JPH10264344A - Method and device for lamination - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and device for lamination with a good efficiency of production by excellently laminating a heat reactive resin film-containing laminated body without creases and traces. SOLUTION: The lamination method has a constitution in which a heat- resistive resin film 24 having at least one or more layers and other films 24c, 24d are adhered by heat-compression through a bridging treatment. In this instance, after conducting temporary lamination in which the laminated body is heated at a softening temperature being a bridging treatment temperature or lower to be adhesion integrated, lamination is carried out by effecting the bridging treatment. In addition, when the laminated body is adhered through a bridging treatment by intermittent compression (a compression part 7) and heating (a heating plate 5), a difference between the supply transportation speed of the heat-resistive resin film and the supply transportation speed in the bridging treatment is absorbed by an accumulator 26 in order to avoid the laminated body from loosening.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminating apparatus for performing continuous processing by repeatedly heating a sheet-shaped continuous substrate while applying pressure, and more specifically, to a thin film photoelectric conversion apparatus having a flexible substrate. The present invention relates to a laminating apparatus for a thin film photoelectric conversion module in which a plurality of elements (cells) are bonded and protected on both sides with a flexible weatherproof film.

[0002]

2. Description of the Related Art FIG. 6 is a sectional view of a flexible thin film photoelectric conversion module. A first electrode film 24g and a thin film a-Sipn are formed on a resin film 24f such as a polyimide film.
Thin-film photoelectric conversion part 24p formed by bonding or the like, second electrode film 2
The thin-film photoelectric conversion cell 24b in which 4h is formed is laminated and sealed at least on the sunlight incident side with two transparent resin sealing sheets 24a and 24d.

In order to manufacture such a continuous product such as a thin film photoelectric conversion module, a flat type laminating apparatus suitable for continuous processing is required. The equipment that performs each treatment of cross-linking occupies the majority. FIG. 7 shows a conventional laminating apparatus, in which (a)
Is a front view, and (b) is a right side view. The heat-reactive film 24a, which is a light-transmitting and weather-resistant film wound on the delivery roll 21, is conveyed in the direction of arrow 29, and the thin-film photoelectric conversion cell 24b is heated at the mounting position 28 manually or by a supply device (not shown). It is mounted on the reactive film 24a. Here, in order to fix and seal the thin-film photoelectric conversion cell 24b to the heat-reactive film 24a, a laminated body 24 in which a weather-resistant heat-reactive resin film 24d is fed out from the feed roll 23, and closely adhered and laminated by press rolls 25a, 25b. Is transported.

The periphery of an elastic sheet 7 made of silicone rubber or the like is fixed to the periphery of the upper vacuum vessel 2 to form a pressure chamber 9. A heating plate 5 having a heater 5a is fixed to a portion located below the elastic sheet 7.
After transporting the laminate 24 to the hot plate 5, the control valve 15 is switched to supply pressure from the pressure source 16 to pressurize the inside of the pressurizing chamber 9, thereby lowering the elastic sheet 7 and pressing the laminate 24 against the laminate 24. In this state, the hot plate 5 is heated, heat bonding and crosslinking are performed for a predetermined time, and after laminating, the hot plate 5 is cooled, and the control valve 15 is switched to make the inside of the pressurized container 2 normal pressure to expand and contract. The functional sheet 7 is raised, and the module 2 is mounted while the thin-film photoelectric conversion cells 24b are mounted on the heat-reactive film 24a.
4 m is conveyed by one pitch.

The module 24m being conveyed is step-conveyed at a conveying pitch 33 shorter than the laminating range 30 so that the laminating range 30 and the current laminating range 31 overlap each other, and from the next laminating range 31 the previous laminating is performed. Stop at a position where the part does not come off. During this transport, the laminated module 24m is wound up by a take-up roll 27.

The above operation is repeated to perform heat bonding and cross-linking treatment of the laminate 24, and a continuous module is taken up by a take-up roll 27 to produce a long-sized thin film photoelectric conversion module.

[0007]

In the above-described laminating apparatus, when the laminate 24 is supplied between the hot plate 5 and the stretchable sheet 7, the laminate 24 is formed by press rolls 25a, 25a.
b, and is not adhered, the control valve 15 is switched to supply pressure from the pressure source 16 to pressurize the inside of the pressurizing chamber 9 to lower the stretchable sheet 7 to lower the laminate 24. When pressed against the thin film photoelectric conversion cell 2
Wrinkles are generated in the heat-reactive film 24a that fixes and seals 4b and the weather-resistant heat-reactive resin film 24d, and when the crosslinking treatment is performed in this state, a residue appears as it is. Further, if the heat-reactive film 24a and the weather-resistant heat-reactive resin film 24d are transported in a state where they are not adhered, slipping or the like is likely to occur when sandwiched between the press rolls 25a and 25b, and the supply of the base material is difficult. It is not stable, which also causes wrinkles and undulations, making it impossible to laminate the continuous laminate 24 with good quality.

