JP2006218658A - Vacuum laminating apparatus and vacuum laminating method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress the manufacturing cost of a product manufactured by a vacuum laminating apparatus.
SOLUTION: A breathable sheet 20 is placed on a mounting area of a laminate module surrounded by a frame body 12W fixed on a substrate 11, and a solar cell module constituent material 18 is placed on the breathable sheet 20. The lid member 17 covers the peripheral edge of the frame body 12W and the solar cell module constituent material 18 and forms a space for performing a laminating process.
[Selection] Figure 3

Description

  The present invention relates to a vacuum laminating apparatus and a vacuum laminating method, and more particularly to a vacuum laminating apparatus and a vacuum laminating method in which a constituent material of a laminating module is evacuated and laminated.

  The vacuum laminating apparatus is applied as a final manufacturing apparatus for the purpose of covering elements related to semiconductors, in particular, solar cells and the like used by being exposed to the outside air. FIG. 11 is a perspective view of the conventional vacuum laminating apparatus with the lid member removed, viewed from above, and FIG. 12 is an EE arrow with the solar cell module constituent material placed on the conventional vacuum laminating apparatus. FIG. A procedure for producing a solar cell module using the vacuum laminating apparatus 100 is roughly as follows.

  First, the net 109 is placed in a space sandwiched between the base material 101 and the rectangular annular frame 102W. Then, a breathable sheet 110 is placed at the center of the substrate 101, the solar cell module constituent material 108 is placed thereon, the breathable sheet 110 is placed thereon, and the top is covered with a lid member 107.

  Next, the vacuum pump 104 is activated to evacuate the space formed by the base material 101, the rectangular ring frame 102W, the lid member 107, and the solar cell module constituent material 108, so that the air in the space and the solar cell The air between the materials of the module constituent material 108 is discharged or degassed from a discharge port provided on the inner peripheral side of the rectangular annular frame 102W. Then, with the vacuum pump 104 operating, the vacuum laminating apparatus 100 is put into a high-temperature oven, the temperature is increased to a temperature at which the filler contained in the solar cell module constituent material 108 is cured, and is maintained until the curing is completed. To do. After the filler is cured, it is removed from the oven and cooled, and the vacuum pump 104 is stopped to return the space to atmospheric pressure. With the above procedure, the creation of the solar cell module is completed.

Conventionally, there is a vacuum laminating device that suppresses the occurrence of cracks in the lid member by installing a cushioning material along the inside of the cylindrical tube and slowing down the steep angle configuration of the lid member by vacuuming (for example, , See Patent Document 1). In addition, there is a vacuum laminating apparatus having rigidity capable of withstanding a large area of a laminate module while slowing down a steep angle configuration of a lid member by vacuuming (see, for example, Patent Document 2).
JP-A-9-51111 (paragraph numbers [0017] to [0026], FIG. 3) JP 2004-306420 A (paragraph numbers [0021] to [0026], FIG. 1)

  However, if the constituent material of the product manufactured by laminating becomes very large, the size of the lid member becomes very large accordingly. The lid member is made of a sheet-shaped material such as silicon resin in order to satisfy heat resistance, flexibility, light weight, and airtightness when evacuated. Therefore, as the area increases, the weight of the lid member becomes heavier, so that the silicone resin is damaged when the lamination is repeated, and the risk of particularly impairing airtightness increases. Therefore, in order to ensure airtightness, it is necessary to periodically replace the lid member, and there is a problem that the manufacturing cost increases accordingly.

  The present invention has been made in view of such points, and can reduce the risk of scratching the lid member, and can reduce the frequency of replacement of the lid member. An object of the present invention is to provide a vacuum laminating apparatus capable of reducing the manufacturing cost of the apparatus.

  Another object of the present invention is to provide a vacuum laminating method that can reduce the risk of damaging the lid member and reduce the frequency of replacement of the lid member. Is to provide.

  In the present invention, in order to solve the above-mentioned problem, in a vacuum laminating apparatus having a space for performing a laminating process, a base material for placing a laminating module is fixed between the base material and the base material. Forming a passage for evacuation, a frame disposed so as to surround a mounting region of the laminate module, and the frame and the frame in a state where the laminate module is mounted on the base material A lid member for covering the periphery of the laminate module and forming a space for performing the lamination process between the base material and the laminate module; A vacuum laminating apparatus is provided.

  According to such a vacuum laminating apparatus, the periphery of the laminate module is covered with the lid member, and the laminate module itself is used for forming a space area of the space portion where the lamination process is performed. Therefore, it is not necessary to cover the entire laminate module with the lid member. The area of the lid member can be reduced.

