JP2019106470A - Laminating device - Google Patents

Abstract

To provide a laminating device that can manufacture a solar panel having a resin protection cover and an extending part thinner than a main body part, with high quality.SOLUTION: In a laminating device, a laminate tool 3 supports a laminate 40 from a back face cover 43 side. The laminate 40 has a main body part 40a and an extending part 40b. The main body part 40a includes a protection cover 41, the back face cover 43, a solar battery cell 451, and an encapsulation material 47. The extending part 40b is composed of only the protection cover 41. The extending part 40b is located outside the main body part 40a. The laminate tool 3 has: a first support 31 formed with a first supporting surface 310 abutting on the main body part 40a to support the main body part 40a; and a second supporting body 33 formed with a second supporting surface 334 abutting on the extending part 40b to support the extending part 40b. A thermal capacity per unit area of the second supporting surface 334 is smaller than that of the first supporting surface 310.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a laminating apparatus.

  Generally, a solar panel is manufactured by pressure-bonding a laminate while heating by a laminating apparatus. Here, the laminate includes a protective cover, a back cover, a plurality of solar cells, and a sealing material. Such a laminating apparatus is disclosed, for example, in Patent Document 1.

  The laminating apparatus includes a housing, a laminating jig, a heater, and a diaphragm. The housing forms a vacuum chamber inside. The laminating jig is disposed in the vacuum chamber and supports the laminate. The heater is disposed in the vacuum chamber. The heater can heat the laminating jig while placing the laminating jig. The diaphragm is disposed in the vacuum chamber and faces the laminating jig.

  Further, the protective cover of the laminate is made of glass and has translucency from the front surface to the back surface. The back cover is located on the back side of the protective cover. The back cover is made of aluminum foil, fluorine resin or the like. The sealing material is constituted by two sealing material sheets made of ethylene vinyl acetate copolymer (EVA). And in a laminated body, a protection cover, the 1st sealing material sheet, a plurality of photovoltaic cells, the 2nd sealing material sheet, and a protection cover are laminated in this order.

  In this laminating apparatus, in manufacturing the solar panel, the laminate is placed on the laminating jig with the protective cover facing the laminating jig. Thus, the laminating jig supports the laminate from the protective cover side while in contact with the surface of the protective cover. Then, by heating the laminating jig by the heater, the heat of the laminating jig softens the both sealing material sheets. In this state, after the vacuum chamber is put into a vacuum state, the laminated body is crimped while the diaphragm is sandwiched between the laminated jig and the laminated body. For this reason, by integrating both sealing material sheets, the sealing material holds each solar battery cell in a sealed state between the protective cover and the back cover. Thereby, a protective cover, a back cover, each solar cell and sealing material are integrated, and a solar panel is manufactured. In this solar panel, the surface of the protective cover constitutes a design surface.

JP 10-214987 A

  By the way, in recent years, from the viewpoint of weight reduction and the like, a protective cover made of resin may be adopted instead of the protective cover made of glass. In addition, when a solar panel is adopted for a vehicle, the protective cover is generally fixed to the roof panel of the vehicle on the back side of the protective cover, so the protective cover is fixed to the roof panel or the like. In order to secure, it is formed larger than a back cover etc. Thus, in the laminate, and hence the solar panel, it has the main body including the protective cover, the back cover, the solar battery cell and the sealing material, and the extension only consisting of the protective cover and located outside the main body It will be. And an extension part becomes thin compared with a main-body part by consisting only of a protective cover.

  When such a solar panel is to be manufactured by the above-described conventional laminating apparatus, the surface of the protective cover is heated to a high temperature by being in contact with the laminating jig, and the surface of the protective cover is easily roughened by heat. For this reason, the aesthetics of the manufactured solar panel will be impaired.

  Therefore, in order to prevent the surface of the protective cover from coming into contact with the laminating jig, the laminate is placed on the laminating jig with the back cover directed to the laminating jig and laminated from the rear cover side to the laminating jig. It is conceivable to support the body. However, even in this case, since the extension portion is thinner than the main body portion, the extension portion is easily softened by being heated by the laminating jig. For this reason, when the laminated body is pressure-bonded, distortion or the like is easily generated in the extending portion by the pressurization by the diaphragm. Due to these, in this laminating apparatus, it is difficult to manufacture the above-described solar panel with high quality.

  The present invention has been made in view of the above-mentioned conventional circumstances, and provides a laminating apparatus having a protective cover made of resin and capable of manufacturing a solar panel having a thin extension portion thinner than a main body portion with high quality. The problem is to be solved.

The laminating apparatus according to the present invention comprises a protective cover made of a resin that transmits light from front to back, a back cover positioned on the back side of the protective cover, a solar battery cell, the protective cover, and the back cover A laminating apparatus having a sealing material for holding the solar battery cells in a sealed state between them while heating and pressing to manufacture a solar panel,
A housing that forms a vacuum chamber inside;
A laminating jig disposed in the vacuum chamber and supporting the laminate from the back cover side;
A heater disposed in the vacuum chamber and capable of heating the laminating jig while placing the laminating jig;
And a diaphragm that is disposed in the vacuum chamber and faces the laminating jig, and holds the laminated body with the laminating jig, and can crimp the laminated body.
The laminate includes the protective cover, the back cover, a main body including the solar battery cell and the sealing material, and an extension which is formed only of the protective cover and located outside the main body. ,
The laminating jig has a first support formed with a first support surface in contact with the main body to support the main body, and a second support in contact with the extension and supporting the extension. And a second support having a support surface formed thereon,
The heat capacity per unit area of the second support surface is smaller than the heat capacity per unit area of the first support surface.

