper frame.

Effect of the Invention

In the solar battery module device according to the present invention, the solar battery module can be mounted on the installing member and installed on the sloping roof by fixing the installing member on the roof, then fitting the top-side end part serving as one side of the rectangular shape of the solar battery module from the lower side in the sloping direction of the roof in the engagement part of the upper frame in the installing member, and then mounting the fixing cover on the lower frame with the bottom-side end part serving as the opposite side of the rectangular shape of the solar battery module placed on the placing surface of the lower frame to fix the bottom-side end part on the placing surface. Therefore, a plurality of installing members corresponding to a required number of solar battery module devices, for example, are previously fixed on the roof. The solar battery module can be individually mounted on the installing member at an arbitrary position at an arbitrary time.

Therefore, it is possible to mount the solar battery modules on the installing members in order from the ridge to the edge of eaves of the sloping roof, for example, which was impossible in the conventional solar battery module device installed in the same manner as the normal roofing material. The chances that a worker must get on the solar battery module can be significantly reduced to improve the safety of installation operations and prevent the solar battery module from damage by suitably setting the order in which the solar battery modules are mounted in conformity with the shape or the like of the roof.

Furthermore, the solar battery module at the arbitrary position can be individually removed from the installing member in a procedure opposite to the foregoing procedure without removing the other solar battery modules. Therefore, operations in a case where misconnection is found in a test during or after installation, for example, or a case where a failure or the like is found at the time of maintenance and inspection operations of the photovoltaic power generating system can be also significantly simplified.

When the lower frame in the installing member has the flat plate-shaped extended part extended in a slopingly downward direction of the surface of the solar battery module to be mounted on the lower side in the sloping direction of the roof, and the fixing cover has the flat plate-shaped mounting part overlapped with the extended part and mounted thereon and the fixing part abutted against the end surface and the upper surface of the bottom-side end part of the solar battery module for fixing the bottom-side end part to the lower frame with the mounting part mounted on the extended part, the solar battery module can be mounted on the installing member more reliably without producing backlash or the like.

That is, when the mounting part of the fixing cover is mounted on the extended part extended in a slopingly downward direction of the surface of the solar battery module of the lower frame with the fixing part of the fixing cover abutted against the end surface and the upper surface of the bottom-side end part of the solar battery module, a fixing force directed downward in the thickness direction, i.e., toward the placing surface of the lower frame can be applied to the bottom-side end part of the solar battery module from the upper surface thereof, and a fixing force directed toward the upper side in the sloping direction of the roof, i.e., toward the upper frame can be also applied to the end part from the end surface thereof.

Therefore, the solar battery module mounted on the installing member can be prevented from backlash of the solar battery module and more reliably mounted, for example. The deterioration of the solar battery module due to the occurrence of corrosion, for example, can be reliably prevented by preventing a protective film such as an alumite layer, a plating layer, or a clear coat layer for covering a surface of a frame formed of an aluminum alloy or the like, of the solar battery module from damage and chipping and thinning due to backlash of the solar battery module against the installing member, for example.

By extending the extended part slopingly downward from the surface of the solar battery module to reduce the length thereof in the sloping direction of the roof, the ratio of the length of the lower frame to the length in the same direction of the whole solar battery module device can be reduced. Therefore, the power generation efficiency can be also improved by reducing the loss of the power generation area per unit area of the photovoltaic power generating system.

In a case where a projection is formed in the fixing part of the fixing cover, the tip of the projection can be stuck in the frame by pressing the tip against the end surface of the bottom-side end part in the frame of the solar battery module at the time of the mounting to penetrate the protective layer for covering the frame, for example. Therefore, the solar battery module and the lower frame can be reliably ground-connected to each other. Further, in a case where the projection has a slant with the end surface of the bottom-side end part of the solar battery module, the projection is obliquely stuck in the frame of the solar battery module, the solar battery module is more reliably prevented from backlash in the sloping direction of the roof and the transverse direction perpendicular thereto, and the ground connection between the solar battery module and the lower frame can be more reliably maintained by sticking the projection in the frame.

In a case where a projection is formed in the engagement part of the upper frame, the tip of the projection can be stuck in the frame by pressing the tip against the end surface of the top-side end part in the frame of the solar battery module at the time of the mounting to penetrate the protective layer for covering the frame, for example. Therefore, the solar battery module and the upper frame can be reliably ground-connected to each other. Further, in a case where the projection has a slant with the end surface of the top-side end part of the solar battery module, the projection is obliquely stuck in the frame of the solar battery module, the solar battery module is more reliably prevented from backlash in the sloping direction of the roof and the transverse direction perpendicular thereto and the ground connection between the solar battery module and the upper frame can be more reliably maintained by sticking the projection in the frame.

When the fixing cover in the solar battery module closer to the edge of eaves of the roof is replaced with one having a projection for snow stop formed therein, snow can be prevented from dropping from the edge of eaves. In this case, the solar battery module, the upper frame, and the lower frame, which are principal members constituting the solar battery module device, can be shared with the other solar battery module device having no projection for snow stop formed therein. Therefore, the number of components can be reduced, and the construction can be simplified. Further, the fixing cover can be easily replaced after installation. Therefore, it is easy to change specifications after the installation, for example, to change the position where a projection for snow stop is formed, to cancel providing a projection, and to conversely add a projection.

In a case where the engagement part of the upper frame has the supporting part abutted against the lower surface of the top-side end part of the solar battery module for supporting the end part from below, the pressing part located above the supporting part in the sloping direction of the roof and abutted against the upper surface of the end part supported from below by the supporting part, and the groove part located at a position above the supporting part in the sloping direction of the roof and opposite to the pressing part and recessed toward the roof compared with the supporting part, workability in mounting the solar battery module on the installing member can be improved.

That is, in the engagement part, the top-side end part of the solar battery module can be inserted into the groove part diagonally from above through an opening between the supporting part and the pressing part with the solar battery module inclined, which leads to insertion easy. Further, the bottom-side end part of the solar battery module whose top-side end part is inserted into the groove part can be placed on the placing surface of the lower frame by rotating the end part downward with the vicinity of the top-side end part used as a support, and the top-side end part of the solar battery module can be fixed in the vertical direction by the supporting part and the pressing part by supporting the end part from below by the supporting part as well as abutting the pressing part against the upper surface of the end part.

Therefore, workability in mounting the solar battery module on the installing member can be improved. Further, damage to the solar battery module can be also prevented by preventing pressure and distortion from being forcedly applied to the solar battery module at the time of insertion. The waterstop properties of the solar battery module device can be also improved by the groove part to function as a gutter. In addition, the waterstop properties of the solar battery module device can be further improved by stopping water between the solar battery module and the upper frame using an elastic member.

