JP2012030381A - Laminating device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminating device that improves a maintenance property by suppressing the height of the device, reduces the cost and prevents deterioration in quality of a body to be laminated.SOLUTION: The laminating device 1 forms upper and lower chambers using upper an lower cases to which diaphragms are mounted, in which the insides are partitioned by the diaphragms, heats the body to be laminated and provides a plurality of laminating parts 2, 3 in a vertical direction which executes lamination work by pressing the body to be laminated by the diaphragms. The upper case 22 of the laminating part 2 and the lower case 31 of the laminating part 3 are integrally constituted. The device includes an endless sheet 101 passing through the lower side of the upper case 22 and the upper side of the lower case 31.

Description

  The present invention relates to a laminating apparatus for a solar cell module.

  As a laminating apparatus for manufacturing a solar cell panel, a configuration including an upper chamber having a diaphragm that is expandable downward and a lower chamber having a heater plate is known (see, for example, Patent Document 1). The upper and lower chambers are sealed and evacuated (depressurized) with the object to be laminated placed on the heater plate, and then the object to be laminated is heated to melt the resin as the filler, and the atmosphere in the upper chamber Thus, the solar cell module is laminated by sandwiching the object to be laminated between the upper surface of the heater plate and the diaphragm.

  In recent years, a multi-stage laminating apparatus including a plurality of heater plates has been used to improve throughput.

  As a multistage laminating apparatus, for example, a configuration in which a plurality of laminating units perform a laminating process independently of each other has been proposed (see, for example, Patent Document 2). However, in such a configuration, since the release sheet for preventing the resin from adhering to the diaphragm is provided in each stage, the height of the laminate portion and the height of the entire apparatus are increased, and maintenance such as sheet replacement is performed. There was a problem that became difficult. There is also a problem that the apparatus cost increases.

  Further, a multi-stage laminating press for laminating by a hot double belt press method is known (see, for example, Patent Document 3). This allows the conveyor belt portion of the conveyor belt to function as a diaphragm, improving process efficiency and reducing the cost of diaphragm replacement. However, because Teflon (registered trademark) is used for the conveyor belt of the conveyor belt, it does not have the stretchability and followability required for the diaphragm of the laminating device, and the laminated body (especially near the four corners of the laminated body) There was a risk that wrinkles could occur due to the inability to press down. Generation | occurrence | production of wrinkles had the problem of reducing the quality of a to-be-laminated body (solar cell module).

Utility Model Registration No. 3017231 Patent No. 4209458 specification JP 2008-296280 A

  SUMMARY OF THE INVENTION An object of the present invention is to provide a laminating apparatus that suppresses the height of the apparatus, improves maintainability, reduces costs, and prevents the quality of the object to be laminated from deteriorating.

  A laminating apparatus according to one aspect of the present invention includes an upper case to which a diaphragm that is expandable downward is attached, and a lower case having an inner space with an open upper surface, the upper case and the lower case being A laminating apparatus comprising a plurality of laminating portions in the vertical direction for forming an upper and lower chamber partitioned by the diaphragm, heating the object to be laminated, and narrowing the object to be laminated by the diaphragm. The upper case of the first laminate part and the lower case of the second laminate part provided in the upper stage of the first laminate part are integrally configured, and the lower side of the upper case of the first laminate part and An endless sheet passing through the upper side of the lower case of the second laminate portion is provided.

  In the laminating apparatus according to one aspect of the present invention, the sheet is positioned between the laminated body and the diaphragm in the first laminating section, and the laminated body is conveyed in the second laminating section. Is preferred.

  In the laminating apparatus according to an aspect of the present invention, it is preferable that the laminating apparatus further includes a removing unit that removes filler soot adhering to the sheet.

  In the laminating apparatus according to one aspect of the present invention, the laminating unit is moved up and down to a position corresponding to the laminating unit opened and closed by the opening and closing unit, and the laminated body is carried into the laminating unit. It is preferable to further include a carry-in portion that carries out and a carry-out portion that moves up and down to a position corresponding to the laminate portion that is opened and closed by the opening and closing portion and carries out the object to be laminated from the laminate portion.

  In the laminating apparatus according to the aspect of the present invention, it is preferable that the second laminating unit further includes a release sheet positioned between the object to be laminated and the diaphragm.