  In the laminating apparatus of the present invention, since the laminating jig supports the laminate from the back cover side, the surface of the protective cover does not abut on the laminating jig. Thereby, even if the protective cover is made of resin, the surface thereof is not easily affected by the heat of the laminating jig, and the surface is not easily roughened by the heat.

  In addition, immediately after the laminate is placed on the laminating jig and the first and second support surfaces respectively support the main body portion and the extension portion, the laminate is the first and second support surfaces, and hence the first and second supports. It is colder than the body. Here, in this laminating apparatus, the heat capacity per unit area of the second support surface is smaller than the heat capacity per unit area of the first support surface. Therefore, when the second support surface supports the extension portion, the second support surface is cooled by the extension portion and becomes cooler than the first support surface. In addition, even if the second support is heated by the heater, the temperature of the second support surface is less likely to rise compared to the first support surface. As a result, in the laminating apparatus, the extension portion is less likely to be heated by the second support surface, so the extension portion is less likely to be softened. Thus, in this laminating apparatus, distortion or the like does not easily occur in the extending portion even when pressure is applied by the diaphragm when the laminate is pressure-bonded.

  Therefore, according to the laminating apparatus of the present invention, it is possible to manufacture a solar panel having a protective cover made of resin and having a thinner extension than the main body with high quality.

  The first support is preferably formed in a solid, and the second support is preferably formed in a hollow box shape. In this case, the heat capacity per unit area of the second support surface can be reduced, while the heat capacity per unit area of the first support surface can be increased. For this reason, while it is hard to heat about an extension part, it can heat suitably about a main-body part.

  Also, in this case, the second support is connected to the support plate on which the second support surface is formed, the bottom plate that is separated from the support plate and abuts the heater, and the support plate at one end side and the other end The side plate may be connected to the bottom plate and have a support plate and a side plate extending along the bottom plate. The thickness of the support plate is preferably thinner than the thickness of the bottom plate. Thereby, the heat capacity per unit area of the second support surface can be suitably reduced.

  Also, the first support may be formed solid. And a 2nd support body is spaced apart and arranged from a heater, is arranged between a support part in which the 2nd support surface was formed, a support part, and a heater, and while connecting with a support part by one end side, others It is also preferable to have a standing wall that abuts the heater at the end side.

  In this case, in the second support, the support is separated from the heater, and a space is formed between the support and the heater. Also by this, the heat capacity per unit area of the second support surface can be suitably reduced.

  It is also preferable that a flow path through which the coolant can flow is formed in the second support. In this case, the cooling liquid cools the second support, whereby the heat capacity per unit area of the second support surface can be suitably reduced.

  Preferably, the first support and the second support are spaced apart. In this case, since the heat of the first support is less likely to be transmitted to the second support, it is possible to suppress the heating of the second support by the first support.

  According to the laminating apparatus of the present invention, it is possible to manufacture a solar panel having a resin protective cover and having a thin extension portion thinner than the main body portion with high quality.

FIG. 1 is a cross-sectional view of the laminating apparatus of the first embodiment. FIG. 2 is a top view of a laminating jig according to the laminating apparatus of the first embodiment. FIG. 3 is an enlarged sectional view of a laminate and the like according to the laminating apparatus of the first embodiment. FIG. 4 is an enlarged sectional view of an essential part showing a state in which the laminating jig supports the laminated body according to the laminating apparatus of the first embodiment. FIG. 5 is an enlarged cross-sectional view of the laminating apparatus according to the first embodiment, showing a state in which the laminate is pressure bonded with a diaphragm and a laminating jig. 6 is a cross-sectional view of a solar panel manufactured by the laminating apparatus of Example 1. FIG. FIG. 7 relates to the laminating apparatus of the first embodiment, and is a graph showing temperature changes of the first support surface and the second support surface when manufacturing a solar panel. FIG. 8 is an enlarged sectional view of an essential part showing a state in which the laminating jig supports the laminated body according to the laminating apparatus of the second embodiment. FIG. 9 is an enlarged sectional view of an essential part showing a state in which the laminating jig supports the laminated body according to the laminating apparatus of the third embodiment. FIG. 10 is a graph showing a temperature change of the first support surface and the second support surface when manufacturing a solar panel according to the laminating apparatus of the third embodiment.

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

Example 1
As shown in FIG. 1, the laminating apparatus according to the first embodiment includes a housing 1, a laminating jig 3, a heater 5, a diaphragm 7, a first pipe 9, a second pipe 11, and a first pump 13. , And a second pump 15.

  In this embodiment, the left side of the paper surface of FIG. 1 is the front side of the laminating apparatus, and the right side of the paper surface of FIG. 1 is the rear side of the laminating apparatus to define the front-rear direction of the laminating apparatus. Further, the upper side of the sheet of FIG. 1 is the upper side of the laminating apparatus, and the lower side of the sheet of FIG. 1 is the lower side of the laminating apparatus, thereby defining the vertical direction of the laminating apparatus. Then, in FIG. 2 and thereafter, the front-rear direction and the up-down direction are defined corresponding to FIG. 1. Further, in FIG. 2, the upper side of the sheet is the right side of the laminating apparatus, and the lower side of the sheet is the left of the laminating apparatus to define the left-right direction of the laminating apparatus. Note that each of these directions is an example for the convenience of description.

