US20120168077A1 - Laminate press device, carrier plate, laminating system and laminating method - Google Patents

Laminate press device, carrier plate, laminating system and laminating method Download PDF

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Publication number
US20120168077A1
US20120168077A1 US13/417,560 US201213417560A US2012168077A1 US 20120168077 A1 US20120168077 A1 US 20120168077A1 US 201213417560 A US201213417560 A US 201213417560A US 2012168077 A1 US2012168077 A1 US 2012168077A1
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United States
Prior art keywords
chamber
inner pressure
diaphragm
press
laminate
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US13/417,560
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English (en)
Inventor
Shizuaki Okazaki
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Kitagawa Seiki KK
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Kitagawa Seiki KK
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Priority to US13/417,560 priority Critical patent/US20120168077A1/en
Assigned to KITAGAWA SEIKI KABUSHIKI KAISHA reassignment KITAGAWA SEIKI KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OKAZAKI, SHIZUAKI
Publication of US20120168077A1 publication Critical patent/US20120168077A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1009—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/12—Photovoltaic modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means

Definitions

  • the present invention relates a laminate press device, a carrier plate, a laminating system and a laminating method for manufacturing a laminate structure, such as a solar battery panel.
  • a solar panel is manufactured through laminate processing in which a solar battery assembly (lamination materials) formed by stacking components, including a glass plate, a filler, a solar battery cell, a filler and a rear plate, is hot-pressed to be formed to have a predetermined thickness.
  • a solar battery assembly laminate materials formed by stacking components, including a glass plate, a filler, a solar battery cell, a filler and a rear plate, is hot-pressed to be formed to have a predetermined thickness.
  • Japanese Patent Provisional Publication No. 2008-47765A describes a laminate press device for manufacturing a solar battery panel using a diaphragm.
  • the conventional laminate press device described in 2008-47765A is provided with a pair of chambers arranged in the vertical direction to be comparted by a diaphragm having elasticity.
  • One of the chambers is provided with a platen, and a solar battery assembly is arranged between the platen and the diaphragm.
  • the conventional diaphragm type laminate press device described in 2008-47765A is configured to hot-press the lamination materials in a vacuum state. Therefore, there is a case where the filler molten by the heating flows out from the lamination materials and the laminating is not performed properly. In addition, if the filler flows out from the lamination materials, the filler adheres to the inner wall of the chamber, and thereby hampers a next lamination processing. For this reason, it is necessary to clean the inner wall of the chamber each time the filler flows out from the lamination materials, and to remove the filler adhered to the inner wall of the chamber, which is a factor of decreasing the work efficiency.
  • a laminate press device for forming a laminate structure body by hot-pressing a lamination body, comprising: a diaphragm; first and second chambers comparted by the diaphragm; an inner pressure control unit configured to individually control inner pressures of the first and second chambers; and a first platen which is provided in the first chamber to perform press-forming for the lamination body between the first platen and the diaphragm.
  • the inner pressure control unit controls the inner pressure of the first chamber to be within a predetermined inner pressure range within which flowing out of a filler contained in the laminate body is prevented, without vacuumising the first chamber.
  • a laminating method for controlling inner pressures of first and second chambers comparted by a diaphragm and thereby hot-pressing a lamination body between a first platen arranged in the first chamber and the diaphragm to form a laminate structure body.
  • the method includes: a press-forming step of hot-pressing the lamination body by setting the inner pressure of the second chamber to be higher than the inner pressure of the first chamber.
  • the inner pressure of the first chamber is set to be within a predetermined pressure range within which flowing out of a filler contained in the lamination body is prevented, without vacuumising the first chamber.
  • the lamination body is hot-pressed under a constant temperature condition, it becomes possible to prevent occurrence of the phenomenon that bubbles in the filler being molten during the press-forming expand due to pressure reduction and thereby the filler flows out from the lamination body. As a result, it becomes possible to manufacture an excellent quality laminate structure body in a high degree of yield ratio. Furthermore, it is possible to eliminate the need for the work for wiping out the filler which has flowed out from the lamination body and has adhered to the platen or the diaphragm.
  • the laminating method further may include a vacuum defoaming step of removing bubbles from the lamination body by setting the inner pressure of the first chamber to be a negative pressure, before executing the press-forming step.
  • a vacuum defoaming step of removing bubbles from the lamination body by setting the inner pressure of the first chamber to be a negative pressure, before executing the press-forming step.
  • the inner pressure of the second chamber may be controlled to be lower than or substantially equal to the inner pressure of the first chamber so that the lamination body is not pressurized by the diaphragm.
  • the softened filler is pressed out from the lamination body due to expansion or movement of the bubbles in the lamination body.
  • the lamination body is pressed under a decompressed condition during the vacuum defoaming, the flowing out of the filler to the outside of the lamination body comes into prominence correlatively with expansion of the bubbles due to the air pressure difference. Therefore, by executing the inner pressure control as described above, it becomes possible to prevent occurrence of flowing out of the filler from the lamination body before the press-forming.
  • the laminating method may further include a diaphragm heating step of heating the diaphragm while causing the diaphragm to closely contact the second platen arranged in the second chamber by setting the inner pressure of the second chamber to be lower than the inner pressure of the first chamber, before the press-forming step.
  • a diaphragm heating step of heating the diaphragm while causing the diaphragm to closely contact the second platen arranged in the second chamber by setting the inner pressure of the second chamber to be lower than the inner pressure of the first chamber, before the press-forming step.
  • the laminating method may further include a curing step of heating the lamination body until the filler is stabilized, after the press-forming step.