  Further, in the present invention, in a vacuum laminating method for manufacturing a laminating module using a vacuum laminating apparatus in which an exhaust passage is formed in an annular shape in the vicinity of the outer peripheral edge of the base material or on two opposite sides of the base material. And a module material arranging step of arranging the constituent material of the laminate module on the base material inside the frame body, covering the frame body, the base material, and the outer peripheral edge of the laminate module with a lid member, and laminating processing A laminate space forming step for forming a space portion for performing a vacuum, a vacuum drawing step for evacuating the space portion, and heating the space portion while maintaining the evacuation, thereby configuring the laminate module There is provided a vacuum laminating method comprising a laminating process for laminating a material.

  According to such a vacuum laminating method, the frame body, the base material, and the outer peripheral edge of the laminate module are covered with the lid member, and the laminate module itself is used for forming a space area in the space portion where the lamination process is performed. Even if the area is reduced, vacuum lamination can be performed.

  According to the vacuum laminating apparatus of the present invention, the area of the lid member can be reduced, and an increase in its own weight due to the increase in area can be suppressed, so that the risk of damage to the lid member can be suppressed. The replacement frequency of members can be reduced. This also makes it possible to reduce the manufacturing cost of products manufactured by vacuum lamination.

  In addition, according to the vacuum laminating method of the present invention, since the vacuum laminating can be performed even if the area of the lid member is reduced, an increase in the weight of the lid member can be suppressed. Therefore, the risk that the lid member is damaged can be suppressed, and the replacement frequency of the lid member can be reduced. This also makes it possible to vacuum laminate at a low cost.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[First Embodiment]
FIG. 1 is a perspective view of the vacuum laminating apparatus according to the present embodiment from which the lid member is removed, as viewed from above, and FIG.

  The vacuum laminating apparatus 10 of the present embodiment has a base 11 for installing a laminate module, and an exhaust port fixed on the base 11 for evacuating the mounting area of the laminate module. A rectangular ring-shaped frame 12W having a mesh 19 inserted in the exhaust port, a breathable sheet 20 disposed in the frame 12W on the substrate 11 and constituting a mounting area of the laminate module, and a laminate module And a lid member to be described later for sealing the mounting area. Furthermore, it has the connection part 15 which is a path | route for connecting the frame 12W and the vacuum pump 14, and the valve | bulb 16. FIG. In the following description, a laminate module will be described as a solar cell module constituent material.

  The substrate 11 is a member that constitutes the bottom of the vacuum laminating apparatus 10. The plate-like substrate 11 used in the solar cell module manufacturing apparatus is required to have characteristics such as heat resistance, rigidity, light weight, and surface adhesion. The material used for the substrate 11 is mainly a metal such as iron or aluminum, but stainless steel is used from the viewpoint of weldability and corrosion resistance. In order to reduce the heat capacity or reduce the weight, it must be thinned, but if it is made too thin, the rigidity will be lowered. Therefore, a stainless steel plate having a thickness of about 0.8 to 2.0 mm is used for the base material 11.

  The frame body 12 </ b> W is formed by fixing four plate members 12 around the base material 11, and an annular exhaust space is formed in the vicinity of the outer peripheral edge of the base material 11 by the frame body 12 </ b> W and the base material 11. Properties required for the plate material 12 include heat resistance, rigidity, lightness, and the like. Stainless steel is mainly used as the material.

  As shown in FIG. 2, the cross-sectional shape of the frame body 12W includes a first bent surface 12a, a second bent surface 12b, a third bent surface 12c, and a fourth bent surface 12d. The first bent surface 12a and the second bent surface 12b are bent at substantially right angles, and the outer peripheral side of the base material 11 is abutted with the first bent surface 12a, and spot welding is performed at intervals of about 100 mm by electric resistance welding. Yes. The third bent surface 12 c is bent into a shape having an included angle of about 30 ° with respect to the base material 11. The fourth bent surface 12 d is bent so that the bent portion between the third bent surface 12 c and the fourth bent surface 12 d has a certain gap with respect to the base material 11. In order for this gap to become an exhaust port and to improve exhaust efficiency, the height should be such that it substantially matches the thickness of the mesh 19 inserted between the base material 11 and the fourth bent surface 12d. Is desirable.

  The net | network 19 is used in order to ensure the flow of the air at the time of deaeration between each layer in the below-mentioned solar cell module constituent material by evacuating. That is, it is located between the base material 11 and the frame body 12W in the space portion to be evacuated, and the frame body 12W and the base material 11 bent at the time of evacuation come into contact with each other to block the flow of air. Use to prevent. The required properties are heat resistance, flexibility, lightness, and the like. The material used is a net made of a metal mesh such as stainless steel or aluminum, or a heat-resistant resin fiber such as polyester.

