JP2011066305A - Method and apparatus of manufacturing electrode using sheet wire - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To markedly enhance the yield of a product such as a solar panel by correcting an electrode material, even if it consists of a sheet wire wound around a reel to sufficient linear accuracy and avoiding poor connections. <P>SOLUTION: A method of manufacturing an electrode includes a reel 2 around which a sheet wire as an electrode material R is wound. The electrode material R is reeled out from the reel 2 and is cut to fabricate an electrode Ro having a predetermined length. At that time, the electrode material R to be reeled out from the reel 2 is pulled in a transfer direction Df by means of a pulling roller mechanism 3 with a first pull force F1; while at the same time, the electrode material R is placed under tension, in a direction Dr opposite from the transfer direction Df by means of a brake roller mechanism 4 arranged between the pulling roller mechanism 3 and the reel 2, with a second pull force F2 smaller than the first pull force F1, and the electrode material R fed out from the pulling roller mechanism 3 is cut by means of a cutting mechanism 5, to obtain the electrode Ro having the predetermined length. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

The present invention relates to a method and an apparatus for manufacturing an electrode using a sheet-like wire that manufactures an electrode from the electrode material fed from a reel wound with an electrode material made of a sheet-like wire.

In general, a solar panel (solar cell panel) that performs photovoltaic power generation is known, and this type of solar panel forms a plurality of solar cells (photoelectric conversion cells) by a semiconductor thin film on the surface of a glass substrate. The generated electric power is taken out by connecting an electrode using a sheet wire to the semiconductor thin film. Many of the electrodes used have a copper foil with a width of 3 to 5 [mm] and a thickness of around 0.1 [mm], but in the case of a large solar panel of 1.0 × 1.5 [m] size, the length of the electrode Since the length is about 1 [m], it is not easy to connect an electrode maintaining a linear accuracy at a fixed position on the semiconductor thin film, and it is usually dedicated to manufacturing and connecting (mounting) this type of electrode. The manufacturing method (manufacturing apparatus) is used.

Conventionally, as a method for manufacturing such an electrode, a manufacturing method disclosed in Patent Document 1 is known. In the same document 1, a thin-film photoelectric conversion cell is used when an electrode is attached to a solar battery panel. Apply a liquid conductive adhesive in a point-like manner to the position where the electrode is placed, place the electrode on it, and place multiple short adhesive tapes on the electrode in a direction intersecting the electrode. A manufacturing method is disclosed in which the electrode is temporarily fixed so as not to move and the adhesive is solidified, and the electrode is temporarily fixed by both the adhesive strength of the adhesive and the adhesive tape. Note that the electrode temporarily fixed by both the adhesive force of the adhesive and the adhesive tape is fixed on the photoelectric conversion cell by a laminating process performed in a subsequent process.

JP 2009-182066 A

However, the conventional manufacturing method (manufacturing apparatus) for connecting the above-described electrodes on a semiconductor thin film has the following problems.

First, since the electrode is placed on the conductive adhesive applied point-by-point, linear accuracy of a certain level or more is required, but the electrode is a sheet-like wire wound around a reel. Since the electrode material is cut and manufactured, the linear accuracy is not so high. Therefore, when the electrode material is unwound from the reel, a certain amount of tensile force is applied to the electrode material to be in a tensioned state, but sufficient linear accuracy cannot be ensured. In the case of an electrode having a length of [mm] and a length of 1 [m], an error (offset) occurs in the range of about 15 [mm] with respect to the width direction. After all, this error is directly connected to poor connection and becomes a non-negligible factor that leads to a decrease in the yield of products (solar cell panels).

Secondly, when an electrode material is obtained by cutting an electrode material with a sheet-like wire rod, an electrode having a length of about 1 [m] is in a tension state until just before being cut, so that elongation, springback, etc. occur. The length of the electrode and the positional accuracy at the time of mounting, such as the position of the electrode after cutting and also the position when mounting on the semiconductor thin film are likely to be unstable. May adversely affect

An object of the present invention is to provide a method and an apparatus for manufacturing an electrode using a sheet-like wire material that solves the problems existing in the background art.

In order to solve the above-described problems, the method for manufacturing an electrode using a sheet-like wire according to the present invention includes a reel 2 around which an electrode material R made of a sheet-like wire is wound. When manufacturing the electrode Ro having a predetermined length by cutting the electrode material R, the electrode material R fed from the reel 2 is pulled by the pulling roller mechanism 3 in the transport direction Df by the first pulling force F1, and the pulling roller mechanism 3 And the brake roller mechanism 4 disposed between the reel 2 and the electrode material R are tensioned in the reverse direction Dr with respect to the transport direction Df by the second tensile force F2 smaller than the first tensile force F1, and the drawing roller mechanism 3 The electrode material R delivered from is cut by the cutting mechanism 5 to obtain an electrode Ro having a predetermined length.