  • a curing step of heating the lamination body until the filler is stabilized, after the press-forming step.
  • the curing step is a step of heating the lamination body which has been subjected to the press-forming and curing the filler until the level required for securing the performance (e.g., the long-term reliability) required for the laminate structure body. Since the fluidity of the filler almost disappears after the press-forming, a problem that the filler flows out from the lamination body does not occur even when the lamination body is pressurized in the vacuum state in the curing step. Therefore, the lamination body may be hot-pressed in the vacuum condition in the curing step.
  • a program for causing the computer to execute the above described curing step is provided.
  • a carrier plate adapted for laminate press processing for a laminate structure body including a brittle component.
  • the carrier plate includes a frame body which has a hollow part and is a substantially rigid member, and a flexible thin plate fixed to an upper surface of the frame body to cover the hollow part of the frame body.
  • the hollow part of the frame body has a size capable of accommodating a lower side platen of a pair of platens performing the laminate press processing.
  • the carrier plate is configured such that the carrier plate is placed between the pair of platens in a state where a lamination body configured by stacking components of the laminate structure body is placed on the thin plate and the carrier plate is pressed together with the lamination body.
  • the carrier plate configured as described above, it is possible to prevent the brittle component (e.g., a glass substrate of a solar battery) contained in the laminate structure body from damaged by vibration caused during the carrying. Furthermore, since the lamination body can be processed together with the carrier plate, there is no necessity to replace the lamination body on the carrier plate for each process. As a result, effective processing can be realized.
  • the brittle component e.g., a glass substrate of a solar battery
  • FIG. 1 illustrates an outer appearance of a laminating system according to an embodiment of the present invention.
  • FIG. 2 is a block diagram generally illustrating a configuration of a control device of according to the embodiment of the invention.
  • FIG. 3 is a perspective view of a carrier plate according to the embodiment of the invention.
  • FIG. 4 is a side view of a laminate press device according to the embodiment of the invention.
  • FIG. 5 is a cross sectional view of a fixed plate and a moving plate of the laminate press device according to the embodiment of the invention.
  • FIG. 6 is a flowchart illustrating a process of laminate press according to according to the embodiment of the invention.
  • FIG. 7 is a front view of a curing processing device according to the embodiment of the invention.
  • FIG. 8 is a flowchart illustrating a curing process according to the embodiment of the invention.
  • FIG. 1 illustrates an outer appearance of a solar battery laminating system 1 according to the embodiment of the invention.
  • the laminating system 1 includes a lamination device 100 , a carrying-in conveyer 200 , a laminate press device 300 , a curing processing device 400 , a carrying-out conveyer 500 and a control device 700 .
  • the laminating system 1 is connected via a communication cable to each component constituting the laminating system 1 , and controls the operation of each component.
  • the lamination device 100 is configured to assemble a solar battery assembly A by overlaying a plurality of components (e.g., a glass plate, a filler, a solar battery cell, a filler and a rear plate) constituting a solar battery.
  • the solar battery assembly A assembled by the lamination device 100 is carried to the laminate press device 300 by the carrying-in conveyer 200 .
  • the laminate press device 300 hot-presses the solar battery assembly A to from a plate-like body having a predetermined thickness.
  • the hot-pressing by the laminate press device 300 continues until the fluid nature of the filler at the press temperature disappears.
  • the solar battery assembly A after forming is carried to the curing device 400 by a carrying unit accommodated in the laminate press device 300 .
  • the curing device 400 performs a curing process in which the solar battery assembly A formed by the laminate press device 300 is heated while applying a light pressure to maintain the shape to the solar battery assembly A, so that the filler of the solar battery assembly A which is a heat-hardening resin is stabilized.
  • a solar battery panel is made.
  • the completed solar battery panel which has been subjected to the curing process is carried out from the laminating system 1 by the carrying-out conveyer 500 .
  • the above described sequence of processes is performed by controlling the lamination device 100 , the carrying-in conveyer 200 , the laminate press device 300 , the curing processing device 400 and the carrying-out conveyer 500 by the control device 700 .
  • FIG. 2 is a block diagram generally illustrating a configuration of the control device 700 .
  • the control device 700 includes a ROM (Read-Only Memory) 720 storing a control program 721 for controlling the laminating system 1 , a CPU (Central Processing Unit) 710 which reads and executes a program stored in the ROM 720 , a RAM (Random-Access Memory) 730 which is a main memory, a communication interface 740 for communicating with each of the components constituting the laminating system 1 , and a display device 750 which is a touch panel display which displays an operating state of the laminating system 1 and receives a user input.
  • the control program 721 according to the embodiment includes a sub-program for executing control of a laminate press process executed ( FIG.
  • a curing process ( FIG. 8 ) executed by the curing device 400 as well as control for cooperation between the devices, such as a timing adjustment of handing over of a work piece, and the laminate press process and the curing process are executed under control of the control device 700 .
  • the solar battery assembly A and the solar battery panel after processing are carried while being placed on a carrier plate 800 which is explained later, and are pressed together with the carrier plate 800 by the laminate press device 300 and the curing device 400 .
  • FIG. 3 is a perspective view of the carrier plate 800 used in this embodiment.
  • the carrier plate 800 according to the embodiment includes a frame body 810 having a hollow part H formed in a central portion thereof, and a thin plate 820 fixed to a top face of the frame body 810 to cover the hollow part H.
  • the thin plate 820 is fixed to the frame body 810 , for example, with an adhesive.
  • the frame body 810 is a structural material having an adequate degree of rigidity to the extent that the frame body 810 does not substantially deform in the manufacturing process of a solar battery panel.