In a case where at least one of the top-side end part and the bottom-side end part of the solar battery module is mounted on at least one of the upper frame and the lower frame through the conductive fitting integrally formed of a plate material having the plate-shaped upper surface part abutted against the upper surface of the end part, the plate-shaped lower surface part abutted against the lower surface of the end part, the claw parts respectively extending upward and downward in the thickness direction of the plate from both the parts, and the connecting part for connecting the upper surface part and the lower surface part, the solar battery module and the upper and lower frames can be reliably ground-connected to each other by sticking the claw parts in the frame of the solar battery module, the upper frame, the lower frame, the fixing cover, and so on when the solar battery module is mounted.

In a case where the connecting part is the cushioning part to be an elastically deformed, when the solar battery module is mounted, the cushioning part is crushed by being inserted into the engagement part of the upper frame or being sandwiched between the placing surface of the lower frame and the fixing cover to be elastically deformed to produce a reaction force, so that the solar battery module can be more reliably mounted on the installing member without producing backlash.

In a case where the installing member comprises the right and left side frames respectively holding the right and left sides of the rectangular shape of the solar battery module, both the right side frame and the left side frame are formed in such shapes that when the plurality of installing members are arranged in the direction perpendicular to the sloping direction of the roof, the right side frame of the left installing member and the left side frame of the right installing member are overlapped with each other, and the installing members are respectively provided with the protruding parts that are overlapped with and conductively connected to each other when they are arranged in the direction perpendicular to the sloping direction of the roof with both the side frames overlapped with each other, the plurality of solar battery module devices arranged in the transverse direction perpendicular to the sloping direction of the roof can be reliably ground-connected to one another through the protruding parts. Therefore, wiring operations can be simplified by omitting wiring for the ground connection over the plurality of solar battery modules.

In the method of installing the solar battery module device according to the present invention, by undergoing the steps (a) to (d) previously described for the engagement part of the upper frame having the supporting part abutted against the lower surface of the top-side end part of the solar battery module for supporting the end part from below, the pressing part located above the supporting part in the sloping direction of the roof and abutted against the upper surface of the end part supported from below by the supporting part, and the groove part located at a position above the supporting part in the sloping direction of the roof and opposite to the pressing part and recessed toward the roof compared with the supporting part, workability in mounting the solar battery module on the installing member and waterstop properties of the solar battery module device can be improved while preventing the solar battery module from damage.

That is, in the engagement part, the top-side end part of the solar battery module can be fixed in the vertical direction by the supporting part and the pressing part by inserting the top-side end part into the groove part through an opening between the supporting part and the pressing part, then rotating the bottom-side end part of the solar battery module downward with the vicinity of the top-side end part used as a support for placing the bottom-side end part on the placing surface of the lower frame, and supporting the top-side end part from below by the supporting part as well as abutting the pressing part against the upper surface of the end part, for example.

Therefore, a clearance between the supporting part and the pressing part is made larger than the thickness of the solar battery module, so that the top-side end part of the solar battery module can be easily inserted, and the end part can be fixed in the vertical direction only by rotating the solar battery module after insertion downward. As a result, workability in mounting the solar battery module on the installing member can be improved. Further, damage to the solar battery module can be also prevented by preventing pressure and distortion from being forcedly applied to the solar battery module at the time of insertion. In addition, the waterstop properties of the solar battery module device can be also improved by the groove part to function as a gutter. When the elastic member stops water between the solar battery module and the upper frame, the waterstop properties of the solar battery module device can be further improved.

EXPLANATION OF REFERENCE NUMERALS

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1is a perspective view showing an example of an embodiment of a solar battery module device14according to the present invention.FIG. 2is a cross-sectional view of the solar battery module device14in the example shown inFIG. 1.FIG. 3is an exploded sectional view of the solar battery module device14in the example shown inFIG. 1.FIG. 5is a cross-sectional view showing one step in construction for constructing a photovoltaic power generating system of a roof-integration type by installing the solar battery module device14in the example shown inFIG. 1on a roofer7of a sloping roof. A black arrow in the figure indicates the sloping direction of the roofer7. In the figure, the left side is the lower side, and the right side is the upper side in the sloping direction. The same applies toFIGS. 6 and 7.FIG. 8is a perspective view of an installing member15in the solar battery module device14in the example shown inFIG. 1.

Referring toFIGS. 1,2, and5, the solar battery module device14in this example comprises a rectangular flat plate-shaped solar battery module16, and an installing member15for installing the solar battery module16on the roofer7of the sloping roof. Referring toFIGS. 1,3, and8, the installing member15comprises a frame17formed in a rectangular shape so as to surround the solar battery module16in order to hold the solar battery module16and a pair of leg bodies18mounted on a lower surface of the frame17.

Referring toFIGS. 1 to 3,5, and8, the frame17comprises an upper frame21disposed parallel to a transverse direction perpendicular to the sloping direction of the roofer7and having a groove-shaped engagement part20in which a top-side end part19serving as one side of a rectangular shape of the solar battery module16is fitted from the lower side in the sloping direction of the roofer7, a lower frame24disposed below the upper frame21in the sloping direction of the roofer7and parallel to the upper frame21and having a plane-shaped placing surface23on which a bottom-side, end part22serving as the opposite side of the rectangular shape of the solar battery module16is placed with the end part19of the solar battery module16fitted in the engagement part20of the upper frame21, and a pair of side frames25disposed parallel to the sloping direction of the roofer7for connecting both respective ends of the upper frame21and the lower frame24to each other to constitute the rectangular frame17.

Referring toFIGS. 2 and 3, the upper frame21and the lower frame24can be respectively formed using metal materials having corrosion resistance such as an aluminum alloy or stainless steel and integrally forming the metal materials into a cross-sectional shape shown in both the figures using a processing method such as extrusion or drawing, integrally forming normal steel materials or the like and subjecting their surface to zinc plating or the like to have corrosion resistance, assembling a plurality of members made of metal, or subjecting a metal plate material to bending processing. Referring toFIGS. 2,3, and8, it is preferable that a lower-side surface in the figures forming the groove-shaped engagement part20of the upper frame21is made longer than an upper-side surface thereof. This allows the top-side end part19of the solar battery module16to function as a guide placed on the lower-side surface for forming the engagement part20for introducing the end part19into the engagement part20when the end part19is fitted in the engagement part20to improve fitting workability.

Referring toFIGS. 1 to 3andFIG. 8, the lower frame24comprises a plane-shaped upper surface26parallel to the placing surface23and disposed above the placing surface23, and a fixing cover27for fixing the bottom-side end part22of the solar battery module16placed on the placing surface23of the lower frame24is detachably mounted with a screw28screwed into a threaded hole29formed on the upper surface26. The fixing cover27is formed in a flat plate shape.