Moreover, in order to solve the above-mentioned problem, the apparatus 1 for manufacturing an electrode using a sheet-like wire according to the present invention cuts the electrode material R fed out from a reel 2 around which the electrode material R made of a sheet-like wire is wound. A manufacturing apparatus for manufacturing an electrode Ro having a length, a pulling roller mechanism 3 that pulls an electrode material R fed from a reel 2 in a transport direction Df by a first pulling force F1, and a gap between the pulling roller mechanism 3 and the reel 2. The brake roller mechanism 4 for tensioning the electrode material R in the reverse direction Dr with respect to the transport direction Df by the second tensile force F2 smaller than the first tensile force F1 and the drawing roller mechanism 3 And a cutting mechanism 5 that cuts the electrode material R to obtain an electrode Ro having a predetermined length.

According to a preferred aspect of the present invention, an electrode using a copper foil connected to the semiconductor thin film 71 of the solar panel 70 can be applied to the electrode Ro. The interval Lp between the drawing roller mechanism 3 and the brake roller mechanism 4 can be set corresponding to the electrode material R. On the other hand, the electrode material R delivered from the drawing roller mechanism 3 can be held by the moving chuck mechanism 6 and guided in the transport direction Df by the third tensile force F3 smaller than the second tensile force F2. Furthermore, in the manufacturing apparatus 1 according to the present invention, the encoder mechanism 7e that outputs the encoder signal Pe corresponding to the rotation amount of the reel 2, the rotation amount of the reel 2 is obtained based on the encoder signal Pe, and the obtained rotation amount The remaining amount of the electrode material R wound on the reel 2, and a processing unit 7p for performing a predetermined process when the remaining amount reaches one or more preset values set in advance. 7 can be provided.

According to the electrode manufacturing method and apparatus 1 using the sheet-like wire according to the present invention, the following remarkable effects are obtained.

(1) The electrode material R fed out from the reel 2 is pulled in the transport direction Df by the first pulling force mechanism F1 by the pulling roller mechanism 3, and the electrode material R is pulled by the brake roller mechanism 4 disposed between the pulling roller mechanism 3 and the reel 2. Even when the electrode material R made of a sheet-like wire wound around the reel 2 is used, the second tensile force F2 smaller than the first tensile force F1 is tensioned in the reverse direction Dr with respect to the transport direction Df. , Can be corrected with sufficient linear accuracy. Thereby, the error (offset) in the width direction range of the electrode Ro can be greatly reduced, and the yield of products such as solar panels can be dramatically increased by avoiding connection failure.

(2) If an electrode using a copper foil connected to the semiconductor thin film 71 of the solar panel 70 is applied to the electrode Ro according to a preferred embodiment, the most desirable performance from the viewpoint of ensuring the linear accuracy in the longitudinal direction of the electrode Ro. Obtainable.

(3) If the distance Lp between the drawing roller mechanism 3 and the brake roller mechanism 4 is set corresponding to the electrode material R according to a preferred embodiment, it is easily optimized when correcting the electrode Ro to a sufficient linear accuracy. be able to.

(4) According to a preferred embodiment, the electrode material R delivered from the drawing roller mechanism 3 is held by the moving chuck mechanism 6 and guided in the transport direction Df by the third tensile force F3 smaller than the second tensile force F2. By doing so, unnecessary tensile force is not applied to the electrode material R (electrode Ro) between the drawing roller mechanism 3 and the moving chuck mechanism 6, so that there is almost no elongation or springback or the like on the cut electrode Ro. The length accuracy of the electrode Ro and the positional accuracy at the time of mounting can be improved, such as reducing the variation in the length of the electrode Ro and the variation in the position when mounting on the semiconductor thin film.

(5) According to a preferred embodiment, an encoder mechanism 7e that outputs an encoder signal Pe corresponding to the amount of rotation of the reel 2, and a rotation amount of the reel 2 is obtained based on the encoder signal Pe, and the reel 2 is obtained from the obtained amount of rotation. A remaining amount monitoring device 7 having a processing unit 7p for obtaining a remaining amount of the wound electrode material R and performing a predetermined process when the remaining amount reaches one or more preset values set in advance is provided. For example, since the remaining amount of the electrode material R wound on the reel 2 can be known more accurately, the end time of the electrode material R, an arbitrary time before the end of the electrode material R can be accurately known, and the electrode material R Waste can be reduced.