  • the frame body 810 is made of metal or heat resisting resin (e.g., polyimide resin) so as to maintain an adequate degree of rigidity also during the hot-pressing.
  • the frame body 810 formed through a bending process of a stainless steel plate is used.
  • the thin plate 820 is a support member having flexibility and a low degree of rigidity so as to elastically hold and protect the solar battery cell and the glass plate, which are brittle members.
  • the thin plate 820 is made of heat resisting materials, such as a fluorocarbon resin sheet, a fiber reinforced heat resisting resin sheet or a metal thin plate (e.g., a stainless steel plate or a copper plate), having an adequate degree of strength under a high temperature condition so as not to be damaged even when the hot-pressing is repeated.
  • the thickness of the thin plate 820 is set to be within a range achieving a balance between durability and flexibility. For example, when the thin plate 820 made of carbon-fiber reinforced plastic based on polyimide is used, the thickness of the thin plate 820 is set to be within the range of 0.05 to 1.5 mm, and preferably within the range of 0.5 to 1.0 mm.
  • the central portion thereof facing the hollow part H maintains flexibility.
  • the solar battery assembly A is placed on the central part of the thin plate 820 having flexibility, and is supported flexibly by the thin plate 820 .
  • the carrier plate 800 is carried by the carrying units, such as the carrying-in conveyer 200 and the carrying-out conveyer 500 , the frame body 810 is supported by the carrying units. Therefore, the solar battery assembly A placed on the carrier plate 800 is prevented from receiving a strong shock during the carrying, and thereby the solar battery assembly A being carried is prevented from being damaged.
  • FIG. 4 is a side view of the laminate press device 300 .
  • the laminate press device 300 includes a pair of conveyers 310 for carrying the carrier plate 800 on which the solar battery assembly A is placed (in FIG. 4 , only one conveyer on the near side is illustrated).
  • the direction in which the carrier plate 800 on which the solar battery assembly A is placed is carried (the left and right direction in FIG. 4 ) is referred to as a “carrying direction”, and the horizontal direction (a direction perpendicular to the paper face of FIG. 4 ) perpendicular to the carrying direction is referred to as a “width direction”.
  • the pair of conveyers 310 is arranged along the width direction.
  • a fixed plate 320 is arranged between the pair of conveyers 310 .
  • a moving plate 330 is provided above the fixed plate 320 .
  • the fixed plate 320 is fixed to a frame of the laminate press device 300 .
  • the moving plate 330 is fixed to the frame via cylinder units 340 , and can be driven in the vertical direction by the cylinder units 340 .
  • laminate press of the solar battery assembly A using a diaphragm 333 which is described later is performed.
  • the size of the fixed plate 320 in the width direction and the depth direction is set so that the entire top face of the fixed plate 320 is accommodated in the hollow part H (see FIG. 3 ) of the carrier plate 800 .
  • the conveyer 310 is arranged to be movable in the vertical direction by an actuator not shown.
  • a top face 311 of the conveyer 310 is moved to a position which is higher than a top face 321 of the fixed plate 320 . Therefore, the carrier plate 800 and the solar battery assembly A are carried without interfering with the fixed plate 320 .
  • the top face 311 of the conveyer 310 is moved to a position lower than the top face 321 of the fixed plate 320 , and the thin plate 820 of the carrier plate 800 is directly placed on the top face 321 of the fixed plate 320 .
  • the frame 810 is brought to a state where the frame body 810 hangs from the top face 321 of the fixed plate 320 via the thin plate 820 .
  • FIGS. 5 ( a ) to ( e ) are cross sections of the fixed plate 320 and the moving plate 330 during the laminate press viewed along a plane perpendicular to the carrying direction.
  • FIG. 6 is a flowchart illustrating the laminate press process.
  • the moving plate 330 includes a moving plate body 331 and a frame body 332 attached to a lower surface 331 a of the moving plate body 331 .
  • the frame body 332 is made of an elastic material, such as heat resisting rubber.
  • the frame body 332 includes an upper frame body 332 a and a lower frame body 332 b . Between the upper frame body 332 a and the lower frame body 332 b , the diaphragm 333 for sealing an opening of the frame body 332 is sandwiched.
  • the diaphragm 333 is a sheet-like member having flexibility, airtightness and a heat resisting property, and is jointed to the upper frame body 332 a and the lower frame body 332 b with an adhesive in a hermetic sealing manner.
  • an upper chamber UC is formed by the diaphragm 333 , the lower surface of the moving plate body 331 and the frame body 332 (specifically, the upper frame body 332 a ).
  • a communicating path 331 c is formed to connect the upper chamber UC with the outside space. Openings of the communicating path 331 c are formed on the lower surface 331 a and a side face of the moving plate body 331 .
  • a vacuum pump and a compressor (or a high pressure gas container) not shown are connected to the opening of the communicating path 331 c formed on the side face of the moving plate body 331 , so that the inner pressure of the upper chamber UC can be increased or decreased.
  • Heaters not shown are accommodated in the moving plate body 331 and the fixed plate 320 , and the moving plate body 331 and the fixed plate 320 are maintained at a temperature required for heating the solar battery assembly A to the forming temperature.
  • FIG. 5 ( a ) illustrates a state after completion of step S 1 .
  • FIG. 5 ( b ) illustrates a state after completion of step S 2 .
  • the volume of the upper chamber UC reduces due to the difference between the inner pressure of the upper chamber UC and the atmospheric pressure. That is, the diaphragm 33 protrudes toward the upper chamber UC and contacts the lower surface 331 a of the moving plate body 331 . Due to this contact, the heat rapidly moves from the moving plate body 331 to the diaphragm 333 , and the diaphragm 33 is heated to the forming temperature for the solar battery assembly A.