  The air-permeable sheet 20 is also used to secure the air flow when performing deaeration between layers in the solar cell module constituent material described later, as with the net 19. The breathable sheet 20 has the same shape and size as the inside of the annular body formed by the frame body 12W. The required properties are heat resistance, flexibility, lightness, and the like. The material used is a net made of a metal mesh such as stainless steel or aluminum, or a heat-resistant resin fiber such as polyester. Note that the two of the net 19 and the air permeable sheet 20 do not need to be separate and independent, and the two may be substituted by using one net-like sheet.

  3 is a perspective view of the solar cell module constituent material placed in the vacuum laminating apparatus of the present embodiment as seen from above, and FIG. 4 is a view taken along the line BB in the vacuum laminating apparatus of FIG. It is sectional drawing.

  In the vacuum laminating apparatus 10 shown in FIG. 3, the solar cell module constituent material 18 is placed on the breathable sheet 20 on the base material 11 of the vacuum laminating apparatus 10 shown in FIG. A lid member 17 is placed so as to cover the laminate module mounting area to be formed.

  The lid member 17 has a structure that covers the solar cell module constituent material 18 so as to cover a part of the frame body 12 </ b> W and the solar cell module constituent material 18. In FIG. 3, the lid member 17 is indicated by hatching for convenience. The vacuuming space for laminating is formed by a space surrounded by the base material 11, the frame body 12 </ b> W, the lid member 17, and the solar cell module constituent material 18 that is a material to be laminated.

  The lid member 17 has a rectangular opening 17a whose outer periphery is larger than the outer periphery of the frame body 12W and whose inner periphery is smaller than the central solar cell module constituent material 18. The lid member 17 covers the frame 12W and the peripheral edge portion of the solar cell module constituent material 18 placed on the base material 11, and is a space for evacuating the base material 11 and the frame body 12W. Used for the purpose of building parts. The characteristics required for the lid member 17 are heat resistance, flexibility, light weight, airtightness when evacuated, and the like. The material used is mainly silicon resin, and the shape is a sheet. For example, a silicon resin general-purpose type made of Tigers polymer having a thickness of 2 mm and a hardness of 50 is used.

  As shown in FIG. 4, the breathable sheet 20 is used by placing the breathable sheet 20 on the substrate 11, placing the solar cell module constituent material 18 thereon, and placing the lid member 17 thereon. By sucking the air in the space with the vacuum pump 14, the lid member 17 is drawn toward the base material 11, and the peripheral portion of the solar cell module constituent material 18 is pushed, whereby the solar cell module constituent material 18 and the lid member 17 are brought together. In close contact.

  Further, atmospheric pressure is applied to the solar cell module constituent material 18 excluding the opening 17a of the lid member 17, and the lid member 17, the frame body 12W, and the solar cell module constituent material 18 are applied when evacuating. Since the pressure in the space surrounded by is reduced, there is an effect similar to that when the solar cell module constituent material 18 is pushed from above by the difference from the atmospheric pressure. That is, the opening 17a of the lid member 17 covers the entire solar cell module constituent material 18 and presses the entire solar cell module constituent material 18 so as not to push out air between the constituent materials. An effect can be obtained.

  Thus, even if the opening 17a is provided in the lid member 17, it is possible to push out air between the constituent materials. Since the lid member 17 is provided with the opening 17a, its own weight is reduced. It is possible to reduce the risk of damage. In addition, since the replacement frequency of the lid member 17 can be lowered accordingly, the manufacturing cost can be suppressed.

  Next, a procedure for creating a laminate module by a laminate module manufacturing apparatus to which the vacuum laminating apparatus 10 of the present embodiment is applied, and results of actual creation will be described. In the present embodiment, a solar cell module is arranged as a laminate module. FIG. 5 is a diagram showing a configuration example of a laminate module manufacturing apparatus to which the vacuum laminating apparatus of the present embodiment is applied.

  In the laminating module manufacturing apparatus 30, ten vacuum laminating apparatuses 10 are horizontally arranged inside a hot-air circulating heating furnace 31. However, the discharge side of the valve 16 of each vacuum laminating apparatus 10 is collectively connected to the manifold 32, the manifold 32 is connected to the vacuum pump 14, and each vacuum laminating apparatus 10 is collectively evacuated.

