JPH0465556B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an apparatus for laminating solar cell modules made of silicon wafers, and in particular covers one or both sides of the solar cell module with polyvinyl butyrol or the like.
The present invention relates to a solar cell module laminating device characterized in that the solar cell module is laminated and coated with a reinforcing member by heating it in a vacuum and at high temperature.

In recent years, solar cells have been developed in a variety of ways, from cutting-edge space exploration to the effective use of solar energy, a natural resource, for consumer use. Furthermore, there are various forms, and various solar cells have been devised. Basically, they use single crystal silicon, polycrystalline silicon, and non-crystalline silicon (amorphous). However, there are problems with manufacturing costs and solar energy conversion efficiency, and many of the solar cells currently in practical use use single-crystal silicon. This is thought to be because single-crystal silicon wafers have relatively high energy exchange efficiency, and although they are somewhat difficult to handle, they can be put into practical use by attaching reinforcing materials. Now, active use of single-crystal silicon wafers for power use (large capacity type) is being considered.

However, single-crystal silicon wafers are sensitive to impacts and are easily damaged, so it is necessary to pay close attention to handling operations. For experimental or laboratory use, great care is taken in handling single-crystal silicon wafers, but for general-purpose use, handling is generally unfamiliar and silicon is likely to be damaged.

Therefore, it is not only dangerous to use the solar cell module for general purposes without covering or reinforcing it, but also to prevent corrosion of the electrode parts, etc. Surround it with
Furthermore, in order to protect the entire device including the single crystal silicon wafer and lead wires, a method has been adopted in which the entire device is covered with a reinforcing member (filled with silicon, etc.) having a certain thickness. However, all of the conventional methods have low productivity due to poor work efficiency, are heavy, and are not suitable for mass production, and require the use of heat-resistant tempered glass for the surface.

An object of the present invention is to provide a novel solar cell module laminating device that eliminates the drawbacks of the prior art.

According to the solar cell module laminating device according to the present invention, polyvinyl butyrol is used as a reinforcing member to protect both sides or one side of the silicone, and the front side is made of heat-resistant glass or transparent vinyl fluoride film, and the back side is made of heat-resistant glass or transparent vinyl fluoride film. is covered with white fluorinated vinyl film. In addition, since it is heated in a vacuum, no air bubbles remain on the surface.
Product quality is good. Therefore, the completed solar cell module is not only easy to handle, but also lightweight and convenient to carry, and can be mass-produced, resulting in extremely low manufacturing costs. Furthermore, in manufacturing it, the equipment that laminates polyvinyl butyroll, vinyl fluoride film, and heat-resistant glass into the solar cell module is made up of two aluminum plates, a heat-resistant silicone rubber edge, and a box made of heat-resistant rubber. Since the polyvinyl butyrol is melted at a high temperature, the air bubbles generated at that time can be evacuated and defoamed. This allows air bubbles to be removed and complete coverage to be achieved.

Hereinafter, the present invention will be described in detail based on embodiments shown in the drawings.

FIG. 1 is a sectional view of an embodiment showing a solar cell module lamination process using a solar cell module laminating apparatus according to the present invention.

In this example, the polymerization was performed upside down for convenience of vacuum work, but first, a reinforcing member of polyvinyl vinyl was applied to the surface (at the bottom in the drawing) of the solar cell module 11, which was made up of a large number of wired silicon wafers. Butyrol 12 (PVB) and heat-resistant glass 14
is layered, and white or transparent vinyl fluoride film 16 (PVF) is layered on the back side (upper part). After the materials are piled up in this way, the whole is heated under vacuum to a high temperature. Polyvinyl butyrol 12 melts in about 2 minutes at a temperature of about 140 degrees. In this example, after the vacuum state was established, the temperature was raised to 138 degrees and 2 minutes elapsed. As a result, polyvinyl butyrol (PVB) among the superimposed materials is dissolved,
It penetrates between the solar cell modules and penetrates all the wiring parts of the solar cell modules. When polyvinyl butyrol is dissolved, bubbles are generated in the solution. Since the inside of the apparatus is in a vacuum state, all of these air bubbles are forcibly drawn out to the outside, and the polyvinyl butyrol becomes completely defoamed. The high temperature heating is completed in 2 minutes, and the melted polyvinyl butyrol is gradually cooled and solidified accordingly. The polymerized solar cell module 11, heat-resistant glass 14, and vinyl fluoride film 16 are adhered by melted polyvinyl butyrol 12, and the polyvinyl butyrol is solidified while being pressed by a device 36 such as a diaphragm made of silicone rubber. As the layers are stacked, they are gradually laminated in close contact with each other over the entire upper and lower surfaces.

FIG. 2 is a sectional view showing an embodiment of another solar cell lamination process using the solar cell module laminating apparatus according to the present invention.