Referring toFIGS. 1 to 3andFIG. 8, the opening width of a groove of the engagement part20of the upper frame21may be such a size that the top-side end part19of the solar battery module16can be inserted thereinto. However, in a state where the top-side end part19of the solar battery module16is fitted into the engagement part20, and the bottom-side end part22is fixed to the lower frame24by placing the end part22on the placing surface23and then screwing the screw28into the threaded hole29from above to mount the fixing cover27on the lower frame24(which may be hereinafter referred to as a “mounted state”), it is preferable that the opening width is set to a size that substantially coincides with the thickness of the end part19such that the lower-side surface forming the groove-shaped engagement part20and the upper-side surface are respectively abutted against a lower surface and an upper surface of the end part19.

In the above-mentioned mounted state, it is preferable that a bottom surface of the groove-shaped engagement part20(an innermost surface on the right side of the engagement part20inFIGS. 2 and 3) is abutted against a top-side end surface of the solar battery module16, and the distance from the bottom surface to a stepped surface between the placing surface23and the upper surface26is set to a size that substantially coincides with a size between the upper side and the lower side of the rectangular shape of the solar battery module16such that the stepped surface is abutted against a bottom-side end surface thereof. In the above-mentioned mounted state, it is preferable that the distance between the pair of side frames25is set to a size that substantially coincides with a size between both the lateral sides of the solar battery module16such that the side frames25are respectively abutted against both the lateral sides of the rectangular shape of the solar battery module16.

Furthermore, in the above-mentioned mounted state, it is preferable that the height of a step between the placing surface23and the upper surface26is set to a size that substantially coincides with the thickness of the bottom-side end part22of the solar battery module16such that the upper surface of the bottom-side end part22of the solar battery module16is made flush with the upper surface26of the lower frame24and is abutted against the lower surface of the fixing cover27mounted on the upper surface26. The employment of these configurations allows the solar battery module16to be held in the frame17in the installing member15without forcedly applying a force to the solar battery module16and with preventing backlash.

FIG. 9is a front view of the installing member15shown inFIG. 8(view on arrow in a direction A shown inFIG. 8). Referring toFIGS. 2,3,8and9, the leg18comprises a base part30having a length extending between both the frames12and24, disposed parallel to the side frame25, and having its one end fixed to the lower surface of the upper frame21and the other end fixed to the lower surface of the lower frame24, a pair of front legs31extended downward from both the sides of the vicinity of an end on the side of the lower frame24of the base part30, mounting parts32to the roofer7that are extended in a transverse direction perpendicular to the sloping direction of the roofer7and in opposite directions from respective lower ends of the pair of front legs31, a rear leg33extended downward from an end on the side of the upper frame21of the base part30, and a mounting part34extended the upper side in the sloping direction of the roofer7from a lower end of the rear leg33for mounting on the roofer7. In the leg18, the foregoing parts can be integrally formed by cutting one metal plate or the like having corrosion resistance as well as subjecting the metal plate to bending processing, for example. It is preferable that each of the mounting parts32and34is provided with a through hole through which a nail, a screw, or the like for mounting on the roofer7is inserted, though not illustrated.

FIG. 10is a front view showing a state where a plurality of installing members15as shown inFIG. 8are piled. Referring toFIGS. 9 and 10, when the plurality of installing members15are piled, it is preferable that the leg18is formed to incline the pair of front legs31such that spacing therebetween gradually increases downward from the base29such that the respective front legs31in the upper and lower installing members15do not interfere with each other. This allows to reduce a space in conveying and storing the installing member15, for example, by restraining a height in a case where the plurality of installing members15are piled.

FIG. 4is a cross-sectional view showing the internal configuration of the solar battery module16in the solar battery module device14in the example shown inFIG. 1. Referring toFIG. 4, the solar battery module16in this example is formed in a rectangular flat plate shape by respectively sandwiching a plurality of solar battery cells38electrically connected to one another through connection tubs37between a translucent substrate35and a back sheet36as well as bonding with adhesives a laminated body sealed by filling clearances among the parts with respective fillers39and40on the side of a light receiving surface and the side of a rear surface, for example, to hold the laminated body in a frame made of metal (not shown). An output of the solar battery cell38is introduced to the outside of the solar battery module16through output wiring41.

FIGS. 6 and 7are cross-sectional views respectively showing steps subsequent to the steps shown inFIG. 5, constructing a photovoltaic power generating system of a roof-integration type by installing the solar battery module device14in the example shown inFIG. 1on the roofer7of the sloping roof. The figures show a case where the solar battery module device14is installed on the roofer7together with a roofing material42having a cross-sectional shape similar to that of the solar battery module device14to construct the roof-integration type photovoltaic power generating system. Therefore, in terms of the ease of installation and the appearance of the photovoltaic power generating system after installation, it is preferable that the plane shape of the solar battery module device14defined by the external shape of the frame17is made substantially equal in shape and size to that corresponding to one roofing material42or a plurality of (two or more) roofing materials42.

Referring toFIGS. 5 and 6, in order to install the solar battery module device14in the example shown inFIG. 1comprising the foregoing parts together with the roofing material42on the roofer7of the sloping roof, the roofing material42and the installing member15in the solar battery module device14are fixed on the roofer7with crosspieces12equally spaced on the roofer7used as a reference. In both the figures, the members are fixed in order from an edge of eaves to a ridge of the roof, as in the conventional example. However, the members may be conversely fixed in order from the ridge to the edge of eaves, or may be fixed at random. In the case, the roofer7is exposed in a portion between the frame17and the leg18in the installing member15. Therefore, a worker can operate for fixing the installing member15and the roofing material42by standing directly on the exposed roofer7or standing on the roofing material42, resulting in improving safety.

Referring toFIG. 7, at the time when the fixing of all the roofing materials42and the installing members15is completed or even at the time when the fixing operations are in progress, the solar battery modules16are successively mounted on the installing members15already fixed. Specifically, the top-side end part19of the solar battery module16is fitted in the engagement part20of the upper frame21in the installing member15fixed on the roofer15from the lower side in the sloping direction of the roofer7(from the left side inFIG. 7), and the bottom-side end part22of the solar battery module16is fixed to the lower frame24by placing the bottom-side end part22on the placing surface23of the lower frame24and then screwing the screw28into the threaded hole29from above to mount the fixing cover27on the lower frame24to mount the solar battery module16on the installing member15. In addition thereto, output wiring41in the solar battery module16is connected to a bus (not shown). In this manner, the installation of one solar battery module device is completed.

Operations for mounting the solar battery module16can be mainly performed from the lower side of the mounting member15. Accordingly when the mounting operations are performed starting with the uppermost installing member15in the sloping direction of the roofer7(the right installing member inFIG. 7), as shown inFIG. 7, the worker can operate for mounting the solar battery module16by standing directly on the roofer7exposed in a portion between the frame17and the leg18of the installing member15on which the solar battery module16is not mounted yet of the mounted installing member15or standing on the roofing material42. Therefore, it is possible to improve the safety of the mounting operations as well as to prevent the solar battery module from damage.