  The housing 1 has a first housing 17 and a second housing 19. The first housing 17 has a flat bottom wall 17 a and a first side wall 17 b extending upward from the bottom wall 17 a toward the second housing 19. The second housing 19 is attached to the first housing 17 so as to be openable and closable, and is disposed above the first housing 17. The second housing 19 has an upper wall 19 a formed in a planar shape, and a second side wall 19 b extending downward from the upper wall 19 a toward the first housing 17.

  When the second housing 19 is closed with respect to the first housing 17, the first side wall 17b and the second side wall 19b abut. Thus, a vacuum chamber 21 is formed in the housing 1. Although not shown, sealing members for sealing between the vacuum chamber 21 and the outside of the housing 1 are provided on the first side wall 17 b and the second side wall 19 b.

  The first pipe 9 is attached to the bottom wall 17a, and the second pipe 11 is attached to the upper wall 19a. A first pump 13 is provided in the first pipe 9, and a second pump 15 is provided in the second pipe 11. The first and second pumps 13 and 15 can discharge the air in the vacuum chamber 21 through the first and second pipes 9 and 11, respectively, and can supply the air into the vacuum chamber 21. The first pipe 9 may be attached to the first side wall 17b. Similarly, the second pipe 11 may be attached to the second side wall 19b.

  The laminating jig 3 is disposed in the first housing 17, that is, in the vacuum chamber 21. The laminating jig 3 is formed in a curved shape projecting toward the upper side of the vacuum chamber 21. More specifically, the laminating jig 3 is curved toward the upper side of the vacuum chamber 21 with a curvature along the protective cover 41 shown in FIG. 3.

  As shown in FIGS. 1 and 2, the laminating jig 3 is composed of a first support 31 and a second support 33. The first support 31 is formed of aluminum. As shown in FIG. 1, the first support 31 is formed in a solid block shape. Thus, the first support 31 has the first support surface 310, the bottom surface 311, and the outer peripheral surface 312.

  As shown in FIG. 2, the first support 31 has a rectangular shape in which the length in the front-rear direction is longer than the length in the left-right direction in top view. Here, while the first support 31 is larger than the back cover 43 shown in FIG. 3, the first support 31 is formed smaller than the protective cover 41.

  The first support surface 310 constitutes the upper surface of the first support 31 and is curved toward the upper side of the vacuum chamber 21 with a curvature along the protective cover 41. The bottom surface 311 is located opposite to the first support surface 310 and is flat. The outer circumferential surface 312 is continuous with the first support surface 310 and the bottom surface 311. Further, as shown in FIG. 2, a first engagement hole 31 a recessed downward from the first support surface 310 is formed at the center of the first support 31, that is, at the center of the laminating jig 3.

  The second support 33 is provided on the outside of the first support 31. As shown in FIG. 4, the second support 33 includes a support plate 330, a bottom plate 331, a first side plate 332, and a second side plate 333. The support plate 330, the bottom plate 331, and the first and second side plates 332 and 333 are made of aluminum plate members. That is, the second support 33 is also formed of aluminum. The first and second supports 31 and 33 may be made of other than aluminum.

  As shown in FIG. 2, the support plate 330 is formed in a rectangular frame shape that encloses the first support 31 from the outside in top view. Further, as shown in FIG. 4, the support plate 330 is formed with a second support surface 334 which protrudes toward the upper side of the vacuum chamber 21, that is, the laminate 40 described later. The support plate 330 including the second support surface 334 is curved toward the upper side of the vacuum chamber 21 with a curvature along the protective cover 41. As a result, the second support surface 334 has a shape that gradually protrudes toward the stacked body 40 as it approaches the first support 31. The bottom plate 331 is spaced apart from the support plate 330 at the lower side. Although detailed illustration is omitted, like the support plate 330, the bottom plate 331 is formed in a rectangular frame shape that encloses the first support 31 from the outside in top view. Further, the bottom plate 331 is formed flat. The first and second side plates 332 and 333 are connected to the support plate 330 at the upper end side and to the bottom plate 331 at the lower end side, and extend along the support plate 330 and the bottom plate 331 while facing each other. Thus, the first side plate 332 constitutes the outer peripheral surface of the second support 33, and the second side plate 333 constitutes the inner peripheral surface of the second support 33. The upper end and the lower end of the first and second side plates 332 and 333 are examples of “one end of the side plate” and “the other end of the side plate” in the present invention.

  Here, the thickness of the support plate 330 is thinner than that of the bottom plate 331. Details of the thickness of the support plate 330 will be described later. The second support 33 is formed into a hollow box shape by the support plate 330, the bottom plate 331, and the first and second side plates 332 and 333. Accordingly, a space 335 partitioned from the vacuum chamber 21 by the support plate 330, the bottom plate 331 and the first and second side plates 332 and 333 exists inside the second support 33.

  Further, in the laminating jig 3, the first support 31 and the second support 33 are disposed apart from each other. Thereby, between the first support 31 and the second support 33, more specifically, between the outer peripheral surface 312 of the first support 31 and the second side plate 333 of the second support 33, A gap S is formed. The size of the gap S can be designed as appropriate. Further, as shown in FIG. 2, a second engagement hole 33 a is formed at a position on the front side of the second support 33 on the second support surface 334. The second engagement hole 33a is formed larger than the first engagement hole 31a. In addition, in FIG. 1 etc., in order to demonstrate easily, in addition to the 1st engagement hole 31a and the 2nd engagement hole 33a, shapes, such as clearance gap S, are exaggerated and shown in figure.