Further, in order to raise the upper vacuum vessel 2 and supply the laminate 24 between the hot plate 5 and the stretchable sheet 7, it is necessary to alternately repeat the inside of the vacuum vessel at atmospheric pressure and vacuum, and after lamination, It is also necessary to lower the temperature of the hot plate 5 below the softening temperature of the thermoreactive resin. Such a pressure change and a temperature change require time, resulting in poor production efficiency and high running cost.

It is an object of the present invention to stably supply a laminate in which a thin-film photoelectric conversion cell or the like is sandwiched between heat-reactive resin films without wrinkles, pressurize without wrinkles, and perform good lamination with no residue. It is an object of the present invention to provide a laminating method and a laminating apparatus which can be produced, have good production efficiency and low running cost.

[0010]

Means for Solving the Problems In order to achieve the above-mentioned object, a laminate in which at least one or more layers of a heat-reactive resin film and another film are laminated by cross-linking treatment under pressure and heat and bonded. In the method, the laminate is heated to a softening temperature that is equal to or lower than the crosslinking temperature of the heat-reactive resin, and a temporary lamination for bonding and integrating is performed, and then the crosslinking is performed to perform lamination.

Prior to the crosslinking treatment, the laminate is preferably placed under reduced pressure and defoamed. In a laminating method in which a laminate obtained by laminating at least one or more layers of a heat-reactive resin film and another film is supplied at a constant conveyance speed, and the laminate is intermittently cross-linked by applying pressure and heat and adhered, The difference between the supply and transfer speed of the heat-reactive resin film and the transfer speed in the cross-linking process is absorbed by an accumulator to prevent the laminate from loosening.

A pressurizing / heating means for laminating a laminate obtained by laminating at least one layer of a thermoreactive resin film and another film by subjecting the thermoreactive resin film to a crosslinking treatment; In the laminating apparatus provided with a supply unit for supplying the pressurized / heated unit and a collecting unit for collecting the laminated body, wherein the heat is applied between the supply unit and the pressurized / heated unit. A heating roll for heating to a softening temperature which is equal to or lower than the crosslinking temperature of the reactive resin, bonding and integrating, and temporarily laminating is provided.

[0013] Alternatively, there is provided a pressurizing / heating means for cross-linking and laminating a laminate in which at least one or more layers of a heat-reactive resin film and another film are laminated intermittently while transporting the laminate. In a laminating apparatus provided with a supply unit for supplying the pressurizing / heating unit and a collecting unit for collecting the laminated body, at least the laminate and the pressurizing / heating unit are in contact with the laminate. The surface is inside the vacuum chamber.

[0014] Alternatively, a pressurizing / heating means for laminating by laminating a laminate obtained by laminating at least one layer of a heat-reactive resin film and another film intermittently while intermittently conveying the laminate is provided. In a laminating apparatus provided with a supply unit for supplying to the pressurizing / heating unit and a collecting unit for collecting the laminated body, an accumulator including a roll between the supplying unit and the pressurizing / heating unit And the roll always pulls the laminate so as not to loosen the laminate.

Further, the laminating apparatus is a first apparatus including the supply means, the heating roll, and a collecting means for collecting the temporarily laminated body, and a supply apparatus for supplying the temporarily laminated body. Means, a pressurizing / heating means, and a separate apparatus including a collecting means for supplying the laminated product, and a part of the supplying means of the second apparatus is the first apparatus. It is good to be a part of the collection means.

