JP2016187013A - Solar battery module manufacturing apparatus and solar battery module manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a solar battery module manufacturing apparatus that can avoid deformation of a diaphragm sheet and perform laminate processing on solar battery modules having different sizes by proper pressure.SOLUTION: A solar battery module manufacturing apparatus includes an upper chamber 20, a lower chamber 30 having a heating and cooling mechanism 15, and diaphragm sheets 13. A space formed by the diaphragm sheets 13 and the upper and lower chambers 20 and 30 are divided into small chambers 20A, 20B, 20C comprising plural closed spaces. The small chambers 20A, 20B, 20C respectively include control valves 11a, 11b, 11c, 12a, 12b and 12c for exhaust and intake. The displacements of the diaphragm sheets 13 in the small chambers 20A, 20B, 20C can be controlled independently of one another. A laminate 100S of a resin sheet and a solar battery cell which is mounted in the lower chamber 30 is heated and pressurized in the space.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a solar cell module manufacturing apparatus and a solar cell module manufacturing method, and more particularly to a laminating apparatus that seals solar cells using a sealing resin.

  A general solar cell module includes a solar cell stack that receives sunlight and generates power by photoelectric conversion, and a support member such as a frame. A solar cell laminate is a laminate in which a resin sheet, a solar cell, a resin sheet, and a water-resistant resin sheet such as PET are sequentially laminated on a translucent substrate, and subjected to heat and pressure treatment with a laminating apparatus. Thus, the members are brought into close contact with each other.

  Conventionally, various laminating apparatuses used for manufacturing solar cell modules have been disclosed. For example, in the apparatus disclosed in Patent Document 1, a diaphragm is sandwiched between an upper chamber and a lower chamber, and a mounting plate provided in the lower chamber is installed in a lower space of the mounting plate. A workpiece to be processed including a solar battery cell to be processed is placed on the mounting plate.

  Next, the cock is opened and the inside of the upper chamber is evacuated by a vacuum pump so as to make a negative pressure, and the workpiece is heated by heating the mounting plate by the heating and cooling unit. Further, by setting the lower chamber to a negative pressure by opening the cock, after the bubbles generated from the workpiece are discharged to the outside, the cock is opened to bring the upper chamber to atmospheric pressure. By making the inside of the upper chamber atmospheric pressure, the diaphragm is pressed against the workpiece. Then, after a certain time, the mounting plate is cooled by the heating and cooling unit, the cock is opened, and the inside of the lower chamber is brought to atmospheric pressure. The solar cell module is completed by separating the upper chamber and the lower chamber by taking the atmospheric pressure in the lower chamber as described above, and taking out the processed solar cell module.

Japanese Patent No. 36555076

  However, in the laminating apparatus disclosed in Patent Document 1, a solar cell is sandwiched between resin sheets, a work piece made of a laminate laminated on a light-transmitting substrate is heated, and the work piece is processed by one diaphragm sheet. , The resin sheet is thinned and brought into close contact with the solar battery cell to manufacture a solar battery module. For this reason, for example, when a large solar cell module is processed after processing a small solar cell module, the deformation of the diaphragm sheet generated by pressurizing the small solar cell module may cause the resin sheet or water resistant resin of the large solar cell module It may be transferred to the sheet. Deformation of the diaphragm sheet causes defects such as wrinkling and leaving a step on the resin sheet, and there is a problem that the yield decreases. In addition, even when a large solar cell module is continuously processed, there is a problem that the deformation of the diaphragm sheet is transferred to the resin sheet or the water-resistant resin sheet of the solar cell module due to misalignment.

  The present invention has been made in view of the above, and it is possible to manufacture a solar cell module capable of avoiding deformation of a diaphragm sheet and laminating the solar cell modules having different sizes by appropriate pressurization. The object is to obtain a device.

  In order to solve the above-described problems and achieve the object, the solar cell module manufacturing apparatus of the present invention includes an upper chamber and a temperature control unit that forms a space between the upper chamber and heats or cools the space. A lower chamber provided, and a diaphragm sheet sandwiched between the upper chamber and the lower chamber and displaceable in the space of the upper chamber and the lower chamber. A space formed by the diaphragm sheet, the upper chamber, and the lower chamber is divided into small chambers composed of a plurality of closed spaces. Each of the small chambers is provided with a control valve for exhaust and intake, and the displacement of the diaphragm sheet can be independently controlled in the small chamber, and the resin sheet and the solar battery cell placed in the lower chamber can be controlled. The laminate is heated and pressurized in a space.

  According to the present invention, it is possible to obtain a solar cell module manufacturing apparatus capable of avoiding deformation of a diaphragm sheet and capable of laminating a solar cell module having a different size by appropriate pressurization. Play.