  As shown in FIG. 1, the heater 5 is disposed in the vacuum chamber 21. More specifically, the heater 5 is located below the laminating jig 3 in the first housing 17. The heater 5 has a heater case 5a and a plurality of heater bodies 5b. The heater case 5a is formed of a metal such as stainless steel. The heater case 5 a is formed in a rectangular shape larger than the laminating jig 3, and the laminating jig 3 is placed. Thus, the bottom surface 311 of the first support 31 and the bottom plate 331 of the second support 33 are in contact with the heater case 5a. The heater case 5a is fixed to the bottom wall 17a of the first housing 17 by the leg 5c. Each heater body 5 b is accommodated in the heater case 5 a and extends in the left-right direction of the laminating jig 3. As each heater main body 5b, a ceramic heater etc. are employable, for example. Each heater body 5b generates heat when power is supplied from a power supply device (not shown). Thus, the heater 5 can heat the laminating jig 3. The number of heater bodies 5b can be appropriately designed.

  The diaphragm 7 is formed of synthetic rubber or the like having heat resistance to the heat of the laminating jig 3 and is elastically deformable. The diaphragm 7 is mounted in the second housing 19 by fixing its outer peripheral edge to the second side wall 19 b of the second housing 19. Thus, the diaphragm 7 is disposed above the laminating jig 3 in the vacuum chamber 21 and faces the laminating jig 3. Further, the vacuum chamber 21 is divided by the diaphragm 7 into a first vacuum region 21 a below the diaphragm 7 and a second vacuum region 21 b above the diaphragm 7.

  In this laminating apparatus, a vehicle solar panel 50 shown in FIG. 6 is manufactured. The vehicle solar panel 50 is an example of the “solar panel” in the present invention. The vehicle solar panel 50 has a protective cover 41, a back cover 43, a solar cell string 45, and a sealing material 47. The vehicle solar panel 50 is employed in the vehicle 100, and is attached to the roof panel 101 of the vehicle 100. In addition, the detail about the protective cover 41, the back cover 43, the solar cell string 45, and the sealing material 47 is mentioned later. Hereinafter, manufacture of the solar panel 50 for vehicles by a laminating apparatus is demonstrated concretely.

  First, as shown in FIG. 3, a laminate 40 including the protective cover 41, the back cover 43, the solar cell string 45, and the sealing material 47 is prepared.

  The protective cover 41 is formed larger than the back cover 43, the solar cell string 45, and the sealing material 47. The protective cover 41 has a cover main body 41a and a concealing member 41b. The cover main body 41 a is formed in a rectangular plate shape by a transparent resin containing polycarbonate as a main component, and has translucency from the front surface 410 to the back surface 411. As shown in FIG. 6, the surface 410 constitutes the surface of the vehicle solar panel 50, that is, the design surface of the vehicle solar panel 50. Here, the cover main body 41 a and hence the protective cover 41 are formed in advance in a curved shape that protrudes from the back surface 411 toward the front surface 410 at a curvature along the roof panel 101 of the vehicle 100. As a result, the cover main body 41 a, and hence the protective cover 41, has a shape along the roof panel 101 of the vehicle 100. As shown in FIG. 3, the concealing member 41b is formed of a resin whose main component is polycarbonate colored in opaque black or the like. The concealing member 41 b is formed by injection molding on the back surface 411 of the cover main body 41 a and is integral with the back surface 411. The cover main body 41a and the concealing member 41b may be formed of a resin whose main component is other than polycarbonate. In addition, the protective cover 41 may be configured only by the cover main body 41a.

  The concealing member 41 b has a peripheral portion 412 and a plurality of connecting portions 413. The peripheral portion 412 is formed in a frame shape surrounding the solar cell string 45 along the outer edge of the cover main body 41 a. The peripheral portion 412 prevents the connection tab line 453 of the solar cell string 45 and the fixed portion between the protective cover 41 and the roof panel 101 from being seen from the surface 410 side of the cover main body 41 a. Each connecting portion 413 is disposed inside the peripheral portion 412, and extends in the left-right direction of the cover main body 41a. Each connecting portion 413 prevents the interconnect 452 of the solar cell string 45 from being seen from the surface 410 side.

  Further, a first engaging protrusion 414 is integrally formed on the connecting portion 413 passing through the center of the protective cover 41 among the connecting portions 413. The first engagement protrusion 414 is located at the center of the protective cover 41 and hence at the center of the stack 40. The first engagement protrusion 414 linearly extends downward from the connection portion 413. In addition, a second engagement protrusion 415 is integrally formed at a position on the front side of the protective cover 41 in the peripheral portion 412. The second engagement protrusion 415 has the same configuration as the first engagement protrusion 414.

  The back cover 43 is formed of a resin whose main component is polycarbonate. The back cover 43 has a bottom plate 43a formed by bending in advance with a curvature along the protective cover 41, and a peripheral wall 43b extending upward from the bottom plate 43a while surrounding the bottom plate 43a. The bottom plate 43 a is formed with a through hole 430 through which the first engagement protrusion 414 can be inserted. In addition, you may form the back cover 43 with metal etc. other than resin which has other than a polycarbonate as a main component. In addition, the back cover 43 may be configured to have only the bottom plate 43a.

  The solar cell string 45 includes a plurality of solar cells 451, a plurality of interconnectors 452, and a plurality of connection tab lines 453. Each solar battery cell 451 is arranged in a matrix. Each photovoltaic cell 451 is connected to be electrically conductive by each interconnector 452 and each connection tab wire 453.