  According to the present invention, it is possible to suppress the height of the apparatus, improve the maintainability, reduce the cost, and prevent the deterioration of the quality of the laminate.

It is a top view of the laminating apparatus concerning the embodiment of the present invention. It is a side view of the laminating apparatus which concerns on the same embodiment. It is a schematic sectional drawing of a laminate part. It is a schematic block diagram of a peeling sheet supply part.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 and 2 show a schematic configuration of a laminating apparatus according to an embodiment of the present invention. 1 is a plan view, and FIG. 2 is a side view. A laminating apparatus 1 includes a plurality of laminating units 2 and 3, an opening and closing unit 4 that opens and closes each laminating unit 2 and 3, and a solar cell module that performs laminating processing on each laminating unit 2 and 3 (hereinafter referred to as a module). A carry-in unit 5 for carrying in, and a carry-out unit 6 for carrying out the laminated module from the respective laminate units 2 and 3 are provided. The laminate parts 2 and 3 are arranged in a horizontal state parallel to the upper surface of the base 7. Laminate portions 2 and 3 are stacked in the vertical direction. Laminate portion 2 is a lower laminate portion and laminate portion 3 is an upper laminate portion.

  The opening / closing part 4 is provided on the front side and the back side (front side and rear side in FIG. 2) of the base 7. The opening / closing part 4 can open and close any laminate part among the plurality of laminate parts 2 and 3.

  The carry-in unit 5 includes support columns 51 and 52 and a lifting device 53 provided between the support columns 51 and 52. The elevating device 53 receives and places the module before lamination processing that has been conveyed by a supply conveyor (not shown), moves up and down according to the laminating units 2 and 3 opened by the opening / closing unit 4, and carries it in.

  The module that the carry-in unit 5 carries into each of the laminate units 2 and 3 includes, for example, a transparent cover glass disposed on the lower side and a protective material disposed on the upper side, and between the cover glass and the protective material. It has a configuration in which a string is sandwiched through a filler. The string has a configuration in which a plurality of solar cells are connected between two electrodes via lead wires. As the protective material, for example, a transparent material such as PE resin is used. As the filler, for example, ethylene vinyl acetate resin or the like is used.

  The carry-out unit 6 includes support columns 61 and 62 and a lifting device 63 provided between the support column 61 and the support column 62. The elevating device 63 moves up and down in accordance with the laminating units 2 and 3 opened by the opening / closing unit 4, and receives and places the module after laminating processing from the laminating units 2 and 3. And the raising / lowering apparatus 63 carries out the module after a lamination process to the carrying-out conveyor which is not shown in figure.

  Next, the structure of the lamination parts 2 and 3 is demonstrated using the schematic sectional drawing shown in FIG. Here, a state where the laminate parts 2 and 3 are opened is shown.

  First, the laminate part 2 will be described. The laminate unit 2 includes a lower case 21 and an upper case 22. The lower case 21 is formed with a lower chamber 23 that is a space opened upward. The lower chamber 23 is provided with a heater plate 24 for heating the module along the horizontal direction so as to close the opening. The heater plate 24 is provided with a heater inside a metal plate made of, for example, aluminum. A heat insulating support member 24 a that supports the heater plate 24 is provided between the heater plate 24 and the inner wall bottom surface of the lower case 21. Further, an intake / exhaust port (not shown) for evacuating the lower chamber 23 is provided on the side surface of the lower case 21.

  The lower case 21 is provided with a conveyance sheet 25 for loading and unloading a module. The conveying sheet 25 moves so as to circulate by the driving pulley P1, the driven pulleys P2 to P4, and the chain wound between the driving pulley P1 and the driven pulleys P2 to P4. The conveyance sheet 25 is configured to pass through the upper side and the lower side of the lower case 21. Moreover, the conveyance sheet 25 is formed in an endless shape, that is, endless. For example, a heat-resistant glass cloth sheet coated with a fluororesin can be used as the transport sheet 25.

  In the vicinity of the driven pulley P <b> 3, a removing unit C <b> 1 that scrapes and removes the filler or the like attached to the surface of the conveyance sheet 25 is provided so as to contact the surface of the conveyance sheet 25. The removal part C1 is comprised with a nylon brush, for example. The removal portion C1 can be moved in an oblique direction by a cylinder or the like.

  The conveyance sheet 25 receives the module from the carry-in unit 5 and conveys the module to the central portion of the heater plate 24 or delivers the module to the carry-out unit 6.

