JPH11216832A - Manufacturing of laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate which is highly weatherable and of high productivity and useful for manufacturing solar cell modules by arranging two or more temperature control systems in a device for manufacturing a laminate formed by heat pressurizing, and controlling temperatures independently by the control systems. SOLUTION: Two or more temperature control systems are arranged in a device for manufacturing laminates, and each of the parts of a material to be laminated is placed at an individually independent temperature. Therefore, even when making the laminate for a solar cell module of a large area, it is possible to perform each step such as the melting, degassing, crosslinking or the like of a sealer resin gradually from the center part of the laminate by changing temperature to the periphery of the laminate. When manufacturing the solar cell module by a single vacuum system, the laminate for the solar cell module is placed on a plate 301, and a silicone rubber sheet is superposed thereon, and the laminate is contact-bonded with silicone rubber by exhausting air from an exhaust vent 304 in the plate 301. After that, the plate 301 is heated to melt a sealer resin and then cooled.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an apparatus and a method for manufacturing a laminate such as a solar cell module.

[0002]

2. Description of the Related Art A solar cell module usually has a structure in which a photovoltaic element is sealed between an upper surface member and a lower surface member with an organic polymer resin. When manufacturing a solar cell module having such a structure, for example, a surface member from the front side,
A laminate of a surface sealing material resin, a photovoltaic element, a back surface sealing material resin, and a back member in this order (hereinafter referred to as a solar cell module laminate) is pressed and heated by pressing and heating. When the surface member is a resin film, a surface protection reinforcing material may be interposed between the surface sealing material resin and the photovoltaic element in order to increase the strength on the surface side.

By the way, in order to manufacture a solar cell module by bonding a front member and a back member using a sealing material resin, it is necessary to provide a "solar cell module laminating apparatus" of Japanese Patent Publication No. 4-65556 and "Real registration 3017231". Laminating apparatus using a double vacuum chamber system disclosed in "Laminating apparatus" or laminating apparatus using a single vacuum chamber system disclosed in "Solar cell module and manufacturing method thereof" in JP-A-9-36405 is common. .

Generally, organic polymer resins such as ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB), epoxy resin, silicone resin and fluororesin are used as a sealing material resin for a solar cell module. It is desirable that these organic polymer resins are crosslinked from the viewpoint of weather resistance and durability. Usually, when a photovoltaic element is sealed with a laminating device to produce a solar cell module, these organic polymer resins are crosslinked in the process of heating and pressing. An example of the process is shown below. The object to be laminated is placed on a laminating apparatus and is vacuum-pressed. Heat to the temperature at which the encapsulant resin melts. The gas generated from the sealing material resin is degassed or dissolved in the molten sealing material resin. Heat to the crosslinking start temperature to crosslink the sealing material resin. Maintain the crosslinking temperature until the crosslinking is completed. Through the above steps, a solar cell module in which an organic polymer resin as a sealing resin is crosslinked is obtained.

[0005]

However, since the conventional laminating apparatus has only one heating control system, it is impossible to perform heating control according to the shape or size of the solar cell module laminate. In other words, in the conventional uniform heating method, since the entire solar cell module laminate is heated at the same temperature, each process such as melting, degassing, and cross-linking of the organic polymer resin as the encapsulant resin is laminated. Get up on the whole body at the same time. In particular, when the size of the module is increased, since the gas generated in the central portion of the module is not sufficiently degassed, the bridging of the peripheral portion of the module starts, and air bubbles remain inside the module. Such air bubbles not only impair the appearance of the solar cell module, but when an organic polymer resin is used for the front surface member or the back surface member, moisture penetrates into the air bubbles and promotes peeling of the sealing material resin. Or it may cause corrosion of a metal member such as a collecting electrode. In addition, the heating is often not uniform depending on the lamination structure and size of the solar cell module laminate. In this case, the sealing resin is heated and cross-linked under a non-uniform temperature distribution. Unevenness occurs in the characteristics.

Further, in the case of a module which is only partially laminated, there is a problem that the conventional apparatus has a large amount of energy loss since a part is heated unnecessarily.