  • the conveyer 310 ( FIG. 4) is lowered (S 3 ), and the thin plate 820 of the carrier plate 800 is placed on the fixed plate 320 .
  • the moving plate 300 moves downward, and the thin plate 820 of the carrier plate 800 is brought to the state of being sandwiched between the lower surface of the frame body 332 and the upper surface 321 of the fixed plate 320 (S 4 ).
  • the frame body 332 formed of elastic material closely contacts the thin plate 320 . That is, the frame body 332 functions as a packing, and a lower chamber LC is formed to be sealed by the thin plate 820 of the carrier plate 800 , the frame body 332 and the diaphragm 333 .
  • a communicating path 332 c is formed in the lower frame body 332 b of the frame body 332 to penetrate therethrough in the horizontal direction.
  • a vacuum pump and a compressor (or a high pressure gas container) not shown are connected, so that the inner pressure of the lower chamber LC can be increased or decreased.
  • the communicating path 332 c is opened to the atmospheric air, and the inside of the lower chamber LC is kept at the atmospheric pressure.
  • the upper chamber UC is kept at a negative pressure, and the diaphragm 333 is continuously heated by the moving plate body 331 .
  • the pressure in the lower chamber LC is decreased to become substantially equal to the inner pressure of the upper chamber UC by the vacuum pump connected to the communicating path 332 c of the lower frame body 332 b , and the lowered pressure state is maintained for a certain time period (S 5 ).
  • the diaphragm 333 returns to the natural state having a substantially flat shape.
  • the diaphragm 33 departs from the lower surface 331 a of the moving plate body 331 , the diaphragm 333 is brought to a state of not being heated.
  • the heat-releasing amount from the diaphragm 333 is small, and therefore the temperature of the diaphragm 333 hard to decrease and is maintained at a substantially constant temperature.
  • the solar battery assembly A contacts the heated fixed plate 320 via the thin plate 820 of the carrier plate 800 . Therefore, heat rapidly moves from the fixed plate 320 to the solar battery assembly A, and the temperature of the solar battery assembly A rapidly increases to the forming temperature and the filler included in the solar battery assembly A gets soft.
  • the ambient pressure of the solar battery assembly A (inside of the lower chamber LC) has become a low pressure close to the vacuum state, bubbles in the softened filler are released, and thereby the filler is defoamed in a short time.
  • the solar battery assembly A since the inner pressure of the upper chamber UC and the inner pressure of the lower chamber LC are substantially equal to each other, the solar battery assembly A is prevented from being pressed by the diaphragm 333 due to an inner pressure difference. Therefore, the filler is prevented from flowing out from an edge of the solar battery assembly A together with expanding bubbles when the solar battery assembly A in which the filler is softened is pressed in the vacuum state, as in the case of the conventional diaphragm type laminate press device.
  • the lower chamber LC is maintained to have an inner pressure higher than the inner pressure of the upper chamber UC. Therefore, during depressurizing of the lower chamber LC, the diaphragm 333 does not press the solar battery assembly A.
  • the filler of the solar battery assembly A is in a softened state due to the heat propagating from fixed plate 320 . At this state, the filler contains a number of bubbles, and the bubbles in the filler expand in accordance with decrease of the inner pressure of the lower chamber LC.
  • the inner pressures of the upper and lower chambers UC and LC are increased gradually while maintaining the inner pressures of the upper and lower chambers UC and LC to be substantially equal to each other (S 6 ).
  • the diaphragm 333 maintains its shape shown in FIG. 5( d ). Therefore, the diaphragm 333 does not press the solar battery assembly A during pressurizing.
  • the inner pressure of the upper chamber UC is increased to be a positive pressure (a pressing pressure) by a compressor connected to the communicating path 331 of the moving plate body 331 while maintaining the inner pressure of the lower chamber LC at the atmospheric pressure (S 7 ).
  • the upper chamber UC expands due to the difference between the upper and lower chambers, and the diaphragm 333 protrudes toward the lower chamber LC side and closely contacts the upper surface of the solar battery assembly A.
  • the diaphragm 333 presses, between the diaphragm 333 and the moving plate 320 , the heated solar battery assembly A at a pressing pressure substantially equal to the difference between the inner pressures of the both chambers.
  • the diaphragm 333 presses, between the diaphragm 333 and the moving plate 320 , the heated solar battery assembly A at a pressing pressure substantially equal to the difference between the inner pressures of the both chambers.
  • the ambient air of the solar battery assembly A has become substantially equal to the atmospheric pressure. Therefore, the filler softened during the pressurizing is prevented from flowing out from an edge of the solar battery assembly A in accordance with expansion of the bubbles.
  • the diaphragm 333 since the diaphragm 333 has been heated to the appropriate temperature, the diaphragm 333 does not deprive the large amount of heat from the solar battery assembly through contact between the diaphragm 333 and the solar battery assembly A, and does not cause a nonuniform temperature distribution in the solar battery assembly A. Since the solar battery assembly A is pressed in a state of being heated to a substantially uniform temperature, it is possible to manufacture a solar battery panel having a uniform thickness and having a low degree of residual thermal stress.
  • the inner pressure of the upper chamber UC is decreased to the atmospheric pressure (S 8 ).
  • the shape of the diaphragm 333 returns to the state shown in FIG. 5( d ). Then, the moving plate 330 moves upward, and the frame 332 departs from the thin plate 820 of the carrier plate 800 (S 9 ).
