JPH1093126A - Manufacture of roof tile with solar battery - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a roof tile provided with a recessed part, wherein a solar battery is set by supplying fiber reinforced cement composition into a molding die, curing and hardening a plain roof tile body with a recessed part formed in a surface by dehydrating press molding, thereafter painting a surface and a side surface and mounting a solar battery whose shape is almost the same as a recessed part. SOLUTION: A molding die which can be opened and closed is used for forming a plain roof tile body 1 with a recessed part 11 in a surface, and a fiber reinforcement cement composition is supplied to a cavity of a molding die. After the molded item is dehydrated to retain its shape, it is taken out of a die and surface is painted after the molded item has hardened. Acrylic resin emulsion paint is suitable, since it is alkali resistant and weather resistant. A solar battery 2 is set and fixed in a recessed part of the molded item obtained by a setting method, including sealing by an adhesive and fixing by a fixing metallic part 3 and a screw 4. A roof tile provided with a recessed part, wherein the solar battery 2 is set can be formed in such a simple manufacturing process.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a roof tile with a solar cell.

[0002]

2. Description of the Related Art Conventionally, a solar cell is installed on a roof of a house or the like, and various methods of applying the solar cell to save the power consumption by supplementing the original power consumption by utilizing the energy of the sunlight are devised. Have been.

For example, Japanese Patent Laid-Open Publication No. Sho 57-68454 and Japanese Utility Model Laid-Open Publication No. 4-28524 describe a method in which a solar cell is built in a roof tile and the roof tile is laid on the roof. Further, Japanese Patent Application Laid-Open No. Hei 5-243598 describes a method in which a panel-shaped solar cell unit is fixed to a dedicated frame and used.

[0004]

However, the method of using the solar cell unit described in Japanese Patent Application Laid-Open No. Hei 5-243598, which is the latter example, is fixed to a dedicated stand, when the solar cell unit is installed on a roof. There is a problem that the construction of the waterproofing process of the joint with the surrounding roof material other than the battery unit is complicated, requires many man-hours, and is expensive.

On the other hand, the former Japanese Patent Application Laid-Open No. Sho 57-68445.
In the case of a roof tile with a built-in solar cell described in Japanese Unexamined Patent Application Publication No. Hei 4-28524 or Japanese Unexamined Utility Model Publication No. 4-28524, since the roof tile can be laid in the same manner as the original roof tile, the labor for the construction is the same as before. Although there is an advantage that the construction can be performed simply and at low cost, it is necessary to form a concave portion for fitting the solar cell into the surface of the roof tile as in the above-mentioned reference.

In such a case, it is conceivable to provide the above-mentioned concave portion by cutting in a later step, but this complicates the manufacturing process, requires a considerable number of processing steps, and makes the cost too expensive. Therefore, there is a problem that it is difficult to establish it as industrial production.

The present invention has been made in view of the above-mentioned problems. It is an object of the present invention to solve these problems and to provide a concave portion for fitting a solar cell. The present invention provides a method of manufacturing a roof tile with a solar cell, which can efficiently manufacture a roof tile with a solar cell by a simple manufacturing process in a short time.

[0008]

In the method for manufacturing a roof tile with a solar cell according to the present invention, the fiber-reinforced cement composition is supplied into a mold that can be opened and closed, and the surface is dewatered by press forming. A first step of forming a flat tile body having a concave portion formed thereon, a curing and curing of the flat tile body, and a second step of painting the surface and side surfaces thereof; and forming a solar cell having substantially the same shape as the concave portion into the concave portion. It is characterized in that it is manufactured through a third step of mounting on a device.

In the method for manufacturing a roof tile with a solar cell according to the second aspect of the present invention, the fiber-reinforced cement composition in the method for manufacturing a roof tile with a solar cell according to the first aspect comprises water,
An aqueous solution in which a water-soluble polymer substance is dissolved, or an aqueous solution being dissolved, is mixed with an inorganic filler, and then mixed with a reinforcing fiber. No. B in which rocking mixing is performed by adding cement to the mixed mixture
It is characterized by being generated through a process.

