JP6535089B2 - 太陽電池モジュールの製造装置及び太陽電池モジュールの製造方法 - Google Patents
太陽電池モジュールの製造装置及び太陽電池モジュールの製造方法 Download PDFInfo
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- JP6535089B2 JP6535089B2 JP2017517600A JP2017517600A JP6535089B2 JP 6535089 B2 JP6535089 B2 JP 6535089B2 JP 2017517600 A JP2017517600 A JP 2017517600A JP 2017517600 A JP2017517600 A JP 2017517600A JP 6535089 B2 JP6535089 B2 JP 6535089B2
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Description
実施形態において参照する図面は、模式的に記載されたものであり、図面に描画された構成要素の寸法比率などは、現物と異なる場合がある。具体的な寸法比率等は、以下の説明を参酌して判断されるべきである。
太陽電池モジュール10は、複数の太陽電池11と、太陽電池11の受光面側に設けられた第1保護部材12と、太陽電池11の裏面側に設けられた第2保護部材13とを備える。複数の太陽電池11は、第1保護部材12及び第2保護部材13により挟持され、各保護部材の間に充填された封止材14により封止されている。太陽電池モジュール10は、例えば隣り合う太陽電池11同士が導線15で接続されてなるストリングを複数有する。ストリングとは、列状に配置された複数の太陽電池11が導線15によって直列接続されたものである。
太陽電池モジュールの製造装置20は、ラミネート装置30と、光源ユニット40とを備える。ラミネート装置30は、太陽電池11、封止材14、第1保護部材12、及び第2保護部材13を重ね合せて加熱圧着することにより積層体16を作製する装置である。光源ユニット40は、積層体16に光照射して積層体16の太陽電池11を優先的に加熱し、当該太陽電池11の温度上昇により封止材14を間接的に加熱する装置である。太陽電池モジュールの製造装置20は、さらに積層体16の搬送手段であるベルトコンベア21と、積層体16の全体を加熱する加熱炉23とを備える。
光源ユニット40は、基材41と、基材41上に複数配置された光源42と、光源42から出力される光の光路上に配置された集光部材43と、集光部材43から出射する光の光路上に配置された透光板44とを有する。基材41と透光板44が対向配置され、これらの間に光源42及び集光部材43が挟まれた構造を有する。光源ユニット40は、さらに基材41と透光板44との間において透光板44の主面44aに沿った水平方向に冷却風を流す冷却装置45を有する。冷却装置45は、集光部材43等の光源ユニット40の構成部材を冷却して、集光部材43等が過熱状態になることを防止する。
図5(A)に示すように、送風ダクト46から吹き出した冷却風は、基材41と透光板44の間を短辺方向βに沿って流れ、基材41の短辺方向両端部において基材41と透光板44の間から排気される。図5(B)に示す熱分布は、20〜45℃の冷却風を風速0.5〜5.0m/秒で流したときの条件で、基材41と透光板44の間における温度をシミュレーションした結果であって、温度が高い領域ほど単位面積当たりのドット数を多くしている(図8〜図11についても同様)。本実施形態では、短辺方向中央部に配置された送風ダクト46から吹き出した冷却風が集光部材43等を冷却しながら短辺方向両端部に流れるため、中央部に比べて下流側である両端部で冷却風の温度が上昇し、これにより両端部で温度が高くなっている。但し、上述のように冷却風の風路長は短いため、基材41の短辺方向両端部においても温度上昇の程度は小さい。また、熱分布は長辺方向αに沿って一様である。