  • FIG. 7 is a front view of the curing processing device 400 viewed along the carrying direction.
  • the curing processing device 400 includes a top moving plate 411 , a first intermediate moving plate 421 , a second intermediate moving plate 422 , a third intermediate moving plate 423 and a bottom moving plate 431 which are arranged in the vertical direction.
  • Each carrier plate 800 on which the solar battery assembly A is placed is arranged between adjacent ones of the moving plates, and the curing processing device 400 is able to simultaneously execute the curing process for four solar battery assemblies at the maximum.
  • the top moving plate 411 , the first intermediate moving plate 421 , the second intermediate moving plate 422 and the third intermediate moving plate 423 are provided to be movable in the vertical direction with respect to a frame of the curing processing device 400 .
  • the curing processing device 400 includes a driving unit 441 which drives the bottom moving plate 431 in the vertical direction with respect to the frame.
  • the driving unit 441 has a driving mechanism (e.g., a lead screw mechanism) which is able to precisely control the height of the bottom moving plate 431 .
  • each of the top moving plate 411 , the first intermediate moving plate 421 , the second intermediate moving plate 422 and the third intermediate moving plate 423 has substantially the same structure as that of the moving plate 330 ( FIG. 5 ) of the laminate press device 300 . That is, each of the top moving plate 411 and the intermediate moving plates 421 to 423 has a built-in heater, and has a frame body having a lower surface to which the diaphragm 333 is adhered. To a communicating path formed in the frame body of each of the top moving plate 411 and the intermediate moving plates 421 to 423 , a vacuum pump and/or a compressor (or a high pressure gas container) (not shown) for adjusting the air pressure of the upper and lower chambers UC and LC are connected.
  • a vacuum pump and/or a compressor or a high pressure gas container
  • the bottom moving plate 431 has substantially the same structure as that of the fixed plate 320 ( FIG. 5 ) of the laminate press device 300 . That is, the bottom moving plate 431 has a built-in heater.
  • the bottom moving plate 431 is moved upward by the driving unit 441 .
  • the third intermediate moving plate 423 , the second intermediate moving plate 422 , the first intermediate moving plate 421 and the top moving plate 411 are lifted sequentially.
  • each carrier plate 800 is sandwiched between moving plates situated on the upper side and the lower side thereof by the weight of each of the top moving plate 411 and the intermediate moving plates 421 to 423 .
  • the solar battery assembly A is placed on and contacts each of the bottom moving plate 431 and the intermediate moving plates 421 to 423 , and is heated via the carrier plate 800 by these moving plates from the lower side. Furthermore, by giving a higher pressure to the upper chamber UC relative to the lower chamber LC and pushing out the air from the lower chamber LC by the compressor in a state where the carrier plate 800 is sandwiched between the lower side moving plate (one of the bottom moving plate 431 and the intermediate moving plates 421 to 423 ) and the upper side moving plate (one of the intermediate moving plates 421 to 423 and the upper plate 411 ), the diaphragm 333 provided on the lower surface of the upper side moving plate (one of the intermediate plates 421 to 423 and the top moving plate 411 ) protrudes to the lower chamber LC side and closely contacts the solar battery assembly A.
  • Each of the intermediate moving plates 421 to 423 and the top moving plate 411 is heated by the built-in heater, and the solar battery assembly A is heated also from the upper side due to the fact that the heat moves to the solar battery assembly A via air in the upper chamber UC and/or via the diaphragm 333 which has been heated before the curing process while closely contacting the upper side moving plate (one of the moving plates 421 to 423 and 411 ).
  • the curing process for the solar battery assembly A is performed in the state where the solar battery assembly A is heated from both of the upper and lower side.
  • a solar battery is formed.
  • the curing processing device 400 includes a pair of conveyer 450 .
  • the pair of conveyers 450 receives, from the conveyer 310 ( FIG. 4 ) of the laminate press device 300 , the carrier plate 800 on which the solar battery assembly A before the curing process is placed, moves the carrier plate 800 to the moving plate of the cure processing device 400 , and passes the carrier plate 800 on which the solar battery assembly A after the curing process is placed, to the carrying-out conveyer 500 .
  • the conveyer 450 is able to move between a carrying position (indicated by a solid line in FIG.
  • the conveyer 450 is able to carry the carrier plate 800 and a retracted position (indicated by a dashed line in FIG. 7 ) which is shifted from the carrying position obliquely and downward to the outside in the width direction.
  • the height of the conveyer 450 at the carrying position is set to be the same height of the conveyer 310 of the laminate press device 300 and the carrying-out conveyer 500 .
  • the carrier plate 800 on which the solar battery assembly A is placed can be moved and placed on a desired one of the intermediate moving plates 421 to 423 and the bottom moving plate 431 .
  • one of the upper surfaces of the intermediate moving plates 421 to 423 and the bottom moving plate 431 can be moved to have substantially the same height as that of the upper surface of the conveyer 450 .
  • the lower surface of a desired one of the top moving plate 411 and the intermediate moving plates 421 to 423 can be maintained at a predetermined height which is sufficiently higher than the upper surface of the conveyer 450 .
  • a desired moving plate one of the bottom moving plate 431 and the intermediate moving plates 421 to 423
  • a desired moving plate one of the bottom moving plate 431 and the intermediate moving plates 421 to 423
  • a space for accommodating the carrier plate 800 on which the solar battery assembly A is placed can be secured between the upper surface of the desired moving plate and the lower surface of the moving plate on the upper side of the desired moving plate.
  • the carrier plate 800 on which the solar battery assembly A is placed can be moved to the desired moving plate.