A procedure for creating a solar cell module using the laminate module manufacturing apparatus 30 will be described below.
First, for each vacuum laminating apparatus 10, a breathable sheet 20 is placed on the substrate 11 as in FIG. 4, and a solar cell module constituent material 18 is further placed thereon. Then, the lid member covers the quadrangle formed by the frame body 12 </ b> W and the edge of the opening 17 a located in the middle of the lid member 17 comes near the peripheral edge of the solar cell module constituent material 18 placed on the base material 11. 17 is put.

  After the arrangement of each member, the discharge side of the valve 16 of each vacuum laminating apparatus 10 and the manifold 32 are connected to each other. And the vacuum pump 14 is started, the lamination space part of each vacuum laminating apparatus 10 is evacuated, and the air between the materials of the solar cell module constituent material 18 arrange | positioned at each vacuum laminating apparatus 10 is deaerated.

  With the vacuum pump 14 deaerated, the temperature is raised to a temperature at which the filler contained in each solar cell module constituent material 18 is cured (about 150 ° C.) and held for 30 minutes until the curing is completed. Thereafter, the valve 16 of each vacuum laminating apparatus 10 is closed, each vacuum laminating apparatus 10 is taken out from the hot air circulation type heating furnace 31 while being cooled and cooled, and the valve 16 is opened to laminate the space of each vacuum laminating apparatus 10. Return the part to atmospheric pressure.

By such a procedure, 10 solar cell modules having a size of 500 × 2000 mm were produced at a time.
[Second Embodiment]
Next, a second embodiment of the present invention will be described. The vacuum laminating apparatus of the present embodiment is the same as the structure shown in the first embodiment except that the weight is placed on the overlapping portion between the lid member and the solar cell module constituent material. For this reason, about the component similar to the said 1st Embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted suitably.

6 is a perspective view seen from above when a weight is placed on the vacuum laminating apparatus of FIG. 3, and FIG. 7 is a cross-sectional view taken along the line CC in the vacuum laminating apparatus of FIG.
In the vacuum laminating apparatus 210, a frame-shaped weight 17 b is placed at an overlapping portion between the lid member 17 and the solar cell module constituent material 18. The weight 17 b is a metal frame-shaped weight, which is larger than the opening 17 a of the lid member 17 and smaller than the solar cell module constituent material 18.

  When there is not enough overlap between the lid member 17 and the solar cell module constituent material 18 or the overlapping portion between the solar cell module constituent material 18, the weight 17 b is placed on the overlap portion so that the lid 17 is more firmly attached. And air leakage can be prevented. The weight 17b needs to have a certain weight, for example, 5 kg here. Further, although the weight is used in the present embodiment, it may be pressed by an apparatus or the like as long as the degree of adhesion between the lid member 17 and the solar cell module constituent material 18 can be increased.

[Third Embodiment]
Next, a third embodiment of the present invention will be described. The vacuum laminating apparatus of the present embodiment is the same as the configuration shown in the first embodiment except that the exhaust passage is provided on two opposite sides instead of the four sides of the frame. For this reason, about the component similar to the said 1st Embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted suitably.

FIG. 8 is a perspective view of the vacuum laminator of the present embodiment with the lid member removed, as viewed from above.
The vacuum laminating apparatus 310 according to the present embodiment is similar to the vacuum laminating apparatus 10 according to the first embodiment in that the base material 11, the frame 312W, the connection portion 15, the valve 16, the net 19, and the air permeability. It has the sheet | seat 20 and the lid member mentioned later.

  The frame body 312W of the vacuum laminating apparatus 310 of the present embodiment includes an exhaust passage forming portion 312 having an exhaust passage and a frame forming portion 313. The exhaust passage forming portion 312 is fixed to two opposing sides on the base material 11, and is fixed to the frame forming portion 313 at the end in the width direction of the exhaust passage forming portion 312. Further, a corresponding hole of the frame forming portion 313 fixed to one end of the exhaust passage forming portion 312 has a hole for exhaust, and a route for connecting the hole and the vacuum pump 14 is provided. A connection 15 is connected.

  FIG. 9 is a perspective view of a solar cell module constituent material placed in the vacuum laminating apparatus of the present embodiment as viewed from above, and FIG. 10 is a view taken along the line DD in the vacuum laminating apparatus of FIG. It is sectional drawing.