光源ユニット40は、上記のように加熱炉23内の積層体16に特定光を照射する。このため、加熱炉23の壁部24の少なくとも一部には、特定光を透過する透光性部材25が取り付けられている。光源ユニット40は、加熱炉23の外部に設けられ、透光性部材25を通して加熱炉23内の積層体16に特定光を照射する。本実施形態では、加熱炉23の底部を構成する壁部24の一部に、積層体16よりも大面積に透光性部材25が設けられている。光源ユニット40は、透光性部材25との間に隙間をあけて透光性部材25の下方に設けられている。透光性部材25を介して加熱炉23内に入射した特定光は、ベルトコンベア21のバーの間を通って積層体16に照射される。
Claims (12)
- 太陽電池、封止材、及び保護部材を重ね合せて加熱圧着することにより積層体を作製するラミネート装置と、
前記積層体に光照射して前記積層体の前記太陽電池を優先的に加熱し、当該太陽電池の温度上昇により前記封止材を間接的に加熱する光源ユニットと、
を備え、
前記光源ユニットは、
基材と、
前記基材上に複数配置され、最大ピーク波長が1500nm以下の光を出力する光源と、
前記光源から出力される前記光の光路上に配置され、当該光を集光する集光部材と、
前記集光部材から出射する前記光の光路上に配置された透光板と、
前記基材と前記透光板との間において前記透光板の主面に沿った水平方向に冷却風を流す冷却装置と、
を有する、太陽電池モジュールの製造装置。 - 前記光源は、前記基材の第2方向よりも当該第2方向に直交する第1方向に沿って多く配置され、
前記冷却装置は、前記第2方向に前記冷却風を流すように構成されている、
請求項1に記載の太陽電池モジュールの製造装置。 - 前記冷却装置は、前記第2方向に前記冷却風を流すためのダクトを有し、
前記ダクトは、前記第1方向に沿って設けられている、請求項2に記載の太陽電池モジュールの製造装置。 - 前記光源は、前記基材上の前記ダクトの前記第2方向両側にそれぞれ略同数ずつ配置されている、請求項3に記載の太陽電池モジュールの製造装置。
- 前記ダクトは、前記第2方向両側に冷却風を吹き出す送風ダクトである、請求項4に記載の太陽電池モジュールの製造装置。
- 前記送風ダクトは、冷却風を吹き出す送風口(47)を有し、
前記第2方向において前記送風口と対向する位置に排気口を更に備え、
前記基材の前記第1方向の端部での排気量は、前記排気口での排気量より小さい、請求項5に記載の太陽電池モジュールの製造装置。 - 前記光源は、前記光のうち波長1500nm以上の光の強度が、最大ピークの1%以下のLEDである、請求項1〜6のいずれか1項に記載の太陽電池モジュールの製造装置。
- 前記基材は、冷却水の流通路を有し、冷却水を用いて冷却される、請求項1〜7のいずれか1項に記載の太陽電池モジュールの製造装置。
- 前記積層体の全体を加熱する加熱炉を備え、
前記加熱炉の壁部の少なくとも一部には、複数のガラス板を積層して構成された透光性部材が取り付けられており、
前記光源ユニットは、前記加熱炉の外部に設けられ、前記透光性部材を通して前記加熱炉内の前記積層体に前記光を照射する、請求項1〜8のいずれか1項に記載の太陽電池モジュールの製造装置。 - 前記透光性部材を構成する前記各ガラスは、互いに隙間をあけて対向配置されており、
前記隙間には空気若しくは不活性ガスが充填されているか、又は、前記隙間は真空状態である、請求項9に記載の太陽電池モジュールの製造装置。 - 請求項1〜10のいずれか1項に記載の製造装置を用いた太陽電池モジュールの製造方法であって、
太陽電池、封止材、及び保護部材を重ね合せて加熱圧着することにより積層体を作製する第1の工程と、
前記積層体に前記光を照射して前記積層体の前記太陽電池を優先的に加熱し、当該太陽電池の温度上昇により前記封止材を間接的に加熱する第2の工程と、
を備える太陽電池モジュールの製造方法。 - 前記第2の工程では、前記光源ユニットによる光照射位置に前記積層体が連続的に搬送され、
前記光源ユニットは、前記冷却風により少なくとも前記集光部材及び前記透光板を冷却しながら前記光を連続照射する、請求項11に記載の太陽電池モジュールの製造方法。
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