The second device conveys the laminated body therebetween, and the pressurizing / heating means comprises a belt rolled around a heating roll heated to a crosslinking temperature or higher and a cooling roll maintained at room temperature. It is good to consist of two sets, and each belt should sandwich a laminated body. Further, all means of the second device are preferably provided in a vacuum chamber.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. 1 shows a laminating apparatus provided with a heating roll and an accumulator according to the present invention, wherein (a) is a front view and (b) is a right side view. The heat-reactive film 24a wound on the delivery roll 21 is transported in the direction of the arrow 29, and the thin-film photoelectric conversion cell 24b is loaded at the mounting position 28 manually or by a supply device (not shown).
4a. Here, in order to fix and seal the thin-film photoelectric conversion cell 24b to the heat-reactive film 24a, the heat-reactive film 24d having a release surface is sent out from the delivery roll 23 with the release surface facing up, and the heating rolls 25a, 25
The set temperature b is set to a softening temperature region where the heat-reactive films 24a and 24d do not cause a crosslinking reaction, soften, adhere, and integrate, and the laminated body 24 that has been provisionally laminated and stacked is transported. The softening temperature here varies depending on the type of the heat-reactive film used as the substrate. In the case of the specific example using this means, ethylene vinyl acetate (EVA) is used as the heat-reactive film, and the measurement results of the dynamic viscoelastic properties show that the viscosity suddenly decreases from a temperature exceeding around 50 ° C. Therefore, the softening temperature point is set to 50 ° C. Further, the mounted thin film photoelectric conversion cell 24b and the heat-reactive film 24a are fed to a power supply terminal of the thin film photoelectric conversion cell 24b before the heating rolls 25c and 25d.
Supplies and connects the conductive tape 24c to perform the current collection wiring of the thin-film photoelectric conversion cell 24b.

An accumulator 26 is provided between the heating rolls 25a and 25b and the hot plate 5, and the accumulator 26 is provided for the laminated body 24 caused by continuous feeding by roll lamination (temporary lamination) and intermittent feeding by cross-linking. The transfer control is performed so as to absorb the difference in the feed amount and operate the transfer system before the accumulator 26 at a constant speed without stopping.

The periphery of an elastic sheet 7 made of silicone or the like is fixed to the periphery of the upper vacuum vessel 2 to form a pressure chamber 9. At a position facing the lower surface of the elastic sheet 7, a heater whose temperature can be controlled is provided.
A hot plate 5 controlled to a crosslinking temperature of 4d is attached. The hot plate 5 has a cooling function for lowering the heat-reactive films 24a and 24d to a temperature lower than the softening temperature range in order to transport the laminate 24 after the crosslinking treatment.

The temporarily laminated laminate 24 is intermittently fed at a predetermined pitch by an accumulator 26, and is conveyed between the stretchable sheet 7 and the hot plate 5. The pressure in the pressurizing chamber 9 which is the same as the atmospheric pressure is set to the pressurized state, the elastic sheet 7 is expanded, and the laminate 24 is pressed against the heating surface of the hot plate 5 and pressurized. Chamber 9 and pressure source 16
Is connected, and the cross-linked treatment is performed by pressing and heating the conveyed laminate 24. After performing the crosslinking treatment for a predetermined time in this state, the hot plate 5 is cooled, the control valve 14 is switched, and the pressure chamber 9 is switched.
Is returned to the atmospheric pressure, the elastic sheet 7 is restored and raised, and the laminate 24 is conveyed by one pitch, and the crosslinked module 2 is
4 m is taken up by a take-up roll 27. Example 2 FIGS. 2A and 2B show a laminating apparatus for processing a laminate according to the present invention in a vacuum, wherein FIG. 2A is a front view and FIG. 2B is a right side view.

Here, only portions different from the description of FIG. 1 in the first embodiment will be described. The periphery of an elastic sheet 7 such as silicone rubber is fixed to the periphery of the upper vacuum vessel 2 to form a pressure chamber 9. An O-ring 4 is attached to the outer peripheral portion of the pressurizing chamber 9 and matches the O-ring 3 of the lower vacuum vessel 1 in a closed state. In the lower vacuum vessel 1, a heating plate 5 having a heater and a cooling pipe is provided.
Attached through.

After transferring the laminate 24 to the hot plate 5, the upper vacuum vessel 2 is lowered by the opening / closing mechanism 50, and the O-rings 3 and 4 sandwich the laminate 24 to seal around the lower vacuum vessel 1. The lower vacuum chamber 8 is constituted. Vacuum pump 16
a, and the inside of the lower vacuum chamber 8 and the pressurizing chamber 9 is evacuated to evacuate the space between the heat-reactive films. After the degassing is sufficiently performed, the control valve 15 is switched to bring the inside of the pressurizing chamber 9 to the atmospheric state, and the elastic sheet 7 is pressed against the laminate 24 by the pressure difference between the lower vacuum chamber 8 and the pressurizing chamber 9. Press. In this state, the hot plate 5 is heated, and lamination is performed by cross-linking and bonding with heat for a predetermined time, then the hot plate 5 is cooled, the control valve 15 is switched, and the pressurizing chamber is connected to the vacuum pump 16a. 9, the inside of the lower vacuum chamber 8 is switched to the control valve 14 to introduce the atmosphere to the atmospheric state, the upper vacuum container 2 is raised by the opening / closing mechanism 50, and the stack 24 is transported by one pitch.
The crosslinked module 24m is wound around a winding roll 27. Example 3 This example is a case where the temporary laminate and the laminate are separate devices.