FIG. 11is a perspective view showing a modified example of the fixing cover27.FIG. 12is a cross-sectional view showing a state where the fixing cover27shown inFIG. 11is combined with the solar battery module device14in the example shown inFIG. 1. Referring to both the figures, the fixing cover27in this example differs from the previously described flat plate-shaped fixing cover27in that a flat plate-shaped projection43for snow stop is extended over the whole length of the fixing cover27upward from its upper surface. The fixing cover27may be integrally formed by a processing method such as extrusion or drawing and may be formed by assembling a plurality of members and subjecting a plate material to bending processing, similarly to the upper frame21or the like.

Referring toFIG. 12, a snow stopping function for preventing snow from dropping from the edge of eaves can be given to the solar battery module device14in the example shown inFIG. 1using the fixing cover27for fixing the bottom-side end part22of the solar battery module16in place of the normal flat plate-shaped fixing cover27. In this case, the solar battery module16serving as a principal member constituting the solar battery module device14and the installing member15including the upper frame21and the lower frame24can be shared with the other solar battery module device14having no projection43for snow stop formed therein, so that the number of components can be reduced and the construction can be simplified. Further, the fixing cover27can be always replaced with the normal flat plate-shaped fixing cover27. Therefore, it is easy to change specifications after installation, for example, to change the position where the projection43for snow stop is formed, to cancel providing the projection43, and to conversely add the projection43.

FIG. 13is a perspective view showing another example of the embodiment of the solar battery module device14according to the present invention.FIG. 16is an enlarged sectional view of a lower frame24and a fixing cover27constituting a principal part of the solar battery module device14in the example shown inFIG. 13.FIG. 18is an exploded perspective view of an installing member15in the solar battery module device14in the example shown inFIG. 13.

Referring to the figures, the solar battery module device14in this example differs from that in the example shown inFIG. 1in that a lower frame24has a flat plate-shaped extended part44extended in a slopingly downward direction of a surface of a solar battery module16to be mounted on the lower side in the sloping direction of a roofer7(on the left side inFIG. 16), and a fixing cover27has a flat plate-shaped mounting part45overlapped with and mounted on the extended part44and a fixing part49abutted against an end surface47and an upper surface48of a frame46forming a bottom-side end part22in a frame of the solar battery module16for fixing the bottom-side end part22to a lower frame24.

This example also differs from the example shown inFIG. 1in that the installing member15does not have a side frame25. The functions of the other parts are the same as those in the example shown inFIG. 1except that an upper frame21is formed by subjecting a plate material to bending processing, for example. Therefore, the same parts are denoted by the same reference numerals and hence, the description thereof is omitted. In the example shown inFIG. 13, a frame forming a side of the solar battery module16in the frame of the solar battery module16is used to function as a substitute for the side frame25. However, rainwater can be also prevented from entering from an area between adjacent solar battery modules16and a clearance between the solar battery module16and a roofing material42without omitting the side frame25but giving the side frame25a function as a gutter, for example.

Referring toFIGS. 16 and 18, the lower frame24is formed by subjecting the plate material to bending processing similarly to the upper frame21, and comprises a flat plate part having its upper surface serving as a placing surface23and the above-mentioned extended part44formed continuously to the flat plate part below the flat plate part in the sloping direction of the roofer7. The extended part44is provided with a threaded hole51in which a screw50for fixing a mounting part45overlapped therewith is screwed. Referring toFIGS. 13 and 16, the fixing cover27is also formed by subjecting a plate material to bending processing similarly to both the frames21and24, and comprises a fixing part49formed in an angle shape abutted against the end surface47and the upper surface48of the end part22of the solar battery module16, and the above-mentioned mounting part45formed continuously from a lower end of a portion abutted against the end surface47of the fixing part49slopingly downward along the extended part44of the lower frame24. Further, the mounting part45is formed with a through hole52through which the screw50is inserted and in which the head thereof is fitted.

FIGS. 14 and 15are perspective views showing states during the step of assembling the solar battery module device14in the example shown inFIG. 13.FIGS. 21 to 24are cross-sectional views respectively showing states during the above-mentioned steps. In order to assemble the solar battery module device14in this example, a top-side end part19of the solar battery module16is placed on a surface on the lower side in the figures, forming a groove-shaped engagement part20of the upper frame21from the lower side in the sloping direction of the roofer7(from front side in both the figures) with reference toFIGS. 14 and 21. As indicated by a hollow arrow inFIG. 21, the bottom-side end part22of the solar battery module16is rotated downward having the position where the top-side end part19is abutted against a lower-side surface of the engagement part20used as a support for placing a portion in the vicinity of the bottom-side end part22on the placing surface23of the lower frame24.

Referring toFIG. 22, the solar battery module16is then moved toward the upper frame21, as indicated by a hollow arrow in the figure, having the lower-side surface of the engagement part20and the placing surface23used as a guide to fit the top-side end part19of the solar battery module16into the engagement part20of the upper frame21. Then referring toFIGS. 15,23, and24, the fixing part49in the fixing cover27is abutted against the end surface47and the upper surface48of the bottom-side end part22of the solar battery module16, and the mounting part45in the fixing cover27is overlapped with and mounted on the extended part44by inserting the screw50through the through hole52and screwing the screw50into the threaded hole51with the mounting part45overlapped with the extended part44of the lower frame24.

Consequently, referring toFIG. 16, as a component of a fixing force53directed diagonally downward, which is perpendicular to a plane direction of the extended part44in the figures, generated by screwing the screw50into the threaded hole51for fixing the mounting part45on the extended part44, a fixing force54directed downward in the thickness direction, that is, toward the placing surface23of the lower frame24can be applied to the bottom-side end part22of the solar battery module16from the upper surface48thereof through the fixing part49, and a fixing force55directed toward the upper frame21can be applied to the end part22from the end surface47through the fixing part49.

Therefore, the solar battery module16mounted on the installing member15can be more reliably mounted by preventing backlash or the like of the solar battery module16. Consequently, it is possible to reliably prevent the solar battery module16from deterioration, for example, due to the occurrence of corrosion by preventing a protective film such as alumite or a plating layer for covering a surface of the frame of the solar battery module16from being damaged and chipped to thinning down due to backlash of the solar battery module16against the installing member15, for example. Further, a balance between the fixing forces54and55can be also adjusted by adjusting respective angles of slope of the extended part44and the mounting part45.

The extended part44is extended in a slopingly downward direction of the surface of the solar battery module16to reduce the length thereof in the sloping direction of the roofer7, so that the ratio of the length of the lower frame24to the length in the same direction of the whole solar battery module device14can be reduced. Therefore, the power generation efficiency of the photovoltaic power generating system can be also improved by reducing the loss of the power generation area thereof per unit area.