  The sealing material 47 is comprised by the 1st sealing material 47a and the 2nd sealing material 47b. The first and second sealants 47a and 47b are made of EVA and are each formed in a sheet shape. Further, through holes 471 and 472 through which the first engagement protrusions 414 can be inserted are formed in the first and second sealing materials 47a and 47b, respectively. The first and second sealants 47a and 47b may be formed of, for example, a silicone resin or a polyolefin other than an ionomer resin, instead of EVA. Further, in FIG. 3 and the like, the thickness and the size of the first and second sealing materials 47a and 47b and the respective solar battery cells 451 and the like are exaggerated to facilitate the description. The shapes of the engagement protrusions 414, 415, etc. are exaggerated.

  In the laminated body 40, the protective cover 41, the first sealing material 47a, the solar cell string 45, the second sealing material 47b, and the back cover 43 are stacked in this order. Thereby, the back cover 43 is positioned on the back surface 411 side of the cover main body 41 a. Here, in the laminated body 40, the protective cover 41 and the back cover 43 are disposed in a state in which the first sealing material 47a, the solar cell string 45, and the second sealing material 47b are disposed between the protective cover 41 and the back cover 43. And are temporarily fixed by double-sided tape etc. As a result, the first engagement protrusion 414 protrudes downward relative to the back cover 43 through the through hole 471, the through hole 472 and the through hole 430.

  Here, the protective cover 41 is larger than the rear cover 43 and the like. As a result, the laminate 40, and hence the vehicle solar panel 50, includes the main body 40a including the protective cover 41, the first sealing material 47a, the solar cell string 45, the second sealing material 47b, and the back cover 43; And an extending portion 40b consisting of only 41. The extension portion 40b is located outside the main body portion 40a and surrounds the main body portion 40a. Moreover, since the extension part 40b consists only of the protective cover 41, it is thinner than the main-body part 40a.

  Next, power is supplied to each heater main body 5b shown in FIG. 1 to heat each heater main body 5b, thereby heating the laminating jig 3, that is, the first support 31 and the second support 33. As shown in FIG. 7, in the present embodiment, the first support 31 and the second support 33 are heated to X 1 ° C. by the heater 5. X1 ° C. is a temperature at which the first and second sealants 47a and 47b shown in FIG. 3 can be softened.

  Next, as shown in FIGS. 3 and 4, the laminate 40 is placed on the laminating jig 3. At this time, in the laminate 40, the back cover 43 is directed to the laminating jig 3. Then, as shown in FIG. 3, the first engagement projection 414 is inserted into the first engagement hole 31a, and the second engagement projection 415 is inserted into the second engagement hole 33a. Thereby, the laminated body 40 and the laminating jig 3 are positioned. Thus, as shown in FIG. 4, the laminating jig 3 supports the laminate 40 from the back cover 43 side. More specifically, in the first support 31, the first support surface 310 abuts on the bottom plate 43 a of the back cover 43. Thus, the first support surface 310 supports the main body 40 a of the stacked body 40. On the other hand, in the second support 33, the second support surface 334 abuts on the peripheral portion 412 of the protective cover 41. Thus, the second support surface 334 supports the extending portion 40 b of the stack 40.

  Here, the thickness of the support plate 330 is set such that the heat capacity per unit area of the support plate 330 is substantially equal to the heat capacity per unit area of the protective cover 41. The heat capacity per unit area is calculated by multiplying the value of specific gravity, the value of specific heat, and the value of plate thickness. Specifically, the specific gravity of aluminum forming the support plate 330 is 2.4. The specific heat is 0.88. On the other hand, the specific gravity of the polycarbonate-based resin forming the protective cover 41 is 1.2, and the specific heat is 1.2. Therefore, for example, when the thickness of the protective cover 41 is 5 mm, the heat capacity per unit area of the support plate 330 and the thickness of the protective cover 41 can be set by setting the thickness of the support plate 330 to about 3.4 mm. The heat capacity per unit area is approximately equal. When the thickness of the protective cover 41 is 8 mm, the heat capacity per unit area of the support plate 330 and the unit area of the protective cover 41 can be set by setting the thickness of the support plate 330 to about 5.44 mm. And the heat capacity of the

  Next, a preheating step is performed. In the preheating step, the laminate 40 is heated for a fixed time while the laminate 40 is supported by the laminating jig 3. Thereby, the main body portion 40a is heated by the first support surface 310, and the first sealing material 47a and the second sealing material 47b begin to soften. On the other hand, the extension portion 40 b is heated by the second support surface 334. Here, since the second support 33 is formed larger than the protective cover 41, the peripheral portion 412 does not come off the second support surface 334 even when the protective cover 41 thermally expands. The second support surface 334 can support the extension 40 b. Furthermore, since the second engagement hole 33a is formed larger than the first engagement hole 31a, the second engagement protrusion 415 moves in the second engagement hole 33a when the protective cover 41 is thermally expanded. It is possible to

  After the preheating process is completed, the crimping process is performed. In the pressure bonding step, as shown in FIG. 5, the first and second pumps 13 and 15 are operated to make the inside of the vacuum chamber 21, that is, the inside of the first and second vacuum regions 21a and 21b be in a vacuum state. Thus, the air present in the stack 40 is discharged. Thereafter, air is supplied to the second vacuum region 21 b by the second pump 15 to make the second vacuum region 21 b higher in pressure than the first vacuum region 21 a. Thereby, the diaphragm 7 is pressed against the laminate 40 from the side of the protective cover 41 while being elastically deformed. At this time, the first and second support surfaces 310 and 334 continue to support the main body 40a and the extension 40b from the back cover 43 side, that is, the opposite side of the diaphragm 7. Thus, the diaphragm 7 crimps the laminated body 40 while sandwiching the laminated body 40 with the laminating jig 3. For this reason, the softened first sealing material 47a and the second sealing material 47b are integrated. Therefore, the sealing material 47 holds the solar cell strings 45, that is, the respective solar cells 451, the respective interconnectors 452, and the respective connection tab lines 453 in a sealed state between the protective cover 41 and the back cover 43. . Thereby, the protective cover 41, the back cover 43, the solar cell string 45, and the sealing material 47 are integrated. Thus, the pressure bonding step is completed, and the vehicle solar panel 50 shown in FIG. 6 is manufactured from the laminate 40.