In the method for manufacturing a roof tile with a solar cell according to the present invention, the fiber-reinforced cement composition in the method for manufacturing a roof tile with a solar cell according to the first aspect comprises water 2.
After adding and mixing 10 to 200 parts by weight of an inorganic filler to an aqueous solution in which 5 to 100 parts by weight and 0.05 to 3 parts by weight of a water-soluble polymer substance are dissolved or being dissolved, the reinforcing fiber is added. No. A in which 3 to 7 parts by weight is added to perform rocking mixing
It is characterized by being produced through a step and a B step in which 100 parts by weight of cement is added to the mixture obtained in the A step to perform rocking mixing.

The cement in the present invention is not particularly limited as long as it is an inorganic substance having a curability when kneaded with water. For example, simple cements such as ordinary Portland cement, special Portland cement, alumina cement, Roman cement, etc. Acid-resistant cement, fire-resistant cement, special cement such as water glass cement, gypsum, lime, porous cement such as magnesia cement, etc., especially strength,
Portland cement and alumina cement are preferably used in terms of water resistance.

A water-soluble polymer substance is a polymer substance which dissolves in water to impart viscosity, enhances the dispersibility of the inorganic filler and the reinforcing fiber, and enhances the fluidity of the mixture to improve the shapeability. There is no particular limitation, and examples thereof include cellulose ethers such as methylcellulose, hydroxymethylcellulose, hydroxyethylcellulose, carboxymercellulose, and hydroxypropylmercellulose, polyvinyl alcohol, and polyacrylic acid.

The inorganic filler is not particularly limited as long as it does not dissolve in water and inhibits the hardening reaction of the hydraulic inorganic substance and does not significantly inhibit the action of any constituent material used in the production method of the present invention. Not included, for example, aggregates for cement mortar such as silica sand and river sand, aggregates for mixed cement such as fly ash, silica flower, silica fume, bentonite, blast furnace slag, natural minerals such as sepiolite, wollastonite, calcium carbonate, mica And the like. These substances may be used alone or in combination of two or more.

The above-mentioned inorganic filler has an average particle size of 0.03.
If it is less than μm, the dispersibility of the particles between the reinforcing fibers is not further improved, and there is difficulty in production,
If it exceeds μm, it becomes difficult to disperse the particles between the reinforcing fibers, and the reinforcing fibers are easily condensed. Therefore, the average particle size of the inorganic filler is preferably 0.03 to 500 μm.

Examples of the reinforcing fibers include synthetic fibers such as vinylon, polyamide, polyester, polypropylene, and rayon, glass fibers, carbon fibers, aramid fibers, pulp, etc., having a thickness of 1 to 40 denier and a length of 1 to 40. ~
A 15 mm one is used.

The oscillating mixing in the present invention is a device in which a flexible rubber container is mounted on a disk-shaped oscillating plate without using a stirring blade, and the oscillating plate adjusts its inclination direction and angle. By continuously changing, the rubber container containing the material to be mixed is deformed and rocked, accelerating the contents,
This refers to mixing the particles by scattering them in random directions by changing the speed and direction. The cycle of this rocking movement is 1
Performed at ~ 3 times / sec.

In the first step of the present invention, in order to form a flat tile having a concave portion on the surface, a mold that can be opened and closed (for example, constituted by an upper mold and a lower mold) is used, and the fiber is reinforced. The cement composition is supplied to the cavity of the mold by supplying the cement composition.However, by using a mixture having improved fluidity by supplying an excessive amount of water, the mixture is quickly filled into the cavity, Complete press molding. After dewatering to such an extent that the molded body can retain its shape, the molded body is removed and the molded body is taken out.

In the subsequent second step, the obtained molded body is cured and cured by a conventional method such as steam curing, underwater curing, autoclave, natural curing, and then the surface and side surfaces are painted.
This coating method can be performed using a coating device such as a spray, a roll coater, a flow coater, and a shower coater, but since the molded body has a complicated shape,
Spray painting is preferred.

The paint used for the coating is a water-based paint,
Either a solvent-based paint or an inorganic paint may be used, but an acrylic resin emulsion is preferred from the viewpoint of alkali resistance and weather resistance.

The third step is a step of fitting and fixing a solar cell of the same shape into the concave portion of the molded article obtained through the second step. The method of fixing the solar cell is not particularly limited, and a fixing method using an adhesive, a fixing method using a fixing bracket, a fixing method using a screw or an anchor, or the like can be adopted.