The flowchart for demonstrating the main processes of the manufacturing method of the electrode by the sheet-like wire which concerns on suitable embodiment of this invention, A flow chart for explaining a procedure for assembling a solar panel using the same electrode, A flowchart for explaining the monitoring process of the remaining amount of electrode material used when manufacturing the electrode, The typical side block diagram which shows the principal part of the manufacturing apparatus of the electrode by the sheet-like wire which concerns on suitable embodiment of this invention, Schematic plane configuration diagram showing the main part of the electrode manufacturing apparatus, The schematic block diagram for demonstrating the function of the brake roller mechanism of the manufacturing apparatus of the same electrode, and the drawing roller mechanism, Schematic configuration diagram for explaining the functions of a fixed chuck mechanism, a cutting mechanism and a moving chuck mechanism of the electrode manufacturing apparatus, Configuration diagram of the encoder mechanism of the remaining amount monitoring device provided in the manufacturing apparatus of the electrode, Overall configuration diagram of a remaining amount monitoring device provided in the electrode manufacturing apparatus, A bottom view including a partially extracted enlarged view of a solar panel using the same electrode, Sectional drawing which shows a part of solar panel using the electrode, Configuration diagram of output circuit (connector) for the solar panel, The typical block diagram which shows a part of manufacturing apparatus of the electrode by the sheet-like wire which concerns on the modified embodiment of this invention, The typical block diagram which shows a part of manufacturing apparatus of the electrode by the sheet-like wire which concerns on other modified embodiment of this invention,

Next, preferred embodiments according to the present invention will be given and described in detail with reference to the drawings.

First, in order to facilitate understanding of the electrode manufacturing method according to the present invention, a solar panel using an electrode made of a sheet-like wire will be described with reference to FIGS.

The illustrated solar panel 70 includes a panel body 73 having a size of 1.0 × 1.5 [m] in which a semiconductor thin film 71 serving as a solar cell is formed on the surface of a glass substrate 72, and the semiconductor thin film 71 in the panel body 73. A solar panel base 74 is configured by connecting a pair of electrodes Ro. In this case, one electrode Ro (Roa) is on the positive electrode side, and the other electrode Ro (Rob) is on the negative electrode side. Each of the electrodes Roa is a copper foil having a width of 3 [mm] and a thickness of 0.1 [mm], and is manufactured using the electrode manufacturing method (manufacturing apparatus 1) using the sheet-like wire according to the present embodiment. . Each of the electrodes Roa and Rob is disposed along the long side edge on the left and right sides of the panel body 73 (up and down positions in FIG. 10).

Further, an output circuit 75 is attached to the solar panel base 74. The output circuit 75 includes a pair of electrode leads 76a and 76b attached to the solar panel base 74, and connects one ends of the electrode leads 76a and 76b to the electrodes Roa and Rob, respectively. For the electrode leads 76a and 76b, the same copper foil as that of the electrodes Roa and Rob, that is, a copper foil having a width of 3 [mm] and a thickness of 0.1 [mm] is used. When mounting, as shown in FIG. 10, one end of each electrode lead 76a, 76b is brought into contact with each electrode Roa, Rob, and the other end is erected at right angles to reach the vicinity of the center of the solar panel base 74. Make it. At this time, insulating sheets 77 a and 77 b are interposed between the electrode leads 76 a and 76 b and the solar panel base 74 to electrically insulate the electrode leads 76 a and 76 b from the solar panel base 74.

Further, as shown in FIG. 12, a case main body 81m constituting the connector case 81 is mounted on the solar panel base 74 where the other ends of the electrode leads 76a and 76b are located. The case main body 81m includes connection terminals 82a and 82b, and output cables 83a and 83b are connected to the rear ends of the connection terminals 82a and 82b, respectively, and led out to the outside. On the other hand, since the other ends of the electrode leads 76a and 76b enter the inside through the opening 81h of the case main body 81m, the other ends of the connection terminals 82a and 82b and the electrode leads 76a and 76b are subjected to a surface treatment (cleaning treatment) by plasma treatment. Thus, after the adhesion (adhesiveness) is improved, the other ends of the electrode leads 76a and 76b are bent and soldered to the upper surfaces of the connection terminals 82a and 82b. The case body 81m is filled with a potting material, and the case cover 81c is attached. The above is the main configuration of the solar panel 70.

Next, the configuration of the electrode manufacturing apparatus 1 according to the present embodiment will be described with reference to FIGS.

As shown in FIG. 4, the manufacturing apparatus 1 includes a machine body 10. The machine body 10 is roughly divided from the supply side of the electrode material R into the reel loading unit 11, the encoder mechanism 7 e in the remaining amount monitoring device 7, and the conveyance. A mechanism 12, a brake roller mechanism 4, a drawing roller mechanism 3, a fixed chuck mechanism 13, a cutting mechanism 5, a moving chuck mechanism 6, an elevating support mechanism 14, and a suction extraction mechanism 15 are provided. In addition, a controller 16 that controls driving of each unit is provided. The controller 16 includes a processing unit 7 p in the remaining amount monitoring device 7.