In addition, in the conventional device, when a convex member such as an electrode or a diode is provided on the front or back surface of the photovoltaic element, the amount of the sealing material resin is smaller than that of other flat portions. It was difficult to fill. In order to sufficiently impregnate the convex portion with the sealing resin, it is necessary to slow the temperature rise and lengthen the state in which the sealing resin is melted. Therefore, it is necessary to adjust the entire temperature profile to the convex member portion where the temperature rise is the slowest, and long-time heating is required to crosslink the organic polymer resin as a sealing material resin to a required crosslink density. there were.

[0008] In addition, for a solar cell module integrated with a roofing material or a building material, a flat plate-shaped module is manufactured by a known laminating apparatus and then bent by a roller former, a bender or a press. In the laminating apparatus, since the sealing material resin at the bent portion is also uniformly crosslinked, stress is concentrated on the bent portion after processing, and the resin is easily peeled.

An object of the present invention is to provide a manufacturing apparatus and a manufacturing method of a laminate capable of manufacturing a solar cell module having high weather resistance and high productivity in order to solve the above-mentioned problems.

[0010]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a manufacturing apparatus and a manufacturing method of a laminate according to the present invention include a temperature control system in a manufacturing apparatus of a laminate formed by heating and pressurizing an object to be laminated. , And at least two systems for independently controlling the temperature. The present invention is also characterized in that partial lamination is performed by temperature control, and the crosslink density of the sealing resin of the laminate is partially changed.

(Operation) In the present invention, since there are two or more temperature control systems in the laminate manufacturing apparatus, an independent temperature profile can be provided for each part of the laminated body. Therefore, even in a large-area solar cell module, by changing the temperature profile from the center to the periphery, each process such as melting, degassing, and crosslinking of the encapsulant resin is performed from the center of the solar cell module laminate. This can be performed gradually, and a solar cell module free of air bubbles can be manufactured.

Further, in the case of a module which is partially laminated, heat can be applied only to necessary parts, so that efficient heating can be performed.

Further, electrodes are provided on the front or back surface of the photovoltaic element,
When there is a convex member such as a diode, the temperature of the convex portion is made slower than that of the other portions, so that the time during which the sealing material resin is melted is increased, and the sealing resin is sufficiently impregnated. Can be followed. At this time, the temperature of the other flat portion can be increased quickly, so that the crosslink density of the sealing resin on the photovoltaic element, which requires the most weather resistance, can be increased.

Further, in a portion where a high adhesive force is required between the sealing resin and the front surface member or the back surface member, for example, a module end portion, a terminal take-out portion, or the like, the crosslinking temperature holding time may be locally increased. , By increasing the crosslinking temperature,
The crosslink density can be increased and the adhesive strength can be increased.

Conversely, by controlling the temperature at which the sealing material resin does not crosslink, it is possible to partially reduce the crosslink density or the crosslink density. Therefore, in the case of a solar cell module that is folded after lamination, stress can be reduced with respect to bending by lowering the crosslink density of the bent portion. If this non-crosslinked or low-crosslinked portion is secondary-crosslinked after bending, there is no problem in weather resistance and adhesiveness, and the degree of freedom in processing is increased. Further, secondary cross-linking can be performed again according to the purpose, such as bonding between non-cross-linked portions of two or more modules or bonding between modules and other members. As a method of such secondary cross-linking, not only a method by heating but also various methods such as electron beam cross-linking and photo-cross-linking with ultraviolet rays can be selected depending on applications and workability.

[0016]

FIG. 1 is a schematic structural view of a solar cell module. In FIG. 1, 101 is a photovoltaic element,
102 is a transparent sealing material resin on the front surface, 103 is a transparent surface member located on the outermost surface, 104 is a rear sealing material resin, 10
5 is a back surface member. Light from the outside is transmitted to the surface member 103.
And reaches the photovoltaic element 101, and the generated electromotive force is extracted to the outside by an output terminal (not shown).

As the photovoltaic element 101, 1) crystalline silicon solar cell, 2) polycrystalline silicon solar cell, 3) amorphous silicon solar cell, 4) copper indium selenide solar cell, 5) compound semiconductor solar cell, etc. Various known elements may be selected and used depending on the purpose.