  A diaphragm 27 is attached to the upper case 22 so as to horizontally divide the lower surface of the internal space. The space surrounded by the diaphragm 27 and the inner wall surface of the upper case 22 constitutes the upper chamber 28. For the diaphragm 27, a silicon-based material or a butyl-based material can be used.

  An intake / exhaust port (not shown) is provided on the side surface of the upper case 22 so as to communicate with the upper chamber 28. The upper chamber 28 can be evacuated or the atmosphere can be introduced into the upper chamber 28 through the intake / exhaust port.

The upper case 22 is configured integrally with a lower case 31 of a laminate part 3 described later.
The upper case 22 is provided with a sheet 101. The sheet 101 is a release sheet for preventing the module filler melted in the laminating process from adhering to the diaphragm 27.

  The seat 101 moves in a circulating manner by the driving pulley P11, the driven pulleys P12 to P14, and the chain wound between the driving pulley P1 and the driven pulleys P12 to P14. The sheet 101 is configured to pass through the lower side of the upper case 22 and the upper side of the lower case 31 of the laminate unit 3. The sheet 101 is endless, that is, endless.

  The sheet 101 in the laminating unit 3 has the same role as the transport sheet 25 in the laminating unit 2. In the laminating unit 3, the sheet 101 receives a module from the carry-in unit 5 and delivers the module to the carry-out unit 6.

  That is, the sheet 101 is a release sheet for the lower laminate section and a conveying sheet for the upper laminate section. As the sheet 101, for example, a heat-resistant glass cloth sheet coated with a fluororesin can be used.

  For example, the sheet 101 can be composed of two sheets fixed at both ends with a belt pressing bar and connected with a chain. When one sheet functions as a release sheet in the laminate unit 2, the other sheet functions as a transport sheet in the laminate unit 3.

  In the vicinity of the driving pulley P <b> 11, a removing unit C <b> 2 that scrapes off and removes the filler adhering to the surface of the sheet 101 is provided so as to contact the surface of the sheet 101. Similarly, in the vicinity of the driven pulley P <b> 13, a removing unit C <b> 3 that scrapes and removes the filler or the like attached to the surface of the sheet 101 is provided so as to contact the surface of the sheet 101. The removal parts C2 and C3 are made of nylon brushes, for example. The removal portions C2 and C3 can be moved in an oblique direction by a cylinder or the like.

  By laminating the upper case 22 so as to be placed on the lower case 21, the laminate portion 2 composed of the upper chamber 28 and the lower chamber 23 can be closed and sealed. On the other hand, by raising the upper case 22 from the sealed state, the laminate part 2 composed of the upper chamber 28 and the lower chamber 23 can be opened.

  Next, the laminate part 3 will be described. The laminate unit 3 has a lower case 31 and an upper case 32. The lower case 31 is configured integrally with the upper case 22 of the laminate unit 2. The lower case 31 is formed with a lower chamber 33 that is a space opened upward. A heater plate 34 for heating the module is provided in the lower chamber 33 along the horizontal direction so as to close the opening. The heater plate 34 is provided with a heater inside an aluminum metal plate, for example. A heat insulating support member 34 a that supports the heater plate 34 is provided between the heater plate 34 and the bottom surface of the inner wall of the lower case 31. An intake / exhaust port (not shown) for evacuating the lower chamber 33 is provided on the side surface of the lower case 31.

  The lower case 31 is provided with a sheet 101 for loading and unloading a module. As described above, the sheet 101 is configured to pass through the lower side of the upper case 22 and the upper side of the lower case 31 of the laminate unit 3, and functions as a release sheet in the laminate unit 2. Functions as a conveyance sheet. The sheet 101 receives the module from the carry-in unit 5 and conveys the module to the central portion of the heater plate 34 or delivers the module to the carry-out unit 6.

  A diaphragm 37 is attached to the upper case 32 so as to horizontally divide the lower surface of the internal space. The space surrounded by the diaphragm 37 and the inner wall surface of the upper case 32 constitutes the upper chamber 38. For the diaphragm 37, a silicon-based material or a butyl-based material can be used.

  An intake / exhaust port (not shown) is provided on the side surface of the upper case 32 so as to communicate with the upper chamber 38. The upper chamber 38 can be evacuated or the atmosphere can be introduced into the upper chamber 38 through the intake / exhaust port.