According to a second aspect of the present invention, in the step (A), 0.05 to 3 parts by weight of a water-soluble polymer is first dissolved in 25 to 100 parts by weight of water. , The sedimentation of the inorganic filler added thereafter can be suppressed to improve the dispersibility, and the fluidity can be further imparted to facilitate shaping. In particular, in the case of methyl cellulose which is easily dissolved in water, it is possible to mix it with water at the same time as the inorganic filler.

If the amount of water is less than 25 parts by weight, fluidity cannot be ensured, and if it exceeds 100 parts by weight, the strength of the obtained molded article decreases, so that the amount is limited to 25 to 100 parts by weight. And preferably 30 to 80 parts by weight, more preferably 30 to 60 parts by weight.

If the amount of the water-soluble polymer substance is less than 0.05 part by weight, the reinforcing fibers to be added later cannot be sufficiently dispersed in the composition. Is limited to 0.05 to 3 parts by weight, preferably 0.1 to 2 parts by weight, more preferably 0.1 to 1 part by weight.

As described above, the reinforcing fibers are added to the viscous water in which the inorganic filler is dispersed and mixed by shaking, whereby the reinforcing fibers are uniformly dispersed without being damaged or cut. In this case, the average particle size of the inorganic filler is 100
If it is not less than μm, the particles of the inorganic filler hardly enter between the fibers of the reinforcing fibers, and the fibers tend to agglomerate without being dispersed. Therefore, the average particle diameter is preferably 100 μm.

If the amount of the inorganic filler is less than 10 parts by weight, there is a problem that the molded product is warped or cracked due to curing shrinkage, and if it exceeds 200 parts by weight, the strength of the obtained molded product is reduced. Therefore, it is limited to 10 to 200 parts by weight, preferably 20 to 150 parts by weight, more preferably 30 to 100 parts by weight.

If the amount of the reinforcing fibers is less than 0.3 parts by weight, the desired strength cannot be obtained in the molded article. Conversely, if the amount exceeds 7 parts by weight, the dispersibility of the fibers deteriorates and Due to poor fluidity, it is limited to 0.3 to 7 parts by weight, preferably 0.5 to 5 parts by weight, more preferably 0.5 to 3 parts by weight.

In the subsequent step B, 100 parts by weight of the cement is added to the fiber-reinforced cement composition obtained in the first step, and the mixture is shaken again, whereby the fine particles of the cement are easily reinforced with the inorganic filler. It can be a fiber reinforced cement composition dispersed between fibers.

The fiber-reinforced cement composition obtained above is
Since the composition is dispersed in viscous water, moisture is not separated during press molding and is quickly filled into the cavity of the molding die, so that a favorable molded body can be molded.

[0029]

According to the method of manufacturing a roof tile with a solar cell of the present invention, the fiber reinforced cement composition of claims 2 and 3 is used as described in detail above, By manufacturing through the third step from the step, a roof tile having a concave portion with excellent quality can be efficiently manufactured in a short time.

Also, since the solar cell is incorporated so as to fit in the concave portion of the roof tile having the concave portion, the solar cell is mixed and arranged on a part of the roof in the same manner as when the original roof tile is laid. There are advantages that can be.

Further, the solar energy can be installed without deteriorating the design of the external appearance, and the solar energy can be effectively used simply and inexpensively.

[0032]

Embodiments of the present invention will be described below with reference to tables and drawings. Using the fiber-reinforced cement composition shown in Table 1, a flat roof tile 1 having a concave portion 11 on the surface was manufactured as shown in FIG.

The above fiber reinforced cement composition contains ordinary Portland cement (manufactured by Chichibu Onoda Cement Co., Ltd.) as cement, and hydroxypropyl methylcellulose and poval (viscosity of 2% water soluble station at 20 ° C. as water soluble polymer). 30000 cps), fly ash (equivalent to JIS A6201; true specific gravity 2.3, bulk specific gravity 0.6, manufactured by Kanden Kako Co., Ltd.) as an inorganic filler, and silica sand (average particle size 100 μm, manufactured by Sumitomo Cement Co.) reinforcing fibers Vinylon fiber (1.8 denier, fiber length 6m
m) and a polypropylene fiber (thickness: 2 denier, fiber length: 5 mm).