FIG. 19is a perspective view showing one step in construction for constructing a photovoltaic power generating system of a roof-integration type using the solar battery module device14in the example shown inFIG. 13.FIG. 20is a perspective view showing a part of the completed photovoltaic power generating system. The figures show a case where the solar battery module device14in the example shown inFIG. 13is installed on a roofer7together with a roofing material42having a cross-sectional shape similar to the solar battery module device14to construct a photovoltaic power generating system of a roof-integration type. Although a plane shape of the solar battery module device14is made substantially equal in shape and size to one roofing material42in both the figures, it can be also made substantially equal in shape and size to a plurality of (two or more) roofing materials42.

Referring toFIG. 19, in order to install the solar battery module device14in the example shown inFIG. 13comprising the above-mentioned parts on the roofer7of the sloping roof, together with the roofing material42, the roofing material42and the installing members15in the solar battery module device14are fixed on the roofer7with crosspieces12equally spaced on the roofer7used as a reference, as in the example shown inFIG. 1, and the solar battery module16may be mounted on the fixed and optional installing member15in order in the procedure previously described. Referring toFIG. 20, the completed photovoltaic power generating system has a superior appearance in which the roofing material42and the solar battery module device14having a plane shape substantially equal to that of the roofing material42are harmonized with each other.

FIG. 17is a cross-sectional view showing the modified example of the fixing cover27and the upper frame21. Referring toFIG. 17, a fixing cover27in this example differs from the fixing cover27in the example shown inFIG. 13in that a projection56is formed on a surface abutted against an end surface47of a bottom-side end part22of a solar battery module16of a fixing part49. The projection56is formed integrally with the fixing cover27formed by subjecting a plate material to bending processing as previously described, by cutting and raising a plate material forming a surface abutted against the end surface47of the fixing part49in the fixing cover27, for example.

Furthermore, an upper frame21in this example differs from the upper frame21in the example shown inFIG. 13in that a projection57similar to the one described above is formed on a bottom surface of a groove-shaped engagement part20(an innermost surface on the right side of an engagement part20inFIG. 17). The projection57is formed integrally with the upper frame21formed by subjecting the plate material to bending processing as previously described, by cutting and raising a plate material forming a bottom surface of the engagement part20of the upper frame21, for example.

Referring toFIG. 17, in order to mount the solar battery module16on the installing member15comprising the fixing cover27and the upper frame21respectively having the projections56and57in the same procedure as in the example shown inFIG. 13, when a fixing force for fixing the mounting part45to the extended part44by screwing the screw50into the threaded hole51is produced, a fixing force55directed toward the upper frame21is applied as its component to the end part22from the end surface47through the fixing part49, so that a tip of the projection56can be stuck in the frame46forming the bottom-side end part22by being pressed against the end surface47of the frame46in the frame of the solar battery module16and penetrating a protective layer or the like covering the frame46. Therefore, the solar battery module16and the lower frame24can be reliably ground-connected to each other.

In addition thereto, the tip of the projection57can be stuck in the frame58forming the top-side end part19by being pressed against the end surface59of the frame58in the frame of the solar battery module16and penetrating a protective layer or the like covering the frame58. Therefore, the solar battery module16and the upper frame21can be also reliably ground-connected to each other.

When both the projections56and57respectively has a slant to both with the end surfaces47and59of the solar battery module16, backlash of the solar battery module16in the sloping direction of the roofer7and in the transverse direction perpendicular thereto can be more reliably prevented by obliquely stacking the projections56and57in the frames46and58forming the frame of the solar battery module16, and the ground connection between the solar battery module16and the upper and lower frames21and24by stacking the projections56and57in the frames46and58can be more reliably maintained over a long time period.

FIG. 25is a perspective view showing another example of the embodiment of the solar battery module device14according to the present invention.FIGS. 26 and 27are perspective views respectively showing steps in process of installing the solar battery module device14in the example shown inFIG. 25on a roofer7by an installing method according to the present invention.FIGS. 28 to 30are cross-sectional views respectively showing steps in process of installing the solar battery module device14in the example shown inFIG. 25on the roofer7by the installing method according to the present invention.FIG. 31is a perspective view showing an upper frame21constituting a principal part of the solar battery module device14in the example shown inFIG. 25.

Referring toFIGS. 25 to 31, the solar battery module device14in this example differs from that in the example shown inFIG. 13in that an engagement part20in an upper frame21has a plane-shaped supporting part60abutted against a lower surface of a top-side end part19of a solar battery module16for supporting the end part19from below, a plane-shaped pressing part61located above the supporting part60in the sloping direction of the roofer7(on the innermost side in both the figures) and abutted against an upper surface of the end part19supported from below by the supporting part60, and a groove part62having a semicircular shape in cross section, located at a position above the supporting part60in the sloping direction of the roofer7and opposite to the pressing part61and recessed toward the roofer7compared with the supporting part60. Since the other parts are the same as those in the example shown inFIG. 13, the same parts are denoted by the same reference numerals and hence, the description thereof is omitted. The frame21is formed by subjecting a plate material to bending processing, as in the example shown inFIG. 13.

Referring toFIGS. 26 to 28, in order to install the solar battery module device14in the example shown inFIG. 25on the roofer7by the installing method according to the present invention, an installing member15is first fixed on the roofer7[step (a)], and the top-side end part19of the solar battery module16is then inserted into the groove part62through an opening between the supporting part60and the pressing part61of the fixed installing member15on the lower side in the sloping direction of the roofer7(on the front side inFIGS. 26 and 27and on the left side inFIG. 28) and diagonally downward from above the upper frame21with the solar battery module16sloping such that the top-side end part19is below the bottom-side end part22[step (b)].

Referring now toFIGS. 27 and 28, the bottom-side end part22of the solar battery module16is rotated downward, as indicated by a hollow arrow in both the figures having the vicinity of the end part19inserted into the groove part62used as its support for placing the end part22on a placing surface23of a lower frame24, and the top-side end part19thereof is supported from below by the supporting part60, and the pressing part61is abutted against an upper surface of the end part19[step (c)]. Consequently, referring toFIGS. 29 and 30, the top-side end part19of the solar battery module16can be fixed in the vertical direction by the supporting part60and the pressing part61.

Thereafter, when the mounting part45of the fixing cover27is fixed to the extended part44in the lower frame24by screwing a screw50into a threaded hole51in the extended part44through a through hole52in the mounting part45with the mounting part45overlapped with the extended part44to fix the bottom-side end part22of the solar battery module16to the lower frame24by the fixing cover27, the mounting of the solar battery module16is completed [step (d)].