  • the solar battery after the curing process is carried out, adjacent two moving plates sandwiching the carrier plate 800 , on which the solar battery assembly to be carried out is placed, and the conveyer 450 are moved to the position set at the time of carrying-in.
  • the carrier plate 800 is pushed out to the carrying-out conveyer 500 (see FIG. 1 ) by driving the conveyer 450 . That is, by driving the conveyer 450 , the solar battery assembly A before the curing process can be carried to the position between the moving plates and the solar battery after the curing process can be carried out from the position between the moving plates.
  • the conveyer 450 While the conveyer 450 is at the retraced position, the conveyer 450 does not contact the carrier plate 800 even when the moving plates sandwiching the carrier plate 800 are moved in the vertical direction.
  • each of the top moving plate 411 and the intermediate moving plates 421 to 423 is provided with two pairs of engagement holes h (only one pair of engagement holes is illustrated in FIG. 7 ) arranged in the carrying direction at the both ends thereof in the width direction (in the left and right direction in FIG. 7 ).
  • the curing processing device 400 includes two pairs of holding members 460 respectively corresponding to the two pairs of engagement holes h. Specifically, the holding members 460 are provided at positions which face the engagement holes h when the moving plate is arranged at the predetermined height.
  • Each of the holding members 460 has a cylinder 461 and a rod 462 .
  • the cylinder 461 is fixed to a support frame not shown.
  • the rod 462 is configured to protrude to the inside from the cylinder 461 in the width direction, i.e., to the engagement hole h.
  • the rod 462 is configured to be retractable between a fixing position (the state shown in FIG. 7 ) protruded from the cylinder 461 so that the tip of the rod 462 is inserted into the engagement hole h and a retracted position retracted into the cylinder 461 so that the tip of the rod 462 is pulled out from the engagement hole h of the moving plate.
  • the rod 462 moves between the fixing position and the retracted position by a driving unit not shown of the holding member 460 .
  • the driving unit is configured to drive the rod 462 with a hydraulic pressure, an air pressure or a solenoid.
  • the bottom moving plate 431 is driven by the driving unit 441 , and one of the moving plates is moved so that the engagement hole h thereof reaches the predetermined height.
  • the rod 462 of the holding member 460 held at the predetermined height is moved from the retraced position to the fixing position, the rod 462 is inserted into the engagement hole h of the moving plate.
  • the moving plate to which the rod 462 is inserted other moving plates situated on the upper side of the moving plate, the carrier plate 800 and the solar battery assembly A are held on the holding member 460 .
  • the bottom moving plate 431 is moved downward from this state by the driving unit 441 , a lower side moving plate departs from the moving plate to which the rod 462 is inserted, and thereby a space is formed between the both moving plates.
  • FIG. 8 is a flowchart illustrating the curing process executed by the curing processing device 400 .
  • the curing process is executed by the control device 700 ( FIG. 1 ) of the laminating system 1 by controlling the components (including the conveyer 450 , the driving unit 441 and the holding member 460 ) in the curing processing device 400 .
  • the laminating time for the solar battery assembly A by the laminate press device ( FIG. 5 ) is five minutes, and the carrier plate 800 on which the solar battery assembly A is placed is sent to the curing processing device 400 every five minutes.
  • step S 21 first, carrying-in and/or carrying-out of the carrier plate 800 to and/or from the upper surface of the bottom moving plate 431 is performed (S 21 ).
  • step S 21 first, the control device 700 drives the bottom moving plate 431 of the curing processing device 400 to move the third intermediate moving plate 423 so that the engagement hold h of the third intermediate moving plate 423 has the height equal to the height of the rod 462 .
  • the control device 700 moves the rod 462 of the holding member 460 from the retracted position to the fixing position, and inserts the tip of the rod 462 into the engagement hole h of the third intermediate moving plate 423 .
  • control device 700 drives again the bottom moving plate 431 so that the upper surface of the bottom moving plate 431 is lowered to a position which is lower than the upper surface of the conveyer 450 of the carrying position. At this time, a space for carrying-in and/or carrying-out of the carrier plate 800 is formed between the upper surface of the bottom moving plate 431 and the lower surface of the third intermediate moving plate 423 .
  • control device 700 carries the conveyer 450 from the retracted position to the carrying position, and thereafter the control device 700 drives the conveyer 450 to carry out the carrier plate 800 on which the solar battery after the curing process is placed from the space between the moving plates, and carries in the carrier plate 800 on which the solar battery assembly A before the curing process is placed to the space between the moving plates. Consequently, the curing processing device 400 becomes the state shown in FIG. 7 . Thus, step S 21 is finished.
  • step S 22 first, the control device 700 moves the carrier plate 800 carrying the solar battery assembly A on the conveyer 450 to the position on the bottom moving plate 431 by moving upward the bottom moving plate 431 , and thereafter the control device 700 moves the conveyer 450 from the carrying position to the retracted position. Then, the control device 700 further moves upward the bottom moving plate 431 so that the carrier plate 800 placed on the bottom moving plate 431 is sandwiched between the bottom moving plate 431 and the third intermediate moving plate 423 . Then, the control device 700 moves the rod 462 of the holding member 460 from the fixing position to the retracted position so as to pull out the tip of the rod 462 from the engagement hole h of the third intermediate moving plate 423 .
  • control device 700 drives the vacuum pump and/or the compressor connected to the third intermediate moving plate 423 so as to cause the diaphragm to press the solar battery assembly A.
  • the state is maintained, for example, for five minutes, until the next step S 23 starts.