The perspective view which shows the structure of the laminating apparatus used with the solar cell module manufacturing apparatus concerning Embodiment 1. FIG. AA sectional view of the laminating apparatus Bottom view of the upper chamber of the laminator Bottom view showing a state where the diaphragm of the upper chamber of the laminating apparatus is removed. The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator (A) to (d) is a process cross-sectional view showing a method for manufacturing a solar cell module The perspective view of the solar cell module formed by the method of Embodiment 1 The perspective view which shows the structure of the laminating apparatus used with the solar cell module manufacturing apparatus concerning Embodiment 2. FIG. Bottom view of the upper chamber of the laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The perspective view which shows the structure of the laminating apparatus used with the solar cell module manufacturing apparatus concerning Embodiment 3. FIG. The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The perspective view which shows the structure of the laminating apparatus used with the solar cell module manufacturing apparatus concerning Embodiment 4. FIG. The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator The figure which shows the lamination process using the same laminator

  Below, the manufacturing method of the solar cell module manufacturing apparatus and solar cell module concerning embodiment of this invention is demonstrated in detail based on drawing. It should be noted that the present invention is not limited to the present embodiment, and can be appropriately changed without departing from the gist. In the drawings shown below, the scale of each layer or each member may be different from the actual for easy understanding, and the same applies to the drawings. Further, even a cross-sectional view may not be hatched for easy viewing of the drawing. Moreover, in each figure, the same code | symbol is attached | subjected about the same or similar component.

Embodiment 1 FIG.
FIG. 1 is a perspective view showing a configuration of a laminating apparatus used in the solar cell module manufacturing apparatus according to the first embodiment, FIG. 2 is a sectional view taken along line AA of the laminating apparatus, and FIG. FIG. 4 is a bottom view showing a state in which the diaphragm of the upper chamber of the laminating apparatus is removed, and FIGS. 5 to 7 are views showing a laminating process using the laminating apparatus. FIG. 6 is a diagram showing a state in which a workpiece is placed, FIG. 6 is a diagram showing a case where both the upper chamber and the lower chamber are under negative pressure, and FIG. It is a figure which shows the state which pressurized the workpiece. The laminating apparatus 10 of the first embodiment divides the upper chamber 20 concentrically into a plurality of small chambers 20A to 20C, and can control the internal pressure of each of the small chambers 20A to 20C independently. By independently controlling the internal pressure of each of the small chambers 20A to 20C, deformation of the diaphragm sheet 13 is avoided, and the solar cell modules having different sizes are laminated by appropriate pressure. 5 to 7 are schematic diagrams. The lower chamber is also provided with an exhaust control valve and an intake control valve, but is provided at the upper end portion of the lower chamber and without the adhesion preventing sheet 18. The object to be processed does not appear as a shadow because it is on the back side of the object.

  In the laminating apparatus according to the first embodiment, solar cells 1 are connected by tab wires 2 and an array is formed through resin sheets 3a and 3b, a glass substrate 4 as a substrate, and a protective sheet that is a back surface protective material. 5 between which the layered body 100S is formed is placed and heated and pressed. The laminating step includes a first step of heating and pressurizing the entire surface of the laminate, and a second step of heating and pressurizing the laminate so that the peripheral portion of the laminate has a pressing force smaller than that of the central portion. .

  As shown in FIG. 2, the laminating apparatus 10 has a diaphragm sheet 13 sandwiched between an upper chamber 20 and a lower chamber 30. The temperature can be raised and lowered freely by the mounting plate 14 provided in the lower chamber 30 and the heating / cooling mechanism 15 provided in the lower portion of the mounting plate 14. A laminate 100S that is a workpiece is disposed. The heating / cooling mechanism constitutes a temperature control unit that controls the mounting plate 14 to exhibit an appropriate temperature according to the processing step. The small diaphragms 13A to 13C constituting the diaphragm sheet 13 are respectively locked to the lower ends of the first to third side walls 21a to 21c that are vertically lowered from the upper wall of the upper chamber 20. The small diaphragms 13A to 13C and the first to third side walls 21a to 21c constitute the three small chambers 20A to 20C concentrically from the inside, via the exhaust control valves 11a to 11c, respectively. And connected to a vacuum pump 16.

  On the other hand, the lower chamber 30 is connected to the vacuum pump 16 via the control valve 11d. The three small chambers 20A to 20C of the upper chamber 20 are provided with intake control valves 12a to 12c, respectively, and the lower chamber 30 is provided with an intake control valve 12d.

  Then, the air flows into the small chambers 20A to 20C and the lower chamber 30 by opening these intake control valves 12a to 12d. For example, the control valves 11a and 11b for exhaust are opened, and the inside of the small chambers 20A and 20B in the central portion of the upper chamber is set to a negative pressure by the vacuum pump 16, and the mounting plate 14 is heated by the heating and cooling mechanism 15 to thereby place the mounting plate. The laminate 100S, which is a workpiece placed on the plate 14, is heated. Next, the exhaust control valve 11d is opened, and the inside of the lower chamber 30 is set to a negative pressure, whereby bubbles generated from the stacked body 100S that is a workpiece are discharged to the outside of the stacked body 100S.

  After the bubbles are discharged, the intake control valves 12a and 12b are opened, and the small chambers 20A and 20B of the upper chamber 20 are brought close to the atmospheric pressure, whereby the atmospheric pressure is applied to the small chambers 20A and 20B and the lower chamber 30 of the upper chamber 20. The small diaphragms 13 </ b> A and 13 </ b> B are stretched to the lower chamber 30 side by making a difference, and pressurize the laminated body 100 </ b> S as a workpiece while continuing heating. When pressurizing, the pressure applied by the small diaphragms 13A and 13B is adjusted by adjusting the air flowing into the small chambers 20A and 20B of the upper chamber 20 by adjusting the open / closed state of the control valves 12a and 12b for intake. it can. After pressurizing the laminated body 100S, which is a workpiece, with the small diaphragms 13A and 13B for a desired time, the mounting plate 14 is cooled by the heating / cooling mechanism 15, the control valve 12d for intake is opened, and the inside of the lower chamber 30 is opened to the atmosphere. Open. After the upper chamber 20 becomes negative with respect to the lower chamber 30, the upper chamber 20 is opened to the atmosphere. The processed and sealed solar cell module can be taken out by separating the upper chamber 20 and the lower chamber 30. The heating / cooling mechanism 15 performs the cooling operation, but may be natural cooling.