Hereinafter, the structure of each part is demonstrated concretely. As shown in FIGS. 8 and 9, the reel loading unit 11 includes a rotation support shaft 11 s provided in the machine body 10, and the rotation support shaft 11 s is a reel around which an electrode material R made of a sheet-like wire is wound. 2 can be detachably loaded. On the other hand, the encoder mechanism 7e includes an encoder base 21 that is attached to the rotation support shaft 11s and rotates integrally with the rotation support shaft 11s, and an optical sensor 22 that is disposed facing the encoder base 21. A monochrome pattern 21p is displayed along the circumferential direction on the encoder board 21, and the optical sensor 22 can detect the monochrome pattern 21p as a “0” or “1” signal. Therefore, when the reel 2 rotates, the encoder signal Pe corresponding to the rotation amount is output from the optical sensor 22 and is given to the processing unit 7 p in the controller 16. The monochrome pattern 21p may be displayed directly on the reel 2. In this case, the encoder base 21 can be omitted.

In the illustrated example, the transport mechanism unit 12 includes a first guide roller 24, a second guide roller 25, a third guide roller 26, and a fourth guide roller 27, and between the third guide roller 26 and the fourth guide roller 27. The straightening roller 28 for bending the electrode material R in the opposite direction to the bending in the reel 2 is provided. The transport mechanism unit 12 has a function of guiding the electrode material R fed from the reel 2. On the other hand, the brake roller mechanism 4 includes an upper roller 4u and a lower roller 4d that sandwich the electrode material R that has passed through the transport mechanism unit 12 from above and below, and the rotating shaft of the lower roller 4d is connected to a tension applying unit (brake) via the rotation transmission mechanism 31. Part) 32. Thereby, since the rotation of the lower roller 4d is braked by the tension applying unit 32, a back tension by the second tensile force F2 can be applied to the electrode material R being conveyed. On the other hand, the drawing roller mechanism 3 includes an upper roller 3u and a lower roller 3d that sandwich the electrode material R delivered from the brake roller mechanism 4 from above and below, and the rotation shaft of the lower roller 3d is a rotation drive unit via the rotation transmission mechanism 33. 34. As a result, the lower roller 3d is rotated by the rotation drive unit 34 and can be pulled in the transport direction Df with respect to the electrode material R by the first pulling force F1.

In this case, the relationship between the first tensile force F1 and the second tensile force F2 is set so that the second tensile force F2 is smaller than the first tensile force F1. Therefore, with respect to the electrode material R between the drawing roller mechanism 3 and the brake roller mechanism 4, the drawing roller mechanism 3 has a function of pulling in the transport direction Df by the first pulling force F1, and the brake roller mechanism 4 has a second function. A function of tensioning in the reverse direction Dr with respect to the transport direction Df by the tensile force F2 is provided. Further, since the distance Lp between the drawing roller mechanism 3 and the brake roller mechanism 4 affects the effect of correcting the linear accuracy of the electrode material R, it corresponds to the type (material, width, thickness, etc.) of the electrode material R. To set the optimal interval. By setting the distance Lp, it is possible to easily optimize the electrode Ro when correcting it to a sufficient linear accuracy. The magnitudes of the first tensile force F1, the second tensile force F2, the distance Lp, and the like can be easily selected by experiments on the electrode material R to be used.

The fixed chuck mechanism 13 includes a fixed chuck portion 36 that has an open / close chuck 13c that is fixed with the upper and lower surfaces of the electrode material R sandwiched between the closed and open states and that is released from being fixed to the electrode material R when opened. The cutting mechanism 5 includes cutters 5c that can cut the electrode material R, and the cutting mechanism 5 can cut the electrode material R that is fed from the drawing roller mechanism 3. Reference numerals 37... Denote a plurality of guide plates arranged at predetermined positions for regulating the position of the conveyed electrode material R.

The moving chuck mechanism 6 has a function of holding the electrode material R delivered from the drawing roller mechanism 3 and guiding it in the transport direction Df by a third tensile force F3 smaller than the second tensile force F2. Accordingly, the moving chuck mechanism 6 includes a moving chuck portion 38 having an opening / closing chuck 6c that holds the upper and lower surfaces of the electrode material R when closed and releases the holding of the electrode material R when opened. A chuck moving mechanism 39 is provided for moving the electrode 38 in the conveying direction Df or the reverse direction Dr of the electrode material R delivered from the drawing roller mechanism 3. In this case, the movable chuck portion 38 holds the tip of the electrode material R at least at the position shown in FIG. 7 (starting position Xs) close to or in contact with the cutting mechanism 5, and from this starting position Xs to FIG. 4 and FIG. The electrode Ro can be moved forward to the indicated position (end position Xe), and the electrode Ro having a predetermined length can be obtained by cutting the electrode material R by the cutting mechanism 5 at the end position Xe.

The lift support mechanism 14 includes a support base 41 that can support the electrode Ro cut by the cutting mechanism 5, and a lift mechanism 42 that lifts and lowers the support base 41. On the other hand, the suction extraction mechanism 15 includes a head portion 44 having a plurality of suction portions 44 s arranged along the longitudinal direction of the electrode Ro. As a result, the suction part 44 has a function of adsorbing the electrode Ro supported by the support base 41 with a negative pressure and taking it out from the support base 41. Further, the suction extraction mechanism 15 includes a moving mechanism 45 that moves the head portion 44 to the use position (use place) of the electrode Ro.

