JP2012038940A - Solar cell module manufacturing apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar cell module manufacturing apparatus which prevents filler flowed from an area between a transparency board and a weatherability board from attaching to the rollers for transferring a laminate assembly.SOLUTION: The solar cell module manufacturing apparatus comprises: a laminator 1 for forming a laminate assembly 3 by sealing a solar cell array with a filler 5 between a glass 4 and a back seat 6; a conveyor 2 for transferring the laminate assembly 3 by rotation of a plurality of rollers 8 where the laminate assembly 3 is loaded; a sensor 7 for detecting the laminate assembly 3 discharged from the laminator 1; and a control part 20 for evacuating the rollers 8 downward which the filler 5 flowed from an area between the glass 4 of the in-transferring laminate assembly 3 and the back seat 6 approaches and for returning the evacuated rollers 8 to the original position after the flowed filler 5 passes, based on the output of the sensor 7.

Description

  The present invention relates to a solar cell module manufacturing apparatus for manufacturing a solar cell module configured by connecting a plurality of solar cells.

  A conventional method for manufacturing a solar cell module is disclosed in Patent Document 1, for example. In a laminating apparatus (laminator) that includes an upper chamber and a lower chamber that are partitioned by a diaphragm and that has a conveyor belt that conveys a workpiece, and that performs laminating, which is a process of manufacturing a solar cell module, At least one or more types of scrapers provided outside so as to be in contact with the belt conveying surface for conveyance, and a brush roll provided so as to be in contact with the conveying surface of the conveying belt and driven by a rotary actuator. By setting it as such a structure, it laminates so that the filler adhering to the conveyance belt in a laminator may be removed, and it may not adhere to a module glass surface.

JP 2004-238196 A, (0027-0043, FIG. 1, FIG. 2)

  In the process of manufacturing a solar cell module, when laminating with a laminator, the filler protruding from the module glass surface adheres to the conveyor that is transported to the next process after the lamination is completed, and the filler adhered to the conveyor is the module glass. There was a problem of adhering to the surface.

  In other words, the conventional solar cell module manufacturing method described above is to remove the filler adhering to the conveyor belt in the laminator, but it is insufficient to prevent the filler from adhering to the module glass. .

  The present invention has been made in view of the above, and a filler that protrudes from between a transparent substrate and a weather-resistant substrate during lamination is applied to a roller that conveys a laminated assembly (laminated body) after lamination. It aims at obtaining the solar cell module manufacturing apparatus which does not adhere.

  In order to solve the above-mentioned problems and achieve the object, the present invention provides a laminator for forming a laminate assembly by sealing a solar cell array with a filler between a light-transmitting substrate and a weather-resistant substrate, and a laminator. A plurality of rollers on which the laminate assembly discharged from the apparatus is placed, a conveyor that conveys the laminate assembly by rotation of the plurality of rollers, a sensor that detects the laminate assembly discharged from the laminator, and an output of the sensor The roller approaching the filler protruding from between the translucent substrate and the weatherproof substrate of the laminate assembly being conveyed is retracted downward, and the original position after the filler protruding from the retracted roller has passed And a means for returning to.

  According to the present invention, it is possible to prevent the filler from adhering to the module glass surface by preventing the filler from adhering to the conveyor conveyed to the next process after the completion of the lamination. There is an effect that a defect can be prevented.

FIG. 1 is a top view showing the configuration of the main part of the solar cell module manufacturing apparatus according to Embodiment 1. FIG. FIG. 2 is a side view showing the configuration of the main part of the solar cell module manufacturing apparatus according to Embodiment 1. FIG. 3 is an exploded perspective view of the main part showing the laminated structure of the laminated assembly. FIG. 4 is a perspective view showing a process of attaching a frame around the laminate assembly. FIG. 5 is a view showing a state where the laminated assembly after lamination is viewed from the glass side. FIG. 6 is a cross-sectional view of the laminated assembly after being laminated as seen from the side. FIG. 7 is a diagram illustrating a state where the filler is attached to the roller of the conveyor. FIG. 8 is a diagram showing the configuration of the conveyor. FIG. 9 is a diagram illustrating a specific example of the movement of the roller according to the output of the sensor. FIG. 10 is a top view showing the configuration of the main part of the solar cell module manufacturing apparatus according to Embodiment 2. FIG. 11 is a side view showing the operation of the solar cell module manufacturing apparatus according to Embodiment 2.