  By laminating the upper case 32 so as to be placed on the lower case 31, the laminate portion 3 composed of the upper chamber 38 and the lower chamber 33 can be closed and sealed. On the other hand, by raising the upper case 32 from the sealed state, the laminate part 3 composed of the upper chamber 38 and the lower chamber 33 can be opened.

  A release sheet 111 supplied by a release sheet supply unit 110 described below can enter between the upper case 32 and the lower case 31. The release sheet 111 is a sheet for preventing the module filler melted in the laminating process from adhering to the diaphragm 37. As the release sheet 111, for example, a heat-resistant glass cloth sheet coated with a fluororesin can be used.

  As shown in FIG. 4, in the release sheet supply unit 110, rotating rolls 112 and 113 are disposed on both ends of the release sheet 111, respectively. When the rotating roll 112 rotates counterclockwise in FIG. 4, the release sheet 111 can be moved in the right direction 114 in the drawing. Further, the rotating roll 113 rotates clockwise in FIG. 4 so that the release sheet 111 can be moved in the left direction 115 in the figure. Thus, by rotating one of the rotating rolls 112 and 113, the release sheet 111 can be moved in a desired direction.

  A guide roll 116 is rotatably disposed below the rotary roll 112, and the release sheet 111 is wound around the rotary roll 112 after changing its direction along the circumferential surface of the guide roll 116. The release sheet 111 fed out from the rotary roll 112 is wound around the rotary roll 113 after changing its direction horizontally along the peripheral surface of the guide roll 116. By disposing the rotating roll 113 and the guide roll 116 at the same height on the left and right outer sides of the laminate unit 3, the release sheet 111 is supplied in a horizontal posture between the upper case 32 and the lower case 31.

  Further, the removing roll 117 is disposed so as to contact the lower surface side of the release sheet 111 that moves between the guide roll 116 and the rotating roll 113. This removal roll 117 can scrape off the filler adhering to the lower surface side of the release sheet 111, and is made of, for example, a nylon brush.

  As described above, the release sheet of the laminating unit 2 and the conveying sheet of the laminating unit 3 are connected and the endless (endless) sheet 101 is provided. Compared with the case where a conveyance sheet is provided separately, the height of the laminating units 2 and 3 and the overall height of the laminating apparatus 1 can be reduced. Therefore, it is possible to improve maintainability such as sheet exchange and reduce the apparatus cost.

  Next, a method for laminating a module using such a laminating apparatus 1 will be described.

  First, the carry-in unit 5 carries in a module for performing a laminating process into the laminate units 2 and 3. Note that the laminating units 2 and 3 are opened by the opening / closing unit 4 before the module is loaded.

  When the module is carried into the laminating units 2 and 3, the conveyance sheet 25 and the sheet 101 convey the module to the central portions of the heater plates 24 and 34.

  Next, the opening / closing part 4 seals the laminate parts 2 and 3.

  Subsequently, the upper chamber 28, the lower chamber 23, the upper chamber 38, and the lower chamber 33 are evacuated to, for example, 0.7 to 1.0 Torr through the intake and exhaust ports of the laminate portions 2 and 3, respectively. By this evacuation, the inside of the module is deaerated. The module is heated by the heater plates 24 and 34. The heater plates 24 and 34 are heated at a temperature of about 150 ° C., for example. By heating, the chemical reaction (melting) of the filler in the module is promoted and crosslinking is performed. In this state, the atmosphere is introduced into the upper chambers 28 and 38 through the intake / exhaust ports to bring the upper chambers 28 and 38 to atmospheric pressure, whereby the diaphragms 27 and 37 expand downward. Thereby, the module is narrowed between the heater plates 24 and 34 and the diaphragms 27 and 37. A sheet 101 and a release sheet 111 are sandwiched between the module and the diaphragms 27 and 37.

  The diaphragms 27 and 37 are configured using a silicon-based material or a butyl-based material, and have stretchability and followability. Therefore, the module can be reliably pressed, wrinkles can be suppressed, and quality degradation can be prevented.

  When the laminating process by heating and narrow pressure is completed, the atmosphere is introduced into the lower chambers 23 and 33 through the intake and exhaust ports. Moreover, the laminate parts 2 and 3 are opened.