FIG. 3 is a front view of the temporary roll laminating apparatus according to the present invention. The heat-reactive film 24a wound around the delivery roll 21 is transported, and the thin-film photoelectric conversion cell 24
b is mounted on the heat-reactive film 24a manually or by a supply device (not shown). Here, in order to fix and seal the thin-film photoelectric conversion cell 24b to the heat-reactive film 24a, the heat-reactive film 24d is sent out from the feed roll 23, and the set temperature of the heating rolls 25a, 25b is adjusted by the heat-reactive films 24a, 24d. The temperature is set to a softening temperature region where softening, adhesion, and integration are performed without causing a cross-linking reaction, and temporary lamination is performed and wound around a roll 21a.

FIG. 4 shows a laminating apparatus according to another embodiment of the present invention, wherein (a) is a front view and (b) is a right side view. In this laminating apparatus, the temporarily laminated laminate 24 is mounted in the comprehensive vacuum chamber 1v,
Unwind from a. The vacuum chamber 1v is evacuated by the pressure source 16 via the control valve 14 to a vacuum state.
Can be conveyed between the elastic sheet 7 and the hot plate 5 in a vacuum space.

The upper vacuum container 2 and the hot plate 5 are connected to O-rings 40a, 40b by vertical mechanisms 50a, 50b provided outside the vacuum chamber.
b, the hot plate 5 is lowered to a position lower than the transport height of the laminate 24 while maintaining the temperature of the heating surface. After the transport of the laminate 24 is completed, the hot plate 5 is raised,
The upper vacuum container 2 is lowered, the control valve 15 is switched to the pressurizing chamber 9, the elastic sheet 7 is inflated at the same pressure as the atmospheric pressure, the laminate 24 is pressed against the heating surface of the hot plate 5, pressurized and heated. To perform deaeration and crosslinking. This operation is repeated to continuously produce the module 24m. Embodiment 4 FIG. 5 is a front view showing a laminating apparatus of another embodiment according to the present invention.

Also in this laminating apparatus, the laminated body 24 temporarily laminated in the same manner as in Embodiment 3
Attach to A set of transport belts 27a hung on a plurality of heating rolls 25e and a plurality of cooling rolls 25g whose temperature can be controlled in the comprehensive vacuum chamber 1v, and a transport carried on a similar plurality of heating rolls 25f and a plurality of cooling rolls 25h. A set of belts 27b is provided. Further, the heating roll 25e, the cooling roll 25g, and the transport belt 27
Pressing means between the surfaces of the transport belts 27a and 27b can be pressed by the own weight of a or a pressing means such as a spring (not shown). Sandwiching the laminate 24 between the conveyor belts 27a and 27b,
The heating roll 2 is conveyed while pressing and heating.
The cross-linking treatment can be performed at the same speed as the transfer speed of 5a, 25b,
The transport speed can be adjusted to adjust the crosslinking time.

[0027]

According to the present invention, there is provided a laminating method in which a laminate obtained by laminating at least one or more layers of a heat-reactive resin film and another film is crosslinked by pressure and heat and adhered. After performing a temporary lamination for heating and bonding to a softening temperature that is equal to or lower than the crosslinking temperature of the heat-reactive resin, and then performing lamination by performing the crosslinking treatment, before the laminating step, the laminated body is The members constituting the laminate are not displaced with respect to the heat-reactive resin film to be formed, high-quality lamination without wrinkles can be performed, and stable module formation can be performed.

Alternatively, an accumulator absorbs the difference between the supply and transfer speed of the heat-reactive resin film and the transfer speed in the cross-linking process so that the laminate does not loosen. It is not necessary to stop the supply means, and the production efficiency can be improved. Further, wrinkles due to the intermittent operation of the supply means do not occur, and the yield is improved.

Further, since the vacuum degassing was performed before the laminating step, no bubbles were generated, the adhesion was good, and the sealing reliability was high. Further, for example, in the case of a photoelectric conversion module, light reflection between different members at the bubble portion is eliminated, and the photoelectric conversion efficiency is improved.

[Brief description of the drawings]

FIG. 1 shows a laminating apparatus provided with a heating roll and an accumulator according to the present invention, wherein (a) is a front view and (b) is a right side view.