The surface sealing material resin 102 covers the unevenness of the photovoltaic element with a resin, protects the element from a severe external environment such as temperature change, humidity and impact, and secures the adhesion between the surface member and the element. Needed to do so. Therefore, weather resistance,
Adhesion, filling, heat resistance, cold resistance, and impact resistance are required. Examples of resins satisfying these requirements include polyolefins such as ethylene-vinyl acetate copolymer (EVA), ethylene-methyl acrylate copolymer (EMA), ethylene-ethyl acrylate copolymer (EEA), and polyvinyl butyral resin. Thermoplastic or thermosetting resins such as a base resin, a urethane resin, a silicone resin, and a fluororesin. Among them, EVA has a well-balanced physical property for solar cells and is preferably used. However, since the heat deformation temperature is low as it is, it easily deforms and creeps under high temperature use. Therefore, it is desirable to increase the heat resistance by crosslinking.

In the case of EVA, it is common to crosslink with an organic peroxide. Crosslinking with an organic peroxide is performed by free radicals generated from the organic peroxide extracting hydrogen and halogen atoms in the resin to form a CC bond. Activation methods for organic peroxides include thermal decomposition,
Redox decomposition and ionic decomposition are known. Generally, the thermal decomposition method is preferred. Specific examples of the chemical structure of the organic peroxide include hydroperoxide, dialkyl (allyl) peroxide, diacyl peroxide, peroxyketal, peroxyester, peroxycarbonate, and ketone peroxide. The amount of the organic peroxide is 0.5 to 5 parts by weight based on 100 parts by weight of the sealing resin.

The above organic peroxide is added to a sealing resin,
Crosslinking and thermocompression bonding can be performed while heating under pressure under vacuum. It can be determined by the heating temperature and the thermal decomposition temperature characteristics of each organic peroxide. In general, the heating and pressurization is completed at a temperature and time at which the thermal decomposition proceeds by 90%, more preferably 95% or more. It is sufficient to measure the gel fraction in order to confirm the crosslinking of the sealing material resin, and in order to prevent the deformation of the sealing material resin at a high temperature, it is desirable to perform the crosslinking so that the gel fraction becomes 70 wt% or more.

In order to carry out the above crosslinking reaction efficiently, triallyl isocyanurate (TAI), which is called a crosslinking aid, is used.
It is also possible to use C). Generally, sealing resin 1
The amount is 1 to 5 parts by weight based on 00 parts by weight.

In order to increase the weather resistance of the sealing material resin and the lower layer of the sealing material resin, an ultraviolet absorber may be used in combination.
Known compounds are used as the ultraviolet absorber. However, it is preferable to use a low-volatility ultraviolet absorber in consideration of the usage environment of the solar cell module. In particular,
Examples include salicylic acid-based, benzophenone-based, benzotriazole-based, and cyanoacrylate-based organic compounds.

If a light stabilizer is added in addition to the ultraviolet absorber, a sealing material more stable to light can be obtained. Representative light stabilizers are hindered amine light stabilizers. Hindered amine light stabilizers do not absorb ultraviolet light, unlike ultraviolet light absorbers. However, when used in combination with an ultraviolet absorber, a remarkable synergistic effect is exhibited. Of course, some other than the hindered amine-based compounds function as light stabilizers. However, it is often colored, which is not desirable for the encapsulant resin of the present invention. The amount of the UV absorber and the light stabilizer added is 0.1 to 1.
0 wt% and 0.05 to 1.0 wt% are desirable.

Further, an antioxidant can be added for improving heat resistance and heat workability. The chemical structure of the antioxidant includes a monophenol type, a bisphenol type, a polymer type phenol type, a sulfur type and a phosphoric acid type.
The addition amount of the antioxidant is 0.05 to
Preferably, it is 1.0 wt%. When it is assumed that the solar cell module is used in a more severe environment, it is preferable to improve the adhesive force between the sealing resin and the photovoltaic element or the surface member. By adding a silane coupling agent or an organic titanate compound to the sealing material resin, it is possible to improve the adhesive strength. The addition amount is preferably 0.1 to 3 parts by weight based on 100 parts by weight of the sealing material resin,
0.25 to 1 part by weight is more preferred.

Since the surface member 103 used in the present invention is located on the outermost layer of the solar cell module, it has long-term reliability in outdoor exposure of the solar cell module, including transparency, weather resistance, stain resistance, and mechanical strength. Performance is required to ensure Materials preferably used in the present invention include white plate reinforced glass, fluororesin film, and acrylic resin film. White sheet tempered glass is widely used as a surface member of a solar cell module because it has high transparency, is strong against impact, and is hard to break.