The controller 16 has computer functions including a CPU, a memory, a power supply unit, and the like. Thereby, control of the whole apparatus including a series of sequence control regarding the manufacturing apparatus 1 can be performed, and the control program for implement | achieving these control is stored. Further, the controller 16 obtains the rotation amount of the reel 2 based on the encoder signal Pe obtained from the optical sensor 22 described above, and obtains the remaining amount of the electrode material R wound around the reel 2 from the obtained rotation amount. When the remaining amount reaches one or two or more preset values, a processing unit 7p that performs a predetermined process is included.

Next, the operation (function) of the manufacturing apparatus 1 including the electrode manufacturing method according to the present embodiment will be described according to the flowchart shown in FIG. 1 with reference to FIGS.

First, preparation for operating the manufacturing apparatus 1 is performed (step So). First, the reel 2 around which the electrode material R made of a sheet-like wire is wound is loaded on the rotation support shaft 11 s of the reel loading unit 11. In the example, the electrode material R is a copper foil having a width of 3 [mm] and a thickness of 0.1 [mm], and the total length wound around the reel 2 is 100 [m]. Then, as shown in FIG. 4, the electrode material R fed from the reel 2 is loaded in the order of the first guide roller 24, the correction roller 28, the second guide roller 24 to the fourth guide roller 27, and the brake roller mechanism. 4, the drawing roller mechanism 3, the fixed chuck mechanism 13, and the cutting mechanism 5 are loaded in this order. At this time, the upper rollers 4u and 3u of the roller mechanisms 4 and 3 are set in a released state displaced upward, the open / close chucks 13c of the fixed chuck mechanism 13 are set in an open state, and the moving chuck mechanism 6 The movable chuck portion 38 is at the end position Xe. Therefore, when the electrode material R is loaded up to the cutting mechanism 5, a loading end key (not shown) is turned ON. As a result, the open / close chucks 13c of the fixed chuck mechanism 13 are closed to fix the electrode material R, and the cutting mechanism 5 performs a cutting operation to cut an unnecessary front portion of the electrode material R. On the other hand, the controller 16 inputs (sets) data related to various necessary items such as the total length of the electrode material R and the length of the electrode Ro using the attached setting means.

When preparation is completed, a start key (not shown) is turned ON. This starts the manufacturing process. First, the moving chuck portion 38 of the moving chuck mechanism 6 at the end position Xe moves backward to the start position Xs (step S1). At the start position Xs, the open / close chuck 6c... Closes and holds the tip of the electrode material R (step S2). This state is indicated by a virtual line in FIG. Further, the open / close chuck 13c of the fixed chuck mechanism 13 is opened to release the electrode material R from the fixed state (step S3).

Next, a conveyance process that also serves as a correction process for the electrode material R is performed (step S4). That is, in the transport process, the chuck moving mechanism 39 in the moving chuck mechanism 6 is controlled to move the moving chuck portion 38 forward, and at the same time, the rotation driving portion 34 is controlled to rotate the drawing roller mechanism 3 (step). S4a, S4b). As a result, the electrode material R is transported in the transport direction Df, and at the same time, correction for the electrode material R is performed (steps S4c and S4d). In this case, as shown in FIG. 6, since the drawing roller mechanism 3 rotates in the direction of the arrow Rf, the electrode material R sandwiched between the upper roller 3u and the lower roller 3 has a first tensile force F1 in the transport direction Df. The electrode material R sandwiched between the upper roller 4u and the lower roller 4d by the brake roller mechanism 4 disposed in front of the conveying direction by a predetermined distance Lp is pulled by the tension applying portion (brake portion) 32, A back tension is applied by the second tensile force F2 in the reverse direction Dr with respect to the transport direction Df. That is, the electrode material R is transported in the transport direction Df by the brake roller mechanism 4 and the drawing roller mechanism 3, and at the same time, the first tensile force F1 and the second tensile force between the brake roller mechanism 4 and the drawing roller mechanism 3 are processed. The tensile force based on the force F2 is put in a tension state, and an effective correction process by plastic deformation is performed. That is, the linear accuracy of the electrode material R is improved by finally removing (correcting) the curvature in the width direction and the warp in the thickness direction, etc. existing in the electrode material R.

Further, the tip of the electrode material R delivered from the drawing roller mechanism 3 is held by the moving chuck mechanism 6 and guided in the transport direction Df by a third tensile force F3 smaller than the second tensile force F2. At this time, the third tensile force F3 is sufficient to maintain the electrode material R sent from the drawing roller mechanism 3 so as not to loosen. As a result, an unnecessary tensile force is not applied to the electrode material R (electrode Ro) between the drawing roller mechanism 3 and the moving chuck mechanism 6, so that almost no elongation or springback occurs in the cut electrode Ro. The length accuracy of the electrode Ro and the position accuracy at the time of mounting can be increased, such as variation in the length of the electrode Ro and variation in position when the electrode Ro is placed on the semiconductor thin film.