The above-mentioned fiber-reinforced cement composition was subjected to oscillating mixing using an omni mixer (capacity: 20 liters, manufactured by Chiyoda Giken Kogyo Co., Ltd.) at a pressure of about 60 kg / cm ² for 10 seconds by dehydration press molding. At 90% RH for 12 hours.

[0035]

[Table 1]

Table 1 shows the observation results of the dispersion state of the fibers before shaping and the surface state of the molded body after curing in each of Examples (1 to 4) and Comparative Examples (1 to 3). The results of observation of the fluidity of the powder and the degree of filling of the molded article into the mold (in the cavity) are shown. As a result, the results of the examples according to the present invention were all good in fiber dispersibility, molded article surface properties, mixture fluidity, and molded article filling property.

Subsequently, the molded article was finished by spray coating using a water-based acrylic emulsion paint (manufactured by Dainippon Paint Co., Ltd.). In addition, both preheating and baking were heated and dried under the condition of 90 ° C. to complete the flat roof tile 1.

Thereafter, as shown in FIG. 1, the solar cell 2 using the tempered glass for surface protection is placed in the recess 1 of the flat roof tile 1.
1 and fixed using the fixing bracket 3 and the screw 4 to obtain a roof tile 10 with a solar cell as shown in FIG.

As shown in FIG. 3, the roof tile with a solar cell 10 can be partly mixed and laid in the same manner as the conventional flat tile 5, and can be constructed inexpensively and simply. It is possible to use solar energy effectively.

[0040]

According to the method for manufacturing a roof tile with a solar cell of the present invention, as described in detail above, the fiber reinforced cement composition according to claims 2 and 3 is used.
That is, by manufacturing through the first step through the third step,
Roof tiles having recesses of excellent quality can be efficiently manufactured in a short time.

Also, since the solar cell is incorporated so as to fit in the concave portion of the roof tile having the concave portion, the solar cell is installed on a part of the roof in the same manner as when the original roof tile is laid. There are advantages that can be.

Furthermore, the solar energy can be installed without deteriorating the design of the external appearance, and the solar energy can be effectively used simply and inexpensively. Therefore, it is suitable as a method for manufacturing a roof tile with a solar cell.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing an example of a roof tile with a solar cell obtained by the method for manufacturing a roof tile with a solar cell of the present invention.

FIG. 2 is a perspective view of the roof tile with solar cells shown in FIG. 1;

FIG. 3 is a perspective view showing an example of use of a roof tile with a solar cell of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Flat tile 11 Concavity 2 Solar cell 3 Fixture 4 Screw 5 (Conventional) flat tile 10 Roof tile with solar cell

Claims (3)

[Claims] 1. A first step in which a fiber reinforced cement composition is supplied into a mold that can be opened and closed, and a dewatering press molding is performed to form a flat tile having a concave portion formed on a surface thereof, and the flat tile is cured and cured. And manufacturing a roof tile with a solar cell, characterized by being manufactured through a second step of painting the surface and the side surface and a third step of mounting a solar cell having substantially the same shape as the concave part in the concave part. Method. 2. The above-mentioned fiber-reinforced cement composition is mixed with water, an aqueous solution in which a water-soluble polymer substance is dissolved, or an aqueous solution in which a dissolving solution is being dissolved, and an inorganic filler is added thereto. The solar cell according to claim 1, wherein the mixture is produced through a step A of performing dynamic mixing and a step B of performing rocking mixing by adding cement to the mixture obtained in step A. Roof tile manufacturing method. 3. The method according to claim 1, wherein the fiber reinforced cement composition comprises water 25
After adding and mixing 10 to 200 parts by weight of an inorganic filler to an aqueous solution or a solution in which 0.05 to 3 parts by weight of a water-soluble polymer substance is dissolved or being dissolved, the reinforcing fiber 0.3 The mixture is produced through the A-step in which rocking mixing is performed by adding ~ 7 parts by weight and the B-step in which 100 parts by weight of cement is added to the mixture obtained in the first step and rocking mixing is performed. The method for producing a roof tile with a solar cell according to claim 1, wherein: