JP2012196835A - Laminator, and method for manufacturing solar cell module using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminator capable of preventing a problem such as the mutual shift of constituent members or the cracking of a glass substrate when the constituent members of a solar cell module are laminated, and to provide a method for manufacturing the solar cell module using the same.SOLUTION: In the laminator for performing a lamination process of an object 80 to be processed, wherein the constituent members of the solar cell module are superposed one upon another, by placing the object 80 to be processed on a heater plate 40 and allowing a flexible sheet 20 to fall while heating the object 80 to be processed on the heater plate 40 to pressurize the object 80 to be processed from above, a spacer 50 for preventing the flexible sheet 20 from hanging down from the upper surface end part of the object 80 to be processed during the lamination process is provided to any place of the periphery of the object 80 to be processed between the heater plate 40 and the flexible sheet 20.

Description

  The present invention relates to a laminating apparatus and a method for manufacturing a solar cell module using the same, and in particular, a workpiece on which constituent members of a solar cell module are stacked is placed on a heater plate, and the workpiece is processed by the heater plate. The present invention relates to a laminating apparatus for laminating the workpiece by lowering a flexible sheet while heating the object and applying pressure from above, and a method for manufacturing a solar cell module using the laminating apparatus.

  2. Description of the Related Art Conventionally, a panel-like solar cell module in which a plurality of solar cells are connected to obtain necessary voltages and currents is known. A general solar cell module has a configuration in which a solar cell element or a glass substrate on which a solar cell element is formed is bonded to a cover glass with a filler such as EVA (ethylene vinyl acetate) or PVB (polyvinyl butyral). Become.

  In the manufacturing process of the solar cell module using these fillers, a glass substrate on which a cover glass, a filler, and a solar cell element are formed is superposed in this order, and then these are vacuum-heated with a laminator. Thus, there is a laminating process for fixing the cover glass and the glass substrate on which the solar cell element is formed through the filler.

  In order to perform such a laminating process, a laminating apparatus having an upper chamber in which the inside of the apparatus is partitioned by a diaphragm and a lower chamber that is installed at a position facing the upper chamber and in which a heater plate is disposed is known ( For example, see Patent Document 1).

  Here, with reference to FIG. 1, the lamination process of the conventional solar cell module is demonstrated. FIG. 1 is a diagram for explaining a laminating process by a conventional laminating apparatus.

  As shown in FIG. 1, the conventional laminating apparatus includes an upper chamber 110 including a flexible sheet called a diaphragm 120 and a lower chamber 130 including a heater plate 140. In the laminating process, first, a workpiece 180 in which constituent members of a solar cell module such as a cover glass, a filler, a solar cell element, and a glass substrate are overlaid is placed on the heater plate 140 of the lower chamber 130.

  FIG. 2 is a diagram for explaining a specific procedure of a conventional laminating process. FIG. 2A is a view showing a state in which the upper chamber 110 and the lower chamber 130 are sealed. As shown in FIG. 2A, by covering the lower chamber 130 with the upper chamber 110, the workpiece 180 made of a constituent member of the solar cell module is sealed.

  FIG. 2B is a diagram showing a defoaming step. After the upper chamber 110 and the lower chamber 130 are sealed as shown in FIG. 2A, in the defoaming process, the workpiece 180 is heated by the heater plate 140 and the lower chamber 130 and the upper chamber 110 are heated. The formed sealed space is evacuated using a vacuum device. Specifically, the sealed space formed by the upper chamber 110 and the lower chamber 130 is evacuated from the exhaust port 111 of the upper chamber 110 and the exhaust port 131 of the lower chamber 130 by a vacuum device such as a vacuum pump. Thereby, each component of the workpiece 180 is degassed. Further, in the defoaming process, the diaphragm 120 is sucked to the inner wall of the upper chamber 110.

  FIG. 2C is a diagram showing a laminating process. In the laminating process, the sealed space surrounded by the diaphragm 120 and the inner wall of the upper chamber 110 is opened to the atmosphere while the sealed space below the diaphragm 120 where the workpiece 180 exists is kept in a vacuum state. Thereby, the diaphragm 120 pressurizes the workpiece 180 made of the constituent members of the solar cell module, and laminates the solar cell module.

JP 2008-147255 A JP 2010-94889 A

  However, in the laminating process of the conventional laminating process, when the diaphragm 120 pressurizes the workpiece 180, a stress that pulls in the lateral direction acts on the workpiece 180. In the gap, there is a problem that the components are easily misaligned. In addition, since stress that pulls downward acts on the upper end portion of the work piece 180, there is also a problem that damage is likely to occur at the upper end portion.

  FIG. 3 is a diagram for explaining problems in the conventional laminating process. FIG. 3A is a diagram for explaining a phenomenon in which the constituent members of the solar cell module are displaced. 3A, a workpiece 180 includes a cover glass 181 which is a constituent member of a solar cell module, a filler 182 and a glass substrate 184 on which a solar cell element 183 is formed, and these are stacked. Configured. As shown in FIG. 3A, in the conventional laminating process, when the diaphragm 120 pressurizes the constituent members 181 to 184 of the solar cell module, the diaphragm 120 is pulled in the direction of the heat plate 140, and the solar cell module It sinks in the edge part of the structural members 181-184. Therefore, as shown to FIG. 3 (A), a downward force acts in the edge part of the superimposed structural member 181-184, and a horizontal force is between the structural members 181-184 of a solar cell module. Works. Therefore, as shown in FIG. 3A, the constituent member 184 in contact with the diaphragm 120 is moved by the sinking of the diaphragm 120. As a result, the constituent members 181 to 184 are displaced from each other. The problem of movement of this member is not limited to the structure of a thin film solar cell module in which two glass plates are bonded via a filler, but a solar cell element such as crystalline silicon between the glass plate and the protective sheet. Is also a problem that arises in the structure of a crystalline solar cell module in which the above is enclosed via a filler.

  FIG. 3B is a diagram for explaining a phenomenon in which damage occurs at the end of the solar cell module. As shown in FIG. 3B, when the solar cell module in which the solar cell element 183 is sealed between the cover glass 181 and the glass substrate 184 via the filler 182 is laminated, the above-described diaphragm 120 sinks. Bends the glass substrate 184. As a result, the glass substrate 184 is cracked.

  In addition, in the defoaming process in which the sealed space before the laminating process is evacuated, the heat from the previous laminating process remains and the high-temperature diaphragm 120 hangs down and contacts the workpiece to melt the filler. In order to prevent this, the laminating apparatus is provided with a rod-shaped contact prevention member parallel to the workpiece loading direction so as to prevent the diaphragm 120 from coming into contact with the workpiece during evacuation. Is known (see, for example, Patent Document 2).

  However, in the laminating apparatus described in Patent Document 2, when the evacuation is completed and the laminating process is performed, the diaphragm does not contact the heater, but is in a state where it hangs down from the upper end of the workpiece. Also, there is a problem that downward tensile stress acts on the upper end portion of the work piece, and it is impossible to prevent displacement and breakage between the constituent members of the solar cell module.

  Accordingly, the present invention provides a laminating apparatus capable of preventing problems such as displacement between constituent members and cracking of a glass substrate when laminating constituent members of a solar cell module, and manufacture of a solar cell module using the same. It aims to provide a method.

In order to achieve the above object, a laminating apparatus according to an embodiment of the present invention places a workpiece on which constituent members of a solar cell module are superimposed on a heater plate, and uses the heater plate to dispose the workpiece. In a laminating apparatus that performs a laminating process of laminating the workpiece by lowering the flexible sheet while heating and pressurizing from above,
The flexible sheet hangs down from the top edge of the workpiece during the laminating process at any location around the workpiece between the heater plate and the flexible sheet. It is characterized by providing a spacer to prevent.

  Further, the spacer may have a height equal to or higher than the height of the workpiece.

  Moreover, the said spacer may be comprised from resin.

  The spacer may have a hollow structure.

  The spacer may be a convex member provided on the lower surface of the flexible sheet.

  The flexible sheet may be a diaphragm.

  The flexible sheet may be a release sheet provided below the diaphragm.

In addition, the sheet further includes a transport sheet that transports the workpiece onto the heater plate in a state where the workpiece is placed.
The spacer may be a convex member provided on the transport sheet.

  The spacer may be arranged so as to sandwich two opposing sides of the workpiece from the outside.

  The spacer may be arranged so as to cover the entire periphery of the workpiece.

Further, the heater plate has an area where a plurality of the workpieces can be placed,
The spacer may be provided on each workpiece.

In a method for manufacturing a solar cell module according to another embodiment of the present invention, a workpiece on which constituent members of a solar cell module are overlaid is placed on a heater plate, and the workpiece is heated by the heater plate. In the method of manufacturing a solar cell module having a laminating step of laminating the workpiece by lowering the flexible sheet and pressurizing from above,
A spacer is provided at any location around the workpiece between the heater plate and the flexible sheet to prevent the flexible sheet from drooping from the upper surface end of the workpiece. The laminating process is performed.

  Further, the spacer may have a height equal to or higher than the height of the workpiece.

  Moreover, the said spacer may be comprised from resin.

  The spacer may have a hollow structure.

  The spacer may be a convex member provided on the lower surface of the flexible sheet.

  The flexible sheet may be a diaphragm.

  The flexible sheet may be a release sheet provided below the diaphragm.

The workpiece is conveyed on the heater plate in a state of being placed on a conveyance sheet,
The spacer may be a convex member provided on the transport sheet.

  The spacer may be arranged so as to sandwich two opposing sides of the workpiece from the outside.

  Further, the spacer may be arranged so as to cover the entire periphery of the workpiece.

Further, a plurality of the workpieces are placed on the heater plate,
The spacer may be provided on each workpiece.

  ADVANTAGE OF THE INVENTION According to this invention, it can prevent that flexible sheets, such as a diaphragm which contacts a workpiece, hang down in a heat-plate direction, and can prevent that unnecessary stress is added to a workpiece.

It is explanatory drawing of the lamination process by the conventional laminating apparatus. It is explanatory drawing of the specific procedure of the conventional lamination process. FIG. 2A is a view showing a state in which the upper chamber 110 and the lower chamber 130 are sealed, and FIG. 2B is a view showing a defoaming process. FIG. 2C is a diagram showing a laminating process. It is explanatory drawing of the problem of the conventional lamination process. FIG. 3 (A) is an explanatory diagram of a phenomenon in which the components of the solar cell module are displaced. FIG. 3B is an explanatory diagram of a phenomenon in which breakage occurs at the end of the solar cell module. It is the section lineblock diagram showing an example of the laminating device concerning Example 1 of the present invention. It is the cross-sectional block diagram which expanded and showed the edge part and spacer of the to-be-processed object. It is the cross-sectional block diagram which showed an example of the laminating apparatus which concerns on Example 2 of this invention. It is explanatory drawing of the manufacturing method of the solar cell module which concerns on Example 2 of this invention. FIG. 7A is a diagram showing a state where the upper chamber and the lower chamber are sealed. FIG. 7B is a diagram showing an example of the defoaming step. FIG. 7C is a diagram illustrating an example of a laminating process. It is the cross-sectional block diagram which showed an example of the laminating apparatus which concerns on Example 3 of this invention. It is the cross-sectional block diagram which showed an example of the laminating apparatus which concerns on Example 4 of this invention. It is the cross-sectional block diagram which showed an example of the laminating apparatus which concerns on Example 5 of this invention. It is the figure which showed an example of the plane structure of the spacer of the lamination apparatus which concerns on Example 6 of this invention. It is the figure which showed an example of the plane structure of the spacer of the laminating apparatus which concerns on Example 7 of this invention. It is the cross-sectional block diagram which showed an example of the laminating apparatus which concerns on Example 8 of this invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

  FIG. 4 is a cross-sectional configuration diagram illustrating an example of a laminating apparatus according to Embodiment 1 of the present invention. In FIG. 4, the laminating apparatus according to the first embodiment includes an upper chamber 10, a diaphragm 20, a lower chamber 30, a heater plate 40, and a spacer 50. The upper chamber 10 includes an exhaust port 11, and the lower chamber 30 includes an exhaust port 31. Moreover, in FIG. 4, the workpiece 80 is shown as a related component.

  The workpiece 80 is an object to be laminated, and is in a state where the constituent members of the solar cell module are overlaid. The constituent members of the solar cell module may include a cover glass, a filler, a solar cell element, a glass substrate, and the like, and may be stacked from below in the order described above. The solar cell element is formed by being formed on a glass substrate and is substantially integrated with the glass substrate. Therefore, in the laminating process, the filler is melted and pressed to perform a process of bonding the cover glass and the glass substrate. FIG. 4 shows a state in which two workpieces 80 are laminated at the same time. In this way, a plurality of workpieces 80 may be laminated at the same time.

  The upper chamber 10 is a housing that forms a sealed space together with the lower chamber 30 by covering the workpiece 80 from above. Similarly, the lower chamber 30 is a housing that forms a sealed space together with the upper chamber 10 by surrounding the workpiece 80 from below. Therefore, the upper chamber 10 and the lower chamber 30 are configured such that the contact portions of the upper chamber 10 and the lower chamber 30 are the same so that a sealed space is formed inside. If the upper chamber 10 and the lower chamber 30 can form the sealed space which accommodates the workpiece 80 inside, they can be comprised from various shapes and materials. For example, the workpiece 80 on which the constituent members of the solar cell module are superimposed is often configured in a rectangular shape. Therefore, the upper chamber 10 and the lower chamber 30 may be configured in a rectangular shape so that the rectangular workpiece 80 can be easily accommodated.

  Further, as shown in FIG. 4, the upper chamber 10 and the lower chamber 30 are configured to have a size capable of accommodating a plurality of workpieces 80 when a plurality of workpieces 80 are simultaneously laminated. Various materials such as metal can be used for the material of the upper chamber 10 and the lower chamber 30.

  The upper chamber 10 includes a diaphragm 20 on the lower side. The diaphragm 20 is provided on the lower side of the inner wall of the upper chamber 10 so as to partition the sealed space formed by the upper chamber 10 and the lower chamber 30 into two spaces 12 and 32. Above the diaphragm 20, a closed space 12 is formed by the inner wall of the upper chamber 10 and the inside of the upper surface. Further, an exhaust port 11 communicating with the space 12 is provided on the upper surface of the upper chamber 10 so that the space 12 can be evacuated and released to the atmosphere.

  Similarly, the lower chamber 30 is also provided with an exhaust port 31 on the bottom surface, so that the pressure in the space 32 below the diaphragm 20 can be adjusted when sealed. By simultaneously evacuating from the exhaust ports 11 and 31, the workpiece 80 can be defoamed, and the defoaming step described in FIG. 2B can be performed.

  The diaphragm 20 is a mediating means for pressurizing the workpiece 80 from above. The diaphragm 20 may be made of a flexible sheet, and may be made of an elastic material such as rubber, for example. The thickness of the diaphragm 20 may be various thicknesses depending on the application, but may be configured to have a thickness of 2 to 4 mm, for example.

  Since the exhaust port 11 is provided in the space 12 above the diaphragm 20 as described above, the pressure in the space 12 can be controlled by evacuation and release to the atmosphere. After the above-described defoaming step, if the exhaust port 11 is opened to the atmosphere and the exhaust port 31 is evacuated, the diaphragm 20 can be lowered to pressurize the workpiece 80 at atmospheric pressure. A laminating process for laminating can be performed.

  The lower chamber 30 includes a heater plate 40 on the bottom surface. The heater plate 40 is configured to be supported by support legs 41. The heater plate 40 is configured such that the upper surface reaches the vicinity of the contact surface between the upper chamber 10 and the lower chamber 30, and the workpiece 80 on the heater plate 40 can be pressurized by the diaphragm 20. It has become. The heater plate 40 is configured in a flat plate shape so that the workpiece 80 can be placed on the upper surface. A workpiece 80 is placed on the heater plate 40, and the diaphragm 20 is lowered and pressed in a state where the heater plate 40 is heated and maintained at a constant temperature to laminate the workpiece 80. Do. The heater plate 40 in the laminating process may be appropriately determined according to the workpiece 80 and processing conditions, but may be set to around 180 ° C., for example. By heating the workpiece 80 with the heater plate 40, the filler of the workpiece 80 can be melted. In this state, the workpiece 80 is pressurized from above by using the diaphragm 20, thereby processing the workpiece. Lamination of the object 80 can be performed. Further, as shown in FIG. 4, the heater plate 40 is configured to have an area on which a plurality of workpieces 80 can be placed when a plurality of workpieces 80 are laminated at the same time.

  The spacer 50 is used to prevent the diaphragm 20 from drooping from the upper end of the workpiece 80 when the workpiece 80 is pressed from above by lowering the diaphragm 20 during the laminating process. It is a member provided around the workpiece 80. As described with reference to FIGS. 3A and 3B, during the laminating process, a force acts on the diaphragm 20 in the direction of the heater plate 40, so that a lateral direction and a downward direction are applied to the upper end of the workpiece 80. May cause the workpiece 80 to be displaced or damaged. In the laminating apparatus according to this embodiment, the spacer 50 is arranged around the workpiece 80 so that the spacer 50 receives the lateral and downward forces generated by the diaphragm 20 and does not act on the workpiece 80. It has become. As shown in FIG. 4, the spacer 50 is provided outside the end portion of the workpiece 80 and is configured to sandwich the workpiece 80 from both sides. As a result, there is no state in which the diaphragm 20 hangs down from the upper surface end of the workpiece 80, and only the pressing force from above is applied to both end portions of the workpiece 80, and no lateral or downward force acts. It is in a state. Note that the spacer 50 does not necessarily have to be provided around the entire workpiece 80, and may be provided at any location around the workpiece 80 where it is necessary to prevent the diaphragm 20 from sagging. .

  FIG. 5 is an enlarged cross-sectional view illustrating the end portion of the workpiece 80 and the spacer 50. In FIG. 5, a workpiece 80 has a configuration in which a cover glass 81, a filler 82, a solar cell element 83, and a glass substrate 84 are stacked in order from the bottom, and is placed on the heater plate 40. Spacers 50 are provided outside the end face 85 of the work piece 80 with a slight gap D therebetween. Since the spacer 50 is configured to have the same height as the workpiece 80, the diaphragm 20 is supported horizontally on both the upper surface of the workpiece 80 and the upper surface of the spacer 50, and the upper surface of the workpiece 80. It is in a state where no sagging or sinking occurs from the end. Thereby, the pressure received from the diaphragm 20 becomes only the component downward in the vertical direction, and it is possible to prevent the lateral displacement between the constituent members 81 to 84 of the workpiece 80 and the breakage of the end portion of the glass substrate 84. In particular, when the glass substrate 84 is made of glass that is not so strong and contains soda lime as a main component, unlike the cover glass 81 using tempered glass, the glass substrate 84 is damaged by providing the spacer 50. Can be greatly reduced.

  In the workpiece 80, various fillers 82 can be used depending on the application. For example, EVA (ethylene vinyl acetate) or PVB (polyvinyl butyral) may be used. Moreover, although the solar cell element 83 may have various structures, for example, it may be formed as a thin film on the lower surface of the glass substrate 84 as a CIS solar cell element.

  4 and 5 show an example in which the height of the spacer 50 is the same as that of the workpiece 80. However, the spacer 50 only needs to be higher than the height of the workpiece 80. The height of the workpiece 80 may be higher.

  The spacer 50 can be made of various materials as long as the material does not deform due to the heating temperature of the heater plate 40 and the pressurization by the atmospheric pressure (1 atm). For example, you may comprise by resin, such as a silicon-type resin and a fluorine resin. These resin materials can be suitably used because there is no possibility of causing damage to the constituent members 81 to 84 of the solar cell module even when the workpiece 80 comes into contact.

  The spacer 50 can take various installation methods according to the application. For example, it may be installed as a convex member provided on the lower surface of the diaphragm 20 or may be installed as a convex member provided on the upper surface of the heater plate 40. Alternatively, as an independent rectangular parallelepiped piece, the workpiece 80 may be inserted and installed at a predetermined position around the workpiece 80 after the workpiece 80 is carried onto the heater plate 40. The spacer 50 can be installed by various methods as long as the spacer 50 is arranged around the workpiece 80 at the time of laminating.

  The distance D between the spacer 50 and the end face 85 of the workpiece 80 should be set to various distances depending on the application within a range in which the diaphragm 20 does not hang down from the upper end of the workpiece 80 during the laminating process. Can do. That is, if the rigidity of the diaphragm 20 is high, the distance D between the spacer 50 and the end face 85 of the workpiece 80 can be set relatively large, and the alignment between the workpiece 80 and the spacer 50 can be facilitated. is there.

  As described above, according to the laminating apparatus according to the first embodiment, by providing the spacer 50 having a height equal to or higher than the height of the workpiece 80 at any location around the workpiece 80, the workpiece is processed. The diaphragm 20 can be prevented from drooping from the upper surface end of the object 80, and the lateral displacement between the constituent members 81 to 84 of the solar cell module that is the workpiece 80 and the breakage of the glass substrate 84 can be prevented. .

  Hereinafter, in the second and subsequent embodiments, various installation methods and configurations of the spacer 50 will be described more specifically based on the configuration of the laminating apparatus according to the first embodiment. Further, the same components as those of the laminating apparatus according to the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Further, after the second embodiment, the same description as in the first embodiment is not repeated. However, the contents related to the height, arrangement, material, and the like of the spacer 50 and the contents described in the first embodiment regarding the other components are the same as in the second embodiment. It can be applied to later.

  FIG. 6 is a cross-sectional configuration diagram illustrating an example of a laminating apparatus according to Embodiment 2 of the present invention. In FIG. 6, the laminating apparatus according to the second embodiment includes an upper chamber 10, a diaphragm 21, a lower chamber 30, a heater plate 40, and a spacer 51. Two workpieces 80 are placed on the heater plate 40.

  As shown in FIG. 6, in the laminating apparatus according to the second embodiment, the spacer 51 is provided on the lower surface of the diaphragm 21, that is, the surface facing the heater plate 40. Thus, the spacer 51 may be provided on the lower surface of the diaphragm 21. Moreover, since the spacer 51 is provided so as to form a convex shape on the lower surface of the diaphragm 21, it may be called a convex member. The spacer 51 may be installed by being adhered to the lower surface of the diaphragm 21, or may be formed integrally with the diaphragm 21.

  As described with reference to FIG. 5, the spacer 51 considers the size of the workpiece 80 placed on the heater plate 40, and has an appropriate interval D around the workpiece 80 during the lamination process. It is provided on the lower surface of the diaphragm 21 so as to be disposed. In addition, the work piece 80 is disposed at a predetermined position on the heater plate 40 such that the distance D between the work piece 80 and the spacer 51 is appropriate. Thereafter, when the upper chamber 10 is lowered to form a sealed space with the lower chamber 30, the state shown in FIGS. 4 and 5 is obtained, and lamination can be performed without applying unnecessary stress to the workpiece 80. it can.

  Next, the manufacturing method of the solar cell module using the laminating apparatus which concerns on Example 2 is demonstrated using FIG. FIG. 7 is a diagram for explaining a method of manufacturing a solar cell module according to Example 2 of the present invention, and shows a series of operations in a laminating process.

  FIG. 7A is a view showing a state where the upper chamber 10 and the lower chamber 30 are sealed and the workpiece 80 is accommodated in the sealed space. In this state, the spacer 51 is disposed outside the spacer 51 so as to sandwich the plurality of workpieces 80 from both sides, and is placed on the heater plate 40.

  FIG. 7B is a diagram showing an example of the defoaming step. In the defoaming step, vacuum evacuation is performed from both the exhaust port 11 of the upper chamber 10 and the exhaust port 31 of the lower chamber 30 to eliminate bubbles contained in the workpiece 80. At this time, the diaphragm 21 is attracted to the inner wall of the upper chamber 10, and the spacer 51 is separated from the heater plate 40.

  FIG. 7C is a diagram illustrating an example of a laminating process. In the laminating process, evacuation is continued from the exhaust port 31 of the lower chamber 30, the exhaust port 11 of the upper chamber 10 is opened to the atmosphere, the atmosphere enters the space 12, and the diaphragm 21 has an atmospheric pressure of about 1 atm. To pressurize the workpiece 80. At this time, the spacers 51 provided on the diaphragm 21 are arranged on both sides of the workpiece 80, and the diaphragm 21 prevents the workpiece 80 from generating stress in the lateral direction and the downward direction. Therefore, the diaphragm 21 pressurizes the workpiece 80 in the vertical direction. Further, since the heater plate 40 heats the workpiece 80 at a predetermined temperature at which the filler 82 is melted, the lower cover glass 81 and the upper glass substrate 84 are bonded and laminated. Note that the timing for starting heating the heater plate 40 may be determined in consideration of the temperature rise rate of the heater plate 40 and the melting temperature of the filler 82, and a predetermined timing after the upper chamber 10 and the lower chamber 30 are sealed. May be determined.

  After the laminating process shown in FIG. 7 (C) is completed, the upper chamber 10 is raised to the state shown in FIG. And the to-be-processed object 80 which finished the lamination process is carried out, and the new to-be-processed object 80 is carried in. In addition, the to-be-processed object 80 which the lamination process was complete | finished performs a subsequent required process, and is manufactured as a solar cell module.

  As described above, according to the method for manufacturing a solar cell module according to Example 2, lamination can be performed without applying unnecessary stress to the workpiece 80, and the solar cell module is reliably manufactured with high yield. be able to.

  Note that the defoaming step shown in FIG. 7B is a step that may be provided as necessary, and is omitted if unnecessary, and immediately after the sealed state shown in FIG. The laminating process shown in C) may be performed.

  FIG. 8 is a cross-sectional configuration diagram showing an example of a laminating apparatus according to Example 3 of the present invention. In FIG. 8, the configuration of the laminating apparatus according to the third embodiment is the same as that of the laminating apparatus according to the second embodiment in the configuration of the upper chamber 10 and the lower chamber 30, but the spacer 52 is not the lower surface of the diaphragm 20 but the heater plate. 42 is different from the laminating apparatus according to the second embodiment in that it is provided on the upper surface of 42.

  As described above, the spacer 52 may be provided toward the heater plate 42. In this case, since the spacer 52 is provided so as to form a convex shape on the upper surface of the heater plate 42, it may be called a convex member. In the laminating apparatus according to the third embodiment, the work piece 80 is placed at a predetermined position between the spacers 52 when the work piece 80 is carried into the laminating apparatus. Thereby, it can be set as the state where the spacer 52 is arrange | positioned around the to-be-processed object 80 as shown in FIG.

  Also in the laminating apparatus according to the third embodiment, during the laminating process, pressurization is performed in a state where the spacers 52 are arranged around the work piece 80, so that the work piece 80 is caused to be laterally displaced or damaged. Lamination can be performed without any problem.

  FIG. 9 is a cross-sectional configuration diagram showing an example of a laminating apparatus according to Example 4 of the present invention. In FIG. 9, the laminating apparatus according to the fourth embodiment has the same configuration as the laminating apparatus according to the second embodiment with respect to the configurations of the upper chamber 10, the diaphragm 21, the lower chamber 30, the heater plate 40, and the spacer 51. Have That is, the spacer 51 is provided on the lower surface of the diaphragm 21. On the other hand, in the laminating apparatus according to the fourth embodiment, the conveyance sheet 60 is provided on the lower chamber 30 side, and the workpiece 80 is placed on the heater plate 40 via the conveyance sheet 60. 2 is different from the laminating apparatus according to 2.

  The conveyance sheet 60 is a conveyance unit that places the workpiece 80 on the upper surface thereof and moves the workpiece 80 of the placement object when the conveyance sheet 60 moves. The conveyance sheet 60 is provided so as to cross the heater plate 40 on the lower chamber 30, and the workpiece 80 is carried onto the heater plate 40 in the laminating apparatus by the movement of the conveyance sheet 60 in the horizontal direction. Then, the upper chamber 10 and the lower chamber 30 are sealed while the workpiece 80 is placed on the conveyance sheet 60, and a laminating process including a defoaming process and heating by the heater plate 40 is performed. That is, in the laminating process, the workpiece 80 is heated by the heater plate 40 via the conveyance sheet 60, and the spacer 51 is also pressed while being placed on the heater plate 40 via the conveyance sheet 60. Is done. Even in this case, the spacer 51 holds a gap of a necessary height on the conveyance sheet 60 and prevents the diaphragm 20 from drooping from the end of the workpiece 80. The workpiece 80 can be laminated without being added to the workpiece 80. Further, after the laminating process is completed, the conveyance sheet 60 moves in the horizontal direction, and the workpiece 80 is carried out of the laminating apparatus.

  As described above, according to the laminating apparatus according to Example 4, even when the workpiece 80 is easily carried in / out using the conveyance sheet 60, the spacer 51 is provided on the lower surface of the diaphragm 21, Lamination can be performed reliably.

  As a modification of the fourth embodiment, the spacer 51 is provided on the upper surface of the transport sheet 60 in a convex shape, and the workpiece 80 is placed on the heater plate 40 in a state where the workpiece 80 is placed at a predetermined position between the spacers 51. You may make it carry in on top. Since the spacers 51 are already provided around the workpiece 80, lamination can be performed without performing complicated alignment on the heater plate 40.

  FIG. 10 is a cross-sectional configuration diagram showing an example of a laminating apparatus according to Example 5 of the present invention. 10, the laminating apparatus according to the fifth embodiment is the same as the laminating apparatus according to the fourth embodiment shown in FIG. 9 with respect to the configurations of the upper chamber 10, the lower chamber 30, the heater plate 40, and the conveyance sheet 60. To do. However, the present embodiment differs from the laminating apparatus according to the fourth embodiment in that a release sheet 70 is provided below the diaphragm 20 and a spacer 53 is provided on the lower surface of the release sheet 70.

  As described above, the release sheet 70 may be provided below the diaphragm 20, that is, on the upper chamber 10 side between the diaphragm 20 and the heater plate 40 or the conveyance sheet 60. Similar to the diaphragm 20, the release sheet 70 is composed of a flexible sheet. The release sheet 70 is a sheet for preventing the filler 82 from adhering to the diaphragm 20 when the filler 82 melts and protrudes outside the workpiece 80 in the laminating process. The diaphragm 20 is usually made of rubber, and the filler 82 is easily attached thereto, but the release sheet 70 is made of a material that is difficult to attach the filler 82 to a film. Therefore, by providing the release sheet 70 below the diaphragm 20, it is possible to prevent the diaphragm 20 and the workpiece 80 from adhering after the lamination process. In addition, the peeling sheet 70 is comprised by the thickness of 0.4-0.8 mm, for example, and is a very thin sheet | seat compared with 2-4 mm of a diaphragm.

  When the release sheet 70 is provided, it is not the diaphragm 20 but the release sheet 70 that is in direct contact with the workpiece 80. Also, the release sheet 70 is a kind of flexible sheet similar to the diaphragm 20, and thus moves in the same manner as the diaphragm 20 when the exhaust port 11 is opened to the atmosphere. That is, the release sheet 70 descends in a state where it is overlapped with the diaphragm 20 and presses the workpiece 80 together with the diaphragm 20 from above. At this time, similarly to the diaphragm 20, a tensile force in the direction toward the heater plate 40 is generated, so that a lateral force or a downward force is applied to the workpiece 80, and the components 81 to 84 of the workpiece 80 are provided. It may be a factor that causes a lateral shift between the two and a breakage of the upper end portion.

  Therefore, when the release sheet 70 that covers the workpiece 80 is provided, the spacer 53 is provided on the lower surface of the release sheet 70 to prevent lateral and downward stress from being applied to the workpiece 80 by the release sheet 70. is doing.

  Thus, according to the laminating apparatus according to Example 5, even when the release sheet 70, which is a kind of flexible sheet, is provided below the diaphragm 20, the workpiece 80 is processed in the laminating process. Unnecessary stress is prevented from being applied, and lamination can be performed reliably.

  FIG. 11 is a diagram illustrating an example of a planar configuration of the spacer during the laminating process of the laminating apparatus according to the sixth embodiment of the present invention. 11, in the laminating apparatus according to the sixth embodiment, two workpieces 80 are placed at intervals in the longitudinal direction on the heater plate 40, and two opposing sides of each workpiece 80 are placed from the outside. It has a planar configuration in which spacers 54 are provided so as to be sandwiched.

  As described above, the spacer 54 may be provided so as to sandwich two opposing sides of the workpiece 80 from both sides. As shown in FIG. 11, since the heater plate 40 has a horizontally long rectangular planar shape, the flexible sheet (diaphragm 20 or release sheet 70) facing the heater plate 40 is also the same as the heater plate 40. It has a horizontally long rectangular planar shape. Therefore, the tensile stress due to the flexible sheet is generated in the horizontal direction larger than the vertical direction in FIG. Therefore, in the laminating apparatus according to the sixth embodiment, the spacers 54 are provided on both sides of the workpiece 80 in the lateral direction to completely guard the workpiece 80.

  On the other hand, the vertical direction in FIG. 11 is not completely absent although the influence of the tensile stress by the flexible sheet is weakened. Therefore, the spacer 54 is formed longer than the vertical side of the workpiece 80, and the influence of the tensile stress in the vertical direction in FIG. 11 is reduced in the vicinity of the spacer 54.

  Thus, the spacers 54 do not necessarily have to be provided all around the workpiece 80, and may be provided at necessary locations around the workpiece 80 according to the application. In FIG. 11, the workpiece 80 is sandwiched from both sides in the longitudinal direction of the heater plate 40, but if the tensile stress due to the flexible sheet is not so strong, the workpiece 80 is formed at the four corners outside the workpiece 80. Or may be provided separately in an island shape along the outer edge of the workpiece 80. The planar shape of the spacer 54 can have various configurations depending on the application. In FIG. 11, two examples of the workpiece 80 are given. However, the workpiece 80 may be one, or may be three or more. Even if the number of the workpieces 80 increases, the workpieces 80 can be reliably protected by providing the spacers 54 corresponding to the respective workpieces 80.

  In addition, about the cross-sectional structure of the laminating apparatus which concerns on Example 6, all the structures demonstrated in Examples 1 thru | or 5 can be applied, and since it is the same as these structures, the description is abbreviate | omitted.

  FIG. 12 is a diagram illustrating an example of a planar configuration of the spacer during the laminating process of the laminating apparatus according to the seventh embodiment of the present invention. 12, in the laminating apparatus according to the seventh embodiment, two workpieces 80 are placed with a gap in the longitudinal direction of the heater plate 40, and the spacer 55 surrounds the entire periphery of the workpiece 80. It has the structure provided.

  As described above, the spacer 55 may be provided so as to surround not only both sides of the workpiece 80 but also all sides including both sides. The work piece 80 is protected in all directions, is not subjected to unnecessary stresses other than the vertical direction from the flexible sheets such as the diaphragms 20 and 21, or the release sheet 70, and is laminated without causing lateral displacement or breakage. Processing can be performed reliably.

  In addition, about the cross-sectional structure of the laminating apparatus which concerns on Example 7, all the structures demonstrated in Example 1 thru | or 5 are applicable, and since it is the same as these structures, the description is abbreviate | omitted.

  FIG. 13 is a cross-sectional configuration diagram showing an example of a laminating apparatus according to Example 8 of the present invention. In FIG. 13, the laminating apparatus according to the eighth embodiment is different from the laminating apparatuses according to the first to seventh embodiments in that the laminating apparatus 56 includes a hollow structure spacer 56. As long as the spacer 56 has a height equal to or higher than that of the workpiece 80 and the upper surface is formed in a planar shape, the spacer 56 can take various configurations, and has a hollow structure as shown in FIG. Also good.

  By making the spacer 56 have a hollow structure, the spacer 56 can be configured to be lightweight, and heat dissipation can be facilitated. The laminating apparatus according to the eighth embodiment can be combined with the laminating apparatuses according to the first to seventh embodiments. In each of the embodiments, each of the spacers 50 to 55 can have a hollow structure.

  Further, the spacer 56 is merely an example of a hollow structure, and may have other hollow structures and can have various configurations.

  The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the present invention. Can be added.

  In particular, Embodiments 1 to 8 can be combined within a consistent range. For example, Examples 1 to 5 are examples related to the cross-sectional configuration of the laminating apparatus according to this example, Examples 6 and 7 are examples related to the planar configuration, and Example 8 is an example related to the configuration of the spacer. It is naturally possible to combine any of Examples 1 to 5, any of Examples 6 and 7, and Example 8.

  Moreover, although the manufacturing method of the solar cell module using the laminating apparatus which concerns on a present Example has demonstrated only in Example 2, it can apply all to another Example.

  Furthermore, in the first to eighth embodiments, an example in which two workpieces 80 are laminated at the same time has been described. However, one workpiece 80 may be laminated in one laminating process. Three or more workpieces 80 may be placed on the heater plate 40 and laminated at the same time.

  In the first to eighth embodiments, a substrate structure in which a cover glass 81 and a glass substrate 84 on which a thin-film solar cell element 83 is formed is bonded as a workpiece 80 with a filler 82 will be described as an example. However, the workpiece 80 that can be handled by the laminating apparatus according to the present invention is not limited to this, and can be applied to a superstrate structure in which a thin-film solar cell element 83 is formed on the cover glass 81 side. The present invention can also be applied to the structure of a crystalline solar cell module in which a solar cell element is sealed between a cover glass 81 and a protective sheet.

  INDUSTRIAL APPLICABILITY The present invention can be used for a laminating apparatus for laminating constituent members of a solar cell module and a solar module manufacturing process using the laminating apparatus.

DESCRIPTION OF SYMBOLS 10 Upper chamber 11, 31 Exhaust port 12, 32 Space 20, 21 Diaphragm 30 Lower chamber 40, 42 Heater plate 41 Support leg 50-56 Spacer 60 Conveyance sheet 70 Release sheet 80 Workpiece 81 Cover glass 82 Filler 83 Solar cell Element 84 Glass substrate 85 End face

Claims (22)

The work piece on which the constituent members of the solar cell module are stacked is placed on a heater plate, and the work piece is heated by the heater plate while lowering the flexible sheet and pressurizing the work piece from above. In a laminating apparatus that performs a laminating process for laminating a workpiece,
The flexible sheet hangs down from the top edge of the workpiece during the laminating process at any location around the workpiece between the heater plate and the flexible sheet. A laminating apparatus comprising a spacer for preventing.   The laminating apparatus according to claim 1, wherein the spacer has a height equal to or higher than a height of the workpiece.   The laminating apparatus according to claim 1 or 2, wherein the spacer is made of a resin.   The laminating apparatus according to any one of claims 1 to 3, wherein the spacer has a hollow structure.   The laminating apparatus according to any one of claims 1 to 4, wherein the spacer is a convex member provided on a lower surface of the flexible sheet.   The laminating apparatus according to claim 5, wherein the flexible sheet is a diaphragm.   The laminating apparatus according to claim 5, wherein the flexible sheet is a release sheet provided below the diaphragm. A conveyance sheet that conveys the workpiece onto the heater plate in a state where the workpiece is placed;
The laminating apparatus according to any one of claims 1 to 4, wherein the spacer is a convex member provided on the transport sheet.   The laminating apparatus according to any one of claims 1 to 9, wherein the spacer is disposed so as to sandwich two opposing sides of the workpiece from outside.   The laminating apparatus according to any one of claims 1 to 9, wherein the spacer is disposed so as to cover the entire periphery of the workpiece. The heater plate has an area where a plurality of the workpieces can be placed;
The laminating apparatus according to any one of claims 1 to 10, wherein the spacer is provided on each workpiece. The work piece on which the constituent members of the solar cell module are stacked is placed on a heater plate, and the work piece is heated by the heater plate while lowering the flexible sheet and pressurizing the work piece from above. In the method for manufacturing a solar cell module having a laminating process for laminating a workpiece,
A spacer is provided at any location around the workpiece between the heater plate and the flexible sheet to prevent the flexible sheet from drooping from the upper surface end of the workpiece. A method for producing a solar cell module, comprising performing the laminating process.   The method of manufacturing a solar cell module according to claim 12, wherein the spacer has a height equal to or higher than a height of the workpiece.   The method for manufacturing a solar cell module according to claim 12 or 13, wherein the spacer is made of resin.   The laminating apparatus according to any one of claims 12 to 14, wherein the spacer has a hollow structure.   The method of manufacturing a solar cell module according to claim 11, wherein the spacer is a convex member provided on a lower surface of the flexible sheet.   The method for manufacturing a solar cell module according to claim 16, wherein the flexible sheet is a diaphragm.   The method for manufacturing a solar cell module according to claim 16, wherein the flexible sheet is a release sheet provided below the diaphragm. The workpiece is conveyed on the heater plate in a state of being placed on a conveyance sheet,
The method for manufacturing a solar cell module according to any one of claims 12 to 18, wherein the spacer is a convex member provided on the transport sheet.   The method for manufacturing a solar cell module according to any one of claims 12 to 19, wherein the spacer is disposed so as to sandwich two opposing sides of the workpiece from the outside.   The method for manufacturing a solar cell module according to any one of claims 12 to 19, wherein the spacer is arranged so as to cover the entire periphery of the workpiece. A plurality of the workpieces are placed on the heater plate,
The method for manufacturing a solar cell module according to any one of claims 12 to 21, wherein the spacer is provided on each workpiece.

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