FIG. 2 shows a laminating apparatus for processing a laminate according to the present invention in a vacuum, wherein (a) is a front view and (b) is a right side view.

FIG. 3 is a front view of a temporary roll laminating apparatus according to the present invention.

FIG. 4 shows a laminating apparatus according to another embodiment of the present invention, wherein (a) is a front view and (b) is a right side view.

FIG. 5 is a front view showing a laminating apparatus of another embodiment according to the present invention.

FIG. 6 is a sectional view of a flexible thin-film photoelectric conversion module.

FIG. 7 shows a conventional laminating apparatus, wherein (a) is a front view and (b) is a right side view.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Lower vacuum container 1v Comprehensive vacuum chamber 2 Upper vacuum container 3 O-ring 4 O-ring 5 Hot plate 5a Heater 6 Insulating member 7 Elastic sheet 9 Pressurizing chamber 14 Control valve 15 Control valve 16 Pressure source 16a Vacuum pump 21 Delivery roll 21a Roll 22 Delivery roll 23 Delivery roll 24 Stacked body 24m Module 25a Press roll 25b Press roll 25c ... 25f Heating roll 25g Cooling roll 25h Cooling roll 26 Accumulator 27 Take-up roll 27a Transport belt 27b Transport belt 28 Transport position 29 Mounting position 40a O-ring 40b O-ring 50 vertical mechanism 50a vertical mechanism 50b vertical mechanism

Claims (9)

[Claims] 1. A laminating method in which a laminate obtained by laminating at least one or more layers of a heat-reactive resin film and another film is cross-linked by pressure and heat and adhered, wherein the laminate is formed of the heat-reactive resin. A laminating method, comprising: performing a temporary lamination for bonding by laminating by heating to a softening temperature that is equal to or lower than a crosslinking temperature, and then laminating by performing the crosslinking treatment. 2. The laminating method according to claim 1, wherein the laminate is placed under reduced pressure and defoamed before the crosslinking treatment. 3. A laminate in which at least one or more layers of a heat-reactive resin film and another film are laminated is supplied at a constant transport speed, and the laminate is intermittently pressurized and heated to be crosslinked and adhered. In the laminating method, a difference between a feeding speed of the heat-reactive resin film and a feeding speed in the crosslinking treatment is absorbed by an accumulator so that the laminated body is not loosened. 4. A pressurizing / heating means for laminating a laminate obtained by laminating at least one layer of a heat-reactive resin film and another film by subjecting the heat-reactive resin film to a crosslinking treatment, Supply means for supplying the laminate to the pressurizing / heating means, and a laminating apparatus provided with a collecting means for collecting the laminated laminate, between the supplying means and the pressurizing / heating means, A laminating apparatus comprising: a heating roll that is heated to a softening temperature that is equal to or lower than a crosslinking treatment temperature of the heat-reactive resin, bonded together, and temporarily laminated. 5. A pressurizing and heating means for laminating by laminating a laminate obtained by laminating at least one layer of a heat-reactive resin film and another film intermittently while intermittently conveying the laminate. In a laminating apparatus provided with a supply unit for supplying the pressurizing / heating unit and a collecting unit for collecting the laminated body, at least the laminate and the pressurizing / heating unit are in contact with the laminate. A laminating apparatus characterized in that the surface is inside a vacuum chamber. 6. A pressurizing / heating means for laminating by laminating a laminate obtained by laminating at least one layer of a heat-reactive resin film and another film intermittently while intermittently conveying the laminate. In a laminating apparatus provided with a supply unit for supplying to the pressurizing / heating unit and a collecting unit for collecting the laminated body, an accumulator including a roll between the supplying unit and the pressurizing / heating unit A laminating apparatus characterized in that the roll always pulls the laminate and does not loosen the laminate. 7. The laminating apparatus according to claim 1, wherein the laminating apparatus includes a first unit having the supplying unit, the heating roll, and a collecting unit that collects the temporarily laminated body, and a supply unit for supplying the temporarily laminated body. Means, a pressurizing / heating means, and a collecting means for supplying the laminated body.
The laminating apparatus according to claim 4, wherein a part of the supply means of the apparatus is a part of the collection means of the first apparatus. 8. The second apparatus, which conveys the laminate with the laminate interposed therebetween, wherein the pressurizing / heating means is hung on a heating roll heated to a crosslinking temperature or higher and a cooling roll maintained at room temperature. The laminating apparatus according to claim 7, comprising two sets of belts, each belt sandwiching a laminated body. 9. The laminating apparatus according to claim 7, wherein all means of the second apparatus are provided in a vacuum chamber.