Then, when the moving chuck portion 38 of the moving chuck mechanism 6 reaches the end position Xe, stop processing is performed (steps S5 and S6). That is, the chuck moving mechanism 39 is controlled to stop the forward movement of the moving chuck portion 38, and the rotation driving portion 34 is controlled to stop the rotation operation of the drawing roller mechanism 3. Next, the elevating mechanism 42 in the elevating support mechanism 14 is controlled, and the support base 41 is raised below the electrode material R and to the virtual line position shown in FIG. 4 adjacent to the electrode material R (step S7). On the other hand, the open / close chucks 13c of the fixed chuck mechanism 13 are closed to fix the electrode material R (step S8). Further, the cutting mechanism 5 is controlled, and the upper and lower cutters 5c shown in FIG. 7 are moved up and down to cut the electrode material R, and the open / close chuck 6c of the moving chuck mechanism 6 is opened to open the electrode material R (electrode Ro). Is released (steps S9 and S10).

Thereafter, the suction portions 44 in the suction extraction mechanism 15 are lowered to the position just above the electrodes Ro, the suction portions 44s are brought into a suction state (negative pressure state), the electrodes Ro are sucked and held, and the moving mechanism 45 is controlled. To a use position (use place), that is, to a predetermined mounting position on a panel body 73 described later (step S11). If the electrode Ro is moved, the support base 41 is lowered to the release position (solid line position) shown in FIG. 4 (step S12). The manufacture of one electrode Ro is completed through the above steps. Further, when the electrode Ro is continuously manufactured, the moving chuck portion 38 at the end position Xe is moved backward to the start position Xs, and thereafter the same process (operation) is repeated (steps S13, S1,...). ).

Therefore, according to the electrode manufacturing method (manufacturing apparatus 1) according to this embodiment, the electrode material R fed from the reel 2 is pulled in the transport direction Df by the pulling roller mechanism 3 by the first pulling force F1, and The electrode roller R is tensioned in the reverse direction Dr with respect to the transport direction Df by the second pulling force F2 smaller than the first pulling force F1 by the brake roller mechanism 4 disposed between the drawing roller mechanism 3 and the reel 2. Therefore, even when the electrode material R made of a sheet-like wire wound around the reel 2 is used, it can be corrected with sufficient linear accuracy. In particular, when the manufacturing method (manufacturing apparatus 1) according to this embodiment is not used, as described above, an electrode having a width of 3 [mm] and a length of 1 [m] is about 15 [mm] in the width direction. In the case of the same electrode, the error (offset) is within a range of 1 [mm] in the width direction by using the manufacturing method (manufacturing apparatus 1) according to this embodiment. Could be suppressed. Thus, the error in the width direction range of the electrode Ro can be greatly reduced, and the yield of products such as solar panels can be dramatically increased by avoiding poor connection.

Next, the remaining amount monitoring device 7 provided in the manufacturing apparatus 1 according to the present embodiment will be described according to the flowchart shown in FIG. 2 with reference to FIGS. 8 and 9.

As described above, when the electrode Ro is manufactured, the electrode material R is unwound from the reel 2 and transported (step S21 (S4c)). At this time, since the reel 2 rotates, the encoder base 21 provided on the rotation support shaft 11s also rotates integrally. As shown in FIG. 9, since the monochrome pattern 21p along the circumferential direction is displayed on the encoder base 21, the optical pulse from the optical sensor 22 facing the monochrome pattern 21p corresponds to the encoder pulse Pe corresponding to the monochrome pattern 21p. Is output (step S22). Since the encoder pulse Pe is given to the processing unit 7p in the controller 16, the processing unit 7p counts the number of encoder pulses Pe (step S23). In this case, since the count number corresponds to the amount of rotation of the reel 2, if the count number is monitored, the amount (length) of the electrode material R fed out from the reel 2 can be known, and the reel 2 is wound around the reel 2. The remaining amount of the electrode material R can be known from the total length of the electrode material R (step S24).

On the other hand, one or two or more set values for the remaining amount are set in advance, and necessary processing corresponding to the state of the remaining amount is performed. In the embodiment, two setting values, the main setting value and the preliminary setting value, are set. The main set value is a set value for determining the end point at which the remaining amount runs out and the electrode Ro cannot be manufactured any more. Further, the preliminary set value is a set value for determining a time point before the main set value, that is, a time point at which the remaining N electrodes Ro can be manufactured. Therefore, the count number is monitored, and when the count number reaches the preset value, the processing unit 7p gives the alarm command signal Ea related to the preliminary alarm to the alarm unit 7a as shown in FIG. As a result, a preliminary warning is output from the alarm unit 7a (steps S25 and S26). The preliminary alarm allows the operator to know that the number of electrodes Ro that can be manufactured is N, so that a new reel 2 to be replaced can be prepared. Further, after that, when the count reaches the main set value, as shown in FIG. 9, the processing unit 7p outputs the end command signal Ec and gives the alarm command signal Ea related to the main alarm to the alarm 7a. . Thereby, the controller 16 performs a predetermined end process and outputs a main warning from the alarm 7a (steps S27, S28, S29). Therefore, the operator can quickly replace the reel 2 with a new one (Steps S30 and S31). Note that the count number is reset by the termination process.