In this embodiment, a solar cell module 11 consisting of a large number of wired silicon wafers is fixed in advance onto a printed wiring board 23 with a conductive adhesive, solder, or the like. In this embodiment, polyvinyl butyrol 22 is superimposed on a solar cell module 21 that has been fixed in advance on an aluminum base 23 with a conductive adhesive or solder, and a transparent fluorinated vinyl film 26 is placed on top of it. Wear heavy weight. In the embodiment shown in FIG. 1, the molding is done upside down, so the sunlight passes through the lower heat-resistant glass 24.
In the example shown in FIG. 2, the light passes through the transparent vinyl fluoride film 26 in this state. Therefore, the surface film must be made of a material with high sunlight transmittance, such as vinyl fluoride film 26.

FIG. 3 is a perspective view showing the entire solar cell module laminating apparatus according to the present invention.

The solar cell module laminating device 30 includes an air vent cloth material 38a, a box part 35 in which a silicone rubber frame 34 is provided on an aluminum plate 32a, an air vent cloth material 38b, a heat-resistant rubber plate 36, and an air vent cloth material 38.
It consists of a lid portion made by stacking the aluminum disc 32b and the aluminum disc 32b. Air vent holes 3 are provided in the panel surfaces 32a and 32b of the aluminum panel that constitutes the box part and the lid part, respectively.
9a and 39b are perforated, and the vacuum pump 40
A pipe is connected to the air extraction hole 39.

In this device, in order to maintain an appropriate vacuum state, air venting cloth materials 38 are used, one each on the upper and lower sides of the diaphragm 36, and one on the box portion. This embodiment is more efficient than the embodiment that does not use air venting fabric, as will be described later. As a result, the vacuum state can be appropriately controlled, and complete defoaming of air bubbles can be expected without damaging the cells. In addition, with this method, by applying moderate pressure to the entire polymerized material using a diaphragm at atmospheric pressure after vacuum heating, it is possible to prevent air from entering, so it is possible to stack the materials in a completely defoamed state. can be maintained.

Air venting cloth materials 38a and 38b are placed above and below the solar cell module 11 whose both sides are covered with reinforcing members, and the whole is placed in the box portion of the solar cell module laminating apparatus according to the present invention. Heat resistant rubber plate 3
6 and an air vent cloth material 38c are placed on top of the solar cell module 38c, and an aluminum plate 32b is placed over the lid to seal the inside of the solar cell module device.

The vacuum pump 40 is operated, and the air vent valve connected to the air vent hole 39b of the aluminum plate 32b of the lid is opened to gradually evacuate air from the lid to create a vacuum state. This lifts the diaphragm 36, thereby creating a negative pressure in the box, lifting the material placed therein, and making it easier for air to escape from the box. In this embodiment, air is removed from the lid for about 2 minutes. At this time, since the air vent cloth material 38c is interposed between the aluminum plate 32b of the lid body and the heat-resistant rubber plate 36, the heat-resistant rubber plate 38 is inserted into the air vent hole 39.
It is efficient because it does not stick to the hole and block the hole. Since the vacuum device operates sufficiently when the air vent cloth material 38 is present, a vacuum state can be effectively created despite the use of heat-resistant rubber. Of course, it is also possible to implement a method that does not use a heat-resistant rubber plate.

Next, similarly, the air vent valve connected to the air vent hole 39 is opened to gradually evacuate the box portion. In this example, the valve is opened for approximately 8 minutes to remove air from the box. As mentioned above, since the lid is already in a vacuum, the heat-resistant rubber diaphragm is lifted and the air pressure in the box is reduced, so the air in the box can be completely evacuated. .

After the lid and the box are evacuated, the aluminum plate is heated to a temperature of 138 degrees using the heating device 50.
Maintain temperature for 2 minutes. As a result, the polyvinyl butyrol melts and enters the gap between the solar cell modules, completely surrounding and penetrating the solar cell modules. When polyvinyl butyrol dissolves, bubbles are generated from within it. Since the solar cell module laminating apparatus is in a vacuum state, all generated air bubbles are guided and removed to the outside through the air extraction holes 39a and 39b.

Next, the heating device is stopped and the whole is cooled to solidify the polyvinyl butyrol. At this time, first,
When air is sent into the lid, the heat-resistant rubber plate 36 is pulled by the vacuum of the box and is pressed downward. As a result, the entire material is appropriately pressed from above by the heat-resistant rubber plate that is the diaphragm.

In the embodiment in which the heat-resistant glass 14 is the front surface, the front surface side is the aluminum plate 32a of the box part of the device.
The white vinyl fluoride film 16 is pressed from above with the heat-resistant rubber plate 36, which is a diaphragm, through the air venting fabric 38b. In addition, in an embodiment in which the solar cell module 21 is fixed in advance on the printed wiring board 23 with conductive adhesive or solder, the printed wiring board is placed at the bottom of the box part with the printed wiring board facing down. The constituent transparent fluorinated vinyl film 26 is vented from the upper part by a cloth material 38.
It will be pressed with the heat-resistant rubber plate 36 via b.