However, recently, the module is often required to be lightweight and flexible, and in such a case, a resin film is used as a surface member. Among them, a fluororesin film is preferably used because it has excellent weather resistance and stain resistance. Specific examples include a polyvinylidene fluoride resin, a polyvinyl fluoride resin, and an ethylene tetrafluoride-ethylene copolymer. Polyvinylidene fluoride resin is excellent in terms of weather resistance, but ethylene tetrafluoride-ethylene copolymer is excellent in terms of compatibility between weather resistance and mechanical strength and transparency.

When a resin film is used as the surface member, the thickness of the film must be increased to some extent in order to secure mechanical strength. There is also a problem that the thickness is too large from the viewpoint of cost. Specifically, 20 to 200
μm is preferred, and 30 to 100 μm is more preferred.

It is preferable that the surface resin film is subjected to a surface treatment such as a corona treatment or a plasma treatment in order to improve the adhesiveness with the sealing material resin.

The back sealing resin 104 is used for the photovoltaic element 1
01 and the back surface member 105. As the material, a material which can secure sufficient adhesiveness to the conductive substrate, has excellent long-term durability, can withstand thermal expansion and thermal contraction, and has flexibility is preferable. Suitable materials include hot melt materials such as EVA and polyvinyl butyral, double-sided tapes, and flexible epoxy adhesives. Of course, it is also possible to use the same material as the surface sealing material resin, and usually such a case is often used. That is, the crosslinked EVA described above is generally used also on the back surface.

The back surface member 105 is necessary for maintaining electrical insulation between the conductive substrate of the photovoltaic element 101 and the outside. As the material, a material which can secure sufficient electric insulation with the conductive substrate, has excellent long-term durability, can withstand thermal expansion and thermal contraction, and has flexibility is preferable. Suitable films include nylon and polyethylene terephthalate.

A reinforcing plate may be attached to the outside of the back member in order to increase the mechanical strength of the solar cell module, or to prevent distortion or warpage due to a temperature change. This reinforcing plate can also serve as a base material for a roofing integrated solar cell module or a building material integrated solar cell module. As a material, a steel plate, a plastic plate, and an FRP (glass fiber reinforced plastic) plate are preferable.

Next, a method of forming a solar cell module using the above-described photovoltaic element, sealing resin, surface member, and back surface member will be described. There is no particular limitation on the heating and pressing method of the laminate manufacturing apparatus of the present invention, and various methods such as a known double vacuum chamber system and a single vacuum chamber system may be selected and used depending on the purpose.

Here, an example of the single vacuum chamber system will be described in detail with reference to FIG. (1) The solar cell module stack is placed on the plate 301, and a silicone rubber sheet is stacked. (2) Exhaust air is exhausted from the exhaust port 304 of the plate, and the laminate is pressed with a silicone rubber sheet. (3) The plate is heated to melt the sealing resin, and the laminate is laminated. (4) The temperature of the plate is partially controlled according to the module. (5) After cooling, take out the module. Through the above steps, a solar cell module is manufactured.

As a heating device provided in the above laminating device, a hot air circulation type oven, an infrared lamp,
A planar heater is exemplified. Heating or cooling control may be performed by attaching a heat transfer tube using a medium such as silicone oil or water (steam or cooling water) to these devices. Specifically, when a hot-air circulation oven (FIG. 3B) is used, a large number of holes 308 for sending hot air are provided above or below the metal plate 301, and temperature control is performed by controlling the amount of outflow. . When an infrared lamp is used, a required number of lamps are arranged at appropriate positions, and temperature control is performed by controlling the output of each lamp. When a planar heater is used, it is controlled by dividing and arranging it in an appropriate pattern on or inside the metal plate. In the present invention, a planar heater such as a silicone rubber heater or a hot plate is more suitable because it is easier to control.

[0035]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on embodiments.