Thus, the encoder mechanism 7e that outputs the encoder signal Pe corresponding to the rotation amount of the reel 2, and the rotation amount of the reel 2 obtained based on the encoder signal Pe, and the electrode wound around the reel 2 from the obtained rotation amount When the remaining amount of the material R is obtained and the remaining amount monitoring device 7 having the processing unit 7p for performing a predetermined process is provided when the remaining amount reaches one or more preset set values, the reel 2 can be provided. Since it is possible to know the remaining amount of the wound electrode material R more accurately, it is possible to accurately know the end time of the electrode material R, an arbitrary time before the end of the electrode material R, and the like, and reduce waste of the electrode material R. be able to.

Next, an outline of a method for assembling the solar panel 1 including a method for using the manufactured electrode will be described according to a flowchart shown in FIG. 3 with reference to FIGS. 10 and 11.

First, the panel body 73 is set at a predetermined position (step S41). As described above, the panel body 73 has a size of 1.0 × 1.5 [m] in which the semiconductor thin film 71 to be a solar cell is formed on the surface of the glass substrate 72, and is manufactured in advance in a separate manufacturing process. Is done. And silver paste J ... is apply | coated to the semiconductor thin film 71 of the set panel body 73 by the paste application | coating apparatus which abbreviate | omitted illustration at fixed intervals (step S42, S43). In this case, the silver paste J ... applies one electrode Ro along the long side edge on one side of the panel body 73 (steps S42 and S43). In the case of illustration, the interval between the silver pastes J to be applied is 25 [mm].

Next, the electrode Ro manufactured in the above-described electrode manufacturing process (step S1m), that is, the electrode Ro manufactured in steps So to S11 shown in FIG. 1 and extracted by the adsorption extraction mechanism 15 in step S11, Under the control of the moving mechanism 45 in the adsorption / removal mechanism 15, it is placed on the silver paste J ... in the panel body 73 along the silver paste J ... (step S44). Thereafter, the electrode Ro is temporarily fixed on the panel body 73 by applying a fixed tape T... Of a predetermined length along the electrode Ro at regular intervals by a tape applying device (not shown) (steps S45 and S46). ). This state is shown in FIGS. Since the mounting of one (positive electrode side) electrode Ro (Roa) is completed through the above steps, the other (negative electrode side) electrode Ro (Rob) is then mounted in the same manner (steps S47, S42...). Thereby, the solar panel base body 74 can be obtained.

If the solar panel substrate 74 is obtained, the output circuit 75 described above is assembled (step S48). When all the assembly of the output circuit 75 is completed, at least one entire surface of the solar panel base 74 including the output circuit 75 is laminated by a laminating process (step S49). Thereby, the target solar panel 70 is obtained. Furthermore, when the solar panel 70 is continuously assembled, the next panel body 73 is set at a predetermined position, and the solar panel 70 is manufactured by the same procedure (steps S50, S41...).

If the electrode Ro manufactured by the manufacturing method and apparatus 1 according to the present embodiment is applied to an electrode using a copper foil connected to the semiconductor thin film 71 of the solar panel 70, the linear accuracy in the longitudinal direction of the electrode Ro There is an advantage that the most desirable performance can be obtained from the viewpoint of ensuring.

Next, the manufacturing apparatus 1 which concerns on the modified embodiment of this invention is demonstrated with reference to FIG.13 and FIG.14.

The modified embodiment shown in FIG. 13 shows an example in which a separate option unit 51 is disposed between the brake roller mechanism 4 and the drawing roller mechanism 3. As the option unit 51, a heat treatment unit that makes it easier to correct by heat-treating the conveyed electrode material R, or a surface treatment (cleaning treatment) on the lower surface of the electrode material R being conveyed by plasma treatment. By doing so, a plasma processing unit or the like for improving adhesion (adhesiveness) can be applied. In FIG. 13, the same parts as those in FIG. 6 are denoted by the same reference numerals to clarify the configuration, and detailed description thereof is omitted.

14 shows an example in which the position of the brake roller mechanism 4 in the transport direction can be changed (adjusted). In this case, the brake roller mechanism 4 is disposed on a slider 53 that can move along the rail portion 52, and the slider 53 can be fixed at an arbitrary position on the rail portion 52 or a predetermined selectable position. Yes, the distance Lp between the drawing roller mechanism 3 and the brake roller mechanism 4 can be easily changed. Therefore, it can be easily optimized in response to changes in the electrode material R or environmental changes. FIG. 14 shows an example in which the tension applying unit 32 is directly coupled to the rotating shaft of the lower roller 4d. In FIG. 14, the same components as those in FIG. 6 are denoted by the same reference numerals to clarify the configuration, and detailed description thereof is omitted.