  • the third intermediate moving plate 423 is placed on the bottom moving plate 431 until the process returns to step S 21 again via steps S 23 to S 29 which are described later, and the curing process for the solar battery assembly A placed on the upper surface of the bottom moving plate 431 continues.
  • step S 23 carrying-in and/or carrying-out of the carrier plate 800 to and/or from the upper surface of the third intermediate moving plate 423 is performed.
  • step S 23 by initially driving the bottom moving plate 431 of the curing processing device 400 , the control device 700 moves the second intermediate moving plate 422 to the position at which the engagement hole h of the second intermediate moving plate 422 has the same height as that of the rod 462 of the holding member 460 . Then, the control device 700 moves the rod 462 of the holding member 460 from the retracted position to the fixing position so as to insert the tip of the rod 462 to the engagement hole h of the second moving plate 422 .
  • step S 23 is completed.
  • step S 24 by initially moving upward the bottom moving plate 431 , the control device 700 moves the carrier plate 800 carrying the solar battery assembly A on the conveyer 450 to the position on the third intermediate moving plate 423 .
  • the control device 700 moves the conveyer 450 from the carrying position to the retracted position. Then, the control device 700 moves upward the bottom moving plate 431 so that the carrier plate 800 placed on the third intermediate moving plate 423 is sandwiched between the third intermediate moving plate 423 and the second intermediate moving plate 422 .
  • control device 700 moves the rod 462 of the holding member 460 from the fixing position to the retracted position so as to pull out the tip of the rod 462 from the engagement hole h of the second intermediate moving plate 422 .
  • control device 700 drives the vacuum pump and/or the compressor connected to the second intermediate moving plate 422 so as to cause the diaphragm to press the solar battery assembly A.
  • the state is maintained, for example, for five minutes, until the next step S 25 starts.
  • the second intermediate moving plate 422 is placed on the third intermediate moving plate 423 and the curing process for the solar battery assembly A placed on the second intermediate moving plate 422 continues until the process returns to step S 23 again via steps S 25 to S 29 which are described later and steps S 21 to S 22 .
  • step S 25 carrying-in and/or carrying-out of the carrier plate 800 to and/or from the upper surface of the second intermediate moving plate 422 is performed.
  • step S 25 by initially driving the bottom moving plate 431 of the curing processing device 400 , the control device 700 moves the first intermediate moving plate 421 to the position at which the engagement hole h of the first intermediate moving plate 421 has the same height as that of the rod 462 of the holding member 460 . Then, the control device 700 moves the rod 462 of the holding member 460 from the retracted position to the fixing position so as to insert the tip of the rod 462 to the engagement hole h of the first moving plate 421 .
  • step S 25 is completed.
  • step S 26 by initially moving upward the bottom moving plate 431 , the control device 700 moves the carrier plate 800 carrying the solar battery assembly A on the conveyer 450 to the position on the second intermediate moving plate 422 , and then moves the conveyer 450 from the carrying position to the retracted position. Then, the control device 700 moves upward the bottom moving plate 431 so that the carrier plate 800 placed on the second intermediate moving plate 422 is sandwiched between the second intermediate moving plate 422 and the first intermediate moving plate 421 . Next, the control device 700 moves the rod 462 of the holding member 460 from the fixing position to the retracted position so as to pull out the tip of the rod 462 from the engagement hole h of the first intermediate moving plate 421 .
  • control device 700 drives the vacuum pump and/or the compressor connected to the first intermediate moving plate 421 so as to cause the diaphragm to press the solar battery assembly A. This state is maintained, for example, for five minutes, until the next step S 27 starts. It should be noted that the first intermediate moving plate 421 is placed on the second intermediate moving plate 422 and the curing process for the solar battery assembly A placed on the second intermediate moving plate 422 continues until the process returns to step S 25 again via steps S 27 to S 29 which are described later and steps S 21 to S 24 .
  • step S 27 carrying-in and/or carrying-out of the carrier plate 800 to the upper surface of the first intermediate moving plate 421 is performed.
  • step S 27 by initially driving the bottom moving plate 431 of the curing processing device 400 , the control device 700 moves the first intermediate moving plate 421 to the position at which the engagement hole h of the top moving plate 411 has the same height as that of the rod 462 of the holding member 460 . Then, the control device 700 moves the rod 462 of the holding member 460 from the retracted position to the fixing position so as to insert the tip of the rod 462 to the engagement hole h of the top moving plate 411 .
  • step S 27 is completed.
  • step S 28 by initially moving upward the bottom moving plate 431 , the control device 700 moves the carrier plate 800 carrying the solar battery assembly A on the conveyer 450 to the position on the first intermediate moving plate 421 .
  • the control device 700 moves the conveyer 450 from the carrying position to the retracted position. Then, the control device 700 moves upward the bottom moving plate 431 so that the carrier plate 800 placed on the first intermediate moving plate 421 is sandwiched between the first intermediate moving plate 421 and the top moving plate 411 .
  • control device 700 moves the rod 462 of the holding member 460 from the fixing position to the retracted position so as to pull out the tip of the rod 462 from the engagement hole h of the top moving plate 411 .
  • control device 700 drives the vacuum pump and/or the compressor connected to the top moving plate 411 so as to cause the diaphragm to press the solar battery assembly A. This state is maintained, for example, for five minutes, until the next step S 29 starts. It should be noted that the top moving plate 411 is placed on the first intermediate moving plate 421 and the curing process for the solar battery assembly A placed on the first intermediate moving plate 421 continues until the process returns to step S 27 again via steps S 29 which is described later and steps S 21 to S 26 .