  The lower chamber 30 of the laminating apparatus 10 includes a mounting plate 14 including a temperature sensor and a heating / cooling mechanism 15 and an adhesion preventing sheet 18 such as a fluororesin. The mounting plate 14 can be set to an arbitrary temperature by controlling the output of the heating / cooling mechanism 15 with a temperature sensor. The adhesion preventing sheet 18 is placed on the mounting plate 14, and the solar cell module is further placed thereon. A workpiece made of the laminate 100S in which the above materials are laminated is placed. In the adhesion preventing sheet 18, the resin sheets 3 a and 3 b in the laminated body 100 </ b> S heated by heat exchange from the mounting plate 14 heated by the heating / cooling mechanism 15 are melted and protrude from the glass substrate 3. Prevents from adhering to.

  The upper chamber 20 of the laminating apparatus 10 is provided with a diaphragm sheet 13 and a control valve 9. For example, three diaphragm sheets 13A, 13B, and 13C are provided from the center of the chamber, and the upper chamber 20 is partitioned and sealed individually. Control valves 12a to 12c for intake and control valves 11a to 11c for exhaust are provided for each sealed space. At this time, the area pressed by the small diaphragm 13A is smaller than the laminated body 100S that is a workpiece, and the outer edge of the area pressed by the small diaphragm 13B is located outside the outer edge of the laminated body 100S. With this structure, the amount of flow into each sealed space can be controlled, and the force with which the diaphragm sheet 13 in each sealed space pressurizes the workpiece can be avoided, deformation of the diaphragm sheet 13 can be avoided, and solar cells of different sizes Lamination can be performed on the module by appropriate pressure.

  Next, a laminating method using the laminating apparatus of this embodiment will be described. 5 to 7 are diagrams showing a laminating process using the laminating apparatus of the present embodiment. Prior to the description of the laminating process, first, the manufacturing process of the solar cell module will be briefly described. 8A to 8D are process cross-sectional views illustrating a method for manufacturing a solar cell module.

  First, as shown in FIG. 8A, resin sheets 3a and 3b are formed.

  On the other hand, the solar cell 1 is formed, and the tab wire 2 connects the positive electrode of the cell to the negative electrode of the adjacent cell to form a string connected to the solar cells 1 as shown in FIG.

  Next, as shown in FIG.8 (c), on the glass substrate 4, the stretched resin sheet 3a, the string which connected the photovoltaic cell 1 with the tab wire 2, the stretched resin sheet 3b, A protective sheet 5 made of a water resistant resin such as polyethylene terephthalate (PET) is sequentially laminated to form a laminate 100S.

  Then, the laminated body 100 </ b> S is conveyed to the laminating apparatus 10, and laminating processing is performed by the laminating apparatus 10.

  In the laminating apparatus 10, first, as shown in FIG. 5, the mounting plate 14 is raised to an arbitrary temperature by the heating / cooling mechanism 15 provided on the mounting plate 14 of the lower chamber 30, so that the upper chamber 20 and the lower chamber 20 The chamber 30 is separated, and the laminated body 100 </ b> S as a workpiece is placed on the adhesion preventing sheet 18 provided above the mounting plate 14 of the lower chamber 30. At this time, the laminated body 100S shown in FIG. 8C is placed so that the glass substrate 4 side is on the upper side.

  Then, the exhaust control valves 11a to 11c are opened and exhausted by the vacuum pump 16, whereby the space defined by the upper chamber 20 and the small diaphragms 13A to 13C is set to a negative pressure, and the upper chamber 20 is disposed above the lower chamber 30. , The exhaust control valve 11d is opened, and the vacuum pump 16 causes the space defined by the plurality of small diaphragms 13A to 13C in the lower chamber 30 and the upper chamber 20 to have a negative pressure. After discharging bubbles generated from the laminated body 100S to the outside, a small diaphragm is formed so that the diaphragm sheet 13 does not come into contact with the peripheral edge of the glass substrate 4 of the laminated body 100S in accordance with the size of the laminated body 100S that is a workpiece. The control valve 12a for intake is opened in a space sealed by 13A and the upper chamber 20, and the central portion of the laminate 100S is pressurized as shown in FIG.

  Subsequently, the intake control valve 12b is opened, and air is sucked into the space defined by the small diaphragm 13B located above the peripheral edge of the glass substrate 4 of the laminated body 100S. As shown in FIG. Pressurize the entire 100S. At this time, by adjusting the control valves 12a and 12b for intake, the force with which the small diaphragm 13B pressurizes the peripheral portion of the glass substrate 4 of the laminated body 100S that is a workpiece is applied to the central portion of the laminated body 100S. The force is smaller than the pressing force so that the trace of the glass substrate 4 does not remain on the small diaphragm 13A.

  After performing the laminating process in the laminating apparatus as described above, as shown in FIG. 8D, the laminated body 100S is heated and pressed to take out the sealed solar cell module 100 that has been sealed. be able to.

  The frame 101 is attached to the solar cell module 100 sealed in the above process, and the solar cell module 100 is completed as shown in the perspective view of FIG.

  According to Embodiment 1 of the present invention, since the force for pressing the center portion of the workpiece and the peripheral portion of the glass substrate 4 can be controlled independently when pressing the workpiece, the peripheral edge of the glass substrate 4 can be controlled independently. The contact pressure between the portion and the diaphragm sheet 13 is reduced, and the trace due to the step at the peripheral edge of the glass substrate 4 or the water-resistant resin 5 is not transferred to the diaphragm sheet 13, so that deformation can be suppressed. Therefore, the occurrence of wrinkles of the protective sheet 5 or defects such as a step remaining on the protective sheet 5 does not occur. By controlling the internal pressure of each chamber independently, the pressing force of the workpiece can be controlled. At the same time, pressing with different pressures or changing the pressing force with time, the workpiece Appropriate processing can be performed according to the size.

  As described above, according to the first embodiment, the diaphragm sheet 13 does not straddle the peripheral edge of the glass substrate 4, so that deformation of the diaphragm sheet 13 can be avoided. Further, even when the diaphragm sheet 13 is applied to the peripheral edge of the glass substrate 4, the pressure applied to the plurality of small chambers 20A to 20C can be individually controlled, so that the load on the diaphragm sheet 13 corresponding to the peripheral edge of the glass substrate 4 can be reduced. The trace of the peripheral part of the glass substrate 4 does not remain in the diaphragm sheet 13. Further, since the laminating step includes a first step of heating and pressurizing the entire surface of the laminated body and a second step of heating and pressurizing the laminated body with a pressing force smaller than that of the central portion at the peripheral portion, It is possible to keep no trace. In the first step, the diaphragm sheet 13 pressurizes the peripheral portion of the glass substrate 4, so a trace remains at the step portion of the peripheral portion. However, in the second step, the peripheral portion is not pressurized, so the heating / cooling mechanism The restoring force acts by the heat from 15, and the trace disappears.

  In the first embodiment, the upper chamber is concentrically divided into three small chambers, and the internal pressure of each chamber is independently controlled to control the pressing force of the workpiece. It goes without saying that the number and the temporal and spatial adjustment of the pressing force can be appropriately changed.

Embodiment 2. FIG.
Next, a laminating apparatus according to Embodiment 2 of the present invention will be described. FIG. 10 is a perspective view showing a configuration of a laminating apparatus used in the solar cell module manufacturing apparatus according to the second embodiment of the present invention, FIG. 11 is a bottom view of the upper chamber 20 of the laminating apparatus, and FIGS. FIG. 11 is a process cross-sectional view illustrating a laminating process using the laminating apparatus, and corresponds to a cross-sectional view taken along the line BB of the laminating apparatus in FIG. 10. In the first embodiment, an example is shown in which the chamber 21 is divided into three small chambers by the side wall 21 and the three small diaphragms 13A to 13C that are concentrically provided as partition walls. An example in which the matrix is divided into 40 matrix-shaped small chambers 20i will be described.

  Similar to the laminating apparatus of the first embodiment, the laminating apparatus 10 of the second embodiment divides the upper chamber 20 into a plurality of small chambers and can control the internal pressure of each small chamber independently. The difference is the arrangement of the small chambers, which are separated into 5 rows and 8 columns and 40 small chambers 20i, and by independently controlling the internal pressure of each small chamber 20i, deformation of the small diaphragm 13i can be avoided, Lamination processing is performed on different solar cell modules by appropriate pressure.

  Also in the laminating apparatus of the second embodiment, as in the first embodiment, the solar battery cells 1 shown in FIG. 8C are connected by the tab wires 2 and the resin sheets 3a and 3b are arranged in an array. Then, it is sandwiched between a glass substrate 4 as a substrate and a protective sheet 5 which is a back surface protective material, and a laminate 100S is placed and heated and pressed.

  As shown in FIG. 12, the laminating apparatus 10 has a diaphragm sheet 13 </ b> S sandwiched between an upper chamber 20 and a lower chamber 30. The temperature can be increased and decreased freely by a mounting plate 34 provided in the lower chamber 30 and a heating / cooling mechanism 35 provided in the mounting plate 34. A roller is mounted on the mounting plate 34. The stacked body 100 </ b> S, which is a workpiece, is conveyed on the belt 33 that is suspended between the belts 32. The diaphragm sheet 13 </ b> S is integrally formed and is divided into small diaphragms 13 i by being locked to the lower ends of the side walls 21 of 5 rows and 8 columns vertically lowered from the upper wall of the upper chamber 20. In this way, the small chambers 20i of 5 rows and 8 columns are arranged in a matrix by the small diaphragms 13i and the side walls 21, and the vacuum pump 16 passes through the exhaust control valves 11i of 5 rows and 8 columns, respectively. It is connected to the. On the other hand, a control valve 12i for intake of each small chamber 20i is provided. A pipe 17 is connected between the exhaust control valve 11 i and the vacuum pump 16.

  The lower chamber 30 of the laminating apparatus 10 includes a mounting plate 34 provided with a heating / cooling mechanism 35 and a temperature sensor (not shown), and an adhesion prevention sheet 18 such as a fluororesin. It can move in the chamber 30. The roller 32 is supported by a support device 31 shown in FIG. 10, and the support device 31 can translate the roller 32. In the adhesion preventing sheet 18, the resin sheets 3 a and 3 b in the laminate 100 </ b> S as the workpiece heated by heat exchange from the mounting plate 34 heated by the heating / cooling mechanism 35 are melted, and the laminate 100 </ b> S is melted. This prevents the glass substrate 4 from sticking to the mounting plate 34. The lower chamber 30 is also provided with an exhaust control valve and an intake control valve. However, the lower chamber 30 is provided at the upper end of the lower chamber and at the portion without the adhesion preventing sheet 18. It is not visible on the back side of the processed material.

  The upper chamber 20 of the laminating apparatus is provided with a small diaphragm 13i that constitutes the diaphragm sheet 13S, an exhaust control valve 11i, and an intake control valve 12i, and each of the small diaphragms 13i has five vertical portions, The upper chamber 20 is divided into eight horizontally and sealed, and control valves 11i and 12i are provided for each individual sealed space. With this structure, the amount of intake air to each sealed space can be controlled, and the force with which the small diaphragm 13i in each sealed space pressurizes the stacked body 100S as a workpiece can be controlled.

  Next, a laminating method using the laminating apparatus of the second embodiment will be described. FIG. 12 shows a case where both the upper chamber 20 and the lower chamber 30 of the laminating apparatus of FIG. 10 are under negative pressure. In FIG. 13, the air flowing from the intake control valve 12i of the upper chamber 20 is controlled as a workpiece. The state which pressurized the laminated body 100S of this is shown.

  First, as shown in FIG. 12, the mounting plate 34 is raised to an arbitrary temperature by the heating / cooling mechanism 35 and the temperature sensor provided on the mounting plate 34 of the lower chamber 30, and the upper chamber 20 and the lower chamber 30. The laminate 100S as a workpiece is placed on the adhesion preventing sheet 18 provided above the mounting plate 34 of the lower chamber 30 so that the glass substrate 4 is on the top.

  Then, as shown in FIG. 13, the exhaust control valve 11 i is opened, and the space defined by the upper chamber 20 and each small diaphragm 13 i is made negative by the vacuum pump 16, and the upper chamber 20 is placed above the lower chamber 30. The vacuum pump 16 causes the individual spaces of the lower chamber 30 and the upper chamber 20 separated by a plurality of small diaphragms 13i to be negative pressure. After discharging bubbles generated from the laminated body 100S as a workpiece, the small diaphragm 13i is not in contact with the peripheral portion of the glass substrate 4 of the laminated body 100S in accordance with the size of the laminated body 100S. The control valve 12i is opened to pressurize the central portion of the laminate 100S.

  Subsequently, all the intake control valves 12i are once closed, and all the exhaust control valves 11i are opened. After that, all the exhaust control valves 11i are closed, and the intake control valve 12i is opened again to control the intake air amount independently, so that the glass substrate 4 of the laminate 100S can be controlled as shown in FIG. The pressure in the space partitioned by the small diaphragm 13i located above the peripheral edge is controlled to pressurize the entire laminate 100S. At this time, the force for pressing the peripheral portion of the glass substrate 4 of the laminated body 100S is less than the force for pressing the central portion of the laminated body 100S so that the trace of the glass substrate 4 does not remain on the small diaphragm 13i.

  In addition, when there is a portion that is located between the adjacent small diaphragms 13i and cannot be pressurized, all the sealed spaces partitioned by the upper chamber 20 and the small diaphragms 13i are set to negative pressure, and pressure is applied to the laminated body 100S. After the release, the roller 32 in the lower chamber 30 is rotated and the support device 31 of the roller 32 is moved in parallel so that the position at the boundary of the small diaphragm 13i of the laminated body 100S is positioned at the center of the small diaphragm 13i. Moving.

  Thereby, it becomes possible to pressurize the part which has not been pressurized again and to improve a moldability.

  According to the second embodiment, when pressing the laminated body 100S, the force for pressing the central portion of the laminated body 100S and the peripheral portion of the glass substrate 4 can be controlled independently. The contact pressure with the diaphragm 13i is reduced, and the trace of the glass substrate 4 is not transferred to the small diaphragm 13i, so that deformation can be suppressed. Therefore, the generation of wrinkles of the protective sheet 5 constituting the laminated body 100S or a defect such as a step remaining in the resin sheets 3a and 3b does not occur. The protective sheet 5 is a back surface protective material made of a water resistant resin.

Embodiment 3 FIG.
Next, a laminating apparatus according to Embodiment 3 of the present invention will be described. FIG. 15 is a perspective view showing a configuration of a laminating apparatus used in the solar cell module manufacturing apparatus according to Embodiment 3 of the present invention, and FIGS. 17 to 19 are process cross-sectional views showing a laminating process using the laminating apparatus. And corresponds to a cross-sectional view taken along the line CC of the laminating apparatus of FIG. 17 is a cross-sectional view taken along the line C-C when both the upper chamber 20 and the lower chamber 30 of the laminating apparatus of FIG. 15 are under negative pressure, and FIG. 18 controls the air flowing from the intake control valve 12 i of the upper chamber 20. 15 is a cross-sectional view of the laminating apparatus shown in FIG. 15 when the entire laminate 100S as the workpiece to be described in the third embodiment is pressed, and FIG. 19 alternately presses adjacent diaphragm sheets in FIG. It is CC sectional drawing of the laminating apparatus in FIG. 15 of the state which carried out. Also in the present embodiment, as in the second embodiment, it is divided into 40 small chambers 20i of 5 rows and 8 columns. The difference from the second embodiment is that there is no transport mechanism for transporting the workpiece in the horizontal direction in the laminating apparatus, and the pressurizing method is different.

  As in the laminating apparatus of the second embodiment, the laminating apparatus 10 of the third embodiment is divided into 40 rows of 40 small chambers 20i in 5 rows and 8 columns, and the internal pressure is changed such that the small chambers 20i are alternately pressurized. By controlling independently, the deformation | transformation of the small diaphragm 13i is avoided and the lamination process is performed by the appropriate pressurization also to the solar cell module from which size differs.

  Similar to the second embodiment, the upper chamber 20 of the laminating apparatus includes a small diaphragm 13i, an exhaust control valve 11i, and an intake control valve 12i. A plurality of small diaphragms 13i are provided vertically and horizontally, and an exhaust control valve 11i and an intake control valve 12i are provided for each sealed space. With this structure, the amount of inflow into each sealed space can be controlled, and the force with which the small diaphragm 13i in each sealed space pressurizes the stacked body 100S as a workpiece can be controlled.

  Next, a laminating method using the laminating apparatus of Embodiment 3 will be described. First, the mounting plate 34 is raised to an arbitrary temperature by the heating / cooling mechanism 35 and the temperature sensor provided on the mounting plate 34 of the lower chamber 30, the upper chamber 20 and the lower chamber 30 are separated, and the laminating apparatus is open. Next, as shown in FIG. 16, a laminated body 100 </ b> S as a workpiece in which the material of the solar cell module is laminated on the adhesion preventing sheet 18 provided above the mounting plate 34 of the lower chamber 30. As shown in FIG. 17, the vacuum pump 16 causes the space defined by the upper chamber 20 and the small diaphragm 13 i to be negative pressure, the upper chamber 20 is overlaid on the lower chamber 30, and the lower pump 30 A space defined by 30 and a plurality of small diaphragms 13i in the upper chamber 20 is also set to a negative pressure.

  After the bubbles generated from the laminated body 100S are discharged to the outside, the small diaphragm 13i is not brought into contact with the peripheral edge of the glass substrate 4 of the laminated body 100S in accordance with the size of the laminated body 100S. The control valve 12i for intake in the corresponding region is opened, and the central portion of the laminate 100S is pressurized as shown in FIG.

  Subsequently, the intake control valve 12 i in the region corresponding to the peripheral edge of the glass substrate 4 is opened. At this time, as shown in FIG. 18, the entire laminate 100S is pressurized by sucking air into the space defined by the small diaphragm 13i located above the peripheral edge of the glass substrate 4 of the laminate 100S. At this time, the force for pressing the peripheral portion of the glass substrate 4 of the laminated body 100S is less than the force for pressing the central portion of the laminated body 100S so that the trace of the glass substrate 4 does not remain on the small diaphragm 13i.

  Further, when there is a portion that is located between the adjacent small diaphragms 13i and cannot be pressurized, the upper chamber 20 is closed by closing the intake control valves 12i of all the small chambers 20i and opening the exhaust control valves 11i. The individual sealed spaces partitioned by the side wall 21 and the small diaphragm are all made negative. Then, the intake control valves 12i are alternately opened, and the exhaust control valves 11i of the small chambers 20i other than the corresponding small chamber 20i are alternately opened. Thereby, as shown in FIG. 19, by alternately pressurizing the adjacent diaphragm sheets 13i, it is possible to pressurize a portion that has not been pressed again and improve the moldability.

  According to Embodiment 3 of the present invention, when pressing the laminated body 100S, the force for pressing the central part of the laminated body 100S and the peripheral part of the glass substrate 4 can be controlled, respectively. The contact pressure with the diaphragm 13i is reduced, and the trace of the glass substrate 4 is not transferred to the small diaphragm 13i, so that deformation can be suppressed. For this reason, there is no occurrence of defects such as wrinkles of the water-resistant resin or remaining steps in the resin sheets 3a and 3b. Moreover, since the diaphragm sheet | seat to pressurize can be controlled separately, since it can press in order from the center of the laminated body 100S for forming a solar cell module, the residual of the bubble in a solar cell module is prevented. You can also.

Embodiment 4 FIG.
Next, a laminating apparatus according to Embodiment 4 of the present invention will be described. FIG. 20 is a perspective view showing a configuration of a laminating apparatus used in the solar cell module manufacturing apparatus according to Embodiment 4 of the present invention, and FIGS. 21 to 24 are process cross-sectional views showing a laminating process using the laminating apparatus. And corresponds to a DD cross-sectional view of the laminating apparatus of FIG. FIG. 22 shows a case where both the upper chamber 20 and the lower chamber 30 of the laminating apparatus are under negative pressure. 23 and 24 are cross-sectional views of the laminating apparatus in FIG. 19 when the air flowing from the intake control valve 12i of the upper chamber 20 is controlled to pressurize the laminate 100S described in the fourth embodiment. The fourth embodiment is different from the laminating apparatus of the third embodiment only in that an outer diaphragm sheet 23 is added to the outer side of the diaphragm sheet in the laminating apparatus of the third embodiment. The description is omitted here because it is the same. The same symbols are assigned to the same parts.

  In the fourth embodiment, the upper chamber 20 of the laminating apparatus is provided with a diaphragm sheet 13S composed of a combination of small diaphragms 13i, an outer diaphragm sheet 23, an exhaust control valve 11i, and an intake control valve 12i. A plurality of small diaphragms 13i together with the side walls 21 individually partition and seal the upper chamber 20, and an exhaust control valve 11i and an intake control valve 12i are provided for each small chamber 20i which is an individual sealed space. Yes. The entire space divided by the side wall 21 and the small diaphragm 13i is covered with a larger outer diaphragm sheet 23. With this structure, by controlling the amount of air flowing into the small chambers 20i, which are individual sealed spaces, the small diaphragms 13i of the small chambers 20i pass through the outer diaphragm sheet 23 to form a laminate 100S as a workpiece. It is possible to control the force for pressurizing. Further, the influence of the boundary between the small diaphragms 13i can be eliminated by the outer diaphragm sheet 23 covering the whole.

  Also in the present embodiment, the lower chamber 30 of the laminating apparatus is provided with a mounting plate 34 having a heating / cooling mechanism 35 and a temperature sensor, and an adhesion preventing sheet 18 such as a fluororesin. Therefore, the mounting plate 34 can be set to an arbitrary temperature by controlling the output of the heating / cooling mechanism 35 by the temperature sensor, and the adhesion preventing sheet 18 is removed from the mounting plate 34 heated by the heating / cooling mechanism 35. The resin sheets 3a and 3b in the workpiece heated by the heat exchange are melted and prevented from sticking out of the glass substrate 4 to the mounting plate 34.

  Next, a laminating method using the laminating apparatus of Embodiment 4 will be described. First, the mounting plate 34 is raised to an arbitrary temperature by the heating / cooling mechanism 35 and the temperature sensor provided on the mounting plate 34 of the lower chamber 30, the upper chamber 20 and the lower chamber 30 are separated, and the laminating apparatus is open. Next, as illustrated in FIG. 21, a stacked body 100 </ b> S as a workpiece in which the material of the solar cell module is stacked on the adhesion prevention sheet 18 provided above the mounting plate 34 of the lower chamber 30 is mounted. Then, as shown in FIG. 22, the vacuum pump 16 causes the space defined by the upper chamber 20 and the small diaphragm 13 i to be negative pressure, the upper chamber 20 is overlaid on the lower chamber 30, and the lower pump 30 A space defined by 30 and a plurality of small diaphragms 13i in the upper chamber 20 is also set to a negative pressure.

  After the bubbles generated from the laminated body 100S are discharged to the outside, the small diaphragm 13i is not brought into contact with the peripheral edge of the glass substrate 4 of the laminated body 100S in accordance with the size of the laminated body 100S. The control valve 12i for intake in the corresponding region is opened, and the laminate 100S is pressurized as shown in FIG.

  At this time, the outer diaphragm sheet 23 pressurizes the adjacent small diaphragms 13i without a gap.

  Subsequently, the intake control valve 12 i in the region corresponding to the peripheral edge of the glass substrate 4 is opened. At this time, as shown in FIG. 24, the inflow of air into the space defined by the small diaphragm 13i located above the peripheral edge of the glass substrate 4 of the laminated body 100S is controlled by the intake control valve 12i. The entire laminate 100S is pressurized. At this time, the force for pressing the peripheral portion of the glass substrate 4 of the laminated body 100S is made smaller than the force for pressing the central portion of the laminated body 100S.

  According to the laminating apparatus of the fourth embodiment, since the workpiece can be pressed with one outer diaphragm sheet 23, it is possible to press between adjacent small diaphragms 13i among a plurality of small diaphragms 13i.

  Furthermore, also in Embodiment 4, since the force which pressurizes the center part of the laminated body 100S and the peripheral part of the glass substrate 4 when pressurizing the laminated body 100S can be controlled, respectively, the peripheral part of the glass substrate 4 and the small diaphragm 13i. And the trace of the glass substrate 4 is not transferred to the small diaphragm 13i, and deformation can be suppressed. Therefore, there is no occurrence of defects such as generation of wrinkles of the water-resistant resin and a step remaining on the resin sheet.

  In the fourth embodiment, after the first step of pressurizing the whole, without using the two-step pressurization by reducing the pressurizing force of the peripheral portion, even when the pressurization is performed by the one-step pressurization step, Good pressurization can be performed without generation of wrinkles.

  In the first to fourth embodiments, only the upper chamber is divided. However, the heating / cooling mechanism on the mounting plate on which the substrate of the lower chamber is mounted is also divided into a plurality of parts, and temperature control can be performed independently. By making it possible, it becomes possible to perform the laminating process more efficiently.

  In the first to fourth embodiments, the diaphragm sheet has a divided shape corresponding to the small chamber, and may be mounted independently, or may be constituted by a single sheet. In the case of a single sheet, it may be divided into a plurality of regions by a locking portion provided at the lower end of the side wall of the upper chamber. In the case of the split shape, an extra area is required for mounting on each side wall, but it is easy to replace, and it is difficult to wrinkle only the peripheral part, and it is possible to change the material depending on the area, such as an elastic body. It is. On the other hand, when it is composed of a single sheet, there is an advantage that it is easy to handle and less material is used as a whole.

  Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope of the invention, and are included in the invention described in the claims and the equivalents thereof.

  100S laminate, 100 solar cell module, 101 frame, 1 solar cell, 2 tab wire, 3a, 3b resin sheet, 4 glass substrate, 5 protective sheet, 10 laminating device, 11a, 11b, 11c, 11d, 11i For exhaust Control valve, 12a, 12, 12c, 12d, 12i intake control valve, 13, 13S diaphragm seat, 13A, 13B, 13C, 13i small diaphragm, 14 mounting plate, 15 heating / cooling mechanism, 16 vacuum pump, 17 Pipe, 18 adhesion prevention sheet, 20 upper chamber, 20A, 20B, 20C, 20i small chamber, 21 side wall, 21a first side wall, 21b second side wall, 21c third side wall, 23 outer diaphragm sheet, 30 lower chamber 31 support device, 32 rollers, 33 bells G, 34 mounting plate, 35 heating and cooling mechanism.

Claims (15)

An upper chamber;
A lower chamber provided with a temperature controller for forming a space between the upper chamber and heating or cooling the space;
A diaphragm sheet displaceable in the space,
The space formed by the diaphragm sheet and the upper chamber is divided into small chambers composed of a plurality of closed spaces,
Each of the small chambers includes a control valve for exhaust and intake,
The displacement of the diaphragm sheet can be independently controlled in the small chamber, and the laminate of the resin sheet and the solar battery cell placed in the lower chamber is heated and pressurized in the space. A solar cell module manufacturing apparatus. The upper chamber includes a plurality of side walls suspended in a space formed between an inner top surface and the lower chamber,
The solar cell module manufacturing apparatus according to claim 1, wherein the diaphragm sheet is locked to a lower end of the side wall.   The said small chamber was comprised by the several small chamber formed concentrically, The solar cell module manufacturing apparatus of Claim 1 or 2 characterized by the above-mentioned.   The said small chamber was comprised by the some small chamber arranged in the matrix form, The solar cell module manufacturing apparatus of Claim 1 or 2 characterized by the above-mentioned.   The solar cell module manufacturing apparatus according to any one of claims 1 to 4, wherein the diaphragm sheet has a divided shape corresponding to the small chamber and is mounted independently. The diaphragm sheet is composed of a single sheet,
The solar cell module manufacturing apparatus according to any one of claims 1 to 4, wherein the solar cell module manufacturing apparatus is divided into a plurality of regions by a locking portion provided at a lower end of the side wall. The lower chamber is
The solar cell module manufacturing apparatus according to any one of claims 1 to 6, further comprising a transport unit configured to transport the stacked body, wherein the position of the stacked body can be changed. The diaphragm sheet includes an outer diaphragm sheet integrally disposed on the outside of the diaphragm sheet constituting the plurality of small chambers,
The said laminated body is pressed via the said outer side diaphragm sheet, The solar cell module manufacturing apparatus of any one of Claim 1 to 7 characterized by the above-mentioned. A laminating step of sandwiching solar cells with a resin sheet on a substrate to form a laminate,
A laminate step of heating and pressurizing the laminate to form a solar cell module,
The laminating step
A first step of heating and pressurizing the entire surface of the laminate;
And a second step of heating and pressurizing the laminated body at a peripheral edge of the laminated body with a pressing force smaller than that of the central part. The laminating step includes
An upper chamber;
A lower chamber provided with a temperature controller for forming a space between the upper chamber and heating or cooling the space;
A diaphragm sheet displaceable in the space,
Using a laminating apparatus in which the space formed by the diaphragm sheet and the upper chamber is divided into small chambers composed of a plurality of closed spaces,
The displacement of the diaphragm sheet in the small chamber is controlled independently, and the laminate mounted on the lower chamber is heated and pressurized in the space. The manufacturing method of the solar cell module of description. The upper chamber includes a plurality of side walls suspended in a space formed between an inner top surface and the lower chamber,
The diaphragm is locked to the lower end of the side wall,
The method for manufacturing a solar cell module according to claim 10, wherein the pressing force of each small chamber is controlled by the intake / exhaust to each small chamber and the intake / exhaust to the lower chamber.   The method for manufacturing a solar cell module according to claim 10 or 11, wherein the small chamber includes a plurality of small chambers formed concentrically.   The method for manufacturing a solar cell module according to claim 10 or 11, wherein the small chamber includes a plurality of small chambers arranged in a matrix. The laminating step includes
A first pressurizing step for heating and pressurizing the laminate;
A moving step of shifting the laminate so that the region between the small chambers is a region in the small chamber;
The method for manufacturing a solar cell module according to claim 13, further comprising a second pressurizing step of heating and pressurizing the laminate again after the moving step. The diaphragm sheet includes an outer diaphragm sheet integrally disposed on the outside of the diaphragm sheet constituting the plurality of small chambers,
The method for manufacturing a solar cell module according to any one of claims 9 to 14, wherein the laminating step is a step of pressing the laminated body through the outer diaphragm sheet.

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