  In the vehicle solar panel 50, the extended portion 40 b is fixed to the roof panel 101 by bonding the peripheral portion 412 of the concealing member 41 b to the roof panel 101 of the vehicle 100. The main body 40 a is disposed in the opening 102 formed in the roof panel 101. Thus, the vehicle solar panel 50 is attached to the roof panel 101. In the vehicle solar panel 50, a portion of the first engagement protrusion 414 that protrudes from the back cover 43 is cut away. In addition, the second engagement protrusion 415 is also cut off.

  As described above, in the laminating apparatus, the laminating jig 3 supports the laminated body 40 from the back cover 43 side. Thereby, the surface 410 of the cover main body 41 a in the protective cover 41 does not abut on the laminating jig 3, that is, the first and second supports 31 and 33. For this reason, even if the cover main body 41a and hence the protective cover 41 are made of resin, the surface 410 is not easily affected by the heat of the first and second supports 31 and 33, and roughening by the heat is less likely to occur. .

  Further, in the laminating apparatus, the extension portion 40 b is less likely to be heated by the second support surface 334. This action will be specifically described based on the graph of FIG. In this graph, from time T1 to time T2, it is the preheating time in which the preheating step is performed. Moreover, from time T2 to time T3, it is a crimping | compression-bonding time in which a crimping | compression-bonding process is performed. The sum of the preheating time and the pressure bonding time, that is, from time T1 to time T3 is a manufacturing time for manufacturing the solar panel 50 for a vehicle from the laminate 40.

  As described above, the first support 31 and the second support 33 are heated by the heater 5 before the stacked body 40 is placed, and thus become X 1 ° C. Here, since the temperature of the laminated body 40 is about room temperature before being heated by the first support 31 and the second support 33, the temperature is lower than that of the first and second supports 31 and 33. For this reason, the laminated body 40 is placed on the laminating jig 3 at time T1, and the first and second support surfaces 310 and 334 support the main body 40a and the extension 40b, respectively. Is cooled by the main body 40a, and the second support surface 334 is cooled by the extension 40b.

  Here, while the first support 31 is formed in a solid block, the second support 33 is formed in a hollow box. Furthermore, in the second support 33, the thickness of the support plate 330 is thinner than the thickness of the bottom plate 331. From these, the heat capacity per unit area of the second support surface 334 is smaller than the heat capacity per unit area of the first support surface 310. Therefore, the temperature of the first support surface 310 of the first support 31 is lowered from X1 ° C. to X2 ° C. by placing the laminate 40 on the laminating jig 3. In the support 33, the temperature of the second support surface 334 is lowered to X3 ° C. lower than X1 ° C. to X2 ° C.

  Then, while the first and second supports 31 and 33 are both heated by the heater 5 and the temperature gradually rises during the preheating step, there is a space 335 in the second support 33. Thus, the temperature of the second support surface 334 is less likely to rise than that of the first support surface 310. For this reason, in the preheating step, the extension portion 40 b is less likely to be heated by the second support surface 334. That is, in the second support 33, even if the bottom plate 331 is heated by the heater 5, the space 335 makes it difficult for the heat of the bottom plate 331 to be transmitted to the support plate 330. For this reason, since the temperature of the second support surface 334 hardly rises, the second support surface 334 does not easily heat the extension portion 40 b. Thereafter, at time T2, the preheating step is completed and the crimping step is started. At this time, since the vacuum chamber 21 is in a vacuum state and the diaphragm 7 abuts on the laminate 40, the temperatures of the first and second support surfaces 310 and 334 slightly decrease.

  Then, by continuing to be heated by the heater 5 during the pressure bonding step, the temperature of the first support surface 310 of the first support 31 rises to almost X1. Therefore, the main body portion 40 a is heated to approximately X 1 ° C. by the heat of the first support surface 310. On the other hand, even if the second support 33 continues to be heated by the heater 5, the temperature of the second support surface 334 does not rise to X 1 ° C. during the pressure bonding process. For this reason, also in the pressure bonding step, the extension portion 40 b is less likely to be heated by the second support surface 334.

  Furthermore, in the laminating apparatus, since the first support 31 and the second support 33 are separated by the gap S, it is difficult for the heat of the first support 31 to be transmitted to the second support 33. For this reason, the heating of the second support 33 by the first support 31 suppresses the temperature rise of the second support surface 334.