  Embodiments of a solar cell module manufacturing apparatus according to the present invention will be described below in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

Embodiment 1 FIG.
FIG. 1 is a top view showing a configuration of a main part of the solar cell module manufacturing apparatus according to Embodiment 1 of the present invention. FIG. 2 is a side view showing the configuration of the main part of the solar cell module manufacturing apparatus according to Embodiment 1. The solar cell module manufacturing apparatus according to the present embodiment includes a laminator 1 and a conveyor 2 that conveys the laminate assembly 3 laminated in the laminator 1 to the next process.

  FIG. 3 is an exploded perspective view of the main part showing the laminated structure of the laminate assembly 3. As shown in FIG. 3, the laminate constituting the main part of the laminate assembly 3 includes a glass 4 as a light-transmitting substrate formed of a transparent material, a light-receiving surface sealing material 5a formed of a transparent resin, and a grid pattern. Solar cell array 13 provided with a plurality of solar cells 11 arranged in a line and lead wires 12 connecting them in series, back side sealing material 5b formed of transparent resin, and back sheet as a weather-resistant substrate 6 are laminated in this order from the light receiving surface side. Each layer is bonded by heat treatment in the laminator 1 and integrated as a laminate. The light-receiving surface side sealing material 5a and the back surface side sealing material 5b are fillers 5, which are integrated by heat treatment, and the solar cell array 13 is resin-sealed to form a resin sealing layer. In FIG. 3, the glass 4, the filler 5, and the back sheet 6 are substantially the same size, but the back sheet 6 is slightly larger than the glass 4, and the filler 5 is also larger than the glass 4. Is also slightly larger. In the process after being discharged from the laminator 1 as the laminate assembly 3, it is cut into the same shape as the glass 4.

  The filler 5 is typically ethylene vinyl acetate copolymer resin (EVA), and the solar cell array 13, the glass 4, and the back sheet 6 are bonded by heating and pressurizing.

  The laminated assembly 3 laminated by the laminator 1 is conveyed toward a curing furnace (not shown) for bridging the filler 5 by the conveyor 2 so as to be cut and arranged in substantially the same shape as the glass 4, and after leaving the curing furnace to the cutting device. It is conveyed toward.

  FIG. 4 is a perspective view showing a step of attaching a frame to the periphery of the laminate assembly 3 cut into the same shape as the glass 4 in the step of assembling the solar cell module. In FIG. 4, the solar cell module includes a laminate assembly 3 having a substantially rectangular flat plate shape, and a rectangular frame-shaped frame 80 that surrounds the outer edge of the laminate assembly 3 over the entire circumference and supports the laminate assembly 3 from a fixing bracket or the like. The frame 80 includes a first frame 80A and a third frame 80C that cover two opposing long sides, a second frame 80B and a fourth frame 80D that cover two opposing short sides, and a second frame 80B on the back side of the laminate assembly 3. A reinforcing frame 80G is provided between the first frame 80A and the third frame 80C. Note that the configuration may be such that the reinforcing frame 80G is omitted. Of course, although not shown, a terminal BOX (also including a cable and a connector) for taking out the output is attached before attaching the frame.

  As described above, the laminated assembly 3 after lamination is transported to a curing furnace (not shown) by the conveyor 2, and the laminated assembly 3 after lamination has a back sheet 6 with a filler 5 protruding from the glass 4. It is in a state of sticking to. FIG. 5 is a view showing a state where the laminated assembly 3 after lamination is viewed from the glass 4 side. FIG. 6 is a cross-sectional view of the laminated assembly 3 after lamination as viewed from the side.

  FIG. 7 is a diagram illustrating a phenomenon in which the filler 5 adheres to the conveyor 2. When the unfilled filler 5 comes into contact with the conveyor 2, the filler 5 adheres to the rollers 8 of the conveyor 2 as shown in FIG. 7.

  FIG. 8 is a diagram illustrating a configuration of the conveyor 2. A sensor 7 for detecting the laminate assembly 3 is installed in the vicinity of the exit of the laminator 1. The roller 8 is configured to be moved up and down by the control unit 20 according to the output of the sensor 7, and the roller 8 moved downward is not in contact with the laminate assembly 3 being conveyed. That is, each of the rollers 8 is retracted downward to a position where it does not come into contact with the laminate assembly 3 being conveyed according to the output of the sensor 7.

  The controller 20 detects the laminate assembly 3 with the sensor 7 and moves the rollers 8 up and down so that the rollers 8 of the conveyor 2 do not come into contact with the filler 5. Even if each of the rollers 8 moves up and down, the position in the transport direction (the distance in the transport direction from the laminator 1) does not change. In order to prevent the filler 5 from adhering to the roller 8 because the filler 5 is exposed to the lower surface of the laminate assembly 3 is the periphery of the glass 4 (a region that is the difference between the back sheet 6 and the glass 4). The roller 8 only needs to be retracted when this portion passes. By designating the dimensions of the laminate assembly 3 in advance, the control unit 20 causes the sensor 7 to start detecting the laminate assembly 3, the timing at which the sensor 7 no longer detects the laminate assembly 3, and the laminate assembly 3. Based on the conveyance speed and the dimensions of the laminate assembly 3, the timing at which the filler 5 passes through each roller 8 is predicted, and each roller 8 is moved up and down.

  FIG. 9 is a diagram illustrating a specific example of the movement of the roller 8 according to the output of the sensor 7. In addition, in order to avoid complication of drawing, illustration of the control part 20 is abbreviate | omitted in FIG. When the sensor 7 detects the leading portion of the laminate assembly 3, the controller 20 lowers the first roller 8 as shown in FIG. When the portion of the filler 5 has passed, the control unit 20 raises the first roller 8 as shown in FIG. 9B. Similarly, the controller 20 lowers the second roller 8 when the filler 5 approaches the second roller 8. If the filler 5 passes, the control part 20 will raise the 2nd roller 8 as shown in FIG.9 (c). The roller 8 is moved up and down in accordance with the conveyance speed of the laminate assembly 3 based on the detection result of the sensor 7.

  When the laminate assembly 3 passes through the sensor 7 and the sensor 7 no longer detects the laminate assembly 3, the controller 20 receives the change of the signal, and the control unit 20 receives the first change as shown in FIG. The roller 8 is lowered again so that the filler 5 protruding to the rear side in the transport direction of the laminate assembly 3 does not contact the first roller 8. And as shown in FIG.9 (e), the control part 20 raises the 1st roller 8 again at the timing which the tail part of the laminate assembly 3 passed. Similarly, with respect to the second and subsequent rollers 8, the rollers 8 are moved up and down so as to avoid the filler 5 protruding to the rear side of the laminate assembly 3 in the conveying direction.

  In order to prevent the filler 5 on the side parallel to the traveling direction of the laminate assembly 3 from contacting the roller 8 of the conveyor 2, a roller 8 having a narrower width than the glass 4 may be used for the conveyor 2. That is, the roller 8 may be installed in a range narrower than the width of the glass 4 in the direction orthogonal to the transport direction (see FIG. 1).

  As described above, in the present embodiment, the roller 8 of the conveyor 2 does not contact the filler 5, and the filler 5 does not adhere to the roller 8 of the conveyor 2. Therefore, the yield of the solar cell module can be improved.

  In the above description, each roller 8 is moved up and down based on the detection result of the sensor 7 installed in the vicinity of the exit of the laminator 1 and the conveying speed of the laminate assembly 3 as an example. The sensor 7 may be provided corresponding to the above, and the roller 8 may be moved up and down according to the detection result of each sensor 7. By providing the sensor 7 individually on the roller 8, the approach / passage of the laminate assembly 3 can be detected more accurately, and therefore the timing for moving the roller 8 up and down becomes accurate. Thereby, it can prevent more reliably that the filler 5 which has not hardened adheres to the roller 8. FIG.

Embodiment 2. FIG.
FIG. 10 is a top view showing the configuration of the solar cell module manufacturing apparatus according to Embodiment 2 of the present invention. In the figure, the same parts as those of the solar cell module manufacturing apparatus of Embodiment 1 shown in FIG. A cooling mechanism 9 is provided between the rollers 8 of the conveyor 2 after the laminator 1 for cooling the filler 5 that is not solidified. The cooling mechanism 9 includes a cooling mechanism 9a arranged along the conveying direction of the conveyor 2 and a cooling mechanism 9b arranged so as to be orthogonal to the conveying direction of the conveyor.

  FIG. 11 is a diagram illustrating the operation of the solar cell module manufacturing apparatus according to the present embodiment. As shown in FIGS. 11A to 11C, the cooling mechanism 9 b operates according to the conveying speed of the laminate assembly 3 according to the detection result of the laminate assembly 3 by the sensor 7 and protrudes from the glass 4. Only the portion of the filler 5 is cooled. That is, the cooling mechanism 9b performs a cooling operation intermittently. In this embodiment, the position of the roller 8 is fixed and does not move in the vertical direction.

  The start / end of cooling is controlled by a timer according to the conveying speed of the laminate assembly 3. The sensor 7 may be provided individually for each roller 8 of the conveyor 2 and may control the start / end of cooling in each cooling mechanism 9b. On the other hand, the cooling mechanisms 9a on both sides of the conveyor 2 continue cooling while the laminate assembly 3 flows. The reason for cooling only the filler 5 protruding from the glass 4 is to prevent the glass 4 from being warped or damaged by suddenly cooling the glass 4 and applying stress due to a temperature difference. Air 10 is used for cooling. The unfilled filler 5 is solidified by cooling and is not attached to the roller 8.

  In addition, by providing the cooling mechanism 9b on the downstream side of the first roller 8, the once solidified filler 5 is remelted by the residual heat of the laminate assembly 3 and adheres to the second and subsequent rollers 8. Can be prevented.

  Here, the configuration in which the air 10 is used for cooling the filler 5 is taken as an example, but a method other than the injection of the air 10 may be used as long as the filler 5 can be cooled without damaging the glass 4. . For example, a gas different from air may be injected, or a coolant may be injected.

  Since the solar cell module manufacturing apparatus according to the present embodiment can quickly cool the filler protruding from the glass in a non-hardened state, the filler adheres to the roller when transported to the next process after lamination. Can be prevented. Therefore, the appearance defect of the solar cell module due to the filler adhering to the roller further adhering to the glass of the laminate assembly can be prevented.

  As described above, the solar cell module manufacturing apparatus according to the present invention is useful in that the filler does not adhere to the rollers of the conveyor subsequent to the laminator.

DESCRIPTION OF SYMBOLS 1 Laminator 2 Conveyor 3 Laminated assembly 4 Glass 5 Filler 6 Back sheet 7 Sensor 8 Roller 9, 9a, 9b Cooling mechanism 10 Air 11 Solar cell 12 Lead wire 13 Solar cell array 20 Control unit 80 Frame 80A First frame 80B First 2 frames 80C 3rd frame 80D 4th frame 80G Reinforcement frame

Claims (5)

A laminator that forms a laminate assembly by sealing a solar cell array with a filler between a light-transmitting substrate and a weather-resistant substrate;
A plurality of rollers on which the laminate assembly discharged from the laminator is placed; and a conveyor that conveys the laminate assembly by rotation of the plurality of rollers;
A sensor for detecting the laminate assembly discharged from the laminator;
Based on the output of the sensor, the roller approaching the filler that protrudes from between the light-transmitting substrate and the weather-resistant substrate of the laminate assembly being conveyed is retracted downward, and the retracted roller is A device for manufacturing a solar cell module, comprising: means for returning the protruding filler to its original position after passing.   The solar cell module manufacturing apparatus according to claim 1, wherein the sensor is individually provided corresponding to each of the rollers.   3. The solar cell module manufacturing apparatus according to claim 1, wherein the roller is installed in a range narrower than a width of the translucent substrate with respect to a direction orthogonal to a transport direction of the laminate assembly. A laminator that forms a laminate assembly by sealing a solar cell array with a filler between a light-transmitting substrate and a weather-resistant substrate;
A plurality of rollers on which the laminate assembly discharged from the laminator is placed; and a conveyor that conveys the laminate assembly by rotation of the plurality of rollers;
A sensor for detecting the laminate assembly discharged from the laminator;
Based on the output of the sensor, before the filler that protrudes between the light-transmitting substrate and the weather-resistant substrate of the laminate assembly being conveyed contacts each of the rollers, the protruding filling A solar cell module manufacturing apparatus, comprising: a cooling mechanism for cooling the material.   5. The solar cell module manufacturing apparatus according to claim 4, wherein the cooling mechanism cools only the protruding portion of the filler of the laminate assembly being conveyed.

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