  The cross-sectional shape of the exhaust passage forming portion 312 has a substantially triangular shape, similar to the frame body 12W of the first embodiment. However, at the time of the fourth bent surface 12d, in order to keep the lid member 17 in close contact with each other, there is left a sealed range for preventing air from being exhausted to a predetermined range at both ends in the width direction of the exhaust passage forming portion 312. Bending is performed from the bending surface 12c. For example, the sealing range is 10 mm. On the other hand, the cross-sectional shape of the frame forming portion 313 is an L-shape including only the first bent surface 312a and the second bent surface 312b.

  During the laminating process, air is exhausted from the processing space sealed by the lid member 17 to the exhaust passage through the exhaust port by the vacuum pump 14, and the air is exhausted from the exhaust passage through the connection portion 15. The

  Note that in the vacuum laminating apparatus 310 of the present embodiment as well, as in the second embodiment corresponding to the first embodiment, the pressure for bringing the lid member 17 and the solar cell module constituent material 18 into close contact with each other. Alternatively, when the overlapping portion with the solar cell module constituent material 18 is insufficient, by placing a weight on the overlapping portion, it is possible to adhere more firmly and prevent air leakage.

It is the perspective view which looked at what removed the cover member of the vacuum laminating device of a 1st embodiment from the top. It is AA arrow sectional drawing in the vacuum laminating apparatus of FIG. It is the perspective view which looked at what mounted the solar cell module constituent material in the vacuum laminating apparatus of 1st Embodiment from the top. It is BB arrow sectional drawing in the vacuum laminating apparatus of FIG. It is a figure which shows the structural example of the lamination module manufacturing apparatus to which the vacuum laminating apparatus of 1st Embodiment is applied. It is the perspective view seen from the top when a weight was mounted in the vacuum laminating apparatus of FIG. It is CC sectional view taken on the line in the vacuum laminating apparatus of FIG. It is the perspective view which looked at what removed the cover member of the vacuum laminating device of 3rd Embodiment from the top. It is the perspective view which looked at what put the solar cell module constituent material in the vacuum laminating apparatus of 3rd Embodiment from the top. It is DD arrow sectional drawing in the vacuum laminating apparatus of FIG. It is the perspective view which looked at what removed the cover member of the conventional vacuum laminating apparatus from the top. It is EE arrow sectional drawing of the state which mounted the solar cell module structural material on the conventional vacuum laminating apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Vacuum laminating apparatus 11 Base material 12 Plate material 12W Frame 14 Vacuum pump 15 Connection part 16 Valve 19 Net | air 20 Breathable sheet

Claims (7)

In a vacuum laminating apparatus having a space for laminating,
A base material for placing the laminate module;
A frame that is fixed on the base material and forms a passage for vacuuming with the base material, and is disposed so as to surround a mounting region of the laminate module;
In a state where the laminate module is placed on the substrate, the laminate module is arranged so as to be spanned between the frame and the laminate module, covers a peripheral edge of the laminate module, and includes the substrate and the laminate module. A lid member for forming a space for performing the laminating process in between;
A vacuum laminating apparatus comprising:   The lid member is made of a flexible frame-shaped sheet material, and the vicinity of the opening is in close contact with the laminate module during the evacuation, and the periphery of the laminate module is removed from the opening. The vacuum laminating apparatus according to claim 1, wherein the vacuum laminating apparatus is configured to expose a portion.   2. The vacuum laminating apparatus according to claim 1, further comprising pressing means for pressing an overlapping portion of the lid member with the laminating module in the base material direction.   4. A vacuum laminating apparatus according to claim 3, wherein the pressing means is a frame-shaped weight.   The frame body is provided in the vicinity of the outer peripheral edge of the base material, the cross-sectional shape is substantially triangular, and the inner end portion of the frame body is in communication with the space portion with respect to the base material. 2. The vacuum laminating apparatus according to claim 1, wherein the vacuum laminator has a certain gap.   The frame body is provided on two opposing sides of the base material to form an exhaust passage forming portion that forms a passage for evacuation, and the exhaust passage forming portion is provided on two remaining sides of the base material. The vacuum laminating device according to claim 1, further comprising a frame forming portion disposed so as to surround the space portion. In a vacuum laminating method for manufacturing a laminating module by using a vacuum laminating apparatus in which an exhaust passage is formed in an annular shape in the vicinity of the outer peripheral edge of the base material or on two opposite sides of the base material,
A module material arrangement step of arranging the constituent material of the laminate module on the base material inside the frame;
A laminate space forming step of covering the frame body, the base material, and an outer peripheral edge of the laminate module with a lid member to form a space portion for performing a lamination process;
A evacuation step of evacuating the space;
A laminating process for laminating the constituent material of the laminating module by heat-treating the space while maintaining the evacuation,
A vacuum laminating method comprising:

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