Example 1 <Preparation of Photovoltaic Element> An amorphous silicon (a-Si) solar cell (photovoltaic element) having the structure shown in FIG. 2 was produced as follows. That is, an Al layer (thickness 5000 °) and a ZnO layer (thickness 5000) were formed on the cleaned stainless steel substrate 201 by sputtering as a back reflection layer 202.
Å) was sequentially formed. Next, n-type a-Si is obtained from a mixed gas of SiH4, PH3 and H2 by plasma CVD.
The i-type a-Si layer was formed from a mixed gas of SiH4 and H2.
From a mixed gas of SiH4, BF3 and H2, p-type microcrystal
An Si layer is formed and an n-layer thickness of 150 ° / i-layer thickness of 4000
Å / p layer thickness 100Å / n layer thickness 100Å / i layer thickness 8
Tandem type aS having a layer configuration of 00 / p layer thickness of 100
An i photoelectric conversion semiconductor layer 203 was formed. Next, as the transparent conductive layer 204, an In2O3 thin film (thickness:
It was formed by vapor deposition of In by a resistance heating method under two atmospheres. Thereafter, a process of removing defects of the photovoltaic element was performed. That is, a photovoltaic element and an electrode plate are immersed in an aqueous solution of aluminum chloride adjusted to have an electric conductivity of 50 to 70 mS so as to face the transparent conductive layer of the element. The transparent conductive layer in the shunted portion was selectively decomposed by applying a positive potential of 3.5 volts for 2 seconds. By this processing, the shunt resistance of the photovoltaic element becomes 1 kΩ · cm 2 to 10 kΩ before processing.
50 kΩ · cm 2 after treatment
To 200 kΩ · cm 2.

Finally, a grid electrode 205 for current collection is provided. A copper wire having a diameter of 100 microns is laid along a line of a copper paste having a width of 200 microns formed by screen printing, a cream solder is placed thereon, and then the solder is melted to form a copper paste. It was fixed on the top to form a current collecting electrode. As a negative terminal, a copper tab was attached to a stainless steel substrate using stainless steel solder, and as a positive terminal, a tin foil tape was attached to a current collecting electrode by solder to form an output terminal 206 to obtain a photovoltaic element.

<Modularization> The module size is 12
The size was set to 00 mm x 5000 mm, and a solar cell module was manufactured using the following members.

On a back member (0.4 mm-thick polyester-coated galvalume steel plate), a back seal resin (230 μm) was used.
m EVA / 100 μm PET / 230 μm EVA integrated laminated film), photovoltaic element (amorphous silicon semiconductor), surface sealing resin (460 μm EV)
A), surface protection reinforcing material (glass fiber nonwoven fabric, weighing 40 g /
m ² : 10 μm diameter 13 mm long glass fiber formed into a non-woven fabric with an acrylic binder), surface member (50 μm thick ethylene-tetrafluoroethylene copolymer (hereinafter ETF)
E)) were laminated in this order to obtain a solar cell module laminate. The EVA used here was 2,5 as a crosslinking agent with respect to 100 parts by weight of the EVA resin (vinyl acetate content 33%).
1.5 parts by weight of dimethyl-2,5-bis (t-butylperoxy) hexane, γ- as a silane coupling agent
1.0 parts by weight of (2-aminoethyl) aminopropyltrimethoxysilane, 2-hydroxy-
0.3 parts by weight of 4-n-octoxybenzophenone, bis (2,2,6,6-tetramethyl-4) as a light stabilizer
(Piperidyl) sebacate (0.1 part by weight) and tris (mono-nonylphenyl) phosphite (0.2 part by weight) as an antioxidant. ETFE is E
In order to increase the adhesion with VA, the adhesion side was subjected to plasma discharge treatment.

The above solar cell module laminate was mounted on a metal plate of a single vacuum chamber type laminating apparatus as shown in FIG.

As shown in FIG. 5, the heater used for heating is
Using a four-part silicone rubber heater, each part could be controlled independently. Among them, 503 and 504 corresponding to the center of the solar cell module laminate are shown in FIG.
In the temperature profile of FIG.
Nos. 1 and 502 were laminated by heating according to the temperature profile of FIG. 7A (601). The manufactured solar cell module was evaluated for items described below.

(Embodiment 2) When the module size is 600 mm
× 3000 mm, 503 and 504 corresponding to the center of the solar cell module laminate of the heater are shown in FIG.
In the temperature profile of FIG. 7A, 501 and 502 corresponding to the peripheral portion (the portion to be bent later) are heated and laminated according to the temperature profile of FIG.
2). Then, after bending as shown in FIG. 8, only the bent portion was irradiated with an electron beam of 5 Mrad by an electron beam irradiation device to perform secondary crosslinking. Except for the above, a module was prepared with the same formulation as in Example 1 and evaluated.