  • step S 29 it is judged whether to repeat the operation of the above described steps S 21 to S 28 . Whether to repeat the steps may be determined based on instructions from an operator through an input unit not shown, or may be determined whether the repeat count recorded by a counter reaches a predetermined number of times.
  • step S 29 : YES the process returns to step S 21 .
  • step S 29 : NO the flowchart terminates.
  • the solar battery assembly A arranged between the bottom moving plate 431 and the third intermediate moving plate 423 in the previous execution of step S 21 is carried out by the conveyer 450 as a solar batter after the curing process.
  • the carrier plate 800 on which the solar battery after the curing process carried out by the conveyer 450 is placed is passed to the carrying conveyer 500 ( FIG. 1 ), and is sent to the stocker (not shown) by the carrying conveyer 500 .
  • one solar batter assembly A is pressed by the curing processing device 400 while the four cycles of the lamination pressing is repeated (i.e., for about twenty minutes).
  • the curing processing device 400 is able to perform, about every Five minutes, the process where a new solar battery assembly A is carried in and the solar battery assembly A after the curing process is carried out. Therefore, in this embodiment, it is possible to start, at an appropriate time (e.g., about every five minutes), the laminate pressing for the solar battery assembly A for which lamination pressing having a short processing time is finished while securing an adequate period of time for the curing process for each solar battery assembly A.
  • the inner pressure of the chamber in which the work piece is placed is maintained at the atmospheric pressure during the hot-pressing
  • the inner pressure during the hot-pressing may be set to be higher than or equal to the atmospheric pressure.
  • the inner pressure of the chamber in which the work piece is placed is set to a pressure lower than or equal to 2 atm, or preferably set to a pressure lower than or equal to 1.5 atm.
  • the advantage of the invention can also be achieved even when the inner pressure of the chamber in which the work piece is placed is set to be slightly lower than the atmospheric pressure during the hot-pressing. Specifically, by setting the inner pressure during the hot-pressing to be higher than or equal to 0.1 atm. a certain degree of effect of preventing flowing out of the filler can be achieved. However, in order to obtain adequate advantages, it is preferable that the inner pressure of the chamber in which the work piece is placed during the hot-pressing is set to be higher than or equal to 0.5 atm, or more preferably set to be higher than or equal to 0.8 atm.
  • the work piece is placed in the lower chamber LC
  • the work piece may be placed in the upper chamber UC.
  • the diaphragm is fixed to the lower chamber LC
  • the upper chamber UC is configured to be openable and closable.
  • the work piece is placed, for example, on the diaphragm.
  • the inner pressures of the chambers are controlled in a reverse way in comparison with the above described embodiment. That is, the inner pressure of the lower chamber LC is set to a positive pressure while maintaining the inner pressure of the upper chamber UC at the atmospheric pressure so that the diaphragm protrudes to the upper chamber UC side and the work piece is pressed between the ceiling surface of the upper chamber and the diaphragm.
  • a moving platen may be additionally provided between the diaphragm and the work piece so that the work piece is hot-pressed between the moving platen and the ceiling surface of the upper chamber UC.
  • the laminate press device employs the configuration where the lower chamber is supported by the fixed plate and the upper chamber UC is supported by the moving plate.
  • the lower chamber LC and the upper chamber UC may be supported respectively by the moving plate and the fixed plate.
  • both of the chambers may be supported separate moving plates.
  • the laminate press device employs the configuration where the inner pressures of both of the upper and lower chambers UC and LC are increased to the atmospheric pressure in the state where the inner pressure of the upper chamber UC and the inner pressure of the lower chamber are balanced.
  • another control of the inner pressures may be employed.
  • the inner pressure of the lower chamber LC in which the work piece is placed may be increased to the atmospheric pressure while keeping the upper chamber UC at the decreased pressure, and thereafter the upper chamber UC may be pressurized.
  • Such a control also makes it possible to prevent the softened filler from flowing out from the work piece due to the fact that the work piece is hot-pressed in the vacuum state.
  • the curing processing device 400 is configured to have three intermediate moving plates, and to be able to execute the curing process for four solar battery assemblies A simultaneously.
  • the present invention is not limited to such a configuration.
  • solar batteries can be effectively manufactured by using a curing processing device having a larger number of intermediate moving plates.
  • each of the moving plates 411 , 421 , 422 , 423 and 431 of the curing processing device 400 and the fixed plate 320 and the moving plate 330 of the laminate press device 300 is heated by the electrothermal heater provided therein.
  • each of the moving plates and the fixed plate may be configured to be heated by a heat medium (e.g., oil) circulating therein.
  • a heat medium e.g., oil
  • control of the laminate press process and the curing process are controlled by the control device 700 which is provided separately from the laminate press device 300 and the curing processing device 400 .
  • the laminate press device 300 and the curing processing device 400 may be respectively provided with control units so that the laminate press process and the curing process can be executed under control of these control units.
  • cooperation between devices is controlled by the control device 700 .
  • cooperation between the devices may be achieved through communication between control units provided respectively in the devices of the laminate processing system 1 without providing the control device 700 executing central control for the laminate processing system 1 .
  • the present invention can also be applied to various types of forming of a laminate structure body.
  • the present invention can be applied to manufacturing of a plate-like laminate structure body, such as a print wiring board which is formed by hot-pressing a laminated body of structural materials including pre-preg.
  • the present invention can also be applied to manufacturing of display panels, such as a plasma display panel and an organic electro luminescent display.
US13/417,560 2009-09-10 2012-03-12 Laminate press device, carrier plate, laminating system and laminating method Abandoned US20120168077A1 (en)

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US13/417,520 US8540000B2 (en) 2009-09-10 2012-03-12 Curing processing device and laminating system
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