The solar battery module device14in the example shown inFIG. 25and the installing method according to the present invention using the same improve workability in mounting the solar battery module16on the installing member15and can prevent the solar battery module16from damage at the time of the mounting. That is, a worker can operate insertion in a relatively comfortable position because the top-side end part19of the solar battery module16can be inserted into the groove part62from a high viewing location by holding the vicinity of the bottom-side end part22of the solar battery module16, for example. Further, when a bottom-side edge of the supporting part60in the sloping direction of the roofer7is set to a position slightly shifted upward from a top-side edge of the pressing part61in the sloping direction of the roofer7, for example, the insertion can be more easily performed by increasing the distance between both the edges for defining the opening width of an opening for inserting the end part19of the solar battery module16into the groove part62larger than the thickness of the end part19.

Moreover, after the top-side end part19is inserted, the top-side end part19can be fixed in the vertical direction only by rotating the bottom-side end part22of the solar battery module16downward, as previously described, for placing the end part22on the placing surface23of the lower frame24, and supporting the end part19from below by the supporting part60as well as abutting the pressing part61against the upper surface of the end part19. Thus, the number of steps in operations for mounting the solar battery module16on the installing member15can be also reduced. Therefore, workability in mounting the solar battery module16on the installing member15can be improved, and damage to the solar battery module16can be also prevented by preventing pressure and distortion from being forcedly applied thereto at the time of insertion.

FIGS. 32 and 33are perspective views respectively showing a modified example of the upper frame21. First referring toFIG. 32, an upper frame21in the example as shown in the figure differs from that in the previously described example shown inFIG. 31in that a cross-sectional shape of a groove part62is substantially rectangular. Referring toFIG. 33, an upper frame21in the example as shown in the figure differs from that in the example shown inFIG. 31in that a cross-sectional shape of the groove part62is substantially triangular. Further, the cross-sectional shape of the groove part62can be also a shape other than the shapes in the examples shown in the above-mentioned figures. In short, the cross-sectional shape of the groove part62is not particularly limited, provided that the rotation of an end part22of a solar battery module16having an end part19thereof inserted thereinto is not prevented.

FIG. 34is a perspective view for explaining the flow of rainwater in the upper frame21in the solar battery module device14in the example shown inFIG. 25. Referring toFIG. 34, the solar battery module device14in the example shown inFIG. 25, it is possible to improve the waterstop properties thereof by the groove part62of the upper frame21to function as a gutter to prevent rainwater63entered from a clearance between the solar battery module16and a pressing part61of the upper frame21from entering onto the roofer7as indicated by a solid-line arrow and a broken-line arrow in the figure.

FIG. 35is a cross-sectional view showing a state in process during the step of inserting a rubber sheet64serving as an elastic member into an area between the solar battery module16and the pressing part61of the upper frame21.FIG. 36is a cross-sectional view showing a state where the rubber sheet64is inserted. Referring to both the figures, in the installing method according to the present invention, the rubber sheet64is previously mounted on the pressing part61prior to the step (b). As the end21of the solar battery module16is rotated downward (indicated by a hollow arrow inFIG. 35), the end part19thereof inserted into the groove part62is conversely rotated upward to insert the rubber sheet64into an area between the end part19and the pressing part61. Consequently, the waterstop properties of the solar battery module device14can be further improved by shutting off an entrance path of the rainwater63, previously shown inFIG. 34, using the rubber sheet64.

FIG. 37is a perspective view showing a modified example of the elastic member65inserted between the solar battery module16and the upper frame21in the solar battery module device14in the example shown inFIG. 25.FIG. 38is a perspective view showing an elastic member65inserted on the opposite side ofFIG. 37. Referring to both the figures, an elastic member65in this example has a cross-sectional shape corresponding to a space66between an upper frame21and a top-side end part19of a solar battery module16fitted in the upper frame21in a state as shown in both the figures where the installation of the solar battery module16in an installing member15is completed. The waterstop properties of a solar battery module device14can be further improved by inserting the elastic member65into the space66from both sides of the upper frame21to shut off an entrance path of the rainwater63, previously shown inFIG. 34.

FIG. 39is a cross-sectional view showing a modified example of the lower frame24in the solar battery module device14shown inFIG. 25.FIG. 40is a cross-sectional view showing a state where a bottom-side end part22of a solar battery module16is fixed to the lower frame24. Referring to both the figures, the lower frame24in this example differs from the lower frame24in the example shown inFIG. 25in that when the bottom-side end part22of the solar battery module16is placed on a placing surface23, a projection67abutted against an end surface47of the end part22is formed upward from the lower side of the placing surface23in the sloping direction of a roofer7(from the left side inFIG. 39).

As previously described, according to the solar battery module device14in the example shown inFIG. 25and the installing method according to the present invention using the same, the top-side end part19of the solar battery module16can be fixed in the vertical direction only by inserting the top-side end part19into the groove part62, then rotating the bottom-side end part22of the solar battery module16downward for placing the end part22on the placing surface23of the lower frame24, and supporting the top-side end part19thereof from below by the supporting part60as well as abutting the pressing part61against the upper surface of the end part19.

In the fixing operations, the bottom-side end part22of the solar battery module16can be placed at a predetermined fixing position on the placing surface23while being aligned at the same time that the bottom-side end part22is rotated downward and placed on the placing surface23. If the projection67is provided as in the example shown inFIG. 39and used as a reference for alignment by abutting the end surface47of the end part22of the solar battery module16against the projection67, operations for placing the end part22at the predetermined position on the placing surface23can be performed more simply.

Furthermore, the projection67can function as a stopper for the solar battery module16having the end part22placed on the placing surface23. Even on a sloping roof, therefore, the solar battery module16can be temporarily placed without fixing the end part22by mounting a fixing cover27on the lower frame24. The number of variations of the procedure for installing the solar battery module device14can be increased by adding the temporarily placing step.

In the lower frame24shown in the example, a part of the weight of the solar battery module16can be received by the projection67. When the end part22of the solar battery module16is fixed on the placing surface23by abutting a fixing part49of the fixing cover27against a surface of the projection67opposite to a surface against which the end surface47of the end part22is abutted and an upper surface48of the end part22as well as inserting a screw50through a through hole52and screwing the screw50into a threaded hole51with a mounting part45in the fixing cover27overlapped with an extended part44in the lower frame24, the weight of the solar battery module16can be avoided being concentrically applied to the screw50and a portion of the threaded hole51into which the screw50is screwed in the extended part44.

FIG. 41is a perspective view showing an example of a conductive fitting68that can be used for the solar battery module device14according to the present invention.FIG. 42is a plan view showing a state where the conductive fitting68shown inFIG. 41is attached on an end part of the solar battery module16. Referring to both the figures, the conductive fitting68in this example has a plate-shaped upper surface part71abutted against an upper surface of a frame70forming an end of at least one of a top-side end part and a bottom-side end part of the solar battery module16in a frame69of the solar battery module16, a plate-shaped lower surface part72abutted against a lower surface of the frame70, claw parts73to76respectively extending upward and downward in the thickness direction from a plate from both the parts71and72, a connecting part77for connecting both the parts71and72, and a corner part78abutted against a corner between an end and a side of the frame69of the solar battery module16integrally formed of a metal plate material, having good conductive properties, being hard, and being superior in corrosion resistance, such as stainless steel.