  The conveyance sheet 25 and the sheet 101 deliver the module to the carry-out unit 6. The carry-out unit 6 carries out the laminated module. The filler soot adhering to the transport sheet 25, the sheet 101, and the release sheet 111 is removed by the removal units C <b> 1 to C <b> 3 and the removal roll 117.

  As described above, according to the present embodiment, the release sheet of the laminate unit 2 is connected to the transport sheet of the laminate unit 3, and the release sheet of the laminate unit 2 is provided by providing the endless sheet 101. And compared with the case where the conveyance sheet | seat of the lamination part 3 is provided separately, the height of the lamination parts 2 and 3 and the height of the lamination apparatus 1 whole can be made low. Therefore, it is possible to improve maintainability such as sheet exchange and reduce the apparatus cost.

  In addition, by reliably pressing the modules with the diaphragms 27 and 37 to prevent the generation of wrinkles, it is possible to prevent deterioration of the quality of the laminated module.

  In the above-described embodiment, an example in which the laminating units 2 and 3 perform the laminating process at the same time has been described. However, while the laminating unit 3 performs the laminating process, the module is operated independently such as loading a module into the laminating unit 2. Also good.

  Moreover, in the said embodiment, the peeling sheet 111 of the laminate part 3 is good also as what was formed in the endless form (endless) which passes the upper side and lower side of the upper case 32. FIG.

  Moreover, although the example which provided two laminate parts was demonstrated in the said embodiment, the number of laminate parts may be three or more. Even in the case where three or more layers of laminate parts are provided, the upper case and the lower case of the lower laminate part are integrally formed in the upper and lower laminated parts, and the release sheet of the lower laminate part The conveyance sheet of the upper laminate part is connected and formed in an endless shape (endless).

  Therefore, the height of the laminating unit and the entire laminating apparatus can be reduced compared to the case where the release sheet of the lower laminating unit and the conveying sheet of the upper laminating unit are provided separately, such as sheet replacement The maintenance cost can be improved and the device cost can be reduced.

  Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying the constituent elements without departing from the scope of the invention in the implementation stage. In addition, various inventions can be formed by appropriately combining a plurality of components disclosed in the embodiment. For example, some components may be deleted from all the components shown in the embodiment. Furthermore, constituent elements over different embodiments may be appropriately combined.

DESCRIPTION OF SYMBOLS 1 Laminating apparatus 2, 3 Laminating part 4 Opening / closing part 5 Carry-in part 6 Carry-out part 7 Base 21 Lower case 22 Upper case 23 Lower chamber 24 Heater plate 25 Conveying sheet 27 Diaphragm 28 Upper chamber 31 Lower case 32 Upper case 33 Lower chamber 34 Heater plate 37 Diaphragm 38 Upper chamber 101 Sheet 110 Release sheet supply unit 111 Release sheet 112, 113 Rotating roll 116 Guide roll 117 Removal roll

Claims (5)

It has an upper case to which a diaphragm that is expandable downward is attached, and a lower case having an internal space whose upper surface is open, and is partitioned by the diaphragm using the upper case and the lower case. A laminating apparatus comprising a plurality of laminating portions in the vertical direction for forming upper and lower chambers, heating the object to be laminated, and narrowing the object to be laminated by the diaphragm.
The upper case of the first laminate part and the lower case of the second laminate part provided in the upper stage of the first laminate part are integrally configured,
A laminating apparatus comprising: an endless sheet passing through a lower side of the upper case of the first laminating unit and an upper side of the lower case of the second laminating unit.   2. The laminate according to claim 1, wherein the sheet is positioned between the object to be laminated and the diaphragm in the first laminating part, and the object to be laminated is conveyed in the second laminating part. apparatus.   The laminating apparatus according to claim 1, further comprising a removing unit that removes filler soot adhering to the sheet. An opening and closing portion for opening and closing the plurality of laminate portions;
Raising and lowering to a position corresponding to the laminating part opened and closed by the opening and closing part, a carry-in part for carrying the laminated body into the laminating part,
Elevating and lowering to a position corresponding to the laminate part opened and closed by the opening and closing part, a carry-out part for carrying out the laminated body from the laminate part,
The laminating apparatus according to any one of claims 1 to 3, further comprising:   The laminating apparatus according to any one of claims 1 to 4, wherein the second laminating unit further includes a release sheet positioned between the object to be laminated and the diaphragm.

Images