The polyvinyl butyrol is gradually cooled and solidified. Since the polyvinyl butyrol heated in a vacuum forms an irregular wave shape, a gap exists between the solar cell module and the polyvinyl butyrol despite the vacuum. For this reason,
When the vacuum is released and air is introduced, a situation occurs in which air instantly enters the small gap between the polyvinyl butyroll and the heat-resistant glass or vinyl fluoride film. In order to avoid this, as mentioned above, first release the vacuum on the lid, let air in, and then press the heat-resistant rubber plate 36.
is absorbed into the vacuum state of the box part. Thereby, using the heat-resistant rubber plate 36 as a diaphragm, the solar cell module in the device is pressed from above and left until it is gradually cooled and solidified. This pressure from above can block air that may enter the gap between the solar cell module, polyvinyl butyrol, heat-resistant glass, and vinyl fluoride film. In addition, at this time, since the uncoagulated polyvinyl butyroll is pressed through the air venting fabric, the pattern of the grain (plain, etc.) of the air venting fabric is formed on the front or back side of the solar cell module. be done. This makes scratches on the surface less noticeable, and furthermore, the adhesive strength between polyvinyl butyroll and vinyl fluoride film is greatly improved.

In the embodiment shown in the drawings, the aluminum plate 32a
A heating device 50 is attached to the aluminum plate to directly heat the aluminum plate. According to the heating method of this structure, heating is completed in only 2 minutes as described above.
This dramatically improved work efficiency and enabled mass production.

FIG. 4 is a perspective view showing another embodiment of the solar cell module laminating apparatus according to the present invention.
In this embodiment, the entire transparent cell solar cell module laminating apparatus is placed in a constant temperature oven 60 (oven), and a hot air generator 52
(heating device) is installed inside the thermostat.
The vacuum mechanism 40 is the same as described above. The heating device consists of a hot air generator 52, and the generated hot air fills the thermostatic oven. This makes it possible to raise the temperature inside the thermostatic chamber to a constant temperature and maintain the temperature. In this device, approximately 1 to 2 hours are required to heat the entire aluminum plate to the above-mentioned temperature of 138 degrees.

The device invention detailed above can be used not only for solar cell modules fixed in advance with conductive adhesive or solder on a printed wiring board, but also for solar cell modules of any shape. things are possible. In addition, polyvinyl butyrol is not limited to reinforcing both sides of the solar cell module, and may be laminated only on one side.

Since the solar cell module laminating apparatus according to the present invention has the structure as described in detail above, it is possible to produce solar cell modules in large quantities and at low cost, with both or one side protected with polyvinyl butyroll. The solar cell module produced by this method is easy to use and handle;
It is suitable for general purpose use and has the advantage of not requiring the care and complexity of conventional methods. Furthermore, since polyvinyl butyrol is used as a reinforcing member, heat-resistant glass, vinyl fluoride film, etc. can be bonded to the front and back surfaces, and the connections of the solar cell module can be protected at the same time. In addition, since it is heated in a vacuum, there are no air bubbles left in the polyvinyl butyrol, so the surface of the product is beautifully finished. In addition, the direct heating method can be used in the laminating equipment, making it possible to shorten production time and lower manufacturing costs.The automatic control device enables completely automated production, making it suitable for mass production. have an effect.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of an embodiment for explaining the solar cell module laminating method according to the present invention. FIG. 2 is a sectional view showing another embodiment of the solar cell module laminating method according to the present invention. FIG. 3 is a perspective view showing the entire solar cell module laminating apparatus according to the present invention. Fourth
The figure is a perspective view showing another embodiment of the solar cell module laminating apparatus according to the present invention. 11... Solar cell module, 12, 22...
Polyvinyl butyrol, 14...Heat-resistant glass,
16, 26... Fluorized vinyl film, 28,
38...Air ventilation cloth material, 30...Solar cell module laminating device, 32a, 32b...Aluminum plate, 35...Box section, 34...Silicone rubber frame section, 36...Heat-resistant rubber plate, 39...Air Extraction hole, 40... Vacuum device, 50... Heating device, 52
... Hot air generator, 60 ... Constant temperature bath.

Claims (1)

[Claims] 1. A device for heating and laminating solar cell modules and their reinforcing members in a vacuum state, which includes a box portion 35 in which a silicone rubber frame portion 34 is provided on an aluminum plate 32a, and the function of a pressurizing diaphragm. A lid section made by stacking a heat-resistant rubber plate 36, an air venting cloth 38c, and an aluminum board 32b, air venting cloth sections 38a and 38b that cover the stacked solar cell modules from both upper and lower sides, and a board surface 32a of the aluminum board. , 32b.
Vacuum pump 40 for removing air from a and 39b
and heating means 50 for the aluminum plate surface. 2. The solar cell module laminating device according to item 1 above, characterized in that the aluminum disk surface heating means 50 is directly connected to the surface of the aluminum disk in order to directly heat the surface of the aluminum disk. A solar cell module laminating apparatus according to claim 1. 3. In the solar cell module laminating apparatus described in item 1 above, the entire solar cell module laminating apparatus is installed in a box-shaped constant temperature bath 60, and the constant temperature bath is used as a means for heating the surface of the aluminum plate. 2. The solar cell module laminating apparatus according to claim 1, wherein a hot air generator 52 for blowing hot air into the solar cell module is installed outside the thermostatic oven.