(Embodiment 3) When the module size is 1000
mm × 1200 mm, and the surface member, the surface sealing resin,
The solar cell module 401 is formed by laminating a photovoltaic element and a back sealing resin. Two of the laminates were placed in the laminating apparatus shown in FIG. 3, and only the heaters 502 and 504 corresponding to a certain portion of the laminate were heated with the temperature profile of FIG. 7A and laminated (603). .
Except for the above, a module was prepared with the same formulation as in Example 1 and evaluated.

Example 4 A solar cell was obtained by using a hot-air circulation type oven (FIG. 3B) instead of the silicone rubber heater and controlling the amount of hot air coming out of an outlet on the oven wall. The portion corresponding to the central portion of the module laminate was heated according to the temperature profile ′ in FIG. 7B, and the portion corresponding to the peripheral portion was heated according to the temperature profile ′ in FIG. Other than the above, Example 1
A module was prepared with the same formulation as described above, and was evaluated.

COMPARATIVE EXAMPLE 1 Instead of dividing the heating heater into two temperature control systems, the temperature control system was divided into one system and heating was performed according to the temperature profile shown in FIG. 7A. A module was prepared with the same formulation as in Example 1, and evaluated.

(Comparative Example 2) The temperature profile of FIG. 7 (a) is divided into two temperature control systems instead of splitting the heater and performing secondary crosslinking by electron beam. After heating in, a module was prepared with the same prescription as in Example 1 except that the module was bent as shown in FIG. 8, and the module was evaluated.

(Comparative Example 3) A module was prepared with the same recipe as in Comparative Example 2 except that the module was bent after being heated according to the temperature profile of FIG. 7 (a). The following items were evaluated for the solar cell modules manufactured in the examples and comparative examples described above. (1) Initial appearance Immediately after lamination, the appearance of the solar cell module was evaluated. ：: No problem in appearance. ×: Air bubbles remaining. (2) Adhesion The initial adhesion between the sealing material resin (EVA) and the back surface member was evaluated. Good: Adhesive strength of 8 kgf / 25 mm or more. Δ: Adhesive strength of 4 kgf / 25 mm or more and 8 kgf / 25 m
less than m. (3) Temperature cycle A temperature cycle test of −40 ° C./1 hour and 90 ° C./1 hour was performed 50 times, and changes in the appearance of the solar cell module after the test were observed. ：: No change in appearance. ×: Wrinkles occurred in the sealing resin. (4) Temperature / humidity cycle A temperature cycle test of −40 ° C./1 hour and 85 ° C./85% RH / 4 hours was performed 50 times, and changes in the appearance of the solar cell module after the test were observed. ：: No change in appearance. X: What peeled off the sealing resin.

Table 1 shows the results.

[0049]

[Table 1]

As in Example 1, even a large-area solar cell module could be manufactured without any problem by partially controlling the temperature profile differently.

In the module manufactured in Example 2, no peeling occurred even after the temperature / humidity cycle test. This is because the stress was relieved by making the sealing resin of the bent portion non-crosslinked or low-crosslinked at the time of bending.

In the case of partial lamination as in Example 3, sufficient lamination could be achieved by heating only necessary portions, and energy loss could be reduced.

Even if the heating device is a hot-air circulation type oven as in Example 4, by controlling the temperature appropriately, a large-area solar cell module having no problem can be manufactured.

On the other hand, in Comparative Example 1, since the module size was too large, the gas generated at the center of the module during lamination could not be sufficiently degassed, and many bubbles were generated. Therefore, the initial adhesive force between the sealing material resin and the back surface member was weak, and peeling of the sealing material resin was observed even after the temperature cycle and the temperature / humidity cycle.

In Comparative Examples 2 and 3, small air bubbles remained in the module, and peeling occurred at the bent portion after the temperature / humidity cycle test. This is because the sealing material resin was bent after being crosslinked, so that the stress at the bent portion remained.