  As described above, in this laminating apparatus, after the second support surface 334 is cooled by the extension portion 40 b, the temperature of the second support surface 334 hardly increases throughout the manufacturing time. Thus, the extension 40b is less likely to be heated by the second support surface 334 throughout the manufacturing time. For this reason, the extension part 40b is difficult to soften. As a result, in this laminating apparatus, even when pressure is applied by the diaphragm 7 when the laminate 40 is pressure-bonded, distortion or the like does not easily occur in the extending portion 40 b. On the other hand, in this laminating apparatus, the heat capacity per unit area of the first support surface 310 is increased by forming the first support 31 in a solid block shape. As a result, the heat of the first support surface 310 can suitably heat the first and second sealing materials 47 a and 47 b. Therefore, in the pressure bonding step, the protective cover 41, the back surface cover 43, the solar cell string 45, and the sealing material 47 can be suitably pressure-bonded and integrated. In other words, since the first and second sealing members 47a and 47b do not exist in the extension portion 40b, there is no need to raise the temperature of the second support surface 334 to X1 ° C. to heat the extension portion 40b. . As described above, in this laminating apparatus, it is difficult to heat the extension portion 40b, but the main body portion 40a can be suitably heated.

  Therefore, according to the laminating apparatus of the first embodiment, the vehicle solar panel 50 having the resin protective cover 41 and the extension portion 40 b thinner than the main body portion 40 a can be manufactured with high quality.

  Here, even after the solar panel 50 for a vehicle is completed and the solar panel 50 for a vehicle is taken out from the laminating apparatus, the first and second supports 31 and 33 continue to be heated by the heater 5, thereby a second support Finally, the temperature of the second support surface 334 also rises to X 1 ° C. However, in this laminating apparatus, when the new laminate 40 is placed on the laminating jig 3, the second support surface 334 can be cooled to X3 ° C. each time. Thus, in the laminating apparatus, it is not necessary to individually perform heating control on the first and second supports 31 and 33.

  Further, in this laminating apparatus, since the second support surface 334 of the support plate 330 protrudes toward the laminate 40, the second support surface 334 is protected even if the extension 40b is thinner than the main body 40a. It is possible to suitably contact the peripheral portion 412 of the cover 41. Thereby, the second support surface 334 can suitably support the extension portion 40 b.

  Furthermore, since the second engagement hole 33a is formed larger than the first engagement hole 31a, when the protective cover 41 is thermally expanded, the second engagement projection 415 extends in the second engagement hole 33a. It can move. For this reason, the second engagement hole 33 a is difficult to restrict thermal expansion of the protective cover 41, and can prevent the occurrence of wrinkles and the like on the protective cover 41.

(Example 2)
As shown in FIG. 8, in the laminating apparatus of the second embodiment, the laminating jig 3 includes the first support 31 and the second support 37. Similar to the second support 33, the second support 37 is also formed of aluminum. The second support 37 may also be formed other than aluminum.

  The second support body 37 has a support portion 370 and an upright wall portion 371, and is formed in a substantially box-like shape whose lower side is opened. The support portion 370 is formed in the same shape as the support plate 330 of the second support 33. Further, a second support surface 372 is formed on the support portion 370. The second support surface 372 has the same shape as the second support surface 334, and a second engagement hole 33a is formed. Thus, the support portion 370 can support the extension portion 40 b through the second support surface 372. The upright wall portion 371 is integrally formed with the support portion 370. The upright wall portion 371 is connected to the support portion 370 at the upper end side and in contact with the heater case 5a at the lower end side, and encloses the support portion 370. Further, in the second support 37, the support portion 370 is separated above the heater 5 by the standing wall portion 371. Thus, a space 373 is formed between the support portion 370 and the heater 5 in the second support 37. The other configuration of this laminating apparatus is the same as that of the laminating apparatus of the first embodiment, and the same reference numerals are given to the same components and the detailed description of the components will be omitted.

  The second support 37 has a substantially box shape whose lower side is opened, and a space 373 is formed between the support 370 and the heater 5. As a result, in the second support 37, the space 373 makes it difficult for the heat of the heater 5 to be transmitted to the support portion 370. Furthermore, since only the lower end side of the standing wall portion 371 abuts on the heater case 5a, the contact area with the heater 5 is small in the second support 37. For this reason, the heat of the heater 5 is difficult to be transmitted to the support portion 370 also through the standing wall portion 371. Thus, the heat capacity per unit area of the second support surface 372 is smaller than the heat capacity per unit area of the first support surface 310. For this reason, also in the second support body 37, the second support surface 372 is difficult to heat the extending portion 40b. Thus, this laminating apparatus can also perform the same function as the laminating apparatus of the first embodiment.

(Example 3)
As shown in FIG. 9, in the laminating apparatus of the third embodiment, the laminating jig 3 includes the first support 31 and the second support 39. The second support 39 is formed of aluminum. The second support 39 is formed in a block shape and has an annular shape surrounding the first support 31. The second support 39 may also be formed other than aluminum.

  The second support 39 has an upper surface 390, a bottom surface 391, and an outer peripheral surface 392. The shape of the upper surface 390 is the same as the support plate 330 of the second support 33. The upper surface 390 is formed with a second support surface 393 having the same shape as the second support surface 334. A second engagement hole 33 a is formed in the second support surface 393. The upper surface 390 can support the extension 40 b through the second support surface 393. The bottom surface 391 is in contact with the heater case 5a. The outer circumferential surface 392 is continuous with the top surface 390 and the bottom surface 391 and extends in the vertical direction.

  Further, inside the second support 39, a first flow path 394a and a second flow path 394b are formed. Although not shown in detail, the first and second channels 394 a and 394 b extend annularly inside the second support 39. The coolant 60 can flow in the first and second channels 394a and 394b. The coolant 60 is supplied from the outside of the laminating apparatus into the first and second flow paths 394a and 394b by a supply path (not shown). Note that only the first flow path 394a may be formed inside the second support 39, or may be formed in addition to the first and second flow paths 394a and 394b. The other configuration of this laminating apparatus is the same as that of the laminating apparatus of the first embodiment.