The preferred embodiment (modified embodiment) has been described in detail above, but the present invention is not limited to such an embodiment, and the present invention is not limited to the detailed configuration, shape, material, quantity, numerical value, and method. Changes, additions and deletions can be made arbitrarily without departing from the scope of the invention. For example, although the electrode using the copper foil connected to the semiconductor thin film 71 of the solar panel 70 is illustrated as the electrode Ro, the material or form (shape) other than the copper foil is not excluded. Further, the moving chuck mechanism 6 is not necessarily provided, and may be configured such that the electrode material R (electrode Ro) fed from the drawing roller mechanism 3 is accommodated in a tray or the like as it is. Furthermore, although the case where the reel 2 is mounted on the rotation support shaft 11s in the reel loading unit 11 of the machine body 10 is illustrated, the reel 2 is housed inside the cassette and is cassette-type with respect to the reel loading unit 11 of the machine body 10. The reel 2 may be exchanged more easily, and there is an advantage that a part of the guide roller in the transport mechanism unit 12 can be omitted.

The method and apparatus for manufacturing an electrode using a sheet-shaped wire according to the present invention can be used for manufacturing an electrode obtained by cutting the electrode material fed from a reel wound with an electrode material into a predetermined length. It can be applied to electrodes of various products including solar panels.

1: Electrode manufacturing apparatus, 2: reel, 3: drawer roller mechanism, 4: brake roller mechanism, 5: cutting mechanism, 6: moving chuck mechanism, 7: remaining amount monitoring device, 7e: encoder mechanism, 7p: processing unit , 70: Solar panel, 71: Semiconductor thin film, R: Electrode material, Ro: Electrode, F1: First tensile force, F2: Second tensile force, F3: Third tensile force, Df: Transport direction, Dr : Reverse direction, Lp: Interval, Pe: Encoder signal

Claims (8)

  In the method of manufacturing an electrode with a sheet-like wire rod comprising a reel wound with an electrode material with a sheet-like wire rod, feeding out the electrode material from this reel, and cutting the fed-out electrode material to produce an electrode of a predetermined length, The electrode material fed from the reel is pulled in the transport direction by a first pulling force by a pulling roller mechanism, and the electrode material is made smaller than the first pulling force by a brake roller mechanism arranged between the pulling roller mechanism and the reel. A sheet shape characterized by tensioning in a direction opposite to the conveyance direction by a second tensile force and cutting an electrode material fed from the pulling roller mechanism by a cutting mechanism to obtain an electrode having a predetermined length. An electrode manufacturing method using a wire.   The said electrode is an electrode using the copper foil connected to the semiconductor thin film of a solar panel, The manufacturing method of the electrode by the sheet-like wire rod of Claim 1 characterized by the above-mentioned.   The method for manufacturing an electrode using a sheet-like wire according to claim 1 or 2, wherein an interval between the drawing roller mechanism and the brake roller mechanism is set corresponding to the electrode material.   4. The electrode material delivered from the pull-out roller mechanism is held by a moving chuck mechanism and pulled in the transport direction by a third tensile force smaller than the second tensile force. Manufacturing method of electrode by sheet-like wire rod.   In an apparatus for manufacturing an electrode using a sheet-like wire rod that cuts the electrode material fed from a reel wound with the electrode material made of a sheet-like wire rod to produce an electrode of a predetermined length, the electrode material fed out from the reel is first pulled. A pulling roller mechanism that pulls in the transport direction by a force, and the electrode material is placed opposite to the transport direction by a second pulling force that is smaller than the first pulling force by arranging between the pulling roller mechanism and the reel. An apparatus for manufacturing an electrode using a sheet-like wire rod, comprising: a brake roller mechanism that tensions in a direction; and a cutting mechanism that cuts an electrode material fed from the drawing roller mechanism to obtain an electrode having a predetermined length .   The said electrode is an electrode using the copper foil connected to the semiconductor thin film of a solar panel, The manufacturing apparatus of the electrode by the sheet-like wire rod of Claim 5 characterized by the above-mentioned.   The sheet-like wire rod according to claim 5 or 6, further comprising a moving chuck mechanism that pulls the electrode material fed from the pulling roller mechanism in a transport direction by a third tensile force smaller than the second tensile force. Electrode manufacturing equipment by.   An encoder mechanism that outputs an encoder signal corresponding to the amount of rotation of the reel, and obtains the amount of rotation of the reel based on the encoder signal, and obtains the remaining amount of electrode material wound around the reel from the obtained amount of rotation The sheet-like wire according to claim 5, further comprising a remaining amount monitoring device having a processing unit that performs a predetermined process when the remaining amount reaches one or more preset set values. Electrode manufacturing equipment.

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