Referring toFIGS. 1,41and42, the bottom-side end part22is placed on the placing surface23of the lower frame24with the conductive fitting68attached on the frame70forming the bottom-side end part22in the frame69of the solar battery module16constituting the solar battery module device14in the example shown inFIG. 1, then the fixing cover27is then mounted on the lower frame24by screwing the screw28into the threaded hole29to fix the end part22to the lower frame24.

Consequently, the claw part73projected upward in the thickness direction of the plate from the upper surface part71of the conductive fitting68is stuck in the fixing cover27, and the claw part74projected downward is stuck in the upper surface of the frame70. In addition thereto, the claw part75projected downward in the thickness direction of the plate from the lower surface part72of the conductive fitting68is stuck in the placing surface23, and the claw part76projected upward is stuck in the lower surface of the frame70. Therefore, between the solar battery module16and the lower frame24can be reliably ground-connected to each other. The same applies to the upper frame21.

FIG. 43is a perspective view showing another example of the conductive fitting68. A conductive fitting68in the figure differs from the conductive fitting in the previous example shown inFIG. 41in that the connecting part77for connecting the upper surface part71and the lower surface part72is a cushioning part79to be elastically deformed in the form of substantially circular in cross section and the corner part78is omitted. Since the other parts are the same as those in the previous example, the same parts are denoted by the same reference numerals and hence, the description thereof is omitted.

Referring toFIGS. 1 and 43, when a bottom-side end part22in the frame of the solar battery module16constituting the solar battery module device14in the example shown inFIG. 1is fixed to the lower frame24in the same manner as that in the previous example with the conductive fitting68mounted on a frame forming the end part22, a claw part73projected upward in the thickness direction of a plate from the upper surface part71of the conductive fitting68is stuck in a fixing cover27, and a claw part74projected downward is stuck in an upper surface of the frame forming the end part22. Further, a claw part75projected downward in the thickness direction of the plate from the lower surface part72of the conductive fitting68is stuck in a placing surface23, and a claw part76projected upward is stuck in a lower surface of the frame forming the end part22. Therefore, between the solar battery module16and the lower frame24can be reliably ground-connected to each other.

In addition thereto, the cushioning part79is crushed by being sandwiched between the placing surface23of the lower frame24and the fixing cover27and is elastically deformed to produce a reaction force in this example, so that the solar battery module16can be more reliably mounted on the installing member15without producing backlash. The same applies to the upper frame21.

The conductive fitting68shown in FIGS.41and43is not only limited to use for the solar battery module device14according to the present invention, but can be effectively utilized in mounting the solar battery module16on the roofer7by various mounting structures to construct a photovoltaic power generating system of a roof-integration type. For example,FIG. 44is a perspective view showing one step in construction for constructing the roof-integration type photovoltaic power generating system by mounting the solar battery module16on a transverse rail80fixed on the roofer7through the conductive fitting68shown inFIG. 41or43.FIG. 45is a cross-sectional view showing in enlarged fashion of a state during the step in process of mounting the solar battery module16on the transverse rail80through the conductive fitting68shown inFIG. 41.

Referring toFIG. 44, a plurality of transverse rails80are disposed on the roofer7in place of the conventional crosspieces12. Each of the transverse rails80has the function of holding the lower side of the solar battery module16disposed on the upper side in the sloping direction of the roofer7(on the innermost side inFIG. 44) as well as holding the upper side of the solar battery module16disposed on the lower side in the sloping direction thereof (on the front side). The adjacent transverse rails80are equally spaced such that the rails can respectively hold the upper side and the lower side of the one solar battery module16. Each of the transverse rails80is formed to have a length that is not less than an integral multiple of the length in a transverse direction perpendicular to the sloping direction of the roofer7of the solar battery module16such that a plurality of solar battery modules16can be held by a pair of adjacent transverse rails80.

Referring toFIGS. 44 and 45, each of the transverse rails80is formed by subjecting a plate material to bending processing, and comprises a first placing surface81on which a frame70forming a bottom-side end part22in a frame69of the solar battery module16disposed on the upper side in the sloping direction of the roofer7(on the right side inFIG. 45) is placed, a second placing surface83disposed below the first placing surface81on which a frame82forming a top-side end part19in the frame69of the solar battery module16disposed on the lower side in the sloping direction thereof (on the left side) is placed, and a pair of leg parts84for mounting the transverse rail80on a surface of the roofer7.

The solar battery module16is fixed to the transverse rail80by a fixing cover85detachably mounted on the transverse rail80. Further, the fixing cover85is detachably mounted on the transverse rail80by a screw87meshed into a threaded hole86formed on the first placing surface81of the transverse rail80. The fixing cover85has a through hole88through which the screw87is inserted, and comprises a main body90serving as a first pressing surface89having its upper-side lower surface in the sloping direction of the roofer7disposed opposite to the first placing surface81, and an extended part92extended downward from an end, below the through hole88in the sloping direction of the main body90and having its tip whose lower surface is disposed opposite to the second placing surface83. The fixing cover85is formed in a cross-sectional shape as illustrated by a processing method such as extrusion or drawing using a metal material having corrosion resistance such as an aluminum alloy.

Referring toFIGS. 41,42, and45, in order to fix the solar battery module16on the transverse rail80, the bottom-side end part22of the solar battery module16disposed above the transverse rail80in the sloping direction is placed on the first placing surface81of the transverse rail80with the screw87loosened, for example, and the top-side end part19of the solar battery module16disposed below the transverse rail80in the sloping direction is placed on the second placing surface83. The screw87is then tightened with the first pressing surface89of the fixing cover85applied on the end part22of the upper solar battery module16placed on the first placing surface81of the transverse rail80and the second pressing surface91applied on the end part19of the lower solar battery module16placed on the second placing surface83.

Consequently, the bottom-side end part22of the upper solar battery module16is sandwiched between the first placing surface81and the first pressing surface89, so that the claw parts73to76of the conductive fitting68mounted on the frame70forming the end part22are respectively stuck in the first pressing surface89of the fixing cover85, the upper surface of the frame70, the first placing surface81of the transverse rail80, and the lower surface of the frame70. Therefore, the upper solar battery module16and the transverse rail80are reliably ground-connected to each other, and the lower side of the upper solar battery module16is fixed to the transverse rail80.

In addition thereto, the top-side end part19of the lower solar battery module16is sandwiched between the second placing surface83and the second pressing surface91, so that the claw parts73to76of the conductive fitting68mounted on the frame82forming the end part19are respectively stuck in the second pressing surface91of the fixing cover85, the upper surface of the frame82, the second placing surface83of the transverse rail80, and the lower surface of the frame82. Therefore, the lower solar battery module16and the transverse rail80are reliably ground-connected to each other, and the upper side of the lower solar battery module16is fixed to the transverse rail80. When this operation is repeated in order in the sloping direction of the roofer7and the transverse direction perpendicular to the sloping direction, the roof-integration type photovoltaic power generating system can be formed.

Referring toFIG. 44, in the formed photovoltaic power generating system, the transverse rails80and the solar battery modules16above and below the transverse rail80are reliably ground-connected to each other through the conductive fittings68, as previously described. Therefore, ground wiring93may be only connected to the lowermost transverse rail80, as illustrated, for example, the construction can be facilitated by simplifying wiring.

FIG. 46is a cross-sectional view showing in enlarged fashion a state during the step in process of mounting the solar battery module16on the transverse rail80through the conductive fitting68shown inFIG. 43. Referring toFIGS. 43 and 46, in a case where the conductive fitting68having the cushioning part79to be elastically deformed is employed, when the screw87is tightened, the bottom-side end part22of the upper solar battery module16is sandwiched between the first placing surface81and the first pressing surface89, as in the case shown inFIG. 45, so that the claw parts73to76of the conductive fitting68mounted on the frame70forming the end part22are respectively stuck in the first pressing surface89of the fixing cover85, the upper surface of the frame70, the first placing surface81of the transverse rail80, and the lower surface of the frame70. Therefore, the upper solar battery module16and the transverse rail80are reliably ground-connected to each other. In addition thereto, the cushioning part79is crashed by being sandwiched between the first placing surface81and the first pressing surface89and is elastically deformed to produce a reaction force, which allows the lower side of the solar battery module16to be more reliably fixed to the transverse rail80without producing backlash.

As in the case shown inFIG. 45, the top-side end part19of the lower solar battery module16is sandwiched between the second placing surface83and the second pressing surface91, so that the claw parts73to76of the conductive fitting68mounted on the frame82forming the end part19are respectively stuck in the second pressing surface91of the fixing cover85, the upper surface of the frame82, the second placing surface83of the transverse rail80, and the lower surface of the frame82. Therefore, the lower solar battery module16and the transverse rail80are reliably ground-connected to each other. In addition thereto, the cushioning part79is crashed by being sandwiched between the second mounting surface83and the second pressing surface91and is elastically deformed to produce a reaction force, which allows the upper side of the solar battery module16to be more reliably fixed to the transverse rail80without producing backlash.

FIG. 47is a perspective view showing another example of the embodiment of the solar battery module device14according to the present invention.FIG. 48is a perspective view of an installing member15in the solar battery module device14shown inFIG. 47.FIG. 49is a perspective view showing a state where a plurality of installing members15shown inFIG. 48are fixed on a roofer7.FIG. 50is a perspective view showing a part ofFIG. 49in enlarged fashion. Referring to the figures, the solar battery module device14in this example differs from that in each of the examples shown in the previous figures in that the installing member15comprises right and left side frames25respectively holding the right and left sides of a rectangular shape of a solar battery module16, and both the side frames25are respectively formed in such shapes that when the plurality of installing members15are arranged in a transverse direction perpendicular to the sloping direction of the roofer7(in the right-and-left direction in each of the figures), the right side frame25of the left installing member15and the left side frame25of the right installing member15are overlapped with each other.

Furthermore, the solar battery module device14in this example also differs from that in each of the examples shown in the previous figures in that the insulating members15are respectively provided with protruding parts94that are overlapped with and conductively connected to each other when they are arranged in the transverse direction with both the frames25overlapped therewith. Since the other parts are the same as those in the examples shown in the previous figures, in particular the example shown inFIG. 1, the same parts are denoted by the same reference numerals and hence, the description thereof is omitted.

Referring to each of the figures, the right and left side frames25are respectively formed to have thicknesses that are one-half those of the upper frame21and the lower frame24, and the left side frame25is disposed offset downward from the frame17and the right side frame25is disposed offset upward from the frame17in each of the figures. In a case where the installing members15are arranged in the transverse direction, therefore, the right side frame25of the left installing member15and the left side frame25of the right installing member15can be overlapped with each other.

Furthermore, a pair of protruding parts94is provided by protruding the side frames25from both right and left ends at an end part on the upper side in the sloping direction of the roofer7(on the innermost side in each of the figures) of the upper frame21upward in the sloping direction. The protruding parts94are respectively formed by extending the side frames25, as described above, so that they are respectively formed to have thicknesses that are one-half the thicknesses of the upper frame21and the lower frame24, similarly to the side frames25, and the left protruding part94is disposed offset downward and the right protruding part94is disposed offset upward from the frame17in each of the figures. Therefore, they can be overlapped with each other in the vertical direction by arranging the installing members15with the side frames25overlapped with each other in the vertical direction in the transverse direction perpendicular to the sloping direction of the roofer7, as previously described.

In order to conductively connect the protruding parts94overlapped with each other in the vertical direction, a screw95is used. That is, a threaded hole96into which the screw95is screwed is formed in the left protruding part94in each of the figures that is the lower protruding part in the case of overlapping, and a through hole97through which the screw95is inserted is formed in the right protruding part94that is the upper protruding part. Therefore, the upper and lower protruding parts94can be made to conductively connected with contact each other by inserting the screw95into the through hole97in the upper protruding part94to screw the screw95into the threaded hole96in the lower protruding part94and tighten the screw95. Therefore, wiring operations can be simplified by omitting wiring for ground connection over a plurality of solar battery module devices14.

FIG. 51is a cross-sectional view showing an example of a configuration in which installing members15fixed on the upper and lower sides in the sloping direction of a roofer7are ground-connected to each other. Referring toFIG. 51, both ends of a fitting98for conductive connection are respectively fixed with screws99to a lower frame24of the installing member15fixed on the upper side in the sloping direction of the roofer7(on the right side in the figure) and an upper frame21in the installing member15fixed on the lower side in the sloping direction thereof (on the left side), to ground-connect the upper and lower installing members15by the fitting98. Therefore, wiring operations can be further simplified by further omitting wiring for ground connection over a plurality of solar battery module devices14.

FIG. 52is a perspective view showing the appearance of a photovoltaic power generating system of a roof-integration type whose installation is completed. The figure shows a case where solar battery module devices14together with roofing materials42having a cross-sectional shape similar to that of the solar battery module devices14are installed on a roofer7to construct the roof-integration type photovoltaic power generating system. The plane shape of the solar battery module device14defined by the external shape of a frame17is formed such that two solar battery module devices14are substantially equal in shape and size to eleven roofing materials42. Therefore, the completed photovoltaic power generating system has a superior appearance in which the roofing materials42and the solar battery module devices14are harmonized with each other.

The configuration of the solar battery module device according to the present invention is not limited to that in each of the examples shown in the figures described above. Various design changes can be made without departing from the scope of the present invention.