  In this laminating apparatus, the cooling fluid 60 flowing in the first and second flow paths 394 a and 394 b cools the second support 39. For this reason, even if the second support 39 is heated by the heater 5, the temperature of the second support 39 does not easily rise, and the temperature of the second support surface 393 does not easily rise. Thus, the heat capacity per unit area of the second support surface 393 is smaller than the heat capacity per unit area of the first support surface 310. Specifically, as shown in FIG. 10, in this laminating apparatus, the first support 31 and the second support 39 are heated by the heater 5 before the laminate 40 is placed. While the temperature of the surface 310 rises to X1 ° C., the temperature of the second support surface 393 rises only to Y1 ° C. which is lower than X1 ° C. or X2 ° C. The temperature of the second support surface 393 is lowered from Y1 ° C. to Y2 ° C. by placing the laminate 40 on the laminating jig 3 at time T1. Thereafter, the cooling liquid 60 also cools the second support 39 while the heating process and the pressure bonding process are performed. For this reason, since the temperature of the second support 39 hardly rises throughout the manufacturing time, the temperature of the second support surface 393 also hardly rises. Thus, in this laminating device, the extending portion 40b is less likely to be heated by the second support surface 393 throughout the manufacturing time than in the laminating devices of Examples 1 and 2, and distortion or the like occurs more in the extending portion 40b. It is difficult.

  Although the present invention has been described based on the first to third embodiments in the above, the present invention is not limited to the first to third embodiments described above, and can be appropriately modified and applied without departing from the scope of the present invention Needless to say.

  For example, in the laminating apparatus of the first to third embodiments, the laminating jig 3 and the bottom plate 43a of the back cover 43 are formed in a curved shape along the curved shape of the protective cover 41. However, not limited to this, when the protective cover 41 is flat, the shapes of the laminating jig 3 and the bottom plate 43a of the back cover 43 can be designed accordingly.

  In addition, the heat capacity per unit area of the second support surface 334 can be set to the first support surface by forming the second support 33 in a honeycomb shape or the like or by using a material different from that of the first support 31. The heat capacity per unit area of 310 may be smaller. The same applies to the laminating apparatus of the second and third embodiments.

  INDUSTRIAL APPLICABILITY The present invention is applicable to the manufacture of solar panels and the like used in various solar power generation facilities in addition to solar panels for vehicles.

DESCRIPTION OF SYMBOLS 1 ... Housing 3 ... Lamination jig 5 ... Heater 7 ... Diaphragm 31 ... 1st support body 33 ... 2nd support body 37 ... 2nd support body 39 ... 2nd support body 40 ... Laminated body 40a ... Main-body part 40b ... Extension Part 41 ... protective cover 43 ... back cover 47 ... sealing material 50 ... solar panel for vehicles (solar panel)
DESCRIPTION OF SYMBOLS 60 ... Cooling fluid 310 ... 1st support surface 330 ... Support plate 331 ... Bottom plate 332 ... 1st side plate (side plate)
333 ... 2nd side plate (side plate)
334 second supporting surface 370 supporting portion 371 standing wall portion 372 second supporting surface 393 second supporting surface 394a first flow path (flow path)
394b: second flow path (flow path)
410 ... surface 411 ... back surface 451 ... solar battery cell

Claims (6)

A protective cover made of a transparent resin from the front to the back, a back cover located on the back side of the protective cover, a solar cell, and the solar cell between the protective cover and the back cover It is a laminating apparatus which manufactures a solar panel by pressure-bonding while heating a laminate having a sealing material which holds the sealing material in a sealed state,
A housing that forms a vacuum chamber inside;
A laminating jig disposed in the vacuum chamber and supporting the laminate from the back cover side;
A heater disposed in the vacuum chamber and capable of heating the laminating jig while placing the laminating jig;
And a diaphragm that is disposed in the vacuum chamber and faces the laminating jig, and holds the laminated body with the laminating jig, and can crimp the laminated body.
The laminate includes the protective cover, the back cover, a main body including the solar battery cell and the sealing material, and an extension which is formed only of the protective cover and located outside the main body. ,
The laminating jig has a first support formed with a first support surface in contact with the main body to support the main body, and a second support in contact with the extension and supporting the extension. And a second support having a support surface formed thereon,
The heat capacity per unit area of the second support surface is smaller than the heat capacity per unit area of the first support surface.   The laminating apparatus according to claim 1, wherein the first support is formed in a solid, and the second support is formed in a hollow box shape. The second support is connected to the support plate on which the second support surface is formed, a bottom plate spaced from the support plate and in contact with the heater, and the other end connected to the support plate at one end side A side plate connected to the bottom plate and having a support plate and a side plate extending along the bottom plate;
The laminating apparatus according to claim 2, wherein a thickness of the support plate is thinner than a thickness of the bottom plate. The first support is solidly formed,
The second support is disposed apart from the heater, and is disposed between a support formed with the second support surface, the support and the heater, and is connected to the support at one end side The laminating apparatus according to claim 1, further comprising: an upright wall portion contacting the heater at the other end side.   The laminating apparatus according to claim 1, wherein a flow path through which a cooling fluid can flow is formed in the second support.   The laminating apparatus according to any one of claims 1 to 5, wherein the first support and the second support are spaced apart.

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