[0056]

According to the apparatus and method for manufacturing a laminate of the present invention, at least two or more temperature control systems are provided in the manufacturing apparatus. A laminate that could not be produced can also be produced. Also, by controlling the temperature,
Partial lamination can be performed efficiently. Also,
The crosslink density of the sealing material resin of the laminate can be arbitrarily varied, and the degree of freedom in bending after lamination is increased. Further, by laminating the non-crosslinked or low-crosslinked portion with the secondary crosslink, the laminates can be bonded to each other or to another member.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a solar cell module.

FIG. 2 is an example of a schematic cross-sectional view ((a)) and a top view ((b)) of a light-receiving surface showing a basic configuration of a photovoltaic element.

FIG. 3 is a schematic cross-sectional view of a single vacuum chamber type laminating apparatus (when the heating apparatus is a silicone rubber heater (a),
This is an example of a hot air circulation type oven (b)).

FIG. 4 is an example of a solar cell module partially laminated on a back surface member.

FIG. 5 is an example of a division example of a heating control system.

FIG. 6 is an example of a heating control method of the present invention.

FIG. 7 shows an example of a temperature profile used in the present invention (when the heating device is a silicone rubber heater (a), and when a hot air circulation oven is used (b)).

FIG. 8 is an example of a bending process of the solar cell module of the present invention.

[Explanation of symbols]

101, 802 Photovoltaic element 102 Surface sealing resin 103 Surface member 104 Back sealing resin 105 Back member 106, 205 Current collecting electrode 107 Glass fiber nonwoven fabric 201 Conductive substrate 202 Back reflecting layer 203 Semiconductor photoactive layer 204 Transparent Conductive layer 206 Terminal 207 Conductive paste 208 Solder 301 Plate 302 Silicone rubber 303 Heater 304 Exhaust port 305 O-ring 306 Solar cell module laminated body 307 Oven wall surface 308 Hot air outlet 401 Solar cell module 402 Laminated parts 501, 502, 503, 504 Divided heater 601 Example of temperature control used in Example 1 602 Example of temperature control used in Example 2 603 Example of temperature control used in Example 3 801 Bending unit

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hidetoshi Zemitsu 3-30-2 Shimomaruko, Ota-ku, Tokyo Canon Inc. (72) Inventor Satoshi Yamada 3-30-2 Shimomaruko, Ota-ku, Tokyo Kyano Inc.

Claims (13)

[Claims] 1. An apparatus for manufacturing a laminate having a heating device or a cooling device, wherein the heating device or the cooling device has at least two or more independent temperature control systems. 2. A method for producing a laminate, wherein the temperature of the laminate is controlled partially independently. 3. The method according to claim 2, wherein the object to be laminated is partially laminated. 4. The method for producing a laminate according to claim 2, wherein the object to be laminated contains a thermoplastic or thermosetting sealing material resin, and the sealing material resin is provided with a crosslinking density gradient. 5. The method for producing a laminate according to claim 4, wherein a non-crosslinked or low-crosslinked portion of the sealing resin of the laminate is bent after lamination. 6. The method for producing a laminate according to claim 4, wherein the non-crosslinked or low-crosslinked portion of the sealing resin of the laminate is secondarily crosslinked after lamination. 7. The method for producing a laminate according to claim 4, wherein the secondary crosslinking is thermal crosslinking, electron beam crosslinking, or photocrosslinking. 8. The method for producing a laminate according to claim 2, wherein the temperature rise in the central portion of the laminated body is faster than the temperature rise in the peripheral portion. 9. The method according to claim 2, wherein the object to be laminated includes a member having a convex portion, and the temperature of the convex portion is slower than that of the other portions. . 10. The method for producing a laminate according to claim 2, wherein the laminate is a solar cell module. 11. A solar cell element is sealed on a reinforcing material with a thermoplastic or thermosetting sealing resin, and the sealing resin has a non-crosslinked or low-crosslinked portion. A method for manufacturing a solar cell module, comprising bending the reinforcing material corresponding to a crosslinked or low-crosslinked portion after lamination. 12. The method for manufacturing a solar cell module according to claim 11, wherein the non-crosslinked or low-crosslinked portion of the sealing material resin is subjected to secondary crosslinking after bending. 13. The method according to claim 13, wherein the secondary crosslinking is a thermal crosslinking, an electron beam crosslinking,
The method for producing a solar cell module according to claim 12, wherein the method is photocrosslinking.